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Summary of Contents for Arca Caldaie ASPIRO DUO TECH
- Page 1 Installation Operation Maintenance www.arcacaldaie.com...
- Page 3 ARCA s.r.l. will have no liability for any printing or translation mistake. The manufacturer has the right to modify its products if such modifications would be necessary or useful, without affecting the basic characteristics of the product. The present documentation is also available in PDF format. To get it, please contact ARCA s.r.l. technical department.
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Page 4: Table Of Contents
INDEX GENERAL PRESCRIPTIONS ........................6 TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS ............7 2.1. BOILER ................................... 7 2.2. ARCHIMEDEAN SCREW ............................8 2.3. FUEL TANK ................................8 MAIN BOILER COMPONENTS........................9 3.1. WOOD CHARGING BOX............................9 3.2. MAIN BURNER REFRACTORY CEMENT FRAME AND CAST IRON BARS............9 3.3. - Page 5 HYDRAULIC CONNECTION DIAGRAMS....................43 9.1. GENERAL CONNECTION DIAGRAMS FOR HEATING ONLY - OPEN EXPANSION TANK....... 43 9.1.1. GENERAL CONNECTION DIAGRAM FOR HEATING ONLY PURPOSES WITH OPEN EXPANSION TANK .......44 9.1.2. GENERAL CONNECTION DIAGRAM FOR HEATING ONLY PURPOSES WITH OPEN EXPANSION TANK AND MIXING VALVE ..................................44 9.1.3.
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Page 6: General Prescriptions
GENERAL WARNINGS The instruction and maintenance manual is an integral part of the product, and it must be the delivered to the customer along with the product. Read carefully any warning shown in the manual because they provide important guidelines and details concerning the installation, use and maintenance security. Store the manual in a safe place for further reference. -
Page 7: Technical Characteristics And Overall Dimensions
TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS 2.1. Boiler Key: Electronic control board Heating circuit delivery Top door Heating circuit return Pellet burner Boiler water descharging Sanitary hot water heat exchanger connections Primary air stream adjusting (wood operation) (only SA ver.) Secondary air stream adjusting (wood operation) Security heat exchanger connections Flame control bull's eye (wood operation) Temperature sensors receptacles (S4) -
Page 8: Archimedean Screw
2.2. Archimedean screw (code COC0502) 1920 1694 1. Archimedean screw gear motordrive 2. Fuel feeding auger first boiler firing, recommend to manually activate the archimedean screw motordrive (LOAD MENU) so to have the whole auger tube filled with fuel getting by this way a constant fuel feeding rate not to have boiler operation problems. -
Page 9: Main Boiler Components
MAIN BOILER COMPONENTS 3.1. Wood charging box fuel box This is the boiler . In this box, located in the boiler upper part, the wood logs are charged after being succesfully performed the ignition procedure, getting a first layer of hot ashes. 3.2. -
Page 10: Hot Sanitary Water Heat Exchanger
3.6. Hot sanitary water heat exchanger (SA versions only) The heat exchanger can be equipped with an internal copper pipe coil plunged in the heating circuit water gap around the boiler main body to produce hot sanitary water (SA models only), with the hidraulic connections in the rear part of the boiler. -
Page 11: Circuit Filling Water
Pellet inlet OPERATION MODES ASPIRO DUO TECH boiler is a biomass boiler using wood as fuel, implementing the gasification technology of wood with reverse flame; the boiler can also use natural wood pellets installing a pellet burner on the front upper door with completely automated firing and cutting off operation. -
Page 12: Installation
5.1. Installation in the boiler room ASPIRO DUO TECH boilers must be installed only in rooms having the characteristics stated by the rules and regulations in force regarding boiler installation rooms (please contact the fire department to get more details). -
Page 13: External Boiler Case Packing
5.2. External boiler case packing ASPIRO DUO TECH boilers come without external case: the case and the accessory kit are delivered separately in boxes. EXTERNAL CASE PACKING: Key : Packing box Accessories bag Right side Boiler body insulation Cover Left side... -
Page 14: System Expansion
5.4. Heating system expansion tank According to the regulations in force in Italy, any heating appliance with solid fuels must be equipped with open expansion tanks. 5.5. Chimney The flue duct is very important for what concerns a proper boiler operation; it must be completely waterproof and adequately insulated. -
Page 15: Emergency Heatsink Relief Valve Connection
during its standby periods and condensation products buildups in the air inlet ducts. Inversely, a flue duct with too much drafting action will cause thermal inertia related issues and poor fuel economy. We recommend under any circumstance to use a draft adjusting device to keep a constant depression value in the duct. -
Page 16: Electronic Control Sy 400 (Code Pel0100Duo)
ELECTRONIC CONTROL SY 400 (code PEL0100DUO) Fig.1 Key: Main switch Security thermostat Display keyboard 6.1. The display Fig.2... -
Page 17: Electronic Control Board
6.2. Electronic board (inside the electronic control panel) -
Page 18: Sensors Connection
6.3. Sensors connection For a proper boiler operation, we recommend to control the correct positioning of the temperature control sensors and the security thermostat. The control board comes with the heating system delivery temperature sensor S4 with a 3 mt length cable (terminals 47.48 page16), the heating system return temperature sensor S5 with a 3 mt length cable (terminals 45.46 page16) and the security thermostat (terminals 63.64 page16) wired. -
Page 19: Terminal Strip Wirings
6.5. Terminal strip electrical wiring Key : System pump Bypass pump Hot sanitary water tank / puffer circuit pump Solar panels pump Termostato ambiente Microswitch door Deflection valve... - Page 20 NOTE: Terminals 16 and 17 (TA) are bridged together to allow system pump operation if a room thermostat is not employed. WARNING: When a room thermostat is used, remove the wire bridge and control for a correct wiring of the room thermostat.
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Page 21: Operation Modes
OPERATION MODES 7.1. Wood operation cycle PHASE 1 Mount the upper front door. PHASE 2 - MODULATOR ADJUSTING - Open the combustion air thermostatic device, rotating the ring located on the left side of the modulator device until the disc is at a distance from the hole of about 3 cm. - Page 22 PHASE 3 - OPERATION MODE SETTING - Before proceeding with firing, the electronic control must be set on wood operation: − Turn on the control panel pressing the main green switch (pic.1 - pos.1 – page 16). The keyboard is on and the nr. 5 display will show the time, while nr. 7 display will show the boiler delivery side water temperature.
- Page 23 PHASE 4 - BOILER FIRING – Put at the center of the burner refractory frame, over the cast iron grate, small pieces of dry wood in a cross pattern. Over the pieces of wood put some easy flammable material; avoiding large and square shaped pieces.
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Page 24: Operation Cycle
secondary air stream is used to complete the oxidation process of the flame; to adjust the secondary air amount rotate the secondary air adjusting screw located under the inlet duct. In the ashes which remain over the catalyst elements only few unburnt materials must be present. If the primary air is too much, in the ashes will be found glowing coals and small carbon pieces, the flame will be quick, too bluish and noisy;... -
Page 25: Pellet Operation
7.2. Pellet operation PHASE 1 − Mount the upper door with the pellet burner. − Wire the burner cable to the electronic control panel. − Connect the flexible auger device tube to the burner fuel inlet (be sure that the flexible tube has a proper inclination, without less inclined sections which may cause inconstant fuel feeding rate). -
Page 26: Operation Cycle
PHASE 3 - OPERATION MODE SETTING - Before proceeding with firing, the electronic control must be set on pellet operation following the instructions shown at page 21. PHASE 4 - BOILER FIRING To start the firing cycle, press button nr. 10 and keep it pressed for 3 seconds. PHASE 5 –... -
Page 27: The Menus
− When the temperature value is reached 5°C less then the working temperature, on the display will appear ; in this step the drafting fan is driven to its minimum speed. The display could also show this icon when the boiler enters the modulation step because a too high smoke temperature has been reached (set to 190°C). - Page 28 Menus and customer menu submenus list: CUSTOMER MENU ITEM DESCRIPTION SUBMENUS System operation menu Heating system configuration menu Temperature sensors display menu Clock menu Submenu crono; one of the setting modes below may be chosen PROGRAM CRONO Submenu , programming mode daily Cronothermostat DAILY menu...
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Page 29: System Operation Menu
8.3. System operation menu Boiler operation mode selection menu. Available operation modes list in function of system configuration: Heating system Operation[P44] configuration[P43] Description Customer menu Protected menu Hidden menu Wood only operation. (WOOD only) “LEGN” Wood only operation. Pellet operation only with automatic (WOOD / PELLET) “PELL”... -
Page 30: Heating System Operation Menu
8.4. Heating system configuration menu This menu permits the selection of the heating system type which the boiler is connected to. The various temperature sensors connected to the electronic control board can be set active or not. Different types of heating systems which can be selected: Heating system Different types of water Different types of... -
Page 31: Temperature Sensors Reading Menu
On the top display will appear the value corresponding to the currently type of heating system chosen, while on the two bottom displays will be shown the parameter identification code. Enter the modification mode; the top display blinks Menu Menu + Select the type of heating system the boiler is connected to Menu - Save the settings... - Page 32 SMOKE TEMPERATURE (°C) BOILER DELIVERY SIDE WATER TEMPERATURE (°C) BOILER RETURN SIDE WATER TEMPERATURE (°C) HOT SANITARY WATER STORING TANK / PUFFER TEMPERATURE (TOP MEASURE POINT - °C) HOT SANITARY WATER STORING TANK / PUFFER TEMPERATURE (BOTTOM MEASURE POINT - °C) SOLAR PANELS TEMPERATURE (°C) TEMPERATURE DIFFERENCE BETWEEN BOILER DELIVERY SIDE WATER...
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Page 33: Clock Menu
TEMPERATURE DIFFERENCE BETWEEN SOLAR PANELS AND HOT SANITARY WATER TANK - BOTTOM SIDE/"PUFFER" TANK (°C) PROGRAM RELEASE 8.6. Clock menu time date To set the and the PROCEDURE INSTRUCTIONS BUTTONS Enter the Clock menu following the previously shown procedure Menu + Modify the selected value Menu - Enter the minutes setting mode, the minutes blink... - Page 34 PROCEDURE INSTRUCTIONS BUTTONS Enter the Programming menu following the previously shown procedure The top display will show the current selected Crono program Menu Enter the modification mode; the top display blinks Menu + Select the desired Crono setting Menu - Menu Save the settings Don't save the settings and revert back to the previous value...
- Page 35 DAILY PROGRAMMING PROCEDURE INSTRUCTIONS BUTTONS Enter the Daily settings menu following the previously shown procedure Navigate in the Daily settings submenu up to the Menu + desired day of the week (Monday through Sunday). Chosen time interval (1 through 3) Menu - ON time.
- Page 36 CRONO SETTING, TUESDAY CRONO SETTING, WEDNESDAY WEEKLY CRONO Permits to set the same firing/cutting off times for every day of the week, from Monday through Sunday. 3 different time intervals are available (each of them includes the and the time). The top display shows: ⇒...
- Page 37 Menu + Navigate in Weekly settings up to the desired time interval (1 through 3) ON time. Menu - Set the desired time interval. FIRING To get the hyphens canceled, keep pressed the start press button nr. 7 button nr. 7 for at least 3 seconds. NOTE: both the ON time and the OFF time are for 3 seconds...
- Page 38 CRONO WEEK END from Monday through Permits to set the same boiler firing/cutting off times for every day of the week Friday Saturday and Sunday. and the same settings for Three different time intervals are available (each of them includes an ON and an OFF time) for the days of the week from Monday through Friday and three different time intervals for Saturday and Sunday The top display shows: ⇒...
- Page 39 Menu + Modify the selected value Menu - Save the settings Menu Menu + Select the OFF time Menu - OFF time Repeat the operations 4 through 8 for setting the Exit from the Crono Week End menu NOTE: TIME INTERVAL SETTING EXTENDING FROM BEFORE TO AFTER MIDNIGHT Set the OFF time for a time interval at 23:59 Set the ON time for another time interval setting at 00:00 When is required to set an on time interval beginning before and ending after midnight from Friday to...
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Page 40: Manual Auger Activation Menu
8.8. Manual auger activation menu Permits a manual activation of the auger in the OFF state and in pellet operation mode to have the auger completely filled with pellets. Only visible when in pellet operation. PROCEDURE INSTRUCTIONS BUTTONS Be sure the boiler is OFF LOAD Enter the menu following the previously shown... - Page 41 Menu Entering the submenu on the top display, the fan speed will blink Raises/lowers the fan speed The fan speed is controlled by mean of percentage points: Menu + − 0% motor off Menu - − 1% - 50% minimum speed −...
- Page 42 Menu + Pass to the next submenu HEATING SYSTEM CIRCULATION PUMP (PI) Menu - As for AUGER Menu + Pass to the next submenu BY PASS PUMP (PR) Menu - As for AUGER Menu + Pass to the next submenu HOT SANITARY WATER STORING TANK PUMP (PB) Menu - As for AUGER...
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Page 43: Summer / Winter Menu
8.10. Summer / winter operation This function of the boiler thermostatic control permits two different types of control, one for the summertime and the other for wintertime. The operation mode may be set from the control panel pressing the summertime / wintertime button (nr. -
Page 44: General Connection Diagram For Heating Only Purposes With Open Expansion Tank
9.1.1. General connection diagram for heating only purposes - open expansion tank System pump Non return valve Bypass pump Heating system delivery temperature sensor Heating system Heating system return temperature sensor 9.1.2. General connection diagram for heating only purposes - open expansion tank and mixing valve Key: System pump Non return valve... -
Page 45: General Connection Diagram For Heating Only Purposes With Plate Type Heat Exchanger
9.1.3. General connection diagram for heating only purposes - plate type heat exchanger Key: System pump Non return valve Bypass pump Heating system delivery temperature sensor Heating system Heating system return temperature sensor Plate heat exchanger 9.1.4. General connection diagram for heating only purposes - closed type expansion tank on the hot sanitary water circuit (SA version) Key: System pump... -
Page 46: General Connection Diagrams For Heating Purposes With Hot Sanitary Water Storing Tank
9.2. General schematic diagrams for heating purposes with hot sanitary water storing tank A heating system with hot sanitary water storing tank arrangement may be divided in the following parts: 1. Boiler delivery side temperature sensor (S4): is located in its receptacle close to the boiler water delivery connection (A6) and is used by the electronic control to decide whether and when the boiler must pass from a step to another and to activate the various pumps. -
Page 47: General Connection Diagrams For Heating Purposes With Hot Sanitary Water Storing Tank
9.2.1. General connection diagram for heating purposes withhot sanitary water storing tank Key: System pump Non return valve Bypass pump Heating system delivery temperature sensor Heating system Heating system return temperature sensor Hot sanitary water tank circuit pump Hot sanitary water tank sensor - top side 9.2.2. -
Page 48: Coil Type Heat Exchanger And Solar Panels
9.2.3. General connection diagram for heating purposes with closed type expansion tank on the plate type heat exchanger circuit, with hot sanitary water storing tank equipped with double coil type heat exchanger and solar panels Key : System pump Bypass pump Hot sanitari water tank circuit pump Solar panels pump... -
Page 49: Tank
9.3. General connection diagrams for a system with "puffer" or "puffer combi" tank A system with "puffer" or "puffer combi" tank can be divided in the following parts: 1. Boiler delivery side temperature sensor (S4): is located in its receptacle close to the boiler water delivery connection (A6) and is used by the electronic control to decide whether and when the boiler must pass from a step to another and to activate the various pumps. -
Page 50: General Connection Diagram With "Puffer Combi" Tank And Solar Panels
9.3.1. General connection diagram with "puffer combi" tank and solar panels Key: System pump Solar panels temperature sensor Bypass pump "Puffer" tank bottom side temperature sensor "Puffer" tank pump "Puffer" tank top side temperature sensor Solar panels pump Heating system delivery temperature sensor Heating system Heating system return temperature sensor Non return valve... -
Page 51: General Connection Diagrams For Heating Purposes With Hot Sanitary Water Storing Tank And "Puffer" Tank
9.4. General connection diagrams for heating purposes, with hot sanitary water storing tank and "puffer" tank A heating system with hot sanitary water storing tank and "puffer" tank can be divided in the following parts: 1. Boiler delivery side temperature sensor (S4): is located in its receptacle close to the boiler water delivery connection (A6) and is used by the electronic control to decide whether and when the boiler must pass from a step to another and to activate the various pumps. -
Page 52: General Connection Diagram For Heating Purposes With "Puffer" Tank And Hot Sanitary Water Storing Tank Equipped With Double Coil Type Heat Exchanger And Solar Panels
9.4.1. General connection diagram for heating purposes with "puffer" tank and hot sanitary water storing tank equipped with double coil type heat exchanger and solar panels Key: "Puffer" tank pump Solar panels temperature sensor Hot sanitary water storing tank temperature Bypass pump sensor - bottom Hot sanitary water storing tank temperature... -
Page 53: N" Zones Systems Connections
10. “N” ZONES SYSTEMS CONNECTIONS As a separate accessory, Arca S.r.l. may supply the 4 zones control board to control a 4 zone heating system ( code SCH 0005C ) which will be connected to the main control system SY400. -
Page 54: Maintenance And Cleaning
MAINTENANCE AND CLEANING Before proceeding with any maintenance operation the boielr must be turned OFF and wait until has reached the room temperature. Empty the heating circuit only if absolutely necessary. Periodically check the proper operation of the smoke exhausting devices and of the flue duct. Do not perform any cleaning operation on the boiler using flammable liquids (gasoline, alcool, solvents, etc.) Do not leave flammable liquids or materials in the same room where the boiler is installed! -
Page 55: Monthly Maintenance
11.3. Monthly maintenance Clean the fan impeller from buildups. Usually, with compressed air or a soft brush a perfect cleaning can be gotten. If the buildups are harder to be swept away, we recommend to work softly anyway to avoid unbalancing the fan subassembly, which may cause a noisy operation and a less efficient drafting action. -
Page 56: Boiler Problems Fixing
TROUBLESHOOTING 12.1. Electronic control system problems fixing Display/State/Alarms/Clock: the 4 digits display shows the current boiler state code, the active alarms and the time. The dysplayed codes to identify the boiler current state are the followings: = Check UP = Firing = Stabilization = Firing retry = Modulation... -
Page 57: Boiler Problems Fixing (Wood Operation)
12.2. Boiler problems fixing (wood operation) Symptoms Possible causes Solutions The boiler tends to cut off leaving a curved unburnt wood mass in the a) The grate is plugged. a) Unplug the grate slots wood chamber. The refiring takes b) Not enough primary air b) Increase the primary air much time with difficulties in flame formation. -
Page 58: General Technical Tips
GENERAL TECHNICAL TIPS 13.1. Settings and maximum allowed temperatures High power boilers are often used to heat industrial plants in wood processing plants. In such situations, the different processes wastes are frequently used to fuel the boiler. Often the waste materials are very dry and contain synthetic resins and paints which should not be used as fuel. -
Page 59: Consumable Materials
13.6. Consumable materials The burner cast iron bar elements are high temperature proof and the cast iron used has a high resistance to the combustion gases. Therefore, they are well suited for many hours of operation, whose number will depend anyway upon the average boiler working temperature which is determined by many other factors, such as the type of wood more frequently used, its humidity degree, the number and duration of the standby periods, etc.. - Page 60 Mounting warnings: the piece with longer slots must be firstly positioned on the boiler back plate side. The grate with longitudinal slots (pic. 1,2,3,4) is better suited with types of wood producing thinner ashes. When changing the grate for wearing related issues, it is important taking into adequate account the kind of wood usually used.
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Page 61: Warnings
13.7. Warnings Using wet wood (greater than 25%) and/or a total amount of fuel not suited for the heating system needings (with long stop periods with the wood chamber full of unburnt wood) is cause of relevant condensation issues in the wood chamber. Once a week, control the wood chamber steel walls. - Page 63 ARCA s.r.l. Head office and steel boilers production MN Nord) 46030 San Giorgio (Mantova)P.IVA IT 01588670206 Tel.: 0376/372206 - Fax: 0376/374646 - E-mail: arca@arcacaldaie.com - Tlx 301081 EXPMN I Sales direction - Tel.: 0376/372617 - Customers management - Tel.: 0376/371454 - Ph.: 0376/371454 Technical Department Gas boilers production...
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