Chappee 1.45 FF HTE, 1.55 FF HTE, 1.65 FF HTE Installers And Users Instructions

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Wall-mounted

condensing boilers

Installer’s and User’s Instructions

2

2

Dear Customer,

We are sure your new boiler will comply with all your requirements.

Purchasing one of our products satisfies your expectations: good func­tioning, simplicity and ease of use.

Do not dispose of this booklet without reading it: you can find here some
very useful information, which will help you to run your boiler correctly
and efficiently

.

Do not leave any parts of the packaging (plastic bags, polystyrene, etc.) within children’s reach as
they are a potential source of danger.

The boilers bear the CE mark in compliance with the basic requirements as laid down
in the following Directives:

- Gas Directive 90/396/CEE

- Performance Directive 92/42/CEE

- Electromagnetic Compatibility Directive 89/336/CEE

- Low Voltage Directive 73/23/CEE

Contents

1. Instructions prior to installation 34

2. Instructions prior to commissioning 34

3. Commissioning of the boiler 35

4. Filling the boiler 41

5. Turning off the boiler 41

6. Prolonged standstill of the system. Frost protection 41

7. Servicing instructions 41

Instructions pertaining

to the user

8. General information 42

9. Instructions prior to installation 42

10. Boiler installation 43

11. Boiler size 43

12. Installation of flue and air ducts 44

13. Connecting the mains supply 49

14. Gas valve adjustment 56

15. Setting the boiler parameters 58

16. Control and operation devices 59

17. Positioning of the ignition and flame sensing electrode 59

18. Check of combustion parameters 60

19. Activating the chimney-sweeper function 60

20. Annual service 60

21. Boiler schematic 61

22. Illustrated wiring diagram 62

23. Technical data 63

Instructions pertaining

to the installer

3

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Instructions pertaining to the user

2. Instructions prior to
commissioning

Initial lighting of the boiler must be carried out by a licensed technician. Ensure the following ope­rations are carried out:
a) compliance of boiler parameters with (electricity, water, gas) supply systems settings.
b) compliance of installation with the laws and regulations in force.
c) appropriate connection to the power supply and grounding of the appliance.
Failure to observe the above will render the guarantee null and void.
Prior to commissioning remove the protective plastic coating from the unit. Do not use any tools or
abrasive detergents as you may spoil the painted surfaces.

This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure.
The boiler must be connected to a central heating system and to a domestic hot water supply system
in compliance with its performances and output power.
Have the boiler installed by a Qualified Service Engineer and ensure the following operations are
accomplished:

a) careful checking that the boiler is fit for operation with the type of gas available. For more details

see the notice on the packaging and the label on the appliance itself.

b) careful checking that the flue terminal draft is appropriate; that the terminal is not obstructed and

that no other appliance exhaust gases are expelled through the same flue duct, unless the flue is
especially designed to collect the exhaust gas coming from more than one appliance, in conformity
with the laws and regulations in force.

c) careful checking that, in case the flue has been connected to pre-existing flue ducts, thorough

cleaning has been carried out in that residual combustion products may come off during operation
of the boiler and obstruct the flue duct.

d) to ensure correct operation of the appliance and avoid invalidating the guarantee, observe the

following precautions:

1.

Hot water circuit:

If the water hardness is greater than 20 °F (1 °F = 10 mg calcium carbonate per litre of water)

a polyphosphate or comparable treatment system responding to current regulations.

2. Heating circuit

2.1. new system
Before proceeding with installation of the boiler, the system must be cleaned and flushed

out thoroughly to eliminate residual thread-cutting swarf, solder and solvents if any, using
suitable proprietary products.

To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid

and non alkaline. The recommended products for cleaning are:

SENTINEL X300 or X400 and FERNOX heating circuit restore. To use this product proceeding

strictly in accordance with the maker’s directions.

2.2. existing system

Before proceeding with installation of the boiler, the system must be cleaned and flushed

out to remove sludge and contaminants, using suitable proprietary products as described in
section 2.1.

To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid

and non-alkaline such as SENTINEL X100 and FERNOX heating circuit protective. To use
this product proceeding strictly in accordance with the maker’s directions.

Remember that the presence of foreign matter in the heating system can adversely affect the

operation of the boiler (e.g. overheating and noisy operation of the heat exchanger).

Failure to observe the above will render the guarantee null and void

.

1. Instructions prior to

installation

4

KEYS DISPLAY SYMBOLS

Central heating mode setting key

Data display reset key

Parameter setting key (increase value)

Parameter setting key (decrease value)

Program access and scroll key

Program access and scroll keys

Reset key

Domestic hot water temperature setting
key

Central heating water temperature setting
key

Domestic hot water on/off key

Resettable alarm warning

Flame present (on)

Outdoor temperature

Standby (off)

Operation in manual mode at minimum
temperature

Operation in manual mode at the maxi­mum temperature set

Operation in automatic mode

Operation in central heating mode

Operation in domestic hot water mode

020503_1

Figure 1

SECONDARY display

MAIN display

IMPORTANT: The instructions contained in this manual relating to the operation of the hot
water circuit are relevant only if the appliance is actually connected to a domestic hot water
system.

To correctly light the burner proceed as follows:

1) provide power supply to the boiler;

2) open the gas cock;

3) follow the directions given below regarding the adjustments to be made at the boiler control pa­nel.

3. Commissioning
of the boiler

5

020503_0800

Figure 2

a)

Automatic operation. Operation of the boiler is controlled by the timed program as described

in point 3-5.1 “Daily timed program for operation of the central heating system”;

b)

Manual operation at the maximum temperature set. The boiler comes into operation

regardless of the timed program set. The operating temperature is that set using the
key (point 3-3: “Setting the maximum central heating temperature”);

c)

Manual operation at minimum temperature. The operating temperature is that set in

point 3-6: “setting the minimum central heating temperature”.

The manual transition from positions a) and b) to position c) involves shut-down of the burner

and disconnection of the pump after the post-circulation delay interval (the factory setting
for this parameter is 3 minutes).

d)

standby. The boiler does not work in central heating mode, although the antifreeze function

is still enabled.

(1) Domestic hot water on/off key: Press this key to activate or inhibit this function, which

is identified by the appearance on the display of two black dashes under the

symbol.

(4) Reset key. In case of a fault, referred to in point 3-7 “Faults and resetting the boiler”,

the boiler can be restarted by pressing this key for at least two seconds.

If this key is pressed with no fault present, the display will show the message “E153”, and

the same key has to be pressed again (for at least two seconds) to restart the boiler.

(9) Data key. This key can be pressed repeatedly to display the following information:

- Temperature (°C) of the domestic hot water (

);

- outdoor temperature (°C) (

); only provided with the outdoor temperature sensor probe

connected.

Press either of the

keys to return to the main menu.

Dash

“Automatic mode”

active

(2) This key can be pressed to set the central heating water output temperature as described

in point 3-3.

(3) This key can be pressed to set the domestic hot water temperature as described in point 3-

4.

(10) Central heating mode operating key

The

key can be pressed to activate four boiler central heating operating modes; these
modes are identified by a black cursor line underneath the relative symbol on the display,
and are as follows:

3.1 Description of keys

6

a) Press either of the

keys to access the programming function;

the display will show the letter P followed by a number (program line);

020503_0700

Figure 3

b) press the

keys until the display shows P1, referring to the time to be set;

c) press the

keys to set the time; on the display, the letter P will start to flash;

d) press the

key to save and exit the programming function;

- Press the

key (2-figure 1) to set the central heating water temperature;

- Press the

keys to set the temperature required;

- press either of the

keys (1 or 10 - figure 1) to save and return to the main menu.

N.b – With the outdoor sensor probe connected, the

key (2 - figure 1) can be used to shift the

central heating curve. Press the

keys to decrease or increase the room temperature in

the premises to be heated.

- Press the

key (3-figure 1) to set the maximum domestic hot water temperature;

- Press the

keys to set the temperature required;

- press either of the

keys (1 or 10 - figure 1) to save and return to the main menu.

- Press either of the

keys to access the programming function;

a) press these keys until the display shows P11, referring to the program start time;

b) press the

keys to set the time;

- press the

key; the display will show P12, referring to the program end time;

- repeat the operations described in points a and b until the third and last cycle is reached (program

line P16);

- press the

key to save and exit from the programming function.

3.2 Setting the time

3.3 Setting the maximum cen­tral heating temperature

3.4 Setting the maximum

domestic hot water tempe­rature

3.5 Setting the daily program for

operation in central heating
and domestic hot water
modes

3.5.1 Setting the daily times

for central heating mode
operation

7

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- As supplied by the factory the appliance is set up with the domestic hot water function always

enabled and the domestic hot water programming function disabled.

The instructions for enabling this program are given in chapter 15, which is addressed specifically

to installers (parameter H91).

If the program is enabled program lines from 31 to 36 must be set up as described in heading 3-

5.1.

- press either of the

keys to access the programming function;

- press these keys until the display shows P5, referring to the temperature to be set;

- press the

keys to set the temperature required.

This operating mode is enabled when minimum temperature central heating mode

“

”

is activated

or when the daily central heating program does not require heat

.

N.b – With the outdoor sensor probe connected, parameter P5 can be used to set the minimum

room temperature in the premises to be heated.

Range

0…23:59

25..80

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

0...1

Factory

setting

———-

25

6:00

22:00

0:00

0:00

0:00

0:00

0:00

24:00

0:00

0:00

0:00

0:00

0

Parameter description

Time of day setting

Minimum central heating temperature setting (°C)

Start of first daily period of automatic central heating

End of first daily period of automatic central heating

Start of second daily period of automatic central heating

End of second daily period of automatic central heating

Start of third daily period of automatic heating

End of third daily period of automatic central heating

Start of first daily period of domestic hot water production (*)

End of first daily period of domestic hot water production (*)

Start of second daily period of domestic hot water production (*)

End of second daily period of domestic hot water production (*)

Start of third daily period of domestic hot water production (*)

Fine End of third daily period of domestic hot water production (*)

Reset of daily central heating and domestic hot water production programs (factory
settings). Press the - + keys together for about 3 seconds; the number 1 appears on
the display. Confirm by pressing either of the

keys

Parameter

N.

P1

P5

P11

P12

P13

P14

P15

P16

P31

P32

P33

P34

P35

P36

P45

3.7 Table of user-settable para­meters

Note: Parameters from P31 to P36 can be displayed only if the domestic hot water program has been
enabled as described in chapter 15 for the attention of the installer (parameter H91).

3.5.2 Setting the daily
times for domestic
hot water mode
operation

3.6 Setting the minimum
central heating tempe-

rature

8

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If a fault occurs, a flashing warning code appears on the display.

The fault warnings appear on the main display (figure 1 a) together with the

symbol (Figure 4).

To reset, press the reset

button for at least two seconds.

020503_0500

Figure 4

Fault warnings appear on the secondary display (figure 1 b) alternating with the time, both of them
flashing (figure 4.1). It is not possible to reset malfunction warnings which appear on the secondary
display as the cause of the alarm has first to be removed.

3.8 Fault warnings and
resetting the boiler

020503_0600

Figure 4.1

9

All the faults are displayed in order of importance; if several faults occur simultaneously, the first to
be displayed is the one with highest priority. After the cause of the first fault has been removed, the
second one will be displayed, and so on.
If any given fault occurs frequently, contact the authorised Service Centre.

Fault description

outdoor temperature probe sensor
failure

ntc output sensor failure

domestic hot water ntc sensor failure

safety or flue gas thermostat tripped

Loss of flame during operation (the
ionization current has fallen below
the limit)

Minimum fan speed limit is hurt

floor thermostat tripped

no gas

boiler circuit board error

th e re set key has been pressed
inappropriately

internal error on boiler circuit module

fan speed threshold not reached

no hydraulic pressure switch enabling
signal

3.9 Fault warnings table

Fault

code

E10

E20

E50

E110

E128

E129

E132

E133

E151

E153

E154

E160

E164

action required

call the authorised service centre.

call the authorised service centre

call the authorised service centre

press the reset key (for about 2 seconds: if this device is triggered
repeatedly, call the authorised service centre)

Call an authorised service centre.

Call an authorised service centre.

call the authorised service centre

press the reset key (for about 2 seconds); if the fault persists, call the
authorised service centre)

Press the reset button if the display presents the (

) symbol, otherwise
switch off the boiler at the mains and switch it on again after 10 seconds.
If the fault persists, call an authorised service centre. Check the position
of the ignition electrodes (chapter 19).

press the key again (about 2 seconds)

Press and hold reset button (2 seconds approx.) then press again when
warning E153 appears

call the authorised service centre.

check that the system is at the rated pressure. (refer to the section on filling
the system). if the fault persists, call the authorised service centre.

10

To maintain efficient and safe operation of your boiler have it checked by a Qualified Service En­gineer at the end of every operating period. Careful servicing will ensure economical operation of
the system.
Do not clean the outer casing of the appliance with abrasive, aggressive and/or easily flammable
cleaners (i.e.: gasoline, alcohol, and so on). Always isolate the electrical supply to the appliance
before cleaning it (see section 5 Turning off the boiler).

These boilers produced for natural gas can be converted to work with LPG.
Any gas change be effected by a Qualified Service Engineer.

7. Servicing instructions
and gas change

To shut down the boiler switch off the electrical supply to the appliance.5. Turning off the boiler

Important: Regularly check that the pressure displayed by the pressure gauge is 1 to 1.5 bar, with

boiler not operating.
In case the pressure is lower open the boiler filling tap.
We recommend you open the tap very slowly in order to let off the air.
In case pressure drops occur frequently have the boiler checked by a Qualified Service Engineer.

4. Filling the boiler

6. Prolonged standstill of the
system. Frost protection

We recommend you avoid draining the whole system as water replacements engender purposeless
and harmful limestone deposits inside the boiler and on the heating elements.
In case the boiler is not operated during wintertime and is therefore exposed to danger of frost we
suggest you add some specific-purpose anti-freeze to the water contained in the system (e.g.: propy­lene glycole coupled with corrosion and scaling inhibitors).
The electronic management of boilers includes a ‘frost protection’ function which operates the bur­ner to reach a heating flow temperature of 30° C when the system heating flow temperature drops
below 5°C.

The frost protection function is enabled if:

* electrical supply to the boiler is on;
* the gas service cock is open;
* the system pressure is as required;

* the boiler is not blocked.

11

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Instructions pertaining to the installer

This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure. The
boiler must be connected to a central heating system and, on models withis option, to a domestic hot
water supply system in compliance with its performances and output power.

IMPORTANT! The gas boiler is supplied without the following components witch must be performed
exclusively by qualified personnel:

• Expansion vessel;

• Pressure relief valve;

• Circulating pump;

• Boiler filling tap.

Before connecting the boiler have the following operations effected:

a) careful checking that the boiler is fit for operation with the type of gas available. For more details

see the notice on the packaging and the label on the appliance itself.

b) careful checking that the flue terminal draft is appropriate; that the terminal is not obstructed and

that no other appliance exhaust gases are expelled through the same flue duct, unless the flue is
especially designed to collect the exhaust gas coming from more than one appliance, in conformity
with the laws and regulations in force.

c) careful checking that, in case the flue has been connected to pre-existing flue ducts, thorough

cleaning has been carried out in that residual combustion products may come off during operation
of the boiler and obstruct the flue duct.

To ensure correct operation of the appliance and avoid invalidating the guarantee, observe the
following precautions:

1.

Hot water circuit:

If the water hardness is greater than 20 °F (1 °F = 10 mg calcium carbonate per litre of water)

a polyphosphate or comparable treatment system responding to current regulations.

2. Heating circuit

2.1. new system
Before proceeding with installation of the boiler, the system must be cleaned and flushed

out thoroughly to eliminate residual thread-cutting swarf, solder and solvents if any, using
suitable proprietary products.

To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid

and non alkaline. The recommended products for cleaning are:

SENTINEL X300 or X400 and FERNOX heating circuit restore. To use this product proceeding

strictly in accordance with the maker’s directions.

2.2. existing system

Before proceeding with installation of the boiler, the system must be cleaned and flushed out

to remove sludge and contaminants, using suitable proprietary products as described in section

2.1.

9. Instructions prior to instal­lation

The following remarks and instructions are addressed to Service Engineers to help them carry out a
faultless installation. Instructions regarding lighting and operation of the boiler are contained in the
‘Instructions pertaining to the user’ section.
Note that installation, maintenance and operation of the domestic gas appliances must be performed
exclusively by qualified personnel in compliance with current standards.
Please note the following:
* This boiler can be connected to any type of convector plates, radiators, thermoconvectors. Design

the system sections as usual though taking into account the available output / pump head perfor­mances.

* Do not leave any packaging components (plastic bags, polystyrene, etc.) within children’s reach

as they are a potential source of danger.

* Initial lighting of the boiler must be effected by a Qualified Service Engineer.

Failure to observe the above will render the guarantee null and void.

8. General information

12

Figure 6

11. Boiler size

Decide upon the boiler location, then tape the template on the wall.
Connect the pipework to the gas and water inlets prearranged on the template lower bar.
If you are either installing the boiler on a pre-existent system or substituting it, we suggest you also
fit settling tanks on the system return pipework and under the boiler to collect the deposits and scaling
which may remain and be circulated in the system after the purge.
When the boiler is fixed on the template connect the flue and air ducts (fittings supplied by the ma­nufacturer) according to the instructions given in the following sections.
Connect the condensate outlet to the siphon supplied with the boiler. Connect the siphon to a drain,
making sure there is a continuous slope. Horizontal sections must be avoided.
The boiler unit is fitted for connection to an external boiler. For this purpose, unscrew the two plugs
on the heating system delivery/return fittings if a hydraulic separator is not used (see fig. 12).

10. Boiler installation

MR: G 1” heating flow
GAS: G 3/4” gas inlet to the boiler
RR: G 1” heating return
SC: condensation drain

0310_0103

Figure 5

TEMPLATES FIXING POINTS

DRILL HOLES WITH A Ø12 BIT

BOILER TEMPLATE

FLUE

N.B. INCLUDE CONDENSATE DRAIN POINT

BOILER HEIGHT

BOILER WIDTH 600

gas inlet to the boiler

heating fl

To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non­alkaline such us SENTINEL X100 and FERNOX heating circuit protective. To use this product
proceeding strictly in accordance with the maker’s directions.
Remember that the presence of foreign matter in the heating system can adversely affect the operation
of the boiler (e.g. overheating and noisy operation of the heat exchanger).

Failure to observe the above will render the guarantee null and void

.

0506_1301

13

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Figure 7

and air ducts

12. Installation of flue

We guarantee ease and flexibility of installation for a gas-fired forced draft boiler thanks to the fittings

and fixtures supplied (described below).
The boiler is especially designed for connection to an exhaust flue / air ducting, with either coaxial,
vertical or horizontal terminal. By means of a splitting kit a two-pipe system may also be installed.

In case exhaust and intake flues not supplied by CHAPPEEhave been installed, these must be
certified for the type of use and must have a maximum pressure drop of 100 Pa.

Warnings for the following types of installation:

C

The terminals for the split flue must be provided for within a square with 50 cm sides. Detailed

, C

33

13

instructions are given together with each accessory.

C

The terminals for combustion air intake and for the expulsion of combustion products must

53

not be provided for on opposite walls of the building.

The maximum pressure drop of the ducts must not exceed 100 Pa. The ducts must be certified

C

63

for the specific use and for a temperature of over 100°C. The chimney flue must be certified
in accordance with the prEN 1856-1 Regulation.

C

The chimney or flue used must be suitable for the use.

, C

83

43

0310_0104

14

Flue
terminal
diameter

133 mm
133 mm

-

Each 45° bend

reduces the duct

max. length by

0,5 m
0,25 m
0,25 m

Each 90° bend

reduces the duct

max. length by

1 m
0,5 m
0,5 m

Max. length

of flue duct

10 m
15 m
60 m

Flue duct terminal

Coaxial Ø 80/125 mm

Vertical two-pipe

Horizontal two-pipe

Outer
terminal
diameter

125 mm

80 mm
80 mm

… coaxial flue - air duct (concentric)

990519_0400

Concentric outlet

Figure 8

Horizontal flue terminal

Ø 80/125 mm

installation options

LAS flue duct

Ø 80/125 mm

installation options

0310_0105

L max = 10 m

0310_0106

This type of duct allows to disengage exhaust gases
and to draw combustion air both outside the building
and in case a LAS flue is fitted.
The 90° coaxial bend allows to connect the boiler to a
flue-air duct in any direction as it can rotate by 360°.
It can moreover be used as a supplementary bend and
be coupled with a coaxial duct or a 45° bend.

If the flue outlet is placed outside, the flue-air ducting
must protrude at least 18mm out of the wall to allow
alluminium weathering tile to be fitted and sealed to
avoid water leakages.
Ensure a minimum downward slope of 1 cm towards
the outside per each metre of duct length.

• A 90° bend reduces the total duct length by 1 metre.

• A 45° bend reduces the total duct length by 0.5 metre.

15

Vertical flue terminal Ø 80/125 mm installation options

This type of installation can be carried out both on a flat or pitched roof by fitting a terminal, an
appropriate weathering tile and sleeve, (supplementary fittings supplied on demand).

… twin flue-air ducting

This type of ducting allows to disengage exhaust flue gases both outside the building and into single
flue ducts.
Comburant air may be drawn in at a different site from where the flue terminal is located.
The splitting kit consists of a flue duct adaptor (125/80) and of an air duct adaptor.
For the air duct adaptor fit the screws and seals previously removed from the cap.

The 90° bend allows to connect the boiler to flue-air ducting regardless of direction as it can be ro­tated by 360°. It can moreover be used as a supplementary bend to be coupled with the duct or with
a 45° bend.

L max = 10 m

L max = 10 m L max = 9 mL max = 8 m

0310_0107

0310_0108

Intake air duct adaptor

Intake air cap

• A 90° bend reduces the total duct length by 0.5 metre.

• A 45° bend reduces the total duct length by 0.25 metre.

031

16

Twin horizontal flue terminals installation options

IMPORTANT: Ensure a minimum downward slope of 1 cm toward the outside per each metre of

duct length
Make sure that the exhaust and intake ducts are securely fixed to the walls.

(L1 + L2) max = 60 mL max = 15 m

0310_3002

The maximum length of the suction
duct must be 15 metres.

Twin vertical flue terminals installation options

IMPORTANT: if fitting a single exhaust flue duct, ensure it is adequately insulated (e.g.: with glass

wool) wherever the duct passes through building walls.
For detailed instructions concerning the installation of fittings refer to the technical data accompanying
the fittings.

L max = 14 m

L max = 15 m

0310_01

17

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To ensure the correct rated heat input to the maximum and minimum heat input, it is necessary to

update the speed (rpm) of the fan, it depends on the lenght of the pipes (par. 12), in accordance with
the installation of flue and air pipes as indicated in the tables below. The factory-set value is referred
to the minimum length of flue pipe (0÷4 m for concentric, 0÷20 m for twin). To carry such updating,
changing the speed of the fan (rpm) at the maximum and minimum heat input, refer to par. 15.

COAXIAL PIPE Ø 80/125

(C13-C33-C43)

Pipes length

(m)

0 - 4

5 - 10

Parametres
H536-H613

Max heat output (rpm)

5500
5900

Parametres

H612

Min heat output (rpm)

1900
2100

TWIN-PIPE Ø 80

(C13-C33-C43-C53-C83)

Pipes length

(m)

0 - 20

21 - 40

41 - 60

Parametres
H536-H613

Max heat output (rpm)

5500
5700
5900

Parametres

H612

Min heat output (rpm)

1900
2000
2100

1.45 FF HTE

COAXIAL PIPE Ø 80/125

(C13-C33-C43)

Pipes length

(m)

0 - 4

5 - 10

Parametres
H536-H613

Max heat output (rpm)

5600
6000

Parametres

H612

Min heat output (rpm)

1650
1800

TWIN-PIPE Ø 80

(C13-C33-C43-C53-C83)

Pipes length

(m)

0 - 20

21 - 40

41 - 60

Parametres
H536-H613

Max heat output (rpm)

5600
5800
6000

Parametres

H612

Min heat output (rpm)

1650
1800
1800

1.55 FF HTE

COAXIAL PIPE Ø 80/125

(C13-C33-C43)

Pipes length

(m)

0 - 4

5 - 10

Parametres

H536-H613

Max heat output (rpm)

6000
6500

Parametres

H612

Min heat output (rpm)

1850
2100

TWIN-PIPE Ø 80

(C13-C33-C43-C53-C83)

Pipes length

(m)

0 - 20

21 - 40

41 - 60

Parametres
H536-H613

Max heat output (rpm)

6000
6200
6500

Parametres

H612

Min heat output (rpm)

1850
1900
2100

1.65 FF HTE

12.1 Fan rpm updating
depend of pipes
lenght (e.g. figure 7)

18

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Electrical safety of the appliance is only guaranteed by correct grounding, in compliance with the

applicable laws and regulations.
Connect the boiler to a 230V monophase + ground power supply by means of the three-pin cable
supplied with it and make sure you connect polarities correctly.

Use a double-pole switch with a contact separation of at least 3mm in both poles.

In case you replace the power supply cable fit a HAR H05 VV-F’ 3x0.75mm

2

cable with an 8mm
diameter max.
The fuse, a fast-acting type rated 2A, is incorporated into the power supply terminals (remove the
black fuse holder to enable inspection and/or replacement).

IMPORTANT: Check that the overall current drawn by accessories connected to the appliance is
less than 2 A. If the value is greater, a relay must be wired between the boiler control circuit board
and the accessories drawing the higher current.

13. Connecting the mains
supply

Figure 9

Turn the control box downwards and access the terminal blocks M1 and M3 by taking off the main
protective cover.
The pumps of the heating system (P1 and P2) have to be connected to boiler terminal block follow­ing the wiring of figure 10, a relay must be wired between the boiler control circuit board and the
pumps.
If the boiler unit’s electronic card is wired up to a single pump with these characteristics

230 V AC; 50 Hz; 1 A max; cos φ > 0.8.

then it is not necessary to add a relay.
Check the correct size and rating of the pump by referring to graph n° 1, which shows the boiler
pressure losses.

13.1 Connecting the pump ­heating system

0601_2003/CT_0674

Terminal board

Terminal board

Cover

Terminal board

Cover

19

Figure 10

0601_2002/CT_0676

Terminal board

Terminal board

Terminal board

Cover

Cover

0603_1701/CG_1789

Expansion vessel

Safety valve (*)

(*)

(*)

(*) available optional extra

P1 = Low loss header pump
P2 = Heating circuit pump
SI = Low loss header
(available optional extra)
UR = Central heating unit

20

Turn the control box downward to access terminal board M2 used for the electrical connections by
removing the two protective covers (see figure 9).

Terminals 1-2: connection of SIEMENS model QAA73 temperature regulator supplied as accessory.
Connection polarity is irrelevant.
The jumper fitted across the “TA” terminals 3-4 must be removed.
Read the instructions supplied with this accessory for correct installation and programming proce­dures.
Terminals 3-4: “TA” room temperature thermostat connection. Thermostats with integral accele­rator resistor must no be used. Check that there is no voltage across the ends of the two thermostat
connection wires.
Terminals 5-6: “TP” floor temperature thermostat connection (commercially available device). Check
that there is no voltage across the ends of the two thermostat connection wires.
Terminals 7-8: connection of SIEMENS model QAC34 outdoor temperature probe supplied as
accessory.
Read the instructions supplied with this accessory for correct installation procedures.
Terminals 9-10: connection of domestic hot water precedence temperature sensor supplied as acces­sory for connecting heating-only boilers to an external water heater.

The SIEMENS model QAA73 room temperature regulator (optional accessory) must be connected
to terminals 1-2 of terminal board M2 in figure 9.
The jumper across terminals 3-4, provided for connection of a room temperature thermostat, must
be removed.
The settings of the domestic hot water temperature and domestic hot water production schedule must
be made using this device.
The timed program of the central heating circuit must be set on the QAA73 if there is a single zone,
or in relation to the zone controlled by the QAA73 device.
The timed program for the central heating circuit of the other zones can be set directly on the boiler
control panel.

See the instructions provided with the QAA73 room temperature regulator for the user parameter
programming procedure.

IMPORTANT: For systems divided into zones, parameter 80 “HC2 gradient”, which can be set on
the QAA73 temperature regulator, must be set as _ _ . _ “not active”.

Exchangers pressure drop (mH

2

O)

WATER FLOW RATE (l/h)

Graph 1

0310_0112

- Exchangers pressure drop

l/h

1.45 FF HTE 1000

1.55 FF HTE 1000

1.65 FF HTE 1200

The minimum ga boiler water flow, with at least 1 - 1,5 bar, must be as follow:

13.2 Description of the electri­cal connections to the
boiler

13.3 Connecting the QAA73

room temperature regula­tor.

21

- fault messages

In the event of fault, the display panel on the QAA73 shows the flashing symbol

. Press the infor­mation key ( ) to display the error code and a description of the fault (see Fault warning tables on
paragraph 3.9).

Line no.

70

72

74

75

77

78

79

80

90

91

Default value

15

85

Light

On HC1

On

0

0

—.-

10

24 h/day

Range

2.5…40

25…85

Light, Heavy

on HC1
on HC2
on HC1+HC2
nil

On - off

0…360 min

0…360 min

2.5…40
—.- = not active

10 or 35…58

24 h/day
TSP HC-1h
TSP HC
TSP DHW

Parameter

HC1 gradient
Selection of central heating circuit temperature curve “kt”

HC1 max. output
Central heating system maximum output temperature

Type of building

Room compensation
Activation/deactivation of the influence of the room temperature.
If it is deactivated, the outdoor temperature sensor must be
installed.

Automatic adaptation of the temperature curve “kt” in relation
to the room temperature.

Opt Start Max
Maximum time the boiler is switched on ahead of the timed
program to optimise the temperature in the premises.

Opt Stop Max
Maximum time the boiler is switched off ahead of the timed
program to optimise the temperature in the premises.

HC2 gradient

DHW Red Setp
Minimum temperature of the domestic domestic hot water

DHW program
Selection of the type of timed program for domestic hot water.
24 h/day = always on
PROG HC-1h = as HC1 central heating program
less one hour
PROG HC = as central heating program
PROG DHW = specific domestic hot water
program (see also program lines 30-36)

QAA73: parameters which can be set by the installation engineer (service)

By pressing the two PROG buttons together for at least three seconds it is possible to access the list
of parameters that the installer can display and/or set.
Press either of these buttons to change the parameter to display or change.
Press the [+] or [-] key to change the value displayed.
Press either of the PROG buttons again to save the change.
Press the information button (i) to quit programming.
Here follows a list of the most commonly used parameters:

22

R

The SIEMENS model QAC34 outdoor temperature sensor (optional accessory) must be connected

to terminals 7-8 of terminal board M2 in figure 9.
The procedures for setting the gradient of the temperature curve “kt” vary depending on the acces­sories connected to the boiler.

a) Without QAA73 room temperature control device:

The temperature curve “kt” must be selected by setting parameter H532 as described in section 15
“setting the boiler parameters”.
See graph 2 for selecting the curve referred to a room temperature of 20°C.

The chosen curve can be shifted by pressing the

button (2) on the boiler control panel, and

modifying the value displayed by pressing the

and . keys. See graph 3 for curve selection.
(The example show in graph 3 refers to the curve Kt=15).
Increase the value displayed if the room temperature required is not reached inside the premises for
central heating.

b) with QAA73 room temperature control device:

The temperature curve “kt” must be selected by setting parameter 70 “HC1 gradient” of the QAA73
room temperature control device as described in section 13.3 “QAA73: parameters which can be set
by the installation engineer (service)”.
See graph 4 for selecting the curve referred to a room temperature of 20°C.
The curve is shifted automatically on the basis of the room temperature set using the QAA73 climate
control.
If the system is divided into zones, the temperature curve “kt” relating to the part of the system not
controlled by the QAA73 must be selected by setting parameter H532 as described in section 15
“setting the boiler parameters”.

IMPORTANT: For systems divided into zones, parameter 80 “HC2 gradient”, which can be set on
the QAA73 room temperature regulator, must be set as _ _ . _ “not active” (see section 13.3).

Graph 2 Graph 3

TM = Flow temperature
Te = Composite outside temperature
Sth = Kt Curve

Graph 4

TM = Flow temperature
Te = Composite outside temperature

020523_0600

13.4 Connecting the
outdoor
temperature sensor

020523_1000

23

R

c) with AGU2.500 device for control of a low temperature system:

Refer to the instructions provided with the AGU2.500 accessories for connection and control of a
low temperature zone.
In this case the set of some electronic parameters have to be modified (see § 15).

The electrical connection and settings needed to control a system divided into zones vary depending
on the accessories connected to the boiler.

a) Without QAA73 room temperature control device:

The contact relating to the request for operation of the various zones must be parallel-connected
and connected to terminal 3-4 “TA” of terminal board M2 in figure 11. The jumper present must be
removed.
The central heating temperature is selected directly on the boiler control panel in accordance with
the instructions provided for the user in this manual.

b) with QAA73 room temperature control device:

The pump relating to the room controlled by the QAA73 room temperature control device must be
supplied with electricity by means of terminals 11-12 of terminal board M3 in figure 11.
The contact relating to the request for operation of the other zones must be parallel-connected and
connected to terminal 3-4 “TA” of terminal board M2 in figure 11. The jumper present must be
removed.
The central heating temperature of the zone controlled by the QAA73 is set automatically by the
QAA73 itself.
The central heating temperature of the other zones must be selected directly on the boiler control
panel.

IMPORTANT: For systems divided into zones, parameter 80 “HC2 gradient”, which can be set on
the QAA73 temperature regulator, must be set as _ _ . _ “not active”.

Figure 11

N ZONE
(ROOM THERMOSTAT)

3 ZONE
(ROOM THERMOSTAT)

2 ZONE
(ROOM THERMOSTAT)

c) with AGU2.500 device for control of a low temperature system:

Refer to the instructions provided with the AGU2.500 accessories for connection and control of a
low temperature zone.
In this case the set of some electronic parameters have to be modified (see § 15).

13.5 Connecting a zoned
system

1 ZONE

0601_2004/CT_0675

M2

M3

M1

1 ZONE PUMP

BOILER UNIT

CIRCULATING

PUMP

24

R

The domestic hot water pump (P3), which directs flow into an eternal storage tank, is connected to

terminals 13-14 of boiler terminal strip M3 (figure 12).
The electrical specifications of the pump must be as follows:

230 V AC; 50 Hz; 1 A max; cos φ > 0.8.

If the specifications of the installed pump are different, a relay must be wired between the boiler
control circuit board and the pump.
Remove the resistor from terminals 9-10 of terminal strip M2 (figure 12), and connect the hot water
priority NTC sensor, which is supplied as an accessory.
The sensing element of the NTC device must be located in the recess provided on the storage tank
(figure 12).
The temperature and on-off programming of the domestic hot water supply are selected directly from
the boiler control panel, as described in this manual under the user instruction headings.

13.6 Connecting the

pump – hot water circuit

Figure 12

STORAGE TANK
CONNECTION DIAGRAM

KEY:

UB - DOMESTIC HOT WATER HEATER UNIT
UR - CENTRAL HEATING UNIT
M2 and M3 - CONNECTION TERMINAL BOARD
SB - DOMESTIC HOT WATER SENSOR
P1 - LOW LOSS HEADER PUMP
P2 - CENTRAL HEATING PUMP
P3 - D.H.W. PUMP
SI - LOW LOSS HEADER

0603_1702/CG_1790

CAUTION:
In the case of a direct coupling of the boiler coil fitting on the boiler unit’s “T” fitting it is necessary
to modify the control of pump P1.
Configuration of parameter for electronic card H632 = 00001000.
(See § 15).

25

IMPOR TANT: If the appliance is being converted from natural gas to propane (LPG), the following

operations must be performed before calibrating the gas valve as instructed above.

• Turn adjuster screw (V) on the gas valve clockwise through the number of complete revolutions
specified in table 3.

To simplify calibration of the gas valve, the “calibration function” can be set directly on the boiler
control panel by proceeding as follows:

1) Press the

keys (2-3) together until the display shows the pointer “ ” alongside the

symbol (about 6 seconds).

2) Press the

keys to set the fan speed at the minimum and maximum heat output

(%PWM);

N.b - to set the minimum and maximum heat output quickly, press the keys respecti-

vely;

3) press either of the two keys to exit the function.

0307_2201

Figure 14

0310_0114

Figure 13

Pi: Gas supply pressure connection point
P out: Gas pressure to burner connection point
P: Pressure connection point

for measurement of the OFFSET

Pl: Air signal input from fan
V: Gas flow adjuster screw
K: OFFSET adjuster screw

Carry out the following operations in the given sequence:

1) Calibration of the maximum heat output. Check that the CO

2

measured on the flue, with the boiler
operating at the maximum heat output, is the same as that shown in table 1. Otherwise, turn the
regulation screw (V) on the gas valve. Turn the screw clockwise to reduce the concentration of
CO2 and anticlockwise to increase it.

2) Calibration of reduced heat output. Check that the CO2 measured on the flue, with the boiler ope-

rating at the minimum heat output, is the same as that shown in table 1. Otherwise, turn the offset
regulation screw (K) on the gas valve. Turn the screw clockwise to increase the concentration of
CO2 and anticlockwise to reduce it.

14. Gas valve adjustment

26

Table 2

Table 2.1

Counter clockwise
Model turns of screw

(V)

1.45 FF HTE 3

1.55 FF HTE 3

3

/

4

1.65 FF HTE 4

3

/

4

Table 3

Table 1

Gas consumption at 15 °C

1013 mbar

1.45 FF HTE 1.55 FF HTE 1.65 FF HTE

gas

G20 - 2H - 20 mbar

PCI (

MJ/m

3

)

34.02 34.02

34.02

Consumption at max. heat output (m

3

/h)

4.91 6.00 7.08

Consumption at min. heat output (m

3

/h)

1.58 1.69 2.11

Gas nozzle (mm) 8.5 15 ---

Gas consumption at 15 °C

1013 mbar

1.45 FF HTE 1.55 FF HTE 1.65 FF HTE

gas

G31 - 3P - 37 mbar

PCI (MJ/Kg) 46.34 46.34 46.34

Consumption at max. heat output (Kg/h)

3.60 4.40 5.20

Consumption at min. heat output (Kg/h)

1.16 1.24 1.55

Gas nozzle (mm) 8.5 15 ---

G20 - 2H - 20 mbar G31 - 3P - 37 mbar

CO

2

max. heat output 8.7 % 10 %

CO

2

min. heat output 8.4 % 9.8 %

27

If the electronic circuit board is replaced, make sure that the parameters set are those specific to the
boiler model, as indicated in the documentation available from the authorised Service Centre.

Table 4

Parameter N.

H90

H91

H505

H507

H516

H532

H533

H536

H612

H613

H544

H545

H552

H553

H615

H632

H641

H657

Description

Setting for domestic hot water reduced temperature (°C)

D.H.W. (Domestic Hot Water) program
(0 = enabled; 1 = disabled)

Maximum temperature (°C) of the central heating circuit HC1 corresponding to:

- the main circuit in systems with just one zone;

- the circuit of the zone where the QAA73 temperature control device is installed
in case of systems with more than one high-temperature zone;

- the high temperature zone circuit in mixed systems and if the SIEMENS AGU2.500
accessory is used.

Maximum temperature (°C) of the central heating circuit HC2 of a system with
more than one zone, corresponding to the circuit of the low-temperature zone if the
SIEMENS AGU2.500 accessory is used.

Automatic Summer / Winter switching temperature (°C).

Selection of temperature curve of central heating circuit HC1 (see Graph 1)

Selection of temperature curve of central heating circuit HC2 (see Graph 1)

Maximum speed at maximum output in heating mode
(rpm - maximum speed limitation)

Setting value of required speed (rpm) at low-fire

Setting value of required speed (rpm) at high-fire

Pump post-circulation time in central heating mode (min)

Burner operating pause time between two start-ups (s)

Hydraulic system setting (see instructions provided with the SIEMENS AGU2.500
accessory). H552 = 50 with AGU2.500

Configuration of heating circuits
H553 = 12 with AGU2.500

Programmable function

Configuration of system with low loss header P1
H632 = 00001111 with AGU2.500

The value of Bit could be 1 or 0.
Press the keys 5 and 6 to select the bit to modify (b0 is the bit on the right, b7 is the
last bit on the left).
To modify the Bit value press on the keys 7 and 8

Fan post-purge interval (s)

Setpoint of autonomous ANTILEGIONELLA function

60...80 °C = setting temperature range

0 = function inactive

The boiler parameters may only be modified by professionally qualified staff proceeding as fol­lows:
a) press the , keys on the boiler’s front panel together for about 3 s until the parameter H90

appears on the display;
b) press the keys to select the parameter for modification;
c) press the and keys to modify the parameter;
d) press the key to exit the programming function.

The following are the parameters generally used:

15. Setting the boiler
parameters

Factory setting

10

1

80

80

20

15

15

Refer to

paragraph

12.1

10

180

2

21

9

00001100

10

0

28

The boiler has been designed in full compliance with European reference standards and in particular
is equipped with the following

• Overheat thermostat

Thanks to a sensor placed on the heating flow, this thermostat interrupts the gas flow to the main

burner in case the water contained in the circuit has overheated. Under these conditions the boiler
locks out and you can only repeat the ignition procedure by pressing the reset button on the boiler
after you have remedied the cause of the trip.

It is forbidden to disenable this safety device

• Flue thermostat

This device, positioned on the flue inside the boiler, interrupts the flow of gas to the burner if the

temperature exceeds 90 °C. After verifying the cause of the trip, press the reset button positioned
on the thermostat itself, then press the release button on the boiler.

It is forbidden to disenable this safety device

• Flame ionization detector

The flame sensing electrode guarantees safety of operation in case of gas failure or incomplete

interlighting of the main burner.
Under such conditions the boiler is blocked.
You must press the reset button on the boiler to restore the normal operating conditions.

• Supplementary running of the pump

The electronically-controlled supplementary running of the pump lasts 10 minutes, when the

boiler is in the central heating mode, after the burner has switched off due to a room thermostat

intervention.

• Frost protection device

Boilers electronic management includes a “frost protection” function in the central heating system

which operates the burner to reach a heating flow temperature of 30°C when the system heating

flow temperature drops below 5 °C.
This function is enabled as long as the boiler is connected to the a.c. power and gas supplies and

the pressure in the system is as specified.

• Pump-blocking prevention

In case there is no call for heat either from the central heating system or from the DHW system

for 24 hours on end the pump will automatically switch on for 10 seconds.

• Hydraulic pressure sensor

This device enables the main burner only to be switched on if the system pressure is over 0.5

bar.

16. Control and operation
devices

17. Positioning of the ignition
and flame sensing electrode

Figure 15

010905_0200

29

R

To measure combustion performance and hygiene levels of combustion products, the forced draught

boiler models are equipped with two test points on the tapered coupling specifically designed for
this purpose.
One of the two test points is connected to the exhaust flue duct to allow measurements of the com­bustion products hygienic standards and combustion efficiency.
The second test point is connected to the comburant air inlet duct to check possible combustion
products circulation in case of coaxial ducts.
The exhaust flue duct test point allows measurements of the following:

• combustion products temperature;

• concentration of oxygen (O2) or, alternatively, of carbon dioxyde (CO2);

• concentration of carbon monoxyde (CO).
The comburant air temperature must be measured at the test point connected to the air inlet duct.

18. Check of combustion
parameters

Figure 16

To facilitate measurement of the combustion efficiency and improve the cleanliness of the production
products, the flue-sweeper function can be activated by proceeding as described below:

1) press the (2-3) together until the pointer “ ” appears on the display alongside the symbol
(about 3 seconds but no more than 6 seconds). In these conditions, the boiler operates at the ma­ximum heat output set for central heating.

2) press either of the buttons to exit the function

19. Activating the

chimney-sweeper function

020429_0300

gasket

combustion air

flue gas

020429_0200

Figure 17

To ensure the boiler operates at peak efficiency, the following checks must be performed every
year:

• check on the appearance and tightness of the gas and combustion circuit gaskets;

• check on the condition and position of the ignition and flame sensing electrodes (see section

17);

• check on the condition of the burner and its fixing to the aluminium flange;

• check for any dirt in the combustion chamber. Use a vacuum-cleaner for this cleaning opera­tion,

• check if the sifon is dirty;

• check that the gas valve is calibrated correctly (see section 14);

• check on the central heating system pressure.

20. Annual service

30

21. Boiler schematic

Legend:

1 boiler drain point
2 manometer
3 siphon
4 central heating NTC sensor
5 105°C overheat thermostat
6 gas valve
7 flue-water exchanger
8 flame detector electrode
9 main burner
10 ignition electrode
11 air/gas mixture header
12 mixer with venturi
13 gas diaphragm
14 fan
15 flue thermostat
16 coaxial fitting
17 automatic air vent
18 flue joint
19 hydraulic pressure sensor

Figure 18

GAS

HEATING

INLET

HEATING

RETURN

CONDENSATION

DRAIN

SEALED CHAMBER

0411_0501

FR

22. Illustrated wiring diagram

m = brown

n = black

c = blue

r = red

v = green

g/v = green/yellow

b = white

CABLES COLOURS

0411_0502

FAN

HEADER PUMP

230 V - 50 Hz

FUSE

MAIN INPUT

TERMINAL BOARD

HEATING SYSTEM

PUMP

HOT WATER PUMP

PRESSURE SWITCH

FLUE SAFETY

THERMOSTAT

SAFETY

THERMOSTAT

FLAME SENSING

ELECTRODE

GAS VALVE

CENTRAL HEATING

TEMPERATURE SENSOR

ROOM THERMOSTAT

QAA73 CONNECTION

SAFETY SHUT-DOWN

OUTSIDE SENSOR

D.H.W. THANK SENSOR

SPARK

GENERATOR

IGNITION

ELECTRODE

HYDRAULIC PRESSURE SENSOR

31

Boiler model 1.45 FF HTE 1.55 FF HTE 1.65 FF HTE
Category II2H3P

II2H3P

II2H3P

Rated heat input kW 46,4 56,7 67,0
Reduced heat input kW 15 16,0 20,0
Rated heat output 75/60°C kW 45,0 55,0 65,0

- kcal/h 38.700 47.300 55.900

Rated heat output 50/30°C kW 48,7 59,5 70,3

- kcal/h 41.880 51.170 60.460

Reduced heat output 75/60°C kW 14,5 15,5 19,3

- kcal/h 12.470 13.330 15.820

Reduced heat output 50/30°C kW 15,8 16,8 21,0

- kcal/h 13.588 14.450 18.060

Useful efficiency according to 92/42/CEE directive — ★★★★ ★★★★ ★★★★
Central heating system max. pressure bar 4 4 4

Heating circuit temperature range °C 25÷80 25÷80 25÷80

Type — C13 - C33 - C43 - C53 - C63 - C83 - B23

Concentric flue duct diameter mm 80 80 80
Concentric air duct diameter mm 125 125 125
2-pipe flue duct diameter mm 80 80 80
2-pipe air duct diameter mm 80 80 80
Max. flue mass flow rate kg/s 0,022 0,027 0,032
Min. flue mass flow rate kg/s 0,007 0,008 0,010
Max. flue temperature °C 74 78 75
NOx class — 5 5 5

Type of gas used — G20 G20 G20
— G31 G31 G31
Natural gas feeding pressure 2H mbar 20 20 20
Propane gas feeding pressure mbar 37 37 37

Power supply voltage V 230 230 230
Power supply frequency Hz 50 50 50
Rated power supply W 75 80 125

Net weight kg 64 68 72
Dimensions height mm 950 950 950
width mm 600 600 600
depth mm 466 466 466
Protection-limit against humidity and water leakages (**) IPX5D IPX5D IPX5D

(**) according to EN 60529

23. Technical data

32

157, Avenue Charles Floquet
93158 Le Blanc-Mesnil - Cedex
Téléphone : + 33 (0)1 45 91 56 00
Télécopie : + 33 (0)1 45 91 59 50
www.chappee.com

BAXI S.A. au capital de 43 214 640 €
RCS Bobigny B 602 041 675 A.P.E 282 D

3