Estelle HE B4 INOX ErP - Boiler SIME - Free user manual and instructions

USER MANUAL Estelle HE B4 INOX ErP SIME

ESTELLE HE B4 INOX ErP ENGLISH CONFORMITY Our Company declares that ESTELLE HE B4 INOX ErP boilers comply with the essential requirements of the following directives: - Boiler Efficiency Directive 92/42/EEC - Ecodesign Directive 2009/125/EC - Regulation (EU) N. 813/2013 - 811/2013 - Electromagnetic Compatibility Directive 2014/30/UE - Low Voltage Directive 2014/35/UE30

The new “Estelle HE B4 INOX ErP” series of cast iron boilers condens- ing, for heating and the production of domestic hot water, they use light oil and have a perfectly balanced combustion with a very high ther- mal efficiency for economical per- formance. 1 BOILER DESCRIPTION

ESTELLE HE B4 INOX ErP Output 80-60°C kW 33.0 Output 50-30°C kW 35.5 Input kW 34.8 Seasonal energy efficiency class of the heating system A Seasonal energy efficiency of the heating system % 93 D.H.W. load profile declared

KEY 1 Cast iron boiler 2 Water switch 3 Automatic air-vent 4 C.H. pump (not supplied) 5 D.H.W. pump 6 Non-return valve 7 D.H.W. safety valve 6 bar/588 kPa (not supplied) 8 Magnesium anode 9 D.H.W. drain cock 10 Boiler drain cock 11 Burner (not supplied) 12 110 litre tank 13 Air vent valve 14 C.H.safety valve 3 bar/294 kPa (not supplied) 15 D.H.W. tank expansion vessel (not supplied) 16 Hydrometer (not supplied) 17 Stainless steel condenser 18 Condensate drain tap M C.H. flow R C.H. return U D.H.W. outlet E D.C.W. inlet C Recirculation

1.4 FUNCTIONAL DIAGRAM

Fig. 21.5 COMBUSTION CHAMBER (fig. 3) The combustion chamber is of the straight flow type and complies with standard EN 303-3 appendix E. The dimensions are shown in fig. 3.

1.6 COMPATIBLE BURNERS

EN 267 In general, the oil burner that is compatible with the boiler should use spray of the semi solid type.

Section 1.6.1 shows the matching ta-

ble of the burners together with the boilers have been tested with. ATTENTION: Water heater with Nominal Power Pn ›70kW: It is possible to use burners that are not on the list but have the same characteristics, as long as they are conforming to the standard/s, re- ference techniques and suitable field of work. Water heaters with Nominal Power Pn ‹70kW: It is possible to use burners that are not on the list but have the same characteristics, as long as they are conforming to the standard/s, re- ference techniques. When choosing the burner, pay at- tention to the max electrical power absorbed by the burner at 30% of the load and in stand-by that should be the same or less that those indicated in ANNEX AA.1.

1.6.2 Burners assembly

(fig. 3/a) The boiler door details is shown in figure 3/a for burner mounting. The burners must be regulated such that the CO

value is that indicated in point 1.3, with a tolerance of ± 5%.

Rond˜/Estelle B5 Fig. 4 NOTE: Water head losses obtained with t 10°C.

1.7 WATER HEAD LOSSES (fig. 4)

Water flow (l/h) Head losses (mbar) L Volumen mm dm

The boiler room should feature all the characteristics required by standards governing liquid fuel heating systems.

2.2 BOILER ROOM DIMENSIONS

Position the boiler body on the foun- dation bed, which should be at least 10 cm high. The body should rest on a surface allowing shifting, possibly by means of sheet metal. Leave a clearance between the boiler and the wall of at least 0.60 m, and between the top of the casing and the ceiling of 1 m (0.50 m in the case of boilers with incorporated D.H.W. tank). The ceiling height of the boiler room should be less than 2.5 m.

2.3 CONNECTING UP SYSTEM

When connecting up the water sup- ply to the boiler, make sure that the specifications given in fig. 1 are observed. All connecting unions should be easy to disconnect by means of tightening rings. A closed expansion tank system must be used. ATTENTION: The installation of a by-pass or a flow switch (not sup- plied) is mandatory in the case of installations in systems with ther- mostatic valves or motorized two- way valves. The minimum flow rate of the sy- stem, which must be guaranteed, must not be lower than that shown below. Minimum system flow rate 850 (l/h) with ΔT = 35 ° C

2.3.1 Accessories (fig. 2)

To ensure boiler efficiency, and a pressure relief valve set to 3 bar/294 kPa (14) and a hydrometer to check the system pressure (16). Install a pressure relief valve cali- brated to 6 bar/588 kPa (7) on the boiler water outlet pipe to prevent the risk of bursting due to excess pressure build up. If the boiler safety valve cuts in frequently, install a 5-litre expansion vessel (15) with maximum operating pressure of 8 bar/784 kPa on the hot water circuit. The tank should be fitted with a nat- ural rubber food-grade diaphragm. The central heating circuit pump (4) can be installed at the rear of the boiler in place of the connection union 1” pos. 3 fig. 4/a.

2.3.2 Filling the water system

Before connecting the boiler, thoroughly flush the system to eliminate scale which could dam- age the appliance. Filling must be done slowly so as to allow any air bubbles to be bled off through the air valves. In closed-circuit heating systems, the cold water filling pressure and the pre-charging pressure of the expansion vessel should be no less than or equal to the height of the water head of the installation (e.g. for water head of 5 meters, the vessel pre-charging pressure and installation filling pressure should be at least 0.5 bar).

2.3.3 D.H.W. production

During the preparation of hot water, the circulating pump installed on the boiler circuit remains in operation until the boiler thermostat probe detects the pre-selected value. Once the boiler thermostat has reach the set point, and the selec- tor has been set to winter opera- tion with the room thermostat on demand, the central heating circuit pump (not supplied) can be actu- ated. All residual air in the boiler coils must be bled at the first start-up to ensure proper operation. To facilitate this operation, position the slot of the release screw on the check valve horizontally (6 fig. 2). Once the air has been bled, return the screw to its original position. Hot water for sanitary use is pre- pared by the boiler in AISI 316L stainless steel, which is fitted with a special spiral-shaped stainless steel heat exchanger, a magnesium anode to protect the boiler and an in- spection flange to simplify checking and cleaning.

2.3.4 Characteristics

of feedwater To prevent lime scale and damage to the tap water exchanger, the water supplied should have a hardness of no more than 20°F. In all cases the water used should be tested and adequate treatment devi- ces should be installed. To prevent lime scale or deposits on the primary exchanger, the water used to supply the heating circuit should must be treated in accordan- ce with UNI-CTI 8065 standards. The water used for the central heating system should be treated in the fol- lowing cases: – For extensive systems (with high contents of water). – Frequent addition of water into the system. – Should it be necessary to empty the system either partially or totally.

2.4 CONNECTING UP FLUE

The flue is of fundamental importance for the proper operation of the boiler; if not installed in compliance with the standards, starting the boiler will be difficult and there will be a consequent formation of soot, condensation and encrustation. A flue therefore must satisfy the fol- lowing requirements: – be constructed with waterproof materials and resistant to smoke 2 INSTALLATION Fig. 5 KEY 1 Drain hose 2 Condensate drain tap

temperature and condensate; – be of adequate mechanical resil- ience and of low heat conductivity; – be perfectly sealed to prevent cool- ing of the flue itself; – be as vertical as possible; the ter- minal section of the flue must be fitted with a static exhaust device that ensures constant and efficient extraction of products generated by combustion; – have a diameter that is not inferior to that of the boiler union;

to be properly sized to meet the flue gas draught/exhaust requirements necessary for regular operation of the product (EN13384-1); - a specific condensate outlet system must be installed at the bottom of the flue; - rigid pipes must be used for the connection to the flue, resistant to high temperatures, condensation, mechanical stress, sealed and insu- lated. Use material suited to the purpose, such as stainless steel.

CONDENSATION WATER TRAP (fig. 5) The drip board and its water trap must be connected to a civil drain through a pipe (ø 25) with a slope of at least 5 mm per metre to ensure drainage of condensation water. The plastic pipes normally used for civil drains are the only type of pipe which is appropriate for conveying condensation to the buil- ding’s sewer pipes.

CONNECTION (fig. 5/a) The boiler is fitted with an electricity cable, and requires a a single-phase power supply of 230V - 50Hz through the main switch protected by fuses. The room thermostat (required for enhanced room temperature con- trol) should be installed as shown in fig. 5/a. Connect the burner and sys- tem circulation pump power cables supplied. NO TE: Device must be connected to an efficient earthing system. SI ME de cli nes all responsibility for injury caused to persons due to failure to earth the boiler. Always turn off the power supply before doing any work on the elec- trical panel. Fig. 5/a KEY TS Safety stat EI Summer/Winter switch TA Room stat TB Tank stat TC Boiler stat TL Limit stat IG Main switch PB D.H.W. pump PI C.H. pump B1 Permanent Feeding Burner SIME (optional) B2 Direct Feeding Burner (not supplied) R/R2 Relay SA Power on light SPA Water pressure gauge triggered light PA Water switch OP Timer programmer (optional) TM Minimum stat NOTE: When connecting the room stat (TA) remove the bridge between terminals 20-21. When connecting the Timer Programmer (OP) remo- ve the bridge between terminals 30-31.36

THE BOILER When commissioning the boiler always make sure that: – the system has been filled with water and adequately vented; – the flow and return valves are fully open; – the flue and chimney are free from obstructions; – the electrical connections to the mains and the earthing are cor- rect; – no flammable liquids or materials are near the boiler; – check that the circulating pump is not locked.

To light the boiler proceed as fol- lows: – switch on the main switch (1); the green light turns on to indicate that the appliance is powered (3). The burner will start; – set the stat knob (7) to the desired D.H.W. temperature. The boiler pump will continue operating until the preset tem- perature has been reached. While the water is being heated, the boiler will continue automatic operation to maintain the heat- ing temperature shown on the thermometer (5) around 80°C by means of the limit stat (6); – once the water has been heated with the selector (2) set to the summer function position, the burner and the circulating pump will cease operation; when the selector (2) is set to the winter position, the system pump con- trolled by the room stat will start up. In this case, operation of the burn- er will be controlled by the boiler stat (8) at the preset temperature; – for best results, set the boiler stat knob (8) to a temperature no lower than 60°C to prevent the forma- tion of condensate. The set temperature value can be checked on the thermometer (5).

Safety stat (fig. 6) The manually reset safety stat (4) trips to switch-off the burners immediately when the boiler tem-

Fig. 6 WARNINGS – In case of failure or malfunction of the equipment, contact authorised technical staff. – For safety reasons, the User cannot access the internal parts of the appliance. All operations involving the removal of protections or otherwise the access to dan- gerous parts of the appliance must be performed by qualified personnel. – The appliance can be used by children under 8 years and by persons with redu- ced physical, sensory or mental capabilities, or lack of experience or knowledge, provided they are under supervision or after they have been given instructions concerning the safe handling of the appliance and the understanding of the dan- gers inherent to it. Never let children play with the appliance. Children without supervision must not carry out cleaning and maintenance meant to be carried out by the user.37 perature exceeds 95°C. To restart the boiler, unscrew the black cover and press the button underneath. If the problem occurs frequently, call an authorised technical assis- tance centre for the necessary checks to be carried out.

3.2.3 System filling (fig. 6)

If the orange LED (9) switches on due to the enabling of the water pressu- re switch and stops the boiler, it is possible to restart it by resetting the plant pressure to 1-1.2 bar (98-

117.6 kPa). The system pressure is

checked through the hydrometer mounted on the heating delivery tube (16 fig. 2).

3.2.4 Turning OFF boiler (fig. 6)

To turn off the boiler, cut off the volt- age by pressing the mains switch (1). Close both the gas-feed pipe tap and the water tap if the boiler remains inoperative for a long period.

3.3 REGULAR CLEANING

Maintenance of the boiler should be carried out annually by an autho- rised service engineer. Disconnect the boiler from the electrical supply before servicing or maintenance is carried out.

Smoke side boiler (fig. 7) To carry out cleaning of the smoke passages remove the screws that fix the door to the body of the boiler and with the special cleaning brush clean the internal surfaces and the smoke evacuation tube well, remov- ing any deposits. Once the mainte- nance is compled, the baffles have to be fitted onto the original posi- tions.

The shell can be completely disas- sembled for an easy maintenance of the boiler by following the numeric steps shown in fig. 9.

Herefater we outline a number of potential problems that may occur on the appliance and the relevant list of actions required. A working fault, in most cases, pro- vocates the “lock out” signal onto the control panel of the control box. When this light turns on, the burner can operate again only after the reset button has been pressed; if this has been done and a regular ignition occurs, it means the failure can be defined momentary and not dangerous. On the contrary, if the “lock out” stays, the cause of the fault, as well as the relevant action must be made according to the follow- ing chart: The burner does not ignite – Check the electric connections. – Check the regular fuel flow, the cleanness of the filters, of the nozzle and air vent from the tube. – Check the regular spark ignition and the proper function of the burner. The burner ignites regularly but the flame goes out immediately – Check the flame detection, the air calibration and the function of the appliance. Difficulty in regulating the burner and/or lack of yield – Check: the regular flow of fuel, the cleanness of the boiler, the non obstruction of the smoke duct, the real input supplied by the burner and its cleanness (dust). The boiler gets dirty easily – Check the burner regulator (smoke analysis), the fuel quan- tity, the flue obstruction and the cleanness of the air duct of the burner (dust). The boiler does not heat up – Control the cleanness of the shell, the matching, the adjustment, the burner performances, the pre- adjusted temperature, the correct function and position of the regu- lation stat. – Make sure that the boiler is suffi- ciently powerful for the appliance. Smell of unburnt products – Control the cleanness of the boiler shell and the flue, the airtight- ness of the boiler and of the flue ducts (door, combustion chamber,

Fig. 939 smoke ducts, flue, washers). – Control the quality of the fuel. Frequent intervention of the boiler shutoff valve – Control the presence of air in the system, the function of the circu- lation pumps. – Check the load pressure of the appliance, the efficiency of the expansion tanks and the valve calibration.

PROTECTION In freezing weather, make sure that the heating system continues to fun- ction and that the rooms are kept warm enough, including the room in which the boiler is installed; if this cannot be done, both the boiler and the heating system must be comple- tely emptied. Completely emptying the system also means emptying the hot water tank and the hot water heating coil.

It is mandatory that the dedicated power cable is replaced only with a spare cable ordered and connected by professionally qualified personnel. ATTENTION: Before performing any work on the boiler, make sure that the same and its components have cooled in order to prevent the risk of burns due to high temperatures.

EQUIPMENT 2012/19/UE Once it reaches the end of its operating life, the equipment MUST BE RECYCLED in line with current legislation. IT MUST NOT be disposed of together with urban waste. It can be handed over to recycling cen- tres, if there are any, or to retailers that offer this service. Recycling prevents potential damage to the environment and health. It al- lows to recover a number of recyclable materials, with considerable savings in terms of money and energy.

3.7 D.H.W. PUMP (fig. 10)

Press the button (4) briefly (about 1 second) to select the pump operating mode. The relative LEDs will indicate each time the adjustment mode (2) and the characteristic curves set (3). Point 3.7.4 reports the possible com- binations and their meaning. When the LED (1) signals a fault, the pump stops and attempts to run re- start cycles. If the fault is solved, the pump restarts automatically.

3.7.1 Venting the pump

The pump venting function is acti- vated by pressing the button (4) for a long time (3 seconds) and vents au- tomatically.

3.7.2 Factory settings

The factory setting is activated by pressing and holding the button (4) and disabling the pump. When the pump is restarted, it will work with factory settings (delivery state).

3.7.3 Manual restart

When a lockout is detected, the pump tries to start automatically. If the pump does not restart, restart manually by pressing the button (4) for a long time (5 seconds), then re- lease it. The restart function is acti- vated for a maximum of 10 minutes. After the restart, the LED indication shows the previously set values. If the fault persists, replace the pump.

3.7.5 Possible pump faults, causes and possible solutions

• Pressing the button for the 9th time returns to the basic setting (constant speed / characteristic curve III). LED display Control mode Pump curve 1 Constant speed

9 Constant speed III VariabledierentialpressureΔp-v (I, II, III) Recommended for two-pipe heating systems with radi- ators to reduce the ow noise at thermostatic valves. The pump reduces the delivery head to half in the case of decreasing volume ow in the pipe network. Electrical energy saving by adjusting the delivery head to the volume ow requirement and lower ow rates. There are three pre-dened pump curves (I, II, III) to choose from.ConstantdierentialpressureΔp-c (I, II, III) Recommended for underoor heating for large-sized pipes or all applications without a variable pipe network curve (e.g. storage charge pumps), as well as single-pipe heating systems with radiators.The control keeps the set delivery head constant irre-spective of the pumped volume ow. There are three pre-dened pump curves (I, II, III) to choose from.

H/mQ/m³/ hConstantspeed (I, II, III) Recommended for systems with xed system resistance requiring a constant volume ow. The pump runs in three prescribed xed speed stages (I, II, III).

H/mQ/m³/ h NOTICEFactory setting:Constant speed, pump curve III

3.7.4 Setting the pump operating mode

Colour of LED Possible fault Cause Possible solution Flashing red-green Turbine operation The hydraulic system of the pump is pow- ered, but the pump has no mains voltage - Check the mains voltage Idle operation Air in the pump - Check that there are no leaks in the system Overload The motor runs with diculty. The number of revolutions is lower compared to normal operation - Check the mains voltage - Check the system ow rate/pressure - Check the characteristics of the water in the system; remove debris from the system Flashing red Under/overvoltage Supply voltage too low/high - Check the mains voltage Excessive temperature Excessive temperature inside the pump - Check the water temperature level in re- lation to that of the ambient temperature - Check the mains voltage - Check the environmental operating condi- tions Short circuit Motor current too high - Check the mains voltage Steady red “Permanent lockout” stop Rotor blocked - Restart manually

Circuit board and/or motor failure - REPLACE THE PUMP LED O Stopped Electrical power failure - Check the connection to the power supply Faulty LED - Check to see if the pump can work Faulty circuit board - REPLACE THE PUMP41

3.5 MISES EN GARDE POUR

3.5 OPOZORILA UPORABNIKU