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ADI LT boiler - Technical Manual 

 

                  Page 

L338 

 

11/2011 

12 

7. BOILER HEAT EXCHANGER 

 
The  boiler  heat  exchanger  (flues-water)  is  made  of 
stainless steel: is a stainless steel enriched with a special 
alloy  (for  a  better  resistance  to  corrosion  and  to  high 
temperatures). 
 
The  boiler  heat  exchanger  consists  of  2  water  collectors, 
an  upper  one  and  a  lower  one,  connected  by  means  of 
multiple  vertical  tubes  forming  the  combustion  chamber. 
The vertical tubes generate a big heat transfer surface that 
uses the sensible heat of the flues. 
 
During  the  manufacturing  process,  the  boiler  is  subjected 
to  a  strict  quality  control,  realized  through  a  process  of 
three  leak  tests:  one  with  penetrant  liquids,  another  one 
with air pressure and the last one with water pressure. 
 
The boiler heat exchanger is insulated.  
 
Several  manual  purgers  are  installed  in  the  higher  part  of 
the boiler for the air venting of the boiler. 
 
 
 
 
 
 
 
 

 
 

 
 

 
 
 

 
 
 

 
 
 
 
 

 
 

 
 
 

 
 
 

 
 
Front and rear view: models ADI LT 200 and lower                            

Front and rear view ADI LT 250 and higher 

 

Содержание ADI LT

Страница 1: ...L338 11 2011 INSTALLATION OPERATION AND MAINTENANCE MANUAL ADI LT LOW TEMPERATURE BOILER ...

Страница 2: ...3 ADJUSTMENT OF THE SET UP BOILER FLOW TEMPERATURE ______________________________________ 18 10 4 BOILER LOCKOUT CODE______________________________________________________________________ 19 10 5 FUNCTION BOILER MAINTENANCE _____________________________________________________________ 19 10 6 AVAILABLE PARAMETERS THAT CAN BE ADJUSTED BY THE FINAL USER ___________________________ 20 11 DATA AND INF...

Страница 3: ...5 7 1 Data to be considered _______________________________________________________________________ 38 15 7 2 Overpressure safety valve____________________________________________________________________ 38 15 7 3 Hydraulic pressure drop _____________________________________________________________________ 39 15 7 4 Water manifold ___________________________________________________________________...

Страница 4: ...he European directive 92 42 EEC Efficiency up to 105 Boiler certified as Low temperature flow temperature up to 90ºC no limit of return temperature Boiler heat exchanger in stainless steel Power outputs from 104 to 905 kW Maximum efficiency per year Variable temperature on boiler Boiler power modulation according to the demands of the installation High reduction of stop start cycles Minimum heat l...

Страница 5: ...er maintenance must be realized following the instructions of the manufacturer s technical manual and with a minimum regularity as indicated by the current regulations 3 EEC APPROVALS AND CERTIFICATIONS ADISA boilers model ADI LT are certified as follows MODEL ADI LT 105 to 400 475 to 750 850 to 950 GAS BOILERS DIR 90 396 EEC 1312CL5485 AND EFFICIENCY DIR 92 42 EEC 1312CL5488 The European Directiv...

Страница 6: ...kit D Flame indicator E Motor fan variable speed F Fan G Venturi for air inlet and mix with gas H Multiblock gas valve J Boiler control unit and power modulation L Hot water flow M Hot water return N Flues outlet P Gas connection Q Air pressure switch R Air filter S Ignition transformer T Gas pressure switch U Pressure sensor V Air purgers manual Models ADI LT 105 to 200 view from above B D F E C ...

Страница 7: ...ADI LT boiler Technical Manual Page L338 11 2011 7 Models ADI LT 250 and higher A C D B J Q H G F E R S ...

Страница 8: ... 150 1110 774 198 963 635 546 66 62 134 3 250 660 305 177 5 175 1583 937 403 1156 940 775 61 75 217 3 275 660 305 177 5 175 1583 937 403 1156 940 775 61 75 217 3 325 810 360 225 250 1583 936 445 1156 940 775 61 75 292 400 810 360 225 250 1583 936 445 1190 940 775 61 75 249 3 475 810 360 225 250 1583 936 445 1190 940 775 61 75 249 3 Attention Heights H HG HA HF without taking into consideration the...

Страница 9: ...nt block feet supplied with the boiler dimension SB Note data in the present document are liable to changes without prior warning ADI LT 4 5 6 9 12 Diam Diam Diam Diam 105 2 threaded 3 4 H 130 2 threaded 1 H 150 2 threaded 1 H 200 2 threaded 1 H 250 2 to be flanged PN 6 1 1 4 1 1 2 M 275 2 to be flanged PN 6 1 1 4 1 1 2 M 325 2 to be flanged PN 6 1 1 4 1 1 2 M 400 2 to be flanged PN 6 1 1 4 1 1 2 ...

Страница 10: ...ty litros 30 30 30 33 36 76 85 99 Max water pressure bar 5 5 5 5 5 5 5 5 Water ΔT 10ºC m3 h 8 9 11 2 12 8 16 3 19 8 22 5 27 7 32 7 flow ΔT 12ºC m3 h 7 5 9 3 10 7 13 6 16 5 18 8 23 1 27 2 rate ΔT 15ºC m3 h 6 0 7 5 8 6 10 9 13 2 15 0 18 5 21 8 Electric Consumption at max output W 134 182 222 129 201 177 342 445 at min Output W 24 31 41 26 36 22 60 79 Maximum consumption W 255 268 282 256 314 259 342...

Страница 11: ...5 5 5 Water ΔT 10ºC m3 h 39 9 46 9 53 0 59 8 68 8 77 8 flow ΔT 12ºC m3 h 33 3 39 1 44 1 49 8 57 3 64 9 rate ΔT 15ºC m3 h 26 6 31 2 35 3 39 8 45 9 51 9 Electric Consumption at max output W 727 668 859 1165 at min Output W 81 86 115 124 Maximum consumption W 727 668 859 1165 Supply V 1x230 V 1x230 V 1x230 V 1x230 V 3x380 V 3x380 V Natural gas L C V 10 757 kW m3 38 728 MJ m 3 Propane gas CONSULT Elec...

Страница 12: ... forming the combustion chamber The vertical tubes generate a big heat transfer surface that uses the sensible heat of the flues During the manufacturing process the boiler is subjected to a strict quality control realized through a process of three leak tests one with penetrant liquids another one with air pressure and the last one with water pressure The boiler heat exchanger is insulated Severa...

Страница 13: ...n 8 Fan for the air gas mix 9 Motor fan of variable speed 10 Air inlet 11 Flange of the group motor fan to be coupled to the flange of the boiler heat exchanger 12 Ignition ionization kit 13 Pressure connection for the gas valve just models LT 250 and higher 14 Pressure connection for the safety air pressure switch 15 Air filter just models LT 250 and higher 16 Electrodes support 17 Gasket for ele...

Страница 14: ...s valve regulates the gas outlet pressure according to the pressure value in the venturi Note 13 in models LT 250 and higher a coupling pipe between the multi block gas valve and the venturi measures the pressure drop before the mix For lower models there is no pipe the connection between the multi block gas valve and the venturi is internal M The power modulation is realized by varying the fan sp...

Страница 15: ...ADI LT boiler Technical Manual Page L338 11 2011 15 Exploded view of the assembly burner fan gas valve for models LT 250 and higher Motor Fan basculating attached to the body of the boiler ...

Страница 16: ...ow thermal inertia fast cooling for an easier maintenance Fast answer to the changes of the power demand Thanks to its structure and design noise produced by the combustion is very low and without resonance The cylindrical shape of the burner allows the flame to be homogeneously distributed It is vertically introduced in the boiler The boiler incorporates an ionization flame control The minimum io...

Страница 17: ...t mode according to reduced setpoint Standby circuit 1 disconnected anti freezing function activated 4 Adjust boiler set up flow temperature T4 5 Not operational Adjust D H W S set up temperature 6 Button to change the line of the display that you want to select T6 to go down T7 to go up 7 8 To modify the values of adjustment of the parameters on the display To decrease T8 and to increase T9 9 10 ...

Страница 18: ...day adjustments of parameters or error code 6 Heating circuit operation mode Automatic according to the time program at a nominal set up temperature or at a reduced set up temperature operation at a nominal set up temperature all the time operation at a reduced set up temperature all the time boiler in standby waiting 7 Not available D H W S operation mode 8 Time programming of use of the heating ...

Страница 19: ...an 6 seconds and then press both again On the right of the display a pointer will flicker pointing to The display will show the percentage of power at which the boiler is working In order to realize the maintenance operations the action PID of the controller on the boiler will be deactivated The boiler power can be increased or decreased by pressing one of the buttons T8 or T9 If you wish to go di...

Страница 20: ...ther level or line changes will be automatically saved Line Function Adjustment range Unit Resolution Value by default 1 Current time 0 23 59 h min 1 min 5 Boiler reduced set up temperature TRN ºC 0 5 69 0 Time programming 11 Time program Heating circuit 1 phase 1 start up time 00 00 24 00 hh mm 10 min 06 00 12 Time program Heating circuit 1 phase 1 stop time 00 00 24 00 hh mm 10 min 22 00 13 Time...

Страница 21: ...during 3 seconds at least the buttons T6 and T7 The first reading will be visualized on the display corresponding to the letter b0 Choose the required parameter by pressing the buttons T8 and T9 To go back to the initial or normal display press T2 if you do not vary anything after 8 minutes you will automatically go back to the initial display Information of temperatures maintenance level 1 Code D...

Страница 22: ...ons T8 and T9 To go back to the initial or normal display press switch T2 if you do not vary anything after 8 minutes you go automatically back to the initial display Set up temperatures maintenance level 3 Code Description d0 d7 d9 Not used d1 Consigna del regulador modulante controller PID d2 Consigna de temperatura de impulsión de caldera ºC d3 Not available Set up room temperature according to...

Страница 23: ...the Official Technical Service in order to activate it An outside temperature probe should be added supplied separately from the boiler and not included in the price and connected to terminals 1 and 2 of the strip X10 06 positioned in the LMU control unit of the ADI LT boiler These are the possible curves of operation Boiler flow temperature ºC External temperature ºC 11 5 VIEW OF THE BOILER CONTR...

Страница 24: ...regulate the start up and modulation of each boiler So that each boiler can receive and process an external signal type 0 10 V it must be provided with consult prices An additional module or clip in model AGU 2 51 A cable for connecting the additional module to the boiler control unit mod AGU2 104A109 Clipin AGU2 510A109 LMU This module enables an analog entry that can be of two types Probe NTC 10...

Страница 25: ...cation bus type LPB module OCI 420 A cable for connecting the additional module to the boiler control unit mod AGU2 104A109 The Official Technical Service must realize a change in the internal parameters in order to use this regulation on the boiler The additional module OCI 420 must be connected to the LMU control unit of each boiler Clipin OCI420 LMU Just one module type OCI420 can be connected ...

Страница 26: ... realized multiple options can be chosen Sequence control unit RVS 63 K e s s e l 4 K e s s e l 1 K e s s e l 2 K e s s e l 3 L e is t B a n d M a x 8 0 L e is t B a n d M in 4 0 O n O f f K e s s e l 2 O n O f f K e s s e l 3 O n O f f K e s s e l 4 3 0 0 2 0 0 1 0 0 4 0 0 Boiler 1 Boiler 2 Boiler 3 Boiler 4 LMU LMU LMU OCI 420 OCI 420 OCI 420 Boiler 1 Boiler 2 Boiler 3 ...

Страница 27: ...al Manual Page L338 11 2011 27 2379Z05 ON ON 53 53 53 80 40 40 80 80 80 80 80 100 100 100 OFF OFF 53 53 53 80 80 40 40 80 20 In this example the boilers activation and their power regulation would be realized as shown below ...

Страница 28: ...ormer 220 230 V 8 General switch ON OFF 9 Safety overheating thermostat 10 Display of reading 11 Signal of control of the modulation of the variable speed fan PWM 12 Air pressure switch 13 Minimum gas pressure switch 14 Main Electric supply to the boiler ADI LT 105 to 750 220 230 V 50 Hz single phase with earth connection ADI LT 1300 to 950 Tri phasal 380 V 50 Hz with earth connection 15 Stop star...

Страница 29: ...ADI LT boiler Technical Manual Page L338 11 2011 29 12 1 ELECTRIC DRAWING ADI LT 105 ADI LT 200 ...

Страница 30: ...ADI LT boiler Technical Manual Page L338 11 2011 30 12 2 ELECTRIC DRAWING ADI LT 250 ADI LT 325 ...

Страница 31: ...ADI LT boiler Technical Manual Page L338 11 2011 31 12 3 ELECTRIC DRAWING ADI LT 400 ADI LT 750 ...

Страница 32: ... if the DeltaT in the boiler is higher than the maximum Delta T the power drops by 20 Safety 2 if it overcomes the maximum Delta T 8ºC the boiler operates at the minimum power Safety 3 if it overcomes a higher value the boiler stops and an error message appears on the display E 154 434 or E 154 433 Lack of water pressure in the circuit Pressure sensor The boiler stops for safety if pressure in the...

Страница 33: ...t is important to avoid environments with excess of humidity dust and aggressive steams If the boilers room needs to have some building works the boilers should be switched off and protected in order to avoid dust For an easier maintenance it is important to respect the minimum distances indicated by the regulations and the manufacturer s instructions both for one boiler and for several boilers Ev...

Страница 34: ...ch boiler will correspond to the values indicated in this manual see table TECHNICAL DATA 15 4 1 Gas pressure higher than 45 mbar Units Boiler model Inertial volume m3 1 ADI LT 105 0 0102 1 ADI LT 130 0 0128 1 ADI LT 150 0 0146 1 ADI LT 200 0 0186 1 ADI LT 250 0 0225 1 ADI LT 275 0 0251 1 ADI LT 325 0 0310 1 ADI LT 400 0 0368 1 ADI LT 475 0 0449 1 ADI LT 550 0 0529 1 ADI LT 650 0 0598 1 ADI LT 750...

Страница 35: ...ed to realize periodical measurements of the water pH after the neutralization treatment when the value measured is lower than 6 5 it is recommended to replenish with the powder In any case the neutralization treatment must be realized in conformity with the local autonomic and national laws The neutralization system should be placed at a level of height lower than the boiler draining outlet of th...

Страница 36: ...ate the condensed products With regard to boilers these are the data to be considered for calculation Values of CO2 for Natural Gas for all the boilers is recommended to adjust at 8 1 of CO2 Models Range CO2 for Natural Gas ADI LT 105 to 200 7 3 9 1 ADI LT 250 to 325 7 3 8 5 ADI LT 400 to 750 7 3 8 8 ADI LT 850 to 950 Flues temperature Flues temp MAXIMUM POWER MINIMUM POWER Average Water temperatu...

Страница 37: ...nd of rain water 5 Flue draught stabilizer 6 Vertical section of the chimney 7 Chimney outlet 8 Connection between boilers and flues collector 9 T to connect the flues collector to each boiler 10 Flues collector we recommend that it has an upward slope up to the vertical section of the chimney min 3 CAUTION Check that no flues gases are escaping through the damper 5 Damage may be caused to persons...

Страница 38: ...up to 3 PN 6 4 PN 10 Closed expansion vessel calculated and installed according to the regulations Overpressure safety valves and boiler draining in accordance with the current regulations A pressure switch whose function is to stop the boiler if the hydraulic pressure is lower than the minimum value An air venting or automatic purger of big capacity installed in the flow pipe or in the higher par...

Страница 39: ...2 8 16 3 19 8 22 5 27 7 32 7 39 9 46 9 53 0 59 8 68 8 77 8 ΔT 12ºC m3 h 7 5 9 3 10 7 13 6 16 5 18 8 23 1 27 2 33 3 39 1 44 1 49 8 57 3 64 9 ΔT 15ºC m3 h 6 0 7 5 8 6 10 9 13 2 15 0 18 5 21 8 26 6 31 2 35 3 39 8 45 9 51 9 If you have to stop the boiler pump it is required that you stop it with a time delay 3 to 5 minutes once the boiler has stopped This can be obtained by installing a timer disconne...

Страница 40: ...y be distributed between see system drawings in this document o Water header collectors linked by a by pass not closed or one common water header manifold o Water pipes between header collector and boilers OPTION 1 Boiler cascade for 2 or more boilers controlled by a controller o Siemens model RVA 47 RVA 63 RVS 63 o Similar controller from another trademark with 0 10 V control signal per boiler on...

Страница 41: ...G CASES 1 Wide installations with big water contents 2 Characteristics of the refilling water different from the hardness TH indicated in the previous table 3 Frequent refillings of the installation with new water because of drainings water leaks repairing even if the water has a hardness lower than 12ºF 4 When it is exceeded the maximum volume allowed of refilling water see table c A mesh filter ...

Страница 42: ...Mixing valve Keys to clean D H W S PHE secondary circuit Overpressure safety valve Non vibrations mounts Adjusting water flow valve Water meter Water treatment 30 31 32 33 34 36 37 A B C D E F Controller Thermostat Temperature sensor Pressure switch Manometer Thermometer Filter to separate sludge oxides Flow to the heating circuit Return from the heating circuit Cold feed Drain Flow to D H W S cir...

Страница 43: ...ADI LT boiler Technical Manual Page L338 11 2011 43 System drawing of heating circuits 17 11 11 10a 10a 17 11 11 10a 10a 17 17 10a 10a 10a System drawing of one boiler and only D H W S 11 36 36 6 ...

Страница 44: ...L338 11 2011 44 System drawing D H W S and heating circuit 11 36 36 36 36 36 36 See comments under the corresponding paragraph System drawing of an old installation heating circuit 11 11 11 11 36 Ver comentario en apartado correspondiente ...

Страница 45: ...pressure in the secondary circuit very high building with the boilers room in the ground floor or old installation in very bad conditions heating circuit 36 36 36 36 See comments under the corresponding paragraph System drawing of an installation as in the previous case D H W S and heating circuit ...

Страница 46: ...ication plate The gas valves are open the air of the gas installation purged and there are no gas leaks The electric connections are correct 220 230 V 50 Hz single phase earth so that the boiler is electrically supplied The controls are set so as to require heat from the system Instruments required for the start up A manometer to check the combustion chamber pressure drop the gas injectors pressur...

Страница 47: ...inimum gas pressure switch 02 Motor fan is activated revolutions increase 03 Start of the pre venting phase 04 Time out control of the fan speed 05 Time of pre ignition 06 Safety time of ignition and ionization control constant 07 Safety time of ignition and ionization control variable 10 Operation in the heating mode 11 Not available phase D H W S operation according to the installation and to th...

Страница 48: ...zation electrode and to its electric connection Pressure gas Pg combustion chamber Pf air gas mix Pa similar to the values indicated in the combustion document issued in our factory Gas flow Combustion parameters CO2 O2 CO flues temperature air temperature efficiency water temperatures Models Range CO2 for Natural Gas ADI LT 105 to 175 7 3 9 1 ADI LT 200 to 250 7 3 8 5 ADI LT 325 to 750 7 3 8 8 AD...

Страница 49: ...ed in the front corner of the gas valve with the boiler in front By turning clockwise the gas flow increases and so CO2 By turning counter clockwise the gas flow decreases and so CO2 m Repeat the previous steps both at the maximum and the minimum power until the values of CO2 are correct at both stages n Once finished press the button 3 or 2 to go back to the automatic operation mode In this way y...

Страница 50: ...des control panel sight hole The back of the boiler multi block gas valve air damper fan motor This allows that several boilers can be installed in a modular way one beside the other leaving a distance of 10 cm between them 17 1 PROCEDURE TO DISMANTLE THE BURNER Be sure that the boiler general switch is on the OFF position The gas duct to the boiler is closed Take out the frontal casing panel of t...

Страница 51: ...ction cable f Gas valve electric supply connection Note a and b have fast connections by pressing the plastic ring you can remove the pipe Remove the ionization ignition kit If the gas connection has a two pieces coupling disconnect it Disconnect the two flanges of the gas valve each flange has Allen screws of 4 mm Remove the nuts screws of the flange connecting the fan burner group to the boiler ...

Страница 52: ...1 3 5 5 1 2 4 5 5 3 5 5 5 4 2 17 2 POSITION OF PROBES AND SENSORS 1 Water flow temperature sensor 2 Water return temperature sensor 3 Safety overheating thermostat 4 Water pressure sensor 5 Manual air purgers venting their number varies according to the model ...

Страница 53: ...x Chimney natural draught Water temperatures flow return Ionization Gas consumption Gas type Flow Gas pressure inlet injectors Combustion chamber pressure Air gas mix pressure Burner pressure Ignition air gas Gas pressure static boilers operating simultaneously Boiler operation hours Adjustments Gas pressure switch minimum Air pressure switch Revolutions or motor fan speed ...

Страница 54: ... guarantee just covers the material repairing The guarantee does not cover the expenses for the dismantling of the equipments for the installation and or for the local or premises where they are installed neither for the connections of the new equipments or for additional works necessary to repair the material 9 In order to consider as GUARANTEE the spare parts or the replaced components of the bo...

Страница 55: ...s lower than 1 5 bar or higher than 5 bar J No correct sizing or execution of the expansion systems safety valve expansion vessel etc K No correct calculation of the heating consumption of the installation L Natural wear out of the boiler 10 THE GUARANTEE The GUARANTEE loses its effect in case of non fulfilment of the payment conditions established at the moment of the purchase The GUARANTEE does ...

Страница 56: ...ns counter will be reduced Shut off for safety with start prevention The ionisation current has fallen below threshold IonLimitGrenz the repetitions counter will be reduced 128 571 The ionisation current has fallen below threshold IonLimitGrenz several times the repetitions counter has arrived at the end boiler lockout Lockout reset The ionisation current has fallen below threshold IonLimitGrenz s...

Страница 57: ...empGradMax Shut off for safety with start prevention The boiler temperature rises faster than allowed in parameter TempGradMax 154 427 Reset was not possible after error 426 reset boiler temperature boiler set up temperature and dT dTkTrSTB Shut off for safety with start prevention Reset was not possible after error 426 criterion reset boiler temperature boiler set up temperature y Delta T dTkTrST...

Страница 58: ...ted Shut off for safety with start prevention Demand for programming via LPB 184 602 MODEM ACTIVATED Funtion Modem is activated Message Alba_Nr Diagn_Nr DIAGNOSIS TEXT REACTION Complementary 166 81 AIR PRESSURE SWITCH APS air pressure switch does not open if it turns off contactos pegados Lock out reset LP does not open when the boiler stops contactos pegados 181 169 FUNCTION MAINTENANCE The funct...

Страница 59: ...L338 11 2011 ...

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