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BlueHelix HiTech RRT C

cod. 3541V691 - Rev. 00 - 04/2022

Main exchanger replacement

Before carrying out the following instructions it is advisable to protect the room and the boiler’s electrical box
against accidental water spillage.

Disconnect the power supply and close the gas cock ahead of the valve

•

Disconnect the fume sensor connector

•

Disconnect the fan connector

•

Disconnect the connector of the ignition electrode
connected to the board.

•

Drain the water from the boiler heating circuit.

•

Remove the flue connection (concentric or acces-
sory for separate ducts)

•

Remove the fan

•

Remove the clips of the two pipes on the exchan-
ger, pump and hydraulic unit

•

Loosen the 2

bottom screws "5"

securing the ex-

changer to the frame (fig. 52)

•

Remove the 2

top screws "6"

securing the ex-

changer to the frame (fig. 53)

•

Remove the exchanger

•

Insert the new exchanger, resting it on the

bottom

screws "5"

•

For assembly, proceed in reverse order

fig. 49

fig. 50

Содержание 47-267-74

Страница 1: ...BlueHelix HiTech RRT C INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE ____________________________________ BLUEHELIX HITECH RRT 24C GC N 47 267 74 BLUEHELIX HITECH RRT 28C GC N 47 267 75 BLUEHELIX HITECH RRT 34C GC N 47 267 76 ...

Страница 2: ...ith the boiler so that it can be consul ted by the new owner and or installer Installation and maintenance must be carried out by professionally qualified personnel according to current regulations and the manufacturer s in structions Incorrect installation or inadequate maintenance can result in damage or injury The manufacturer declines any liability for damage caused by errors in installation a...

Страница 3: ...ce of installation 19 2 3 Plumbing connections 19 2 4 Gas connection 22 2 5 Electrical connections 23 2 6 Fume ducts 25 2 7 Condensate drain connection 30 3 Service and maintenance 32 3 1 Adjustments 32 3 2 Commissioning 38 3 3 Maintenance 38 3 4 Troubleshooting 46 4 Technical data and characteristics 51 4 1 Dimensions and connections 51 4 2 General view 52 4 3 Hydraulic circuit 52 4 4 Technical d...

Страница 4: ...0 that will soon arrive in Europe to fight global warming The sealed chamber unit is suitable for indoor installation or outdoors in a partially protected place according to EN 15502 with temperatures to 5 C 1 2 Control panel fig 1 Control panel Panel legend fig 1 1 DHW temperature setting decrease button 2 DHW temperature setting increase button 3 Heating system temperature setting decrease butto...

Страница 5: ...d by the flas hing radiator symbol When the burner is lit the flame symbol appears and the 3 levels indicate the actual intensity fig 2 DHW domestic hot water A DHW request generated by hot water draw off is indicated by the flashing faucet icon When the burner is lit the flame symbol appears and the 3 levels indicate the actual intensity fig 3 27 C 29 C 1 2bar 27 C 29 C 1 2bar ...

Страница 6: ...y shows the fault code with different graphics depending on the type A type fault fig 5 To unlock the boiler in the presence of this type of fault press the button until the message Confirm appears Then confirm with the button F type fault fig 4 A fault which will be automatically reset after the problem has been eliminated Message type fault fig 6 The fault is such as not to compromise boiler ope...

Страница 7: ...llowing 20 seconds the display will show FH which identifies the heating system air venting cycle with the fan running fig 8 In the next 280 seconds the venting cycle continues with the fan off fig 9 Open the gas valve ahead of the boiler When the message Fh disappears the boiler is ready to operate automatically whenever hot water is drawn or in case of a room thermostat request To interrupt the ...

Страница 8: ... still powered DHW and heating are disabled The frost protection system re mains on To relight the boiler press the button The boiler will be immediately ready in Winter and DHW mode B The frost protection system does not work when the power and or gas to the unit are turned off To avoid damage caused by freezing during long shutdowns in win ter it is advisable to drain all water from the boiler t...

Страница 9: ...t Use the heating buttons details 3 and 4 fig 1 to ad just the temperature from a minimum of 20 C to a maximum of 80 C The maximum value can be chan ged inside the parameters menu TSP via parameter P40 fig 14 DHW temperature adjustment Use the DHW buttons details 1 and 2 fig 1 to adjust the temperature from a minimum of 40 C to a maxi mum of 55 C The maximum value can be changed in side the parame...

Страница 10: ... the boiler when the faucet is turned on avoiding waiting times The COMFORT function can be disabled by the user ECO mode by pressing the button for 2 seconds In ECO mode the display activates the symbol detail 12 fig 1 To activate COMFORT mode press the button again for 2 seconds the symbol disappears Main menu MENU Pressing the button displays the main menu of the boiler MENU shown in fig 16 The...

Страница 11: ...sword entry Confirm with the button to access the installer menu SERVICE screen where the following menus are available TSP Menu for modifying transparent parame ters Test Activation of boiler Test mode OTC Setting of climatic curves for adjustment with external probe Zone Settings of climatic curves of additional zones Auto Setup This menu is used to activate cali bration Visible only with parame...

Страница 12: ...5 minutes Parameter displayed Description Range CH 1 temp NTC Flow sensor C 0 125 C CH 2 temp NTC Return sensor C 0 125 C DHW temp NTC DHW sensor storage tank probe C 0 125 C Ext temp NTC External sensor C 70 30 C Fume temp NTC Fume sensor C 0 125 C Fan rpm Actual fan rpm 0 9999 RPM Pump speed Actual modulating circulating pump speed 00 Min 100 Max Power Actual burner power 0 100 DHW flow Actual D...

Страница 13: ...at occurred The codes of the faults saved are also displayed in the relevant menu of the Remote Timer Control Press the buttons and Heating to scroll the list of faults Cancel is the last item in the list and which once se lected and confirmed with the button allows all the faults history to be reset To exit the Boiler faults menu ALARM press the button repeatedly until reaching the main screen or...

Страница 14: ...visable to set a maximum value to allow system adjustment throughout its useful operating range The boiler must be adjusted at the time of installation by qualified personnel However the user can make any further adjustments necessary to optimize comfort levels Compensation curve and curve offset From the main screen press the button to access the navigation menu MENU Using the buttons and heating...

Страница 15: ...case of a pressure below 0 8 bar it is advisable to restore it fig 24 Compensation curves fig 25 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 ...

Страница 16: ... boiler first close the shut off valves between the system and boiler before turning the ring nut To connect the safety valve to a disposal system ins tall the kit supplied details 1 and 2 fig 26 fig 26 Optimum pressure Normal operation Pressure slightly low The indication with the symbol is visible only if parameter b09 is set to 1 The boiler continues to work It is advisable to refill the system...

Страница 17: ...andards Codes of Practice BSI Model Water By Laws For Northern Ireland observe the current applicable regulations Safe handling of materials Pay attention when handling the boiler insulation panels because the material they are made of could irritate the skin No part of the boiler contains asbestos mercury or CFC s Advice for transport and handling For lifting and transport always take suitable sa...

Страница 18: ...fective support for the generator A If the unit is enclosed in a cabinet or mounted alongside a space must be provided for re moving the casing and for normal mainte nance operations fig 27 gives the minimum distances to be respected fig 27 2 3 Plumbing connections Important The heating capacity of the boiler must be previously established by calculating the building s heat requirement accor ding ...

Страница 19: ...e run to the out side of the building to prevent the risk of damage or injury caused by discharged hot water in case of overpressure in the system Connections to the boiler are to be made in such a way as to ensure that its internal pipes and fittings are free of stress If a non return valve is installed also on the DHW circuit if provided for it is necessary to install a safety valve between the ...

Страница 20: ... The fitting of a DHW expansion vessel is also recommended Isolation valve kit The isolation valves supplied see fig 30 must be installed between the boiler and heating system to allow the boiler to be isolated from the system if necessary fig 30 Isolation valve kit A Heating Flow 3 4 22mm with isolation valve fitted B DHW outlet elbow 1 2 15mm with outlet union fitted C Gas 3 4 22mm with yellow i...

Страница 21: ...quids declared by the producer suitable for use in heating systems and that do not cause damage to the heat exchanger or other components and or materials of the boiler and system Chemical conditioners must ensure complete deoxygenation of the water contain specific protective agents for yellow metals copper and its alloys anti scaling agents for limestone neutral PH stabilizers and in low tempera...

Страница 22: ...to the grid must be made with a perma nent connection and equipped with a bipolar switch with contact opening of at least 3 mm interposing fuses of max 3A between the boiler and line Make sure to res pect the polarities LINE brown wire NEUTRAL blue wire GROUND yellow green wire in the connections to the electric line B The unit s power cable MUST NOT BE REPLACED BY THE USER If the cable gets damag...

Страница 23: ...he front panel on page 38 to access the terminal block M and fuse F by pro ceeding as follows fig 31 and fig 32 The terminals indicated in fig 31 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 70 fig 31 fig 32 M 5 6 72 139 1 2 3 4 A 138 F ...

Страница 24: ...ation openings etc In case of installation with maximum resistance coaxial or separate flue it is advisable to carry out a calibra tion procedure AUTO SETUP to optimize boiler combustion Parameter b07 Function LC32 Action LC32 0 Manages a secondary gas valve default The contacts are closed when the gas valve in the boiler is powered 1 Use as an alarm output warning light comes on The contacts are ...

Страница 25: ...wards the boiler to prevent possible condensate from flowing back towards the outside and causing dripping fig 34 Starting accessories for coaxial ducts Table 5 Max length coaxial ducts Coaxial 60 100 Coaxial 80 125 Max permissible length horizontal All models 7 m BlueHelix HiTech RRT 24 C 28 m BlueHelix HiTech RRT 28 C 20 m BlueHelix HiTech RRT 34 C 20 m Max permissible length vertical All models...

Страница 26: ...s is less than or equal to the maximum permissible length in table 7 Table 7 Max length separate ducts Type Description C1X Wall horizontal exhaust and intake The inlet outlet terminals must be concentric or close enough to be subjected to similar wind conditions within 50cm C3X Roof vertical exhaust and intake Inlet outlet terminals like for C12 C5X Separate wall or roof intake and exhaust and in...

Страница 27: ...TION with test point 1KWMA70W 0 3 0 3 TERMINAL air wall 1KWMA85A 2 0 fumes wall with antiwind 1KWMA86A 5 0 FLUE Split air fumes 80 80 010027X0 12 0 Fume outlet only Ø80 010026X0 1KWMA86U 4 0 Type Description C8X Exhaust in single or common flue and wall intake B3X Intake from installation room by means of concentric duct that encloses the exhaust and exhaust in common flue with natural draft IMPOR...

Страница 28: ...cker included in the document envelope supplied with the unit B After installation check the tightness of the fumes and gas circuit OTHERWISE THERE IS DANGER OF SUFFOCATION DUE TO THE EMISSION OF COMBUSTION FUMES Position of terminals fig 38 Minimum dimensions of fume exhaust terminals A Directly under an opening air inlet openable window etc 300 mm B Above an opening air inlet openable window etc...

Страница 29: ... SION OF COMBUSTION FUMES THE CONDENSATE DRAIN MUST BE CONNECTED TO THE DRAINAGE SYS TEM IN SUCH A WAY THAT THE LIQUID CONTAINED CANNOT FREEZE fig 39 Condensate drain connection 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 applicab...

Страница 30: ... rigid weather conditions To 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 The pipes outside the building must be in glue joined plastic with increased diameter of up to 32 or 40 mm and at least 3 m long for connection to a condensate collection pit or external drain If using...

Страница 31: ...til the Fh mode has finished Put the boiler in standby mode and activate the calibration mode AUTO SETUP see IMPORTANT on page 32 Checking the combustion values MAKE SURE THE FRONT PANEL IS CLOSED AND THE INTAKE FUME EXHAUST DUCTS ARE COMPLETELY AS SEMBLED 1 Put the boiler in heating or DHW mode for at least 2 minutes 2 Activate the Test Test mode see Test mode Test on page 34 3 Using a combustion...

Страница 32: ...rror code at point will appear fig 41 9 Exit with the button and unlock the boiler Repeat the sequence from point 1 fig 41 The calibration procedure Auto Setup can only be performed if parameter b27 is set to 5 Parameter b27 can be set manually to the value 5 or by changing the parameter gas type b03 setting parameter P67 to 1 changing the value of parameter P68 doing Restore Factory Values with t...

Страница 33: ...han 500 burner operation hours because the system adjusts itself fig 42 To exit the test mode Test hold down the button If the Test mode Test is active and enough hot water is drawn to activate the DHW mode the boiler remains in Test mode Test but the 3 way valve switches to DHW The Test mode Test is automatically disabled in any case after 15 minutes or by stopping hot water draw off if enough ho...

Страница 34: ...r versions with pressure transducer 0 b10 Not implemented b11 Flowmeter timing 0 Deactivated 1 10 seconds 0 b12 Comfort mode 0 Activation with draw off 1 Always active 0 b13 Not implemented b14 DHW factor 0 1 0 b15 Flowmeter type selection 1 Flow 450 imp l 2 Flow 700 imp l 3 Flow 190 imp l 3 b16 Not implemented b17 Not implemented b18 DHW mode activation flow rate 0 100l min 10 do not set this val...

Страница 35: ...ature 0 80 C 40 P44 Comfort mode deactivation hys teresis 0 20 C 20 P45 DHW standby time 30 255 seconds 120 P46 DHW user max setpoint 40 65 C 55 P47 DHW pump Post Circulation 0 255 seconds 30 P48 Max output in DHW 0 100 100 P49 Not implemented b01 2 P50 Not implemented b01 2 P51 Burner shutdown in DHW P42 2 0 100 OFF DHW user setpoint P51 10 P52 Burner ignition in DHW P42 2 0 100 ON DHW user setpo...

Страница 36: ...y values fig 43 P62 Fan minimum speed DO NOT MODIFY The parameters are automatically updated G20 G230 24 kW 47 28 kW 47 34 kW 49 G30 G31 24 kW 49 28 kW 49 34 kW 48 P63 Fan on speed DO NOT MODIFY The parameters are automatically updated G20 G230 24 kW 160 28 kW 160 34 kW 140 G30 G31 24 kW 152 28 kW 152 34 kW 132 P64 Fan maximum speed DO NOT MODIFY The parameters are automatically updated G20 G230 2...

Страница 37: ...ply switching on and off on page 7 After the Fh cycle the display will show the winter mode screen fig 11 do the temperature adjustments heating flow and DHW outlet fig 14 and fig 15 Check if the value of the flue parameter P68 Transparent Parame ters Table on page 34 is suitable for the length of flue installed In case of gas change G20 G30 G31 G230 check if the relevant parameter is suitable for...

Страница 38: ...d chamber After any operation involving opening the boiler carefully check the correct refitting of the front panel and its seal Proceed in reverse order to refit the front panel Make sure it is correctly hooked to the upper fastenings and is correctly positioned at the sides Once the screw 1 is tightened the head must not be below the lower reference fold see fig 45 fig 45 Correct position of fro...

Страница 39: ... positioned and free of scale The electrode can be cleaned of incrustations only with a non metallic brush and must NOT be sanded The gas and water systems must be tight The water pressure in the system when cold must be approx 1 bar otherwise bring it to that value The circulating pump must not be blocked The expansion tank must be filled The gas flow and pressure must match that given in the res...

Страница 40: ...tructions in par Checking the com bustion values on page 32 Gas valve replacement Disconnect the power supply and close the gas cock ahead of the valve Disconnect the electrical connectors 1 fig 46 Disconnect the gas supply pipe 2 fig 46 Undo the screws 3 fig 47 Remove the gas valve 4 and the gas diaphragm 5 fig 48 Fit the new valve carrying out the above steps in reverse order Refer to the instru...

Страница 41: ...nnector Disconnect the connector of the ignition electrode connected to the board Drain the water from the boiler heating circuit Remove the flue connection concentric or acces sory for separate ducts Remove the fan Remove the clips of the two pipes on the exchan ger pump and hydraulic unit Loosen the 2 bottom screws 5 securing the ex changer to the frame fig 52 Remove the 2 top screws 6 securing ...

Страница 42: ...BlueHelix HiTech RRT C 42 EN cod 3541V691 Rev 00 04 2022 fig 51 fig 52 fig 53 5 6 6 ...

Страница 43: ...ck ahead of the valve Undo the two screws 1 and rotate the control panel Raise the electrical box cover by operating on the tabs 2 Undo the screws 3 Raise the board by operating on the side tabs 4 Remove all the electrical connectors Insert the new board and reconnect the electrical connections fig 54 fig 55 1 1 2 2 3 3 4 ...

Страница 44: ...he venturi 3 fig 56 fig 57 Water pressure switch replacement A Before carrying out the following instructions it is advisable to protect the room and the boiler s electrical box against accidental water spillage Disconnect the power supply and close the gas cock ahead of the valve Drain the water from the heating circuit Remove the pressure transducer connector and retaining clip 1 Remove the pres...

Страница 45: ... wiring If the voltage is sufficient Range 195 253 Vac check the fuse 3 15AL 230VAC The fuse is on the card To ac cess it see fig 31 LCD display On In case of operation problems or faults the display shows the fault identification code There are faults that cause permanent shutdowns indicated with the letter A to restore operation just hold down the button until the message Confirm appears and con...

Страница 46: ...electrode Electrode to ground Cable to ground Check the trap and clean it if necessary Card fault Check the card F05 Fan fault No 230V power supply Check the 5 pin connector wiring Tachometric signal interrup ted Fan damaged Check the fan and replace it if necessary A06 No flame after the ignition phase Ionization electrode fault Check the position of the ionization elec trode free it from any enc...

Страница 47: ... the wiring or replace the sensor Wiring shorted Wiring disconnected F13 Fume probe fault Probe damaged Check the wiring or replace the fume probe Wiring shorted Wiring disconnected A14 Fume extraction duct safety device intervention Fault A07 generated 3 times in the last 24 hours See fault A07 F15 A07 High fume temperature The fume probe detects an excessive temperature Check the exchanger Check...

Страница 48: ...ystem Vent the system Incorrect parameter Check the correct parameter setting F62 Calibration required New card or boiler not yet calibrated Do the Calibration procedure AUTO SETUP F64 Maximum number of con secutive Resets exceeded Maximum number of conse cutive Resets exceeded Disconnect the power supply to the boiler for 60 seconds and then reinstate the boiler A65 A97 Specific combustion con tr...

Страница 49: ...Condensate trap blocked Fumes recirculation or com bustion problem Initially solve the problem reset the fault and check correct ignition Do the Calibration procedure AUTO SETUP Replace the board if necessary A99 Generic error PCB hardware or software error Reset the fault and check for correct igni tion Do the Calibration procedure AUTO SETUP If the problem persists replace the board F99 Communic...

Страница 50: ...ions and connections 7 Gas inlet Ø 3 4 8 DHW outlet Ø 1 2 9 Cold water inlet Ø 1 2 10 System flow Ø 3 4 11 System return Ø 3 4 A6 Condensate discharge connection fig 61 Front view fig 62 Side view fig 63 Top view fig 64 Bottom view 420 700 320 112 210 210 45 65 67 67 65 113 83 161 117 45 10 8 7 9 11 A6 79 ...

Страница 51: ...4 DHW exchanger 196 Condensate tray 246 Pressure transducer 350 Fan Burner assembly fig 66 Hydraulic circuit 8 Domestic hot water outlet 9 Cold water inlet 10 System flow 11 System return 14 Safety valve 32 Heating circulating pump 34 Heating temperature sensor 36 Automatic air vent 42 DHW temperature probe 56 Expansion vessel 74 System filling faucet 95 Diverter valve 136 Flowmeter 186 Return sen...

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Страница 56: ...69 Residual head available for system 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 4 0 5 0 6 0 7 0 8 0 9 1 1 1 1 2 1 3 1 4 1 5 1 6 H mCA Q m3 h 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 4 0 5 0 6 0 7 0 8 0 9 1 1 1 1 2 1 3 1 4 1 5 1 6 H mCA Q m3 h 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 ...

Страница 57: ...er on the ter minal block To connect more zones of the hydraulic system controlled by thermostats with voltage free contact and the timer control has to be used as a remote control for the boiler the voltage free contacts of the zones must be connected to terminals 1 2 and the timer control to terminals 5 6 ALL CONNECTIONS TO THE TERMINAL BLOCK MUST BE WITH VOLTAGE FREE CONTACTS NOT 230V X04 X03 X...

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Страница 64: ...RU PRELOH DOOV DUH DOVR LQFOXVLYH LQ DQ EXQGOH RX PD KDYH ZLWK KDYH RXU SKRQH SURYLGHU Phone numbers Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS ALL SPECIFICATIONS SUBJECT TO CHANGE Please note to avoid incurring unnecessary expense in the event of a boiler shut down check this is not caused by lack ...

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