Devex X Boiler BD 23 Instruction Manual Download Page 37

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Instruction Manual

6.4 RANGE OF TECHNICAL MAINTENANCE OPERATIONS PERFORMED BY THE SERVICE COMPANY

•

Maintenance of the combustion chamber, burner, ignition electrode and ionisation electrode

•

Cleaning the condensate siphon

•

Adjusting the pressure in the expansion tank

•

Maintenance of the water-water heat exchanger

•

Checking the temperature sensors (table)

•

Replacing a damaged control board in the control panel

•

Checking the water pump operation according to section. 6.1.6

7. BOILER EQUIPMENT

Table 7.1 is a list of the components required to install the boiler for its correct operation, and other accessories that will enhance

the boiler’s ease of use. Some of these items are supplied together with the boiler (as standard equipment), others are available

to purchase separately.

TABLE 7.1

Name

Part Code

Accessories included in the boiler

Hook for wood 8 x 70

Sparing Sleeve (x2)

Adhesive spacer EPDM

Tank NTC Sensor

Subassembly of Gas Connector

Flue components - Coaxial

60/

100 - Polypropylene PP

Flue Kit Horizontal 60/100 PP

A2Y003

Flue Adapter - Elbow 90 Inspection 60/100 SS

A2Y011

Flue Adapter - Vertical Inspection 60/100 SS

A2Y013

Flue Extension 1m 60/100 PP

A2Y021

Flue Extension 0.5m 60/100 PP

A2Y023

Flue Extension 0.25m 60/100 PP

A2Y025

Flue Elbow 90deg 60/100 PP

A2Y027

Flue Bend 45deg 60/100 PP

A2Y029

Flue Elbow 90deg Inspection 60/100 PP

A2Y031

Flue Extension Inspection 60/100 PP

A2Y033

Vertical Termination - Black 60/100 PP

A2Y035

Vertical Termination - Red 60/100 PP

A2Y037

Horizontal Termination 60/100 PP

A2Y139

Flue Support bracket for Elbow 90deg Dia 100

A2Y319

Flue components - Coaxial

80/

125 - Polypropylene PP

Flue Adapter - Elbow 90 Inspection 80/125 SS

A2Y012

Flue Adapter - Vertical Inspection 80/125 SS

A2Y014

Flue Adapter - Vertical Inspection 80 SS

A2Y015

Flue air Adapter - Vertical Air Inspection 80 SS

A2Y016

Flue Extension 1m 80/125 PP

A2Y022

Flue Extension 0.5m 80/125 PP

A2Y024

Flue Extension 0.25m 80/125 PP

A2Y026

Flue Elbow 90deg 80/125 PP

A2Y028

Flue Bend 45deg 80/125 PP

A2Y030

Flue Elbow 90deg Inspection 80/125 PP

A2Y032

Flue Extension Inspection 80/125 PP

A2Y034

Summary of Contents for X Boiler BD 23

Page 1: ...Instruction Manual Installation Operation and Maintenance X Boiler BD Series BD 23 BD 38 Gas fired condensing central heating boilers ...

Page 2: ... Make sure the installer confirms in writing that the tightness of the gas installation has been checked and approved after connecting the boiler to the system The boiler may be installed and operated only in a room where all building works have been completed Building works are potential sources of dust debris and harsh solvents or vapours which have a negative effect on the boiler s lifespan The...

Page 3: ... this instruction manual will ensure a long reliable and safe operation of the boiler This appliance is unsuitable for use as a pool heater DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE DO NOT MODIFY THIS APPLIANCE When you smell gas do not use any electrical switches that could cause a spark shut down the main g...

Page 4: ...point the outlet of the stopper to the right Fig 3 8 Turn on the boiler Wait until the start up procedure ends during that time the boiler is testing the internal assembly and the ventilation system this takes about 10 30 seconds 9 Fill the boiler with water by using the filling valve mounted on the C H installation It is important to open the filling valve slowly to protect the boiler and the com...

Page 5: ... performed by an Authorised Service Company 13 Remove E01 error code by using the reset button and set the boiler controller on pressure reading mode in the version without an analogue manometer During the first days of a boiler s operation it is recommended to set the water pressure in the C H circuit between 1 8 2 0 bar This will facilitate the work of the air vent on the boiler pump and on the ...

Page 6: ... THE BOILER TO COMBUST ANOTHER TYPE OF GAS 22 4 3 BOILER ADJUSTMENT 23 4 3 1 Gas flow regulation in the boiler without using the flue gas analyser 23 4 3 2 Adjustment of the boiler with a gas analyser 24 4 4 FAN CHARACTERISTICS 24 Fig 4 4 1 Characteristics of the fan type NG40M 24 5 START UP AND OPERATION OF THE X BOILER 24 5 1 INITIAL START UP OF THE X BOILER 24 5 2 OPERATION OF THE X BOILER 24 5...

Page 7: ...with its components labelled is illustrated in Fig 2 2 1 2 and Fig 2 2 1 3 Below are the technical specifications of the boiler 2 1 TECHNICAL SPECIFICATIONS OF THE BOILER Electronic fluent flame modulation for the central heating system and domestic hot water Electronic ignition with ionisation flame control Adjustable boiler power Regulation of heating water and domestic water temp Soft ignition ...

Page 8: ...d in certain cases will be corrected automatically 1 Boiler function selection button switch 2 Temperature selector C H or DHW 3 Heating water domestic water and static pressure and temperature display with error codes diagnostic 4 Control panel Kt K1 ON OFF reset A Central heating system and a storage tank supply B Domestic cold water C Gas D Domestic hot water E Return from central heating syste...

Page 9: ...ue gas Fan characteristics section 4 4 of this manual Flue gas mass flow at full load kg h 34 7 59 0 Flue gas mass flow at partial load kg h 5 2 8 7 The minimum flue gas temperature at minimum thermal power ºC 44 34 3 The maximum flue gas temperature at maximum thermal power ºC 61 66 7 Fan characteristics Time parameters Time of central heating pump rundown s 180 Time preventing the anti cyclical ...

Page 10: ... detected if the current fan speed is different from that expected by the driver of the boiler Protection against exceeding the upper limit temperature of flue gas 115 C Errors which do not require manual reset will cause the boiler to return to normal operation after automatic disappearance of failure See section 5 8 for boiler diagnostics NOTE In case of repeated emergency boiler shut downs in r...

Page 11: ...ope of the heating curve is explained in section 5 5 1 1 Fig 2 4 2 1 Diagram of the heating curve standard heating Fig 2 4 2 2 Diagram of the heating curve floor heating 2 4 3 Heating water with the X Boiler BD Series connected to a domestic water tank The X Boiler BD Series is factory designed to connect with a domestic hot water tank The domestic water temperature is displayed and can be adjuste...

Page 12: ...tion function NOTE To eradicate Legionella bacteria in the storage tank the boiler is turned on every 168 h and the water in the tank is heated to 65 C If the Legionella function does not work in automatic mode the user at any time can manually initiate a single cycle of tank heating to 65 C 2 4 3 1 Manual initiation of domestic tank overheating Anti Legionella function in manual mode applies to t...

Page 13: ...ion lower power consumption An ECO factor value of 0 5 is the maximum for which the control seeks to meet the conditions promoting condensation C H return temperature 55 C regardless of the water temperature setting in C H It is recommended to operate the C H system with an ECO ratio within the range of 0 1 to 0 5 If increasing the set C H heating water temperature does not produce adequate therma...

Page 14: ... for premises where gas appliances are installed should be in accordance with local regulations The room where the boiler is to be installed should meet the air supply and venting system requirements for gas combustion according to regulations In addition the room s temperature should be higher than 6ºC and the location of the ventilation system should not cause the freezing of water The room shou...

Page 15: ...low green Fig 3 3 1 Installation dimensions of the X boiler 3 2 PRELIMINARY CHECK ACTIVITIES Before starting the installation check whether the boiler is factory designed for the type of gas supplied from the gas system The type of gas which the boiler is designed for is specified on the rating plate on the cover of the boiler whether the water system and radiators have been properly rinsed with w...

Page 16: ...nded use The outdoor casing is designed for installation of the boiler in partially sheltered places protecting the boiler from the influence of atmospheric factors and the interference of unauthorized persons Warning The place of installation must be pre protected against rain Protection of the boiler against frost according to the operating instructions of the device ...

Page 17: ...a specific mounting system Before starting the installation of the casing it is necessary to check whether the enclosed mounting dowels are suitable for the installation location Hang the boiler on a hanger inside the casing Connection of the boiler to the gas and hydraulic system as well as installation of the flue gas exhaust system and supply of combustion air should be performed according to t...

Page 18: ... suitable antifreeze fluid as a heat carrier in the winter season Cut off valves need to be installed between the boiler and the C H system so that the boiler can be dismounted without draining the system Do not install any thermostatic valves on radiators in the room where a thermostat is installed as their operation and communication with the boiler will be in conflict with one another It is rec...

Page 19: ...commended to mount modern filters which work on the principle of magnetic and cyclone effect for example Fernox TF1 filter NOTE The method and amounts of specific products used for system cleaning and water treatment should be in accordance with the product manufacturer s instruction The above steps should be performed by an authorised installer or service technician NOTE It is recommended to inst...

Page 20: ...with a coaxial exhaust system Ø60 Ø100 with a maximum pipe length 3m elbow Settings O2 5 For use with other flue gas air systems and longer pipes adjust the boiler as specified in section 4 2 When using coaxial flue gas air pipe Ø80 Ø125 apply a coaxial reduction Ø60 Ø100 x Ø80 Ø125 to adaptor Ø60 Ø100 mounted in the boiler or replace the mounted adaptor Ø60 Ø100 and a reduction ring Ø60 Ø80 with ...

Page 21: ...anging the flow direction Type of Fitting 15º 45º 90º 0 25m 0 5m 1m 3 10 CONNECTION OF ADDITIONAL DEVICES Access to the electrical terminals of the controller can be found at the back of the controller under the two flaps To connect an additional device unscrew the appropriate flap put the cable through the bushing in the flap and connect the ends of the wire to the correct terminals Fig 3 9 1 Ele...

Page 22: ...with a 0 10V signal The signal is translated into RT high state and target value of modulation temperature SETP The range of SETP values can change depending on the value of the set minimum for C H temperature PCOmin and the currently set C H temperature PCO value according to the graph If the weather regulator is active parameter P26 0 then based on the outdoor temperature and Kt factor it modifi...

Page 23: ... Before adjusting the boiler activate the service function of the boiler in the following way set the mode WINTER see section 5 3 press the button twice on the control panel display the appropriate symbol flashes The left field shows the fan rotational speed with the max symbol placed above it The right field shows the C H temperature Within 5 seconds press the button for 2s after service function...

Page 24: ...or about 15 minutes before commissioning it Table 4 3 2 1 The control parameters of the boiler Gas type Unit BD 23 BD 38 Min Power Max Power Min Power Max Power Natural Gas Inlet pressure kPa 1 13 3 00 Parameters P04 12 P06 12 P01 35 P05 66 P04 12 P06 12 P01 40 P05 63 Flue gas content CO2 10 0 0 2 02 4 1 0 4 CO2 9 5 0 2 02 5 2 0 4 CO2 10 0 0 2 02 2 3 0 4 CO2 9 5 0 2 02 4 5 0 4 Gas flow rate l min ...

Page 25: ... The operation of the boiler is in accordance with this instruction manual and appropriate regulations 5 2 OPERATION OF THE X BOILER BD SERIES All boiler functions are performed by the boiler s electronic control panel From the illustration in Fig 5 2 1 changing the boiler s operating mode and settings is achieved using 4 buttons The LCD display shows the current operating status Fig 4 4 1 Charact...

Page 26: ...changing the operating mode to mode SUMMER D H W heating Anti legionella function active only for boilers with tanks 5 4 BOILER ADJUSTMENT When the controller restarts operation after a power loss the display shows a flashing symbol The symbol disappears when the control system is ready to accept user commands Symbol on the display Signalization Remarks BURNER IS OPERATING Left flame DHW mode oper...

Page 27: ...is not connected the display shows when the DHW circuit is heated and in SUMMER mode the left field display shows Ch and the right field shows the value of C H temperature 3 For another 2 5 sec the left field display shows Pr and the right field the value of pump flow for traditional pumps display shows 4 For the last 2 5 sec the display shows Fr on the left field and the value of fan flow on righ...

Page 28: ...ymbol MIN will stop the water heating process in the tank On the left field of the controller display the symbol will be seen To resume water heating in the tank ensure the DHW settings are at the minimum values or higher 2 When the controller is in STANDBY mode service function mode or in the emergency lock out state the C H or DHW settings cannot be changed 5 6 CONTROLLER CONFIGURATION BOILER PA...

Page 29: ...e selection 0 1 0 FIME HONEYWELL FPE4200A 1 SITNG40 1 P24 Operating time at the start power in CH circuit after flame detection 2 30 sec 20 P25 L3 pump overrun time 1 60 min 3 P26 Operating mode of the weather function 0 3 0 off 1 operation with room thermo stat 2 operation without room thermostat 3 operation with room thermostat without possilibity of weather function deactivation via room thermo...

Page 30: ...tons select the desired parameter to change 8 By pressing button it is possible to edit the selected parameter Use the buttons to change the parameter values Parameters P01 and P03 activate the boiler with the desired power of the C H circuit Parameter P02 activates the boiler with the desired power of the DHW circuit if the flow sensor of DHW is working At the end of the gas ignition process the ...

Page 31: ...ut the flashing symbols and the error code are displayed Symbol RESET is blanked In particular cases the error code can be displayed alternately with the temperature or pressure value in the C H circuit After removing the cause of failure the boiler will automatically return to normal operation and the error code disappears 5 8 3 Signalisation of emergency switch off with locking An emergency lock...

Page 32: ...itched off with blockade Call Authorised Service Company Damage in the circuit of NTC sensor of heating water temperature The burner is turned off Call Authorised Service Company Failure in the electronic system of the boiler The burner is turned off Call Authorised Service Company Failure of the measuring system of fan speed or failure of the fan Call Authorised Service Company Failure of water p...

Page 33: ...gaps and deformations on the surface of the burner qualify the burner as unusable It should be replaced clean the electrode with a plastic brush a deformed electrode should be replaced check the condition of the electrode s insulator a dirty insulator should be cleaned a visibly damaged insulator should be replaced In order to get access to the combustion chamber burner and electrode close the gas...

Page 34: ...WEP 6 1 5 Checking the temperature sensors Table 6 1 5 1 Temperature C NTC DHW and NTC CH sensor resistance NTC tank sensor and temperature sensor resistance Sensor ß 3977 10 55218 Ω 0 75 0 32624 Ω 0 75 10 19897 Ω 0 75 20 12 480 Ω 0 75 30 8 060 Ω 0 75 60 2 490 Ω 0 75 80 1 210 Ω 0 75 NTC sensor of C H water DHW and central heating Remove the sleeves from the NTC sensors Measure the sensor resistanc...

Page 35: ...ructions attached to each board assigned as a spare part Parameters of components for X BOILER 23 and 38 Item on the scheme Name Parameters Supply voltage from the controller 5 Fan NG40m Power 75W max 230V AC 7 Pump Yoyos Para PWM Power 45W 230V AC 8 Gas unit SIT SIGMA 848 Valve coil resistance 3 4EV1 0 9kΩ 1 3EV2 6 4 kΩ 230V AC 18 NTCsensorofCHwater temperature 10K 25ºC ß 3977 SELV 19 Heating wat...

Page 36: ...mode of control system configuration M3 Connector coupling PE M5 Flame control connector JKEY User interface connector foil ROP Pump speed regulator TWN Spark gener ator NTCP NTC sensor of heating water temperature return M13 User interface con nector ROV Fan speed regulator 6 3 THE MAINTENANCE OPERATIONS TO BE PERFORMED BY THE USER The user should clean filters periodically preferably before the ...

Page 37: ... components Coaxial Ø60 Ø100 Polypropylene PP Flue Kit Horizontal 60 100 PP A2Y003 Flue Adapter Elbow 90 Inspection 60 100 SS A2Y011 Flue Adapter Vertical Inspection 60 100 SS A2Y013 Flue Extension 1m 60 100 PP A2Y021 Flue Extension 0 5m 60 100 PP A2Y023 Flue Extension 0 25m 60 100 PP A2Y025 Flue Elbow 90deg 60 100 PP A2Y027 Flue Bend 45deg 60 100 PP A2Y029 Flue Elbow 90deg Inspection 60 100 PP A2...

Page 38: ...141 X boiler BD Outdoor Casing A2Y401 Flue Roof Plate with air intake Dia 80 A2Y201 Flue Angular Roof Plate 25 50 Deg Dia 125 A2Y202 Flue Location Bracket Dia 60 A2Y205 Flue Location Bracket Dia 80 A2Y206 Flue Rosette Dia 80 A2Y207 Flue Rosette Dia 100 A2Y208 Flue Rosette Dia 125 A2Y209 Flue Gasket Dia 60 A2Y210 Flue Gasket Dia 80 A2Y211 Flue Gasket Dia 100 A2Y212 Flue Gasket Dia 125 A2Y213 Other ...

Page 39: ...stems com au www devexsystems com au NEW SOUTH WALES 5 83 Bassett Street MONA VALE NSW 2103 PO Box 707 MONA VALE NSW 1660 Phone 1800 636 091 Fax 02 9997 7852 Email info devexsystems com au VICTORIA PO Box 24 OFFICER VIC 3809 Phone 1800 636 091 Fax 03 5986 7399 Email vic devexsystems com au TASMANIA Suite 3 35 Melville Street HOBART TAS 7000 Phone 1800 636 091 Fax 03 6273 9120 Email tas devexsystem...

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