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User's manual
TABLE OF CONTENTS
1. SAFETY MEASURES...................................................................................................................................................4
2. Technical description
........................................................................................................................................................................................... 5
2.1.Boiler's purpose........................................................................................................................................................... 5
2.2. Technical characteristics............................................................................................................................................. 5
2.3. Overall and connection
dimensions................................................................................................................................................................ 6
3. USER'S MANUAL....................................................................................................................................................... 7
3.1. Control Panel.............................................................................................................................................................. 7
3.2. Boiler's operating
modes........................................................................................................................................................................... 8
3.2.1. Standby
mode...................................................................................................................................................................................8
3.2.2. DHW mode.............................................................................................................................................................. 8
3.2.3. Combined
mode.............................................................................................................................................................................. 9
3.2.4. Heating
mode................................................................................................................................................................................ 9
3.3. Additional
functions.......................................................................................................................................................................... 9
3.3.1. Antifreeze
functions......................................................................................................................................................................... 9
3.3.2. Anti-blocking
functions........................................................................................................................................................................ 9
3.3.3. Boiler's operation in heating mode with an external (outdoor) temperature
sensor................................................................................................................................................................................ 9
3.3.4. Boiler's operation at low /high source
voltage............................................................................................................................................................................. 10
4. BOILER SERVICE.................................................................................................................................................... 10
4.1.Examination............................................................................................................................................................... 10
4.2. Boiler Treatment.................................................................................................................................................... 10
4.3. Operations effectuated at technical
service.............................................................................................................................................................................. 11
5. STORAGE
PRECAUTIONS.............................................................................................................................................................. 11
6. GENERAL
REQUIREMENTS.......................................................................................................................................................... 11
7. OPERATIONS BEFORE
INSTALLATION............................................................................................................................................................ 12
7.1. DHW system............................................................................................................................................................. 12
7.2. Heating system......................................................................................................................................................... 12
7.2.1. New heating
system............................................................................................................................................................................ 12
7.2.2. Existing heating
system........................................................................................................................................................................ 12
7.3. Selection of an additional expansion
tank.................................................................................................................................................................................. 12
8. BOILER INSTALLATION......................................................................................................................................... 13
8.1. Mounting the boiler to the
wall......................................................................................................................................................................... 13
8.2. Connecting the boiler to the CH and the DHW
system.............................................................................................................................................................................. 13
8.3. Connecting the boiler to the gas
system.............................................................................................................................................................................. 13
8.4. Connecting the boiler to the balloon with liquefied
gas.................................................................................................................................................................................... 14
8.5. Connecting the boiler to the power
line................................................................................................................................................................................... 14
9. SMOKE EXHAUSTER
INSTALLATION....................................................................................................................................................... 15
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Summary of Contents for BaltGaz NEVALUX 7224
- Page 1 User’s manual TABLE OF CONTENTS 1. SAFETY MEASURES..............................4 2. Technical description ......................................5 2.1.Boiler’s purpose................................5 2.2. Technical characteristics............................. 5 2.3. Overall and connection dimensions………………………............................. 6 3. USER’S MANUAL............................... 7 3.1. Control Panel................................7 3.2. Boiler’s operating modes………………................................. 8 3.2.1. Standby mode....................................8 3.2.2.
- Page 2 11.5. End of operation………............................23 12. RENDERING THE GAS BOILER TO ANOTHER TYPE OF GAS....................................23 13. BOILERS FLOW CHARTS AND control BOILER’S OPERATION................................... 24 13.1. Flow chart of the boiler «BaltGaz NEVALUX- 7224»………………………………..........................24 13.2. Main components…............................... 25 13.2.1. Control system……….................................. 25 13.2.2.
- Page 3 User’s manual 13.3.2. Gas analysis function.................................... 27 13.4. Boiler’s operating logic………………................................. 27 13.4.1. Boiler’s operation in CH mode....................................27 13.4.2. Boiler’s operation in DHW mode……………………………............................ 28 13.4.3. Boiler’s operation in combined mode………………………………..........................28 14. SEARCH FOR FAILURES AND THEIR ELIMINATION................................29 14.1.
- Page 4 User’s manual 17. BOILER’S DISASSEMBLING AND DISMANTLING OF MAIN BLOCKS..................................36 17.1. Burner assembly dismantling..................................36 17.2. Heat exchanger dismantling..................................37 17.3. Pump dismantling..............................37 17.4. Bypass valve dismantling..................................38 17.5. Expansion tank dismantling..................................38 18.UTILIZATION................................38 23. SUPPLY PACKAGE……................................42 Annex I....................................
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Page 5: Safety Measures
User’s manual User’s Manual Dear Customer! Thank you for choosing our product. You have purchased a double circuit wall-hung boiler with a closed combustion chamber. Before purchasing the boiler please check: scope of delivery (see section 23, p. 42) and the boiler’s resalable condition; compatibility of the type of gas (natural or liquefied) used by you with the type of gas indicated in sections 20 and 21 (p.40) of the following manual and with the table on the boiler’s housing. -
Page 6: Technical Characteristics
2.1 Boiler’s destination The wall-mounted double circuit heating boiler with forced water circulation and closed combustion chamber «BaltGaz NEVALUX−7224», hereinafter referred to as “boiler”, is produced according to TU 4931−011−26985921−2012 (GOST R 51733−2001, GOST 20548−93). The boiler «BaltGaz NEVALUX−7224» is designed for heating leaving and non-dangerous industrial premises with an area up to 240 m . -
Page 7: Dimensions
User’s manual power , not less than Performance index at rated heating 87,0 power 30%, not less than Heating circuit: 24,0 Rated heating effect Rated heating power 26,7 Rated gas consumption 2,95/1,00 С 30 ÷ 85 Temperature regulation range 0,1 ÷ 0,2 Operating water pressure Maximum water pressure Volume of inserted expansion tank... -
Page 8: User's Manual
User’s manual pipes) Ø 80 / Ø 80 Inlet air orifice / Output orifice for combustion products (for separate pipes) User’s Manual 2.3. Overall and connection dimensions A- Heating circuit output Г-Cold water inlet G1/2 Д- Heating circuit inlet G3/4(reverse) G3/4 Б-DHW output G1/2;... -
Page 9: Control Panel
User’s manual User’s Manual 3. USER’S MANUAL 3.1. Control Panel The main control element of the boiler is the electronic board which controls all boiler’s operation. The electronic board’s microprocessor collects and processes signal from the control and safety sensors. All information about the boiler’s condition is displayed on the LCD display in real-time operation mode. -
Page 10: Boiler's Operating Modes
User’s manual The symbols on display show the boiler’s operation mode. Around the display there are 6 boiler control buttons. The designation of the control buttons and of the symbols shown on display are represented in the tables 2 and 3 respectively. Control buttons designation Table 2 Symbol... -
Page 11: Combined Mode
User’s manual DHW mode Combined mode Heating mode Scheme 3. Sequence of the boiler’s operating modes change. 3.2.1 Standby mode In the standby mode, when the boiler is waiting for the user’s commands, the symbol is shown on display. The boiler is not in operation, but the possibility of switching on the antifreeze functions (see p.3.3.1, page9) and parameters programming (see p.13.3.1, page 26) remains. -
Page 12: Boiler's Operation In Heating Mode With An External (Outdoor) Temperature Sensor
User’s manual The pump anti-blocking function permits to exclude blocking of the pump shaft in case of the boiler’s long- term idleness. This function works only in standby mode. Once in 24 hours the pump is launched for 15 seconds. 3.3.3. -
Page 13: Boiler Treatment
User’s manual - The air from the heating system must be removed from time to time (see section10, page19); -The heating system must be filled with water until the needed pressure is reached (see section10, page19); -The boiler must be kept clean, for this it is necessary to remove dust from the boiler’s front surface regularly, and also to clean the boiler’s coating first with a wet wiper and then with a dry wiper. -
Page 14: Operations Before Installation
User’s manual Technical staff manual 6. OPERATIONS BEFORE INSTALLATION CAUTION! Boiler installation, putting the boiler into operation and technical service can be effectuated only by a specialized service organization. Boiler installation must be effectuated according to the project which complies with the requirements of Federal and local normative acts, regulating gas appliances installation. -
Page 15: Wall
User’s manual on a distance of not less than 3 cm from the wall. The above mentioned wall covering must get outwards the boiler’s coating’s dimensions for not less than 10 cm; -Placing the boiler above the gas stove or kitchen sink is prohibited; -In front of the boiler there should be a service zone of not less than 1 meter;... -
Page 16: Connecting The Boiler To The Power Line
In order to purchase the necessary parts and details of the smoke exhauster you should contact the trading organization, effecting realization of accessories for the boilers “BaltGaz NEVALUX” in your region. CAUTION! It is prohibited to use ventilation channels for combustion products removal. -
Page 17: Smoke Exhauster Installation
User’s manual - boiler; - coaxial branch pipe; - coaxial smoke exhauster pipe; - joint sleeve; - duct slice; -laying; - ventilator plug; - thermoinsulation Scheme 5. Installation of coaxial smoke exhauster Installation of separate pipes of smoke exhauster and air duct 9.2. -
Page 18: Installation Of Separate Pipes Of Smoke Exhauster And Air Duct
User’s manual Scheme 6. Installation of separate pipes of smoke exhauster and air duct by means of transitional set The transitional set consists of details 7, 8, 9 (see Scheme 6.). The smoke exhauster adapting pipe 7 is installed to the central orifice on the upper surface of the boiler and is fixed by clip 8. - Page 19 User’s manual Make sure that the sealing ring 6 is placed (at the place of connection of the ventilator plug) before installing the separator onto the boiler (see Scheme 9); Install the channel separator 2 onto the boiler, controlling that the plug won’t “bite on” the sealing ring 6 (see Scheme 9);...
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Page 20: Putting The Boiler Into Operation (Initial Run)
User’s manual Technical staff manual 10. PUTTING THE BOILER INTO OPERATION (INITIAL RUN) As a heating agent in the heating system it is necessary to use water. The quality of water used in the heating system must comply with the following parameters: Hydrogen ion exponent РН... -
Page 21: Check Of Combustion Propertie
User’s manual Scheme 10. Circulation pump check Than screw the cover plug up tight. While effecting this operation water leaks from the pump are possible, after installing the cover plug the rests of water must be removed from the boilers components (you must wipe them);also check the boiler connection to the AC outlet of the monophase network of alternate current with rated voltage of 220V, 50Hz frequency, with an earthbonding contact;... -
Page 22: Connection Of External Temperature Sensor
User’s manual The remote control is not included in the boilers standard supply package and is purchased separately if desired by the customer. The cable for connecting the remote control to the boiler is not included in the remote control’s supply package and is purchased separately. The standard cable consists of a connector for connecting the remote control to the electronic board, two wires 1 meter long and a terminal strip for connecting the wires. -
Page 23: Regulator
User’s manual Prestarting 11.1. 10.4 1) Switch the boiler off (see p. , page 21) and throw a cover of a front panel; 2) Unscrew 6 self-threading screws from front panel’s support; 3) remove a front panel with a cover; 4) Put off a plastic cap from the regulating screw C and Б... -
Page 24: Boilers Flow Charts And Control Boiler's Operation
User’s manual 10.4 1) Switch the boiler off (see p. , page 21); 2) Put off a casing from the boiler. For this it is necessary to unscrew 4 casing’s fastening screws (self-threading screws) to the low panel of a boiler and 6 casing’s fastening screws (self-threading screws) to the front panel; 3) Throw a front panel together with a cover down, then remove a casing while pulling it up and over yourself;... - Page 25 User’s manual Boilers flow chart «BaltGaz NEVALUX−7224» 13.1. Combustion products Inlet air Inlet air HC outlet DHW outlet Gas inlet Cold water inlet HC inlet 1 - Air pressure switch; 11 - Ionization plug; 19 - pump; 2 - fan;...
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Page 26: Main Components
User’s manual Main components 13.2. Control system 13.2.1. Component Function To control boiler’s operation and ensure safety in 13.1 Electronic board 22 (see p. , page 24) case of emergency Wiring A set of cables for connecting a board with sensors, components and mechanisms Hydraulic system 13.2.2. -
Page 27: Service Functions
“P2” – minimal heating power40 ÷ 99 (60 steps); “P3” – minimal time from turning off until restarting working 0 ÷ 14 (min). Factory settings of the boiler «BaltGaz NEVALUX−7224»: “P0”=40 for boilers working on NG, “P0”=60 for boilers working on LPG, “P1”=0, “P2”=99, “P3”=3 min. -
Page 28: Function
User’s manual 13.3.2 Gas analysis function 11.2 Gas analysis function enables to control, analyze combustion process and adjust a gas supply regulator (see p. 11.3 , page 22). This function works in CH and Combined modes. To activate a gas analysis function it is necessary to hold the button К6 (RESET) until a symbol will be displayed. -
Page 29: Mode
User’s manual ionization plug 11 is absent, electronic board repeats a procedure of boiler’s staring up from the beginning. There are 2 consecutive start up attempts taken. If both attempts failed, electronic board stops ignition; 8) Electronic board changes voltage in the modulator coil of gas supply voltage 8. Gas supply regulator increases gas supply to the burner block up to maximal power in order to quickly warm the water in the heating system up to the set temperature;... - Page 30 User’s manual Failure Reason of failure Troubleshooting Electric circuit of thermo relay is Check electric circuit and pins damaged (overheat sensor) Heating system is contaminated Clean heating system Failure of thermo relay (normally closed Replace thermo relay at temperature up to 95 °С) Open air duct valve Air lock in the heating system 16.2.2.5.
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Page 31: Other Failures
User’s manual Failure Reason of failure Troubleshooting Replace gas supply regulator Broken modulator coil of gas supply Failure of modulator coil (resistance of modulator coil 80 regulator Ohm) of gas supply regulator Boiler doesn’t work** Electric circuit “modulator coil- Check electric circuit and pins electronic board”... -
Page 32: Handing The Boiler Over To The Customer
User’s manual Failure Reason of failure Troubleshooting Boiler is in stand-by Restore power voltage in range 190 ÷ 250 V. mode, a symbol«- -» is Within 30 seconds will be automatic boiler’s displayed but boiler Power voltage is over 190 ÷ 250 V start up in the previous mode that boiler used doesn’t react to the to be before the power voltage went over the... -
Page 33: External Cleaning Of Heat Exchanger
User’s manual External cleaning of heat exchanger In order to improve gas combustion and to achieve maximum heat exchange in the appliance, it is necessary to 13.1 keep finning of the heat exchanger 4 (p. , page 24) in order. If heat exchanger is contaminated, it is necessary to clean its surfaces where soot has appeared. -
Page 34: Checking Of Water Overheating Protection In The Heating System
User’s manual 16.2.2.2 Checking of water overheating protection in the heating system 13.1 From the operating boiler to put the cables off from the thermo relay 9 (see p. , page 24). Boiler should switch off and display a symbol "02". After eliminating the reasons of the emergent switching off (connecting cables to the thermo relay back) and pressing a button К6 (RESET) , boiler should automatically switch on. -
Page 35: Blocks
User’s manual 16.2.2.11 Checking DHW flow sensor 3.2.2 Render boiler into DHW mode (see p. , page 8), open a tap in DHW line. Put the cables off from the DHW 13.1 flow sensor 15 (see p. , page 24). Boiler should enter into the stand-by mode. After connecting the cables back, boiler should automatically switch on. -
Page 36: Heat Exchanger Dismantling
User’s manual 10) Unscrew 2 screws 4 (see scheme.14) of manifold’s fastening to the burner front bracket; 11) By means of a turnkey 30 unscrew a nut 5 of the fastening of manifold to the gas pipe and put a manifold off; Scheme14. -
Page 37: Bypass Valve Dismantling
User’s manual Scheme 17. Pump dismantling 5) unscrew on the low panel three screws of the pump’s fastening 1 and two screws 2 of bithermic manifold fastening; 6) disconnect a screw termination 3 (see scheme. 17) with the pump’s power cables out of the conneсtor; 7) put off a bracket 4 of pipe’s fastening from the pump’s pipe and put a pipe up;... -
Page 38: Utilization
Boiler and its package consist of materials suitable for recycling. Dismounted boiler is recommended to hand over to a specialized organization. DELIVERY SET Table 6 1. Wall-hung boiler: 1 pcs. «BaltGaz NEVALUX−7224» 2. User’s manual 7224-00.000−01RE 1 exmp. 3. Bracket of boiler’s fastening 8223−20.011 1 pcs. 4. dowel NAT 10 2 pcs. - Page 39 User’s manual Annex I Catalog of boilers components «BaltGaz NEVALUX−7224» Pos. Designation Note Consists of: 1) Back side 7224-01.051 2) Exhaust flue 8223-01.200 Back wall in assembly 3) damper 8223-01.002 4) bar 8230-01.005 5) bearing 8223-00.014 6) bearing 8223-00.015 Applied together with a clamp 0409001010 (pos. 58), thermo relay HD8.5FC-9 (Pos.
- Page 40 User’s manual Pos. Designation Note 13 blades, nozzles Ø 0,79 mm (LPG (G30,3 family, group Burner block 7224-22.000-01 В/Р), 2,9 kPа) cap 8223-10.001 bearing8223-10.002 Viewing window 8223-10.005 fan ERR97/34L Air pressure switch NS2-1245-00 Air pressure switch RB21001 Expansion tank 13С0000619 manometer 066206 4 bar Electronic board MIAD300...
- Page 41 User’s manual Pos. Designation Note Decorative panel 8023-02.002 90 °C Thermo relayHD8.5FC-9 clamp 0409001010 Applied only together with heat exchanger 256350881801 Temperature sensor TP01AH1LQ Copper sensor 8223-02.003 Thermo relay ТY60/А В230AG-90°C 90 °C, Applied only together with heat exchanger Ø 14 мм Temperature sensor JXW-54 (14) QF/DSGLS-L270 Ø...
- Page 42 User’s manual Pos. Designation Note O-Ring OR 9,25x1,78 21000606701000 O-Ring OR 6,75x1,78 21000606700500 O-Ring OR 5,5x2 21000606701700 Manometer’s connector 21000605800300 separator 21000605700400 Pump’s fitting 21000607603700 nut G1/2 G1/2 00046240210080 spacer 21х28х2 21000607900800 bracket 8 21000607000300 bracket 14 21000607000200 Bithermic manifold 21000607700900 Bypass valve HDS 15-300 21000607300500...
- Page 43 User’s manual Components of the burner block pos. 7 Pos. Designation Note Burner blade 3295.07.40.000 nozzles Ø 1,31 mm (NG (G20, Manifold in assembly 3295.07.20.000-10 2 family, group Н), 1,3 kPа) nozzles Ø 0,79 mm (LPG (G30, Manifold in assembly 3295.07.20.000-11 3 family, group В/Р), 2,9 kPа) Ø...
- Page 44 User’s manual Components of wiring Designation Note 220В, 50Hz Power cable CBAB0W008 Main cable CBAB0096 To connect a fan, gas supply regulator, igniter Pump cable CBAB0W020 To connect a pump To connect modulator coil of gas supply regulator, DHW Gas supply regulator cable CBAB0W009 flow sensor, pressure sensor CH temperature sensor cableCBAB0W010 To connect CH temperature sensor...
- Page 45 (for instance; by the car gauge) and then release or add (for instance; by the car gauge) the air up to the set pressure value. Simultaneously you should consider that for the boilers BaltGaz NEVALUX the initial pressure in the expansion tank should be at least 0,1 MPа...
- Page 46 User’s manual Annex III 1 - Ignition plug; 2 - igniter; 3 - gas supply regulator; 4 - fan; 6 - pump; 7 - air pressure switch; 8 - thermo relay 95 °С; 9 - modulator coil of gas supply regulator; 10 - pressure sensor;...
- Page 47 User’s manual Boilers wiring diagram «BaltGaz NEVALUX−7224» Cables colors designation: бел – white; г – blue; ж/з – yellow-green; кор – brown; кр – red; ор – orange; ч – black. Connector Pins Cables colour Cable Parameters brown М1 Power supply...
- Page 48 User’s manual regulator’s cable regulator black black М4 igniter Main cable 220V, ~ 50 Hz Hz Thermo relay 95 °С blue Air pressure switch М6 24V, 10 мА (water overheating sensor) cable brown blue Air pressure switch М6 24 V, 10 мА Air pressure switch cable blue...