Lattner Boiler Company Alkon 90 Installation And Servicing Manual Download Page 49

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Page 1: ...2012 INSTALLATION ANDSERVICING MANUAL Notice This manual is avaible in the English and French language In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Condensing gas boiler LATTNER ...

Page 2: ... 3 20 Wiring diagrams 31 3 21 Ladder diagrams 32 3 22 Starting up 33 3 23 Filling the system 33 3 24 Initial lighting 35 Preliminary checks 35 Ignition and switching off 35 Information to be supplied to the user 35 3 25 Testing ignition safety shut off device 36 3 26 Burner adjustment 37 3 27 Programming of the operational parameters 39 3 28 Variation of input range for high altitude 41 4 SERVICIN...

Page 3: ... resistance to lime scale it is recommended to adjust the domestic hot water temperature as near as possible to the one you really require We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found this period can be extended to two years 1 GENERAL INFORMATION CAUTION INDICATES A POT...

Page 4: ...been purged For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally authorized If the tank has not been correctly purged problems could occur during ignition If this occurs contact the liquid gas tank s supplier 1 5 SAFETY WARNINGS 1 4 INFORMATION TO BE HANDED OVER TO THE USER Go through the information in this manual with the owner operator and...

Page 5: ...se the main gas tap Open all windows and doors where the gas leakage has occurred Inform the gas society or a company specialized in installing and servicing heating systems DANGER Explosive and easily inflammable substances Do not use or leave explosive or easily inflammable material as for example petrol paint paper in the room where the appliance has been installed A sample DataPackaging for a ...

Page 6: ...associated hazard in writing DANGER Gas is flammable and may cause an explo sion Beware if you smell gas there may be an explo sion hazard If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WA...

Page 7: ...ng only original spare parts Non observance of the above requirement may jeopardize the safety of the appliance To guarantee the efficiency and correct functioning of the appliance it is indispensable to have the boiler serviced annually by a qualified person If the boiler remains unused for long periods ensure that any dangerous parts are rendered innocuous Before putting again into service an ap...

Page 8: ...escribed by ANSI Z21 13 CSA 4 9 Gas fired low pressure steam and hot water boilers DESCRIPTION OF COMPONENTSAND FEATURES Aluminium heat exchanger condenser Premixed combustion group working at constant air gas ratio Electronic ignition Safety limit thermostat 2 TECHNICAL FEATURES AND DIMENSIONS Safety high limit thermostat Flow temperature sensor Return temperature sensor Automatic air vent Contro...

Page 9: ... CH flow system DN 80 G Gas Inlet DN 50 Sc Outlet condensate drain siphon Ø 32 2 2 DIMENSIONS 48 4 1238 mm 4 6 118 mm 3 9 100 mm 20 2 513 mm 16 9 430 mm 11 2 284 mm 9 9 251 mm 5 3 134 mm 11 6 295 mm 18 456 mm 12 8 324 mm 6 2 158 mm 3 7 94 mm 23 9 607 mm 4 7 119 mm ...

Page 10: ...ER PRESSURE SWITCH 2 WAY VALVE flow stop RETURN CONDENSATE SENSOR NIVEAU RETURN TEMPERATURE SENSOR FLOW TEMPERATURE SENSOR 2 3 MAIN COMPONENTS H L THERMOSTAT Overheat exchanger protection ALUMINIUM HEAT EXCHANGER CONDENSER IGNITION ELECTRODE FLAME DETECTION ELECTRODE AIR VENT VALVE GAS VALVE FLUE OUTLET PIPE Ø100 mm 3 94 MANUAL VENT VALVE PUMP H L THERMOSTAT SAFETY VALVE ...

Page 11: ...h against lack of water 7 HL thermostat 8 HL thermostat Overheat exchanger protection 9 Manual air vent 10 Air vent valve 11 Heat exchanger 12 Fan 13 Premix 14 Condensate niveau sensor 15 Gas valve 16 Gas ball valve 17 Condensate drain siphon 18 Smoke pressure switch 19 Flue Outlet 20 Safety valve supplied 21 Pressure gauge optional M C H flow G Gas supply R C H return M R G 1 2 3 4 5 7 9 10 11 12...

Page 12: ...al supply Net weight Gross weight 83 300 341 000 307 000 298 600 72 000 87 55 86 44 298 600 72 000 93 66 98 3 97 9 98 4 0 90 101 3 25 50 30 36 IV 4 0 7 3 92 3 5 1 176 86 120 60 298 312 2 5 PERFORMANCE DATA For information regarding the adjustment of INJECTORS BURNER PRESSURES DIAPHRAGMS OUTPUTS GAS CONSUMPTIONS please refer to the paragraph ADAPTMENT TO THE USE OF OTHER GASES 24 41 99 94 89 97 87 ...

Page 13: ... the boiler and chimney flue outlet can be made only after this verification has been carried out WARNING In rooms where there is the presence of aggressive vapours or dust the appliance must operate independently from the air present in the boiler s location room WARNING The appliance must be installed by a qualified engineer who complies to the technical professional requirements who under his o...

Page 14: ...pment for maneuvering steps When shipping the boiler must be secured on the tran sportation equipment to prevent it from falling off Protect all parts against impacts if they are to be transpor ted Follow the transportation markings on the packaging Packaged boilers must always be lifted and carried by two people or you must use a handtruck or special equipment for transport A A 3 2 CODE AND STAND...

Page 15: ...and keep the back straight and feet apart Do not lift and twist at the same time Lift and carry the boiler close to the body Wear protective clothing and gloves to pro tect from any sharp edges Dispose the packaging materials Before positioning the boiler screw down the adjustable feet supplied with the boiler The casing front panel is hinged on the R H side The hinges A are factory fitted on the ...

Page 16: ... choosing the installation place the following items have to be considered To grant an easy access to the boiler components in order to facilitate the ordinary and extraordinary service opera tions The floor should not be of flammable material If the floor is flammable an insulation material with the capacity to withstand to the fire for at least 120 min should be placed between the boiler and the...

Page 17: ...ntake Spray cans containing chloro fluorcarbons Ammonium and or ammonium solutions Permanent wave solutions Chlorinated waxes and or cleaners Swimming pool chemicals based on chlorine Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dry...

Page 18: ...is installed in order to facilitate the flushing of the system The boiler must be valved off from the system while the system is flushed No system cleaner should ever enter the boiler heat exchanger because of its caustic nature it could damage the heat exchanger When the appliance is installed on existing systems ensure yourself that The flue outlet pipe is suitable for condensing boilers for the...

Page 19: ...iler running Minimum 8 inches W C with gas flowing verify during boiler startup Ensure that the high gas pressure regulator is installed at least 6 to 10 feet upstream of the boiler Gas piping Use a gas shut off valve compatible with propane gases A sediment trap must be provide upstream of the gas con trols The connection to the boiler must include a suitable method of disconnection The nominal i...

Page 20: ... the dirt filter scale cartridge or y strainer When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system s components and by the configuration of the same system The route of the piping has to be conceived taking all the necessary precautions in order to avoid air locks and to facilitate the continuous purging of the system C...

Page 21: ... ΔT 36 F 20 C 1326 1097 ALKON 90 3 10 DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP 298 600 87 51 NOTE The use of a mixing header fitted between the boiler circuit and the system circuit is always advisable It becomes INDISPENSABLE if the system requires flow rates superior to the maximum permitted boiler flow rates which is to say lower than 27 F 15 K If determined by the installer o...

Page 22: ...pipe with a funnel and a siphon which lead to an adequate drainage The drainage has to be controllable by sight If this precaution is not made an eventual intervention of the pressure relief valve could cause injury to persons animals or damage to property The manufacturer shall not be held liable for any injury and or damage NOTICE The expansion tank is NOT a part of the delivery and should be so...

Page 23: ...led so as to avoid freezing of the liquid when the boiler is operating and prevent the eventual pres surization of the sewage system consent the correct downflow of the appliance s liquid di scharges it must be made with materials which are resistant to con densate if the condensate outlet of the boiler is lower than the drain a condensate pump must be used The condensate produced by the boiler ha...

Page 24: ... the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the generator in time For this purpose it will be necessary to fix the following chemical physical characteristics of the water PH include between 6 5 and 8 Hardness 6 9 grains 9 15 fr Water hardness When there is a water hardness of more than 6 to 9 grains hardness a water softener m...

Page 25: ...ble materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors Never use chiorine and hydrocarbon containing chemicals such as spray chemicals solution and cleaning agents paints giues etc in the vicinity of the boiler Do not store and use these chemicals in the boiler room Avoid excessive dust formation and buildup NOTICE When one expects contaminated combustion ai...

Page 26: ... can freeze causing ice formations Do not use chimney as a raceway if another boiler or fire place is vented into or through chimney EXHAUST INTAKE 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum NOTICE Terminals should be positioned as to avoid pro ducts of combustion entering openings into bu ildings or other vents NOTICE Terminals should be positioned a...

Page 27: ...ue which will terminate vertically through the roof The combustion air is withdrawn directly from the room where the boiler is installed The flue system must be installed in accordance with the local and national Standards Use only original LATTNER flue outlet systems which are provided from the follow manufacturer TABLE FLUE OUTLET SYSTEM Damages caused by installation errors and for non observan...

Page 28: ...iminary operations Fit the smoke evacuation A pipe Ø 3 94 100 mm supplied in the package into the boiler as shown in the picture Fix the screw B FLUE OUTLETS Ø 3 94 100 mm A B L ATTENTION For boiler have horizontal runs sloping upwards not less than 1 4 in ft 21 mm m from the boiler to the vent terminal ...

Page 29: ... supply cables Do not expose the boiler to sunlight rain etc unless it is explicitly foreseen Do not permit children or inexpert people to use the appliance Mains electrical supply connection 120 V 60 Hz Power supply cord The boiler is provided complete with a mains supply cable 118 3 m long and with a cross section area of 3 x 16 AWG The electric connections of the boiler are shown in the section...

Page 30: ... the connecting terminals 3 and 4 DANGER Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts CAUTION Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts TL TSC CDS 1 Prearrangement for the connection of the additional safety devices BLACK BLUE BLUE BLUE A hot water boiler installed above...

Page 31: ...BROWN BLUE BLUE BROWN E RIV BROWN WHITE DK TF BLACK TA E8 PF RED YEL GREEN BLUE IG VM VG YEL GREEN c no BLUE CDS 1 P BLUE 1 NC SL BLUE PF BROWN 3 C WHITE TSC Minimum water pressure switch Ignition electrode Detection electrode Power switch On Off Motor 3 way valve optional Pump Smoke Pressostat CH sensor CH return sensor DHW sensor optional Limit thermostat Smoke thermostat only pre arrangement Hi...

Page 32: ...ME CAUTION HIGH VOLTAGE SPARK LEAD SPARK ROD A8 1 IG A8 2 IG A8 2 A9 2 A9 6 A6 6 A6 5 A9 5 A9 1 A8 1 A3 5 SRR RIBBON CABLE A3 A3 6 A3 3 SR A3 4 A4 6 PF A4 5 A4 4 A4 5 TL A4 1 CDS 1 A2 3 DK A2 1 8 8 8 DISPLAY A1 4 A1 2 A1 1 A1 3 RL 4 RL 1 RL 2 RL 3 A4 4 A4 3 SL ATTENTION AUTE TENSION CÂBLE D ALLUMAGE A4 2 ...

Page 33: ...ATTNER engineering for further assistance Failure to adhere to the water quality requirements will result in a void of warranty Once all the connections are made it is possible to fill the circuit This operation has to be performed very carefully by obser ving the following steps boiler in Off position open the radiator bleeds and make ascertain the good operation of the automatic air vent fitted ...

Page 34: ...34 Instructions for the installer ...

Page 35: ...en filled with water DANGER Before commissioning the appliance fill the siphon and check the correct drainage of the condensate If the appliance is used with the condensate drain siphon empty there could be danger of intoxication resulting from the escape of flue gasses there are no water leaks all the necessary ventilation conditions and minimum clearance distances are guaranteed for subsequent s...

Page 36: ...n the gas valve knob in OFF position After 1sec boiler switch off LIGHT BLUE Power on by switching ON OFF switch 3 25 TESTING THE IGNITION SAFETY SHUT OFF DEVICE Lock out indicator led illuminated fault indicator led Press Reset Key will displayed the fault code LF loss of flame the boiler will retry ignition cycle 7 seconds after which if was not removed the cause of the fault gas tap the boiler ...

Page 37: ...nds the boiler will operate in the CH mode at the maximum output led 1 illuminated Check that the C02 values are within the values indicated in the table Burner pressures If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to decrease the value and in an ANTICLOCKWISE direction in order to increase it 1 LIGHT BLUE VIOLET YELLOW BLUE 1 1 B Min output adjustment...

Page 38: ...oiler goes into lockout again carry out the above indicated operations until the boiler is lighted At this point carry out the burner adjustment as previously indicated If necessary correct the value by turning the adjustment screw B in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it Type of Gas 7 1 74 11 2 74 7 1 74 11 2 74 0 082 2 33 0 032 0 ...

Page 39: ... setting the desired value pressing the YELLOW key stores this new value in the memory Press the YELLOW key and the LIGHT BLUE key simultane ously to enter in the service mode SE and change the values of the pre set operating parameters PUMP OVERRUN Continue to change to the parameters by pressing the key decrease The successive parameter which can be changed is PUMP OVERRUN Po Repeat the operatio...

Page 40: ...BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE 3 28 VARIATION OF INPUT RANGE FOR HIGH ALTITUDE It is necessary adjust nominal heat input by reducing the fan speed Modify the parameter FH from the boiler panel board See factory parameter supplied separately and modifia ble only with access code LIGHT BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE Insert C...

Page 41: ...d return pipes as well as the cold water inlet valve Remove the appliance s front panel After having carried out all the necessary maintenance work always follow these steps Open the CH flow and return valves as well as the cold inlet valve if previously closed Purge and if necessary proceed with restoring the hea ting system s pressure until a pressure of 0 8 1 bar is rea ched Open the on off gas...

Page 42: ...ails can be found on the back page of this manual Verify that the air ventilation system air intake and air intake pipes are unobstructed After 1 year maintenance Perform cleaning of the burners only by blowing with com pressed air acting from the side flame Verify visually the state of the spot weldings of the L profiles and the burner mesh Compressed air Wash with water the combustion chamber av...

Page 43: ... The flame must burn with a clear ORAN GE stable flame Check the flame through the inspection glass The flame pattern should be as shown in the figures below SATISFACTORY ORANGE FLAME FLAME YELLOW CO2 HIGH NOT SATISFACTORY BLUE CO2 LOW NOT SATISFACTORY ORANGE OK SATISFACTORY After removing inspected and possibly cleaned Flue pipes and air intake replace the tubes correctly Attention to the sense o...

Page 44: ...ect drainage of the condensate If the appliance is used with the condensate drain siphon empty this could lead to danger of intoxication following the escape of flue gasses DANGER It is absolutely necessary to replace the gasket at any time the inspection or mainte nance is made on the burner When refitting the mixer tighten the nuts progressively and in crossed way by using a dynamometric wrench ...

Page 45: ...ns voltage is correct replace the control board Code Description Insufficient gas pressure Corrective action Check the pressure if the pressure is correct check the efficiency of the gas pressure switch and or the wiring Code Description Difference between the heating temperature sensor SR and the heating return sensor SRR too high Corrective action Check the installation Code Code Code Code Descr...

Page 46: ...the sensor s efficiency and or wiring Description Common chimney obstruction Corrective action Verify the chimney Code Code Code Code Code Code The boiler has an integrated system that after 15 000 3 value displayed x 5000 Value switching On or 3 000 3 value displayed x 1000 hours of operation of the burner provides to signal that the boiler needs maintenance Such information is indicated on the d...

Page 47: ...47 Spare parts 6 SPARE PARTS 25 41 24 30 29 28 23 26 49 19 17 35 14 21 47 31 20 14 47 33 15 6 45 16 4 34 3 41 9 13 32 12 11 10 27 46 37 38 42 39 43 44 40 2 7 36 18 48 5 8 1 22 24 ...

Page 48: ...61339 Lock with key 24 95261357 Drain valve 3 4 25 95263579 Ignition transformer 26 95262187 100mm seal 27 95263573 Fan RG137 120V 250W 28 95263597 Stopcock FF 1 1 4 29 95262247 3 way valve 1 1 4 30 95263582 Pump GRUNDFOS UPS 26 99FC 115V 31 95263598 Gas cock MF 1 32 95262451 Mixer 33 95263546 Gas valve Dungs GB WND 057 34 95262464 Level sensor 35 95262556 Safety valve ASME WATTS 174 A 36 95310870...

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Page 52: ... 319 366 0770 www lattner com Lattner declines every responsibility for the possible inaccuracies if owed to errors of transcript or press Also reserves the right to bring those changes that it will hold necessary to it own products or profits without jeopardizing its essential characte ristics LATTNER ...

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