TP3 LN - Boiler FERROLI - Free user manual and instructions

USER MANUAL TP3 LN FERROLI

Dear customer: Thank you for choosing a TP3 LN boiler. This manual was written to provide information, warnings and advice on the proper installation, use and maintenance of the boiler. Please read it carefully and save it for future reference. It is in your own interest to carefully follow and observe the instructions given in this manual, in order to fully enjoy this high-quality product. Failure to comply with and observe the instructions contained in this manual exonerates the manufacturer from all liability, and invalidates the warranty.

- The instructions manual is an integral part of the product, and provides a description of all instructions that must be observed during the installation, use and maintenance phase. - This appliance must only be used for the purpose for which it was expressly intended. - This appliance is intended to heat water to below-boiling temperatures at atmospheric pressure, and must be connected to a cen- tral heating and/or domestic hot water distribution system, in accordance with its characteristics, performance, and heat output. - Before installation, check that the boiler has not been damaged during handling and transport. - The boiler is to be installed on a non-combustible base. - The boiler is to be installed with a distance of at least 100 mm to any combustible material or component. - The installation must be performed by duly qualified personnel, in accordance with current standards. - Before performing any cleaning or maintenance operations, unplug the appliance from the mains power supply. - THE MANUFACTURER is not liable for any damage to people or things due to errors in installation, adjustment, maintenance, or improper use. - The boiler and corresponding system must be commissioned by authorized personnel. - Commissioning is performed in order to verify proper operation of all adjustment and control devices. - Qualified personnel must be contacted if the appliance is not used for an extended period. Standards The installer must observe current local regulations with regard to: the site chosen for the installation of the boiler, compliance with required ventila- tion conditions, the tightness of the connection to the chimney, connections to fuel lines, electrical systems, and any other relevant safety standards. Warranty conditions The warranty is only valid if the standards and recommendations for use contained in this manual are observed. Any non-compliance or modifi-cation will void the warranty. The warranty does not cover damage caused by acidic condensate corrosion from the products of combustion, or the formation of deposits caused by the use of hard or aggressive water, as these are caused solely by system operation.

The CE marking certifies that the products meet the essential requirements of the GAR regulation and other applicable directives. The declaration of conformity may be requested from the manufacturer.

4.1 Description of the appliance

The construction of the TP3 LN series boilers guarantees high output and efficiency at low flue gas temperatures, thus ensuring reduced pollu- ting emissions. The appliances are made according to the EN 303 standard, part 1. The main technical elements of the design are: - the careful design of the shapes, to ensure an optimum ratio between the combustion volumes and the heat exchange surfaces - the choice of materials used, for the long life of the boiler. The boilers use pressurised combustion, with three flue passes, overlapping double plating with completely cooled furnace on the bottom part and the tube bundle on the top part, and featuring turbulators to create a swirling path that increases the heat exchange by convection. On leaving the tube bundle, the flue gas enters the rear chamber and is transferred to the chimney.32

TP3 LN cod. 3545458/0 - 10/2019 The boilers are fitted with a door featuring hinges that can be reversed for opening to the right or the left, and is adjustable in both height and depth. The body plating is insulated with a thick layer of glass wool, and covered with a further layer of tearproof material. The external finish consists of painted steel panels. The hoisting hooks are fitted on the top of the plating. The boilers feature two 1/2” fittings for bulb sheaths (able to house three bulbs each). The pre-wired control panel (to be ordered separately) is located above the boiler, and ensure automatic operation.

4.2 Operating principle

The TP3 LN boilers are fitted with a closed cylindrical furnace, in which the flame produced by the burner is reversed peripherally towards the front, from where the burned gas enters the fire tubes. At the outlet, the gas is collected in the smokebox and is then sent to the chimney. The combustion chamber is always pressurised during the operation of the burner. For the pressure values, see the tables on page 16, under the column Flue gas side pressure drop. The flue and the flue stack fitting must be made in compliance with the standards and the legislation in force, using rigid pipes that are resistant to high temperatures, condensate and mechanical stress, and are airtight (Fig. 1). Key 1 Control panel T2 Water return 2 Burner mounting flange T3 Expansion vessel connection 3 Smoke box cleaning door T4 Discharge/exhaust boiler 4 Flame inspection window T5 Chimney connection T1 Water delivery T6 Burner connection

• Oil fuel: CO2 = 13% - Gas fuel: CO2 = 10%34

The boiler can be identified from the: - Document envelope (1) This is applied to the door, and contains: TECHNICAL MANUAL WARRANTY CERTIFICATE

RATING LABEL CONSTRUCTION CERTIFICATE (certifying that the water pressure tests have been passed) - Rating label (2) This describes the technical specifications and the performance of the appliance. It is included in the document envelope and MUST BE APPLIED by the installer, when installation is complete, to the top front part of one of the side panels of the casing, in a visible position. If the label is lost, contact the Ferroli Technical Service for a duplicate. Tampering with or the removal or absence of rating labels or other means enabling the unit to be identified causes problems during installation and maintenance.

The TP3 LN boilers are supplied complete with the door and smokebox fitted and insulation on the body, while the casing is contained in a se- parate cardboard box (Fig. 2). The instrument panel (accessory to be ordered separately) is supplied in a cardboard box and positioned inside the combustion chamber.

The TP3 LN boilers are fitted with eyebolts for lifting. Make sure the hoisting equipment used is suitable for the weight being lifted. Before positioning the boiler, remove the wooden base support by unscrewing the fastening screws (Fig. 4). fig. 3

The TP3 LN boilers should be installed in rooms exclusively used for this purpose, in accordance with the technical standards and legislation in force and featuring adequately sized ventilation openings. The ventilation openings must be permanent, directly communicating with the outside and located in both a high and low position, in compliance with the standards in force. The location of the ventilation openings, the fuel supply, power and lighting circuits must comply with the legislation in force in relation to the type of fuel used. To assist the cleaning of the flue gas circuit, free space must be left at the front of the boiler no less than the length of the boiler body and, in any case, never less than 1300 mm, checking that with the door open at 90° the distance between the door and the adjacent wall (X), is at least equal to the length of the burner. The boiler support surface must be perfectly horizontal. A flat cement base should be used that is able to support the overall weight of the boiler plus the water content. For the dimensions of the base, see the distances R x Q (table of dimensions). If the burner is supplied with gas fuel whose specific weight is higher than air, the electrical parts must be located more than 500 mm from the floor. The appliance cannot be installed outdoors as it is not designed to operate outside and does not feature automatic frost protection systems. INSTALLATION IN OLD SYSTEMS OR SYSTEMS TO BE UPGRADED When the boiler is installed in old systems or systems to be upgraded, check that: - The flue stack is suitable for the temperature of the products of combustion, calculated and manufactured according to the standards in force, airtight, insulated and not blocked or choked. - The electrical system has been installed in compliance with the relevant standards by qualified personnel. - The fuel supply line and any tanks are made according to the relevant standards. - The expansion vessel/vessels can completely absorb the expansion of the fluid contained in the system. - The flow-rate, discharge head and the direction of the flow of the circulating pumps are suitable. - The system is washed, cleaned of slime, fouling, vented and watertight. - A treatment system is available for special supply/top-up water requirements (see the reference values).

5.4 Discharge of the products of combustion (Fig. 6)

The flue and the flue fitting must be made in compliance with the standards and the legislation in force, using rigid pipes that are resistant to high temperatures, conden- sate and mechanical stress, and are airtight. The flue must ensure the minimum negative pressure specified by the standards in force, considering “zero” pressure at the fitting to the flue. Unsuitable or incorrectly sized flues may increase the noise produced due to combustion, generate problems involving condensation and negatively affect the combustion parameters. Non-insulated flues are a source of potential danger. The joint seals should be made using materials that can resist temperatures of at least 250°C. Suitable points for me- asuring the flue gas temperature and analysing the products of combustion must be prepared in the connection between the boiler and the flue. As regards the cross-sec- tion and the height of the chimney, refer to the national and local standards in force.

WARNING: it may be possible formation of condensation inside the stack, because of

the low temperature of flue gases.

5.5 Water connections

The chemical characteristics of the supply and top-up water are fundamental for the correct operation and the safety of the boiler. The water should be treated using suitable systems. The values shown in the table below can be used as references. TOTAL HARDNESS ppm 10 ALKALINITY mg/l CaCO3 750 PH 8÷9 SILICA ppm 100 CHLORIDES ppm 3500 The water used in the central heating system must be treated in the following cases: - Very large systems - Very hard water - Frequent introduction of water to top up the system. If, in these cases, the system needs to be partially or completely emptied, it must be refilled with treated water. To control the volume of water automatically refilled, an hour counter should be installed. The most common phenomena that occur in heating systems are: - Lime scale deposits Lime scale tends to concentrate at the points where the temperature of the wall is higher. Due to their low heat conductivity, lime scale de- posits cause a reduction in heat exchange to the extent that even when just a few millimetres thick, the heat exchange between the flue gas and the water is limited, bringing an increase in the temperature of the parts exposed to the flame and consequently breakages (cracks) on the tube plate. - Corrosion on the water side Corrosion of the metal surfaces on the water side of the boiler is due to the dissolution of iron into its ions. The presence of dissolved gases, in particular oxygen and carbonic dioxide, play and important part in this process. Softened and/or demineralised water provides protection against lime scale and other deposits, however does not protect against corrosion. The water therefore must be treated with corrosion inhibitors.

5.5.2 Central heating outlet/return pipes

The dimensions of the outlet and return pipes are shown for each model of the boiler, in the table of DIMENSIONS. Check that the system features a sufficient number of vent openings. The boiler fittings must not be stressed by the weight of the connection pipes to the system, and consequently special supports must be installed.

5.5.3 System ll/drain pipes

To fill and drain the boiler, a cock can be connected to fitting T4 at the rear (see the drawing of the DIMENSIONS). fig. 637

5.5.4 Expansion vessel and safety valve pipes

The TP3 LN boilers are suitable for operation with forced water circulation, both with open and closed expansion vessels. An expansion vessel is always required, to allow for the increase in water volume due to heating. In the first case, the height of the hydrostatic column must be at least 3 metres above the boiler casing and must have a sufficient capacity to contain, between the surface of the water in the vessel and the overflow pipe, the increase in volume of all the water in the system. High and narrow vessels are better, as they ensure minimum contact between the water surface and the air, thus reducing evaporation. In the second case, the capacity of the closed expansion vessel must be calculated considering: - the total volume of water contained in the system - the maximum operating pressure of the system - the maximum operating pressure of the expansion vessel - the initial pre-charge pressure of the expansion vessel. The expansion pipes connect the expansion vessel to the system. This pipes that run from fitting T3 (see the table of Dimensions), must not be fitted with on-off valves. On fitting T3, or on the outlet pipe, within 0.5 metres from the first flange, install a safety valve sized for the capacity of the boiler and in compliance with the local standards in force. No type of shut-off device may be installed between the boiler and the expansion vessel, and between the boiler and the safety valves, while the valves should calibrated for activation at values no higher than the maximum admissible operating pressure.

5.5.5 Recirculating pump (Fig. 7)

The condensation of the water vapour contained in the flue gas leaving the boiler (con- densate) occurs when the return water temperature is less than 55°C and is significant above all when starting in the morning, after the boiler has been off all night. This con- densate is acidic and corrosive and, over time, attacks the metal plate on the boiler. Consequently, a recirculating pump with the function of preventing condensate should be installed between the outlet and return fittings, upstream of any mixing valve. The pump must ensure, when the system is operating, a flow-rate of between 20 and 30% of the total; it must also ensure a return water temperature no less than 55°C, while the required discharge head is quite low, as it only needs to overcome the resistance of the boiler and the valves. To measure the effective central heating return inlet tempe- rature for the purpose of controlling the condensate prevention pump or managing the functions for getting the system to stable temperature operation, a probe socket must be fitted at a distance equivalent to 3-5 times the diameter of the return pipe upstream of the water coupling.

5.6 Opening and adjusting the front door

For TP3 LN models the door is hinged, fastened and reversed as regards the direction of opening as shown in Fig. 8. The following ope- rations are required: - The door is supplied with four equal brackets (pos. 3) and hinges. - To establish the direction of opening, RIGHT or LEFT, unscrew the nut (pos. 7), unscrew and remove the R or L nut (pos. 6), depending on which side the door opens from. - Height adjustment of the door is performed using the nut (pos. 2); after having completed the adjustments tighten the dowels (pos. 1). - Longitudinal adjustment is performed using the screw (pos. 8). Key (Fig. 8) 1 Fastening dowel 2 Door support/adjustment nut 3 Hinge bracket 4 Hinge pin 5 Hinge screw 6 Hinge fastening nut 7 Fastening nut 8 Hinge bracket fastening/adjustment screws and nuts fig. 738

The assembly of the burner to the door of the boiler must ensure perfect tightness to the products of combustion. Once having installed the burner on the boiler, the space between the burner draught tube and the refractory material on the door must be filled with the layer of ceramic fibre (A) supplied. This prevents the door from overheating and consequently from being irreversibly deformed. The fuel connections to the burner must be located so as to allow the complete opening of the boiler door with the burner installed. Models L min. (mm) L max. (mm) 70-152 230 300 190-240 250 320 320-401 290 360 500-600 320 390 720-820 320 390 940-1060 340 410 1250-1480 340 470 1890-2360 350 480

TP3 LN cod. 3545458/0 - 10/2019

5.8 Connecting the ame inspection window (Fig. 10)

The flame inspection window features a pressure fitting (1) to be connected via a silicone hose or copper pipe to the outlet on the burner (2). This operation allows the air blown by the fan to cool the glass and prevent it from turning black. Failure to connect the hose or pipe to the window may cause the glass to break. For Ferroli boilers, configurations other than those indicated above are also possible, as each combination has been developed in our facilities through specific laboratory tests.

5.9 Assembling the panels, models 92-190

Assembly sequence (Fig. 11) a) Position the right and left side panels (pos. 1-2) hooking them to the support (pos. 13). To know which of the two sides is the right or the left, refer to the hole for the cable gland plate (pos. 6), which must be facing the front of the boiler. b) Fasten the control panel to the top panel (pos. 3). c) Rest the top right panel (pos. 3), complete with the control panel, to the side panel (pos. 1) complete with springs, closing pins and nuts (pos. 10-11-12). d) Insert the bulbs of the instruments into the sheaths as shown in Fig. 20 and make the electrical connection between the control panel and the power line, burner and any pumps etc. The probes should be inserted fully into the corresponding sockets, to improve contact. Then secure the capillary tubes with the springs. Close the cover on the electrical panel, pass the burner plug through the side plate (pos. 6) and secure the cable with the cable gland supplied. Fasten the plate (pos. 6) with the screws (pos. 7). e) Fit the panel left top (pos. 4) to the left side panel (pos. 2) complete with springs, closing pins and nuts (pos. 10-11-12). f) Fit the rear panel (pos. 8) to the boiler using the screws (pos. 13). g) Fasten the rating label to the boiler, see Chap. 1, after having cleaned and degreased the part in question using a suitable solvent, and apply it so as to ensure perfect adhesion. Do not remove the rating label, as it will lose its adhesiveness. The rating label is included in the document envelope.

TP3 LN cod. 3545458/0 - 10/2019

5.10 Assembling the panels, models 240-2360

Assembly sequence (Fig. 12) a) Position the side panels (pos. 1-2 and 3-4) hooking them to the supports (pos. 19). b) Position the top right panel (pos. 5-6) and then the left panel (7-8) hooking them to the supports on the boiler (pos. 19) and to the crossbeam (pos. 15). c) Fasten the control panel to the top right panel (pos. 5). d) Rest the top panel (pos. 5), complete with the control panel, to the side panel (pos. 1) complete with springs, closing pins and nuts (pos. 12-13-14). e) Insert the bulbs of the instruments into the sheats as shown in Fig. 19 and make the electrical connection between the control panel and the power line, burner and any pumps etc. The probes should be inserted fully into the corresponding sockets, to improve contact. Then secure the capillary tubes with the springs. Close the cover on the electrical panel, pass the burner plug through the side plate (pos. 10) and secure the cable with the cable gland supplied. Fasten the plate (pos. 10) with the screws (pos. 11). f) Fit the support (pos. 15). g) Fit the top panels (pos. 5-6-7-8) hooking them to the side panels (pos. 1-2-3-4) complete with springs, closing pins and nuts (12-13-14). h) Fasten the rating label to the boiler, see Chap. 1, after having cleaned and degreased the part in question using a suitable solvent, and apply it so as to ensure perfect adhesion. Do not remove the rating label, as it will lose its adhesiveness. The rating label is included in the document envelope.

6.1 Preliminary checks

Once the hydraulic, electrical and fuel connections to the boiler have been made, the following must be verified before starting the boiler: - The expansion vessel and safety valve are properly connected and cannot be blocked in any way. - The bulbs for the control and minimum safety thermostats and thermometer have been secured in the corresponding sheaths. - The turbulators have been positioned in all the fire tubes. - The system is filled with water and completely vented of air. - The pump or pumps are operating correctly. - The hydraulic, electrical, safety device, and fuel connections have been performed in accordance with current local and national legislation. - The burner has been installed according to the instructions in the manufacturer’s manual. - The mains voltage and frequency are compatible with the burner and the boiler’s electrical equipment. - The system is able to absorb the amount of heat that will be produced. - The recirculation pump is installed as described in section 5.5.5.

After successfully completing the checks indicated in the previous paragraph, the burner may be ignited for the first time. This must be done by a technician authorized by the manufacturer of the burner. The technician will be fully responsible for the field of calibration within the declared and approved output range of the boiler. After opening the fuel on-off cocks and checking that there are no leaks in the supply line, place all switches in the ON position. The burneris now ready for first ignition, and for the adjustments that may only be made by the authorized technician. On first ignition, check that the door, burner flange and connections to the chimney are tight, and that there’s a slight negative pressure at the base of the flue. The fuel rate must match the information on the boiler’s rating card. Under no circumstances may it exceed the declared maxi- mum rated output value. The temperature of the flue gas must never fall below 160ºC.

6.3 Shutting down the boiler

- Set the operating thermostat to the minimum value. - Turn off the power to the boiler and cut off the fuel supply. - Let the pumps operate until they are stopped by the minimum thermostat. - Disconnect the power to the electrical panel.

7.1 General instructions

Periodic maintenance is essential for the safety, efficiency, and long life of the appliance. All operations must be carried out by qualified personnel. Before performing any cleaning or maintenance operations, the fuel supply must be cut off after first shutting off the power. For proper boiler operation and maximum efficiency, the combustion chamber, fire tubes and smokebox must be cleaned regularly.

7.2 Routine maintenance

Maintenance must be scheduled based on the fuel used, number of ignitions, system characteristics, etc. Maintenance intervals can therefore not be determined in advance. As a reference, we recommend the following cleaning intervals, depending on the fuel: - Gas boilers: Once a year - Gas oil boilers: Twice a year In any case, local maintenance standards must be observed. During routine maintenance, remove the turbulators and then brush the tube bundle and furnace. Remove the deposits accumulated in the smokebox through the open inspection doors. For more thorough cleaning, remove the rear smokebox. If worn, replace the flue gas seal. Check that the condensate drain is not blocked. Make sure the control and measurement devices on the boiler are working correctly. On this occasion, record the amount of top-off water used. After analyzing the water, perform a preventive descaling. After repeated fills, the calcium and magnesium salts dissolved in the water will produce deposits in the boiler, cause the metal plates to over- heat, and may cause damage that is not attributable to materials or workmanship, and is therefore not covered by the warranty. After performing cleaning and maintenance operations and the next ignition, check the tightness of the door and smokebox. In the event of combustion leaks, replace the corresponding gasket. The operations performed must be recorded in the system logbook.42

Special maintenance must be carried out at the end of the season or for extended shutdowns. All of the operations described in the previous section must be performed, in addition to the following: - Check the condition of the turbulators for wear. - After cleaning the flue gas circuit, wipe with a rag dipped in a diluted caustic soda solution. After letting it dry, wipe all surfaces with a rag dipped in oil. - Hygroscopic substances (quicklime, silica gel in small containers) should be placed inside the furnace, which must then be closed herme- ti-cally so air cannot enter. - Do not empty the system or boiler. - Protect the screws, nuts and pins on the door with graphite grease. The operations performed must be recorded in the maintenance logbook.

7.4 Cleaning the boiler

To clean the boiler, proceed as follows: - The boiler comes with a brush for cleaning the fire tubes. - Open the front door (1) and remove the turbulators (2). - Clean the inside surfaces of the combustion chamber and the flue gas path using a brush (3) or other suitable implement. - Remove the deposits accumulated in the smokebox through the open cleaning door (4). For more thorough cleaning, remove the smokebox (5) and replace the gasket before reassembling. - Check periodically that the condensate drain (6) is not blocked.

7.5 Checking boiler operation

Before starting the boiler and running the functional tests, check that: - The turbulators are inside the exchanger tubes. - The cocks on the water circuit and fuel line are open. - There is fuel available. - The expansion vessel is suitably filled. - The pressure of the water circuit, when cold, is over 1 bar and under the maximum limit for the boiler. - The water circuits have been vented. - The electrical connections to the mains power and components (burner, pump, control panel, thermostats, etc.) have been completed. - The phase-neutral connection must be strictly observed, and grounding is mandatory. After completing the steps described above, the following operations are necessary to start the boiler: - If the system is equipped with a temperature controller or timer-thermostat, check that they are on. - Set the room timer-thermostat(s) or temperature controller to the desired temperature. - Place the main system switch in the “on” position. - Set the boiler thermostat located on the control panel. - Place the main switch on the control panel in the “on” position and check that the green indicator light comes on. fig. 13 fig. 14

TP3 LN cod. 3545458/0 - 10/2019 The boiler will run the ignition phase, and will remain on until the set temperatures have been reached. If problems occur during ignition or ope- ration, the boiler will “LOCKOUT,” as signaled by the red light on the burner and the red indicator on the control panel. After a “LOCKOUT,” wait about 30 seconds before resetting the ignition conditions. To reset the ignition conditions, press the burner “button/light” and wait for the flame to ignite. If this operation fails, it can be repeated a maximum of 2 or 3 times. Then check: - The instructions manual for the burner. - The section “CHECKING BOILER OPERATION.” - The electrical connections shown on the diagram next to the control panel. Once the boiler has started, check that it stops and starts again: - Adjust the setting on the boiler thermostat. - Operate the main switch on the control panel. - Set the room thermostat, timer, or temperature controller. - Check that the pumps are not blocked and rotate correctly. - Check that the boiler shuts down completely by operating the main system switch. If all conditions are correct, restart the appliance, check the combustion (flue gas analysis), fuel rate, and tightness of the gaskets on the door and smokebox.

7.6 Checking burner operation

- Check the instructions manual for the burner. - Follow all local regulations and standards with regard to burner maintenance.

The following is a list of the main faults and problems that may occur during boiler operation, specifying possible causes and solutions. FAULT

THE BOILER IS EASILY SOILED

CAUSE: Burner poorly adjusted SOLUTION: Check the burner adjustment (flue gas analysis) Flue blocked Clean the flue gas path and the flue Burner air intake path dirty Clean the burner air intake THE BOILER DOES NOT REACH THE SET TEMPERATURE CAUSE: Boiler body dirty SOLUTION: Clean the flue gas path Boiler/burner combination Check the data and adjustments Burner flow-rate insufficient Check the burner adjustment Control thermostat Check correct operation Check the set temperature BOILER THERMAL SAFETY SHUTDOWN WITH INDICATOR LIGHT ON THE CONTROL PANEL CAUSE: Control thermostat SOLUTION: Check correct operation Check the set temperature Check the electrical wiring Check the probe bulbs Lack of water Check the circuit pressure Air present Check the vent valve THE BOILER REACHES THE SET TEMPERATURE, BUT THE CENTRAL HEATING SYSTEM IS COLD CAUSE: Air present in the system SOLUTION: Vent the system Pump fault Reset the pump Minimum thermostat (if featured) Check the set temperature

ODOR OF UNBURNED SUBSTANCES

CAUSE: Flue gas leaking into the environment SOLUTION: Check that the boiler body is clean Check that the flue is clean Check the tightness of the boiler and flue

FREQUENT ACTIVATION OF THE SAFETY VALVE

CAUSE: System circuit pressure SOLUTION: Check the fill pressure Check the system circuit Check the calibration Check the set temperature System expansion vessel Check44