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BaltGaz NEVALUX-8230 User Manual

Wall-hung combi gas boiler with forced heat carrier circulation
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BaltGaz NEVALUX
WALL-HUNG
COMBI
GAS
BOILER
WITH
FORCED
HEAT
CARRIER
CIRCULATION
BaltGaz
NEVALUX-8230
TU 4931-011-26985921-2012
USER'S MANUAL
(TOGETHER WITH INSTALLATION, TECHNICAL
SERVICE AND REPAIR INSTRUCTIONS)
8224-00.000-01 RE

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Summary of Contents for BaltGaz NEVALUX-8230

  • Page 1 BaltGaz NEVALUX WALL-HUNG COMBI BOILER WITH FORCED HEAT CARRIER CIRCULATION BaltGaz NEVALUX-8230 TU 4931-011-26985921-2012 USER’S MANUAL (TOGETHER WITH INSTALLATION, TECHNICAL SERVICE AND REPAIR INSTRUCTIONS) 8224-00.000-01 RE...
  • Page 2 Dear Customer, Thank you for purchasing our appliance. You have purchased a heating double-circuit wall-hung gas boiler with forced heat carrier circulation «BaltGaz NEVALUX». When purchasing the boiler please check : Scope of delivery (see section 23, page 50) and the boiler’s resalable condition ;...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY MEASURES...................................4 ............................... ………………5 Technical description Boiler’s purpose ................................. ………………5 2.1. 2.2. Technical characteristics.............................. ………………5 2.3. Overall and connection dimensions ..........................………………6 USER’S MANUAL ............................... ………………8 3.1 Control panel ..................................………………8 Boiler’s operating modes ..............................………………9 .................................
  • Page 4 User’s Manual External cleaning of heat exchanger 16.1.2............................38 Internal cleaning (washing) of heat exchanger 16.1.3........................38 Internal cleaning (washing) of secondary heat exchanger 16.1.4....................38 Boiler’s operation check 16.2..................................38 16.2.1. Check of gas system' s, heating systems' and DHW air-tightness of the boiler................39 Check of safety devices operation 16.2.2.

  • Page 5: Safety Measures

    Boiler’s purpose 2.1. Heating wall-hung double circuit boiler with forced heat carrier circulation «BaltGaz NEVALUX-8230» (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 300 m , and also for domestic hot water supply (hereinafter referred to as - DHW) for sanitary use.

  • Page 6: Technical Characteristics

    User’s Manual 2.2. Technical characteristics ___________________________________________________________________________________________________________ Table 1 NAME OF THE CHARACTERISTIC BaltGaz NEVALUX- 8230 Type of gas Natural G20 / Liquefied G30 2-е; Н / 3-е; B/P Family; group of gas Gas pressure in the duct 1,3 - 2,0/2,9...

  • Page 7: Overall And Connection Dimensions

    D – cold water inlet G1/2 E - CHinlet G3/4 (reverse); A - CH outlet G3/4; B – DHW circuit outlet G1/2; F – safety valve tap Ø16 / Ø18 mm C – gas inlet G3/4; Scheme 1. Overall and connection dimensions of the boilers «BaltGaz NEVALUX- 8230»...

  • Page 8: User's Manual

    3. USER’S MANUAL Technical staff 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.

  • Page 9: Standby Mode

    К5 Technical staff manual DHW mode Combined mode Heating mode Scheme. 4 sequence of the boiler’s operating modes change 3.2.1. Standby mode 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) temperature 3.3.3. Technical staff manual sensor For an optimal heat carrier temperature regulation in the CHdepending on external temperature it is recommended to use an external (outdoor) temperature sensor. The correction of heat carrier temperature in the CHis effectuated in accordance with the external temperature and regulation coefficient Kd (see Scheme 5).

  • Page 11: Storage Precautions

    The air inlet system and combustion products outlet must be checked for air-tightness; Technical staff manual Water flow in DHW supply system must be enough for switching the DHW mode on; Checking of the heating system in order to detect contamination. ATTENTION! Technical service operations connected with disassembling of its gas or hydraulic pipelines must be effectuated only after switching off the boiler completely (the taps on heat carrier , water and gas pipelines by the inlet into the boiler must be closed, the boiler must be disconnected from the power line).

  • Page 12: New Heating System

    -it is necessary to use radiators and circulation pumps of increased power, as the boiler’s heating effect reduces Technical staff manual at using Propylenglycolum (for approximately 10%); -in the heating system there must be provided a possibility of Propylenglycolum infeed in case of it leakage. It is necessary to use Propylenglycolum not longer than its shelf life, in accordance with the manufacturers recommendations.

  • Page 13: Connecting The Boiler To The Power Line

    In order to purchase the necessary parts and details of the smoke exhauster you should contact the trading organization, effectuating realization of accessories for the boilers “BaltGaz NEVALUX” in your region. Attention! It is prohibited to use ventilation channels for combustion products removal.

  • Page 14: 1Installation Of Separate Pipes Of Smoke Exhauster And Air Circuit By Means Of Transitional Set Khg 714061510

    The transitional set’ s and the channel separator’s construction provides regulation of amount of combustion inlet air with a butterfly damper. The amount of inlet air Technical staff manual depends on pipe length and is defined with the help of gas sensor. It is necessary to turn the butterfly damper clockwise, reducing the amount of inlet combustion air, until the gas sensor detects the increase of CO level (more than 0,05%) in smoke gases.
  • Page 15 Fix the channel separator by four screws 3 (previously install the plain washer 4, and then the ring 5 on each screw); Technical staff manual Make sure that there are seal rings 7 (2 pcs.) placed on the inlet and outlet of the channel separator before further installation of the smoke exhauster and air circuit pipes The installation of the air inlet pipe and the smoke exhauster pipe must be effectuated in accordance with Scheme 7 (see p.9.2, page 18).
  • 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 9833-73; - 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 bonding...

  • Page 19: Check Of Combustion Parameters

    Technical staff manual ATTENTION! Prevent the heat carrier and water from getting onto the boilers electronic components! ATTENTION! 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 ATTENTION! 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

    ATTENTION! For rendering the boiler to another type of gas it is necessary to use only the branded set of details. In order to purchase the necessary details please contact the trading organization, effectuating realization of the accessories for the boilers «BaltGaz NEVALUX» in your region.

  • Page 23: Flow Charts And Boiler Operation Control

    5-ignition plug; 26-air-tight chamber 6-ionization plug; 117-DHWcircuit temperature sensor; 27-air pressure switch; 7-pump; 18-3 way valve; 28-fan; 8-air outlet valve (automatic); 19-3 way valve electrical motor; 9-gas supply regulator; 20-bypass valve; Scheme 14. Flow chart of the boiler «BaltGaz NEVALUX-8230»...

  • Page 24: Main Components

    13.2 Main components 13.2.1. Control system Device Purpose Boiler operation control and providing safety in case of emergency Electronic board 11 (see p. 13.1, page 27) 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 66) For the heat carrier Minimal heat carrier pressure control and control of absence of air in the Pressure sensor 14 heating system Technical staff manual...

  • Page 26: Gas Analysis Function

    9.1.1. Gas analysis function The gas analysis function permits to control and analyze the combustion process and set up the gas supply Руководство для технического персонала regulator (see p. 11.2 and p. 11.3, page 25). This function works in the heating mode or combined mode. I order to activate gas analysis function, it is necessary to hold the button Кб...

  • Page 27: Boiler's Operation In Dhw Mode

    5) 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.

  • Page 28: 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. , page.
  • Page 29 Code Failure Reason of failure Troubleshooting The smoke exhauster or the air inlet duct is Figure out the reason of contamination contaminated and remove it . The air pressure switch’s tubes’ air-tightness Replace the tubes is damaged Electric circuit of air pressure switch is damaged Check the electric circuit and contacts The air pressure switch is damaged ( the Replace air pressure switch...

  • Page 30: 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 it for 2 days Heat carrier or water entry on the electronic Boiler doesn’t switch on...

  • Page 31: 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 , page 25). Gas supply regulator should be obligatory adjusted (see section After completion of installation and adjustment works, user should be instructed about boiler’s handling: ...

  • Page 32: Internal Cleaning (Washing) Of Secondary Heat Exchanger

    prepare 10% solution of citric acid (100 g of powdered citric acid for 1 liter of warm water); Fill this solution into heat exchanger’s pipeline; Keep this solution there for 10-15 minutes, then drain it and wash heat exchanger’s pipeline (coil) thoroughly with water and if necessary to repeat all the procedure;...

  • Page 33: Check Of Combustion Products Removal Control Devices

    Flame detection is based on the principle of monitoring ionization current. Ionization current is measured by micro ammeter, consequently connecting it to the circuit of the ionization plug. Optimal value of the ionization current is 3…5 μА. Reasons of reduced ionization current can be the following: «current leakage», bad connection with the “ground” or wrong plugs connection ( it is necessary to replace cables of ionization and ignition plugs with each other).

  • Page 34: Primary Heat Exchanger Dismantling

    Scheme 16. Dismantling of the casing and the front panel 5) Throw the front panel with a cap down; 6) Put the casing off pulling it upwards and towards yourself; 7) Unscrew 4 self-threading screws of the sealing cap’s fastening. Put the cap off pulling it hard towards yourself.
  • Page 35 Assembly is performed in reverse order. Scheme 23. Heat exchanger dismantling...

  • Page 36: Pump Dismantling

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

  • Page 37: Secondary Heat Exchanger Dismantling

    Technical staff manual 5) dismount the bracket 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 38: Bypass Valve Dismantling

    Technical staff manual 17.5 3 way valve dismantling In order to dismantle the 3 way valve, it is necessary to: 1) Dismantle the secondary heat exchanger (see p. 5), page 44); 2) Take out the bracket 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 39: Utilization

    Technical staff manual 17.3 Expansion tank dismantling In order to dismount the expansion tank, it is necessary to: 1) Switch the boiler off (see p. 10.4, стр.24); 2) 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 40: Supply Package

    User’s and technical staff manual SUPPLY PACKAGE The supply package for the boiler «BaltGaz NEVALUX-8230» is represented in the table 6: Table 6 1. Wall-hung gas boiler 1 pcs. «BaltGaz NEVALUX-8230» 2. User’s manual 8224-00.000-01RE 1 ex. 3. Boiler’s fastening carrier 8223-20.011 1 pcs.
  • Page 42 User’s and technical staff manual Pos. Name Designation Note Consists of: 1) Back wall 8230−01.051 2) Gas removal device 8223−01.200 3) Damper 8223−01.002 4) Plank 8230−01.005 5) Carrier 3264−02.02 6) Carrier 8223−00.015 Back wall in assembly 8223-01.110 Channel bar 8223-01.110-01 Channel bar 8023-01.002 Carrier...
  • Page 43 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 44 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 Ring OR 17,12×2,62 00046240230350 21000607000600 Fixture 18 Bracket 8 21000607000300 8230-22.060 Ignition and ionization plugs in assembly Hydraulic group components pos.
  • Page 45 User’s and technical staff manual Pos. Name Designation Note 30029605500120 Valves’ body frame 500.324 Pump 21000606507000 OTSL 15/6−3 CLR3 21000605000500 DHW flow restrictor 12 l/min Bottom panel 400.535 21000608003800 21000606900100 3 way valve’s electric motor Electric motor’s bracket 21000607000100 Bypass pipe 21000606608700 014 mm 014 mm...
  • Page 46 Ignition and ionization plugs in the assembly pos.67 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...
  • Page 47 Ignition and ionization plugs in the assembly pos.67...
  • Page 48 Pos. Name Designation Note ELB21003 Ignition plug ELB21003 Ionization plug Plate 8223-22.061 Electric wiring components Name Designation Note Boiler’s electric power supply, 220 V, Power cable CBAB0W008 ~ 50 Hz CBAB0W007 Connecting the fan, gas supply regulator, ignition transformer, Main cable Pump cable CBAB0W005 Pump connection...
  • Page 49 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 50 (for instance; by the car pressure gauge) and then release or add (for instance; by the car pump) the air up to the set pressure value. Simultaneously you should consider that for the boilers “BaltGaz NEVALUX” the initial pressure in the expansion tank should be at least 0,1 MPа...
  • Page 51 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 litres. 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 52 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 53 User’s and technical staff manual Electric wiring of the boiler «BaltGaz NEVALUX-8230» 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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