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BaltGaz NEVALUX-8224 User Manual

Wall-hung combi gas boiler with forced heat carrier circulation
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WALL-HUNG COMBI GAS
HEAT
CARRIER
(TOGETHER WITH INSTALLATION, TECHNICAL SERVICE AND
Thank you for purchasing our appliance. You have purchased a heating combi wall-hung gas boiler with
forced heat carrier circulation «BaltGaz NEVALUX».
BaltGaz NEVALUX-8224
TU 4931-011-26985921-2012
USER'S MANUAL
REPAIR INSTRUCTIONS)
8224-00.000-01 RE
Dear Customer,
BOILER WITH FORCED
CIRCULATION

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Summary of Contents for BaltGaz BaltGaz NEVALUX-8224

  • Page 1 WALL-HUNG COMBI GAS BOILER WITH FORCED HEAT CARRIER CIRCULATION BaltGaz NEVALUX-8224 TU 4931-011-26985921-2012 USER’S MANUAL (TOGETHER WITH INSTALLATION, TECHNICAL SERVICE AND REPAIR INSTRUCTIONS) 8224-00.000-01 RE Dear Customer, Thank you for purchasing our appliance. You have purchased a heating combi wall-hung gas boiler with...
  • Page 2 When purchasing the boiler please check: Scope of delivery (see section 23, page 50) and the boiler’s resalable condition; - correspondence of the type of gas (natural or liquefied) used by you with the type of gas indicated in sections 20 and 21 (page 48) of this Manual and with the table on the boiler’s casing. You should also require from the selling organization to fill in the warranty repair coupons.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY MEASURES...............................4 ………………5 Technical description ………………………………………………………………………………………………... Boiler’s purpose ………………5 ……………………………………………………………………………………………………… 2.1. ………………5 Technical characteristics ………………………………………………………………………………………..2.2. ………….……6 Overall and connection dimensions ………………………………………………………………………… 2.3. USER’S MANUAL …………….…8 ………………………………………………………………………………………….. 3.1 Control panel .......................... ………….…8 3.2 Boiler’s operating modes ....................... ………….…9 3.2.1 Standby mode ........................
  • Page 4 User’s Manual Other failures ............................36 14.2. HANDING THE BOILER OVER TO THE CUSTOMER ............. 37 TECHNICAL SERVICE AND OPERATION CHECK ..............37 Technical service ..........................37 16.1. Cleaning the combuction unit ......................37 16.1.1. External cleaning of heat exchanger....................38 16.1.2.

  • Page 5: Measures

    In case if there is no breath you must immediately bring the injured person to a warm premise with fresh air and make resuscitation before the doctor arrives. TECHNICAL DESCRIPTION Boiler’s purpose 2.1. Heating wall-hung combi boiler with forced heat carrier circulation «BaltGaz NEVALUX-8224»...

  • Page 6: Technical Characteristics

    User’s Manual (hereinafter referred to as “boiler”) s produced in accordance with TU 4931-011-26985921-2012 (GOST R 51733-2001, GOST 20548-93) standards. The boiler is designed for heating dwelling and non-dangerous industrial premises with an area up to 240 m, and also for domestic hot water supply (hereinafter referred to as - DHW) for sanitary use.

  • Page 7: Overall And Connection Dimensions

    User’s Manual 2.3. Overall and connection dimensions D – cold water inlet G1/2 E - CH inlet G3/4 A - CH outlet G3/4; B – DHWoutlet G1/2; (reverse); C – gas inlet G3/4; F – safety valve tap Ø16 / Ø18 mm Scheme 1.

  • Page 8: User's Manual

    Technical staff manual USER’S MANUAL 3.1. Control Panel The main control element of the boiler is the electronic board which controls all boiler’s operation. The electronic board’s microprocessor collects and processes signals from the control and safety sensors. All information about the boiler’s condition is displayed on the LCD display in real-time operation mode. All control over the boiler is effectuated from the control panel, the appearance of which is shown on Scheme 3.

  • Page 9: Standby Mode

    К5 Technical staff manual DHW mode Combined mode Heating mode Scheme. 4 sequence of the boiler’s operating modes change Standby mode 3.2.1. In the standby mode, when the boiler is waiting for the user’s commands, the symbol is shown on display.

  • Page 10: Boiler's Operation In Heating Mode With An External (Outdoor) Temperature Sensor

    Boiler’s operation in heating mode with an external (outdoor) 3.3.3. Technical staff manual temperature sensor For an optimal heat carrier temperature regulation in the CH depending on external temperature it is recommended to use an external (outdoor) temperature sensor. The correction of heat carrier temperature in the CH is effectuated in accordance with the external temperature and regulation coefficient Kd (see Scheme 5).

  • Page 11: Storage Precautions

    Checking the boiler’s gas, heating and hot water supply systems’ air tightness; Technical staff manual Lubrication of moving connections (if necessary), it is recommended to use thick lubricant greases on silicone base; Checking of safety devices, they must work without failures; Checking of air pressure in the expansion tank (once in 3 years), the pressure must be 1,0 bar;...

  • Page 12: Propylenglycolum Usage Conditions

    into the boiler’s standard supply package and is purchased separately. Technical staff manual If the incoming water’s hardness exceeds 9 mg-eq/l, it is necessary to use more powerful water softening installations 7. 2. 2. Propylenglycolum usage conditions It is acceptable to use as a heat carrier in the heating system the low-freezing liquid only on Propylenglycolum base (hereinafter referred to as Propylenglycolum).

  • Page 13: Connecting The Boiler To The Liquefied Gas Cylinder

    (metallopolymeric pipes). It is acceptable to use multi-layered metallopolymeric pipes for inner gas pipelines Technical staff manual at natural gas provision to one-flat domestic buildings not higher than 3 floors in condition if they are confirmed as acceptable for construction use. It is acceptable to connect the boiler to the gas pipeline by a flexible tubing (hose), resistant to transported gas at set pressure and temperature.

  • Page 14: Installation Of Separate Pipes Of Smoke Exhauster And Air Circuit

    Technical staff manual - boiler; - coaxial branch pipe; - coaxial smoke exhauster pipe; - joint sleeve; - duct slice; - gasket; - fan plug; - thermo insulation Scheme 6. Installation of coaxial smoke exhauster When using coaxial pipes it is necessary to additionally take into account the following: - The slope of the horizontal part of the smoke exhauster pipe must be 3°...
  • Page 15 Technical staff manual Scheme 8. Duct slice dismantling 2) install the gasket 1 (supplied in the boiler’s supply package) (see Scheme 9); Scheme 9. Gasket installation Make sure that the seal ring 6 is placed (at the place of connection of the fan plug) before installing the separator onto the boiler (see Scheme 10); Install the channel separator 2 onto the boiler, controlling that the plug won’t “bite on”...
  • Page 16 Technical staff manual - boiler; - channel separator; - screw Ph - 4,8x60 DIN 7981; - plain washer 5,3x10 DIN 125; Scheme 10. Channel separator installation scheme - ring 005-008-19-2-2 GOST 9833- - seal ring; - seal ring...

  • Page 17: Putting The Boiler Into Operation (Initial Run)

    Technical staff manual 10.PUTTING THE BOILER INTO OPERATION (INITIAL RUN) If the boiler was at sub-zero temperature during its transportation and storage, it must be held at positive C) during 2…3 hours before the initial run. temperature (not less than 5 The requirements to the heat carrier of the heating system are represented in p.
  • Page 18 Technical staff manual Than screw the cover plug up tight. While effecting this operation heat carrier leakages from the pump are possible, after installing the cover plug the rests of heat carrier must be removed from the boilers components (you must wipe them); 10) also check the boiler connection to the AC outlet of the monophase network of alternate current with rated voltage of 220V, 50Hz frequency, with an earth...

  • Page 19: Check Of Combustion Parameters

    Technical staff manual CAUTION! Prevent the heat carrier and water from getting onto the boilers electronic components! CAUTION! If Propylenglycolum is used n the heating system as a heat carrier, it is necessary to effectuate special measures in order to fill the boiler and heating system, and also periodic control of Propylenglycolum’s density.

  • Page 20: Connection Of External Temperature Sensor

    Technical staff manual help of the remote control’s temperature sensor (the remote control can display the value of outdoor temperature), or depending on external temperature (see p. 3.3.3, page 10). Before connecting the remote control it is necessary to make sure that it is prepared for connection in accordance with the installation and connection manuals that are included in the remote control’s supply package.

  • Page 21: Boiler's Power Regulation

    Technical staff manual CAUTION! In case of long-term idleness of the boiler in winter time in case of using water as a heat carrier or in case of pipeline freezing danger appearance it is necessary to drain the heat carrier from the boiler and the heating system. 11.

  • Page 22: Regulating Minimal Pressure

    11.3. Regulating minimal pressure Disconnect the wire from the terminal Д, the boiler will pass to minimal power and the error «07» will be shown on display (see p. 14.1, page 34); Check gas pressure in the control point А. It must correspond: —...

  • Page 23: Flow Charts And Boiler Operation Control

    117-DHWcircuit temperature sensor; 6-ionization plug; 26-airtight chamber 18-3 way valve; 7-pump; 27-air pressure switch; 8-air outlet valve (automatic); 19-3 way valve electrical motor; 28-fan; 9-gas supply regulator; 20-bypass valve; 10-expansion tank ; Scheme 14. Flow chart of the boiler «BaltGaz NEVALUX-8224»...

  • Page 24: Main Components

    13.2 Main components 13.2.1. Control system Device Purpose Electronic board 11 (see p. 13.1, page Boiler operation control and providing safety in case of emergency situations appearance Electric wiring A set of wires for connecting the electronic board to the sensors, devices and mechanisms 13.2.2.

  • Page 25: Safety Devices

    13.2.6. Safety devices Device Purpose For control Protecting the electronic board and electric circuits from the power line surcharge and short circuit Safety catch 21 ( see Annex III, page For the heat carrier Minimal heat carrier pressure control and control of absence of air Pressure sensor 14 in the heating system Technical staff manual...

  • Page 26: Boiler's Operating Logic

    or К2; Press the button К5, in order to keep the set parameter value and return to choosing parameters; Руководство для технического персонала Repeat the cycle, beginning from point 6, in order to modify all parameters that you want to change; Press the button К6 (RESET) in order to exit the programming mode.

  • Page 27: Boiler's Operation In Heating Mode

    Boiler’s operation in heating mode: 13.4.1. The electronic board 11 (see p. 13.1 , page 27) checks the 3 way valve’s position; Руководство для технического персонала If the 3 way valve 18 is in the position , corresponding with the DHW mode, the electronic board supplies voltage to its electrical motor 19.

  • Page 28: Boiler's Operation In Dhw Mode

    The electronic board supplies voltage to the fan’s electrical motor 28. The fan starts operating (it can be heard). By means of air flow a pressure difference is created in the air pressure switch 27. A signal about draught presence comes to the electronic board 11. If there is no signal, the boiler’s launching stops; A pause for combustion chamber ventilation is held (it is necessary for gas removal in case of previous failed launching) The ignition transformer 12 transfers high voltage to the ignition plug 5 on the signal of the electronic...

  • Page 29: Search For Failures And Their Elimination

    14. SEARCH FOR FAILURES AND THEIR ELIMINATION 14.1 Error codes Contamination of the boiler’s operation, caused by the refuse or faulty operation of any of its systems, is accompanied by an appropriate error code displayed on the boiler’s control panel (see p. 3.1 , page. 8) which facilitates failure detection.
  • Page 30 Failure Reason of failure Troubleshooting The smoke exhauster or the air inlet duct is Figure out the reason of contaminated contamination and remove it . The air pressure switch’s tubes’ air Replace the tubes tightness is damaged Electric circuit of air pressure switch is damaged Check the electric circuit and contacts The air pressure switch is damaged ( the...

  • Page 31: Other Failures

    14.2 Other failures Failures that do not have an error code shown on the boiler’s display, are shown in Table 5: Table 5 Failure Reason of failure Troubleshooting Lack of electricity Address to the electricity service Fuse is burnt Replace the fuse on the board Dry the board by means of warm air or leave Heat carrier or water entry on the Boiler doesn’t switch on...

  • Page 32: Handing The Boiler Over To The Customer

    15. HANDING THE BOILER OVER TO THE CUSTOMER After mounting the boiler, a specialist of the service organization is obliged to check boiler’s operation at minimal and maximal power in all modes (see section 11, page 25). Gas supply regulator should be obligatory adjusted (see section 11).

  • Page 33: Internal Cleaning (Washing) Of Heat Exchanger

    Check the joints of gas, heat carrier and water subject to disassembling for air tightness (see p 16.2.1, page 39). 16.1.3. Internal cleaning (washing) of heat exchanger During the exploitation there is a chance of scale deposit appearance on the inner surfaces of the heat exchanger 2 (see p.

  • Page 34: Air Removal Valve Check

    16.2.2.5 Air removal valve checking If a cap of the air removal valve 8 (see p.13.1, page 27) is open, the heat carrier should not run out of it. Only air should be removed through the valve. 16.2.2.6 Checking of gas supply regulator operation Set the heat carrier temperature in the heating system 50 °С.

  • Page 35: Burner Block Dismantling

    16.2.5 Checking the heating system for stoppage When boiler is operating in the heating mode (see p. 3.2.4, page9) it is necessary to check whether the bypass pipe gets hot. If bypass pipe is hot constantly, it is necessary to clean the boiler’s inlet hydraulic filter in the heating line (if the filter is mounted), and also in other places of the heating system where contamination is possible.
  • Page 36 Switch the boiler off (see p. 10.4 page 24; Block the boiler’s inlet stop valves on the pipes of the heating system by the inlet into the boiler, drain the heat carrier out of the boiler (see p. 10.5, page24) (if there are no stop valves, drain the heat carrier out of the whole heating system);...

  • Page 37: Pump Dismantling

    Technical staff manual Scheme 21 . Pipe Scheme 22. Heat exchanger dismantling dismantling 17.3Pump dismantling To dismount a pump it is necessary: 1) switch the boiler off( see section 10.4, page 24); 2) block inlet and output stop valves of the boiler, drain the heat carrier out of the boiler (see section 10.5, page24) (if there are no stop valves, drain the heat carrier out of the whole heating system);...

  • Page 38: Secondary Heat Exchanger Dismantling

    Technical staff manual 5) dismount the clip 2 (see Scheme 25) of the pipe’s fastening 1 from the pump’s hose and pull the pipe out upwards ; 6) unscrew on the bottom panel three screws of the pump’s fastening; 7) disconnect cables from the pressure sensor 4; 8) Disconnect the terminal 3 with the pump’s power cables from the connector;...

  • Page 39: Bypass Valve Dismantling

    Technical staff manual 17.5 3 way valve dismantling In order to dismantle the 3 way valve, it is necessary to: Dismantle the secondary heat exchanger (see p. 5), page 44); Take out the clip 1 (see Scheme 27) of the electric motor’s fastening to the 3 way valve’s body frame and take off the electric motor 2;...

  • Page 40: Utilization

    Technical staff manual 17.3Expansion tank dismantling In order to dismount the expansion tank, it is necessary to: Switch the boiler off (see p. 10.4, стр.24); Close the stop valves on the boiler’s inlet and outlet, drain the heat carrier out of the boiler (see p. 10.5, page 24) (if there are no stop valves, drain the heat carrier from the whole heating system);...

  • Page 41: Supply Package

    Руководство для пользователя и технического персонала SUPPLY PACKAGE The supply package for the boiler «BaltGaz NEVALUX-8224» is represented in the table 6: Table 6 1. Wall-hung gas boiler 1 pcs. «NEVALUX-8224» 2. User’s manual 8224-00.000-01RE 1 ex. 3. Boiler’s fastening carrier 8223-20.011 1 pcs.
  • Page 42 Руководство для пользователя и технического персо, Составные части котла «NEVALUX-8624»...
  • Page 43 User’s and technical staff manual Pos. Name Designation Note Consists of: Back wall 8223-01.051 Gas removal device 8223-01.200 Damper 8223-01.002 8223-01.050 Plank 8230-01.005 Plank 8223-01.008 Carrier 8223-01.001 Carrier 8223-00.015 Back wall in assembly 8223-01.110 Channel bar 8223-01.110-01 Channel bar 8023-01.002 Carrier 8223-08.000 10037608005030...
  • Page 44 User’s and technical staff manual Pos. Name Designation Note 8223-15.001 Color-white Panel 8223-15.001-02 Color-light grey 8324-15.100 8223-15.200 Magnet in assembly 8223-15.002 Housing button 8223-15.003 Axis 8223-15.004 Cuff 8023-06.002 8023-00.007 8223-00.006 Loop ССiС-1 0 18 mm Temperature sensor JXW-54 (18) Temperature sensor JXW-54 (14) 0 14 mm 8023-01.004...
  • Page 45 User’s and technical staff manual Pos. Name Designation Note 8223-01.004 Gasket 8223-01.007 Gasket Gasket 8023-00.003 G3/4 8023-00.004 G3/8 Gasket 21000606702200 Ring OR 7,59^2,62 Ring OR 17,86^2,62 21000606701200 21000607000600 Fixture 18 Bracket 8 21000607000300 8223-22.060 Ignition and ionization plugs in assembly Hydraulic group components pos.
  • Page 46 User’s and technical staff manual Pos. Name Designation Note Valves’ body frame 30029605500120 500.324 Pump 21000606506010 OTSL 15/5-3 CLR3 DHW flow restrictor 21000607300400 10 l/min Bottom panel 400.535 21000608003800 3 way valve’s electric 21000606900100 motor Electric motor’s bracket 21000607000100 Bypass pipe 21000606608700 014 mm 014 mm...
  • Page 47 Pos. Name Designation Note 10028605603400 Body frame 400.701 Ring OR 2,9x 1,78 21000606700300 Ring OR 13,10x2,62 21000606700400 Valve 400.13 21000606100100 Spring 400.42 21000606800200 00046240230360 Ring OR 21,89x2,62 21000606200300 Sealing hub 400.325 21000607400100 3 way valve stem 21000605900200 retainer washer 400.14 Ring OR 2,84x2,62 00046240230310 21000606300100...
  • Page 48 Components of the burner block pos. 7 Pos. Name Designation Note 3295.07.40.000 Burner section Nozzles 0 1,31 mm (natural gas family, group Н), 1,3 3264-02.130-10 (G20, 2 kPa) Nozzles 0 1,31 mm ( natural gas family, group Н), 1,3 3295.07.20.000-10 (G20, 2 кПа) Manifold in assembly...
  • Page 49 Pos. Name Designation Note ELB21002 Ignition plug ELB21001 Ionization plug Plate 8223-22.061 Electric wiring components Name Designation Note Boiler’s electric power supply, 220 Power cable CBAB0W008 V, ~ 50 Hz CBAB0W007 Connecting the fan, gas supply regulator, ignition transformer, Main cable Pump cable CBAB0W005 Pump connection...
  • Page 50 Annex II Guidance to select an expansion membrane tank Selecting an expansion membrane tank in case of using water as a heat carrier In case of connecting the boiler to the heating system with a volume of more than 70 liters, it is necessary to install an additional expansion membrane tank, connecting it to the return heating line really close to the boiler.
  • Page 51 User’s and technical staff manual Membrane expansion tanks have nipple apertures which serve for regulating and monitoring of pressure’s values in the gas part of the vessel. After you define the initial pressure, it is necessary to measure the pressure in the gas part of the tank (for instance;...
  • Page 52 In case is volume of the tank is between tyschemeal values, when choosing, follow by the rule “first is larger". In the boiler there is an expansion tank installed with a volume 6 liters. If after calculating it will turn out that for this heating system it is necessary to have an extension tank of bigger volume, it is necessary to install an additional expansion tank, where its value will be equal to the difference between calculated value and volume of the boiler’s extension tank (6 l).
  • Page 53 Electric circuit diagram of the boiler «NEVALUX-8224» - ignition plug; - ignition transformer; - gas supply regulator; - fan; - 3 way valve’s electric motor; - pump; - air pressure switch; - thermo relay 90 °С; - gas supply regulator’s modulator coil;...
  • Page 54 User’s and technical staff manual Electric wiring of the boiler «BaltGaz NEVALUX-8224» Connector Contacts Cable Parameters Cable colors brown М1 Power supply Power cable 220 V, ~ 50 Hz blue orange М4 Main cable 220 V, ~ 50 Hz orange blue М3...

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