Summary of Contents for Hitecsa ADISA ADI CD Series
- Page 1 ADI CD CONDENSING BOILER TECHNICAL MANUAL OF INSTALLATION, USE AND MAINTENANCE 4/2020-uk...
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Page 2: Table Of Contents
ADI CD Boiler – Technical Manual Index Index Index Index 1. INTRODUCTION _________________________________________________________________________________ 4 2. REGULATIONS __________________________________________________________________________________ 5 3. EEC APPROVALS AND CERTIFICATIONS ____________________________________________________________ 5 4. BOILER GENERAL VIEW: DESCRIPTION OF THE COMPONENTS ________________________________________ 6 5. DIMENSIONS ____________________________________________________________________________________ 8 6. TECHNICAL DATA ______________________________________________________________________________ 10 6.1 Models ADI CD 70 to ADI CD 400______________________________________________________________ 10 6.2 Models ADI CD 450 to ADI CD 950_____________________________________________________________ 11 7. - Page 3 21. APPENDIX I: LIST OF ERROR CODESERROR _______________________________________________________ Data indicated in the present manual are liable to changes. ADISA HEATING BY HITECSA (HIPLUS AIRE ACONDICIONADO S.L.) has the right to make modifications without notice of any product of its range.
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Page 4: Introduction
This is why the European campaign known as “20-20-20 in 2020” has been created, with the aim, among others, of cutting carbon dioxide emissions by 20% by 2020. ADISA HEATING, BY HITECSA, company specialized in the manufacturing of gas boilers with high efficiency performances and reduced pollutant emissions (“clean combustion”), has developed an innovating and revolutionary product contributing to a technological evolution in the field of water boilers for centralized installations: the ADI CD boiler. -
Page 5: Regulations
ADI CD Boiler – Technical Manual 2. REGULATIONS The installation must be designed and made by qualified professionals in accordance with the current regulations referring to gas, air venting, flues evacuation, electricity, safeties, fire prevention, etc. The boiler maintenance must be made following the instructions of the manufacturer’s technical manual and with a minimum regularity as indicated by the current regulations. -
Page 6: Boiler General View: Description Of The Components
ADI CD Boiler – Technical Manual 4. BOILER GENERAL VIEW: DESCRIPTION OF THE COMPONENTS Boiler heat exchanger (higher collector) Flanges (boiler heat exchanger – burner – air/gas fan) Ignition-ionization kit Flame indicator Motor fan (variable speed) Venturi for air inlet and mix with gas Gas shut-off valve Boiler control unit and power modulation Hot water flow... - Page 7 ADI CD Boiler – Technical Manual Models ADI CD 200 and higher:...
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Page 8: Dimensions
ADI CD Boiler – Technical Manual 5. DIMENSIONS ADI CD 120-175 ADI CD 70 - 105 ADI CD 200 - 450 F (7) Model 151,5 82,5 1110 82,5 1110 151,5 151,5 82,5 1110 134,3 112,5 1110 134,3 112,5 1110 217,3 177,5 1583 1156... - Page 9 ADI CD Boiler – Technical Manual ADI CD 550 - 950 F (7) Modelo 1628 1060 1396 1040 1040 1628 1060 1396 1628 1060 1396 1040 1040 1658 1063 1393 1083 1658 1063 1393 1083 1040 Attention: Heights H, HG, HA, HF, without taking into consideration the increase due to the silent-block feet supplied with the boiler (dimension “SB”).
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Page 10: Technical Data
ADI CD Boiler – Technical Manual 6. TECHNICAL DATA 6.1 Models ADI CD 70 to ADI CD 400 CONCEPTO Maximum power Power 70,5 161,8 197,5 (average water output temp: 70ºC) Maximum power Power 71,2 86,1 105,6 121,3 163,4 204,5 244,7 302,6 358,7 (average water... -
Page 11: Models Adi Cd 450 To Adi Cd 950
ADI CD Boiler – Technical Manual 6.2 Models ADI CD 475 to ADI CD 950 CONCEPT Units Maximum power 792,7 892,3 Power output (average water temp: 70ºC) Maximum power 443,5 535,5 682,4 802,1 904,1 Power output (average water temp: 40ºC) Minimum power 230,9 259,4... -
Page 12: Boiler Heat Exchanger
ADI CD Boiler – Technical Manual 7. BOILER HEAT EXCHANGER The boiler heat exchanger (flues-water) is made of stainless steel: it 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. -
Page 13: Power Modulation And Combustion System
ADI CD Boiler – Technical Manual 8. POWER MODULATION AND COMBUSTION SYSTEM (1) Burner of fire resisting alloy mesh (2) Ionization electrode (checking the flame presence) (3) Ignition electrode (4) Pilot flame (5) Venturi for the air-gas mix (6) Gas shut-off valve (7) Gas inlet (boiler gas connection to the installation) (8) Fan for the air-gas mix... -
Page 14: Assembly Of Gas Connection - Air/Gas Inlet
ADI CD Boiler – Technical Manual 8.1 Assembly of gas connection – air/gas inlet The ADI CD boiler includes an air-gas premix system of modulating combustion, composed of: Venturi operating as an air-gas mixer, ensuring combustion with a constant proportion of air/gas to the premix burner, throughout its power modulation range. - Page 15 ADI CD Boiler – Technical Manual Exploded view of the burner – fan – gas valve assembly for models CD 325 and higher: Motor-fan rotating backward (ADI 850 – 950) or forward (ADI 325 – 750) depending on the model.
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Page 16: Air Inlet Filter
ADI CD Boiler – Technical Manual 8.2 Air inlet filter The air inlet to the venturi is protected by a filter retaining the dust that is usually in the atmosphere. Attention: it is important to avoid excessively dusty or dirty environments (for ex. -
Page 17: Control Panel - Siemens
ADI CD Boiler – Technical Manual 10. CONTROL PANEL - SIEMENS The boiler control panel is placed in the upper part of the boiler front. (A) Boiler on/off switch (B) Display: readings, messages, errors... 10.1 Display 1 Control knob (push and roll) 2 Display 3 Navigation bar 4 Status bar... - Page 18 ADI CD Boiler – Technical Manual General symbol The following symbols are located on the navigation bar (left, vertical): Accessible for end-user and experts: Start page: Plant status. Access to plant switch (or zone switch). Temperature page. Access to heating and cooling. Domestic hot water page.
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Page 19: Programming
ADI CD Boiler – Technical Manual Operating tips A changed setting reverts to the original state if not confirmed within Editing timeout 5 seconds this period. A long press of the knob on any expert view returns to the "Expert view Long button ≥... - Page 20 ADI CD Boiler – Technical Manual User level The user levels only allow authorized user groups to make settings. To reach the required expert user level, proceed as follows: Overview of setting Parameters setting These examples below show a basic programme process: Setting the time of day and date until “Service/setting pages”...
- Page 21 ADI CD Boiler – Technical Manual Press the control knob for 3 seconds to exit. The start page opens. Setting of boiler flow temperature – Setpoint On the navigation bar, turn the control knob until “Service/setting pages” is preselected. Press the control knob to enter to the page.
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Page 22: Boiler Lockout Code
ADI CD Boiler – Technical Manual Setting of Language On the navigation bar, turn the control knob until “Service/setting pages” is preselected. Press the control knob to enter to the pages. The title “Regional settings (1/3)” is preselected. Press the control knob and text is selected. - Page 23 ADI CD Boiler – Technical Manual Info Pages Topics Error Error 2 Boiler Cascade Heating zona 1 Heating zona 2 Domestic hot water Outside temperature Customer service Display error history To visualize the history of the errors that occurred in the boiler, proceed as follows: On the navigation bar, turn the control knob until “Service/setting pages”...
- Page 24 ADI CD Boiler – Technical Manual Reset of locking errors To reset and unlock the boiler, hold the unlock button down for 0.4...10 seconds. Use a sharp object (e.g. ballpoint pen) or a screwdriver, up to size 2. Reset interactive errors The Info pages ( ) are selected.
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Page 25: Control Of Several Boilers - Cascaded System
ADI CD Boiler – Technical Manual 11. CONTROL OF SEVERAL BOILERS – CASCADED SYSTEM In an installation with several boilers it is important that the power generated by the boilers adapts at any moment to the demand of the installation, always optimizing the generators’ efficiency. 11.1 Boilers sequence included When there are several boilers supplying... - Page 26 ADI CD Boiler – Technical Manual Only the Official Technical Service can modify the internal parameters, in order to use this control on the boiler. Boilers and installation In this example, the boilers’activation and their power control would be made as shown below: 100% 100% 100%...
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Page 27: External Control Signal 0
ADI CD Boiler – Technical Manual 11.2 External control signal 0…10 V to regulate start-up and power modulation of each boiler Each boiler can receive and process an external signal 0…10 V. The external signal 0…10 V will transmit to the boiler a set-up temperature value. The signal 0…10 V must be connected to the terminals shown inside the boiler. -
Page 28: Remote Control Or Telecomputing
ADI CD Boiler – Technical Manual 11.3 Remote Control or telecomputing Boilers provided with the LMS control unit (cascade sequence and circuits control) can be connected to a WEBSERVER OZW672 for communication through ETHERNET, that allows controlling the boilers’operation and the installation via WebBrowser in a computer or Laptop and receiving messages and e-mails in Smartphones. - Page 29 ADI CD Boiler – Technical Manual 11.4 Data communication (remote management) vía Modbus RTU Adding an optional accessory “Modbus RTU Kit”, code 510728, (not supplied, separate acquisition), the data of the boiler (s) are communicated with the building management system, using Modbus RTU protocol. The “Modbus Kit”...
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Page 30: Electric Drawing
ADI CD Boiler – Technical Manual 12. ELECTRIC DRAWING The electric installation must comply with the current rules. The electric power consumed by each boiler is indicated in the table of technical characteristics. ADI CD 70 to ADI CD 750: The electric supply must be 220/230 V, 50 Hz, single phase, ground connection. (Remember: in case of 220/230 V, two phases, it is necessary to install an electric insulating transformer with one of the phases of the secondary connected to ground acting as neutral). -
Page 31: Electric Drawing Adi Cd 70 - 750
ADI CD Boiler – Technical Manual 12.1 Electric drawing ADI CD 70 – 750... -
Page 32: Electric Drawing Adi Cd 850 - 950
ADI CD Boiler – Technical Manual 12.2 Electric drawing ADI CD 850 – 950... -
Page 33: Cover Of The Siemens Control Lms
ADI CD Boiler – Technical Manual 12.3 Cover of the Siemens control LMS The ADI boilers of Low Size / Power, ADI CD 105 to 200, the Siemens control is placed in the front of the boiler, able to access when the boiler front plastic casing is removed / taken off. 12.4 Entry point for the cables / wiring to the boiler Placed at the back part of the boiler. -
Page 34: Heating Circuits
ADI CD Boiler – Technical Manual 13. HEATING CIRCUITS For the heating circuits, a number of functions are available (see parameters table) which can be individually set for each heating circuit. Every heating circuit can be a virtual circuit, pump circuit or mixing circuit. The Mixing function is available only when an external extension module (AGU2.550A109) is needed. - Page 35 ADI CD Boiler – Technical Manual Electric drawing: 1 Boiler with 3 heating circuits...
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Page 36: Heating Circuits Basic Parameters
ADI CD Boiler – Technical Manual 13.1. Heating circuits basic parameters Activation of heating circuits Heating circuits are deactivated in default parametrization (heat demand of the boiler is given by the parameter 1859 “Flow temp setp cons request”). Adjust the following parameters to enable the heating circuits and to assign the extension modules to each heating circuit. - Page 37 ADI CD Boiler – Technical Manual Summer/winter heating limit The summer/winter heating limit is used to switch the heating on and off in the course of the year, depending on the outside temperature. In Automatic operation, switching on/off takes place automatically, so there is no need for the user to do this manually.
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Page 38: Domestic Hot Water
ADI CD Boiler – Technical Manual 14. DOMESTIC HOT WATER (D.H.W.) Connect the storage tank sensor to B3 input (see the following electric drawing) If there is demand for DHW, the heat sources can be switched on at any time. The strategy is to produce the amount of heat required at a certain point in time –... -
Page 39: Basic Parameters
ADI CD Boiler – Technical Manual b) Electric drawing: 1 Boiler and Domestic Hot Water SIEMENS AVS3 7.29 4 BOILER CONTROL 14.1. Basic parameters Activation of Domestic Hot Water Domestic Hot Water is deactivated in default parametrization. D.H.W. Parameter Function Value... -
Page 40: Safeties
ADI CD Boiler – Technical Manual 15. SAFETIES These are the safeties included in the boiler: Cause for safety Safety Boiler restart activation component of the boiler No flame Ionization Manual reset electrode Fan failure/air Air pressure Manual reset passage obstruction switch Overheating Safety... -
Page 41: Installation
ADI CD Boiler – Technical Manual 17. INSTALLATION 17.1 Boilers heat output The boilers total power output to be installed must be the proper one to respond to the demands of the installation. In order to generate heating with the maximum efficiency at every moment, it is important to consider the number of the boilers to be installed, so that the total power should be appropriate for the different demands of the installation in the different periods of the year. -
Page 42: Gas Supply
“Technical data”. To select the type and its volume speed of opening/closing, consult the Technical Units Boiler model Department of ADISA HEATING BY HITECSA. An inertial tank must be installed between the gas 0.0102 ADI CD 105 pressure governor and the boiler, acting as a gas 0.0128... -
Page 43: Draining Of The Boiler Condensate
ADI CD Boiler – Technical Manual 17.5 Draining of the boiler condensate 17.5.1 Water condensing The heat exchanger being in stainless steel, the ADI CD boiler has no limit of the minimum return temperature. This allows obtaining a higher profit of the heat generated by the combustion products: - Sensible heat: the heat transferred due to the cooling of burnt gases. -
Page 44: Chimneys
ADI CD Boiler – Technical Manual 17.6 Chimneys The flue outlet, according to the current rules, must ensure a correct evacuation of the burnt gases, without backward flows and without producing condensate. The natural draught of the chimney must evacuate the burnt gases from the boiler flue outlet. -
Page 45: Flue Draught Stabilizer
ADI CD Boiler – Technical Manual 17.6.2 Flue draught stabilizer In case of excessive draught / depression (this can cause vibrations in the chimney), or a chimney with fan for flues diluted with air, you have to install a flue draught stabilizer inside the chimney. -
Page 46: Adjustable Flue Damper At The Boiler Flue Outlet
ADI CD Boiler – Technical Manual 17.6.4 Adjustable flue damper at the boiler flue outlet Every installation is different because of: different chimney different outdoor temperature (maximum and minimum), according to the height on the sea level. The opening of the flue damper must be adjusted according to the values indicated at the beginning of this chapter, for a correct and quick adjustment of the boiler combustion. -
Page 47: Hydraulic Installation
ADI CD Boiler – Technical Manual 17.7 Hydraulic installation 17.7.1 Data to be considered Concept Value Minimum water working pressure 1 bar Maximum water working pressure 5 bar Maximum flow temperature 87ºC (up to 90ºC in some moments due to PID control) Minimum water pressure safety device The boiler includes a water pressure switch, that stops the boiler when the water pressure achieves a minimum value. -
Page 48: Hydraulic Pressure Drop
ADI CD Boiler – Technical Manual 17.7.3 Hydraulic pressure drop The boiler pressure drop depends on the water flow; the maximum ∆T must be 15 ºC: Units ∆T = 10ºC 10,3 13,9 17,0 20,7 25,3 30,4 37,8 45,6 51,4 58,1 68,2 76,7 ∆T = 13ºC... - Page 49 ADI CD Boiler – Technical Manual 17.7.4 Low Loss Header / Water manifold / Inertial It avoids hydraulic unbalances between the circuits and the boilers. It ensures a constant water flow to the boiler, independently from the consumptions required. In accordance with current regulations. In case of heavy sludge in the water, it drives it to the bottom of the tank.
- Page 50 (see the corresponding paragraph). ADISA HEATING by HITECSA (HIPLUS) disposes of professional staff that, after a visit of the installation, can advise you according to each case.
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Page 51: System Drawings
ADI CD Boiler – Technical Manual 17.7.6 System drawings Boiler Water collector or water manifold Controller D.H.W. buffer vessel Thermostat Plate heat exchanger Temperature sensor Boiler circulation pump Pressure switch Mesh filter Manometer Closed expansion vessel Thermometer Non-return valve Filter to separate sludge, oxides Automatic air venting Mixing valve Flow to heating circuit... - Page 52 ADI CD Boiler – Technical Manual System drawing of heating circuits System drawing of one boiler and only D.H.W.
- Page 53 ADI CD Boiler – Technical Manual System drawing: D.H.W. and heating circuit System drawing of an old installation: heating circuit...
- Page 54 ADI CD Boiler – Technical Manual System drawing of an installation with high 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. System drawing of an installation as in the previous case: D.H.W. and heating circuit.
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Page 55: The Boiler Start-Up
ADI CD Boiler – Technical Manual 18. THE BOILER START-UP 18.1 Before the start-up The first start-up is a very important operation on which the future effectiveness and reliability of the equipment can depend. For this reason, it must be carried out by our own Official Technical Assistance Service. Before the start-up, it is important to check that: The installation is in accordance with this manual’s instructions and with the local regulations. -
Page 56: The Boiler Control Unit And Operating Cycle
ADI CD Boiler – Technical Manual 18.3 The boiler control unit and operating cycle The control unit regulates: The boiler operating cycle. • The boiler safeties (by indicating also the possible reasons for the boiler lockout). • The boiler power modulation. •... -
Page 57: Gas/Air Adjustments
ADI CD Boiler – Technical Manual 18.4 Gas/air adjustments All the boilers are tested in our factory and every one is supplied with a table indicating the combustion figures. Both the start-up and the maintenance must be carried out by authorized technical staff. First of all verify: electric supply, if the gas connection is air vented, type of gas and pressure, if the heating demand is at the maximum value, correct draught of the chimney, if the hydraulic installation is vented, if the pump is correctly working... - Page 58 ADI CD Boiler – Technical Manual On the navigation bar, turn the control knob until “Service/setting pages” is preselected. Press the control knob and the page opens. In the work area, turn the control knob until “Special operations” is preselected. Press the control knob and the special operations list opens.
- Page 59 ADI CD Boiler – Technical Manual Detail of the gas shut-off valve in models ADI CD 70-105 (for the combustion adjustment): First remove the cover and turn the screw inside it: 1. Combustion adjustment at the maximum power: turn it counter clockwise more gas flow.
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Page 60: Change Of Fuel: From Propane Gas To Natural Gas
ADI CD Boiler – Technical Manual 18.4.2 Change of fuel: from Propane gas to Natural gas In order to change fuel, it is enough Re-programm the Siemens controller to adjust the boiler combustion with the new fuel to the correct parameters, either for Natural Gas or for Propane Gas. -
Page 61: Maintenance
ADI CD Boiler – Technical Manual 19. MAINTENANCE The maintenance operations must be carried out from: The front of the boiler (main burner, electrodes, control panel, sight hole). • The back of the boiler (gas shut-off valve, air damper, fan motor). •... - Page 62 ADI CD Boiler – Technical Manual Front view of the boiler inside (model ADI CD 250 and larger models): (c, d) Disconnect the electric connections and the pressure pipes: (a) Pressure pipe connecting the gas valve to the venturi (just included in models starting from ADI CD 250).
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Page 63: Position Of Probes And Sensors
ADI CD Boiler – Technical Manual 19.2 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 venting (their number can vary according to the model). -
Page 64: Boiler Guarantee
ADISA manipulate the boiler, the guarantee would lose its effect. 7. The parts replaced under guarantee will remain property of ADISA HEATING BY HITECSA, and the user is obliged to return them to ADISA HEATING BY HITECSA free of charges within a maximum period of 7 days, otherwise the spare parts provided will be invoiced. - Page 65 In order to exercise the rights of this guarantee, the purchaser must renounce to his own right and submit to the jurisdiction of the courts of Vilanova i la Geltrú (Barcelona – Spain). The guarantee validity excludes any other kind of responsibility for ADISA HEATING BY HITECSA (HIPLUS AIRE ACONDICIONADO S.L.).
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Page 66: Appendix I: List Of Error Codeserror
ADI CD Boiler – Technical Manual 21. APPENDIX I: LIST OF ERROR CODESERROR ERROR DIAGNOSTIC DESCRIPTION OF ERROR - TEXT DIAGNOSTIC CODE CODE No error Outside sensor fault Check connection and component Boiler temperature 1 sensor fault 439-440 Short circuit or Open circuit boiler flow sensor (B2). Check connection and component Flue gas temperature sensor fault 539...544 Short circuit or Open circuit flue gas sensor. - Page 67 ADI CD Boiler – Technical Manual ERROR DIAGNOSTIC DESCRIPTION OF ERROR - TEXT DIAGNOSTIC CODE CODE Flow temp HC2 not reached Check installation and components Maximum boiler temperature exceeded 501-502 Supervision exceeded, no temperature modification after flame DHW charging temperature not reached Check installation and components DHW legionella temperature not reached Check installation and components...
- Page 68 ADI CD Boiler – Technical Manual ERROR DIAGNOSTIC DESCRIPTION OF ERROR - TEXT DIAGNOSTIC CODE CODE Solar integration missing Check connection and component Cascade flow sensor B10 missing Check connection and component B10 Extension module 3 fault Check connection and component Repetition internal Call technical service Repetition speed...
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