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h e a t i n g s y s t e m s installation and maintenance manual FOR THE INSTALLER AND THE USER COILMASTER 100 · 120 kW FLOOR — STANDING COMBINATION BOILER...
Boiler Marking ..........G-7 Connections ............ I-44 .......G-8 roduct escrIPtIon Cables ............. I-44 COILMASTER 100 - 120 ........G-8 Routing the Cables .......... I-44 General Description ..........G-8 Accessing the High and Low Voltage Terminal Frost Protection ............G-8 Strips and Electronic Board ......I-45 Safety Devices ............G-8...
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Removing/Installing the Access Panels ....I-27 Fig. 9. Typical Heating and DHW Circuits ....I-34 Fig. 10. CoilMaster 100 & 120 Gas Valve .......I-43 Fig. 11. Routing the Electrical Cables ......I-44 Fig. 12. Accessing the High and Low Voltage Terminal Strips and Electronic Board........I-45 Fig.
eneral nformatIon Liabilities of the Manufacturer, the Installer and the End user Manufacturer The installer shall provide the end-user with: Any relevant explanation about the op- Our products are manufactured in compliance eration of the appliance and the heat- with the requirements of the applicable Europe- ing system as well as the safety devices an Directives and standards, and are therefore...
eneral nformatIon About this Manual This documentation is part of the product. It will be handed over to the end-user who will keep it, with all the other applicable documents, in a safe place and readily available for use. Before installing, operating or maintaining the appliance, please carefully read this manual and all the applicable documents provided with the components and accessories.
eneral nformatIon Safety Instructions IF YOU SMELL GAS: DO NOT: → DO: → Close the gas supply Use an open fl ame Open all doors and windows to Smoke ventilate the room Use electrical devices (phones, ...
Gas appliance Gas type Country of destination category pressure AIC Europe B.V. The boiler shall be installed by a qualified installer in accordance with Graafschap Hornelaan 163A provided installation and maintenance technical manual, national and NL-6001 AC Weert local requirements, gas safety regulations and relevant standards.
Refer to Some optional equipment can be used with the more information. COILMASTER boilers. Please contact your AIC The primary circuit of the appliance is not provid- representative for more information and a list of ed with a built-in circulating pump. Therefore, the available equipment.
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roduct escriPtion Fig. 2. Boiler Components Concentric chimney connection (Ø 100/150 mm) 14. Gas pressure switch 15. Cold water inlet and DHW safety valve (not shown) Flue gas/air inlet box 16. DHW pump On-Off switch 17. Heating return, with temperature sensor Flue exhaust pipe, with temperature sensor 18.
roduct escriPtion Control Panel and Main Functions 30.12.2019 14:42 Flow temp 35°C Return temp 32°C Outside temp 18°C DHW temp 55°C System Automatic Fig. 3. Control Panel When entering a menu/sub-menu, the slow rotation of the selector to the right 1.
roduct escriPtion Symbols and Messages on the Control Panel special operations (e.g. for maintenance work) The control panel display is divided into several and allows to log in, in expert view (access to Fig. 4): zones (See additional pages for the Installer only). î...
echnIcal PecIfIcatIons Dimensions and Clearances 191 mm 129 mm 698 mm 801 mm Min. Recommended Clearances back front 1,000 1,000 sides 500* * in a cascade configuration, boilers can be installed side-by- side with a 160 mm clearance between them. Side clearance must be complied with for the “outer”...
echnical pecificaTionS CM 100 CM 120 Combustion and Gas Data (min. - max.) (min. - max.) chimney type(s) B 23 , B 23p, C 13 , C 33 , C 43 , C 53 , C 63 , C 83 , C 93 °C flue gas temperature at 80/60°C 60.0 - 62.3...
echnical pecificaTionS Hydraulic Data CM 100 CM 120 water content 83.2 83.2 pressure drop at ∆T = 20k mbar 53.0 71.0 minimum operating pressure maximum operating pressure maximum primary temperature °C water content 24.8 24.8 maximum operating pressure maximum DHW temperature °C Pressure Drop Curve Hydraulic pressure drop for the CM 120...
nstructIons for the Safety Instructions for the User IF YOU SMELL GAS: → DO: DO NOT: → Close the gas supply Use an open fl ame î î Open all doors and windows to ven- Smoke î î tilate the room Use electrical devices (phones, î...
nstructIons for the Periodic checks If works need to be per- î formed close to the appli- ance (e.g. in the boiler room Check regularly that the wa- or close to the air inlets), î ter pressure of the system is make sure that the appli- at least 1.2 bar when cold.
nstructIons for the Starting the Appliance Stopping the Appliance The first start-up of the boiler after its Conditions: installation must be performed by a None qualified professional, according to the “Start-up and Commis- procedure in Procedure: sioning” on page I-49. Push the On/Off switch located on the right side of the boiler.
nstructIons for the Operating the Controller - End User Level 30.12.2019 14:42 Some parameters are only visible if the circuit is installed and enabled. Flow temp 35°C Return temp 32°C Outside temp 18°C DHW temp 55°C System Automatic Selectable/ Icons In the work area Adjustable Remark...
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nstructIons for the Selectable/ Icons In the work area Adjustable Remark Parameters Operating mode When “off ”, Hot water Ҙ heating is switched off ; temp. when “On”, Hot water is heated to the nominal set- setting point as per time program Temporary “Recharging”...
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nstructIons for the Selectable/ Icons In the work area Adjustable Remark Parameters Time 01:00 Regional settings Settings Date 01.01.2030 Regional settings (1/3) Ҙ Regional settings (2/3) Start of summer- Ҙ time 25.03 End of summer- time 25.10 Regional settings (3/3) Language...
nstructIons for the Basic Settings Symbols used for the operation of the selector: turn the selector to the left or to the right. 1 - Time and Date Adjustment depress shortly the rotary se- lector. turn the selector to adjust the value, then depress the se- lector to validate.
roduct nstallatIon Safety Instructions for the Installation When the appliance is con- î nected to the electrical net- î All connections (electrical, fl ue pipe, work, it must be earthed. hydraulic, gas) must be carried out in accordance with current standards Make sure that a fuse or circuit breaker î...
roduct nstallatIon Handling the Product Move the appliance carefully to its final po- sition. Make sure to comply with the recom- This appliance is heavy and re- î “Dimensions and mended clearances (See quires sufficient workforce to Clearances” on page G-12. move and handle it, as well as If some height is required for condensate flow an appropriate means of trans-...
roduct nstallatIon Removing and Installing the Access Panels Top panel Conditions: Push the top panel (4) downwards to engage Tools and Material: the studs into their receptacles. î Wrench, hex head, size 4 Install and tighten the top screw ( ) on the right side panel (if the panel has not been re- Removal Procedure:...
roduct nstallatIon Requirements for the Hydraulic Circuits G3 Requirements (UK only) 3.51 The diameter of discharge pipe (D1) should be not less than the nominal outlet size of the tem- perature relief valve. Discharge pipe from safety valves 3.52 Where a manifold is used it should be sized The Building Regulation G3 requires that any dis- to accept and discharge the total discharge from charge from an unvented system is conveyed to...
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roduct nstallatIon 3.58 The discharge pipe (D2) should be at least Termination of discharge pipe one pipe size larger than the nominal outlet size of 3.61 The discharge pipe (D2) from the tundish the safety device unless its total equivalent hydraulic should terminate in a safe place where there is no resistance exceeds that of a straight pipe 9m long, risk to persons in the vicinity of the discharge.
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roduct nstallatIon temperature relief valve to tundish 600mm maximum Tundish 300mm minimum Discharge below fixed Metal discharge pipe (D2) tundish with grating (3.61 gives continuous fall. See 3.56, Table G3 and alternative points of worked example discharge) Fixed grating Trapped gulley Figure G3: Typical discharge pipe arrangement Maximum resistance Minimum size of dis-...
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roduct nstallatIon Example of discharge pipe sizing Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief Figure on previous page shows a G1/2 tempera- valves equates to 18m. ture relief valve with a discharge pipe (D2) having Subtract the resistance of 4 No.
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roduct nstallatIon Safety Instructions for the Primary Circuit It is recommended to install î the following devices in the system to prevent water contamination : Make sure that the circuit is provided with Water fi lter and/or dirt separator in- î...
roduct nstallatIon Water Quality Requirements to Prevent Scaling and Corrosion (Primary Circuit) Water Hardness To prevent the formation of scale and sludge in a closed heating circuit through the penetration of If the hardness of the fi ll water is higher than î...
(at least 40 mm) between the malfunction. Please contact appliance fl ue piping and combustible your AIC Technical Support materials, and between the fl ue pipe for more information. and air inlet pipe if the latter is made of A condensation outlet connected to the î...
Installing the pipes - General principles General Instructions for the Installation of AIC-approved Chimney Components Component Characteristics Recommendation Clamped at the sleeve...
Remark Can be used for cascading Make sure that the ventilation openings remain unobstructed at all times. Make sure to install AIC-approved components when building B23 and B23p sys- “AIC-Approved Chimney Components” on page I-40. tems. See I-37 G-084383_EN • 01...
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tions - fi tting in: a square of 50 cm î (if appliance < 70 kW) a square of 100 cm î (if appliance is between 70 kW and 1000 kW) roduct nstallatIon Combustion circuit 33(x) Sealed Connection Combustion circuit Vertical terminal Sealed Connection...
Clearance area is suffi cient for combustion air î (min the size of 2 separate ducts) Make sure to install AIC-approved components from Muelink & Grol when build- “AIC-Approved Chimney Components” ing C13, C33, C53 and C93systems. See on page I-40...
Make sure to install the boiler with the short- î est length of combustion air and flue ducts. When several boilers need to be connected î to a common duct, please contact your AIC representative for more information. 2.0 m 1.3 m For C43, C63 and C83 î...
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î When connecting several boilers to the same duct (i.e. types C43, C83), make sure to install an AIC-approved flue gas damper on each boiler in the system. î For B23p chimney cascade, please contact your AIC representative. “Engineering the Chimney System” on...
Use a gas detection device or per- î form a bubble test to check for gas leaks. Never use an open fl ame, as it could result in an explosion. Measuring point Fig. 10. CoilMaster 100 & 120 Gas Valve I-43 G-084383_EN • 01...
roduct nstallatIon Safety Instructions for the Electrical Cables Connections Any damaged power supply ca- î ble must be replaced using ca- bles as described below and in- stalled by a qualified professional. Electrical connections must be carried The cross-section of the wires should î...
roduct nstallatIon Accessing the High and Low Voltage Ter- minal Strips and Electronic Board The electronic bay cover panel is Make sure that the power supply to only secured to the boiler frame the appliance is deactivated (pow- by four screws. Make sure to sup- er supply cable disconnected from port the cover panel at removal, as the boiler) before accessing the high...
roduct nstallatIon Wiring Diagram Gas pressure Switch Casing Gas Valve 230 Vrac Ignition Ignition Transformer Electrode High Voltage Cable Casing 8 9 10 11 12 N L N L Ignition module valve BX1 BX2 L1/NC L1/NO Casing QX2 QX3 230V 50Hz Main Power I-46...
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roduct nstallatIon Flue Gas Pressure Switch Water Pressure Sensor 1 2 3 4 5 6 7 8 1 2 3 4 UX2 UX3 X10a +15V RESET Inlet Temperature Sensor BX4/B7 Outlet Temperature Sensor Operator Unit FAN PWM P1 PWM BSB-EM 5 4 3 2 1 1 2 3 4 5 Legend...
ommIssIonInG Safety Instructions Before Start-up Filling the System Conditions: Procedure: î Check that all connections (electrical, fl ue pipe, hydraulic, gas) have been 1. Connect the fi lling hose ( ) to the system carried out and that they are tight and fi lling valve ( ) and to the water network tap.
ommissioning Start-up and Commissioning Combustion Adjustment Conditions: Conditions: Tools and material: Tools and material: None î Flue gas analyser Procedure: î Screwdriver, flat head, size 3 î Wrench, hex head, sizes 2 and 2.5 Make sure that all connections are tight and there is no leak.
ommissioning Commissioning Wizard The following pages give a view of the When starting up the boiler for the first time, a com- structure of the commissioning wizard missioning wizard will be displayed, unless it has contents. Program numbers are pro- been disabled before (e.g.
Follow the instructions on the screen if you need to change anything, or skip this chapter. Please contact AIC ‘s technical support for additional information. Continue...
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Consumer circuit 2 configurations. Follow the instructions on the screen if you need to change anything or skip this chapter. Please contact Swimming pool circuit AIC’s technical support for additional information. Solar Continue System setup LPB system 6600 - Device address (1..16) 6601 - Segment address (0...14)
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ommissioning Secure 6200 - Save sensors / Yes) 7170 - Telephone customer service (0..) Continue Commissioning wizard 7167 - Commissioning wizard (Off / On ... next time the control device is switched on) Continue Complete parameter list Select this function if any Commissioning wizard changes were made in the Refresh operator unit...
aIntenance Safety Instructions for Maintenance The maintenance of the ap- pliance and its components must be carried out by a qualifi ed professional. Inspection and maintenance tasks Defective parts and components may must be carried out by a qualifi ed and only be replaced by genuine factory certifi...
aintenance Maintenance Requirements @ inspection @ maintenance Tasks (1 year) (2 years max) Check that the boiler room ventilation / boiler air and flue ducts are unobstructed. Verify flue gas and combustion air ducts are in good condition, sealed tight and properly supported. Open the front panel and check the general condition inside the cabinet.
aintenance Shutting Down for Maintenance Restarting after Maintenance Conditions: None Conditions: Procedure: Procedure: Press the On/Off switch located on the right Press the On/Off switch located on the right side of the control panel. side of the control panel. When in the OFF position, the switch When in the On position, the switch internal light comes out.
aintenance Cleaning the Condensate Pipe and Trap Remove the cover gasket ( ). Discard. Clean the deposits in the condensate trap ( Conditions: using clear water and a cloth. Wipe the ball located above the exit pipe. Tools and material: Make sure to put the ball back in î...
aintenance Checking the Flue Pressure Switch oper- ation Conditions: Blow air in the hose while it is connected to the flue pressure switch and to the measur- ing device Tools and material: Verify that the pressure switch switches at î Manometer (measuring range up to min 500 Pa) the set pressure (500 Pa) and that the con- troller displays error 193.
aintenance Removing and Installing the Ignition and Ionisation Electrodes Conditions: Remove the electrode and screws ( ) from the burner plate ( ). Discard, as required. Tools and material: Remove electrode gasket ( ) and discard, as î Wrench, hex head, size 3 required.
aintenance Removing and Installing the Fan and Air- Remove the electrodes, as required, refer to Gas Mixer Assembly “Removing and Installing the Ignition and Ionisation Electrodes” on page I-59. Remove the burner, as required, refer to Conditions: “Removing and Installing the Burner” on page I-62.
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aintenance Fig. 19. Removing and Installing the Fan and Air-Gas Mixer Assembly I-61 G-084383_EN • 01...
aintenance Removing and Installing the Burner Conditions: Installation procedure: Install the burner door insulation plate ( î Fan and air-gas mixer assembly removed, refer “Removing and Installing the Fan and Air- Install burner tube ( ) and new gasket ( ) on burner door ( ) using 6 retained screws and...
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aintenance Fig. 20. Removing and Installing the Burner I-63 G-084383_EN • 01...
aintenance Checking and Cleaning the Combustion Chamber Conditions: “Removing and Install- î Burner removed, see ing the Burner” on page I-62. Tools and material: î Industrial vacuum cleaner î Nylon bristle brush î Torch Check Procedure: Using a torch, visually check the condition of the combustion chamber.
ddItIonal nformatIon for the nstaller Optional Modules Extension Modules Web Server Module Nesta boilers can control 3 heating circuits with Through the use of this module, you can connect mixing functions, using 3 extension modules. Each to an Ethernet and get remote access to the boiler extension supply needs to be provided with power and all the heating system via the Internet.
dditionAl nformAtion for the nstAller Boilers in a Cascade System This boiler has all the logic control of the cascaded system and also regulates the stop/start sequence In a heating system comprised of several boilers, it of each boiler according to the demand of the in- is important that the power generated by the boilers stallation.
For any question related to the menus, please con- Each level allows to set certain specific parameters tact AIC’s technical support. or program the boiler, according to the installed cir- cuits.
dditionAl nformAtion for the nstAller Structure of Menus for the Installer Top menu page Pgm No. Submenu 1 Submenu 2 Default Setting Time of day Hours / Minutes Ҙ 01:00 (hh:min) and date (2 pages) Date 01.01.2030 Ҙ (dd.mm.yyyy) Start of summertime 25.03 Ҙ...
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dditionAl nformAtion for the nstAller Top menu Pgm No. Submenu 1 Submenu 2 Default Setting page Heating Ext’n 24-hour heating limit Ҙ circuit 1 (Ctn’d) Flow temp setpoint min 8°C Ҙ Flow temp setpoint max 90°C Ҙ Flow temp setpoint room Ҙ...
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dditionAl nformAtion for the nstAller Top menu Pgm No. Submenu 1 Submenu 2 Default Setting page Heating Pump speed reduction Operating level Ҙ Characteristic circuit 1 Characteristics Temp differential (Ctn’d) nominal Starting speed 100% Ҙ Pump speed min Ҙ...
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dditionAl nformAtion for the nstAller Top menu Pgm No. Submenu 1 Submenu 2 Default Setting page Service/ 7130 Chimney sweep function Ҙ special operation (8 pages) 7131 Burner output Partial load Ҙ Full load Max heating load ...
Check connection and/or sensor. Re- Outside temperature sen- place as required. sor error Emergency operation Contact AIC technical support. Boiler temperature 1, Short circuit or Open circuit Check connection and sensor. Re- sensor error boiler fl ow sensor. place as required.
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BSB RF communication Check bus connection and compo- error nents. Internal fault in controller, pro- Data overrun in EEPROM Contact AIC technical support. cess sensor Extension module 1, error Chceck extension module connections. Extension module 2, error Chceck extension module connections.
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Check connection and component Lack of gas, Reset, if the fault re-occurs more than 3 times, contact AIC technical support. Safety time for establish- ment of fl ame exceeded Check ignition electrode and ionization Polarity of mains connection,...
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dditionAl nformAtion for the nstAller Error Fault description Explanation Action(s) code Unit in parametrization Wait until parametrization process is mode complete Start prevention signal Short circuit or Open circuit fl ue Check connection and sensor. Replace input pressure switch. as required. Check automatic refi ll system.
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3 times inform AIC technical suport. Internal repetition Contact AIC technical support Repetition speed Contact AIC technical support Shut off gas supply and contact AIC Extraneous light technical support Mains undervoltage Check electric supply in boiler terminals Fan speed tolerance Check air supply Check connection and sensor.
dditionAl nformAtion for the nstAller Error Fault description Explanation Action(s) code Verify pump Dynamic water pressure Expansion tank is defective too high Replace expansion tank Dynamic water pressure Verify pump too low Sensor primary heat ex- Check connection and sensor. Replace changer as required.
dditionAl nformAtion for the nstAller Troubleshooting Problem Cause(s) Solution(s) 1. Check that the power button is in ON position (pushed in and illuminated) 2. Make sure the power supply cable is Boiler does not start No power supply connected to the mains 3.
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dditionAl nformAtion for the nstAller Problem Cause(s) Solution(s) Gas valve malfunction Burner does not start after receiving Fan malfunction Check wiring connections Check components signal from boiler controller Ignition/ionization electrode mal- function Check the values with a gas analyser and Combustion chamber gets dirty Wrong combustion settings readjust as required.
dditionAl nformAtion for the nstAller Installation Checklist Unit Values/Comments General/heating system Type of building/system Commercial purpose (Y/N) ? Year of manufacture Output of system Heated surface m² Number of heating circuits: • Floor heating • Radiators • Other Cascade (Y/N)? Number of boilers? Water Water hardness at start up mol/m³...
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dditionAl nformAtion for the nstAller Unit Values/Comments Plate heat exchanger in the system (Y/N)? Type? Low loss header in system (Y/N)? Type ? Number of mixers ? Buff er tank (Y/N)? Size? DHW tank (Y/N)? Type? Pump(s) (Y/N)? Type? • In which circuit(s) •...
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dditionAl nformAtion for the nstAller Unit Values/Comments Controller Appliance controller? Other controller (Y/N)? Type? Optional modules installed (Y/N) • Type? Optional items installed (Y/N)? • Outdoor sensor (Y/N)? Type? • Room unit(s) (Y/N)? Type? • Others? Miscellaneous The end user has received all rele- vant information (Y/N)? The end user has received all rele- vant documents (Y/N)?
dditionAl nformAtion for the nstAller Water Parameters - Log Sheet Water Water Water Water Name & Filling Top-up Remarks Quality Treatment signature Date Date I-84 G-084383_EN • 01...
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