Ferroli Rendimax 23 CE, Rendimax 30 CE, Rendimax 36 CE, Rendimax 16 CE Installation And Operating Instructions Manual

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RENDIMAX CERENDIMAX CE

RENDIMAX CE

CAST IRON GAS-FIRED BOILERCAST IRON GAS-FIRED BOILER

CAST IRON GAS-FIRED BOILER

for central heatingfor central heating

for central heating

Installation and operating instructionsInstallation and operating instructions

Installation and operating instructions

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Contents

1. Description

2. Dimensions and technical specifications

3. Installation

4. Adjustment

5. Gas conversion

6. Maintenance and cleaning

7. Troubleshooting

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Fig. 1

Version "P.V."Version "BASE"

850

284

590

660

510

590

660

1. DESCRIPTION

1.01 Introduction RENDIMAX CE boilers are heat generators for central heating and domestic hot water production.

The standard version is designed to work with natural gas. To use the boiler with L.P.G., on-site conversion must be carried out following the instructions given below. This conversion must be done by our local Customer Technical Service Center.

2. Dimensions and technical specifications

2.01 Dimensions

KEY 1 C.H. flow inlet

2 C.H. flow outlet 3 1/2" gas inlet 4 Safety valve (only PV vers) 5 Expansion vessel (only PV vers)

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112

8 6

Fig. 2

2.02 Components description

View with open door

KEY

1 Boiler thermostat 2 Boiler temperature / pressure gauge 3 Safety valve 4 Gas valve 5 Circulation pump (only PV version) 6 Boiler drain cock 7 Pilot burner 8 Piezo-Igniter

9 Gas-Manifold 10 Boiler main switch 11 Filling cock 12 Cock 13 Flue thermostat

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Heat output Heat rate

Boiler

Rated Adjiustable up to: Min.Rated

Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE

16,2 23,0 29,5 36,0

kcal/hr

14.000

19.800

25.400

31.000

11,0 16,0 20,0 24,0

kcal/hr

9.500

13.800

17.200

20.600

Section

nr.

3 4 5 6

12,7 18,4 23,0 27,6

kcal/hr

11.000

15.800

19.800

23.800

kcal/hr

15.500

22.000

28.200

34.400

18,0 25,5 32,8 40,0

Natural gas

Boiler

Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE

Nozzle

nr.

2 3 4 5

L.P.G.

Ø Main

burner

2,45 2,35 2,35 2,35

Ø Pilot burner

0,35 0,35 0,35 0,35

Rated

gas

pressure

mbar

13,0 15,2 14,2 13,5

Ø Main

burner

1,55 1,50 1,50 1,50

Ø Pilot burner

0,225 0,225 0,225 0,225

Rated

gas

pressure

mbar

35 35 35 35

Boiler weight

vers.

80 94

112

BASE

vers.

84 102 126

Connections

Boiler

Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE

400 400 500 600

57 62 72 82

33 33 33 58

100 110 130 150

63 25 36 50

73 35 46

515 515 515 525

mm 635

635 635

615 615 615 625

Return

1" 1" 1" 1"

Flow

1" 1" 1" 1"

Gas inlet

1/2" 1/2" 1/2" 3/4"

Max working pressure

bar

4 4 4 4

Boiler water

content

lt.

7,3

9,0 10,7 12,4

Expans.

vessel

vol.

6 6 8

lt.

Boiler

Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE

Rated

1,94 2,70 3,47 4,23

Min. 1,16

1,69 2,46 2,95

Gas flow rate at the

burner for L.P.G. kg/hr

Rated

1,50 2,08 2,68 3,27

Min. 0,90

1,31 1,63 1,96

Gas flow rate at the

burner for N.G. m /hr

Connection dimentions

*Only P.V. version*Only P.V. version

*Only P.V. version

3. INSTALLATION

Installation must be carried out by specialist companies only in accordance with all instructions and current regulations. You are advised to include gate valves between the boiler and the C.H. system so that the boiler can be isolated from the system if necessary.

Notes: If the path followed by the C.H. flow outlet and return inlet pipes is such as to allow for the formation of air pockets at certain points, you are recommended to fit an air valve at these points.

The diameter of the flue connection pipe must not be less than that of the coupling on the draft diverter. From the draft diverter, it must have a vertical section of not less than one and a half meters. When sizing and installing flues and the flue connecting pipe, current regulations must be respected.

If the fuel duct pass through flammable wall it has been well insulated.

2.03 Technical data (Max. working temperature 100

°C)

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230V 50Hz

114

160

142

324357968 1513

11 12 1614

160114

230V 50Hz

Fig. 3

Connection between boiler and chimney has to be sealed.

The rated flow rate of gas counter has to be sufficient for the whole connected appliance.

Be careful that the boilers connections are free of mechanical tensions.

Connect the gas using a rigid pipe and including a gas cock.

The boiler must be connected to a 230 Volt - 50 Hz single phase line (phase/neutral) by means of terminal board of approved socket. A 5 A max. fuse should be included between the boiler and line. It is important to ensure that the boiler is connected to an efficient earth system. The terminal board for connecting the boiler to the room thermostat (if used) is inside the control panel (follow the electrical wiring diagram fig. 3).

3.01 Electrical connection

The electrical connections has be carried out according the following electrical schema. If the boiler is installed below the level of the C.H. system, you are recommended to install a sensor against the water absence.

NB: The manufacturer declines all responsibility for damage to persons or things deriving from

poor earthling of the appliance.

DIAGRAM OF ELECTRICAL CONNECTION

Key

23 Thermocouple 32 C.H. pump (if fitted)

44 Gas valve coil

49 Safety thermostat 63 Boiler thermostat

BASIC ELECTRICAL WIRING DIAGRAM

92 Flue gas thermostat

98 Main switch 114 Water pressure switch (not fitted) 160 Auxiliary contact

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Fig. 4

3.02 Checking and controlling the evacuation of combustion products (total security)

The boiler is fitted with a FLUE GAS THERMOSTAT . This thermostat prevents gas from reaching the burner if the flue is not drawing properly, providing greater security and control over the discharge of combustion products. If the FLUE GAS THERMOSTAT is activated, unscrew the protective cover on the control panel (Fig. 2 part. 13) and “reset” the thermostat manually. The boiler will then operate normally again. If you replace the FLUE GAS THERMOSTAT, use original components only and make sure the electrical connections are carried out correctly. NEVER EXCLUDE THE FLUE GAS THERMOSTAT FROM THE ELECTRICAL CIRCUIT. If it keeps activating, contact qualified personnel only.

3.03 Pressure drop in relation to C.H. water flow rate (fig. 4)

Fig. 5a

3.04 Pump characteristics (only P.V. version) 1,2,3,=position of the built-in pump speed selector knob (fig. 5a)

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Fig. 5b

3.05 C.H. pump head characteristics (only P.V. version)(Fig. 5b)

NB - The diagram refers to maximum pump (Pos. 3) head/flow rate.

4. IGNITION AND SHUT-DOWN

4.01 Checks to carry out before igniting for the first time

When igniting the boiler for the first time, it is good practice to check:

- that the gate valves between the boiler and system are open;

- that the system is correctly filled and vented;

- that there are no gas or water leaks from the system or boiler;

- that the electrical connections are correct and the earth wire has been connected to an efficient earth installation;

- that there are no inflammable liquids or materials near the boiler;

- that the flue is free from obstructions.

4.02 Igniting the boiler with ELETTROSIT gas valve(fig. 6)

Position the boiler thermostat on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos1. Push down gas valve button 2 and hold it down. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler.

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HONEYWELL V4600C GAS VALVEHONEYWELL V4600C GAS VALVE

HONEYWELL V4600C GAS VALVE

Keep gas valve button 2 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Set the button 3 as shown in the fig. 3 Turn on the electricity to the boiler. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).

ELETTROSIT GAS VALVE

fig. 6

Key

1 Downstream pressure test point 2 Ignition/shut down button 3 Key for ignition 4 Shut down button 5 Upstream pressure test point 6 Pilot adjustment screw 7 Main burner adjustment screw

8 Slow opening adjustment screw

4.03 Igniting the boiler with HONEYWELL V4600C gas valve(fig 7a)

Position the boiler thermostat 1 (fig. 2) on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos 3. Turn on the electricity to the boiler. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler. Keep gas valve button 1 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).

fig. 7a

Key

1 Ignition/shut down button 2 Pilot adjustment screw 3 Downstream pressure test point 4 Upstream pressure test point 7 Main burner adjustment screw

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IgniteIgnite

Ignite

pilotpilot

pilot

burnerburner

burner

IgniteIgnite

Ignite

mainmain

main

burnerburner

burner

Shuth-downShuth-down

Shuth-down

completelycompletely

completely

the boilerthe boiler

the boiler

SIT NOVA 820 GAS VALVE

4.04 Igniting the boiler with SIT NOVA gas valve(fig 7b)

Position the boiler thermostat 1 (fig. 2) on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos4. (fig 7b) Push and keep pushed the knob in the position “a”. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler. Keep gas valve button 1 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Turn the knob in the position “b”. Turn on the electricity to the boiler. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).

fig. 7b

Key

1 Command knob 2 Main burner adjustment screw 3 Pilot adjustment screw 4 Inlet gas adjustment screw 5 Upstream pressure test point

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4.05 Temporary shut-down

To temporarily shut down the boiler, just position the main switch 6 on the “0” position.All the electrical part remain not energized and only the pilot burner remain alight.

4.06 Prolonged shut-down

Push the button 4 (fig 6), turn clockwise the knob 1 (fig 7a) or turn the knob 1 in the position “C” (Fig. 7b). By measn this operations the gas connection to main burner and pilot is cut out. Close the gas cock upstream from the boiler and turn off the electricity supply to the boiler. Note: If the boiler is not used for long periods in the winter, to avoid frost damage, either add antifreeze

to the system or drain completely.

4.07 Post ignition checks and controls

On igniting the boiler for the first time: Check there are no gas or water leaks. Check that pilot flame is well regulated eventually it can be adjusted by means of adjustment screw on the gas valve (fig 6 ,7a, 7b). Check the boiler ignites properly by using the regulating thermostat to ignite and shut down the boiler. Check flue efficiency during boiler operation. Check that the fuel consumption indicated on the meter corresponds to the value indicated in the table. Check that water circulates correctly between the boiler and system. Check that flue connection between boiler and chimney is properly sealed.

IMPORTANT: The pilot burner inspection hatch must remain closed during normal boiler operation.

4.08 Gas consumption

The rated gas flow is shown on the technical-table at pag. 6. To get the rated gas-flow the gas pressure has to be adjusted according the technical data sheet. Gas pressure calibration can be carried out bymeans of proper screw (fig 6,7a,7b) After the gas adjustment the consumption can be verified by means of gas-meter after at least 5 min. operation at full output. Further small adjustment can be carried on the gas adjustment screw (fig 6,7a,7b).

5. Gas conversion

The following adjustment and conversion operations must be carried out by qualified personnel only. s sAs standard the boilers are calibrated for N.G.

5.01 From N.G. to L.P.G.

To convert from N.G. to L.P.G., replace the main and pilot burner nozzles then adjust main burner pressure to ensure that nozzle pressure is as indicated for L.P.G. Note: Nozzle diameters and main burner pressures are given in technical data tables.

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5.02 Check and gas pressure regulation

Gas Valve ELETTROSIT

The regulation of gas pressure at the pilot burner has to be done at sight, without instrument but checking the that flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate as follow: To decrease the gas flow rate rotate clockwise the screw PILOT ADJ . To increase the gas flow rate rotate anticlockwise the screw PILOT ADJ. To adjust the pressure at main burner, remove the protection cap and rotate the screw REG. ADJ (fig.

6) clockwise to increase the pressure and anticlockwise to decrease.

ATTENTION:The pressure measured at point 1 and 5 (fig. 5) has be read after 30 second and after the pressure adjustment.

5.03 Adjusting min. flow on slow-opening for N.G.

Gas Valve ELETTROSIT

5.03.1 System nr.1

loosen completely the screw “REG ADJ” (fig. 6) Operate the screw “1 STEP ADJ” (fig 6) until the main burner light-on gradually and noiseless. Adjust the screw “1 STEP ADJ” until the gas pressure is the right one. Seal the screws “1 STEP ADJ” and “REG ADJ”.

5.03.2 System nr.2

(In the even the screw “REG ADJ” is already adjusted and sealed. Tighten the screw “1 STEP ADJ” (fig. 6) Operate the screw “1 STEP ADJ” (fig 6) each time for 1/4 anticlockwise. After rotation switch over the “Pilot” position by means of button 2 (fig. 6). After 30-60 sec switch over again on “Operation” position by means the button nr. 3 (fig. 6). Repeat the previous operations until the main burner light on gradually and noiseless and than seal the screw “1 STEP ADJ”.

5.04 Adjusting min. gas flow on slow-opening for L.P.G.

Gas Valve ELETTROSIT Take out the protection cap and check that the screw “NO PR” (fig. 6) is rotate clockwise completely. Adjust the screw “REG ADJ” until the main burner gas pressure is 12 mbar. Loosen the screw “NO PR” (fig. 6) Adjust the min. gas flow on slow-opening as described on par. 5.03.02 (System nr. 2). Loosen the screw “PILOT ADJ” (fig. 6). Seal the screws “1STEP ADJ” , “REG ADJ”.and “PILOT ADJ”.

ATTENTION:The screw “NO PR” has not to remain on intermediate position.It has to be completely tighten with N.G.and loosen with L.P.G.

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Fig. 8

5.05 Check and gas pressure regulation

Gas Valve “HONEYWELL V4600C” The regulation of gas pressure at the pilot burner has to be done at sight , without instrument but

checking the flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate on the screw 2 (fig. 7a). To adjust the pressure at main burner, operate on the screw 7 (fig. 7a). Rotate clockwise to increase gas flow and pressure, anticlockwise to decrease gas flow and pressure. To convert from N.G. to L.P.G. replace the pilot and main nozzles, tighten completely the screw 7 (fig. 7a) and adjust the gas flow-pressure.

N.B.Complete conversion kits for various gas are supplied separately (on request).

5.06 Check and gas pressure regulation

Gas Valve “SIT 820 NOVA” The regulation of gas pressure at the pilot burner has to be done at sight , without instrument but

checking the flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate on the screw 3 (fig. 7b). To adjust the pressure at main burner,operate on the screw 2 (fig. 7b). Rotate clockwise to increase gas flow and pressure, anticlockwise to decrease gas flow and pressure. To convert from N.G. to L.P.G.replace the pilot and main nozzles, tighten completely the screw 2 (fig. 7a) and adjust the gas flow-pressure.

N.B. Complete conversion kits for various gas are supplied separately (on request).

5.07 Replacing the main and pilot nozzles

To replace the main and pilot burner nozzles, proceed as follows: Turn off the gas and electricity supply upstream of the boiler. Remove the whole gas assembly from the combustion chamber (see paragraph 6.03). Remove the pilot burner (fig. 8) Remove the main burners from the manifold. Replace the main and pilot nozzles. Check that the main nozzles gaskets are not damaged. If so replace them. Reassemble carefully. If necessary, calibrate gas pressure at the nozzles as described above. Check correct operation and that there are no gas leaks.

Pilot burner

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163115

kcal/hr x 1000

mbar

Fig. 9a

mbar

kcal/hr x 1000

2 3

Output variability with L.P.G.

5.08 Heat output variability characteristics

To adjust furnace heat input, simply regulate the main burner via the gas valve (fig. 8). This in turn varies the heat output to the C.H. water. The diagrams in Fig. 9a and 9b show the variations in heat output to the water in relation to variations in burner working pressure. The ability to adjust boiler output to actual C.H. requirements means above all reducing heat dispersion and so saving fuel. In addition, variations in output have very little effect on efficiency and combustion characteristics.

Fig. 9b

Output variability with N.G.

1 = model 16 2 = model 23 3 = model 30 4 = model 36

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IGNITIONIGNITION

IGNITION

ELECTRODEELECTRODE

ELECTRODE

THERMOCOUPLETHERMOCOUPLE

THERMOCOUPLE

6. MAINTENANCE AND CLEANING

The following operations must be carried out by qualified personnel only. The boiler requires no particular maintenance other than general control of boiler and chimney once a year.Each three years the at the end of heating season boiler burner and chimney has to be cleaned.

6.01 Seasonal control of boiler and flue

Once a year before the heating season, the following controls should be carried out:

- the burner and boiler body and chimney should be clean. To clean them, you are advised to use a soft brush or compressed air. Avoid chemical products;

- water pressure in the system (cold) should be between 0.5 and 1 bar. If not, bring it back to this value. If the system is open vessel, check the water level in the tank.

- control and safety devices (gas valve and thermostats) should be working correctly;

- the thermocouple is free from scale and the pilot flame wraps it correctly (fig. 10)

- the pumps must not be blocked;

- the system should be free of gas or water leaks;

- gas flow rate and pressure should be in line with the values given in the table;

- the complete length of the flue gas evacuation pipe (flue and flue to boiler connection pipe) should be clean and free from leaks.

6.02 Flame at pilot burner

Fig. 10

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Fig. 12

Fig. 11

6.03 Cleaning the boiler and burner

To clean the boiler and burner , proceed as follows: a) turn off the gas and the electricity supply upstream of the boiler. b) take out the boiler cover and the draft diverter cover (fig.11). c) disconnect the electric power supply cable to the valve. d) turn off the gas and the electricity supply upstream of the boiler. e) remove the four screws A (fig.12) fixing the gas input pipe to the valve. f) remove the two nuts B (fig. 12) fixing the gas assembly and combustion chamber door to the boiler. g) remove the whole gas assembly.

Now you may clean all the smoke passages in the boiler using a pipe brush 3. Remember you should check and if necessary clean the flue and its connection to the boiler. Be careful not to damage the Flue gas safety thermostat phial or capillary.

Important - Do not clean the burners with chemical or a steel brush, as these might change the airgas mixture outlet holes. When cleaning is complete, re-assemble carefully and in the correct position. The check the seal along the gas and smoke circuits, functioning of the control and safety devices and gas pressure and rate of flow.

Key

1 Fixing screw 2 Draft diverter cover 3 Cleaning brush

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7.TROUBLE SHOOTING

Pilot burner fails to ignite No gas

Open the gas cock

Air in the pipes

vent as described in the section on ignition

Pilot nozzle blocked

Clean the nozzle with compressed air

Insufficient gas flow

Adjust flow using the screw on the valve

Pilot goes out Faulty thermocouple

Control or replace the thermocouple

Incorrect flame adjustment

Adjust the flame using the screw on the gas valve

Insufficient flame

Adjust the flame until it envelopes the thermocouple as indicated in figure 12

Poor contact with the gas valve coil

Tighten the connector on the gas valve

Main burner fails to ignite No current

Restore current

Blocked nozzles

Clean the nozzles thoroughly

Faulty gas valve

Repair or replace the gas valve

Flue gas thermostat activated

Manually reset

Blowout at main burner Insufficient gas

Control gas pressure at the main burner

Boiler dirty

Check and clean the boiler

Burner dirty

Check and clean the burner

Smell of unburnt gas Boiler dirty

Check and clean the boiler body

Insufficient flue draught

Control flue draught efficiency

Insufficient air change

Improve room ventilation

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Remember: To avoid unnecessary expense, before contacting Service Departement, make sure that any boiler failure is not due to the absence of electric power or gas supply.

Incorrect flame regulation

Check flow rate at the gas meter and pressure at the main burner

Boiler functions, but temperature fails to rise Incorrect flame adjustment

Check gas consumption is normal

Boiler dirty

Check and clean the boiler body

Boiler inadequate

Check that the boiler is the right size for the C.H. system

Thermostat trips too high Thermostat bulb out of its sheath

Check the bulb is well inserted

Faulty adjustment on the panel

See section on adjustment

Condensation in boiler Faulty thermostat adjustment

Adjust the thermostat to a higher temperature

Faulty flame adjustment

Check that the main burner flame is properly adjusted

Insufficient gas consumption

Check gas consumption is correct

The boiler becomes dirty easily Faulty flame adjustment

Check the main burner flame is adjusted properly and that gas consumption is in line with boiler output

The boiler including the pilot shut down Insufficient flame

Adjust the flame until it envelopes the thermocouple as indicated in figure 12

Check the flue gas thermostat has not been activated.If so reset it manually

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37047 SAN BONIFACIO - VR - ITALY37047 SAN BONIFACIO - VR - ITALY

37047 SAN BONIFACIO - VR - ITALY tel. 045/6139411 - tlx. 480172tel. 045/6139411 - tlx. 480172

tel. 045/6139411 - tlx. 480172tel. 045/6139411 - tlx. 480172

tel. 045/6139411 - tlx. 480172 fax 045/6100233-6100933fax 045/6100233-6100933

fax 045/6100233-6100933fax 045/6100233-6100933

fax 045/6100233-6100933

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Cod. 3541098/1 12/96