Energy-saving technology Wall-mounted fan-assisted boilers OIL-FIRED INSAN 25 CR, S AND S/A MODELS USERS' INSRUCIONS LB762o - 08/07/1999
Energy-saving technology CONENS: - echnical data.......................................................................................... pag. 3 - General points.......................................................................................... pag 3 - Hydraulic diagrams.................................................................................... pag. 4 - Notes on boiler installation.......................................................................... pag. 6 - Overall dimensions................................................................................... pag. 6 - Connection set......................................................................................... pag. 6 - Connection to system and main................................................................... pag. 6 - Installing the boiler.................................................................................... pag. 7 - Electrical connection.................................................................................. pag. 7 - Available head with standard pump............................................................... pag. 7 - Checking rotation of the circulation pump....................................................... pag. 8 - Control panel........................................................................................... pag. 9 - Operation of the boiler................................................................................ pag. 9 - Fuel supply.............................................................................................. pag. 11 - Conversion of the pumps for single pipe systems............................................. pag. 11 - Boiler supplied by lift pump......................................................................... pag. 12 - Room ventilation...................................................................................... pag. 13 - Snorkel connection for combustion air............................................................ pag. 13 - Connection of flue duct............................................................................... pag. 13 - Regulating combustion............................................................................... pag. 13 - Standard jets fitted to installed burners......................................................... pag. 13 - Operating cycle of the installed burner........................................................... pag. 14 - INSAN 25 electrical diagram and installed burners....................................... pag. 15 - Access to the boiler.................................................................................. pag. 21 - Dismantling the burner.............................................................................. pag. 21 - Replacing the jet and position of the electrodes.............................................. pag. 22 - Maintaining and cleaning the boiler............................................................... pag. 22 - Exploded drawing of the heating control panel................................................ pag. 23 - Exploded drawing of the INSAN 25 heater................................................... pag. 24 - Exploded drawing of the boiler jacket............................................................ pag. 28 - Explosion of the burner.............................................................................. pag. 29
Energy-saving technology INSAN 1F GASOLIO 25 Oil-fired instant 25 CR + S + S/ACE type approval number Rated heat output min/max kcal/h 15.000 21.500 min/max kw 17,4 25 Rated heat output min/max kcal/h 17.200 23.740 min/max kw 20 27,6 Max operating temperature C 90 Max circuit pressure bar 4 Max hot water pressure (*) bar 6 Boiler capacity l 30 Quantity of hot water produced ( t= 35 C) l/min 10,2 at maximum input ( t= 25 C) l/min 14,3 Expansion tank l 10 Expansion tank precharge pressure bar 1 Electrical power supply ~V/Hz 230 / 50 Max rated power W 240 Gross weight kg 112 Diameter of air/flue ducts mm 80 100 (*) = refers to model CR CR = heating and instantaneous production of domestic hot water S = heating only S/A = heating and connection to external hot water storage cylinder GENERAL OINS he high-efficiency INSAN CR boiler is designed to meet all heating and domestic hot water heating needs. he unit is of unparalleled reliability and ensures safe operation, thanks to the extremely robust construction and use of fan-assisted burner technology.articular attention has been paid to safety and quiet operation since this unit is designed mainly for domestic use.he creation of an adequate draft through the combustion chamber and flue circuit by the burner fan prior to ignition, as well as the room-sealed construction of the combustion chamber, guarantees the maximum possible level of safety.domestic hot water is produced using a highly efficient braze-welded plate exchanger made from self-cleaning stainless steel: the self-cleaning action is obtained by virtue of the special shape of the plates. he INSAN S model (S = no domestic hot water) is designed for domestic heating only, while the S/A model provides central heating and also has an outlet for connection to a hot water storage cylinder. INSAN units can be connected to a room thermostat enabling automatic temperature control. Warning: his boiler is designed to raise water to a temperature below boiling point at atmospheric pressure; it must be connected to a heating system and/or domestic hot water production and distribution unit, within the limits of its output and performance specifications. Every other use of this equipment should be regarded as improper and therefore dangerous. he boiler must be installed by qualified professional fitters, in accordance with current standards and regulations on safety. Faulty installation can cause damage to persons and property for which the manufacturer cannot be held responsible. pag. 3
OIL-FIRED INSAN 1F 25 Energy-saving technology HYDRAULIC DIAGRAMS INSAN 25 CR 7 8 2 2A 2B 6 1 5 11 9 4 14,, 3 10 12 1 - boiler unit2 2 - burner 2a - fuel solenoid-valve 2b - fuel pump 3 - fuel filter 4 - expansion tank 5 - circulation pump 6 - boiler drain valve 7 - automatic air vent valve 8 - sensor housing 9 - hot water exchanger 10 - three-way flow assembly 11 - enable microswitch 12 - return assembly 13 - filler valve 14 - system safety valve 13 heating system flow hot water outlet cold water inlet heating system return fuel inlet fuel return INSAN 25 S 7 8 6 1 9 10 5 2 4 2A 2B 1 - boiler unit 2 - burner 2a - fuel solenoid-valve 2b - fuel pump 3 - fuel filter 4 - expansion tank 5 - circulation pump 6 - boiler drain valve,, 3 7 - automatic air vent valve 8 - sensor housing 9 - safety valve 10 - filler valve heating system flow system return water supply fuel inlet fuel return pag. 4
Energy-saving technology OIL-FIRED INSAN 1F INSAN 25 S/A 8 7 1 - boiler unit 2 - burner 2a - fuel solenoid-valve 2b - fuel pump 3 - fuel filter 4 - expansion tank 5 - circulation pump 6 - boiler drain valve 7 - sensor housing 8 - automatic air vent valve 9 - safety valve 10 - hot water cylinder 11 - three-way solenoid valve 12 - boiler thermostat 13 - fuel shut-off valve 14 - fuel shut-off valve 15 - filler valve 6 1,, 3 9 5 15 2 2A 4 2B HO WAER OULE 10 12 Heating system flow B A 13 14 Fuel inlet Fuel return Boiler water inlet Heating system return M 11 COLD WAER INLE o be carried out by the installer pag. 5
OIL-FIRED INSAN 1F 25 Energy-saving technology NOES ON BOILER INSALLAION he boiler must be installed by professionally qualified fitters, observing UNI and CEI standards and following safety regulation procedures. Incorrect installation can cause damage to both persons and property, for which the manufacturer will not be held responsible. OVERALL DIMENSIONS Figure A details the dimensions of the boiler. Warning: a 400 mm. free space above the boiler should be allowed for maintenance. CONNECION SE (supplied with unit) A wall-mounted galvanised steel backplate-template is provided to facilitate water connections and boiler positioning. flue outlet air inlet 600 (boiler width) 70 460 70 465 ø 100 ø 80 346,5 210 600 130 123,5 22 895 895 (boiler height) 95 130 55 55 = = a b c d e f fig. A 2 266 65 47 47 65 70 40 a - Heating system flow G 3/4 b - Hot domestic water G 1/2 c - Fuel inlet ø 17 d - Fuel return ø 17 e - Cold domestic water G 1/2 f - Heating system return G 3/4 fig. B N.B. It is advisable to install a drain outlet (with special 1/2" funnel) for boiler safety valves. Connection kit for INSAN 25 CR Connection kit for INSAN 25 S and S/A a b c d e f a c d e f Fig. C connections referred to figure B. pag. 6
Energy-saving technology OIL-FIRED INSAN 1F INSALLING HE BOILER A A X X - position the bracket (supplied) in the selected location; - using a spirit level, check that the bracket is horizontal; - drill the backplate fixture holes at location A: use plugs of suitable size and strength when fixing the bracket to the wall; - position pipes and following the indications on the lower bracket; the template can be removed by breaking along the perforated line (axis x-x). Fig. 1 Fig. 2 lift from here After mounting the template to the wall (fig. 1), hook boiler unit to backplate as shown in figure 2. Before connecting up the boiler, clean carefully, removing any encrustations and eliminating any foreign bodies which might detract from the efficiency of the unit. he unit should be installed in an accessible position for ease of cleaning. Suitable stopcocks should be fitted on all inlet and outlet pipes. Once the boiler has been mounted on the wall, the water connections can be completed (fig. C page 6). Unit safety valves must be connected up to a suitable outlet. MANUAL FILLER he INSAN 25 boiler unit is equipped with a manual valve for filling the heating system. he INSAN 25 S and S/A boiler (no domestic hot water) is provided with an attachment (on the backplate) including a heating system filler valve for connection to the water supply,. he filling operation should be done slowly so that the air can escape through the series-mounted automatic air-vent valve, as well as through any other valves installed in the heating system. he filling pressure for the boiler when cold is indicated on the boiler pressure gauge on the boiler control panel and must be between 1 and 1.2 bar. his should be checked periodically. If the boiler pressure falls below the minimum value described above, the user must restore pressure by opening the valve. ELECRICAL CONNECION he boiler is connected up using the plug (ref. A) located at the bottom of the unit. IMORAN: he boiler unit must be connected to the electrical power supply following the existing legal safety standards. he supply cable must have a minimum section of 1mm2 for lengths of up to 2 metres, or 1.5mm2 for greater lengths. A Electrical connection must include a section switch with a gap between contacts of at least 3 mm. so as to guarantee unit isolation from the power supply. Lock out Return pag. 7 (room thermostat) 230V 50 Hz Output Negative Earth ositive S3 2 1 N L1 Boiler connection plug S3 2 1 N L1
OIL-FIRED INSAN 1F 25 Energy-saving technology AVAILABLE HEAD WIH SANDARD UM 6 5 Head (m c.a.) 4 3 V1 V2 V3 2 1 0 0,0 0,5 1,0 1,5 2,0 2,5 Flow rate (m 3 /h) CHECKING ROAION OF HE CIRCULAION UM IMORAN: Check before proceeding that neither the pump nor the water are boiling and take necessary precautions to prevent possibility of injury from scalding or damage in the event of leaks. he pump is interlocked to the minimum temperature thermostat and will be shut off temporarily whenever the boiler water temperature falls below a minimum. Bleeding the circulation pump: - loosen the plug A and bleed out any air; - expect water to drip from the cap opening after air bleeding and take precautions to prevent any ensuing damage to ot pump components; - retighten the plug A. Freeing a seized pump: - remove plug A - try to rotate the impeller using a screwdriver inserted into the slot on the shaft, taking care not to damage the slot; - replace plug A, checking that there is no leak. SARING U HE CIRCULAION UM Before turning the appliance and pump on, make certain that the system is filled with water and has been properly bled. Circulation pumps may be noisy when starting up for the first time; this can be caused by a small quantity of air trapped in the circuit. Follow bleeding procedure as above. N.B. After a long period of inactivity, for example the summer period, the pump may seize. o free it, follow the procedure described above. pag. 8
Energy-saving technology OIL-FIRED INSAN 1F 25 CONROL ANEL 10 9.A.S. MINIMA 8 1 INSAN 0 I 1 2 3 4 5 6 7 8 9 7 2 3 4 5 6 RESEING HE SAFEY HERMOSA 3 Unscrew and remove hood. LEGEND 1 emperature and pressure gauge 2 ush button for resetting the flame failure device. In the event of the burner being stopped by the flame detector safety device, the push button will light up; to restart the burner, depress the button. 3 Safety thermostat with manual reset; this cuts in to stop the burner when the water temperature in the boiler exceeds the set value. hermostat is reset manually by depressing the button located beneath the protective cover. 4 Circulation pump indicator. 5 Boiler on/off switch. 6 Summer-winter selector (CR and S/A models only). 7 Boiler thermostat: regulates the temperature of the water in the boiler with the burner in operation or on standby. 8 Fuse 9 Minimum-temperature thermostat: maintains boiler water temperature above set value. When the boiler temperature falls below minimum unit circulation pumps are switched off. 10 Domestic water thermostat (models CR and S/A): controls the boiler temperature when domestic water is in use. his is diffe rent to the temperature of the boiler during heating or standby phases. OERAION OF HE BOILER Use of 0-I switch (all models) and - selector (CR ed S/A) In the 0 position the switch isolates the boiler from the power supply; in position I the control panel is connected to the power supply. In the position the - selector ensures that the boiler produces only domestic hot water; in the position the boiler can deliver central heating and domestic hot water, with hot water taking priority. 0 I CR AND S/A MODELS WINER OERAION (production of domestic hot water and central heating water, hot water taking priority). Set the selector to the symbol (winter operation). In the CR model, the boiler switches on and starts up in central heating mode, raising and maintaining the water temperature in the boiler to the temperature set with the boiler thermostat; the pump starts up whenever the temperature reaches the value set on the minimum temperature thermostat. When the room thermostat contacts open, the heating cycle is completed. If hot water is drawn off, the boiler will automatically switch to hot water production when there is a demand for hot water (e.g. if a tap is turned on); the temperature of the hot water in the boiler is controlled by the domestic hot water thermostat. pag. 9
OIL-FIRED INSAN 1F 25 Energy-saving technology In the S/A model the boiler will start up in hot water mode to meet the temperature set with the cylinder thermostat; the boiler temperature is regulated by the hot water thermostat. When the set temperature has been reached, the three-way valve will switch to heating and the boiler temperature is regulated by the boiler thermostat. When the room thermostat contacts open, the heating cycle is completed. SIMULANEOUS DEMAND FOR HEAING AND HO WAER (CR MODELS) If there is a demand for hot water while the heating is on, the boiler will automatically switch to hot water production (hot water has priority over heating). WARNING: in order to ensure the availability of hot water at any time, as well as safe and trouble-free operation of the equipment, it is advisable not to switch off the unit completely using the 0-I switch (for example at night) but to adjust the room thermostat (or timer/thermostat) or position the season selector to (Summer). SUMMER OERAION (DOMESIC HO WAER RODUCION ONLY) Selector set to In the CR model, the boiler switches on and starts up by raising and maintaining the water temperature set with the boiler thermostat. It will relight automatically if the water temperature falls below the temperature set with the thermostat. In the S/A model, the boiler starts up in response to the temperature set with the boiler thermostat. LEASE NOE: in order to ensure the availability of hot water at all times, a well as safe and troublefree operation of the boiler, it is advisable not to switch off the unit completely using the 0-I switch. S MODELS WINER OERAION (heating only) Switch on the boiler (0-I switch in the I position). he boiler is switched on and, after performing a self-test routine, immediately starts to raise the water temperature to the value set on the boiler thermostat, guaranteeing that the temperature remains at the set value. he circulation pump starts up whenever the minimum set value is reached. Once the room thermostat contacts open, the heating cycle is completed. Use the boiler thermostat to raise or lower the water temperature. pag. 10
Energy-saving technology OIL-FIRED INSAN 1F 25 FUEL ALIMENAZIONE SULY DEL COMBUSIBILE H pipe length in metres metres copper pipe bore = 8mm gravity feed, supplied from the 0,5 38 top of the tank 1 42 1,5 48 2 50 2,5 54 3 58 H H suction feed H pipe length in metres metres copper pipe ø int. 8 mm ø int.10 mm 0,5 30 72 1 25 62 1,5 21 52 2 17 42 2,5 13 31 3 9 21 3,5 5 11 OIL UM DANFOSS BF 11 R3 SUNEC AS 47 S R 2 1 4 V 5 3 1 - Inlet 2 - ressure gauge and breather port 3 - Vacuum gauge port 4 - ressure set screw 5 - Outlet (pressure flow to nozzle) 6 - Return flow 5 2 3 SUNEC 4 1 6 1 6 CONVERSION OF HE UM FOR SINGLE IE SYSEMS DANFOSS UM o convert the DANFOSS pump: 1) Remove the pump cover and the internal filter 2) Remove the screw located inside the return port as shown in the figure on the left. 3) Replace the pump filter and cover. 4) Blank off the return port with a metal plug and seal. SUNEC UM o convert the SUNEC pump: 1) Remove the socket screw A located inside the return port. 2) Blank off the return port with a metal plug and seal. ertire la pompa SUNEC: Warning: unlike double pipe systems, air is not automatically bled out in a single pipe system. It is therefore essential to bleed the line on first operation as even a minimal infiltration of air in the fuel line will cause the burner to shut down. pag. 11
OIL-FIRED INSAN 1F 25 Energy-saving technology WARNING: o guarantee smooth and efficient operation of the appliance, the difference in height between fuel tank and burner should be no more than 3.5 metres. For greater differences it is essential to install a fuel lift pump (see diagram). Also, the condition and cleanliness of the fuel line filter should also be checked periodically, and the filter replaced where necessary. BURNER SULIED BY LIF UM Hydraulic diagram When it is impossible for the pump to draw fuel from the tank atmospherically, due to the boiler being sited on an upper storey, an auxiliary electric pump will need to be installed. he figure shows a possible arrangement, with two separate appliances supplied from a single tank. he electrical connection is made such that the auxiliary pump will switch off when all burners are shut down. N.B. Maximum fuel supply circuit pressure MUS NO exceed 2 bar; the preferred operating pressure is 0.5 bar. H 230 V 50 Hz M M Electrical diagram he auxiliary pump control must not be connected directly in parallel with the burner pump, as this would lead to excess current demand. A relay should therefore be installed, connected as shown in the diagram. pag. 12
Energy-saving technology OIL-FIRED INSAN 1F 25 ROOM VENILAION IMORAN: In case the INSAN GASOLIO thermal unit is mounted without the Snorkel duct for outdoor combustion air suction, it is necessary to make a hole toward outside of, at least, 180 cm 2. SNORKEL CONNECION FOR COMBUSION AIR SUCION FROM HE OUSIDE. he serial Snorkel arrangement of the INSAN GASOLIO thermal unit, allows to connect the burners air intake to the outside through an independent air duct, for the suction of the needed combustion air. Such an air duct must be sealed toward the inside room and respect the following specifications: 90 bend + 5m max of ø80mm duct length. AIR CONNECION OF GAS FLUE Combustion gases must be ducted to a chimney or to an anti-refouler equipped flue, connected to the outside, made in such a way so as to ensure a proper combustion and to avoid the gases to get in contact with walls, peoples, animals etc. Said duct must be designed so as to be in depression and/or sealed, and made of suitable, smoke-corrosion proof materials. In every point, no matter the outdoor conditions, gas temperature must not be higher than the one of dew point. he max. length of gas flue is of 5 m + a 90 bend. NOE: Flue ends must be located in such a way that exhaust gases might not cause damages in case of bad combustion. Sealed air box, soundproof, with serial SNORKEL connection. REGULAING COMBUSION WARNING: Regulation of combustion must be performed by a professionally qualified and authorised technician. INSAN 25 boiler are factory regulated by the manufacturer. In the event of further regulation being required, read the following instructions carefully. 2 3 1 - -Vite Locking di serraggio screw 2 - -serranda Air damper aria 3 - -manopola Knob 1 - Light the boiler ("winter" setting) and set the thermostat to maximum temperature. 2 - osition the air regulator slide according to flow rate (approximate). 3 - Set the pump pressure to the desired value (or replace the oil nozzle, see table below). 4 - Analyse combustion and regulate air flow rate accordingly by adjusting air regulator slide on the burner (having loosened the securing screw) as shown in the figure. min max 1 he sample point must be close to the boiler and the flue connection (no farther than 3-5 times the flue diameter from the boiler connection). DANFOSS oil nozzles fitted as standard on installed burners nozzle type angle atomizer type pump pressure No preheater GH 0,55 60 S 12 bar reheater GH 0,65 60 S 10 bar No preheater NOZZLE ABLE reheater GH ump pressure (bar) 10 11 12 13 14 0.50 1,9 2 2,08 2,17 2,25 0.55 2,1 2,2 2,3 2,4 2,5 Oil flow rate (kg/h) GH ump pressure (bar) 9 10 11 12 13 0.60 2 2,1 2,2 2,3 2,45 0.65 2,2 2,3 2,45 -- -- Oil flow rate (kg/h) pag. 13
OIL-FIRED INSAN 1F 25 Energy-saving technology OERAING CYCLE OF HE INSALLED BURNER MINOR INSAN burner Normal No flame hermostats hermostats Motor Motor ransformer ransformer Solenoid valve Solenoid valve Flame Flame Cutout Cutout a s a s b p b a = re-ventilation time b = re-ignition time s = Safety time p = ost-ignition time MINOR INSAN burner with preheater Normal No flame hermostats hermostats reheater Enable operation contact Motor reheater Enable operation contact Motor ransformer ransformer Solenoid valve Flame Cutout Solenoid valve Flame Cutout reheating time a s reheating time a s b p b a = re-ventilation time b = re-ignition time s = Safety time p = ost-ignition time pag. 14
Energy-saving technology OIL-FIRED INSAN 1F 25 YVg V ELECRICAL DIAGRAM - INSAN 25/CR boiler with oil-fired burner, no preheater Burner electrical diagram MV M 1 ~ B Yvg - Fuel solenoid valve B - Flame detector MV - Fan motor V - Burner ignition transformer BEM22.001 L1 N 1 2 S3 L1 N L2 pag. 15 CEM01.007
OIL-FIRED INSAN 1F 25 Energy-saving technology ELECRICAL DIAGRAM - INSAN 25/CR boiler with oil-fired burner and preheater Burner electrical diagram SCA Yvg Fuel solenoid valve B Flame detector MV MV Fan motor R Resistor SCA Ignition enable thermostat V Burner ignition transformer R YVg B V M 1 ~ BEM22.002 L1 N 1 2 S3 L1 N L2 pag. 16 CEM01.008
Energy-saving technology OIL-FIRED INSAN 1F 25 ELECRICAL DIAGRAM - INSAN 25/S boiler with oil-fired burner, no preheater Burner electrical diagram YVg MV V M 1 ~ ~50Hz 230V E Yvg - Fuel solenoid valve B - Flame detector MV - Fan motor V - Burner ignition transformer B L N Q BEM22.001 L1 N 1 2 S3 L1 N L2 HLB SA CONNECIONS O BE MADE BY INSALLER Q main switch (fused) Z suppressor CC circulation pump FU fuse hour meter HLB flame failure indicator SAL line switch SA room thermostat SL boiler thermostat SS safety thermostat HLCC circulation pump indicator Smin minimum temperature thermostat L1 N 1 2 S3 LANDIS LOA 24 1 2 3 4 5 6 7 8 9 10 11 12 31 32 Z L1 N 1 2 S3 pag. 17 L1 N 1 2 S3 L1 N L2 L N 3 4 5 6 7 8 9 10 11 12 CEM01.003 CC SAL BURNER ELECRICAL OWER INU h SU HLCC SS Smin SL
OIL-FIRED INSAN 1F 25 Energy-saving technology ELECRICAL DIAGRAM - INSAN 25/S boiler with oil-fired burner and preheater Burner electrical diagram SCA Yvg Fuel solenoid valve B Flame detector MV ~50Hz 230V E MV Fan motor R Resistor SCA Ignition enable thermostat V Burner ignition transformer R YVg B V M 1 ~ L N Q BEM22.002 L1 N 1 2 S3 L1 N L2 HLB SA CONNECIONS O BE MADE BY INSALLER Q main switch (fused) Z suppressor CC circulation pump FU fuse hour meter HLB flame failure indicator SAL line switch SA room thermostat SL boiler thermostat SS safety thermostat HLCC circulation pump indicator Smin minimum temperature thermostat L1 N 1 2 S3 LANDIS LOA 24 1 2 3 4 5 6 7 8 9 10 11 12 31 32 Z L1 N 1 2 S3 pag. 18 L1 N 1 2 S3 L1 N L2 L N 3 4 5 6 7 8 9 10 11 12 CEM01.004 CEM01.005 CC SAL BURNER ELECRICAL OWER INU h SU HLCC SS Smin SL
Energy-saving technology OIL-FIRED INSAN 1F 25 ~50Hz 230V E L N HLB Q SA SB B4 B5 6 7 8 ELECRICAL DIAGRAM - INSAN 25 S/A boiler with oil-fired burner, no preheater Burner electrical diagram YVg MV V M 1 ~ Yvg - Fuel solenoid valve B - Flame detector MV - Fan motor V - Burner ignition transformer B BEM22.001 I L1 N 1 2 S3 L1 N L2 JE3V M 1 ~ CONNECIONS O BE MADE BY INSALLER Q main switch (fused) Z suppressor CC circulation pump FU fuse KA KA relay contact KA relay hour meter HLB flame failure indicator SAL line switch SF flow indicator pressure switch SA room thermostat SB cylinder thermostat SL boiler thermostat SS safety thermostat JE3V 3-way motorized valve HLCC circulation pump indicator SAEI summer-winter selector SAS domestic hot water thermostat Smin minimum temperature thermostat L1 N 1 2 S3 LANDIS LOA 24 1 2 3 4 5 6 7 8 9 10 11 12 31 32 Z pag. 19 B5 6 7 8 L1 1 2 S3 B4 N L1 N 1 2 S3 L1 N L2 L N 3 4 5 6 7 8 9 10 11 12 CC SAL BURNER ELECRICAL OWER INU h SU SAS SS KA KA CEM01.005 CEM01.004 HLCC E SL Smin SAEI
OIL-FIRED INSAN 1F 25 Energy-saving technology ~50Hz 230V E L N HLB Q SA I ELECRICAL DIAGRAM - INSAN 25 S/A boiler with oil-fired burner and preheater Burner electrical diagram SCA Yvg Fuel solenoid valve B Flame detector MV MV Fan motor R Resistor SCA Ignition enable thermostat V Burner ignition transformer R YVg B V M 1 ~ BEM22.002 L1 N 1 2 S3 L1 N L2 JE3V M 1 ~ SB CONNECIONS O BE MADE BY INSALLER Q main switch (fused) Z suppressor CC circulation pump FU fuse KA KA relay contact KA relay hour meter HLB flame failure indicator SAL line switch SF flow indicator pressure switch SA room thermostat SB cylinder thermostat SL boiler thermostat SS safety thermostat JE3V 3-way motorized valve HLCC circulation pump indicator SAEI summer-winter selector SAS domestic hot water thermostat Smin minimum temperature thermostat B3 L1 N L2 L1 N 1 2 S3 LANDIS LOA 24 1 2 3 4 5 6 7 8 9 10 11 12 31 32 Z pag. 20 L1 N 1 2 S3 B3 L1 N L2 L1 N 1 2 S3 L1 N L2 L N 3 4 5 6 7 8 9 10 11 12 CC SAL BURNER ELECRICAL OWER INU h SU SAS SS KA KA CEM01.006 HLCC E SL Smin SAEI
.A.S. MINIMA 0 I.A.S. MINIMA 0 I Energy-saving technology OIL-FIRED INSAN 1F 25 ACCESS O HE BOILER H V F,,,, F V1 I INSAN INSAN V V2 S S o gain access to the inside of the boiler, proceed as follows: - Isolate the appliance from the electrical power supply and shut off the fuel valves - Detach the front panel F - Rotate the flap S downwards - Remove the screws V - Rotate the control panel downwards - For cleaning purposes, remove the fixing screws and detach the top panel H - o access electrical parts, remove screws V1 and detach the protective housing I DISMANLING HE BURNER A C C A B fig. 1 fig. 2 o dismantle the burner from the boiler, proceed as follows: - Isolate the appliance from the electrical power supply and shut off the fuel valves - Expose the interior as described above - Remove nut A and long nut B (fig. 1) using a spanner - ake out the burner (rotating in anticlockwise direction to facilitate removal) - he burner is provided with a rear bracket on which it can be supported once removed from the boiler, for ease of servicing. Attach the bracket to the flange stud, securing temporarily with nut A. When reassembling, check the burner insulating flange and replace if worn or damaged. pag. 21
OIL-FIRED INSAN 1F 25 Energy-saving technology WARNING: before each heating season it is advisable to have the appliance cleaned and checked by an ECOFLAM authorised technician. RELACING HE NOZZLE AND VERIYING HE OSIION OF HE ELECRODES Use a suitable wrench when replacing the nozzle, taking care not to damage the electrodes (fig. A). After fitting the new nozzle, check the position of the electrodes; the dimensions must be as indicated in figure B in order for the burner to function correctly. 2 3 mm 3 mm Fig. A Fig. B 5/6 mm MAINAINING AND CLEANING HE BOILER o keep the boiler unit in good working order, clean as instructed below. D D A B C D1 D1 F E F - Isolate the appliance from the electrical power supply and shut off the fuel valves - Expose the interior as described above - Remove the nuts D, detach the boiler top A and burner C from the boiler, and remove the baffles B - Using an appropriate brush and vacuum cleaner, clean the pipes as indicated and vacuum the dirt through the burner aperture. If necessary, detach the bottom E by loosening internal nuts D1 and removing the external bolts F. Make sure parts are reassembled in the correct order. Inspect all seals removed, and replace if damaged or worn. Make certain the baffles fit snugly in the pipes when reinstated. pag. 22
Energy-saving technology OIL-FIRED INSAN 1F 25 EXLODED DRAWING OF HE CONROL ANEL 12 11 9 10 8 INSAN.A.S. MINIMA 7 1 2 0 I 6 1 2 3 4 5 3/A mod. S 3 6 7 8 9 4 5 ref. description code 1 emperature and pressure gauge G3.04 2 Circulation pump indicator E15.09/1 3 Winter/Summer selector * R10.02 3/A lastic cap (S Model) R10.13/1 4 Main 0/I switch R10.01 5 Fuse holder.................................................................................. E8.02/2 Fuse E8.02 6 Boiler thermostat G8.15/1 7 Safety thermostat, manual reset G8.08/2 8 Control unit A1.17/1 9 Control unit housing A4.02 10 Control unit bracket CFA19.105/101 11 Minimum temperature thermostat G8.02 12 Domestic hot water thermostat* G8.02 * CR and S/A models only pag. 23
, OIL-FIRED INSAN 1F 25 Energy-saving technology EXLODED DRAWING OF INSAN 25 CR 8 7 22/D 6 22/C 25 24 26 10 9 22/A 22/B 22/F art. A 11 12 A 22/A 21 1 22/E 2 12/A 13 3 4 23 22 14 5 20 18/A 18 17/A 17 19 15 16 28 15/A 27 pag. 24
Energy-saving technology OIL-FIRED INSAN 1F 25 ref. description code 1 Boiler unit CFA03.058 2 Boiler insulation CFA07.082 3 Bottom boiler top seal J7.18/4 4 Bottom boiler top insulation CFA10.034 5 Bottom boiler top CFA04.303/001 6 op boiler top insulation support net CFA04.096 7 op boiler top insulation CFA07.79 8 op boiler top CFA04.304/001 9 Baffles CF05.034 10 Automatic air vent valve G2.07/1 11 Sensor holder CFA05.007 12 hermostats: boiler safety domestic hot water minimum temperature 12A hermometer 13 Drain valve S8.01 14 System flow pipe CF01.102/001 15 hree way valve assembly GR.RUB.02 15A Microswitch assembly V1.39/2 16 Return valve assembly GR.RUB.01 17 High-pressure pipe CF01.038 17A Low-pressure pipe CF01.039 18 late heat exchanger G13.25/2 18/A O ring Y6.01/29 19 Circulation pump 1.42/3 20 System return pipe CF01.101/001 21 Expansion tank G4.04 22 Burner of Kerosene 55-27-41/830 22/A Clip E22.06/1 22/B Flexible tube S9.51/2 22/C Collar CFA02.007 22/D Stainless steel terminal O1.1121 22/E 22/F KI.INS 23 Burner insulation flange BFG02.013 24 Sight glass seal CFG01.027/1 25 Sight glass CFA05.015 26 Sight glass nut CFA05.014 27 Safety valve G2.10 28 ressure sensor pag. 25
, OIL-FIRED INSAN 1F 25 Energy-saving technology EXLODED DRAWING OF INSAN 25 S - S/A 8 7 20/D 6 20/C 9 20/A 23 22 24 10 20/B 20/F art. A 11 12 A 20/A 20/E 19 1 2 12/A 13 3 4 21 20 14 5 15 26 16 17 25 27 26 18 pag. 26
Energy-saving technology OIL-FIRED INSAN 1F 25 ref. description code 1 Boiler unit CFA03.058 2 Boiler insulation CFA07.082 3 Bottom smoke hood seal J7.18/4 4 Bottom smoke hood insulation CFA10.034 5 Bottom smoke hood CFA04.303/001 6 op smoke hood insulation support net CFA04.096 7 op smoke hood insulation CFA07.79 8 op smoke hood CFA04.304/001 9 Baffles CF05.034 10 Automatic air vent valve G2.07/1 11 Sensor holder CFA05.007 12 hermostats: Boiler safety minimum 12A hermometer 13 Drain valve S8.01 14 System flow pipe CF01.104/001 15 ump/boiler connecting pipe CF01.106/001 16 Circulation pump 1.42/3 17 System return pipe CF01.105/001 18 Safety valve G2.10 19 Expansion tank G4.04 20 Burner of Kerosene 55-27-41/830 20/A Clip E22.06/1 20/B Flexible tube S9.51/2 20/C Collar CFA02.007 20/D Stainless steel terminal O1.1121 20/E 20/F 21 Burner insulation flange BFG02.013 22 Sight glass seal CFG01.027/1 23 Sight glass CFA05.015 24 Sight glass nut CFA05.014 25 ressure sensor 26 Ring nut 3/4' BF01.108/1 27 Ring nut 1/2' BF01.109 pag. 27
0 I OIL-FIRED INSAN 1F 25 Energy-saving technology EXLODED DRAWING OF INSAN 25 CR, S AND S/A CASING 2 3 1 4 7 9 3 INSAN.A.S. MINIMA 6 5 10 8 ref. description code 1 Boiler frame CFA09.103/012 2 op panel CFA12.050/018 3 Side panel CFA12.028/018 4 Upper cross member CFA19.107/001 5 Bottom panel CFA19.104/012 6 Lower cross member CFA19.101/001 7 Control panel protective housing CFA12.202 8 Control panel CFA12.201 9 Front panel CFA12.026/018 10 Flap CFA12.048/018 pag. 28
Energy-saving technology OIL-FIRED INSAN 1F 25 17 15 16 MINOR INSAN 25 22 21 25 19 18 14 23 24 3 2 1 4 10 5 9 29 7 6 12 31 13 30 11 8 pag. 29
OIL-FIRED INSAN 1F 25 Energy-saving technology 20 27 28 25 26 17 15 16 MINOR R INSAN 25 22 21 20 19 18 14 23 24 3 2 1 4 10 5 29 9 7 6 12 31 30 13 11 8 pag. 30
Energy-saving technology OIL-FIRED INSAN 1F 25 MINOR INSAN 25 MINOR R INSAN 25 ref. description code code 1 Cast burner casing BFF04.318/011 BFF04.318/011 2 Burner casing cover BFC09.002/11 BFC09.002/11 3 Ignition transformer 1.23/2 1.20 4 Fan rotor BFV10.001/001 BFV10.001/001 5 Motor flange BFF03.005/001 BFF03.005/001 6 Capacitor C1.07/8 C1.07/8 7 Electric motor M1.10/3 M1.10 8 SUNEC fuel oil pump DANFOSS fuel oil pump 1.21/3 1.21/3 9 SUNEC core DANFOSS core V4.12/1 V4.12/1 10 SUNEC coil DANFOSS coil V5.10/3 V5.10/2 11 ump connector BFR01.103/001 BFR01.103/001 12 Flexible tube S9.52/11 S9.52/2 13 Fuel oil filter S1.06/1 S1.05 14 Duct BFC08.111 BFC08.111 15 Air intake BFC03.028 BFC03.028 16 Nozzle assembly GR.0101/041-17 Diffuser BFB01.005/002 BFB01.005/002 18 Ignition cable BFE01.301/1 BFE01.301/1 19 Nozzle assembly support rod BFA05.109/001 BFA05.005/001 20 reheater assembly - GR.CR.009/5 21 Ignition electrodes BFE01.102 BFE01.026 22 Nozzle U1.0.75/60S U1.0.65/60S 23 Flame detector A2.07/1 A2.07/1 24 Flame detector mounting A2.08/1 A2.08/1 25 Nozzle holder GR.CR.009/2 BFC10.002/1 26 Seal - BF04.013/1 27 hermostat - E7.03 28 Fuel preheater element - R1.05/1 29 Air shutter BFS01.002/001 BFS01.002/001 30 External regulation plate BFS01.201 BFS01.201 31 Internal regulation plate BFS01.202 BFS01.202 pag. 31
ECOFLAM S.p.A. reserves the right to make such modifications to products as are deemed necessary or useful without significantly altering the broad specifications. Ecoflam S.p.A. via Roma, 64-31023 RESANA (V) - Italy - tel. 0423/715345 r.a. - telex 411357 ECOFLA I - telefax 0423/715444