1228 technox3 840 bt-use and maintenance manual(en)

STEEL BOILERS series

Technox3 110÷1900BT

INSTALLATIONUSE AND MAINTENANCE(to be kept safely)

Edition 2008-03

2

GENERAL INFORMATIONSIntroductionThis manual is an essential part of the product and must be consigned to the user.The instructions must be read carefully as they provide important information about the safety rules for installation, use and maintenance.The manual should be kept safely for further references.It provides a summary of all that needs to the done during installation, use and servicing of Technox3 BT Baltur boilers.Choosing a boilerTo choose and utilise Technox3 BT boilers correctly it is essential to follow the instructions laid out.InstallationInstallation of the boilers and accessories relating to the heating system must comply with all the latest legally required safety regulations.Installation and starting up of the boilers and their heating systems must be carried by a registered installer.A registered installer is someone with specific technical skills in the domestic heating system components and hot water production sector andin particular Servicing Centres authorised by the manufacturer.Starting up for the first timeThe main aim when starting up for the first time is to check that all safety any control devices are working properly.Before leaving the system, the installer should check a complete working cycle of the boiler.RegulationsThe installation must be in accordance with the latest regulations regarding boiler rooms, safety devices, flue, fuel supply lines, wiring and anyrelevant local requirements.ApprovalsTechnox3 BT range of Baltur boilers is CE approved in accordance with the following directives:- Gas directives for gas appliances (90/396 EEC).- Efficiency directive (92/42 EEC).- Low tension directive (73/23 EEC).Technical data plate and serial numberThe technical data plate provided in an envelope with the other documents refers to a serial number printed on a small aluminium plate nailedon to the front tube plate in the lower right hand corner.UseThese boilers are for heating water to a temperature that does not exceed boiling point during operation.

GuaranteeThe guarantee is valid only if the regulations and suggestions for use contained in this manual are followed. Any modification or failure tocomply with these will nullify the guarantee.Any damage caused by corrosion from acid condensation of combustion products or by scale from hard or aggressive water is not included inthe guarantee since it is caused by the way the system is run.

ATTENTIONIn case of boiler fonctioning with gas fired pressure jet burner, the appliance being not covered by any category among those considered by theAnnex II of Directive 97/23/CE (Pressure Equipment Directive - PED), and furthermore being covered by the Directive 90/396/CEE (GasAppliances Directive - GAD) to which the 1st article, paragraph 3 (6.5) makes reference, is excluded by the application area of the directive itself.

1

2

TECHNICAL CONSTRUCTIONAND DIMENSIONS ......................................................... page 41.1 Construction of Technox3 BT boilers .................................... page 41.2 Working principle ................................................................... page 41.3 Dimensions and water connections ...................................... page 5

INSTALLATION ................................................................. page 92.1 Packaging .............................................................................. page 92.2 Handling ................................................................................. page 92.3 Positioning in boiler house .................................................... page 92.4 Connection to the chimney ................................................... page 102.5 Water connections ................................................................. page 10

2.5.1 Water supply ................................................................. page 102.5.2 Quality of water ............................................................ page 102.5.3 C.H. flow and return connections ................................ page 102.5.4 Connection of filling and drain tap ............................... page 102.5.5 Connection of the pressure relief valve, expansion pipe and vessel ............................................................ page 102.5.6 Shunt pump .................................................................. page 11

2.6 Furnace door: adjustment, opening, closing ........................ page 112.6.1 Important note .............................................................. page 11

2.7 Burner .................................................................................... page 112.7.1 Conformity of the burner .............................................. page 112.7.2 Choice of the burner .................................................... page 122.7.3 Mounting of two-stage or modulating burners ............ page 12

2.8 Connecting flame sight glass to cooling pipe of burner ...... page 132.9 Casing assembly ................................................................... page 14

CONTROLPANEL ............................................................ page 223.1 Functions description ............................................................ page 223.2 Wiring diagram for burner and single phase pump .............. page 22

4 COMMISSIONING ........................................................... page 234.1 Preliminary check .................................................................. page 244.2 First commissioning .............................................................. page 244.3 Switch off of the boiler ........................................................... page 24

MAINTENANCE ................................................................ page 255.1 General rules ......................................................................... page 255.2 Ordinary maintenance ........................................................... page 255.3 Extraordinary maintenance ................................................... page 255.4 Cleaning of the boiler ............................................................ page 265.5 Check of the boiler operation ................................................ page 265.6 Check of the burner operation .............................................. page 265.7 Boiler house ........................................................................... page 26

LEGISLATION AND WARNINGS ........................ page 276.1 General warnings .................................................................. page 276.2 Summary of warnings ........................................................... page 276.3 Electrical supply .................................................................... page 286.4 Water supply .......................................................................... page 286.5 Boiler fired by gas, oil or other fuel ....................................... page 28

5

6

3

4

1 TECHNICAL CONSTRUCTIONAND DIMENSIONS

1.1 - CONSTRUCTION OFTechnox3 BT BOILERS

The Technox3 BT, three pass boilers, are ofhorizontal type (ovals hape from model 110to 380 and the model 840; eight shape frommodel 500 to 730 and cylindrical shape frommodel 1100 to 1900), with direct flame in thecombustion chamber.The construction completely satisfies therequirements of the EN 303 - part. 1.The sheet metal parts of the pressure vesselare manufactured of certified carbon steel,type S235JRG2, according to EN 10025, withmelting certificate 3.1.B, according EN10024; whereas the pipes are of steel ST 37.0according to DIN 1626.The welders and the WPS (WeldingProcedures Specifications) have beenapproved according to EN 287 and EN 288by TUEV (DE). These boilers have been alsoapproved by - ISCIR (RO).Up to the model Technox3 380BT the furnaceis linked to the rear tube plate.For larger models (Technox3 500BT toTecnox3 1900BT) the furnace is free todilatate [it is supported only by the doublewelding seam (inner and outer) to the fronttube plate].The boilers are equipped with a reversiblehinged door, wich can be opened, for thisreason, from L.H. or R.H. side.The outer shell is insulated with a glass woolmatress, thick 100 mm, protected by a textilein mineral fiber.The upper part of the outer shel is equippedwith uplift hook(s).Note: The Technox3 BT boilers are to beequipped with ON/OFF burner; alternativelythey can be equipped with a two stage or

fig. 1

1.2 - WORKING PRINCIPLE

The NOx formation process is stronglyaffected by:- the flame temperature;- the time during which the combustion gases

stay in a high temperature zone;- oxigen partial pressure and its concentration.The provision to be adopted for the NOxreduction are then:- reduction of combustion temperature;- reduction of the specific thermal input;- permanence time reduction of the gases

in the combustion chamber;- reduction of oxigen concentration.Baltur, to reduce the NOx formation on theTechnox3 BT range of boilers, has adoptedthe following construction solutions:- three pass

the furnace is of direct flame type and notof reversal type any more; the burner flameresults more compact and shorter, thusreducing the permanence time at high

modulating burner, provided the minimumreachable heat input is not lower than thefigure shown on the data plate for the fuelused on site.For two stage or modulating burenr seeparagraph 2.7.1.The boilers are provided with two ½" bulbholders with inner diameter of 15 mm (for 3bulbs each), suitable to locate the thermostatsand thermometer bulbs.

The casing side panels are provided withholes for the cables of the electrical supply,of the pumps, of the burner and any otherauxiliary equipment.

temperature;the direct pass allows a quicker flamecooling down by the water cooled furnacesurfaces;

- specific thermal input reductionthe combustion chamber volume has beenincreased if compared with standard boilersof the same capacity.

With the adoption of the modern Low NOxburners a further reduction of the NOxemissions can be obtained with:- reburning

a part of the combustion gases is takenand sent again to the combustion chamberwith the combustion air.In this way the partial oxygen pressure isreduced and the flame temperature isreduced too.

- reduction of the partial oxygen pressurethanks to an air excess reduction.

During the operation of the burner within theoutput range of the boiler, the combustionchamber is always under positive pressure.For the value of this pressure see tables onpages 5 to 8 under the column “Smoke sidepressure losses”.The chimney has to be calculated in such a waythat at its base there is no positive pressure.

5

ø 1

80

ø 1

50

95

ø 1

65

Fiber wool

Ceramic fiber

Burner plate 350x350

Burner plate insulation gasket 250x250

A

H

G

CD

T6

T4

T5

T1BF

N

E

H

T4

T6

O P

T5

T1-T3-T2

M

T3 T2

Q R

S

41

11

16 17

30

24

12 13

21

14 15

22 23

40

3

2

1

Technox3 110BT÷Technox3 380BT

1 Panel board2 Smoke chamber cleaning door3 Flame sight glass

T1 C.H. flowT2 C.H. returnT3 Expansion vessel connection

T4 Boiler drainT5 Flue connectionT6 Max. burner blast tube dia.

Outputmin/max

kW

T1T2

UNI 2278 PN 16

T3

ISO 7/1

T4

ISO 7/1

T5Ø

mm

T6Ø

mm

DN 50

DN 50

DN 65

DN 80

DN 80

Rp 1¼

Rp 1¼

Rp 1½

Rp 2

Rp 2

Rp ¾

Rp ¾

Rp ¾

Rp ¾

Rp ¾

180

180

180

225

225

132

132

180

180

180

Technox3 BT

Type

Inputmin/max

kW

101÷115

137,7÷163

207÷245

276÷327

350÷414

Boilerwater

content

l

204

270

322

408

475

Water sidepressuredrop (*)

kPa

0,6÷0,8

0,8÷1,0

1,7÷2,0

2,2÷3,5

3,2÷5,3

5,5÷7,5

12÷16

12,5÷17,5

9÷12

15÷21

Smoke sidepressure drop (**)

daPa

Maximumboiler working

pressure

bar

5

5

5

5

5

Weightwith

packaging

kg

426

503

621

812

906

93÷105,4

127÷150

191÷225

255÷300

323÷380

110

150

225

300

380

DIMENSIONSTechnox3 BT

Type

110

150

225

300

380

fig. 2

Amm

820

820

860

890

890

Bmm

885

1145

1210

1275

1470

Cmm

1082

1082

1182

1352

1352

Dmm

190

190

190

190

190

Emm

140

140

140

140

140

Fmm

145

145

145

145

145

Gmm

748

748

828

928

928

Hmm

380

380

400

440

440

M (***)mm

1210

1210

1310

1485

1485

Nmm

175

175

215

255

255

Omm

130

390

340

285

480

Pmm

185

185

250

315

315

Q (***)mm

710

710

750

780

780

R (***)mm

786

1046

1111

1177

1372

(*) Pressure loss for a temperature difference of 15K.; 1 kPa = 10 mbar ≅ 102 mm H2O(**) This refers to light oil fuel.1 daPa ≅ 1 mm H2O(***) Minimum dimensions for boiler room access requirements.

fig. 3 fig. 4

CONNECTIONS

DETAIL FOR DOOR DRILLINGTechnox3 110BT - Technox3 150BT

DETAIL FOR DOOR DRILLINGTechnox3 225BT

fig. 5

DETAIL FOR DOOR DRILLINGTechnox3 300BT ÷ Technox3 380BT

1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS

6

3

1

2


Outputmin/max

kW

T1T2

UNI 2278 PN 16

T3

UNI 2278 PN 16

T4

ISO 7/1

T5Øi

mm

T6Ø

mm

DN 100

DN 100

DN 100

DN 65

DN 65

DN 65

Rp 1

Rp 1

Rp 1

250

250

250

210

210

210

Technox3 BT

Type

Inputmin/max

kW

460÷545

579÷686

671÷795

Boilerwater

content

l

656

737

807


kPa

1,0÷1,5

1,6÷2,3

2,3÷3,3

25÷35

32÷45

35÷49


daPa


pressure

bar

5

5

5

Weightwith

packaging

kg

1198

1304

1431

425÷500

535÷630

620÷730

500

630

730


Type

500

630

730


fig. 6




CONNECTIONS

Amm

920

920

920

Bmm

1605

1800

1995

Cmm

1645

1645

1645

Dmm

190

190

190

Emm

135

135

135

Fmm

195

195

195

Gmm

1110

1110

1110

Hmm

480

480

480

1735

1735

1735

Nmm

298

298

298

Omm

435

630

825

Pmm

440

440

440

Q (***)mm

790

790

790

R (***)mm

1505

1790

1895

DETAIL FOR DOOR DRILLINGTechnox3 500BT ÷ Technox3 730BT

M (***)mm

fig. 7

S (***)mm

860

860

860

7

H

T6

A

DC

Q

G

T4

T5

T1BF

N

E

H

T6

O P

M

T3 T2

R

T4

T5

T1-T3-T2

125

41

11

16 17

30

24

12 13

21

14 15

22 23

40

32

1

Technox3 840BT

Outputmin/max

kW

T1T2

UNI 2278 PN 16

T3

UNI 2278 PN 16

T4

ISO 7/1

T5Øi

mm

T6Ø

mm

DN 100 DN 65 Rp 1¼ 250 270

Technox3 BT

Type

Inputmin/max

kW

772÷915

Boilerwater

content

l

932


kPa

3,5÷5,2 42÷58


daPa


pressure

bar

5

Weightwith

packaging

kg

1581714÷840


Type


fig. 8




CONNECTIONS

Amm

1122

Bmm

2115

Cmm

1432

Dmm

190

Emm

195

Fmm

195

Gmm

1025

Hmm

480

M (***)mm

1540

Nmm

298

Omm

945

Pmm

440

Q (***)mm

1020

R (***)mm

2014

DETAIL FOR DOOR DRILLINGTechnox3 840BT

840

840

fig. 9

8

32

1

G

T4

T5

T3BF

N

E

H

T6

O P

M

T1 T2

R

A

Q

T4

T5

DC

T3-T1-T2

185

H

T6

41

11

16 17

30

24

12 13

21

14 15

22 23

40


Outputmin/max

kW

T1T2

UNI 2278 PN 16

T3

UNI 2278 PN 16

T4

ISO 7/1

T5Øi

mm

T6Ø

mm

DN 150

DN 150

DN 175

DN 175

DN 80

DN 80

DN 100

DN 100

Rp 1½

Rp 1½

Rp 1½

Rp 1½

350

350

400

400

Technox3 BT

Type

Inputmin/max

kW

1012÷1198

1214÷1438

1470÷1743

1745÷2070

Boilerwater

content

l

1580

1791

2297

2496


kPa

1,5÷2,1

2,1÷3,0

2,0÷2,8

2,7÷3,9

45÷62

61÷85

40÷55

52÷73


daPa


pressure

bar

6

6

6

6

Weightwith

packaging

kg

2444

2965

3685

4089

935÷1100

1122÷1320

1360÷1600

1615÷1900


Type


fig. 101 Panel board2 Smoke chamber cleaning door3 Flame sight glass



CONNECTIONS

Amm

1462

1462

1622

1622

Bmm

2282

2652

2692

3014

Cmm

1542

1542

1702

1702

Dmm

190

190

190

190

Emm

230

230

260

260

Fmm

290

290

290

290

Gmm

1120

1120

1245

1245

Hmm

565

565

605

605

M (***)mm

1650

1650

1810

1810

Nmm

561

561

661

662

Omm

510

880

670

990

Pmm

550

550

700

700

Q (***)mm

1360

1360

1520

1520

R (***)mm

2176

2546

2590

2910



1100

1320

1600

1900

1100

1320

1600

1900

270

270

285

285

fig. 11 fig. 12

9

2 INSTALLATION

2.1 - PACKAGING

The Technox3 BT boilers are suppliedcomplete with door and smoke chamberalready fitted, whilst the casing with theinsulation matress are contained in separatecardboard packaging(s).The panel board and the accessories areinside the combustion chamber.Before starting the installation make sure thatthe length and the width of the boiler body

2.2 - HANDLINGThe boiler can be moved into position bylifting, through the upper hook(s), or by theuse of rollers placed under the strong L

profiles of the basement.If it necessary, due to the dimensions of theboiler, it is possible to remove the front door

and the smoke chamber to facilitate theintroduction in the boiler house.

2.3 - POSITIONING IN THEBOILER HOUSE

The installation of the boiler must be inaccordance with the relevant requirementsof the Gas Safety Regulations, current I.E.E.Regulations, local water authority bye lawsand it should also comply with any relevantrequirements of the local gas supplier, localauthority and the relevant Standard Codesof Practice and buildings regulations.The boiler house must be ventilated throughpermanent openings having a total surfacenot lower than 1/30th of the floor area of theboiler house, with a minimum of 0,5 m2.Ventilation by grilles communicating directlywith the outside air is required at both, highand low levels.The boiler must be positioned so that thereis enough space available for the following:- Access around the boiler fore servicing.- Space to open the boiler front door.- Space to access the burner.The installation of the boiler as close aspossible to the chimney position is highlyrecommended.To allow the cleaning of the smoke pipes, infront of the boiler a clearance equal to thelenght of the boiler, has to be available.With the boiler door opened at 90°, thedistance between the front of the door andthe adjacent wall must be equal, at least, atthe lenght of the burner.The boiler must stand on a non-combustiblefloor (i.e. concrete or brick), of dimensionQ x R (see dimensions table) which must beflat, level and of a suitable load bearingcapacity to support the weight of the boiler(when filled with water) and any ancillaryequipment.Once the installation has been made theboiler must result perfectly horizontal and wellstable (to avoid vibrations and noise).

received correspond to the dimension M, Qand R of the ordered boiler, shown in theprevious tables and that the carton, containingthe casing, or part of it, are marked with thecode(s) shown on page 14.In addition to the a.m. panel board, packagedin its own carton, in the combustion chamber,as accessories, there are also:- a carton containing the flanges for flow,

return and safety connection (if applicable)with relevant gaskets and bolts, thecylindrical brush for the cleaning of thesmoke pipes.

- cleaning brush handle extension.- turbulators extractor.- ceramic fiber rope for the insulation

between the door and burner blast tube.

x = not shorter than the boiler bodyxx= sufficient to allow accessibility to all regulation, safety and control devices. fig. 13

X

XX

XX

XX

10

2.4 - CONNECTION TO THECHIMNEY

The chimney has a foundamental importancefor the good operation of the boiler.Due to the low temperature of the smokesduring the intermittent operation, it is necessarythat the chimney is perfectly impermeable tothe condensate of the combustion productsand manufactured with corrosion resistant

materials.The different connections must be sealed withan approved boiler putty so that the inlet offresh air, with consequent increase of thepossibility of condensate formation, is avoided.Furthermore the possible condensate or rainwater comming from the chimney must beavoided from entering the smoke chamberof the boiler.

As far as the cross section and the high ofthe chimney is concerned, it is necessary tomake reference to the local and national rulesin force.In the flue pipe, between the boiler andthe chimney, convenient sampling pointsfor smoke temperature and combustionproducts analysis must be provided.

2.5 - WATER CONNECTIONS

2.5.1 - WATER SUPPLY

The boiler components fed with water arenormally connected to the water mains througha PRV.Ascertain that the hydraulic pressure measureddownstream the PRV is not higher than theMaximum Allowed Pressure of the boiler (seeboiler data plate).Because during the operation of the boiler

the pressure of the water contained in theC.H. system increased, ascertain that thisvalue does not exceed the a.m. MAWP of theboiler.Make sure the drain of the safety valve hasbeen connected to a discharge hopper; if notconnected to a discharge hopper, the safetyvalve can flood the floor of the room in wichthe boiler is installed. The boiler manufactureris not responsible for such a damage.

Make sure the installation pipes are not usedas earthing points for the electrical or telephoneinstallations. In a short time the installationpipes, the boiler and the radiators could sufferserious damages.Once the C.H. system, of closed type, hasbeen filled, the filling valve has to be closedand kept in this position. Eventual water leakswill be shown by a decrease of the waterpressure at the boiler pressure gauge.

2.5.2 - QUALITY OF WATER

The chemical and physical features ofthe water used for heating systems arefundamental to the successful functioningand safety of the boiler.Among the problems caused by poor qualityfeeding water, the most serious and mostfrequent is scaling on the surface of the heatexchanger.Less frequent but equally serious is corrosion

of the water side surfaces of the whole circuit.Lime scaling is known to reduce heat transferbecause of its low conductivity. A fewmillimetres of lime is enough to causedangerous localised overheating.Water should be treated in the following cases:A • very hard water (over 20° f).B • very large systems.C • large quantities of water added due to

leakage.D • subsequent filling as a result of servicing.

To treat water feeding the heating systems itis advisable to contact specialists.The specialist will remove scaling from theboiler.All systems need water to be added eitherbecause of evaporation, minor or majorleakage, or servicing.The amount of water to be added needs tobe controlled through a flow-meter to avoidproblems.

2.5.3 - C.H. FLOW AND RETURNCONNECTIONS

The dimensions of flow and return connectionsare shown, for each boiler model, in the tableDIMENSIONS.

Before connecting the boiler to the C.H. system,this one has to be throughly cleaned.Make sure in the system there is a sufficientnumber of air venter.When connecting flow and return pipes avoidto create mechanical stress onto the boiler

flanges.The boiler is not made to support the pipingof the C.H. system, which needs dedicatedsupports.Once the complete C.H. system is finished,check for water leaks all the connections.

2.5.4 - CONNECTION OF FILLING ANDDRAIN TAP

For the filling and drain of the boiler adedicated tap can be connected to the pointT4, which is in rear part of the boiler.

2.5.5 - CONNECTION OF THEPRESSURE RELIEF VALVE,EXPANSION PIPE AND VESSEL

An expansion vessel is necessary, tocompensate the water volume increase dueto the heating.The Technox3 BT boilers are suitable forfully pumped system, wich can be openvented or sealed.In the 1st case the height of the hydrostaticcolumn must be, at least, 3 m above theboiler casing and the capacity of theexpansion cistern shall be able to contain,between the water surface and the overflowpipe, the volume increase of all the water ofthe C.H. system.

Preference shall be given to high andnarrow cistern, to expose to the air asurface as small possible, thus reducingthe water evaporation.In the 2nd case the vessel capacity has tobe calculated taking into consideration:- The total volume of the water contained

in the system.- The maximum Working Pressure of the

system (see setting of PRV).- The maximum working pressure of the

expansion vessel.- The initial preloading of the expansion

vessel.- The maximum working temperature of the

boiler (the maximum setting of thethermostat fitted onto the panel board is

90°C; under this aspect it is suggested toconsider 100°C).

The expansion pipe connects the C.H.system to the expansion vessel.This pipe which starts from the connectingpoint T3 (see table DIMENSIONS), must haveNO gate valve on it.Fit onto the point T3 or onto the supply pipe,within 0.5 m from the flow flange, a pressurerelief valve properly dimensioned for theboiler capacity and in conformity with the localrules in force.It is forbidden to put any gate valve betweenthe boiler and the pressure relief valve.For maximum working pressure of the boiler,see table DIMENSIONS.

11

L

Ø A

2.5.6 - SHUNT PUMP

The Technox3 BT boilers must always operatein forced circulation hot water systems andwith a minimum return temperature of 50°C.So, it is suggestable to adopt a shunt pump,having also an anti-condensation purpose,installed between the flow and return

connections upstream an eventual 3 or 4 waymixing valve.This pump will be sized according to thefollowing formula:

Q = P x 22

where Q = Water flow rate in liter/hP = Boiler nominal output in kW

and the manometric head 1 - 2 m w.c.

2.6 - FURNACE DOOR:ADJUSTMENT,OPENING & CLOSING

A special attention has been paied to thedesign of the front door, because in all thepressurised boilers a good quality of the doorsis a necessary condition for the best operationof the boiler.With the furnace working in positive pressure,in fact, every minimum fissure could cause aleakage of high temperature combustionproducts, with consequent burning of thegasket and overheating of the door up to itspermanent deformation.

For these reason the door structure of theTechnox3 BT boilers, in addition to the factto be very strong, has also the possibility tobe adjusted: it can be lifted, lowered and alsoslanted, getting, thus, always the perfectcentering of the sealing gasket.The special inner lining in ceramic fiberreduces, furthermore, the time to reach theboiler steady state condition and then reducesdrastically the formation of condensate at theboiler start.

IMPORTANTIt is necessary to open the door when the boileris cold to avoid damages to the insulating fibre,due to thermal shocks.The door insulating fibre, after a short operatingperiod, can present some cracks; in any casethis does not compromise its insulatingcapacity and its operating life.The door insulating fibre is easily replaceableand is two year guaranteed.

2.6.1 - IMPORTANT NOTE

Before opening the furnace door it is necessaryto adopt the following precautions:- Close the fuel cock (oil or gas) to the burner.- Cool down the boiler by keeping the water

circulating through it, and only then switchoff the power.

- Put the boiler a Warning notice with thefollowing text: DO NOT USE, BOILER

UNDER SERVICE, OUT OF ORDER.

2.7 - BURNER

2.7.1 - CONFORMITY OF THEBURNER

All the burner equipping the Technox3 BTboilers must be CE certificated and mustconform to the following directives andstandards:- Gas Appliances Directive (90/396/CEE);- EMC Directive (89/336/CEE).- EN 267 - Automizing oil burners of

monobloc type - Testing -- EN 676 - Automatic forced draught burners

for gaseous fuels.

Before fitting the burner it is necessary toverify the position of the turbulators insidethe smoke pipes: each pipe must have itsturbulator and this one has to be positionedas indicated in the table on page 23.On the next page table are listed the matingsboiler/burner for the Technox3 BT series,according to the different types of gas.The table beside the fig. 14 shows the minimumlenght and the maximum diametre of the burnerblast tube that can pass through the frontdoor.The working range of the burner (fuel flowrate - pressure in the combustion chamber)must correspond to the features of the boiler.When mounting the burner to the boiler frontdoor, check for soundness around the burnerflange and its gasket.

BURNER BLAST TUBE DIMENSIONS

fig. 14

Technox3 110÷150BT 120 180

BOILER TYPE øAmm

Lmm

140 180Technox3 225BT

Technox3 300÷380BT 165 200

Technox3 500÷730BT 185 230

Technox3 840BT 230 280

Technox3 1100÷1320BT 245 320

Technox3 1600÷1900BT 245 350

Each boiler is supplied with a length of ceramicfibre rope.This rope has to be put around the burnertube to completely seal the tube and thehole in the door insulation.Be careful not to leave fissures between theburner tube and the hole in the door.In case a cone, having a diameter larger thanthe burner tube, the cone is to be removedbefore fitting and refitted later on.After the burner has been fitted, check thatthe flexible hoses for the oil and electricalcables are long enough to allow the 90° openingof the boiler door.For gas burners the use of flexible pipes forthe gas is not allowed; so the final part of the

gas feeding line to burner must have thepossibility to be removed, via a threaded orflanged connection.

12

2.7.2 - CHOICE OF THE BURNER

The correct choise and the adjustment of theburner are foundamental for the best operationof the boiler and then they shall be accurateand not undervaluated.The burner will be selected by verifying thatthe working diagram (fuel flow rate - pressurein the furnace) is compatible with the samefeatures declared for the boiler.Remember that the smoke side resistance,i.e. counterpressure in the furnace, are referredto “0” draught at the chimney base.It is also convenient that the burner blast tubehave its length not shorter than that shown

too temperature, can cause important damagesto the boiler.The burner manufacturing companies are ableto supply the flame dimensions developpedby their burners.More informations are given in the paragraph“Commissioning”.

2.7.3 - MOUNTING OF THE TWO-STAGEOR MODULATING BURNERS

The boilers Technox3 BT range may beequipped with a two-stage or modulatingburner provided the following conditions, interms of combustion, smoke temperature andboiler temperature are complied with:1) Combustion:- with light oil having a maximum viscosity

of 1,5°E at 20°C:CO ≅ 12 to 13%.

- with natural gas: CO ≅ 9 to 10%.

2) Smoke temperature: within 160° to 180°Cin any working condition.

3) Boiler working temperature: the temperaturehas to be adjusted through the boilerthermostat within 60° to 80°C, so that thereturn temperature cannot go below 50°Cin any working condition.Make sure, then, there is no condensateformation in the smoke pipes or onto therear tube plate when a two-stage ormodulating burner is in operation at its

minimum input.Pay attention when building the chimney:it must be perfectly sound, to avoiddamages to the walls, due to the smokecondensate, and properly insulated.

in the table 16 and that the flame have a shapesuitable to the characteristics of the Technox3BT furnace.In fact to better exploit all the heating surfaceof the reversed flame furnace it is necessaryto use burners capable to guarantee a longand narrow flame at all operating conditionsor also at minimum input in case of two stageor modulating burners.Too short flames can cause a localizedoverheating of the front part of the furnace,and the combustion products, not sufficientlycooled down, entering the smoke pipes at a

13

Hose in blue PVC

Pressure test nipple onto the flame sight

Fit the plug of 1/4

Combustion chamber test nipple

Hose transfering combustion chamber pressure

2.8 - CONNECTING FLAMESIGHT GLASS TOCOOLING PIPE OFBURNER

The flame sightglass is equipped with a 1/8"threaded connection on wich a pressure testnipple (9 mm dia.) is fitted.This can be used with a silicon pipe for themeasurement of the counterpressure in thecombustion chamber.At the place of this pressure test nipple, whichmust be held, a special microbore pipe willconnect the flame sightglass directly to thepressure room downstream the fan of theburner.The air, blown by the fan, will cool down andclean the sightglass.If the sightglass is not cooled down it can bebrocken down.WARNING: In the proximity of the sightglassthe temperature is very high: be careful!!!For all the matings with SPARKGAS 30 LXand BGN...LX burners, drill a hole 12 mmdia. onto the burner plate, to insert the pressuretest nipple (metallic pipe) in the combustionchamber.Alternatively it is possible to connect the bluePVC hose, supplied with the burner, to thepressure test nipple placed onto the flamesight (see fig. 15), replace the pressure testnipple supplied with the flame sight, by thefitting (part code 88790421) to be orderedseparately (see technical spare part listTechnox3 BT).

fig. 15

14

N.B. For the model Technox3 840BT (ref.fig. 20 & 21), the casing and theinsulation are contained in 3 cartonsstamped:

packing 1/4 (casing front side parts Technox3 1100BT)packing 2/4 (casing rear side parts Technox3 1100BT)packing 3/4 (casing upper parts Technox3 1100BT)packing 4/4 (casing rear panel Technox3 1100BT)packing 1/4 (casing front side parts Technox3 1320BT)packing 2/4 (casing rear side parts Technox3 1320BT)

N.B. For the models Technox3 1100BT toTechnox3 1600BT (ref. fig. 22 & 23),the casing and the insulation arecontained in 4 cartons stamped:

packing 3/4 (casing upper parts Technox3 1320BT)packing 4/4 (casing rear panel Technox3 1320BT)packing 1/4 (casing front side parts Technox3 1600BT)packing 2/4 (casing rear side parts Technox3 1600BT)packing 3/4 (casing upper parts Technox3 1600BT)packing 4/4 (casing rear panel Technox3 1600BT)

packing 1/5 (casing front side parts Technox3 1900BT)packing 2/5 (casing rear side parts Technox3 1900BT)packing 3/5 (casing upper parts Technox3 1900BT)packing 4/5 (casing central parts Technox3 1900BT)packing 5/5 (casing rear panel Technox3 1900BT)

N.B. For the model Technox3 1900BT (ref.fig. 22 & 23), the casing and theinsulation are contained in 5 cartonsstamped:

2.9 - CASING ASSEMBLY

N.B. It is suggested to verify that the boiler ispositioned in its final place and that all thehydraulic connections are made correctlybefore starting the casing assembly.Before opening the casing carton(s) makesure they are stamped with the right boilermodel, corresponding to the boiler to be

installed.N.B.: The packaging containing the panel

board is delivered inside thecombustion chamber, as well as thedocuments and the guaranteecertificate.

packing 1/1 (casing for Technox3 110BT)packing 1/1 (casing for Technox3 150BT)packing 1/1 (casing for Technox3 225BT)packing 1/1 (casing for Technox3 300BT)

packing 1/3 (casing for Technox3 500BT)packing 2/3 (casing for Technox3 500BT)packing 3/3 (insulation Technox3 500BT)packing 1/3 (casing for Technox3 630BT)packing 2/3 (casing for Technox3 630BT)packing 3/3 (insulation Technox3 630BT)

N.B. For the models Technox3 500BT toTechnox3 730BT (ref. fig. 18 & 19),the casing and the insulation arecontained in 3 cartons stamped:

N.B. For the models Technox3 110BT toTechnox3 380BT (ref. fig. 16 & 17),the casing and the insulation arecontained in one carton stamped:

packing 1/1 (casing for Technox3 380BT)

packing 1/3 (casing for Technox3 730BT)packing 2/3 (casing for Technox3 730BT)packing 3/3 (insulation Technox3 730BT)

packing 1/3 (casing front side parts Technox3 840BT)packing 2/3 (casing rear side parts Technox3 840BT)packing 3/3 (casing upper parts Technox3 840BT)

15

67

8

9

5

3

1312

10

2

1

4 11

14

15

Assembly of the casing for Technox3 110BTto Technox3 380BT should be carried out inthe following steps:Refer to diagram on fig. 16 & 17 for details:

A) Fit the insulation blanket (1) onto the boilershell and secure it in to place using theelasticated straps (2) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.

B) Locate the side panels (3) and (4) withthe lower bend inside the bottom L profilesand the upper bend in the seats of frontand rear tube plates.To determine which is the left and rightpanel ensure that the cable glands arepositioned facing toward the front edge.

C) Open the combustion chamber door andfit the front insulation (5), inserting thehinges in the pre-cuts.Insert the side ends of the insulation underthe bend of the two side panels (3 & 4).

D) Fit the rear insulation (pos. 6), fix the rearlower, intermediate and upper panels (pos.7, 15 & 8) with the self tapping screws.Fit the plastic cable clamps (9) to the upperrear panel (8).Note: because the rear insulation issuitable for two different boiler ranges,before removing the pre-cut insulation,follow the instructions supplied with the

insulation it self.E) Remove the cover from the panel board;

fix the base onto the upper panel (pos. 10)threading the electric wiring in through thecentral hole and the capillaries outthrough it.Fit the upper panel (pos. 10), complete withthe panel board, to the side panels (3 and 4).

F) Insert the probes of the thermostats in thebulbs holders on the back sides of the boiler(above the smoke chamber)(Ref. fig. 17);the probe of the thermometer (pos. 1), ofthe working thermostat (pos. 2) and theminimum temperature thermostat (pos. 3)must be inserted in the largest bulb holder(ø = 15 mm), the probe of the safetythermostat (pos. 4), must be inserted inthe smallest bulb holder (ø 7 mm).We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.Close the panel board.

Guide the burner plug through the sidecable clamp plate (11) on the preferredside and clamp the cable using a PG 11cable clamp.Fix the side cable clamp plates (11) to thecasing side panels (3 & 4).Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (9).

G) Fit the longitudinal upper panels (pos. 12and 13) to the side panels.

H) Remove the protective paper film fromdata plate and ventilation requirement label(14) and fit them at the top front cornerof the most accessible side panel afterremoval of dust from the surface.The data plate and label are in thedocuments envelope.

Technox3 110BT to Technox3 380BT

fig. 16

16

2 15

53

4

fig. 17


1 Thermometer probe2 Boiler thermostat probe (with knob)3 Minimum thermostat probe (screwdriver)4 Safety thermostat probe5 Probe retaining clip


A) Fit to the front and rear tube plates thefour upper brackets (pos. 1), supportingthe side panels, using the screws, washersand nuts supplied (pos. 2, 3 and 4).

B) Fit to the front and rear tube plate the fourintermediate and lower brackets (pos. 5)supporting the side panels, using thescrews, washers and nuts supplied (pos.2, 3 and 4).

C) Fit the insulation blanket (6) onto the boilershell and secure it in to place using theelasticated straps (7) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.

D) Position the side lower panels (pos. 9 and18) onto the lower and intermediatebrackets (pos. 5).To determine which one is the left or righthand side panel ensure that the cableglands are positioned facing toward thefront edge.

E) Position the side upper panels (pos. 8 and17) onto the upper brackets (pos. 1) andfix their pivots on the lower side.

F) Fit the 8 screws (pos. 10) to the upperpart of the front and rear counter bend ofthe upper panels (pos. 8 and 17).

G) Fit the front insulation (pos. 11), insertingthe hinges in the insulation pre-cuts.

Note: because the front insulation issuitable for two different boiler ranges,before removing the pre-cut insulation,follow the instructions supplied with theinsulation it self.

H) Fit the rear insulations (pos. 16 and 27)and fix the rear lower panel (pos. 26).

I) Position the panels 12 and 19 betweenthe side upper panels (pos. 8 and 17).

L) Remove the cover from the panel board;fix the base onto the upper panel (pos. 13)threading the electric wiring in through thecentral hole and the capillaries outthrough it.Fit the upper panel (pos. 13), complete withthe panel board, to the side panels (8 and17).Guide the burner plug through the sidecable clamp plate (14) on the preferredside and clamp the cable using a PG 11cable clamp.

M) Insert the probes of the thermostats in thebulbs holders on the back sides of the boiler(above the smoke chamber)(Ref. fig. 19);the probe of the thermometer (pos. 1), ofthe working thermostat (pos. 2) and theminimum temperature thermostat (pos. 3)must be inserted in the largest bulb holder(ø = 15 mm), the probe of the safety

thermostat (pos. 4), must be inserted inthe smallest bulb holder (ø 7 mm).We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.Close the panel board.

N) Fit the cable clamps (pos. 20) onto therear panel (pos. 19).Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (20).

O) Fit the longitudinal upper panels (pos. 21and 25) to the side panels.

P) Remove the protective paper film fromdata plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

17

21

6

6 3

4

5

fig. 18

fig. 19


1 Thermometer probe2 Boiler thermostat probe (with knob)3 Minimum thermostat probe (screwdriver)4 Safety thermostat probe5 Contact spring6 Probe retaining clip


18

2

12

6

5

14

13

15

7

3

9

11

4

1

10

8

16

Assembly of the casing for Technox3 840BTshould be carried out in the following steps:Refer to diagram on fig. 20 & 21 for details:

A) Fit the insulation blanket (1) onto the boilershell and secure it in to place using theelasticated straps (2) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.

B) Locate the side panels (pos. 3, 4, 5 and 6)hooking them to the upper and lowerprofiles.To determine which one is the left or righthand side panel ensure that the cableglands are positioned facing toward thefront edge.

C) Fit the four screws pos. 7 on the innerupper rear side panels.

D) Open the combustion chamber door andfit the front insulation (pos.8), inserting thehinges in the insulation pre-cuts.

E) Remove the cover from the panel board;fix the base onto the upper panel (pos. 9)threading the electric wiring in through thecentral hole and the capillaries outthrough it.Fit the upper panel (pos. 9), complete withthe panel board, to the side panels (3 and5).Guide the burner plug through the sidecable clamp plate (16) on the preferredside and clamp the cable using a PG 11

cable clamp.F) Insert the probes of the thermostats in the

bulbs holders on the back sides of the boiler(above the smoke chamber)(Ref. fig. 21);the probe of the thermometer (pos. 1), ofthe working thermostat (pos. 2) and theminimum temperature thermostat (pos. 3)must be inserted in the largest bulb holder(ø = 15 mm), the probe of the safetythermostat (pos. 4), must be inserted inthe smallest bulb holder (ø 7 mm).We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.Close the panel board.

G) Fit the longitudinal upper panels (pos. 10and 11) to the side panels.

H) Fit the rear insulation (pos.12) and fix therear lower panel (pos. 13).

I) Fit the rear upper panel (pos. 14).L) Fit the plastic cable clamps (pos. 15) onto

the rear upper panel (pos. 14).Fit the cables, leaving the boiler from theback side, with the plastic screws of the

cable clamps (15).M) Remove the protective paper film from

data plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

Technox3 840BT

fig. 20

19

2 15

6

3

4

2 1

5

5 3

41 Thermometer probe2 Boiler thermostat probe (with knob)3 Minimum thermostat probe (screwdriver)4 Safety thermostat probe5 Probe retaining clip

fig. 21

Technox3 840BT

fig. 22

Sequence of probes introduction

Introduce the bulb into the bulb holder, in theupper part of the boiler body, in the followingsequence (Ref. to fig. 22):- (pos. 1) thermometer- (pos. 2) working thermostat- (pos. 3) high limit thermostat- (pos. 4) minimum temperature thermostat.It is recommended to introduce the bulbs upto the bottom of the bulb holder to have abetter response. Introduce then the contactspring (pos. 6) to improve the contact andsecure the capillaries in position by the clip(pos. 5).

1 Thermometer probe2 Boiler thermostat probe (with knob)3 Safety thermostat probe4 Minimum thermostat probe (screwdriver)5 Probe retaining clip6 Contact spring

Technox3 1100BT to Technox31900BT

20

9

10

2

5

6

3a3b

11

12

13

4a 51

4b

7

8

14

Technox3 1100BT to Technox31900BT

We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact.Connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.Close the panel board.Fix the side cable clamp plates (5) to thecasing side panels (3a & 4a).Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (10).

H) Fit the longitudinal upper panels (pos. 12and 13) to the side panels.

I) Remove the protective paper film fromdata plate and ventilation requirement label(14) and fit them at the top front cornerof the most accessible side panel afterremoval of dust from the surface.The data plate and label are in thedocuments envelope.


A) Fit the insulation blanket (1) onto the boilershell and secure it in to place using theelasticated straps (2) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.Make a convenient cut in the upper part ofthe insulation blanket to get easy accessto the bulb holders.

B) Position the side panels (3a, 3b and 4a,4b) with the lower bend inside the bottomL profiles and hook them to the screwsfitted to the upper profiles.To determine which one of the front sidepanels is the left or the right ensure thatthe cable clamp plates (5) are positionedfacing toward the front edge.

C) Open the combustion chamber door and

fit the front insulation (pos. 6), insertingthe hinges in the insulation pre-cuts.Insert the side ends of the insulation underthe bend of the two side panels (3a and 4a).

D) Fit the rear insulation (pos. 7) and fix therear lower panel (pos. 8).

E) Fit the rear upper panel (pos. 9) and fitonto it the plastic cable clamp (pos. 10).

F) Remove the cover from the panel board;fix the base onto the upper panel (pos. 11)threading the electric wiring in through thecentral hole and the capillaries outthrough it.Fit the upper panel (pos. 11), complete withthe panel board, to the side panels (3a and4a).Guide the burner plug through the side cableclamp plate (5) on the preferred side andclamp the cable using a PG 11 cable clamp.

G) Insert the thermometer and thermostatsprobes in the bulbs holders as shown infig. 22.

fig. 23

21

21

3

Electrical cables positioning

The control panel is equipped with a 7 poleburner cable, see wiring diagram on fig. 26.When installing the panel board, connect theleads of the 7 pole cable, to the burner teminalstrip or to the 7 pole plug (see wiring diagramon page 22), after the inserting of the cableinto the cable gland (pos. 2 - fig. 24).The seven pole plug and the cable must comeout from the casing through the cable clampplate (pos. 1), onto which the cable glandmust be fixed.Cable clamps are located on the rear upperpanel of the boiler to fix the service cables.

fig. 24

22

N.B. : With three-phase line the motor must be connected directly; in this case theinstrument panel feeds only the line of the auxiliares of the burner.In case the burner is not provided with the connector, it will be necessary to follow theinstructions reported on the burner's instruction manual.(*) - Disconnect the bridge between the terminals 11 and 12 of the terminal board (MC) prior

of mounting the room thermostat (TA).(**) - When the burner is not provided with connector complying with DIN 4791 norms connect,

the bridge between the terminals 4 and 7 of the terminal boards (MC).(***) - The panel is supplied with the "Tm" set at 40°C, as standard. In case the panel is mounted

on a boiler with integrated sanitary water tank:° The "Tm" thermostat gives way to sanitary water and has therefore to bes set at 70°C at

the first start.° The room thermostat "TA" is to be connected to the pump in series.

N

230 V~ 50 Hz( MAX 4 A)

2 3

TS

TA

S4

S1

1

�

�

(100°C)

4 5 6 7 8

11

9 10

HP1

L1 T2N S3T1 B4

B

4-4

X1SDIN 4791

MC

5-5

6-6

7-7

10-1

0

9-9

8-8

16 18 19

T6 T7B5 T8

17

X2S

H1HP2H2

TC�

(44-84°C)

12

B

H0

(50-90°C)22

21

14

11

12

L

F1

c

21

13

CI

14

S2

15

Tm�

(40°C)

OP

*

***c

2

**

4 5 6 7 8

LN

BL1- PHASE

T2

N- NEUTER

S3- LOCKOUT

T1

B4- VALVE OPERATION

T6T7

B5- Ii° STAGE OPERATING LAMP

T8

- REGULATIONS SYSTEM

- GROUND

- Ii° STAGE REGULATION

LEGENDS1- Luminous main switchS2- System pump switchS4- Burner switch•CI- System pump•B- Burner•F1- F 4A/250V fuse•H0- Burner lock-out lamp•H1- Operating lamp•H2- II stage operating lampMC- Boiler's terminal board•P1- Hour meter•P2- II stage hour meterTC- High/low regulating thermostatTm- Minimum thermostat or precedenceTS- Safety thermostat with manual reset•X1S- Boiler connecting plug•X2S- Boiler's II stage connecting plug•TA- Room thermostat•OP- Programmer timer• Not included

24

40

15

17 30

22

14

16

11 18

2313

21

12

2541

3231 33 34

26

3.1 - FUNCTIONSDESCRIPTION

The mains switch 11 turns on the panel andequipment attached to it.Switches 12 - 13 cut off the supply to theburner and pump.Thermostat 21 controls the workingtemperature of the boiler.The low thermostat 24 stops the main pumpuntil the temperature in the boiler is lower than40°C.If there are burners and/ or a three stagesystem pump or in the event of absorptionover 3A, a remote control unit should be usedbetween the boiler panel and the load.A switch with protective fase should beapplied to the supply line feeding electricityto the control panel.

3

11 Luminous main switch12 Burner switch13 System pump switch21 Boiler high/low regulating thermostat (with knob)22 Safety thermostat with manual reset24 Minimum thermostat of priority (screwdriver adjusted)30 Thermometer

3.2 - WIRING DIAGRAM FOR BURNER AND SINGLE PHASE PUMP

fig. 25

CONTROL PANEL

fig. 26

0002

7227

8100

0270

0871

23

A

COMMISSIONING AND OPERATION

POSITIONING OF THE TURBULATORSThe Technox3 BT boilers are designed to beused in an output range to improve theseasonal efficiency and the possibility to beadopted in all the heating installations.The output must be adjusted at thecommissioning stage, according to the systemdesigner indications and, in any case, withinthe operation range for each boiler modelshown on pages 5 to 8, by the burnertechnician, which will determine the fuelthroughput.In any case the turbulators will be placed,inside the relevent smoke pipes, at adistance, from the front tube plate, asshown in fig. 27.When using the boiler at minimum output thesmoke temperature will not be lower than160°C.In contrary case, before get in touch our AfterSale Service Dept, ascertain that theturbulators are in all the smoke pipes.The commissioning of the burner must beperformed under the responsibility of aspecialized and well trained burner technician,authorised by the burner manufacturer.In that occasion a commissioning report hasto be filled out.

4

Technox3 110BTTechnox3 150BTTechnox3 225BTTechnox3 300BTTechnox3 380BTTechnox3 500BTTechnox3 630BTTechnox3 730BTTechnox3 840BTTechnox3 1100BTTechnox3 1320BTTechnox3 1600BTTechnox3 1900BT

1001002004004002002002002001100150015001800

A =A =A =A =A =A =A =A =A =A =A =A =A =

fig. 27

Detail 1:Fit the brush handle extensiononto the turbulator remover.Whitdraw the pin from turbulator.

Detail 2:Fit the pin in the radial hole with ahammer.

Detail 3:Screw the turbulator remover ontothe turbulator.

Detail 4:Turn up to unblock the turbulator.

Detail 5:Withdraw the turbulator.

Detail 6:Turn the remover counterclockwiseto release the turbulator.

The procedure from detail 3 to 6 has to be repeated for all the turbulators.

Turbulators removal

fig. 28

24

4.2 - FIRST COMMISSIONING

Al the commissioning stage of the boiler aqualified technician has to perform thefollowing checks:- Internal and external sound test of burner

and fuel feeding pipe;- Adjustment of the fuel throughput according

to the nominal input of the boiler (it isconvenient to remember that the nominalinput can be adjusted between the minimumand the maximum shown in the table ofpages 5 to 8), by sharing the output betweenthe 1st and the 2nd stage, knowing thatthe 1st stage flame can go down to the60% of the nominal output (wich at its turncan vary between the minimum and themaximum depending on the outputrequested by the C.H. system).

Proceed, then, in the following way:- Open the fuel feeding cock and check that

there are no leaks in the feeding line.- Ascertain that all the switches of the panel

board are in OFF position and adjust theworking thermostat to the minimum position.

- Switch ON the panel board through themain switch.

- Switch ON the C.H. pump; it will start torotate as soon as the minimum watertemperature thermostat detects 50°C.

- Switch the burner ON.- Position the working thermostats of 1st

and 2nd stages to the maximum settingto create a heat request.

4.1 - PRELIMINARY CHECK

Once all the hydraulic, electrical and fuelconnections have been made, before startingthe boiler we suggest to ascertain that:- The expansion vessel and the pressure

relief valve are correctly connected andare in no way interceptable.

- The probe of thermometer, working, highlimit and minimum thermostats are wellsecured into their proper bulb holder.

- The turbulators are correctly fitted in allthe smoke pipes.

- The C.H. circuit has been washed andrinsed and is free from solid impurities.

- The C.H. circuit is filled with water and

has been completely purged.- The pumps operate properly.- The flow switch, the pressure relief valve,

and the overheating discharge valve, ifany, are adjusted at the right value.

- The fuel, hydraulic, electrical and safetyconnections are executed in conformitywith national and local requirements inforce.

- There are no water leaks.- The burner has been fitted according to

the instructions of the burner manufacturer.- The mains voltage and frequency are

compatible with the burner and the electricalequipment to boiler.

- The burner is adjusted for the fuel type,among those listed in the burner data plate,

available on the installation site, and theburner output range is compatible with theboiler output.

- In the boiler house there also the burnerinstructions.

- The C.H. pipes are properly insulated.- The C.H. system is capable to absorb the

heating quantity produced at the first startof the burner, during the test period.

- The sunt pump is installed as prescribedin the paragraph 2.5.6.

During this phase check that:- There are no smoke leaks from the front

door, the burner plate and the chimneyconnection.

- There is a draught at the chimney basebetween 2 and 4 mm w.g.

- There are no water leaks.- The different thermostats and the other

installation safety devices work properly.- The shunt pump operates correctly.- The burner ignition as good.- The burner characteristics (main adjustments

and nozzle type) correspond to the boilerdata plate.

With a burner properly adjusted it must bepossible to reach easily, from a smoke sampletaken at the chimney base, the values givenbelow:1) With light oil having a maximum viscosity

of 1,5°E at 20°C:- CO ≅ 12÷13%- Smoke index <1- Smoke temperature ≅ 180÷200 °C

2) With Natural Gas:- CO = 9÷10%- Smoke temperature ≅ 160÷180°C

(values related to a clean boiler, with waterat 70°C).It is suggested to adjust the fuel throughputto the actual needs of the C.H. installation(avoid to overcharge the boiler), withoutexceeding the a.m. smoke temperatures

(never go below 160°C).The HIGH EFFICIENCY Technox3 BT boilersare foreseen to operate with a return watertemperature never below 50°C when operatedon light oil, and never below 60°C whenoperated on gas, to avoid, (or, at least, toreduce) the smoke acid condensationphenomenon, which can be the reason of apremature deterioration of the steel boilerbody.The working thermostat, pos. 21 of the panelboard, must be set at a temperature ofapproximately 80° to 85°C.The room temperature will be compulsorilyadjusted through a mixing valve and, eventually,an outer compensator.To homogenise the water temperature, oravoid as maximum as possible, returns intothe boiler at a temperature below 50°C whenoperated on oil, or 60°C when operated ongas, a properly dimensioned shunt pumpmust be fitted between flow and return pipesof the boiler.N.B. The metal sheet corrosion due to theacid condensate is not covered by theguarantee because its depends only from theoperation of the C.H. system.The Technox3 BT panel board is equippedwith a low temperature thermostat not allowingthe operation of the pump when the boilertemperature is below 50°C (protection againstcold starts).

4.3 - SWITCH OFFOF THE BOILER

- Switch OFF the burner (switch No 12 to 0position).

- Leave the pumps working up to when theyare not stopped by the minimum thermostat.

- Switch OFF the power to the boiler panelboard.

- If it is decided not to use the boiler for along period close also the gate valves ofthe fuel.

25

MAINTENANCE5

5.1 - GENERAL RULES

Before effecting any operation of cleaning ormaintenance, disconnect the boiler from theelectrical supply acting on the main switchonto the panel board.In case of failure or bad operation of the boiler,switch it off, abstaining your self from anyattempt of reparation or direct intervention.Exclusively address to professionally qualifiedpersonnel.The possible reparation of the boiler must beeffectued by an authorized service centerusing only original spare parts.

The non respect of the above can jeopardizethe safety of the boiler.To guarantee the efficiency of the boiler andfor its correct operation it is essential to submitthe boiler to an annual maintenance, througha professionally qualified technician, accordingto the indications of the manufacturer.When it is decided not to use the boileranymore, the parts which can be potentialsources of danger shall be made harmless.After a month of boiler operation, open thefront door and ascertain the smoke pipes areclean.

In case of a heavy dirtiness:- Remove the turbulators from smoke pipes.- Clean all the smoke pipes using the brush

delivered with the boiler.- Open the cleaning door on the smoke

chamber and remove, with a vacuumcleaner all the soot.

- Relocate the cleaning door and theturbulators; then close the boiler front doorand check for soundness all around thesealing rope.

- Then adjust the burner.Note: With a burner properly adjusted only acleanup at the season end is necessary.

5.2 - ORDINARYMAINTENANCE

The boiler operating condition are very differentfrom one case to the other and depend onthe fuel used, on the adjustment of the burner,on the number of starting, on the C.H. systemcharacteristics, etc. and for that reason it is notpossible to establish, in advance, the frequencyof the maintenances.It is, then, necessary that the technician, whoperforms the first cleaning, establish thecleaning of frequency on the base of the boilerstatus.Generally, we suggest the following frequency,according to the fuel used:- Gas fired boilers: once a year.- Oil fired boilers: twice a year or more often

if there is reason to doubte of theiradjustment.

In any case the local rules in force have tocomplied with.We suggest to shake the turbulators, withoutremoving them from the smoke tubes, at leastonce a month of operation, not to allow thesoot blocking them and making them extremelydifficult to be removed.During the operations of ordinary maintenanceit will be necessary to brush the tube bundle- after the removal of the turbulators - and

the furnace and collect the soot through thecleaning door on the smoke chamber.Besides it will be necessary to verify the goodoperation of the protection and control devices(thermostats, thermometers) of the boiler andof the plant (manometers, flow and pressureswitches, expansion vessels) and all the safetydevices.In this occasion it will be necessary to noticethe quantity of reinstatement water used anddecide, also in base to its hardness, anintervention of preventive descaling.It must be considered that the calcium andmagnesium salts dissolved in the raw water,with repeated reinstatements, can causedeposits in the boiler that hinder the innercirculation and subsequent overheating of thewall plates with possible serious damagesthat cannot be attributed to be constructivegeometry and/or to the materials used andto the constructive technique and, therefore,they are not covered by guarantee.On the occasion of the ordinary maintenanceit is useful to perform a small discharge fromthe boiler to verify if sludges escape.In affirmative case, it will be necessary toprolong the discharge up to get clear water.At the end of the drainage it will be necessaryto reestablish the level of the water in thesystem.

At the end of the smoke circuit cleaning, tothe next restart check around the burner plateand the smoke chamber for smoke leaks.In the case some smoke leaks were noticed,first of all tighten the nuts fitting the smokechamber and, not getting result, it will benecessary to replace the sealing gasket.Similarly it will be necessary to act on thefront door, increasing at first the tightening thescrews (Technox3 110BT to Technox3 730BT)- or alternatively - the nuts (Technox3 840BTto Technox3 1900BT) (after having loosenedthe inner counternuts) and then, if necessary,by replacing the whole gasket.If it was necessary to center the sealinggasket on the sealing ring of the door it ispossible to adjust the door position by actingas suggested on the paragraph 2.6.At the end check and, if necessary, restorethe sealing of the connection of the chimneyand of the burner with the door.The performed operations must be recordedon the log book of C.H. system.

5.3 - EXTRAORDINARYMAINTENANCE

Extraordinary maintenance of end seasonor for long periods of inactivity.It will be necessary to perform all the operationsdescribed in the preceding chapter andbesides:- Check the state of consumption of the

turbulators to replace them in time.- To facilitate the extraction of the turbulators,

with the Technox3 BT boilers, a specialextractor is supplied.

- After the cleaning of the smoke circuit itis convenient to pass in the smoke pipes

and in the furnace with a rag soaked ofdiluted solution of caustic soda.After having let to dry cross again all thesurfaces with a rag soaked or oil.Pefectly close the burner air intake to avoida continuous passage of damp air throughthe boiler recalled by the chimney it self.It is advisable to put inside the furnacesome alive mortar that has an hygroscopicaction.

- Do not empty the C.H. system and theboiler.

- Protect the screws with graphitized fat,nuts and pivot of the door.

- Show all the operations that must beperform to the following put into operation

particularly the operation of the shuntpump must be checked.

26

5.4 - CLEANING OF THEBOILER

Follow the next sequence:- Close the feeding of the oil.- Cooldown the boiler to the ambient

temperature.- Switch OFF the electrical supply to the

5.5 - CHECK OF THEBOILER OPERATION

For a sale operation of the boiler it is necessaryto check:- The good operation of the working

5.6 - CHECK OF THEBURNER OPERATION

- See the burner instruction manual.- Follow all the local requirement in terms

of burner maintenance.

5.7 - BOILER HOUSEFor the combustion of oil or gas burner needsair.Accordingly wide openings are foreseen forthe entry of the air in the boiler house.These openings never have to be obstructed.

thermostat.- The good operation of the high limit

thermostat.- The adjustment and the good operation

of the minimum thermostat.- The good operation of the shunt system.- The good operation of the outer

compensator (if fitted).- The good operation of all the other safety

and control devices imposed by a localrequirements.

Maintain the boiler house clean and dust free.The boiler house is not a closet: avoid to storeany kind of materials.Maintain the entry of the boiler house freeand easy to reach in any moment.Ascertain that the boiler house is endowed

with efficient emergency lamp.

boiler and the burner.- Open the front door.- Shake and remove the turbulators every

15-20 days of activity of the boiler to avoidthat the residues of combustion can stopthem so much to make difficult theirremoval.

- Clean the turbulators and the smoke pipesby brushing them with the brush supplied.

- Reposition the turbulators (see fig. 27).- Remove the cleaning door and all the soot

from the smoke chamber.- Re-fit the cleaning door.- Verify the state of the refractory insulation

of the combustion chamber door.- Verify the state of the door sealing rope.- Close the door of the furnace.

27

6.1 - GENERALWARNINGS

The instruction manual is an essential andintegral part of the apparatus and must behanded over the user.Carefully read the instructions contained in itas they provide important advice on installationsafety, use and servicing.Keep the instruction manual handy for furtherconsultation.Installation must be carried out in accordancewith the latest regulations, the manufacturer'sinstructions and by specially trained staff.Specially trained staff refers to thosespecifically trained in the field of heatingsystems for domestic use and domestic hotwater systems, in particular the manufacturer'sauthorised Service Centres.Improper installation can cause injuries topeople and animals and damage to the home,for which the manufacturer is not responsible.

After removing the packaging check that thereare no broken or missing parts.If in doubt, do not use the equipment and

contact your supplier.The packing (wooden crate, nails, clips, plasticbags, expanded polystyrene, etc.) are potentiallydangerous and must be kept away fromchildren.

Before starting any cleaning or servicing,switch off the electricity supply using the mainswitch.Do not obstruct the ventilation grilles or heatdissipation grilles.If the equipment breaks down or is notfunctioning correctly, switch it off and do nottry to repair it or interfere it in any way.Contact only authorised personnel.Any repairs must be carried out by anauthorised service centre designated by themanufacturer. Only original spare parts mustbe used.Failure to observe the above instructions canjeopardise the safety of the system.To guarantee efficiency and top performancethe system must be serviced annually byspecialised personnel. The manufacturer'sinstructions must be followed.If it is not to be used, the parts which could bepotentially dangerous should be rendered

harmless.Only original accessories must be used onsystems with optionals extras or kits (includingelectrical parts).This equipment must be used for the purposefor which it was expressly designed. Any otheruse is to be considered improper and thereforedangerous.The manufacturer accepts no responsibilityfor damage caused by improper installationor use. The manufacturer's instructions mustbe fully adhered to.

LEGISLATION AND WARNINGS6

6.2 - SUMMARY OFWARNINGS

This boiler must be used only for the purposefor which it was built.Important: this boiler is for heating water at atemperature below boiling point. It must beconnected to a heating system and/or to adomestic hot water system and must functionwithin its performance and output limits.

Installation

The boiler must be installed in a room thatmeets the requirements laid down in the latestregulations.Before connecting the boiler the followingshould be carried out by registered personnel:a) carefully wash all the pipes to remove any

residue that might harm the boiler;b) check that the boiler is suited to the type

of fuel available. This is shown on the labelshowing the technical data;

c) check that the flue draught is adequate,that there are no blockages and that noother boilers are connected to the sameflue stack, unless this has been done toserve more than one boiler, according tospecific regulations; at this point the boilercan be connected to the flue;

d) if there are connections belonging to previousflues these must be examined to checkthat they are perfectly clean as debris maydislodge and block the smoke passage,putting the user in great danger.

The burner must be installed according to theinstructions contained in the burner instructionmanual.

Commissioning

Commissioning must be carried out by qualifiedstaff.Before starting up the boiler the qualified staffshould check:a) that the data on the label correspond to

the various supplies (electricity, water,gas, oil or other fuel);

b) that the output range of the burner iscompatible with that of the boiler;

c) that the handbook for the burner is alsokept in the boiler room;

d) that the pipelines that exit from the boilerare covered with the proper heat insulatingsheath;

e) that the smoke evacuation duct functionsproperly;

f) that the air is fed in and smokes evacuatedcorrectly and in accordance with the latestregulations.

Warning to the user

It is dangerous and illegal to even partiallyobstruct the air vents in the boiler room.Do not leave the boiler on when it is not to beused for long periods; in such cases the fuelsupply should be cut off and the generalelectricity switch turned off.Do not touch hot parts of the boiler, such as,doors, burner plate, smoke chamber, fluepipe, etc. during and after functioning theseare hot and can cause burns and scalding.Do not allow children or inexperienced personsnear the boiler.Do not let the boiler get wet from splashingliquids.

Do not place anything on top of the boiler.Do not allow anyone inexperienced to usethe boiler.In case of temporary disuse the following stepsshould be carried out:a) switch off electricity, water and fuel

supplies;b) empty the water system, if there is no

antifreeze.If the boiler is no longer to be used at all,qualified staff should carry out the necessaryoperations, checking that the electricity,water and fuel supplies are switched off.

If the output of the boiler requires, it must beoperated by specialised staff in accordancewith the latest regulations.Before carrying out any task that involvesdismounting the burner or opening covers orinspection doors, switch off the electricity andfuel supply taps.

Servicing

Periodically check that the smoke evacuationduct is working properly.Do not clean the equipment and/or its partsusing easily inflammable liquids (eg. petrol,alcohol, etc.).Do not leave containers with inflammableliquids in the boiler room.Do not clean the boiler room when the burneris switched on.At the end of the heating season the boilershould be checked by qualified staff to ensurethat it is in perfectly condition.Careful servicing helps save money andguarantees safety.

28

6.3 - ELECTRICALSUPPLY

The electrical safety of the system is ensuredonly if it is correctly wired up to an efficientand correctly installed earthed system thatcomplies with the latest regulations.This fundamental requisite must be checked.If in any doubt ask for professional advicesince the manufacturer is not responsible fordamage caused by the system not beingearthed.A professional check should be carried outto ensure that the electrical installation is

6.4 - WATER SUPPLY

The water fed components are normallyconnected to the supply by means of a waterpressure reducing valve.Check that the water pressure measuredbeyond the reducing valve is not greater thanthe working pressure indicated on the labelof the boiler, water tank, etc.).Since the pressure of the water in the heatingsystem increases, check that its maximumvalue does not exceed the max. water pressure

6.5 - BOILER FIRED BYGAS, OIL OR OTHERFUEL

General warnings

Boiler installation must be carried out onlyby registered personnel and in accordancewith the latest regulations since improperinstallation can cause damage to persons andobjects for which the manufacturer cannot beheld responsible.Before installing it is advisable to carefullyclean all the fuel feeding pipelines to removeany residue which may harm the boiler.To start up the boiler the registered installershould carry out the following steps:a) check the inner and outer seals of the fuel

feeding system;

b) regulate the fuel flow according to themaximum output indicated on the burnerlabel;

c) check that the burner is receiving theappropriate type of fuel;

d) check that the fuel feed pressure, if gas,is within the values indicated on the burnerlabel;

e) check that the flue feed system is thecorrect size for the flow needed by theboiler and that it has all the safety andcontrol devices required by law.

Special indications for gas

The registered installer should carry out thefollowing steps:a) check that the feeding line and gas ramp

are in accordance with the latest regulations;b) check that all gas connections are sealed;c) check that the air ventilation grilles in the

boiler room are large enough to guaranteethe amount of air required by law andneeded for perfect combustion.

Do not use gas pipes to earth electricalappliances.If there is a smell of gas:a) do not operate electrical switches,

telephones or any other object that mightcause sparks;

b) immediately open doors and windows tocreate a draught;

c) turn off gas taps;d) ask for professional help.Do not obstruct air vents where a gas boileris situated to avoid dangerous situations suchas toxic or explosive mixture.

adequate for the maximum output absorbedby the system. This is indicated on the datalabel.It is also important to ensure that the cablesection is suitable for the absorbed output ofthe boiler.The mains electricity supply must not be usedwith adaptors, multiple plugs and/or extensionleads.A bipolar switch as required by safetyregulations must be used for connection tothe mains.Certain basic rules apply when using anyelectrical apparatus:- never touch the apparatus with wet or

damp parts of the body and/or with barefeet;

- do not pull the wiring;- do not leave apparatus exposed to the

elements (rain , sun, etc.);- do not allow inexperienced persons to

use it.The cable should not be replaced by the user.If the cable is damaged, switch the apparatusoff and have it replaced professionnally.If it is not to be used for some time, it isadvisable to switch off the electricity supplyto all the relevant components (pump,burner, etc.).

indicated on the data plate.Check that the installer has connected theboiler safety valve drain to a collecting funnel.If not connected to a drain the safety valves,when operating, will cause flooding in theboiler room for wich the boiler manufactureris not responsible.Check that the water and heating systempipelines are not used as earthing points forthe electricity or telephone since they arewholly unsuitable; pipelines, boiler andradiators may be damaged as a result.Once a closed heating systems is filled

(closed expansion tank), the feed tap shouldbe closed and kept closed.Leakage may be revealed a drop in waterpressure indicated on the system pressuregauge.

BALTUR S.p.A.Via Ferrarese 10 - 44042 CENTO (Ferrara) ITALIA

Tel. 051.684.37.11 Fax 051.90.21.02 - (International Tel. ++39.051.684.37.11 - Fax ++39.051.683.06.86)http://www.baltur.it - http://www.baltur.com - E-MAIL [email protected]

This catalogue is purely indicative. The manufacturers reserve the right to modify technical data and any other parts of the contents.

For any information about our service centers telephone

1228 technox3 840 bt-use and maintenance manual(en)

Documents

usethese boilers

technox3 bt baltur boilers

efficiency directive

heating water

steel boilers seriestechnox3

low tension directive

safety devices

required safety regulations