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AIC COILMASTER 100, Installation And Maintenance Manual For The Installer And The User

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AIC COILMASTER 100 Installation And Maintenance Manual For The Installer And The User Download Page 38

I-38

G-084383_EN • 03

P

roduct

 I

nstallatIon

Typical Hydraulic Connections - Heating and DHW Circuits

Isolating valve
Filling valve
Draining valve

Check valve

Three-way valve

Expansion vessel

Removable fi lling hose

Circulating pump

Safety valve

Drain

Safety group (automatic air relief 

valve, manometer, safety valve), 

connected to the drain 

Fig. 10. Typical Heating and DHW Circuits

Summary of Contents for COILMASTER 100

Page 1: ...h e a t i n g s y s t e m s EN installation and maintenance manual FOR THE INSTALLER AND THE USER 60 70 80 100 120 kW FLOOR STANDING COMBINATION BOILER G 084383 03 COILMASTER...

Page 2: ...approved Chimney Components I 40 Chimney Connection I 41 AIC Approved Chimney Components I 44 Engineering the Chimney System I 45 Accessories I 45 Calculation of the Chimney Length I 45 Equivalent Len...

Page 3: ...ing the High and Low Voltage Terminal Strips and Electronic Board I 49 Fig 14 Filling the System Typical I 52 Fig 15 Combustion Adjustment on Gas Valve I 53 Fig 16 Draining the Boiler Typical I 60 Fig...

Page 4: ...ons provided herein The applicable regulations and standards The installer shall provide the end user with Any relevant explanation about the op eration of the appliance and the heat ing system as wel...

Page 5: ...and or injuries or death Indicates an important instruction which if not followed could re sult in a hazardous situation that could cause damage to equip ment and or injuries Indicates an essential i...

Page 6: ...all not play with the appliance Any modi cation to the appliance and its components is strictly forbidden without the prior written consent of the manufacturer If components need to be replaced only g...

Page 7: ...evantstandards Please read installation and maintenance manual before installing the boiler The boiler is pre adjusted in the factory to the gas pressure of 20mbar for gas type G20 AIC Europe B V Graa...

Page 8: ...I 73 for more information on cascade system possibilities Frost Protection The COILMASTER boilers have a built in an ti frost protection The pump and the burner are started as required when the return...

Page 9: ...2 DHW safety valve 13 Heating body comprised of a stainless steel fire tube heat exchanger and DHW coil not shown with insulation 14 Ignition and ionisation electrodes 15 Heating circuit safety valve...

Page 10: ...tion 8 Electronic junction box with main board not shown 9 Control panel with LCD display 10 Ignition and Ionization electrodes 11 Gas valve 12 Burner assembly with fan and air gas mixer 13 Gas pipe 1...

Page 11: ...eft or to the right allows to scroll through the menus icons functions or increase decrease a value af ter selecting a function KEY When entering a menu sub menu the slow rotation of the selector to t...

Page 12: ...o adjust the parameters in the Complete parameter list and to access the commissioning wizard Symbols appearing in the horizontal status bar Alarm Indicates an error in the system Maintenance Special...

Page 13: ...G 13 G 084383_EN 03 Technical Specifications Dimensions A B D E C CM 60 70 80 CM 100 120 A mm 632 698 B mm 1 446 1 650 C mm 774 801 D mm 141 191 E mm 125 129...

Page 14: ...4 1222 G 14 G 084383_EN 03 Technical Specifications CM 60 70 80 CM 100 120 dry weight kg 200 285 connections supply return M in 11 2 inlet outlet M in 1 safety valve in 11 4 safety valve in 1 drain in...

Page 15: ...for Boilers in a Cascade Clearances Min Recommended top mm 600 800 back mm 500 800 front mm 1 000 1 000 sides mm 500 in a cascade configuration boilers can be installed side by side with a 160 mm clea...

Page 16: ...70 CM 80 condensing boiler Y N Y Y Y low temp boiler Y N Y Y Y combination heater Y N Y Y Y useful heat output at 30 of rated heat output P1 kW 18 6 22 6 26 0 at rated output and high temp regime P4...

Page 17: ...0 boiler type and model CM 100 CM 120 condensing boiler Y N Y Y low temp boiler Y N Y Y combination heater Y N Y Y useful heat output at 30 of rated heat output P1 kW 32 1 37 5 at rated output and hig...

Page 18: ...e kg h 7 1 8 6 10 0 CO emissions mg kWh 43 3 CO2 contents G20 G25 8 4 0 1 8 8 0 2 CO2 contents G31 10 0 0 2 10 5 0 2 O2 contents G20 5 9 0 18 5 2 0 36 O2 contents G25 5 7 0 18 4 9 0 36 O2 contents G31...

Page 19: ...mass flow rate of flue gases g s 45 5 52 8 max condensate volume kg h 12 4 14 4 CO emissions mg kWh 28 4 CO2 contents G20 G25 0 1 8 4 8 8 CO2 contents G31 0 2 10 0 10 5 O2 contents G20 0 15 5 9 5 2 O...

Page 20: ...aximum primary temperature C 95 water content l 18 25 maximum operating pressure bar 8 maximum DHW temperature C 80 Pressure Drop Curve Flow Rate CM 60 CM 70 CM 80 CM 100 CM 120 minimum water flow rat...

Page 21: ...pliance Do not modify or deactivate any compo nent noranysafetydeviceinthesystem Do not operate the appliance when the casing is open IF YOU SMELL GAS DO NOT Use an open flame Smoke Use electrical dev...

Page 22: ...nel screen Call your installer as required When cleaning the appliance cabinet panels do not use sol vents or aggressive abrasive cleaning agents Wipe the sur faces using a soft clean cloth water and...

Page 23: ...ly and go back to the Home screen de press the rotary selector for more than 3 seconds i What to Do if Cause Action Boiler does not start No power supply 1 Check that the power button is in ON positio...

Page 24: ...s are switched off Energy consumption is re duced to a minimum The building or zones remain however protected e g in protection mode Temp setting Operating mode Protection Automatic Reduced Comfort In...

Page 25: ...ring the storage tank to the nom inal setpoint when there was a high consumption de activates the function Nominal setpoint 60 C Time program Active if operating mode is set to On Info Error error cod...

Page 26: ...operations 1 3 Chimney sweep function These functions can be set to On or Off When set to On the Chim ney Sweep Function remains so for 1 hour then turns off automatically Special operations 2 3 Manua...

Page 27: ...for the operation of the selector turn the selector to the left or to the right depress shortly the rotary se lector turn the selector to adjust the value then depress the se lector to validate Region...

Page 28: ...00 12 24 Set time program Set time program 06 00 to 22 00 08 00 to 18 00 Add phase Start 06 00 End 22 00 06 12 00 18 24 06 12 00 18 24 06 12 00 18 24 06 12 00 18 24 06 12 00 18 24 Start 02 00 06 12 0...

Page 29: ...ircuit isolate the electri cal supply of the appliance through the external power cutting device fuse circuit breaker etc All connections electrical flue pipe hydraulic gas must be carried out in acco...

Page 30: ...or close to the installation location 1 Carefully remove the plastic packaging and foam protections 2 Discard packaging according to applicable local regulations Installing and Preparing the Boiler 1...

Page 31: ...heir receptacles Side Panels 1 Remove six screws 3 or five if the front pan el and or top panel have been removed Re tain hardware for reinstallation Installation procedure Bottom Front Panel 1 Push t...

Page 32: ...diameter of discharge pipe D1 should be not less than the nominal outlet size of the tem perature relief valve 3 52 Where a manifold is used it should be sized to accept and discharge the total disch...

Page 33: ...es should be connected to the pipe Plastic pipes should be joined and assembled with fittings appropri ate to the circumstances in which they are used as set out in BS EN ISO 1043 1 Where pipes cannot...

Page 34: ...of dis charge pipe D1 Minimum size of dis charge pipe D2 from tundish Maximum resistance allowed expressed as a length of straight pipe i e no elbows or bends Resistance created by each elbow or bend...

Page 35: ...cuit can reach temperatures higher than 60 C and cause scalding when drawn unmixed from a tap The in stallation of a thermostatic mixing valve is therefore recommended Do not leave young children eld...

Page 36: ...equired safety devices Make sure to correctly plan your system according to the applicable local regula tions and standard practices i It is recommended to install the following devices in the system...

Page 37: ...the system needs to be refilled frequently check for leaks in the primary circuit Inhibitors may be used according to stand ard EN 14868 An air separator on the appliance supply circuit combined with...

Page 38: ...W Circuits Isolating valve Filling valve Draining valve Check valve Three way valve Expansion vessel Removable filling hose Circulating pump Safety valve Drain Safety group automatic air relief valve...

Page 39: ...e local regulations and stand ards It must be cleaned and serviced regularly Make sure to secure the flue piping to a solid structure Exclusively use the provid ed brackets to support the flue system...

Page 40: ...d with an inspection opening Do not exceed the maximum length rec ommended for the product when con necting the flue pipes or the system pow er might decrease For C type appliances the flue gas exhaus...

Page 41: ...ue Discharged to the outside through posi tive pressure Combustion air Drawn from the boiler room Remark Can be used for cascading B23p Make sure that the ventilation openings remain unobstructed at a...

Page 42: ...me under similar wind conditions fitting in a square of 50 cm if appliance 70 kW with distance between planes of orifices 50 cm a square of 100 cm if appliance is between 70 kW and 1000 kW with distan...

Page 43: ...ply with the category T120 H1 W1 2 O30 LI E U when using parallel piping and T120 H1 W1 2 O00 LI LE E U0 when using concentric piping EN 14471 This type of connection is prohibited in some countries r...

Page 44: ...Support strip TBD 41 008 74 37 Chimney shaft cover 100 TBD 41 008 74 13 Shaft distance holder PP 100 2 pcs TBD 41 008 75 04 Wall bracket 100 PP TBD 41 007 19 02 M G Concentric System 100 150 mm Roof t...

Page 45: ...and regulations The overall installation resistance of each boiler should not exceed the value indicated in the combustion table including maxi mum wind condition measured at the outlet of each boile...

Page 46: ...ely external supplier Air inlet flue outlet orifices May terminate in zones of different pressure Additional requirement Maximum allowable draught is 200 Pa Maximum allowable pressure difference betwe...

Page 47: ...d ards The circuit will be equipped with a meter and a gas pressure regulator if required Do not exceed the maximum gas pressure The conversion of the appliance from natural gas to G31 liquefied petro...

Page 48: ...he recommended rating is installed outside the appliance to allow electri cal isolation Do not touch the appliance with any wet body parts when it is supplied with electrical power Before performing a...

Page 49: ...ore accessing the high voltage terminal strip Also see Optional Modules on page I 72 for more information on available optional electronic components i The electronic bay cover panel is only secured t...

Page 50: ...5 X1f AUX2 QX1 1 5 QX2 QX3 X1b 2 3 L N 1 PE X1a N L N L 3 2 C1 QX1 PE 230V 50Hz N L PE PE N L N L N L QX2 QX3 L N C1 C2 C2 Ignition Transformer Ignition Electrode High Voltage Cable Flue Gas Temperat...

Page 51: ...ow sensor Control panel Flue Gas Pressure Switch H1 Analog 0 10V Digital input H5 On Off Thermostat Key Bk Black Bl Blue Or Orange Y Yellow Y Gr Yellow Green R Red V Violet X13 X12 X60 7 6 5 4 3 8 9 1...

Page 52: ...ve Check that all connections electrical flue pipe hydraulic gas have been carried out and that they are tight and secure Ensure that the condensate trap is full of water before starting up the appli...

Page 53: ...ombustion adjustments Refer to the procedure on the right i Combustion Adjustment Conditions ON Tools and material Flue gas analyser Screwdriver flat head size 3 Wrench hex head sizes 2 and 2 5 Proced...

Page 54: ...rt Enduser Symbols used for the operation of the selector turn the selector to the left or to the right depress shortly the rotary selector turn the selector to adjust the value then depress the selec...

Page 55: ...s chapter Please contact AIC s technical support for additional information i Test wiring This section allows to check that the signals to and from the equipment main board are correct No test is the...

Page 56: ...n setpoint 65 C 1641 Legionella function periodically 3 1642 Legionella function weekday Monday Tuesday Wednesday Sunday Consumer circuit 1 Consumer circuit 2 Swimming pool circuit Solar Skip Skip Red...

Page 57: ...Yes 7170 Telephone customer service 0 Commissioning wizard 7167 Commissioning wizard Off On next time the control device is switched on Redo Complete parameter list Commissioning wizard Select this f...

Page 58: ...pliance permanently Inspection and maintenance tasks must be carried out by a quali ed and certi ed professional at least once a year Water owing out of the drain valve can be extremely hot Use extrem...

Page 59: ...Check boiler water pressure at least 1 2 bar when cold Top up the system with water if required X X Check the operation of the burner flame through the sight glass and that the combustion parameters C...

Page 60: ...iance to operate for a few min utes then bleed the air from the system Follow on tasks 1 Check there is no leak in the water and gas circuits 2 Check the combustion values according to Combustion and...

Page 61: ...te trap inlet are not clogged Clean as required 5 Release two screws 3 and open the con densate trap cover 4 Retain cover and hardware for reinstallation OFF 6 Remove the cover gasket 5 Discard 7 Clea...

Page 62: ...onent of the boiler with any wet body part 1 At the condens dish 3 disconnect the hose 2 running from the condens dish to the flue pressure switch 1 2 Connect a T piece to the hose 3 Connect pressure...

Page 63: ...lectrodes in the scope of the periodic main tenance the electrodes and their gasket must be discarded and re placed by new ones 3 Release two screws 1 from the electrode flange 4 Remove the electrode...

Page 64: ...the gasket check its general condition Discard and replace the gasket if it is cracked or torn OFF i i 10 Remove the electrodes as required refer to Removing and Installing the Ignition and Ionisatio...

Page 65: ...3 4 5 2 1 7 8 Fig 20 Removing and Installing the Fan and Air Gas Mixer Assembly 6 3 I 65 G 084383_EN 03 Maintenance...

Page 66: ...n bad condition after cleaning replace it 3 If the combustion chamber requires clean ing carefully remove burner door insulation plate 6 from combustion chamber OFF i 4 Visually check the condition of...

Page 67: ...X3 3 4 5 2 Fig 21 CM 60 70 80 Removing and Installing the Burner 1 6 I 67 G 084383_EN 03 Maintenance...

Page 68: ...he burner tube 3 2 Clean with compressed air to remove residues If it is in bad condition after cleaning replace it 3 Clean the combustion chamber see Check ing and Cleaning the Combustion Cham ber on...

Page 69: ...3 5 2 1 Fig 22 CM 100 120 Removing and Installing the Burner I 69 G 084383_EN 03 Maintenance...

Page 70: ...t is dirty clean it Cleaning Procedure 1 Using a nylon bristle brush sweep the walls of the combustion chamber 2 Using an industrial vacuum cleaner remove all deposits from the combustion chamber heat...

Page 71: ...hermostatic mixing valve with temperature gauge 3 Draw off tap 4 Controller 5 Manometer 6 Temperature gauge 7 Safety group manometer air vent pressure relief valve 8 Temperature gauge 9 Isolating valv...

Page 72: ...hrough the use of this module you can connect to an Ethernet and get remote access to the boiler and all the heating system via the Internet Using a computer or mobile devices you can monitor and cont...

Page 73: ...ole of the cascade Principal and the others are Sub sequent In the controller menus please note that the Principal boiler is called Mas ter and a Subsequent boiler is called Slave The principal boiler...

Page 74: ...To access the Commissioning and the Engineer levels proceed as follows Menus and Settings The table on the following page contains some of the menus and submenus for the installer The last column all...

Page 75: ...ne 1 and 3 All zones All zones p 2 3 44 Operation HC2 Jointly with zone 1 Independently Jointly with zone 1 46 Operation HC3 P Jointly with zone 1 Independently Jointly with zone 1 48 Warmer cooler de...

Page 76: ...start control max 0 min p 8 16 791 Optimum stop control max 0 min 800 Reduced setp increase start 5 C 801 Reduced setp increase end 15 C p 9 16 809 Continuous pump operation No Yes No 820 Overtemp pro...

Page 77: ...1610 Nominal setpoint 60 C 5 pages 1612 Reduced setpoint 40 C 1620 Release 24h day Time programs HCs Time program 4 DHW p 2 5 1630 Charging priority Absolute Shifting None MC shifting PC absolute 164...

Page 78: ...Diagnostics heat gener ation 20 pages p 9 20 8338 Hours run heating mode p 10 20 8339 Hours run DHW 8378 Total gas energy heating p 11 20 8379 Total gas energy DHW 8380 Total gas energy 8381 Gas energ...

Page 79: ...ror Short circuit or Open circuit boiler return sensor Check connection and sensor Replace as required 46 Cascade return tempera ture sensor error Check connection and sensor Replace as required 47 Co...

Page 80: ...rmation 109 Supervision boiler temper ature Contact AIC technical support 110 STB SLT lockout No heat removal STB interrup tion possible short circuit in the gas valve internal fuse faulty Allow devic...

Page 81: ...tuck in Check reset button 160 Fan speed threshold not reached Fan possibly defective speed threshold set wrongly Check parameters connections and component Replace as required 162 Air pressure switch...

Page 82: ...pressure 243 Swimming pool sensor error Check connection and sensor Replace as required 260 Flow temperature 3 sensor error Check connection and sensor Replace as required 270 Temperature difference...

Page 83: ...dress error Correct device address 351 Primary controller system pump address error Correct device address 352 Pressureless header ad dress error Correct device address 353 Sensor B10 missing Common...

Page 84: ...essure 2 heating circuit too low dropped below lower pressure limit 2 Error code Fault description Explanation Action s 429 Dynamic water pressure too high Expansion tank is defective Verify pump Repl...

Page 85: ...connections and circuit 2 Check that pressure measuring points are closed Unburned gas smell Leak in flue gas circuit 1 Check tightness of connections 2 Check there are no obstructions in the flue sy...

Page 86: ...urner Wrong chimney pressure drop Check chimney pressure drop Temperature too high compared to setpoint Boiler controller malfunction 1 Check temperature setpoint 2 Check controller operation 3 Check...

Page 87: ...ting circuits Floor heating Radiators Other Cascade Y N Number of boilers Water Water hardness at start up mol m or mg l System volume L Additive s Antifreeze Y N Type Quantity Gas Type Heating value...

Page 88: ...gas Open or closed system Dimensions of combustion air open ings if closed system cm2 Material of flue piping Diameter and length of piping sys tem mm m Chimney system engineered by Calculated pressu...

Page 89: ...controller Other controller Y N Type Optional modules installed Y N Type Optional items installed Y N Outdoor sensor Y N Type Room unit s Y N Type Others Miscellaneous The end user has received all re...

Page 90: ...I 90 G 084383_EN 03 Additional Information for the Installer Combustion Parameters Log Sheet CO2 Flue gas T Remarks Name Date Signature...

Page 91: ...I 91 G 084383_EN 03 Additional Information for the Installer Water Parameters Log Sheet Water Filling Date Water Top up Date Water Quality Water Treatment Remarks Name signature...

Page 92: ...I 92 G 084383_EN 03 Declaration of Conformity...

Page 93: ...I 93 G 084383_EN 03 NOTES...

Page 94: ...www myaic eu AIC Europe B V Graafschap Hornelaan 163A NL 6001 AC Weert The Netherlands...

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