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- Page 1 ADI-Nox CD Boiler With LMS Controls Models 70 to 950 Operating & Maintenance Manual ELCO Heating Solutions Ltd 3 Juniper West Fenton Way Southfields Business Park Basildon Essex SS15 6SJ Tel: 01268 546700 Fax: 01268 888270 www.elco.co.uk L348...
- Page 2 11.3 Remote Control or telecomputing ______________________________________________________ Error! Bookmark not defined. 12. ELECTRIC DRAWING _________________________________________________________________________________________ 36 12.1 Electric drawing ADI CD 70 – 850 (single-phase motor) ___________________________________________________________ 37 12.2 Electric drawing ADI CD 950 (three-phase motor) ________________________________________________________________ 38 12.3 Cover of Siemens electronical board __________________________________________________________________________ 39 12.4 Cable entry points _________________________________________________________________________________________ 39...
- Page 3 21. APPENDIX I: LIST OF ERROR CODES _____________________________________________________________________________ 77 Please note that this manual is liable to changes and alterations or withdrawal without prior notice ELCO Heating Solutions Ltd reserve the right to make modifications without notice and any changes made are not necessarily retrospective to older models.
- Page 4 ADI CD boiler - Technical Manual 1. INTRODUCTION The global trend, European and international, aims at improving energy efficiency both in buildings and generators, in order to reduce pollutant emissions in the atmosphere (SAVE directive, treaty of KYOTO). Carbon dioxide (CO ) is one of the greenhouse gases that remain the longest in the atmosphere.
- Page 5 ADI CD boiler - Technical Manual 2. General Regulations / Application / Norms and Regulations General regulations This documentation contains important information, which is a base for safe and reliable installation, commissioning and operation of the Adinox Low Temperature Boiler. All activities described in this document may only be executed by authorized companies.
- Page 6 - Low noise level - Broad control range - Can be supplied in a wide range of models Through active and market oriented research, ELCO Heating Solutions Ltd is in a position to offer solutions for the most challenging heating requirements. The Supplier ELCO Heating Solutions Ltd are proud to supply and technically support the Adinox Low Temperature Boiler Range of boilers throughout the United Kingdom.
- Page 7 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 8 Gas shut-off valve Boiler control unit and power modulation Hot water flow Hot water return Flues outlet Gas connection Air filter Ignition transformer Gas pressure switch Pressure sensor Air vents (manual) Models ADI CD 70 to 175 (view from above): L348...
- Page 9 ADI CD boiler - Technical Manual Models ADI CD 200 and higher: L348...
- Page 10 ADI CD boiler - Technical Manual 5. DIMENSIONS ADI CD 120 - 175 ADI CD 70 - 105 ADI CD 200 - 450 F (7) 151.5 82.5 1110 151.5 82.5 1110 151.5 82.5 1110 134.3 112.5 1110 134.3 112.5 1110 177.5...
- Page 11 ADI CD boiler - Technical Manual ADI CD 550 - 950 F (7) 1628 1060 1396 1040 1628 1060 1396 1040 1628 1060 1396 1040 1658 1063 1393 1083 1040 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”).
- Page 12 The electric protection of each boiler must be prepared considering the maximum value between the electric consumption at the start-up and the electric consumption at the maximum power output. ADI CD 70 to ADI CD 375: modulating power from 30%. Note: data in the present document are liable to changes without prior warning.
- Page 13 ADI CD boiler - Technical Manual 6.2 Models ADI CD 450 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 173.8 195.2...
- Page 14 ADI CD boiler - Technical Manual 7. BOILER HEAT EXCHANGER The boiler heat exchanger (where takes place the heat transfer from flues to 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).
- Page 15 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 16 The power modulation is made by varying the fan speed, which also produces a variation of the air-gas mix flow entering into the burner (B). Minimum inlet pressure switch: adjusted at 15 mbar. In Models ADI CD 70 to 250, these pieces form one only global group: burner, burner-holder plate, motor-fan, venturi and gas shut-off valve.
- Page 17 ADI CD boiler - Technical Manual Exploded view of the burner – fan – gas valve assembly for models CD 325 and higher: Motor-fan rotating forward (ADI CD 325 to 750) or backward (ADI CD 850 and 950). L348...
- Page 18 Optional air filter for ADI CD 120 to 175: General view not assembled to boiler View assembled to the boiler (from above) View of the lower part of the filter once assembled to the boiler Optional air filter for ADI CD 70 to 105: L348...
- Page 19 ADI CD boiler - Technical Manual 9. BURNER The boiler includes an air-gas premix burner of innovative design and material: Fire resisting alloy mesh. Homogeneous and stable combustion in case of any change in the power demand. High mechanic resistance and high resistance to high temperatures.
- Page 20 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... Selection of DHW heating mode Selection of heating operation mode Display of information Confirmation of setting Chimney sweep function...
- Page 21 ADI CD boiler - Technical Manual Turn the setting knob to select parameters. For heating circuits, turn the setting knob to increase or decrease the Comfort setpoint Set the installation in manual operation. The different relays remain in a certain status (on/off) depending on a predefined setting.
- Page 22 ADI CD boiler - Technical Manual Selecting Heating Mode This setting is used to switch between the different operating modes. The selection mode is indicated by a bar which appears below the respective symbol. Automatic operation Heating mode according to the time program ...
- Page 23 ADI CD boiler - Technical Manual Displaying information Various data can be displayed by pressing the Info button. Possible displays Error messages Maintenance messages Operation messages Room temperature Boiler temperature Outside temperature DHW temperature State heating circuits State of DHW State of boiler State of solar Date and time of day...
- Page 24 ADI CD boiler - Technical Manual 10.2 Programming User levels The user levels only allow authorized user groups to make settings. To reach the required user level, proceed as follows: Operation Display example Description This is the basic display. If the basic display is not shown, press ESC to return to it.
- Page 25 ADI CD boiler - Technical Manual Overview of setting USER LEVELS SETTINGS Enduser Time of day and date Commissioning Operator section Heating engineer Wireless Time prog heating circuit 1 Time prog heating circuit 2 Time prog 3/heating circuit 3 Time program 4/DHW Time program 5 Holidays heating circuit 1 Holidays heating circuit 2...
- Page 26 ADI CD boiler - Technical Manual Press OK button and the value will blink. While the value is blinking, use the setting knob to set the correct date. Confirm with OK button. Move the setting knob and set the parameter 3 “Year”. Press OK button and the value will blink.
- Page 27 ADI CD boiler - Technical Manual 10.3 Available parameters at enduser level When you are in the main display, press to enter at “Enduser level”. Choose the required parameter by turning the setting knob and confirm with OK. Modify the parameters depending on the required adjustments.
- Page 28 ADI CD boiler - Technical Manual 10.4 Boiler lockout code Meaning In case of boiler lockout or an error in the installation, the symbol is shown. Press the button INFO and the error code with its meaning appears on the display. To detect the type of error, see the “list of Error Codes”...
- Page 29 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. MASTER BOILER CONTROL SLAVES BOILERS CONTROL CASCADE COMMUNICATION BUS...
- Page 30 (A) Cascade Module OCI345.06/101 (B) Cascade Cable LPB CASCADED SYSTEM CONNECTION MASTER SLAVE 1 SLAVE 2 Only the ELCO Service Technicians can modify the internal parameters in order to use this control on the boiler. Basic parameters: CASCADE Line nr. Function Value...
- Page 31 ADI CD boiler - Technical Manual Lead strategy (3510) The heat sources are switched on and off according to the selected lead strategy while giving consideration to the preset output band. In the strategy “Early on, late off”, additional boilers are switched on as early as possible (output band min) and switched off again as late as possible (output band min).
- Page 32 ADI CD boiler - Technical Manual Switch on delay (3533) Correct adjustment of the switch-on delay ensures that plant operating conditions will be stable. This prevents too frequent switching actions of the boilers (cycling). Auto source sequence changeover (3540) With automatic changeover of the heat source sequence, the boiler loads in a cascaded system can be influenced by defining the order of lead and lag boiler.
- Page 33 ADI CD boiler - Technical Manual b) Example of boilers sequence and power control Example of a possible sequence that can be made (multiple options can be chosen). L e i s t B a n d M a x = 8 0 % L e i s t B a n d M i n = 4 0 % 4 0 0...
- Page 34 ADI CD boiler - Technical Manual 11.2 External control signal 0…10 V to regulate start-up and power modulation of each boiler (A) 0…10 V connection So that each boiler can receive and process an external signal 0…10 V. The 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 in the electric cabinet of the boiler.
- Page 35 ADI CD boiler - Technical Manual These are the setpoints that we get from 0...10 V demand: Voltage (V) Setpoint (ºC) If it is necessary to get different values of temperature, change the following values to get a new linear characteristic: m = (F2-F1) / (U2-U1) F2 = Final Temperature (ºC) F1 = Initial Temperature (ºC)
- Page 36 ADI CD 70 to ADI CD 850: 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 37 ADI CD boiler - Technical Manual 12.1 Electric drawing ADI CD 70 – 850 (single-phase motor) L348...
- Page 38 ADI CD boiler - Technical Manual 12.2 Electric drawing ADI CD 950 (three-phase motor) L348...
- Page 39 ADI CD boiler - Technical Manual 12.3 Cover of Siemens electronical board For the low power / small dimension size of ADI boilers, see attached pictures: 12.4 Cable entry points At the rear part of the boiler. ADI medium/high power: ADI low power: L348...
- Page 40 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 41 ADI CD boiler - Technical Manual Electric drawing: 1 Boiler with 3 heating circuits L348...
- Page 42 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 43 ADI CD boiler - Technical Manual Setpoints The room temperature can be shifted according to different setpoints. These setpoints become active depending on the selected operating mode, thus producing different temperature levels in the rooms. The ranges of adjustable setpoints result from interdependencies, as this is shown in the following diagram: BZ 710 BZ 716 BZ 1010...
- Page 44 ADI CD boiler - Technical Manual Summer/winter heating limit The summer/winter heating limit (730,1030,1330) 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.
- Page 45 ADI CD boiler - Technical Manual Flow temperature setpoint limits Using this limitation, a temperature range for the flow temperature setpoint can be defined. If the flow temperature setpoint called for by the heating circuit reaches the relevant limit and the request for heat increases or decreases, the flow temperature setpoint is maintained at the maximum (741,1041,1341) or minimum (740,1041,1341) limit.
- Page 46 ADI CD boiler - Technical Manual Room influence When a room sensor is used, there is a choice of 3 different types of compensation and it is necessary to adjust this parameter (750, 1050, 1350): Setting Type of compensation % Weather compensation alone 1…99% Weather compensation with room influence...
- Page 47 ADI CD boiler - Technical Manual Quick setback During quick setback (780,1080,1380), the heating circuit pump is deactivated and, in the case of mixing valve circuits, the mixing valve is fully closed. When using the room sensor, the function keeps the heating switched off until the room temperature drops to the level of the Reduced setpoint or the Frost protection level.
- Page 48 ADI CD boiler - Technical Manual Xoff 1/4 °C Meaning Room temperature setpoint Actual value of room temperature Xoff Forward shift of switch-off time Forward shift of switch-on time Time program 14. DOMESTIC HOT WATER 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 49 ADI CD boiler - Technical Manual b) Electric drawing: 1 Boiler and Domestic Hot Water SIEMENS AVS37.294 14.1 Basic parameters Activation of Domestic Hot Water Domestic Hot Water is deactivated in default parametrization. Connect the DHW tank temperature sensor in B3 terminal of the boiler and push the operation mode button until a bar appears below the symbol Adjust the following parameter to enable the relay output for the charging pump Q3.
- Page 50 ADI CD boiler - Technical Manual 14.2 Professional installator parameters Release When DHW heating is On, the release parameter (1620) can be used to determine when – within a 24-hour period – DHW charging shall take place. When “24h/day” is used (the default value), DHW heating is continuously released as long as it is On.
- Page 51 ADI CD boiler - Technical Manual None DHW heating and space heating take place at the same time. In the case of tightly sized boilers and mixing heating circuits, the DHW setpoint may not be reached if space heating calls for considerable amounts of heat. MC shifting, PC absolute The pump heating circuits stay locked until the DHW storage tank is heated up.
- Page 52 ADI CD boiler - Technical Manual 15. SAFETY DEVICES 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 LMS controller Manual reset passage obstruction (low fan speed) Overheating...
- Page 53 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 54 A gas pressure governor must be installed to reduce pressure to a value in accordance with the table of paragraph “Technical data”. To select the type and its Units speed of opening/closing, consult the ELCO Heating Boiler Inertial model volume (m3) Solutions Product Support.
- Page 55 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 56 , for Natural Gas: it is recommended to adjust CO at 8.1%, for all the boilers Models Range CO2 (%) for Natural Gas (min. and max.) ADI CD 70 to 105 7.3 - 9.3 ADI CD 120 to 175 7.2 - 8.7 ADI CD 200 to 250 7.2 - 8.4...
- Page 57 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 58 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, by means of a flues damper sticker with graduated scale, according to the values indicated at the beginning of this chapter, for a correct and quick adjustment of the boiler combustion.
- Page 59 Cut-off/closing valves in the flow and return pipes of each boiler. Do not weld the boiler to the installation piping. Models ADI CD 70 to ADI CD 175: male threaded flow-return connections of 2”. Higher models: ADI CD 200 to ADI CD 450: 2 ½ “, flanged connections, PN 6.
- Page 60 If you have to stop the boiler pump, it is required that you stop it with a time delay of 3 to 5 minutes once the boiler has stopped. This can be obtained by installing a timer-disconnect electrical relay. Pressure drop for ADI CD 70 - 450 ADI CD...
- Page 61 OPTION 2 (see text) Nr. of Boilers 1 boiler 2 boilers 3-4 boilers 1 boiler 2 boilers 3-4 boilers ADI CD 70 - 105 20 lit. 30 lit. 40 lit. 40 lit. 60 lit. 75 lit. ADI CD 120 30 lit.
- Page 62 ADI CD boiler - Technical Manual 17.7.5 Water quality of the installation It is important to follow the instructions indicated in the present manual. The primary circuit of an installation, being a closed circuit, can not be refilled with non-treated water. Periodical refillings with non-treated water could cause a constant input of: Oxygen and dissolved gases (contributing to produce oxidation and corrosion to the installation).
- Page 63 ADI CD boiler - Technical Manual 17.7.6 System drawings Boiler Controller Water collector or water manifold 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 64 ADI CD boiler - Technical Manual System drawing of heating circuits System drawing of one boiler and only D.H.W. L348...
- Page 65 ADI CD boiler - Technical Manual System drawing: D.H.W. and heating circuit System drawing of an old installation: heating circuit L348...
- Page 66 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.
- Page 67 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 68 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. Short description of the boiler operating cycle: LEGEND of the operating phases: Display...
- Page 69 , CO, flues temperature, air temperature, efficiency, water temperatures. Models Range CO2 (%) for Natural Gas (min. and max.) ADI CD 70 to 105 7.3 - 9.3 ADI CD 120 to 175 7.2 - 8.7 ADI CD 200 to 250 7.2 - 8.4...
- Page 70 With the lower control of the gas valve you can move the straight line vertically (movement B in the chart). 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.
- Page 71 ADI CD boiler - Technical Manual 18.4.2 Change of fuel: from Propane gas to Natural gas In order to change fuel, it is sufficient to adjust the boiler combustion with the new fuel to the correct parameters, either for Natural Gas or for Propane Gas. The process is the same if you have to change from natural gas to propane.
- Page 72 ADI CD boiler - Technical Manual Front view of the boiler inside (ADI CD 200 and greater 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 ADI CD 200 and higher). (c) Motor fan: electric supply connection (in the higher part of the motor).
- Page 73 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). L348...
- Page 74 ADI CD boiler - Technical Manual 19.3 Combustion data Combustion data: Air excess CO not diluted Flues temperature Room temperature Efficiency Chimney natural draught Water temperatures (flow, return) Ionization Gas consumption: Gas type Flow Gas pressure (inlet, injectors) Combustion chamber pressure Air/gas mix pressure Burner pressure Ignition (air, gas)
- Page 75 ADI CD boiler - Technical Manual 20. BOILER GUARANTEE 1. ELCO Heating Solutions Ltd guarantees the ADI CD boilers of its own manufacturing as follows: * 3 years for the boiler heat exchanger * 2 years for the rest of components 2.
- Page 76 F. Lack of water. It is obligatory to supply the installation with minimum water content, so that it can circulate through the boiler with constant water flow and without interruption. G. Gas connection: no correct pressure, no proper dimensions or inadequate type of gas. H.
- Page 77 21. APPENDIX I: LIST OF ERROR CODES 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 78 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 79 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...
- Page 80 ELCO Heating Solutions Ltd 3 Juniper West Fenton Way Southfields Business Park Basildon Essex SS15 6SJ T: 01268 546700 F: 01268 888270...
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