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Adisa ADI LT 105, Technical Manual Installation Maintenance

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Adisa ADI LT 105 Technical Manual Installation Maintenance Download Page 45

ADI LT boiler – Technical manual  

 

                  Page 

45 

 
16.2 THE BOILER CONTROL UNIT AND OPERATING CYCLE 
 
The control unit regulates: 

•

 

The boiler operating cycle. 

•

 

The boiler safeties (by indicating also the possible reasons for the boiler lockout). 

•

 

The boiler power modulation. 

 

 
Short description of the boiler operating cycle: 
 

 

 
 
 
LEGEND of the operating phases: 
 

Display 

Meaning 

00 

Boiler in stand-by (the installation is not receiving any request of heat) 

01 

The boiler stops due to lack of gas pressure (minimum gas pressure switch) 

02 

Motor fan is activated (revolutions increase) 

03 

Start of the pre-venting phase 

04 

Time out (control of the fan speed) 

05 

Time of pre-ignition 

06 

Safety time of ignition and ionization control (constant) 

07 

Safety time of ignition and ionization control (variable) 

10 

Operation in the heating mode 

11 

Not available phase: D.H.W.S. operation  
(according to the installation and to the boiler configuration) 

12 

Not available phase: Heating and D.H.W.S. operating in parallel  
(according to the installation and to the boiler configuration) 

20 / 21 

Post air-venting and fan stop 

22 

Self-test and return to the initial position 

99 

Alarm / lockout (alarm code visualized on the display) 

 
 
 

Summary of Contents for ADI LT 105

Page 1: ...5 2010 ADI LT BOILER LOW TEMPERATURE TECHNICAL MANUAL OF INSTALLATION USE AND MAINTENANCE ...

Page 2: ..._____________________________________________________________ 19 11 1 1 Available readings at the maintenance level _____________________________________________________ 19 11 1 2 Available readings at the maintenance level 1 ___________________________________________________ 19 11 1 3 Available readings at the maintenance level 2 ___________________________________________________ 20 11 1 4 Avai...

Page 3: ...___________________________________________________ 38 15 7 5 Water quality of the installation _______________________________________________________________ 39 15 7 6 Hydraulic diagrams _________________________________________________________________________ 40 16 THE BOILER START UP ________________________________________________________________________ 44 16 1 BEFORE THE START UP __________...

Page 4: ...irective 92 42 EEC Nett efficiencies from 96 to 104 ref to L C V Boiler certified as Low temperature flow temperature up to 90ºC no limit of return temperature Boiler heat exchanger in stainless steel Power outputs from 104 to 695 kW Maximum efficiency per year Variable temperature on boiler Boiler power modulation according to the demands of the installation High reduction of stop start cycles Mi...

Page 5: ...r maintenance must be realized following the instructions of the manufacturer s technical manual and with a minimum regularity as indicated by the current regulations 3 EEC APPROVALS AND CERTIFICATIONS ADISA boilers model ADI LT are certified as follows MODEL ADI LT 105 to 400 475 to 750 GAS BOILERS DIR 90 396 EEC 1312CL5485 AND EFFICIENCY DIR 92 42 EEC 1312CL5488 The European Directive of Boilers...

Page 6: ...lame indicator E Motor fan variable speed F Fan G Venturi for air inlet and mix with gas H Multiblock gas valve J Boiler control unit and power modulation L Hot water flow M Hot water return N Flues outlet P Gas connection Q Air pressure switch R Air filter S Ignition transformer T Gas pressure switch U Pressure sensor V Air purgers manual Models ADI LT 105 to 200 view from above B D F E C S Q H P...

Page 7: ...ADI LT boiler Technical manual Page 7 Models ADI LT 250 and higher A C D B J Q H G F E R S N L M P ...

Page 8: ...0 2 1 2 1 1 4 1 1 2 400 810 350 1583 940 2 1 2 1 1 4 1 1 2 475 810 350 1583 940 2 1 2 1 1 4 1 1 2 550 1040 400 1668 975 3 1 1 4 1 1 2 650 1040 450 1668 975 3 1 1 4 1 1 2 750 1040 450 1668 975 4 1 1 4 1 1 2 ADI LT 105 to ADI LT 150 flow return male threaded connections of 2 Higher models flanged connections PN 6 H Height without taking into consideration the increase due to the silent block feet su...

Page 9: ... m3 h Flues residual pressure Pa Max water pressure bar 5 5 5 5 5 5 5 5 5 5 5 5 Boiler weight without water kg 110 112 123 139 330 350 440 445 490 554 579 614 Water capacity litres 30 30 33 36 76 85 99 106 112 210 210 223 T 10ºC m3 h 9 11 13 16 20 23 28 33 40 47 53 60 T 12ºC m3 h 7 9 11 14 16 19 23 27 33 39 44 50 Water flow rate T 15ºC m3 h 6 7 9 11 13 15 18 22 27 31 35 40 Consumption at the max o...

Page 10: ...al tubes forming the combustion chamber The vertical tubes generate a big heat transfer surface that uses the sensible heat of the flues During the manufacturing process the boiler is subjected to a strict quality control realized through a process of three leak tests one with penetrant liquids another one with air pressure and the last one with water pressure The boiler heat exchanger is insulate...

Page 11: ...n for the air gas mix 9 Motor fan of variable speed 10 Air inlet 11 Flange of the group motor fan to be coupled to the flange of the boiler heat exchanger 12 Ignition ionization kit 13 Pressure connection for the gas valve just models LT 250 and higher 14 Pressure connection for the safety air pressure switch 15 Air filter just models LT 250 and higher 16 Electrodes support 17 Gasket for electrode...

Page 12: ... regulates the gas outlet pressure according to the pressure value in the venturi Note 13 in models LT 250 and higher a coupling pipe between the multi block gas valve and the venturi measures the pressure drop before the mix For lower models there is no pipe the connection between the multi block gas valve and the venturi is internal M The power modulation is realized by varying the fan speed whi...

Page 13: ...ADI LT boiler Technical manual Page 13 Exploded view of the assembly burner fan gas valve for models LT 250 and higher ...

Page 14: ...mal inertia fast cooling for an easier maintenance Fast answer to the changes of the power demand Thanks to its structure and design noise produced by the combustion is very low and without resonance The cylindrical shape of the burner allows the flame to be homogeneously distributed It is vertically introduced in the boiler The boiler incorporates an ionization flame control The minimum ionizatio...

Page 15: ... according to reduced setpoint Standby circuit 1 disconnected anti freezing function activated 4 Adjust boiler set up flow temperature T4 5 Not operational Adjust D H W S set up temperature 6 7 Button to change the line of the display that you want to select T6 to go down T7 to go up 8 9 To modify the values of adjustment of the parameters on the display To decrease T8 and to increase T9 10 Access...

Page 16: ...ustments of parameters or error code 6 Heating circuit operation mode Automatic according to the time program at a nominal set up temperature or at a reduced set up temperature operation at a nominal set up temperature all the time operation at a reduced set up temperature all the time boiler in standby waiting 7 Not available D H W S operation mode 8 Time programming of use of the heating circuit...

Page 17: ...conds and then press both again On the right of the display a pointer will flicker pointing to The display will show the percentage of power at which the boiler is working In order to realize the maintenance operations the action PID of the controller on the boiler will be deactivated The boiler power can be increased or decreased by pressing one of the buttons T8 or T9 If you wish to go directly ...

Page 18: ...evel or line changes will be automatically saved Line Function Adjustment range Unit Resolution Value by default 1 Current time 0 23 59 h min 1 min 5 Boiler reduced set up temperature TRN ºC 0 5 69 0 11 Time program Heating circuit 1 phase 1 start up time 00 00 24 00 hh mm 10 min 06 00 12 Time program Heating circuit 1 phase 1 stop time 00 00 24 00 hh mm 10 min 22 00 13 Time program Heating circui...

Page 19: ...g 3 seconds at least the buttons T6 and T7 The first reading will be visualized on the display corresponding to the letter b0 Choose the required parameter by pressing the buttons T8 and T9 To go back to the initial or normal display press T2 if you do not vary anything after 8 minutes you will automatically go back to the initial display Information of temperatures maintenance level 1 Code Descri...

Page 20: ...he buttons T8 and T9 To go back to the initial or normal display press switch T2 if you do not vary anything after 8 minutes you go automatically back to the initial display Set up temperatures maintenance level 3 Code Description d0 d7 d9 Not used d1 Modulating controller set up temperature PID controller d2 Boiler set up flow temperature ºC d3 Not available Set up room temperature according to p...

Page 21: ...ficial Technical Service in order to activate it An outside temperature probe should be added supplied separately from the boiler and not included in the price and connected to terminals 1 and 2 of the strip X10 06 positioned in the LMU control unit of the ADI LT boiler These are the possible curves of operation Boiler flow temperature ºC External temperature ºC 11 5 VIEW OF THE BOILER CONTROL UNI...

Page 22: ...e the start up and modulation of each boiler So that each boiler can receive and process an external signal type 0 10 V it must be provided with consult prices An additional module or clip in model AGU 2 51 A cable for connecting the additional module to the boiler control unit mod AGU2 104A109 Clipin AGU2 510A109 LMU This module enables an analog entry that can be of two types Probe NTC 10 KΏ Vol...

Page 23: ... bus type LPB module OCI 420 A cable for connecting the additional module to the boiler control unit mod AGU2 104A109 The Official Technical Service must realize a change in the internal parameters in order to use this regulation on the boiler The additional module OCI 420 must be connected to the LMU control unit of each boiler Clipin OCI420 LMU Just one module type OCI420 can be connected to the...

Page 24: ... of a possible sequence that can be realized multiple options can be chosen Sequence control unit RVS 63 L e is t B a n d M i n 4 0 O n O f f K e s s e l 2 O n O f f K e s s e l 3 O n O f f K e s s e l 4 3 0 0 2 0 0 1 0 0 4 0 0 Boiler 1 Boiler 2 Boiler 3 Boiler 4 LMU LMU LMU OCI 420 OCI 420 OCI 420 Boiler 1 Boiler 2 Boiler 3 ...

Page 25: ...ilers activation and their power regulation would be realized as shown below 11 6 4 Remote Control or telecomputing Both boilers provided with a LMU control unit and with RVS control units both of sequence and of control of circuits always of the same mark can be connected to a module OCI 611of communication by MODEM that allows both a control of the installation and a control of the boilers opera...

Page 26: ...er 220 230 V 8 General switch ON OFF 9 Safety overheating thermostat 10 Display of reading 11 Signal of control of the modulation of the variable speed fan PWM 12 Air pressure switch 13 Minimum gas pressure switch 14 Electric supply 220 230 V 50 Hz single phase with earth connection main supply to the boiler 15 Stop start switch external to the boiler Stop start external contact open close 16 Sign...

Page 27: ...ADI LT boiler Technical manual Page 27 ELECTRIC DRAWING ADI LT 105 200 NotE 13b only included in model ADI LT 105 ...

Page 28: ...ADI LT boiler Technical manual Page 28 ELECTRIC DRAWING ADI LT 250 325 ...

Page 29: ...ADI LT boiler Technical manual Page 29 ELECTRIC DRAWING ADI LT 400 750 ...

Page 30: ... DeltaT in the boiler is higher than the maximum Delta T the power drops by 20 Safety 2 if it overcomes the maximum Delta T 8ºC the boiler operates at the minimum power Safety 3 if it overcomes a higher value the boiler stops and an error message appears on the display E 154 434 or E 154 433 Lack of water pressure in the circuit Pressure sensor The boiler stops for safety if pressure in the circui...

Page 31: ...portant to avoid environments with excess of humidity dust and aggressive steams If the boilers room needs to have some building works the boilers should be switched off and protected in order to avoid dust For an easier maintenance it is important to respect the minimum distances indicated by the regulations and the manufacturer s instructions both for one boiler and for several boilers Every par...

Page 32: ...icated in this manual see table TECHNICAL DATA 15 4 1 Gas pressure higher than 45 mbar Inertial volume Units Boiler model m3 1 ADI LT 105 0 0102 1 ADI LT 130 0 0128 1 ADI LT 150 0 0146 1 ADI LT 200 0 0186 1 ADI LT 250 0 0225 1 ADI LT 275 0 0251 1 ADI LT 325 0 0310 1 ADI LT 400 0 0368 1 ADI LT 475 0 0449 1 ADI LT 550 0 0529 1 ADI LT 650 0 0598 1 ADI LT 750 0 0672 2 ADI LT 325 0 0621 2 ADI LT 400 0 ...

Page 33: ...realize periodical measurements of the water pH after the neutralization treatment when the value measured is lower than 6 5 it is recommended to replenish with the powder In any case the neutralization treatment must be realized in conformity with the local autonomic and national laws The neutralization system should be placed at a level of height lower than the boiler draining outlet of the cond...

Page 34: ...boiler outlet between 5 Pa and 9 8 Pa In case of excessive draught depression this can cause vibrations in the chimney you have to install a flue draught stabilizer inside the chimney see paragraph 15 6 2 Values of CO2 for Natural Gas Models Range CO2 for Natural Gas ADI LT 105 to 200 7 2 9 ADI LT 250 to 475 7 2 8 2 ADI LT 550 to 750 7 5 9 Flues temperature The base of the vertical chimney must in...

Page 35: ...e up to the vertical section of the chimney min 3 15 6 3 Old installation In case of using a metallic and insulated chimney already existing before installing the boiler it is advisable to verify that the chimney has the right dimensions to allow a correct evacuation of the burnt gases and to clean its interior In case of using a brick chimney already existing it is necessary to fit it with an int...

Page 36: ...e is lower than the minimum value An air venting or automatic purger of big capacity installed in the flow pipe or in the higher part of the flow circuit of the installation A filter with a stainless steel mesh of 0 3 mm in the heating return of every boiler A water meter in the refilling of the primary circuit A draining pipe for the evacuation of condensed products it must be connected to the dr...

Page 37: ...6 46 9 57 1 Flow rate T 10ºC m3 h 10 1 13 0 15 2 18 9 22 4 27 7 32 9 40 0 Flow rate T 12ºC m 3 h 8 4 10 8 12 7 15 8 18 6 23 1 27 4 33 3 If you have to stop the boiler pump it is required that you stop it with a time delay 3 to 5 minutes once the boiler has stopped This can be obtained by installing a timer disconnect electrical relay 0 30 0 80 1 30 1 80 2 30 2 80 7 17 27 37 47 57 Caudal m 3 h Pérd...

Page 38: ...mum height Installations with a sufficient inertial volume and a constant water flow without interruption These are installations where the main circuit s has have a minimum water capacity ensuring a constant and uninterrupted water flow to the boilers unless the boilers stop For example Heating circuits with a main loop to which are connected A H U fan coils where there are the regulation element...

Page 39: ...ide installations with big water contents 2 Characteristics of the refilling water different from the hardness TH indicated in the previous table 3 Frequent refillings of the installation with new water because of drainings water leaks repairing even if the water has a hardness lower than 12ºF 4 When it is exceeded the maximum volume allowed of refilling water see table c A mesh filter should be i...

Page 40: ...valve Keys to clean D H W S PHE secondary circuit Overpressure safety valve Non vibrations mounts Adjusting water flow valve Water meter Water treatment 30 31 32 33 34 36 37 A B C D E F Controller Thermostat Temperature sensor Pressure switch Manometer Thermometer Filter to separate sludge oxides Flow to the heating circuit Return from the heating circuit Cold feed Drain Flow to D H W S circuit Re...

Page 41: ...ADI LT boiler Technical manual Page 41 System drawing of heating circuits 17 11 11 10a 10a 17 11 11 10a 10a 17 17 10a 10a 10a System drawing of one boiler and only D H W S 11 36 36 6 ...

Page 42: ...age 42 System drawing D H W S and heating circuit 11 36 36 36 36 36 36 See comments under the corresponding paragraph System drawing of an old installation heating circuit 11 11 11 11 36 See comments under the corresponding paragraph ...

Page 43: ...e in the secondary circuit very high building with the boilers room in the ground floor or old installation in very bad conditions heating circuit 36 36 36 36 See comments under the corresponding paragraph System drawing of an installation as in the previous case D H W S and heating circuit ...

Page 44: ...plate The gas valves are open the air of the gas installation purged and there are no gas leaks The electric connections are correct 220 230 V 50 Hz single phase earth so that the boiler is electrically supplied The controls are set so as to require heat from the system Instruments required for the start up A manometer to check the combustion chamber pressure drop the gas injectors pressure and th...

Page 45: ... gas pressure switch 02 Motor fan is activated revolutions increase 03 Start of the pre venting phase 04 Time out control of the fan speed 05 Time of pre ignition 06 Safety time of ignition and ionization control constant 07 Safety time of ignition and ionization control variable 10 Operation in the heating mode 11 Not available phase D H W S operation according to the installation and to the boil...

Page 46: ... ionization electrode and to its electric connection Pressure gas Pg combustion chamber Pf air gas mix Pa similar to the values indicated in the combustion document issued in our factory Gas flow Combustion parameters CO2 O2 CO flues temperature air temperature efficiency water temperatures Models CO2 range for Natural Gas ADI LT 105 to 200 7 2 9 ADI LT 250 to 475 7 2 8 2 ADI LT 550 to 750 7 5 9 R...

Page 47: ... the front corner of the gas valve with the boiler in front By turning clockwise the gas flow increases and so CO2 By turning counter clockwise the gas flow decreases and so CO2 m Repeat the previous steps both at the maximum and the minimum power until the values of CO2 are correct at both stages n Once finished press the button 3 or 2 to go back to the automatic operation mode In this way you wi...

Page 48: ...ntrol panel sight hole The back of the boiler multi block gas valve air damper fan motor This allows that several boilers can be installed in a modular way one beside the other leaving a distance of 10 cm between them 17 1 PROCEDURE TO DISMANTLE THE BURNER Be sure that the boiler general switch is on the OFF position The gas duct to the boiler is closed Take out the frontal casing panel of the boi...

Page 49: ...ve electric supply connection Note a and b have fast connections by pressing the plastic ring you can remove the pipe Remove the ionization ignition kit If the gas connection has a two pieces coupling disconnect it Disconnect the two flanges of the gas valve each flange has Allen screws of 4 mm Remove the nuts screws of the flange connecting the fan burner group to the boiler heat exchanger By til...

Page 50: ...5 1 2 4 5 5 3 5 5 5 4 2 17 2 POSITION OF PROBES AND SENSORS 1 Water flow temperature sensor 2 Water return temperature sensor 3 Safety overheating thermostat 4 Water pressure sensor 5 Manual air purgers venting their number varies according to the model ...

Page 51: ...ey natural draught Water temperatures flow return Ionization Gas consumption Gas type Flow Gas pressure inlet injectors Combustion chamber pressure Air gas mix pressure Burner pressure Ignition air gas Gas pressure static boilers operating simultaneously Boiler operation hours Adjustments Gas pressure switch minimum Air pressure switch Revolutions or motor fan speed ...

Page 52: ... period of 7 days otherwise the spare parts provided will be invoiced 8 The guarantee just covers the material repairing The guarantee does not cover the expenses for the dismantling of the equipments for the installation and or for the local or premises where they are installed neither for the connections of the new equipments or for additional works necessary to repair the material 9 In order to...

Page 53: ...he heating consumption of the installation L Natural wear out of the boiler 10 THE GUARANTEE The GUARANTEE loses its effect in case of non fulfilment of the payment conditions established at the moment of the purchase The GUARANTEE does not cover expenses for damage In order to exercise the rights of this guarantee the purchaser must renounce to his own right and submit to the jurisdiction of the ...

Page 54: ...e reduced Shut off for safety with start prevention The ionisation current has fallen below threshold IonLimitGrenz the repetitions counter will be reduced 128 571 IONISATION The ionisation current has fallen below threshold IonLimitGrenz several times the repetitions counter has arrived at the end boiler lockout Lockout reset The ionisation current has fallen below threshold IonLimitGrenz several...

Page 55: ...esign differential dTkTrSTB 16K 154 434 Reset after error 433 has not been possible criterion reset dT dTkTrSTB Shut off for safety with start prevention Reset after error 433 has not been possible criterion reset Delta T dTkTrSTB 154 435 CHECK PUMP OPERATION The error counter has exceeded in error 433 the set up value of GrenzeDeltaT 321 Lock out reset The error counter has exceeded in error 433 ...

Page 56: ...code 183 104 Change to programming mode by means of PC Off for safety with start prevention Change to programming mode by means of PC 183 105 The unit is in programming mode by means of PC Lock out reset Programming mode Operating in programming mode by means of PC 183 279 Parameters setting required via OT bus Off for safety with start prevention No more difference with respect to Albatros code 1...

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