CRONO 4G - Boiler Baxi - Free user manual and instructions

USER MANUAL CRONO 4G Baxi

Burner combined with gas train

1.1 Gas train designation

1 Burner combined with gas train Series: Size: Operation: BASIC DESIGNATION EXTENDED DESIGNATION /1 1

stage mode opening /2 2

stage mode opening /P 1

stage mode opening with air/gas proportional regulator /S only ON-OFF function

Leak detection CT leak detection control device installed on the gas train CQ equipped with pressure switch for leak detection control

Joint type: F standard flange ISO F1 square flange BS1 R threaded joint F2 square flange BS2 F3 square flange BS3 - BS4 Electrical connection: SD Domestic plug SM Medium voltage plug T Terminals - Terminal strip - without pressure governor 0 with governor and air/gas proportional pressure 2 with governor and output pressure up to 20 mbar 3 with governor and output pressure up to 30 mbar 4 with governor and output pressure up to 40 mbar 5 with governor and output pressure up to 50 mbar 8 with governor and output pressure up to 80 mbar 12 with governor and output pressure up to 120 mbar Standard output pressure range: 0 shared 2 separate Valve control: 6 with governor and output pressure up to 60 mbar control:

VGD 50 /1 15 with governor and output pressure up to 150 mbar20138108

Information and general warnings

2.1 Information about the instruction manual

The instruction manual supplied with the gas train: is an integral and essential part of the product and must not be separated from it; it must therefore be kept carefully for any necessary consultation and must accompany the gas train even if it is transferred to another owner or user, or to another system. If the manual is lost or damaged, another copy must be requested from the Technical Assistance Service of the area; is designed for use by qualified personnel; offers important indications and instructions relating to the installation safety, start-up, use and maintenance of the gas train.

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the date of installation, in accordance with the regulations in force and/or the sales contract. Ensure, upon activating it for the first time, that the gas train is undamaged and complete. In particular, the rights to the guarantee and the responsibility will no longer be valid, in the event of damage to things or injury to people, if such damage/injury was due to any of the following causes: incorrect installation, start-up, use and maintenance of the gas train; improper, incorrect or unreasonable use of the gas train; intervention of unqualified personnel; carrying out of unauthorised modifications on the equipment; use of the gas train with safety devices that are faulty, incor- rectly applied and/or not working; installation of untested supplementary components on the gas train; supplying the gas train with inappropriate fuel; faults in the fuel supply system; continuation of use of the gas train when a fault has occurred; repairs and/or overhauls incorrectly carried out; modification of the combustion chamber with inserts that prevent the regular development of the structurally estab- lished flame; insufficient and inappropriate surveillance and care of those gas train components most likely to be subject to wear and tear; use of non-original components, including spare parts, kits, accessories and optional; force majeure. The manufacturer furthermore declines any and every re- sponsibility for the failure to observe the contents of this manual. 2 Information and general warnings WARNING Failure to observe the information given in this manual, operating negligence, incorrect installa- tion and carrying out of non authorised modifica- tions will result in the annulment by the manufacturer of the guarantee that it supplies with the gas train.3

Safety and prevention

It is necessary, however, to bear in mind that the imprudent and clumsy use of the gas train may lead to situations of death risk for the user or third parties, as well as the damaging of the burner or other items. Inattention, thoughtlessness and excessive confi- dence often cause accidents; the same applies to tiredness and sleepiness. It is a good idea to remember the following: the gas train must only be used as expressly described. Any other use should be considered improper and therefore dan- gerous. Modification of the gas train to alter its performance and des- tinations is not allowed. The gas train must be used in impeccably secure conditions. Any disturbances that could compromise safety must be quickly eliminated. It is not permissible to open or handle the components of the gas train, with the exclusive exception of parts necessary to maintenance. Only those parts envisaged by the manufacturer can be replaced.

3.2 Personnel training

The user is the person, the body or the company that has pur- chased the gas train and that intends to use it for the purposes for which it was designed. They are responsible for the gas train and for training those who will operate it. The user: undertakes to entrust the gas train only to personnel who are qualified and trained to use it; undertakes to inform his personnel in a suitable way about the application and observance of the safety instructions. With that aim, he undertakes to ensure that everyone knows the use and safety instructions for his own duties; Personnel must follow all the danger and caution indications shown on the gas train. Personnel must not carry out, on their own initiative, opera- tions or interventions that are not within their province. Personnel are obliged to inform their superiors of every problem or dangerous situation that may arise. The assembly of parts of other makes, or any modifications, can alter the characteristics of the machine and hence com- promise operating safety. The manufacturing company therefore accepts no responsibility whatsoever for any which may result from the use of non-original parts. In addition: 3 Safety and prevention WARNING The manufacturer only guarantees the security of operations if all components of the gas train are undamaged and correctly positioned. must take all the measures necessary to pre- vent unauthorised people gaining access to the gas train; the user must inform the manufacturer if faults or malfunctioning of the accident pre- vention systems are noticed, along with any presumed danger situation; personnel must always use the personal pro- tective equipment envisaged by legislation and follow the indications given in this man- ual.20138108

4.1 Notes on safety for the installation

After carefully cleaning all around the area where the train will be installed, and arranging the correct lighting of the environment, proceed with the installation operations.

4.3 Preliminary checks

Checking the consignment 4Installation DANGER All the installation, maintenance and disassembly operations must be carried out with the electricity supply disconnected. WARNING Train installation must be carried out by qualified personnel, as indicated in this manual and in com- pliance with the standards and regulations of the laws in force. WARNING The handling operations for the train can be highly dangerous if not carried out with the greatest at- tention: keep any unauthorised people at a dis- tance; check the integrity and suitableness of the available means of handling. Check also that the area in which you are working is empty and that there is an adequate escape area (i.e. a free, safe area to which you can quick- ly move if the train should fall). CAUTION Before proceeding with the installation operations, carefully clean all around the area where the train will be installed. CAUTION After removing all the packaging, check the integ- rity of the contents. If in doubt, do not use the gas train; contact the supplier. The packaging elements (cardboard box, nails, clips, plastic bags, etc.) must not be abandoned as they are potential sources of danger and pollu- tion; they should be collected and disposed of in the appropriate places.5

1Filter 2 Minimum gas pressure switch 3 Safety valve 4 Valve body 5 Adjusting valve 6 Screw for gas pressure adjustment 7 Leak detection control (if present)

4.5 Gas train compatibility and leak detection control device

Leak detection control through VPS504 device Gas train Code per 50Hz operational Code per 60Hz operational VGD 50/1 3010123 + 20186306 20050030 + 20186306

VGD 65/1 - 80/1 - 100/1 - 125/1 3010123 (*) 20050030

WARNING (*) Kit code 3010123 (50 Hz) already included in VGD gas trains with codes 20169190, 20169191, 20169192, 20169194, 20169196. Leak detection control through additional pressure switch Gas train Kit code Kit code SIEMENS control box LAMTEC control box VGD 50/1 3010344 + 20185515 (**) 20131430 + 20185515 (**)

VGD 65/1 - 80/1 - 100/1 - 125/1 3010344 20131430

WARNING (**) Code 20185515 always needed in case of leak detection control for VGD 50/1 gas train.20138108

4.6 Gas train installation

Once unpacked, install the gas train as follows:

• Assemble the gas train using the screws supplied.

• Once connected, check the atmospheric seal of tubing. Use leak finder spray on the suspect spot only. After assembly, check the train for leaks and make sure it is operating properly. Tab. A

• Spring mounted in factory ** Supplied spring For possible replacement see “Adjusting the pressure stabiliser” on page 7. It may be necessary to place an adapter between the gas train and the burner (see the burner manual) if the diameters of the train are different from those for which the burner is set up. To avoid excessive stress, you are advised to sustain larger trains with a suitable support. Check that there are no gas leaks. Pay attention when handling the train: danger of crushing of limbs. Explosion danger due to fuel leaks in the pres- ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure that the fuel interception tap is closed before performing any operation. The operator must use the required equipment during installation. WARNING To avoid excess strain it is advisable to support bigger trains using an appropriate support. DANGER The gas train is set to be installed on the left side of the burner.

4.6.1 Minimum gas pressure switch adjustment

Adjust the low gas pressure switch (Fig. 3) after carrying out all the other adjustments of the burner with the gas pressure switch adjusted at the beginning of the scale. Let the burner work at the required output. Close slowly the gate valve until the pressure, measured on the gas pressure switch gauge, comes down of 5 - 6 mbar with regard to the working value. Rotate slowly the gas pressure switch handle until the operation of the same gas pressure switch and the resultant burner shut- down. Open completely the gate valve.

4.6.2 Adjusting the pressure stabiliser

Loosen the protection (Fig. 3) and rotate the screw underneath: tighten it to increase the output pressure, or loosen it to reduce the pressure. The pressure stabiliser is more effective when the pressure loss p between its input and output is greater; it also has more effect when the pressure downstream increases (an increase obtaina- ble - bearing in mind the other operational needs and the mains pressure availability - by limiting the opening of the valves down- stream). The gas train outlet pressure depends on the spring installed un- der the adjustment screw (Fig. 3). The gas train leaves the factory with the yellow spring as indicat- ed in Tab. B. In supplied of the flanged gas trains (DN65-80-100-125) there is a neutral spring (0 ÷ 22 mbar). Springs can be ordered separately: Tab. B Code Model pG (mbar) Color 20181839 AGA29 0 - 22 Neutral 20141900 AGA22 15 - 120 Yellow 20141901 AGA23 100 - 250 Red D4470 Fig. 2

Installation 4.7 Electrical wiringNotes on safety for the electrical wiring4.7.1 Electrical wiringKey (Fig. 4)PG Minimum gas pressureVPS Valve leak detection control deviceVR Adjustment valveVS Safety valves DANGER The electrical wiring must be carried out with the electrical supply disconnected. Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. The manufacturer declines all responsibility for modifications or connections different from those shown in the wiring diagrams. Check that the electrical supply of the train corresponds to that shown on the identification label and in this manual. The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system, made according to current standards. It is necessary to check this fundamental safety requirement. In the event of doubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing system for electrical devices. Do not touch the device with wet or damp body parts and/or in bare feet. Do not pull the electric cables. Fig. 4

WARNING For the electrical wirings to the burner, refer to theburner instruction manual.9

Activation, calibration and functioning

5.1 Notes on safety for the first start-up

The minimum necessary pressure in the network can be obtainedby adding the pressure of the diagram to the burner pressurelosses (see the burner technical instruction) and the back pres-sure of the combustion chamber (see the technical instruction ofthe heat generator). 5 Activation, calibration and functioning WARNING The first start-up of the burner must be carried outby qualified personnel, as indicated in this manualand in compliance with the standards and regula-tions of the laws in force. WARNING Check the correct working of the adjustment, com-mand and safety devices.

Activation, calibration and functioning

Activation, calibration and functioning

6.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation, safety, yield and duration of the gas train. It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time. Before carrying out any maintenance, cleaning or checking oper- ations:

6.2.2 Checking and cleaning

6.2.3 Filter maintenance

The filtering element can be replaced by removing the upper cov- er of the filter (after loosening the screws that fix it in place). 6 Maintenance DANGER The maintenance interventions and the calibration must only be carried out by qualified, authorised personnel, in accordance with the contents of this manual and in compliance with the standards and regulations of current laws. DANGER Disconnect the electrical power using the main switch. DANGER Close the fuel interception tap. Wait for the components in contact with heat sources to cool down completely. The gas combustion system should be checked at least once a year by a representative of the man- ufacturer or another specialised technician. The operator must use the required equipment during maintenance. WARNING You are advised to carry out a periodic check to see how clean it is and, in any case, replace it at least once a year. Where the filter is being replaced regularly it is ad- visable to replace the fixing screws.1