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Ferroli PREXTHERM, Operating Instructions Manual

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PREXTHERM

 

20

Electric diagram

PREXTHERM 100 - 470

TR

First stage regulator thermostat

TR2ST

Second stage regulator thermostat

NS

Lighted switch

STB

Safety thermostat

SL

block-spy

BZ1

First stage consumption meter

BZ2

Second stage consumption meter

PW1

Electronic plate

PT

Test button

TA

Room thermostat

AGW

Flue thermostat

TA

SL

recirculation pump

circulation pump

smoke lock-gate

burner

burner

second stage

BZ2

TR1

PT

S3

B4

N

T2

T1

L1

B5

T6

T7

T8

BZ1

17
16

18

21

20
19

N

AGW

46

48

PGAS

50

7

54

52

6
5

F 6,3A

4

3

L

9
8

38

37

34

NS

33

39

36

44

35

28

30
29

31

32

22

43

12
11

49

4

47

45

10

14

23

13

15

55

N

L

M

220V-50Hz

L1

N

2

41

1

3

STB

N

40

42

58

27

57

26

25

24

1

2

51

56

L

53

TR2ST

PH

2

O

2ST1

Fig. 13

Summary of Contents for PREXTHERM

Page 1: ...06 97 WELDED STEEL BOILER from 86 000 to 860 000 kcal H from 100 to 1000 kW from 341 000 to 3 410 000 BTU HR PREXTHERM INSTALLATIONS AND OPERATING INSTRUCTIONS ...

Page 2: ...PREXTHERM 3 Contents 1 Dimensions and technical data 2 Installation 3 Operation 4 Maintenance ...

Page 3: ...drop Working press Weight Min Max Min Max m3 dm3 Flue gas mbar Water mbar bar kg 100 60 100 65 109 0 083 120 0 6 4 5 270 125 75 125 82 136 0 102 142 0 9 7 5 290 150 90 150 98 163 0 124 162 1 1 10 5 320 200 120 200 131 218 0 174 214 0 8 7 5 430 250 150 250 163 272 0 204 247 1 1 10 5 490 300 180 300 196 327 0 241 283 1 4 16 5 560 350 210 350 229 381 0 286 528 1 8 11 5 830 400 240 400 262 436 0 332 5...

Page 4: ...5 1830 PREXTHERM comb chamber volume Legend 1 Boiler shell 2 Door 3 Burner mounting plate 4 Casing 5 Door insulation 6 Control panel a1 Flow connection a2 Return connection a3 Safety valve tapping a4 Flue outlet a5 Burner flange PREXTHERM A B C D E F G H L M a1 a2 a3 a4 a5 550 1400 1230 2363 746 500 500 340 720 1600 700 DN 100 DN 40 350 240 620 1400 1230 2563 746 700 500 340 720 1800 700 DN 100 DN...

Page 5: ... shell 2 Door with burner mounting plate 3 Flue hood 4 Control panel 5 Casing 6 Insulation PREXTHERM 100 470 Fig 2a Fig 2b 3 2 4 5 1 PREXTHERM 550 1000 Key 1 Boiler shell 2 Door with burner mounting plate 3 Flue hood 4 Casing 5 Insulation ...

Page 6: ...XTHERM 100 470 The boilers are supply in N 3 pieces 1 Boiler shell with door and flue hood 2 Casing 3 Control panel PREXTHERM 550 1000 The boilers are supply in N 2 pieces 1 Boiler shell with door and flue hood 2 Casing and control panel Fig 3 ...

Page 7: ...4 4 Thermometer 4 5 Hours run indicator low fire 4 6 Run indicator high fire 4 7 Burner run light 4 8 On off switch 4 9 Burner connections electrical 5 Casing for assembly see next page 6 Burner door plate 7 Combustion chamber sight glass 8 Combustion chamber pressure test point 9 Pressure gauge and thermostat pocket 10 Thermal insulation Fig 4a PREXTHERM 100 470 ...

Page 8: ...rews 5 and attach the sidings 3 with 6 self threading screws pos 6 Insert the bulbs 9 into sleeves 8 tighten the end of the thermohydrometer 7 into the gauge tap 10 Attach the back cover 11 togheter with the two cable collars 12 using 8 self threading screws pos 6 1 Mount left cover 13 and right cover 14 Mount right padded door 16 using 2 self threading screws pos 6 2 mount left padded door 15 Tak...

Page 9: ...ht glass 8 Combustion chamber pressure test point 9 Pressure gauge and thermostat pocket 10 Thermal insulation Legend 1 Boiler shell 2 Door 3 Flue outlet 4 Control panel fitted with 4 1 Control thermostat 4 2 High low thermostat 4 3 Limit thermostat 4 4 Thermometer 4 5 Hours run indicator low fire 4 6 Run indicator high fire 4 7 Burner run light 4 8 On off switch 4 9 Manometer ...

Page 10: ...ort 2 1 on the front side panel 11 with 8 self taping screws 12 The control panel is fixed with 2 self tapping screws 13 Install the temperature sensing bulbs 14 in socket 15 and connect the pressure gauge 16 connection to the apposit sensing point Install the cable clamps 17 and wire the electrical connections to the control panel Sequence installing jacket side panels 11 2 top panels 8 front pan...

Page 11: ...hat for some reason have not been sealed off The lifting force of the hot gas must overcome the resistance of thestackandoftheflueleadingfromtheboiler whilethegaspressure dropthroughouttheboilerisprevented by the thrust of the burner The boiler must be installed in accordance with these instructions and the local Regulations with materials which resist to the expected temperatures and corrosion Th...

Page 12: ...ted In gas burners decrease the combustion chamber pressure by 15 For ignition pressures consider about 2 5 times the normal operation pressure Legend 1 Combustion chamber sight glass 2 Insulating rope 3 Burner plate 4 Front door 5 Burner 6 Turbulators 7 Boiler shell 8 flexible oil lines Fig 7 CHECK FOR CORRECT POSITION M R E H T X E R P e p y T 0 0 1 5 2 1 0 5 1 0 0 2 0 5 2 0 0 3 0 5 3 0 0 4 0 7 ...

Page 13: ...BZ1 55 2 4 1 AGW SL P GAS 2ST1 BZ2 3 N 6 SL 40 N 43 L 42 L1 N 8 1 4 3 2 second stage BURNERS CONNECTION WITH TERMINAL BOARD without female connections BURNERS THREE PHASE CONNECTION main P C B exclusion P H2O Fig 8 Connection diagram The PREXTHERM 100 470 boiler harness is required for single phase burners at 230 V with female connections In case of burners with terminal board the terminal board w...

Page 14: ...oosen the fourth take out lock nuts 3 and 5 and tighten the fourth bolt 4 Insert and tighten the lock nuts 3 and 5 on the opposite side and repeat the procedure with lock nuts 6 and 7 Sealing Loosen the lock nuts 3 and 5 tighten bolt 4 as needed then tighten lock nuts 3 and 5 Positioning After assembling the burner it might be necessary to adjust the door position This may be done by loosening the...

Page 15: ...th current safety rules Before operating the boiler you should make sure that the front door carrying the mounted burner can rotate 90 in the chosen direction of opening to accommodate a full inspection and cleaning of the tube nest For this purpose it is also recommended to leave an open space in front of the boiler not less than the length of the flue Under normal conditions the boiler not less ...

Page 16: ...boiler would operate in high efficiency also at low capacity To ensure proper operation you should extract from the boiler pipes all the metal turbulence activators and set the burner to work with a single flame or with two smaller flames After performing this small operation the boiler will work in low capacity at a high rate of efficiency After completing this operation you should also check the...

Page 17: ...in the boiler which causes damage to the sheeting and weldings A correct inflow of water TOTAL HARDNESS ppm 10 should be as follows ALKALINITY mg l CaCO3 750 PH 8 5 11 SILICON DIOXIDE ppm 100 CHLORIDES ppm 3500 It is imperative to treat the heating system water in the following cases Very large systems Very hard water Frequent system water replenishing If a partial or total flushing of the system ...

Page 18: ...lphur compounds It is especially important to thus protect the tube nest When the interior of the boiler is dry lubricate the tubes andthecombustionchamberwithfueloilorlightnaphthatoprotectthemfromhumidity Itisadvisabletoplace in the combustion chamber a box of caustic lime to absorb the humidity and keep the boiler interior walls dry Finally you should close the door and the opening to the stack ...

Page 19: ... Electronic plate PT Test button TA Room thermostat AGW Flue thermostat TA SL recirculation pump circulation pump smoke lock gate burner burner second stage BZ2 TR1 PT S3 B4 N T2 T1 L1 B5 T6 T7 T8 BZ1 17 16 18 21 20 19 N AGW 46 48 PGAS 50 7 54 52 6 5 F 6 3A 4 3 L 9 8 38 37 34 NS 33 39 36 44 35 28 30 29 31 32 22 43 12 11 49 4 47 45 10 14 23 13 15 55 N L M 220V 50Hz L1 N 2 41 1 3 STB N 40 42 58 27 5...

Page 20: ...ctronic plate PT Test button TA Room thermostat AGW Flue thermostat TR STB TA circulation pump recirculation pump burner smoke lock gate burner second stage PT 57 N T2 L1 B4 T1 S3 BZ1 54 53 TR2ST 58 220V 50Hz 56 39 52 44 38 46 48 49 F6 3A T7 T6 B5 35 36 45 BZ2 50 37 25 47 22 26 27 23 12 10 13 20 11 14 21 15 T8 19 18 24 16 17 33 31 9 5 L 34 PW3 7 32 28 30 29 51 M NS 41 BZ1 55 2 4 1 AGW SL P GAS 2ST...

Page 21: ...9 10 11 12 TR1 TR2 Connection diagram PREXTHERM 550 1000 TR1 THERMOSTAT REG 1 STAGE TR2 THERMOSTAT REG 2 STAGE IB SWITCH BURNER STB SAFETY THERMOSTAT BZ1 TIME COUNTER 1 STAGE BURNER BZ2 TIME COUNTER 2 STAGE COUNTER SB BURNER WARNING LIGHT B BURNER CONTROL PANEL Fig 15 ...

Page 22: ...PREXTHERM 23 ...

Page 23: ...37047 SAN BONIFACIO VR Italia Tel 045 6139411 Tlx 480172 Fax 045 6100233 6100933 3545022 0 05 97 ...

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