RVR Energy Technology VICTRIX 24kW X Instruction Booklet

Page
Victrix 24kW X Instructions
Instruction Booklet
Wall Mounted Condensing boilers with hot water priority
For Technical assistance, spare parts or service call:
RVR Energy Technology Limited, Kenmare, Co. Kerry Tel: 064 41344, Fax: 064 89520
Read these instructions completely before using or installing the Victrix 24kW X gas boilers
LEAVE THESE INSTRUCTIONS WITH THE USER
VICTRIX 24kW X
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Victrix 24kW X Instructions
Introduction
Boiler Operating Instructions
The Victrix 24kW X boiler is a condensing wall hung, room sealed boiler. This boiler has the highest efficiency possible for a gas boiler, ie 4 stars (****) in conformity with European Directive 92/42 EEC. The boiler provides central heating and may also provide priority heating of the domestic hot water supply if the optional 3 way valve kit is used (RVR Stock No: ACB515). It is designed for use with a fully pumped, sealed and pressurised heating system using Natural Gas or LPG. The boiler is supplied for use with one of these gas types and must be converted before it can be used on another gas. A boiler equipped for natural gas must not be used on LPG or vice versa.
The boiler is supplied with a pump, automatic bypass, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. As supplied, the boiler will automatically modulate to provide central heating outputs between 4.7 and 26 kW .
IMPORTANT
All gas appliances must be installed by a competent and qualified person, in accordance with relevant clauses of applicable standards and recommendations. These include but may not be limited to the following:­I.S. 813 Domestic Gas Installations I.S, 820 Non-Domestic Gas Installations All relevant Building Regulations. Local Water Bye Laws IEE Wiring Regulations Health & Safety legislation
This appliance meets the requirements of IPX4D, ie degree of protection against moisture. Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with. Manufacturer's instructions must NOT be taken in anyway as over­riding statutory obligations.
1. Boiler status indicator display
2. Main Switch OFF-DHW - DHW/Central heating
3. Domestic hot water temperature selector
4. Central Heating temperature selector
5. Pressure Guage
Using the Boiler
Before lighting, make sure that the system is full of water and that the pressure guage (5) indicates a pres­sure of 1 - 1.2 bar.
-Open the gas valve on the gas supply to the boiler.
-Turn main selector (2) to Domestic Hot Water or Domestic Hot Water and Heating N.B. With the switch (2) set to the Central Heating temperature selector(4) is disabled, the domestic hot water temperature is regulated by selector (3): the display shows the Summer symbol . With the selector set to the
Central Heating temperature selector (4) is used to regulate the temperature of radiators while
selector (3) continues to be used for domestic hot water; the display shows the Winter symbol Turn the selectors clockwise to raise the temperature, anticlockwise to lower it. Boiler operation is now automatic.
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Victrix 24kW X Instructions
Rated heating power kW (kcal/h) 27.0 (23219)
Min. heating power kW (kcal/h) 5.0(4328)
Rated heat output (useful) kW (kcal/h) 26.0 (23337)
Min. heat output (useful) kW (kcal/h) 4.7 (4042)
Useful thermal efficiency 80/60 Rated/Min % 96.4 / 93.4
Useful thermal efficiency 50/30 Rated/Min % 104.9 / 105.0
Useful thermal efficiency 40/30 Rated/Min % 106.0 / 105.7
Heat loss at shell with burner Off/On (80-60ºC) % 0.05 / 1.8
Heat loss at flue with burner Off/On (80-60ºC) % 0.15 / 2.0
G20
G30 G31
Gas nuzzle diameter Mm 5.30
3.85 3.85
Supply pressure Mbar (mm H2 0) 29 (204)
29 (296) 37 (377)
Max working pressure heating circuit Bar 3
Max. working temperature heating circuit °C 90
Adjustable heating temperature Pos 1 °C 25-85
Adjustable heating temperature Pos 2 °C 25-45
Total volume heating expansion tank 1 5.7
Heating expansion tank precharge Bar 1.0
Generator water capacity 1 3.4
Head available with flow rate 1000/h kPa (m H2 0) 30.40 (3.1)
* Specific range “D” UB Immergas 80 litre (∆T 30ºC) in accordance with EN 625 1/min 20.2
* Specific range “D” UB Immergas 105 litre (∆T 30ºC) in accordance with EN 625 1/min 22.0
* Specific range “D” UB Immergas 120 litre (∆T 30ºC) in accordance with EN 625 1/min 25.3
* Specific range “D” UB Immergas 200 litre (∆T 30ºC) in accordance with EN 625 1/min 35.9
Drawing capacity with UB Immergas (∆T 30ºC) 1/min 12.8
Weight of boiler full kg 45
Weight of boiler empty kg 48.3
Electricity connection V/Hz 230/50
Rated absorption A 0.60
Installed electrical power W 130
Power absorbed by circulation pump W 78
Power absorbed by fan W 23
Equipment electrical system protection - IPX4D
G20
G30 G31
Mass flow of fumes at rated power Kg/h 40
35 40
Mass flow of fumes at min. power Kg/h 8
7 8
CO2 at Q. Rated/Min. % 9.35/8.9
12.25/11.9 10.45/10.2
CO with 0% O2 at Q. Rated/Min ppm 195/5
575/7 180/5
NOX with 0% O2 at Q. Rated/Min ppm 20/9
80/27 20/15
Temperature of fumes at rated output (50/30) °C 54
60 55
Temperature of fumes at rated output (50/30)
°C
47
52 48
Max. temperature of exhaust gas
°C
75
NOx class
-
5
NOx weighted
mg/kWh
37
CO weighted
mg/kWh
58
Type of appliance
B23 / B33 / C13 / C33 / C43 / C53 / C83
Category
II2H3+
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Victrix 24kW X Instructions
Dimensions – Victrix 24kW X
Key V - Electrical connection G - Gas supply RU - Cylinder return (optional) MU - Cylinder flow (optional) RR - System filling SC - Condensate drain (min internal diameter ø 13mm) R - System return M - System delivery
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Victrix 24kW X Instructions
Main Boiler Components
1. Electrical connection board (very low voltage)
10. Burner 19. Electrodes
2. System drain cock 11. Flue Overheat Stat 20. Delivery sensor
3. Condensation drain air trap 12. Detection Electrode 21. Safety thermostat
4. Gas valve 13. Air intake pipe 22. Air valve
5. Voltage transformer 14. Negative signal pressure point 23. Boiler circulating pump
6. Fan 15. Positive signal pressure point 24. System pressure switch
7. Gas nozzle 16. Intake points (air A) - (funes F) 25. Automatic by-pass
8. Expansion tank 17. Flue extractor hood 26. 3 bar safety valve
9. Venturi 18. Condensing module 27. System filler cock
N.B.: connection assembly (optional)
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Victrix 24kW X Instructions
General Installation Information
Gas Supply
The meter and supply pipes must be sized to deliver the gas rate and pressure given on page 3. The boiler requires at least a 22 mm (3/4”) gas supply pipe. The complete installation, including the meter, must be tested for gas soundness and purged as described in IS 813:2002.
The boiler requires a 220/240 V ~ 50 Hz mains supply, fused at 3 A. The boiler must be earthed. The polarity
of the supply must be correct as otherwise the boiler will not operate.
There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls. Using PVC insulated cable not less than 0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16, the boiler should be connected to a fused three pin plug and unswitched shuttered socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of at least 3 mm in both poles. Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations.
Note: External controls connected to the boiler must be of the volt free type and are connected to terminals 40 and 41 as shown above.
DHW Sensor
If the boiler’s hot water priority feature is to be used, then the optional DHW sensor must be mounted on the hot water heating tank and connected to terminals 36 and 37. If this cable is routed in close proximity to cables carry­ing mains voltages, then screened cable should be used. The resistor connected to terminals 36 and 37 to be re­moved in this case.
Weather Compensation:
A temperature sensor for outdoors is available as an optional accessory for the boiler. This should be fitted in an outdoor location which is not exposed to direct sunlight. A north facing wall is a good location. If the optional weather compensation sensor is used, it should be connected to terminals 38 and 39 as shown above using a two core cable. If this cable is routed in close proximity to cables carrying mains voltages, then screened cable should be used. Contact RVR for more information. When the sensor is connected, the boiler adapts it’s flow temperature to suit the prevailing weather conditions. This results in lower energy usage and enhanced comfort.
Warning! - Connection of a voltage to any boiler terminals other than the mains lead will result in destruc­tion of the boiler control panel. The product warranty does not cover this type of damage.
Clearances and Air Supply
The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cup­board or compartment. The minimum clearances for servicing must always be maintained. Please see table on page 3. Note: A cupboard or compartment used to enclose the boiler must be designed and constructed specifi­cally for the purpose.
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Victrix 24kW X Instructions
Flue Systems
Horizontal intake kits—exhaust ø 60 /100
Install the bend with flange (2) on the central hole of the boiler inserting the seal (1) with the round protrusions facing downwards in contact with boiler flange and tighten using the screws supplied with the kit. Fit the smooth male end of the 60/100 concentric terminal pipe (3) until it reaches to the stop on the female end of the bend (2), making sure the internal and external sealing rings are fitted; this will en­sure the connection is properly sealed. Additional exten­sions and bends may be installed if required using the same method. Ensure that all seals are fitted and that the outer and inner pipes are installed so that all joints are perfectly sealed. Ensure that the terminal is installed the right way up.
A lubricant may assist in overcoming the friction of the seals. Oils and conventional greases are not compatible with the EPDM seals used and should never be used for this pur­pose. Silicone sprays are compatible with EPDM and may be used. Please contact RVR for more information.
A supporting clamp should be installed every three meters. The flue system should be slightly inclined so that any condensate flows towards the boiler. This avoids any drips from the external flue terminal.
The maximum possible overall length after the first bend (2) is 12.9 straight and horizontal meters. See the section on extended flue design for more information
Vertical kit with aluminium tile ø 60 /100
Install the concentric flange (2) on the central hole of the boiler insert­ing the seal (1) with the round protrusions facing downwards in con­tact with boiler flange and tighten using the screws supplied with the kit. Fit the male end (smooth) of the adapter (3) in the female end of the concentric flange (2) until it reaches the stop on the female end of the flange, making sure the internal and external sealing rings are fitted; this will ensure the connection is properly sealed. Additional exten­sions and bends may be installed if required using the same method. Installing the flashing- Replace tiles with the aluminium sheet (5), shaping it to ensure that the rainwater runs off. Position the fixed half­shell (7) on the aluminium tile and insert the intake/exhaust pipe (6). Fit the male end (6) (smooth) of the 60/100 concentric terminal up to the stop on the female end of the adapter(3), making sure that the ring (4) is already fitted; this will ensure hold and joining of the elements making up the kit. Ensure that all seals are fitted and that the outer and inner pipes are installed so that all joints are perfectly sealed. A lubricant may assist in overcoming the friction of the seals. Oils and conventional greases are not compatible with the EPDM seals used and should never be used for this pur­pose. Silicone sprays are compatible with EPDM and may be used. Please contact RVR for more information.
NB: If the terminal or extension pipes need shortening ensure that the inner pipe protrudes by 5mm with respect to the external pipe.
When the boiler is installed on an external wall, the standard horizontal concentric 60/100 flue kit will normally be used to flue the boiler. This is shown in the diagram.
It is often necessary to install a longer flue system to cater for site conditions. There are several different flue system sizes available for the Victrix 24kW boiler.
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Victrix 24kW X Instructions
Separated Flue Systems
Separated 80/80 flue kit
This kit enables separation of the exhaust and air intake pipes as shown in the figure. Combustion products are expelled from pipe (A) (in plastic material resistant to acidic condensates). Air is taken in through pipe (B) (also in plastic material) for combustion. Intake pipe (B) can be installed either on the right or left hand side of the central exhaust pipe (B). Both pipes can be oriented in any direction.
Assembly:
Install the flange (4) on the central hole of the boiler in­serting the seal (1), positioning it with the round protru­sions downwards in contact with the boiler flange and tighten using the screws supplied with the kit. Remove the sealing plate from the air intake and re­place it with flange (3) inserting seal (2) which is already fitted on the boiler and tighten using the screws supplied. Insert bends (5) with the male end (smooth) in the fe­male end of the flanges (3 & 4). Fit the male end of the intake terminal (6) up to the stop on the female end of the bend (5), making sure that the relevant internal and external sealing rings are fitted. Fit the male of the ex­haust pipe up to the stop on the female end of the bend, making sure that the internal sealing ring is fitted; this will ensure a seal and joining of the elements making up the kit.
A lubricant may assist in overcoming the friction of the seals. Oils and conventional greases are not compatible with the EPDM seals used and should never be used for this purpose. Silicone sprays are compatible with EPDM and may be used. Please contact RVR for more information. A supporting clamp should be installed every three meters. The flue system should be slightly inclined so that any condensate flows towards the boiler. This avoids any drips from the external flue terminal.
The maximum possible overall length without any bends is 36 straight, horizontal meters or 41 straight, vertical meters regardless of whether they are used in intake or exhaust. See the section on extended flue design for more information.
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Victrix 24kW X Instructions
Each component of the air inlet/flue system has a resistance factor . These are given in the following tables. The resistance factor varies depending on whether the component in question conveys fresh inlet air or hot combustion gases. All boilers have a maximum resistance factor of 100. The sum of all components in the flue system must not exceed the maximum overall resistance factor of 100.
Flue calculations for more complex systems
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Victrix 24kW X Instructions
Example:
Flue system consists of 9m of 80mm air intake pipe with 3 x 90 bends and 6m of exhaust pipe with 2 x 90 bends. Component Resistances:
Component Resistance Quantity Total
80mm Intake pipe 0.87 9 7.83
90˚ air intake bend 1.9 3 5.7
80mm Flue pipe 1.2 6 7.2
90˚ Flue bend 2.6 2 5.2
25.93
Total Flue Resistance
In this case the total resistance of the system is less than 100. The flue de­sign is acceptable. Care should be taken to insulate the exhaust flue pipe to ensure that condensation is not pos­sible.
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Victrix 24kW X Instructions
Terminal Position Min. Distance
A Directly below an opening, air brick, windows, etc. B Below gutters, soil pipes or drain pipes C Below eaves D Below balconies or car port roof E From a vertical drain pipe of soil pipe F From an internal or external corner G Above ground, roof or balcony level H From a surface facing the terminal I From a terminal facing a terminal J From an opening in the car port (door, window) into dwelling K Vertically from a terminal on the same wall L Horizontally from a terminal on the same wall M Horizontally from an opening, air brick, window etc. Below horizontally hinged windows where exhaust is directed upwards Below horizontally hinged windows where exhaust is not directed upwards
300 mm
75mm 75mm 75mm 75mm
75mm 300mm 600mm
1200mm 1200mm 1500mm
300mm 300mm
3000mm 1000mm
The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times. In certain weather conditions the terminal may emit a plume of steam. Avoid position­ing the terminal where this may cause a nuisance. If the terminal is fitted within 850 mm of a plastic or painted gutter or 450 mm of painted eaves or 300 mm of a plastic car port roof, an aluminium shield at least 1 m long should be fitted to the underside of the gutter or painted surface. If the terminal is fitted less than 2 m above a surface to which people have access, the terminal must be protected by a terminal guard.
IMPORTANT— Failure to install flue systems correctly may lead to serious injury or death. Ensure that:
Only flues specifically designed for condensing boilers and provided by RVR Energy Technology Limited are used.
The flue slopes slightly towards the boiler by between 1 and 2 degrees to ensure any condensate flows towards the boiler. Failure to do this will result in condensate dripping from the flue terminal.
The flue is adequately supported along it’s length so that it is straight and cannot be moved without using a tool.
The flue system has no low points where condensate can collect.
All flue terminals are securely fixed.
No chemicals, detergents, solvents or liquids of any kind are used in the assembly of the flue system.
Talc may be used as a lubricant where necessary.
All joints and connections are properly assembled to prevent leakage and all seals are properly seated.
The flue is thoroughly tested for leaks after installation.
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Victrix 24kW X Instructions
Boiler Location
The boiler is not suitable for external installation. The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier.
The boiler may be installed in any room or internal space, although particular attention is drawn to the re­quirements of the current IEE Wiring Regulations. Where a room sealed boiler is installed in a room con­taining a bath or shower, it must not be possible for a person using the bath or shower to touch any electri­cal switch or boiler control utilising mains electricity. The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that pur­pose.
NB: Adequate clearances are required to allow servicing of the boiler. Please see page 3.
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Victrix 24kW X Instructions
Central Heating System
The boiler is designed for use in a sealed central heating system. The system should be designed to operate with flow temperatures of up to 80°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must be taken into account. The pressure losses in the system must be compatible with the boiler circulation pump. See pump performance graph below
A. Head available to the system at third speed (with by-pass off) B. Head available to the system at second speed (with by-pass on)
System volume - The 8 litre expansion vessel incorporated into the boiler is pre-charged to 1.0 bar and is suitable for a sealed heating system with a maximum water content of 80 litres (18 gal). Above 80 litres, consideration should be given to fitting an additional expansion vessel fitted in the position shown on the schematic below. To check correct operation of the expansion vessel(s) the system pressure should not be more than 2.5 bar when the system is at maximum operating temperature.
The boiler is supplied with the following components built in:­Central Heating Pressure relief valve - complying with BS 6759 and set to operate at 3 bar. The dis­charge pipe must be routed clear of the boiler to a drain, so that it can be seen, but cannot cause injury to persons or property. A Pressure gauge is included to indicate the pressure of the central heating system.
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Victrix 24kW X Instructions
The boiler has two sets of flow/return connections. One set is used for connection to the central system while the other set is connected to the coil of the domestic hot water heating tank. The boiler incorporates a diverter valve which diverts all flow to heat the DHW tank when the temperature of the hot water tank is below the temperature set on the boiler. The optional 3 way valve kit ACB515 and the sensor must be fit­ted to the tank in order for this feature to work.
Alternatively, if hot water priority operation is not required, the boiler may be plumbed as shown below. In this type of installation, the DHW flow and return connections should be capped or connected to each other. If a hot water heating tank is connected as shown below, then it will not be possible to use the boiler’s weather compensation feature as the boiler flow temperature may not be sufficient to heat the hot water tank adequately. The hot water only position on the boiler is not in use for this configuration.
Filling the central heating system
The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head of
10.2 metres of water. Provision should be made to replace water lost from the system. This can be by manual or automatic means.
Filling of the system must be carried out in a manner approved by the local authority. Where allowed, the system may be filled via a temporary connection as shown below or by using the integrated filling valve in the boiler. After filling, always disconnect the flexible hose of the filling loop if used and close the filling valve in the boiler.
All fittings used in the system must be able to withstand pressures up to 3 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained. The heating system should be thoroughly flushed before the boiler is connected and again after the first heating. If it is necessary to add inhibitor to the central heating system, contact RVR Ltd. for guidance.
24 kW X
24 kW X
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Victrix 24kW X Instructions
Operation and Maintenance Instructions
An annual maintenance of the boiler and heating system is recommended. This ensures that the optimal safety, performance and operation characteristics of the boiler remain unchanged over time.
Warnings
Never expose the wall-mounted boiler to direct vapours from a cooking surface. Use of the boiler by un­skilled persons or children is strictly prohibited. Never touch the flue extraction terminal (if fitted) due to the risk of burning caused by high temperatures; For safety purposes, check that the concentric air intake/flue exhaust terminal (if fitted), is not blocked. If temporary shutdown of the boiler is required, proceed as follows: a) drain the heating system if anti-freeze is not used; b) shut off all electrical, water and gas supplies. When building or renovation work is carried out in the vicinity of the flue outlet, switch off the boiler and on completion of work ensure that a qualified technician checks the safety of the installation. Never clean the appliance or connected parts with flammable substances. Never leave containers or flammable substances in the same environment as the appliance.
Electrical Safety
- never touch the appliance with wet hands or other parts of the body and never touch when barefoot.
- never pull electrical cables or leave the appliance exposed to atmospheric agents (rain, sunlight, etc.);
- the appliance power supply cable must never be replaced by the user;
- in the event of damage to the cable, switch off the appliance and contact a qualified service technician.
- in the event of prolonged periods when the boiler is not in use, turn off the main power switch.
1. Boiler status indicator display
2. Stand by—Domestic/Remote control— Domestic and Heating—Reset Selector
3. Domestic hot water temperature selector
4. Heating temperature selector
5. Boiler manometer
Using the Boiler
Before lighting, make sure that the system is full of water and that the manometer (5) indicates a pressure of 1 - 1.2 bar.
-Open the gas valve on the gas supply to the boiler.
-Turn main selector (2) to Domestic/Remote Friend Control or Domestic and Heating N.B. With the switch (2) set to the heating adjustment selector (4) is cut out, the domestic hot water temperature is regulated by selector (3): the display shows the Summer symbol . With the selector set to the heating adjustment selector (4) is used to regulate the temperature of radiators while selector (3) continues to be used for domestic hot water; the display shows the Winter symbol Turn the selectors clockwise to raise the temperature, anticlockwise to lower it. Boiler operation is now automatic.
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Victrix 24kW X Instructions
Operation and Maintenance Instructions
Description
Symbol
Key to control panel display symbols
Figures to indicate temperature, any error codes or optional external temperature sensor correlation factor
Degrees symbol
External sensor connection symbol (Optional)
Symbol of connection to Remote Fiend Control device (Optional)
Summer symbol (domestic hot water production only)
Winter symbol (domestic hot water production and room heating)
Domestic hot water production
Room heating phase on symbol
Flue cleaning function symbol
Malfunction symbol (combined with error code)
Flame present symbol
Burner output scale symbol
Fault and anomaly signalling. The Victrix 24 kW boiler indicates any malfunctions using a code shown on the boiler display (1). In case of malfunction or anomaly the problem is indicated by flashing of the symbol and light-up of the relative error code:
Anomaly signalled Error Code
Ignition Fault 01
Safety thermostat block (over temperature), ex­haust thermostat or flame control anomaly
02
Delivery sensor anomaly 05
Domestic sensor anomaly 06
Reset selector broken 08
Calibration function on (displayed on RFC) 09
System pressure too low 10
Fan anomaly 16
Insufficient circulation 27
Remote control communication loss 31
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Victrix 24kW X Instructions
Annual maintenance procedures
The following checks and maintenance should be performed at least once a year.
- Clean the flue side of the heat exchanger.
- Clean the main burner.
- Make a visual inspection of the flue extraction hood for wear or corrosion.
- Ensure correct ignition and operation.
- Ensure correct settings of the burner in domestic water and heating modes.
- Verify correct operation and adjustment of the boiler, in particular:
- operation of the electrical main switch on the boiler;
- operation of the system control thermostat;
- operation of the domestic water control thermostat or sensor.
- Ensure gas soundness of the gas intake circuit; insert a “U” or digital type pressure gauge in the pres­sure test point upstream of the gas valve and then close the boiler shutoff valve. No pressure variation must occur in the next five minutes on the gauge.
- Ensure activation of the device for protection against the ionisation flame control gas; activation time must be less than ten seconds
- Visually inspect to check for leakage of water or oxidation of fittings.
- Check visually that the water safety valve outlets are not blocked and that the tundish is clear.
- Check that the charge of the expansion vessel after discharging system pressure to the zero setting (check via boiler pressure gauge) is at 1,0 bar.
- Check that the system static pressure (in cold conditions and after system recharging via the filling valve) is between 1 and 1.2 bar.
- Check visually that the safety and control devices have not been tampered with and/or shorted, in particular:
- temperature safety thermostat;
- air pressure switch.
- Ensure correct maintenance and condition of the electrical installation with particular reference to:
-electrical cables must be correctly routed
-no traces of black marking or burns
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Victrix 24kW X Instructions
Variable Heat Output:
Victrix 24kW X
Page 19
Victrix 24kW X Instructions
Victrix 24kW X Wiring Diagram:
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