.......G-9 Engineering the Chimney System ....I-42 roduct escrIPtIon Accessories ............. I-42 Nesta 120 - 160 - 200 - 250 ......G-9 General Description ..........G-9 Safety Instructions for the Gas Connection ..I-43 Frost Protection ............G-9 Gas Conversion ..........I-44 Safety Devices ............G-9 Preparing the Boiler for Gas Conversion ....I-45...
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.. I-66 ddItIonal nformatIon for the nstaller Optional Modules ..........I-66 Additional Heating Circuit Modules & Cable Hub ..I-66 Web Server Module ..........I-66 Cascading module ...........I-66 Boilers in a Cascade System ......I-67 Boiler Settings for the Installer ......I-70 Access Levels ............I-70 Commissioning Menu ..........I-70 Menus and Settings ..........I-70...
Fig. 1. Boiler Packaged for Transport ......G-8 Fig. 2. Data Plate - Typical ..........G-8 Fig. 3. Nesta 120-160 Boiler Components - Front and Rear Views ..........G-10 Fig. 4. Nesta 200-250 Boiler Components - Front and Rear Views ..........G-11 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- î 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: → DO NOT: Close the gas supply î Use an open fl ame î Open all doors and windows to î Smoke î ventilate the room î Use electrical devices (phones, î...
Nesta 120 - 160 - 200 - 250 General Description Safety Devices This floor-standing series of Nesta boilers consists of The Nesta boilers are equipped with a series of compact, low-emission condensing appliances with a sensors and switches that provide safety for your pre-mix burner and a stainless steel heat exchanger.
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Fig. 3. Nesta 120-160 Boiler Components - Front and Rear Views Air inlet duct 16. Control panel with LCD display Fan and burner assembly 17. Burner plate temperature limit switch Ignition electrode 18. Air adapter Hoisting ring 19. Gas valve Water pressure sensor 20.
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roduct escriPtion Fig. 4. Nesta 200-250 Boiler Components - Front and Rear Views Air inlet duct 16. Control panel with LCD display Fan and burner assembly 17. Burner plate temperature limit switch Ignition electrode 18. Air adapter Hoisting ring 19. Gas valve Water pressure sensor 20.
roduct escriPtion Control Panel and Main Functions Fig. 5. Control Panel Chimney sweep function button - This button allows to Domestic Hot Water on/off button - Pressing this button ac- perform a measurement of the flue gas contents. tivates/deactivates of the Domestic Hot Water function ( Manual operation mode button - The operation de- LCD Display - The display illuminates whenever a control pends on the function defined for the relays (Expert Lev-...
roduct escriPtion Symbols and Messages on the Control The following symbols are displayed on the screen Panel (See Fig. 6): The following symbols are present on the control ). The time scale ( Comfort mode active ( panel (See Fig. 6): at the bottom of the display indicates the period during which this mode is active (in Domestic Hot Water mode.
echnical pecificaTionS N 120 FS N 160 FS N 200 FS N 250 FS Combustion Data (min. - max.) (min. - max.) (min. - max.) (min. - max.) chimney type(s) B 23 - B 23P - C 43 - C 53 - C 63 - C 83 flue gas temperature at 80/60°C °C 52 - 60...
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echnical pecificaTionS N 120 FS N 160 FS N 200 FS N 250 FS Gas Data (min. - max.) (min. - max.) (min. - max.) (min. - max.) gas type(s) G20 - G25 - G25.1 - G25.3 - G31 G20 (20 mbar) mbar 17 - 25 G25 (25 mbar)
echnical pecificaTionS Hydraulic Data N 120 FS N 160 FS N 200 FS N 250 FS water content hydraulic pressure drop at ∆T = 20k mbar minimum operating pressure maximum operating pressure maximum boiler supply temperature °C Pressure Drop Curve N 200 FS / N 250 FS N 120 FS / N 160 FS...
nstructIons for the Safety Instructions for the User IF YOU SMELL GAS: → DO NOT: → DO: Close the gas supply î Use an open fl ame î Open all doors and windows to ven- î Smoke î tilate the room 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- î or close to the air inlets), 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 in- Conditions: stallation must be performed by a qual- None ified professional, according to the pro- cedure in “Start-up and Combustion Procedure: Adjustments” on page I-55. Push the On/Off switch located on the right side of the boiler.
nstructIons for the Cause Action What to Do if... 1. Check that the power button is in ON position (pushed in and illuminated). 2. Make sure the power supply is connected to the Boiler does not start No power supply mains.
nstructIons for the Basic Settings Setting Procedure Controls/Screens Press the Heating mode selection button to toggle from one Heating mode mode to the other: selection • Automatic mode ( ) (to be programmed, refer to “Boiler Settings for the Installer” on page I-70. •...
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nstructIons for the Setting Procedure Controls/Screens Press the OK button (2) to access the end user menu. Times of start and end of Rotate the knob (1) to scroll through the menu until “Time Program heating circuit 1” (5) is highlighted. comfort mode schedule Press the OK button (2) to validate the selection...
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nstructIons for the Setting Procedure Controls/Screens Press the OK button (2) to access the end-user menu. Language Selection Rotate the knob (1) to scroll through the menu until “Operator Section” (9) is highlighted. Press the OK button (2) to validate the selection Rotate the knob (1) to select the required language (DE, EN, FR, IT, NL, ES, DA, SV, FI, PT).
nstructIons for the Structure of Menus for the End User Some parameters are only visible if the heating circuit is installed Top menu Submenu 1 Submenu 2 Default Time of day and date Hours / Minutes 01:00 (hh:min) Ҙ (Adjust as required) Day / Month 01.01 (dd.mm) Ҙ...
roduct nstallatIon Safety Instructions for the Installation When the appliance is con- î nected to the electrical net- All connections (electrical, fl ue pipe, î work, it must be earthed. hydraulic, gas) must be carried out Make sure that a fuse or circuit breaker in accordance with current standards 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 î mended clearances (See “Dimensions and requires sufficient work- Clearances” on page G-14). force to move and handle it, If some height is required for condensate flow as well as an appropriate means of transport.
roduct nstallatIon Removing and Installing the Access Panels Top panel Conditions: Push the top panel downwards to engage Tools and Material: the studs into their receptacles. î Wrench, hex head, size 4 Side Panels Removal Procedure: Bottom: install six retained screws. Bottom Front Panel Top : Install four retained screws.
roduct nstallatIon Requirements for the Hydraulic Connec- tions 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 in a Heating System To prevent the formation of scale and sludge in a Additives can be used to keep the oxygen in î closed heating circuit through the penetration of ox- solution in the water.
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roduct nstallatIon Water Parameters Graph description: Above the curves, water treatment is In addition to the water hardness, other pa- î required rameters of the water must be checked. Treat the water if the measured values are outside Below the curves, fi ll with untreated tap ...
roduct nstallatIon Typical Hydraulic Connections - Heating Circuit Isolating valve Filling valve Draining valve Check valve Expansion vessel Safety group (automatic air relief valve, manometer, safety valve), con- nected to the drain Circulating pump Removable fi lling hose Drain Fig. 11. Typical Heating System To make maintenance easier, we recommend to remove the plug from the drain connection and install an optional draining valve (see “Fig.
(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...
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roduct nstallatIon Plastic fl ue pipes should be î Flue pipe elements or PP air î allowed to expand under the inlet elements should not be eff ect of heat. Leave about screwed together. 10 mm between the pipe and the sleeve end stop.
roduct nstallatIon Chimney Connection Description C (Closed) Appliance connected via its two ducts to a common duct system (part of the building) designed for more than one appliance. The common duct system consists of two ducts connected to a terminal, which at the same time admits fresh air to the burner and discharges the products of combustion to the outside through orifi ces that are either concentric or close enough to come under similar wind conditions.
Before installation, check on silenc- î er sticker that it is the correct com- ponent for the boiler model. If not, contact your AIC representative. Be aware that the presence of the si- î lencer (B-type chimney connection) af- fects the fan speed setting when carry- ing out a gas conversion.
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. I-42 A-070336_EN • B_0821...
roduct nstallatIon Gas Conversion Connection of the boiler to a î G31 gas system should com- ply with local regulations and Conversion of the appliance î requirements. from one gas type to another can If the boiler was running before con- î...
Preparing the Boiler for Gas Conversion The boilers are adjusted in factory to î operate with natural gas (G20). When Nesta 120 and 160 boilers Conditions: î need to operate with propane, the gas valve shutter (1) and offset (2) Tools and material: screws must be adjusted.
roduct nstallatIon Adjustment of Fan Speeds 9. Rotating the knob ( ), adjust the ignition fan Conditions: speed for the gas type, boiler type and chim- Table 1 and Table 2 on ney type. Refer to Adjustment Procedure (Fig. 18) page I-44.
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roduct nstallatIon Combustion Adjustment for Gas Conversion Conditions: Check CO contents in the flue gas at max. Tools and material: output as follows: î Flue gas analyser î Press the Information button (2). The mod- î Screwdriver, flat head ulation indicator (5) is displayed (in %). î...
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roduct nstallatIon î If the value is outside the range, adjust the combustion value by turning the gas valve shutter (6) in small steps, to allow the val- ue to stabilise before performing additional adjustments. Decrease CO î N 120 - 160 FS: Increase - Rotate shutter screw (6) counter-clock- wise to increase the CO...
roduct nstallatIon Connections Safety Instructions for the Electrical Connections Any damaged power supply cable must be replaced using cables as described below and installed by a qualified professional. Electrical connections must be carried The cross-section of the wires should out by a qualifi ed professional in accord- be >1.5 mm , equipped with sleeves at ance with current standards and regula-...
roduct nstallatIon Accessing the Low Voltage Terminal Strip and Electronic board Conditions: Tools and material: î Wrench, hex head, size 4 Procedure: Remove center front panel, see “Removing and Installing the Access Panels” on page I-31. Remove one screw ( ) at the bottom of the electronic bay access panel.
roduct nstallatIon Accessing the High Voltage Terminal Strip Routing the Cables Make sure that the power supply to the appliance is deactivated (power supply cable disconnected from the boiler) before accessing the high voltage terminal strip. Route Conditions: voltage cables Route high through these...
roduct nstallatIon Wiring Diagram Flue Gas Temperature pressure Door Tem Gas Valve Sensor switch Limit GNYE Grounding Strip Front Ignition Ignition Transformer E5 G2 Electrode High Voltage Cable GNYE GNYE Safety Water Temperature Switch 8 9 10 11 12 N L N L Ignition module valve...
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roduct nstallatIon Door Temp Condensate Limit Front Panel 1 Level Switch BX1 System temp. sensor /Multifunctional DHW Sensor Outside sensor H1 Enable/Disable /Multifunctional BX2 Cascade return temp. sensor /Multifunctional X15 Boiler pump PWM UX2 Analog output 0-10V UX3 Analog output 0-10V P= 3W 24V DC...
ommIssIonInG Safety Instructions Before Start-up Filling the System Conditions: Procedure: Check that all connections (electrical, î 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...
î Press the heating mode selection button ( Increase CO to exit and go back to the home screen. Nesta 120 - 160 Activate the required heating mode by press- ing the heating mode selection button ( Allow the boiler to operate for a few minutes.
aIntenance Safety Instructions for Maintenance The maintenance of the ap- î pliance and its components must be carried out by a qualifi ed professional. Inspection and maintenance tasks î Defective parts and components may î 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 condi- tion, 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: Conditions: None Procedure: Procedure: Push in the On/Off switch located on the Push the On/Off switch located on the right side of right side of the boiler. the boiler. When in the On position, the switch re- When in the OFF position, the switch mains pushed in and is illuminated.
aintenance Cleaning the Condensate Pipe and Trap Remove the cover gasket ( ). Discard. Wipe clean the condensate level switch ( Conditions: attached to the cover. Remove and replace as required. Clean the deposits in the condensate trap ( Tools and material: using clear water and a cloth.
Discard and replace the O-ring if it is dirty or cracked. Release four nuts (7) securing the fan and air Nesta 120 adapter assembly (1) to the burner assembly. Remove the fan and air adapter assembly (1) and its hardware. Retain for reinstallation.
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aintenance Reconnect all connectors to the electrodes, Follow-on task(s): burner plate limit switch, gas valve and fan. Close all panels, refer to “Removing and In- Reconnect the air hose to the gas valve and air stalling the Access Panels” on page I-31. inlet port.
aintenance Removing and Installing the Ignition and Release two screws ( ) from the electrode Ionization Electrodes flange. Remove the electrode and screws from the burner plate ( ). Discard, as required. Conditions: Remove electrode gasket ( ) and discard, as Tools and material: required.
aintenance Removing and Installing the Burner Conditions: Clean the combustion chamber, see “Check- ing and Cleaning the Combustion Cham- ber” on page I-64. î Fan and air adapter assembly removed, refer to “Removing and Installing the Fan and Air Installation procedure: Adapter Assembly”...
aintenance Checking and Cleaning the Combustion Replacing the Gas Valve Filter Chamber Conditions: Conditions: î Left side top panel removed, refer to “Removing and Installing the Access Panels” on page I-31. î Burner removed, see “Removing and Install- ing the Burner” on page I-63. Cleaning Procedure (Fig.
aIntenance Checking the Flue Gas (FPS) and Air (APS) FPS: blow air into the hose while it is con- nected to the flue pressure switch and to the Pressure Switches operation measuring device. APS: suck air from the hose while it is con- Conditions: nected to the air pressure switch and to the measuring device.
ddItIonal nformatIon for the nstaller Optional Modules Additional Heating Circuit Modules & Cable Web Server Module Through the use of this module, you can connect Nesta boilers can control 3 heating circuits with to an Ethernet and get remote access to the boiler mixing functions, using 3 extension modules.
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.
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dditionAl nformAtion for the nstAller I-68 A-070336_EN • B_0821...
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dditionAl nformAtion for the nstAller I-69 A-070336_EN • B_0821...
dditionAl nformAtion for the nstAller Boiler Settings for the Installer Commissioning Menu Access Levels When starting up the boiler for the first time, a com- missioning screen will come up. It can be exited Three different levels of settings are available for the without adjustments by pressing the ESC ( ) button.
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dditionAl nformAtion for the nstAller Top menu Level Pgm No. Submenu 1 Submenu 2 Default Setting Operator Operation HC2 Jointly with HC1 Ҙ Jointly Section Independently with HC1 (Cnt’d) Operation HC3/P Jointly with HC1 Jointly Ҙ with HC1 Independently ...
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dditionAl nformAtion for the nstAller Top menu Level Pgm No. Submenu 1 Submenu 2 Default Setting Room comfort setpoint Heating Ҙ 20.0°C circuit 1 Room reduced setpoint Ҙ 16.0°C Room frost protection Ҙ 10.0°C setpoint Comfort setpoint max Ҙ 35.0°C Heating curve slope Ҙ...
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dditionAl nformAtion for the nstAller Top menu Level Pgm No. Submenu 1 Submenu 2 Default Setting Excess heat draw Heating cir- Ҙ Heating mode Always cuit 1 (Cnt’d) Always With buffer Ҙ With prim contr/system Ҙ...
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 Check extension module connections. Extension module 2, error Check 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 Recommended parameters to be checked during installation and operation of the boiler: Meter reading before initial filling: Z=…………… m Date Meter Quantity of Total alkaline Conductivity System Addition Signature reading Water earths or total value...
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