Ferroli BLUEHELIX TECH RRT 24C Instructions For Use, Installation & Maintenance Download | Manualshive

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BLUEHELIX TECH RRT 24 C

9

EN

cod. 3541P250 - Rev. 01 - 07/2018

2. Installation

2.1 General Instructions

B

This unit must only be used for its intended purpose. This unit is designed to heat water to a temperature below
boiling point and must be connected to a heating system and/or a water supply system for domestic use, com-
patible with its performance, characteristics and heating capacity. Any other use is deemed improper.

THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN COMPLIANCE WITH ALL THE IN-
STRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT LAW, THE REQUIRE-
MENTS OF THE TECHNICAL STANDARDS (BS) AND ANY LOCAL REGULATIONS AND THE RULES OF PROPER
WORKMANSHIP.
Incorrect installation can cause damage or injury for which the manufacturer cannot be deemed responsible.

The unit must be installed in compliance with these instructions and the following standards applicable in
Great Britain.

Gas Safety Regulations (Installations & Use).
Local Building Regulations.
The Building Regulations (Part L).
The Buildings Standards (Scotland - Consolidated) Regulations).British Standards Codes of Practice (BSI):
The Industry Guidance For Installers On Condensate Drainage Pipe Installation (HHIC)

Model Water By-Laws (Great Britain)

For Northern Ireland the relevant laws in force must be observed.

Safe handling of materials

Pay attention when handling the boiler insulation panels as they contain materials that could irritate the skin. No part of
the boiler contains asbestos, mercury or CFC's.
The use Personal Protective Equipment (PPE) is always recommended.

Advice for transport and handling

For lifting and transporting always take suitable safety precautions: keep your back straight, bend knees, do not turn
your body, move feet, avoid bending forward or sideways and keep the load as close as possible to your body.
If possible, use a trolley or other suitable means to carry the boiler.
Grip the boiler firmly and, before lifting it, try and find the point where the load is concentrated in order to establish the
centre of gravity and suitably reposition yourself. Ideally seek assistance in lifting the boiler.

B.S.

5440

Part 1

Flues

B.S.

5440

Part 2

Air flow and ventilation

B.S.

5449

.........

Forced circulation hot water production systems

B.S.

6798

.........

Installation of gas-fired boilers for hot water

B.S.

6891

.........

Gas systems

B.S.

7671

.........

IEE wiring system standards

B.S.

4814

.........

Specifications for expansion tanks

B.S.

5482

.........

LPG systems

B.S.

7593

.........

Water treatment in central heating systems for DHW production

B.S.

5546

.........

Installation of systems for DHW production

B.S.

7967

.........

Guide for the use of electronic portable combustion gas analysers

B.S.

5955-8

.........

Installation of plastic pipes

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Summary of Contents for BLUEHELIX TECH RRT 24C

Page 1: ...cod 3541P250 Rev 01 07 2018 BLUEHELIX TECH RRT 24 C INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE GC No 47 267 71 ...

Page 2: ...ith the boiler so that it can be consulted by the new owner and or installer Installation and maintenance must be ca rried out by professionally qualified per sonnel according to current regulations and the manufacturer s instructions Incorrect installation or inadequate mainte nance can result in damage or injury The manufacturer declines any liability for da mage caused by errors in installation...

Page 3: ...ce of installation 10 2 3 Plumbing connections 10 2 4 Gas connection 12 2 5 Electrical connections 12 2 6 Fume ducts 14 2 7 Condensate drain connection 20 3 Service and maintenance 21 3 1 Adjustments 21 3 2 Commissioning 32 3 3 Maintenance 33 3 4 Troubleshooting 42 4 Technical data and characteristics 45 4 1 Dimensions and connections 45 4 2 General view 47 4 3 Hydraulic circuit 47 4 4 Technical d...

Page 4: ...nomy or Comfort mode 9 DHW demand 10 Summer mode 12 Multifunction display flashing during exchanger protection function 13 Heating demand 14a Burner lit flashing during calibration function and self diagnosis phases 14b Appears when a fault has occurred causing the unit to shut down To restore unit operation press the RESET button detail 6 17 External sensor detected with optional external probe I...

Page 5: ...the P C B software version fig 5 For the following 20 seconds the display will show FH which Indicates the heating system air venting cycle with the fan operating fig 6 The internal pump will cycle on off during this period In the next 280 seconds the venting cycle continues with the fan off fig 7 again the pump will cycle on off Open the gas isolation valve under the boiler When the message Fh di...

Page 6: ...he sun symbol does not appear on the display but the multifunction numbers are present the boiler is in Winter mode 1 4 Adjustments Winter summer switchover Press the winter summer off button detail 7 fig 1 until the display shows the Summer symbol detail 10 fig 1 the boiler will only deliver domestic hot water The frost protection system remains activated fig 10 To reactivate the Winter mode pres...

Page 7: ...ig 1 for 5 seconds Outside Temperature Compensation OTC When the optional external sensor is installed the boiler adjustment system works with OTC In this mode the heating system temperature is regulated according to weather conditions to ensure a high comfort and energy efficiency throughout the year In particular as the outside temperature increases the system flow temperature decreases accord i...

Page 8: ...e with built in drain tap fig 14 Compensation curves fig 15 Example of compensation parallel curve offset Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel DHW temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel Summer Winter Switchover Summer mode has priority over a possi...

Page 9: ... Britain For Northern Ireland the relevant laws in force must be observed Safe handling of materials Pay attention when handling the boiler insulation panels as they contain materials that could irritate the skin No part of the boiler contains asbestos mercury or CFC s The use Personal Protective Equipment PPE is always recommended Advice for transport and handling For lifting and transporting alw...

Page 10: ...nt according to the current regulations To ensure proper operation and long boiler life the plumbing system must be adequately sized and complete with all the necessary accessories including a room thermostat a thermostatic radiator valve TRV etc The system flow and return pipes must have a diameter of at least 22 mm for the first 3 m of length from the unit If the system delivery and return pipes...

Page 11: ...ction must be disconnected after use Ensure the filling point is on the return pipe to the boiler Attention is drawn to the Model Water Byelaws Filling Loop in fig 19 is supplied with boiler The maximum domestic water pressure for the inlet supply is 9 bar 130 P S I If the cold mains supply exceeds 5 bar 72 P S I a water governor or pressure reducing valve must be fitted by the installer into the ...

Page 12: ...t could affect correct operation of the unit In case of replacement of boiler within existing installations the system must be completely emptied and cleaned of any sludge and pollutants For that purpose only use suitable guaranteed products for heating sys tems see next section that do not harm metals plastics or rubber The manufacturer declines any liability for damage caused to the boiler by fa...

Page 13: ...e and written in Standard UNI 8065 The presence of deposits on the boilers heat exchange surfaces due to non compliance with the above require ments will invoke the remainder of the warranty 2 4 Gas connection B Before making the connection to the Gas supply pipework ensure that the appliance is suitable la belled for operation with the type of fuel available The gas must be connected to the corre...

Page 14: ...el on page 33 to access the terminal block M and fuse F by pro ceeding as follows fig 21 and fig 22 The terminals indicated in fig 22 must be with voltage free contacts not 230V The arrangement of the terminals for the various connections is also given in the wiring diagram in fig 60 NOTE The terminals 14 15 are 230v Live Neutral to power an external clock if required Optional extra Ferroli OpenTh...

Page 15: ...ney flues fig 23 Examples of connection with concentric chimney flues Air Fumes Table 2 Max length concentric chimney flues For concentric flue installations you must use one of the following appliance adaptors For the wall hole dimensions refer to the dimensions on the template or refer to Section 4 Technical data characteristics Any horizontal sections of the flue must slope slight ly back towar...

Page 16: ...ble 4 Table 4 Max length separate ducts Type Description C1X Wall horizontal exhaust and intake The inlet outlet terminals must be together on the same wall to ensure they are in the same pressure zone The terminals should protrude a maximum of 15cm from the wall with a max 50cm separation min 15cm C3X Roof vertical exhaust and intake The inlet outlet ducts are combined within the room sealed vert...

Page 17: ... using G20 gas Losses in meq Air intake Fume exhaust Vertical Horizontal Ø 80 PIPE 1 m M F 1KWMA83W 1 0 1 6 2 0 BEND 45 M F 1KWMA65W 1 2 1 8 90 M F 1KWMA01W 1 5 2 0 PIPE SECTION with test point 1KWMA70W 0 3 0 3 TERMINAL air wall 1KWMA85A 2 0 fumes wall with antiwind 1KWMA86A 5 0 FLUE Fume outlet only Ø80 010036X0 1KWMA86U 4 0 ATTENTION CONSIDER THE HIGH PRESSURE LOSSES OF Ø50 and Ø60 ACCESSORIES U...

Page 18: ... terminal 1200 mm L From a garage opening e g door window with access to the home 1200 mm M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm O From the wall on which the terminal is fitted N A P From a vertical structure on the roof 150 mm Q Above the intersection with the roof 300 mm NOTES N A Not applicable Also the terminal must be at le...

Page 19: ...t bowl before commis sioning the boiler fill the trap with approx 0 5 L of water and connect the hose to a solvent welded waste system For safety reasons the hose must form a tight seal into the waste system B ATTENTION THE UNIT MUST NEVER BE OPERATED WITH THE TRAP EMPTY OTHERWISE THERE IS A DANGER THAT PRODUCTS OF COMBUSTION COULD ENTER THE ROOM fig 29 Condensate drain connection 0 5lt B ...

Page 20: ...o prevent this from occurring it is advisable to reduce the length of the condensate drain pipes and run them on the inside as much as possible before going to the outside It is mandatory to insulate the condensate pipe or apply a trace heat ing device to help prevent freezing of the condensate The pipes outside the building must be in solvent weld plastic with increased diameter of 40 mm covered ...

Page 21: ...il 6 fig 1 for 10 seconds The display shows 100 and the text co flashing press the Heating button detail 4 fig 1 to set and view 120 Then press the DHW button detail 2 fig 1 to set 123 Press the Reset button once detail 6 fig 1 The display shows tS flashing press the Heating button once detail 4 fig 1 The display shows Sc flashing press the Reset button once detail 6 fig 1 The display shows Sc alt...

Page 22: ...nalyser to the flue gas sampling point on the appliance conector check that the CO2 content in the flue matches that given in the below table 4 If the combustion values do not match perform the 100 calibration as described in the following paragraph 5 Value A if the values still do not match do not activate other calibrations as the system needs to work longer to be able to self adapt 6 Value B if...

Page 23: ... button once The display shows Sc alternating with 01 flashing Press the heating button ref 4 fig 1 until displaying Sc alternately with 15 flashing Press the DHW button and the display shows 00 Press the DHW button and the display shows 01 Press the heating button ref 4 fig 1 and the 100 calibration mode will activate displaying the message CA and LI alternating After calibration the display will...

Page 24: ...to minimum 0 Wait about 1 minute for stabilisation By pressing the DHW button detail 2 fig 1 boiler output is immediately adjusted to maximum 100 If the TEST mode is activated and enough hot water is drawn to activate the DHW mode the boiler remains in TEST mode but the 3 way valve goes to DHW To deactivate the TEST mode press the heating buttons simultaneously details 3 and 4 fig 1 for 5 seconds ...

Page 25: ...ort 1 System thermostat 2 Second room thermostat 3 Warning Notifica tion 4 Safety thermostat 2 Second room therm Variable input contact operation selection b01 3 0 Flowmeter off 1 System thermostat 2 Second room thermostat 3 Warning Notification 4 Safety thermostat 2 Second room therm Variable input contact operation selection b01 4 0 Continuous Comfort 1 System thermostat 2 Second room thermostat...

Page 26: ...ter 190 imp l b16 Fan frequency in standby mode 0 100 0 b17 Summer Winter symbol 0 Disabled 1 Enabled 0 Disabled b18 DHW mode activation flow rate b01 1 0 100L min 10 25 No effect on adjustment b01 2 0 100L min 10 25 DHW mode activation flow rate b01 3 0 100L min 10 25 No effect on adjustment b01 4 0 100L min 10 25 b19 DHW mode deactivation flow rate b01 1 0 100L min 10 20 No effect on adjustment ...

Page 27: ...down in DHW b01 3 0 Fixed 1 Linked to setpoint 2 Solar 0 Fixed Legionella protection b01 4 0 7 Activation days 0 No protection P43 Comfort activation temperature b01 1 0 50 C 40 C Hot water tank hysteresis b01 2 0 60 C 2 C Comfort activation temperature b01 3 0 80 C 40 C Hot water tank hysteresis b01 4 0 60 C 2 C P44 Not used b01 1 Do not modify 0 Primary setpoint b01 2 70 85 C Primary circuit tem...

Page 28: ...o effect on adjustment b01 2 0 255 seconds 0 seconds Solar standby time b01 3 0 255 seconds 10 seconds No effect on adjustment b01 4 0 255 seconds 0 seconds P54 Heating deltaT temperature adjustment b01 1 0 60 C 18 C Heating deltaT temperature adjustment b01 2 0 60 C 18 C Heating deltaT temperature adjustment b01 3 0 60 C 18 C Heating deltaT temperature adjustment b01 4 0 60 C 18 C P55 Primary exc...

Page 29: ...mount of gas to be increased or decreased in the ignition phase Due to poor ignition 9 20 0 Sc03 Ignition power Allows the fan speed to be increased or decreased in the igni tion phase in case of poor ignition 16 14 0 Sc04 N A For the UK market 2 13 0 Sc05 Minimum output calibration Allows the minimum output to be increased if necessary 0 25 0 Sc06 Minimum gas valve calibration Self adaptive param...

Page 30: ...r heating or DHW and then press the Reset button ref 6 fig 1 for 10 seconds The display shows 100 and the text Co flashing press the Heating button ref 4 fig 1 until 120 is displayed Then press the DHW button ref 2 fig 1 until the access code 123 is displayed Press the Reset button ref 6 fig 1 once The display shows Ts flashing press the heating button ref 4 fig 1 once The display shows Sc flashin...

Page 31: ... button to display the fault value Press the Reset button to return to the Service Menu Press the Reset button for 10 seconds to exit the PCB Service Menu or exiting occurs automatically after 15 minutes rE History Reset Press the Winter Summer Off On button for 3 seconds to delete all stored faults in the History Menu NOTE the PCB automatically exits the Service Menu in order to confirm the opera...

Page 32: ... the software version number and then Fh and FH air venting cycle see cap 1 3 Connection to the power supply switching on and off on page 5 At the end of the FH cycle the winter mode screen fig 8 will appear on the display Adjust the heating DHW outlet temperature settings as required fig 12 and fig 13 Top change the Gas type G20 G31 check if the relevant parameter is suitable for the type of gas ...

Page 33: ...lding Before carrying out any operation wait for these components to cool or wear suitable hand protection To open the boiler casing 1 Partially undo the screws A see fig 34 2 Pull the panel B towards you and lift it from the upper fastenings fig 34 Front panel opening B This boiler has a room sealed casing After any operation involving opening the boiler You must en sure that the front panel is c...

Page 34: ...ure must match that given in the respective tables The condense pipework must be solvent weld sealed free of debris or blockages The condense trap must be full of water Check the quality of the water in the heating system via an alkalinity test checking the inhibitor concentration Check the condition of the insulation within the exchanger around the burner Replace if cracked or damaged Check the f...

Page 35: ...he left 3 Remove the plate heat exchanger as shown in the figure 4 Note To gain more access you can easily remove the flexible connection on the top of the condense trap When refitting the plate heat exchanger make sure the arrows indicating HEATING are pointing downwards Circulating pump A Before carrying out the following instructions it is advisable to protect the area and the boiler s PCB hous...

Page 36: ... assembly 2 x 4mm Allen key bolts Take care not to damage the cork gasket replace if damaged Remove the 4 x spring clips 1 on the two pipes 2 to the exchanger pump and hydraulic unit lift away Remove the flexible connection from the top of the condense trap 4 Remove the burner assembly fig 43 Remove the fan diaphragm install into the new exchanger Release the clamp to the flexible gas connection S...

Page 37: ... 3 x 10mm nuts securing the burner remove To clean use a soft brush vacuum Check the correct distance of the electrode clean if necessary but do not sand To clean the exchanger it is advisable to remove the electrode see fig 46 Clean the inside of the exchanger with a soft brush wash through with clean warm water then clean out the con dense sediment bowl See the accessories indicated in fig 43 Re...

Page 38: ...maged 1 Rotate the insulating disc 2 and remove it Dispose of the damaged insulation pad safely this cannot be reused Install the new insulation pad to the heat exchanger ensuring its correctly secured to the tab the reassemble the boiler Fan fig 44 Isolate the power supply and close the Gas isolation valve to the boiler Remove the electrical connection to the fan Remove the clamp 1 and undo remov...

Page 39: ...e Gas isolation valve to the boiler Disconnect the white ignition lead from the PCB housing and remove the electrode by undoing the screws 1 Remove the exchanger cover and remove the burner see fig 43 Clean the electrode see fig 43 Refit the clean or new electrode and secure it with the 2 x screws 1 ensure the gasket is replaced or not damaged After securing in place carefully check the distance b...

Page 40: ...remove the diverter valve 2 Replace in reverse order Replacing the Low water pressure switch A Before carrying out the following instructions it is advisable to protect the area and the boiler s PCB housing against accidental water spillage fig 48 Isolate the power supply and close the Gas isolation valve to the boiler Turn off the Flow Return isolation valves drain the boiler see system draining ...

Page 41: ...e to the boiler Remove the diverter valve motor head see fig 47 Close the cold water inlet isolation valve and open a hot water tap in the property Release the retaining clip 4 and remove the flowmeter assembly 5 by pulling upwards The flowmeter components can thus be cleaned or replaced see fig 50 and fig 51 fig 49 Flowmeter 1 Flow rate limiter 2 Impeller 3 Filter 4 Clip 5 Flowmeter Wash the filt...

Page 42: ...nal if installed if the boiler does not restart it will be necessary to eliminate the fault see fault code table Other faults cause temporary shutdowns marked with the letter F for Fault which are automatically reset as soon as the value returns within the boiler s normal working tolerance Make sure that the PCB is powered using a digital multimeter check supply volt age is within tolerance Range ...

Page 43: ...he position of the ionisation electrode and replace it if necessary Flame unstable Check the burner air flue ducts obstructed Remove the obstruction from the flue fume extraction ducts air inlet and terminals Condense trap or pipes blocked Check the trap and pipes clean it if necessary F07 F14 A07 High flue gas temperature The flue gas probe detects an exces sive temperature Check the exchanger Ch...

Page 44: ... the system A23 A24 A26 F15 F20 F21 F40 F47 F50 F51 F53 PCB parameter fault Wrong PCB parameter setting Check the PCB parameter and modify it if neces sary F56 A56 Calibration fault Incorrect parameters Check parameters and carry out a 100 calibra tion Electrode damaged or not correctly positioned Check the position of the electrode replace it if necessary After replacement repeat the 100 calibrat...

Page 45: ... fitted 8 DHW outlet Ø 1 2 15mm with outlet union fitted 9 Cold water inlet Ø 1 2 15mm with Isolation valve fitted 10 System Flow Ø 3 4 22mm with Isolation valve fitted 11 System Return Ø 3 4 22mm with Isolation valve fitted A6 Condensate discharge connection Flexible adaptor supplied fig 53 Front view fig 54 Side view fig 55 Top view fig 56 Bottom view 250 110 210 210 ...

Page 46: ... Return sensor 191 Flue temperature probe 193 Trap 194 DHW plate heat exchanger 196 Main heat exchanger 350 Fan Burner assembly fig 58 Hydraulic circuit 8 Domestic hot water outlet 9 Cold water inlet 10 System Flow 11 System return 14 Pressure relief valve 32 Heating circulating pump 34 Heating temperature sensor 36 Automatic air vent 42 DHW temperature sensor 56 Expansion vessel 95 Diverter valve...

Page 47: ...ciency Pmax 50 30 C 106 1 Efficiency Pmin 50 30 C 107 5 Efficiency 30 109 7 Gas supply pressure G20 mbar 20 Max gas flow G20 m3 h 2 65 Min gas flow G20 m3 h 0 53 CO2 G20 9 0 8 Gas supply pressure G31 mbar 37 Max gas flow G31 kg h 1 94 Min gas flow G31 kg h 0 39 CO2 G31 10 0 8 NOx emissions class 6 NOx Max working pressure in heating bar 2 5 PMS Min working pressure in heating bar 0 8 Heating adjus...

Page 48: ...Ğ ƌĞŐŝŵĞ ΎΎͿ ƚ ĨƵůů ůŽĂĚ ƚ ƉĂƌƚ ůŽĂĚ Ŷ ƐƚĂŶĚďǇ ŵŽĚĞ ƚĂŶĚďǇ ŚĞĂƚ ůŽƐƐ ŐŶŝƚŝŽŶ ďƵƌŶĞƌ ƉŽǁĞƌ ĐŽŶƐƵŵƉƚŝŽŶ ŶŶƵĂů ĞŶĞƌŐǇ ĐŽŶƐƵŵƉƚŝŽŶ ŽƵŶĚ ƉŽǁĞƌ ůĞǀĞů ŵŝƐƐŝŽŶƐ ŽĨ ŶŝƚƌŽŐĞŶ ŽǆŝĚĞƐ ĞĐůĂƌĞĚ ůŽĂĚ ƉƌŽĨŝůĞ tĂƚĞƌ ŚĞĂƚŝŶŐ ĞŶĞƌŐǇ ĞĨĨŝĐŝĞŶĐǇ ĐůĂƐƐ ĨƌŽŵ ƚŽ Ϳ ĂŝůǇ ĞůĞĐƚƌŝĐŝƚǇ ĐŽŶƐƵŵƉƚŝŽŶ ŶŶƵĂů ĞůĞĐƚƌŝĐŝƚǇ ĐŽŶƐƵŵƉƚŝŽŶ tĂƚĞƌ ŚĞĂƚŝŶŐ ĞŶĞƌŐǇ ĞĨĨŝĐŝĞŶĐǇ ĂŝůǇ ĨƵĞů ĐŽŶƐƵŵƉƚŝŽŶ ŶŶƵĂů ĨƵĞů ĐŽŶƐƵŵƉƚŝŽŶ dƌĂĚĞŵĂƌŬ ZZK ŽŶĚĞŶƐŝŶŐ...

Page 49: ...DHW temperature sensor 44 Gas valve 72 Smart thermostat option not supplied 81 Ionistion ignition electrode 95 Diverter valve 114 Low water pressure switch 136 Flowmeter 138 OTC external sensor option 139 OpenTherm Smart thermostat optional 186 Return sensor 191 Flue temperature sensor A ON OFF switch configurable 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 0 0 1 0 2 0 3 0 ...

Page 50: ...r OpenTherm compli ant 139 ALL CONNECTIONS TO THE TERMINAL BLOCK MUST BE WITH VOLTAGE FREE CONTACTS NOT 230V 72 139 1 2 3 4 5 6 138 A 14 15 230V supply to external controls Terminal block rear of PCB housing 14 15 X03 X04 X05 X06 X07 X08 X02 X01 114 34 42 16 44 191 136 95 32 186 1 1 1 1 1 1 1 1 X08 11 X08 10 X08 7 X08 6 X08 2 X08 1 X09 X11 X01 1 X01 2 X08 14 X08 12 X08 13 X08 9 X08 8 X01 4 X01 7 X...

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