cod. 05 rev. 06/06 GITRÈ LN GITRÈ B/00 LN GITRÈ LN EN INSTALLATION AND MAINTENANCE MANUAL
Dear heating engineer, Congratulations on having chosen a R boiler. You have selected a modern, quality product that is designed to give dependable, efficient and safe service and to provide comfort in the home for many years to come. This manual provides information that is essential to the installation of the appliance. Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly. Please accept our thanks and our congratulations on your choice of product. Riello S.p.A. RANGE MODEL CODE GITRÈ 4 LN 055 GITRÈ 5 LN 057 GITRÈ 6 LN 058 GITRÈ 5 B/00 LN 059 ACCESSORIES For a complete list of accessories and details of their compatibility, refer to the Catalogue. CONFORMITY GITRÈ LN boilers conform to the following directives: Directive 9/4/EEC on efficiency requirements Electromagnetic Compatibility Directive 04/0/EU Low Voltage Directive 04/5/EU Ecodesign Directive 009/5/CE for energy-related products Energy Labelling Directive 00/0/EU Delegated Regulation (EU) N. 8/0 Delegated Regulation (EU) N. 8/0 Delegated Regulation (EU) N. 84/0 This product must only be used for the purpose for which it is designed and made, as specified by R. R declines all responsibility, contractual or other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use. ENGLISH
CONTENTS GENERAL INFORMATION... 4. General Safety Information...4. Precautions...4. Description of the appliance...5.4 Safety and control devices...5.5 Identification...6.6 System layout...6.7 Technical specifications...9.7. Water-side pressure drop... 0.8 Location of sensors....9 Control panel... INSTALLATION... 4. Unpacking the product... 4.. Positioning of labels... 4. Overall dimensions and weights... 4. Moving and removing the packing... 5.4 Installation premises... 6.4. Recommended minimum distances... 6.5 Installation in older systems and systems requiring modernisation... 6.6 Water connections...7.7 Typical water system schematics... 8.8 Fuel connections... 9.9 Combustion gas exhaust...0.9. Technical specifications of stack...0.9. Connection to the stack...0.0 System filling and emptying....0. Water quality requirements....0. Filling....0. Emptying.... Wiring diagram...4. Electrical connections...6 COMMISSIONING AND MAINTENANCE... 8. Preparing for initial startup...8. Initial startup...8.. Ignition failure...9.. Resetting the burner and safety thermostat...0. Checks during and after initial start-up...0.. Storage cylinder pump control..... Burner control and adjustment..... Burner functioning and programming....4 Temporary shutdown...40.5 Preparing for extended periods of disuse...40.6 Cleaning and servicing the boiler... 4.7 Annual cleaning... 4.7. Cleaning and servicing the boiler... 4.7. Cleaning the heat exchanger...4.7. Checking and replacing the storage cylinder anode (GITRÈ 5 B/00 LN model)...44.8 Extraordinary cleaning...45.8. Cleaning the storage cylinder...45.9 External cleaning...45.0 Troubleshooting...46 4 RECYCLING AND DISPOSAL... 48 The following symbols are used in this manual: CAUTION! = Identifies actions that require caution and adequate preparation. 00 STOP! = Identifies actions that you MUST NOT do. This manual, Code - Rev. comprises pages. This manual, Code 05 - Rev. (06/06) comprises 5 pages.
GENERAL INFORMATION GENERAL INFORMATION. General Safety Information Check that the product is complete, undamaged and as ordered as soon as you receive it. Report any discrepancies or damage to the R dealer who sold it. 9 9 This product must be installed by a legally qualified heating engineer. On completion of the installation, the installer must issue the owner with a declaration of conformity confirming that the installation has been completed to the highest standards in compliance with the instructions provided by R in this instruction manual, and that it conforms to all applicable laws and standards. This product must only be used for the purpose for which it is designed and made, as specified by R. R declines all responsibility, contractual or other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use. The room where the boiler is installed must be properly ventilated to ensure a sufficient supply of air for correct combustion. If you notice any water leaks, disconnect the boiler from the mains electricity supply and shut off the water supply. The boiler must be serviced at least once a year. Periodically check that pressure in the central heating circuit, when cold, is approximately.5 bar and below the maximum limit specified for the boiler. If the boiler is not going to be used for an extended period of time, perform the operations described later in this manual. This manual is an integral part of the equipment and therefore must be stored carefully and must ALWAYS accompany the boiler even if it is sold to another Owner or User or transferred to another plant. If it is damaged or lost, request another copy from your local Technical Assistance Service R.. Precautions The operation of any appliance that uses fuel, electrical power and water demands that a number of fundamental safety precautions be respected: 00 Do not allow children or infirm persons to operate the system unsupervised. 0 0 It is forbidden to use electrical devices or equipment, such as switches, appliances, etc. if there is a smell of gas or unburnt products. If so: Ventilate the room, opening doors and windows Close the fuel shut-off cock. 00 Do not touch the boiler while barefoot or wet. 00 Never clean or service the boiler without first disconnecting it from the mains electricity supply by turning the mains power switch and the control panel switch OFF. 00 Do not tamper with or adjust the safety or control devices without prior authorisation and instructions from the manufacturer. 00 Never pull, disconnect, or twist the electrical cables coming from the appliance even if it is disconnected from the mains electricity supply. 00 Do not obstruct or restrict the vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion. 00 Do not expose the boiler to the elements. It is not designed for use outdoors. 00 It is prohibited to leave inflammable substances and containers in the room where the boiler is installed. 00 Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation. 00 It is forbidden to operate the boiler without water. 4
GENERAL INFORMATION. Description of the appliance The GITRÈ LN boiler is an oil fuelled hot water boiler capable of low temperature functioning. GITRÈ LN versions are designed only for central heating applications. The GITRÈ B/00 LN version is equipped with a 00 litre vitrified storage cylinder and can be used for central heating and domestic hot water production. The cast iron boiler body features a triple flue pass design and a horizontal combustion chamber. The front cover opens fully to facilitate the inspection, maintenance and cleaning of internal parts and to minimise service time. The boiler body is covered in high density glass wool insulation to reduce heat loss. The boiler is fitted with a single stage, low NOx, fuel oil burner. The GITRÈ LN boiler's control logic incorporates a total shutdown function to minimise energy consumption: The GITRÈ LN (heating only) model only starts up if the central heating system requests heat (i.e. when the room thermostat switches the heating on); If the GITRÈ B/00 LN (heating and DHW) model is in "Summer" mode ("Summer/Winter" selector turned to Summer position), it only starts up to restore the setpoint temperature of the water in the storage cylinder. If it is in "Winter" mode ("Summer/Winter" selector turned to Winter position), it starts up either in response to a request for heat from the heating system (i.e. when the room thermostat switches the heating on) or to restore the setpoint temperature of the water in the storage cylinder (DHW heat requests are prioritised over central heating requests)...4 Safety and control devices GITRÈ LN boilers incorporate the following safety and control devices: A manual reset safety thermostat that forces a safety shutdown if boiler temperature exceeds the safety threshold (0 C). The sensor used to monitor this temperature is located on the body of the heat exchanger; A minimum temperature thermostat that enables the central heating pump only if boiler temperature exceeds the minimum permissible (50 C); An electronic burner controller that monitors the correct functioning of the selected burner program and sends a lockout signal to the control panel in the event of an error. ONLY FOR GITRÈ B/00 LN MODELS A maximum temperature thermostat that shuts down the burner if boiler temperature reaches or exceeds the default maximum limit ( 8 C) during the heating of domestic hot water in the storage tank; A heat dissipation thermostat that starts up the storage tank pump to dissipate excess heat in order to keep boiler temperature below the safety threshold (90 C). The intervention of a safety device indicates a potentially dangerous malfunction in the system. Contact the manufacturer s Technical Assistance Service immediately. Safety devices must only be replaced by the manufacturer's Technical Assistance Service using original spare parts. Refer to the spare parts catalogue supplied with the boiler. 00 Do not use the boiler if any of its safety devices are faulty. Always check that the boiler is functioning correctly after repairs have been made. 5
GENERAL INFORMATION.5 Identification The products are identified by:.6 System layout GITRÈ LN Serial number plate This is located on the boiler body and specifies the serial number, model, and main technical specifications. RIELLO S.p.A. Via Ing.Pilade Riello 7 7045 Legnago (VR) - ITALY T06779GE 4 Mod. Cod. N Qn(max) Pn(max) Pms bar kw kw 5 RIELLO S.p.A. Via Ing.Pilade Riello 7 7045 Legnago (VR) - ITALY T06779GE Mod. Cod. N PAESE DI DESTINAZIONE/PAYS DE DESTINATION/BESTIMMUNGSLAND/LAND VON BESTEMMING COUNTRY OF DESTINATION/PAÍS DE DESTINO/PAÍS DE DESTINO: 6 7 COMBUSTIBILE/COMBUSTIBLE/BRENNSTOFF/BRANDSTOF/FUEL/COMBUSTIBLE/COMBUSTÍVEL: TIPO/TYP/TYP/TYPE/TIPO/TIPO: V~Hz IP W NO X S mg/kwh % 8 Qn(min)= kw kw Pms= bar T = C Pn(min)= Qn(max)= Pmw= bar T = C Pn(max)= kw kw kw kw kw D= l/min kw Data plate This lists the technical specifications and performance of the product. DHW section Central heating section Qn Rated heat input Pn Rated useful heat output IP Electric degree of protection Pmw Maximum operating pressure, DHW circuit Pms Maximum operating pressure, CH circuit T Temperature η Efficiency D Specific flow rate NOx NOx class Burner Boiler body Control panel 4 Sensor socket 5 Lifting holes 6 Flue gas exhaust fitting 7 Casing 8 Drain cock 9 Flue gas diaphragm (GITRÈ 5 LN only) If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper installation and servicing may be rendered difficult. 6
GENERAL INFORMATION GITRÈ B/00 LN 5 6 7 8 9 4 4 5 5 6 7 8 9 0 8 6 4 Control panel Storage cylinder drain cock CH circuit drain cock 4 Automatic vent valve 5 Storage cylinder 6 Casing 7 Non-return valve 8 Boiler circulator 9 Boiler temperature sensor socket 0 Lifting holes Burner Boiler body Flue gas diaphragm 4 Flue gas exhaust fitting 5 Domestic cold water inlet 6 DHW circulation 7 Storage cylinder temperature sensor socket 8 DHW outlet 9 Magnesium anode 7
GENERAL INFORMATION BURNER 9 0 4 6 7 8 5 Pump Burner controller Reset button with lockout indicator 4 Flange with seal 5 Air damper adjuster screw 6 Air intake 7 Oil pump pressure adjuster screw 8 Pressure gauge fitting 9 Photoresistor 0 Combustion head Motor OIL PUMP 7 6 5 4 Suction port Return By-pass screw 4 Pressure gauge fitting 5 Pressure adjuster screw 6 Vacuum gauge fitting 7 Valve 8 Auxiliary pressure measurement fitting 8 8
GENERAL INFORMATION.7 Technical specifications DESCRIPTION Device type Fuel Maximum rated heat input at furnace referred to HVC (LCV) GITRÈ 4 LN GITRÈ 5 LN GITRÈ LN GITRÈ 6 LN GITRÈ 5 B/00 LN Mixed low Low temperature central temperature heating heating B - C (*) - C (*) Heating fuel oil (Light oil) 6,5 (5),9 () 4,4 (40),9 () kw Useful (rated) heat output 4 8 kw Maximum useful heat output P4 (60-80 C),8 0,7 8,5 0,7 kw 0% heat output P with return at 7, 9,,5 9, kw 7 C Seasonal energy efficiency in central heating mode B Seasonal energy efficiency in DHW mode - B Seasonal energy efficiency in central heating mode ηs 86 87 % Efficiency at rated heat output in high temperature mode referred to HCV η4 (60-80 C) 89,8 90,6 90,7 90,6 % Efficiency at 0% rated heat output in low temperature mode referred to HCV η with return at 7 C 9,9 9,6 9,7 9,6 % Energy efficiency in DHW mode ηwh - 7,0 % Storage cylinder charging profile - XL Heat loss in standby mode Pstby 60, 60, 58,6 60, W Combustion efficiency referred to LCV 96,4 96,8 96,6 96,8 % Annual energy consumption QHE 80 0 8 0 GJ Daily electrical energy consumption Qelec - - - 0,05 kwh Annual electrical energy consumption AEC - - - 8,60 kwh Daily fuel consumption Qfuel - - - 7,6 kwh Annual fuel consumption AFC - - - 6,50 GJ Noise level (sound power) LWA 59 db(a) NOx (referred to HCV) <0 mg/kwh CO,5 % Emissions at maximum heat input CO w.a. < <50 ppm Flue gas T At Pn (60-80 C) 97 9 9 9 C Smoke scale <0,5 Flue gas mass flow rate 9,6, 6,, g/s Maximum working pressure bar Safety thermostat trip temperature 0 C Maximum operating temperature 55-8 C Minimum return temperature 7 C Boiler water capacity 9 4 8 4 l Turbulators 6 n Power supply 0-50 V-Hz Electric degree of protection X0D IP Consumption at full load Elmax 87 85 40 85 W Consumption at part load Elmin 56, 55,5 7,0 55,5 W Electrical consumption in standby mode P sb W LCV: Lower calorific value of fuel HCV: Higher calorific value of fuel Test conditions: Room temperature C Atmospheric pressure 08 mbar 9 (*) In conjunction with the 80/5 concentric flue kit available from the catalogue (FRANCE ONLY).
GENERAL INFORMATION STORAGE CYLINDER GITRÈ 5 B/00 LN Type of storage cylinder Vitrified steel Storage cylinder layout Vertical Heat exchanger layout Vertical Maximum power absorbed 4,9 kw DHW water temperature setting range 0-70 C Storage cylinder capacity 00 l Coil water capacity 5 l Coil heat exchange surface area,0 m Domestic hot water production ( T 5 C) (*) 6 l/h Water draw in 0 minutes with primary buffer tank at: 48 C 70 l 60 C 0 l Specific flow rate (EN 0) l/min Replenishment time with T 5 C) 0 min Maximum operating pressure of storage cylinder 6 bar STORAGE CYLINDER PUMP Electrical consumption 5 W EEI Part (**) 0,0 P L, Avg (***) 4 W Minimum pressure at pump suction inlet 0,5 bar (*) Inlet water temperature 0 C and average outlet water temperature 45 C with coil inlet temperature of 80 C (**) Energy efficiency rating according to regulations 64/009-6/0 (***) Approximate average annual electricity consumption according to regulations 64/009-6/0.7. Water-side pressure drop GITRÈ LN boilers come without a pump. A pump must therefore be provided as part of the installation. In order to choose a pump of the right size, bear in mind the boiler s water-side pressure drop, as shown in the figure below. Pressure drop [mbar] 50 45 40 5 0 5 0 5 0 5 0 0,0 0, 0,4 0,6 0,8,0,,4,6,8,0,,4,6,8,0,,4,6,8 4,0 GITRÈ 5 LN - 5B/00 LN GITRÈ 6 LN GITRÈ 4 LN Flow-rate [m³/h] 0
GENERAL INFORMATION.8 Location of sensors GITRÈ LN TS Safety thermostat sensor Tm Minimum temperature thermostat sensor TR Boiler thermostat sensor Boiler temperature gauge TS Tm TR GITRÈ B/00 LN TB TR Boiler thermostat sensor TS Safety thermostat sensor TB Storage cylinder thermostat sensor TL Maximum temperature thermostat sensor TL Heat dissipation thermostat sensor Tm Minimum temperature thermostat sensor Boiler temperature gauge DHW thermostat TL TL Tm TR TS
GENERAL INFORMATION.9 Control panel GITRÈ LN 40 60 80 0 00 0 0 4 6 5 7 Function selector 0 Off I On II Remote burner reset Boiler temperature gauge Displays the temperature of the central heating water Boiler thermostat Allows you to set the temperature of the central heating water (setting range 55-8 C) 8 55 4 Electrical power indicator (green) Lights to show that the boiler is receiving electrical power 5 Burner lockout indicator (red) Lights to show that the burner locked out 6 Manual reset for safety thermostat Allows you to reset the boiler if the safety thermostat trips. Unscrew the protective cover to access the reset button 7 Protective cover over control panel
GENERAL INFORMATION GITRÈ B/00 LN 6 40 0 60 80 00 40 0 60 80 00 7 0 0 0 0 8 4 9 5 0 Function selector 0 Off I On II Remote burner reset Boiler temperature gauge Displays the temperature of the central heating water Boiler thermostat Allows you to set the temperature of the central heating water (setting range 55-8 C) 8 55 4 Electrical power indicator (green) Lights to show that the boiler is receiving electrical power 5 Burner lockout indicator (red) Lights to show that the burner locked out 6 Summer (I) / Winter (II) selector 7 Storage cylinder temperature gauge Displays the temperature of the domestic hot water in the storage cylinder 8 Manual reset for safety thermostat Allows you to reset the boiler if the safety thermostat trips. Unscrew the protective cover to access the reset button 9 Storage cylinder thermostat Allows you to set the temperature of the domestic hot water (setting range 0-70 C) 70 0 0 Protective cover over control panel
INSTALLATION INSTALLATION. Overall dimensions and weights. Unpacking the product GITRÈ LN boilers are delivered on a pallet, packed and protected by a wooden cage. The following items are delivered in a plastic bag () inside the boiler: User manual Installation and maintenance manual Spare parts catalogue Hydraulic test certificate Energy label.. Positioning of labels GITRÈ LN H L P GITRÈ B/00 LN A H A Packing label The instruction manual is an integral part of the boiler. Once located, read it thoroughly and keep it safe. 9 9 Keep the documentation envelope in a safe place. Any replacement documents must be ordered from Riello S.p.A. who reserve the right to charge for the cost of the replacement. L P Description GITRÈ 4 LN GITRÈ 5 LN GITRÈ 6 LN GITRÈ 5 B/00 LN L 450 450 450 600 mm P 797 897 047 900 mm H 850 850 850 500 mm Net weight 8 4 49 86 kg 4
INSTALLATION. Moving and removing the packing If the installation involves a lot of moving (e.g. to a rooftop or cellar utility room) do not remove the protective wooden cage until the boiler is at its place of installation. 9 9 Wear suitable personal protection equipment when moving the boiler and removing the packing. Only use lifting equipment that is suitable for the weight involved. Remove the polystyrene edge protectors () Pull off the protective bag (). Proceed as follows to remove the packing: Remove the staples (A) fixing the wooden cage () to the pallet A 00 Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation. With the packing removed, remove the front panel (). Lift off the wooden cage () or slide it off to the rear. (Pull out the staples (B) and remove the front of the cage first in order to slide it off to the rear.) B Locate the bag containing the documentation, remove the energy label and apply it to the boiler casing. 0 mm 5 kw 5 mm 5
INSTALLATION To move the boiler manually, proceed as follows: Remove the fixing screws (C) to free the boiler from the pallet; Lift the boiler by inserting two " diameter pipes () through the lifting holes () in the boiler body. Check that the appliance's electrical protection level is suitable for the place of installation. 9 9 Make sure that comburent air is not contaminated by substances containing chlorine or fluorine (elements found in sprays, paints, detergents etc.). 00 These boilers must be installed indoors. They are not designed for outside use. 00 Do not obstruct or restrict the air vents in the room where the boiler is installed. A free air supply is essential for correct combustion..4. Recommended minimum distances This figure shows the minimum installation distances that must be respected in order to allow proper maintenance of the boiler. m C Take care because the boiler might swing when lifted. Provided the floor is smooth and level, the boiler can be lifted a little () and moved on wheels (). m 0,5 m 0,5 m m.5 Installation in older systems and systems requiring modernisation Level off the boiler by adjusting the feet at the front of the boiler..4 Installation premises GITRÈ LN boilers must be installed in rooms with suitably sized air vents conforming to the technical standards and regulations applicable at the place of installation. When installing the boiler, allow sufficient space around it to access all safety and control devices and to permit easy maintenance. When installing these boilers in older systems or systems requiring modernisation, always perform the following checks: Make sure that the flue is able to withstand the temperature of the combustion gases and that it has been designed and made in compliance with applicable standards. The flue must also be as straight as possible, sealed, insulated and not blocked or choked. Refer to the "Combustion gas exhaust" section on page0for further information. Make sure that the electrical supply system has been installed by a qualified electrician in compliance with applicable standards Make sure that the fuel feed line and any storage tank are made and installed in compliance with applicable standards Make sure that expansion vessels are big enough to contain the additional volume generated by thermal expansion Make sure that the flow rate, head and direction of flow of the pumps are suitable and correct Make sure that the central heating circuit has been flushed out to remove all sludge and lime scale, and that it has been bled and seal tested Make sure that a suitable water treatment system is installed if the quality of the supply/recirculation water so demands. (Refer to the reference values on page); See Riello S.p.A. s Catalogue The manufacturer declines all responsibility for damage caused by incorrectly constructed flue systems. 6
INSTALLATION.6 Water connections The following figures and tables give the dimensions and positions of the water fittings for (GITRÈ LN and GITRÈ B/00 LN) boilers. Before installing the boiler, flush out all the pipes of the central heating circuit to remove any machining residues. GITRÈ B/00 LN ES US RC GITRÈ LN E F G A MI C MI RI C RI B A D A B A DESCRIPTION GITRÈ 4 LN GITRÈ LN GITRÈ 5 LN GITRÈ 6 LN A 96 mm B 0 mm C 555 mm MI (CH flow) "/4 F Ø RI (CH return) "/4 F Ø DESCRIPTION GITRÈ LN GITRÈ 5 B/00 LN A 70 mm B 60 mm C 555 mm D 0 mm E 67,5 mm F 65 mm G 67,5 mm MI (CH flow) "/4 M Ø RI (CH return) "/4 M Ø US (DHW outlet) /4 M Ø RC (DHW recirculation) /4" F Ø ES (domestic cold water inlet) /4 M Ø 7
INSTALLATION.7 Typical water system schematics Typical schematic - Central heating system - GITRÈ LN Boiler Central heating system manifolds Disconnect valves 4 Pumps 5 Non-return valves 6 Automatic vent valve 7 Boiler safety valve 8 Boiler drain cock 9 System filling cock 0 Water softener filter CH expansion vessel 7 6 CENTRAL HEATING RETURN CENTRAL HEATING FLOW 5 4 0 9 8 DRAIN DRAIN Schematic diagram - central heating and domestic hot water production - GITRÈ B/00 LN Boiler Central heating system manifolds Disconnect valves 4 Pumps 5 Non-return valves 6 Automatic vent valve 7 Boiler safety valve 8 Boiler drain cock 9 Storage cylinder safety valve 0 System filling cock CH expansion vessel Storage cylinder Storage cylinder drain cock 4 DHW expansion vessel 5 Water softener filter 6 Pressure reducer 7 DHW recirculation pump 7 5 6 0 CENTRAL HEATING RETURN CENTRAL HEATING FLOW 5 4 DHW USER 7 5 9 5 6 4 INLET 8 DRAIN DRAIN The DHW and central heating circuits must incorporate expansion vessels of adequate capacity as well as suitably rated safety valves. The condensate drain must be connected to a suitable collection and drain system. 9 9 The choice of system components and the method of their installation are left up to the heating engineer installing the system. Installers must use their expertise to ensure proper installation and functioning in conformity to all applicable legislation. If needed, water supplies and recovery circuits must be conditioned by suitable treatment systems. Refer to the values listed in the table on page. 00 Never run the boiler or the pumps dry. 8
INSTALLATION.8 Fuel connections GITRÈ LN boilers have their fuel connections at the rear. Fuel supply hoses must pass through the hole () in the back of the boiler before being connected to the fuel pump. Connect the hoses provided and pass a length of about 500 mm through the corresponding holes on the rear. A A Priming the pump To prime the oil pump simply start up the burner and check for a flame. If the burner enters lockout before any fuel reaches it, wait at least 0 seconds then turn the function selector to position (II) "Reset burner" for at least second before returning it to position (I). Wait for the burner to complete the entire ignition cycle again, up to the ignition of the flame. B C H (*) max. 4 m DESCRIPTION GITRÈ 4 LN GITRÈ 5 LN GITRÈ 6 LN A 50 mm B 50 mm C 4 mm H (*) Automatic shut-off device (if fitted). For details of electrical connections, see the "Automatic shut-off device (DAI)" section on pages 4 and 5 DESCRIPTION GITRÈ 5 B/00 LN A 07 mm B 96 mm C 47 mm If the oil feed system is in negative pressure, the return line must reach the same height as the suction line. This avoids having to install a bottom valve, which would be essential if the return hose were to be located above the level of the fuel. The installer must ensure that the negative pressure differential in the oil feed never exceeds 0.4 bar (0 cm Hg). If this value is exceeded, the fuel oil will release gas. Make sure that the oil hoses are perfectly oil-tight. 9 9 Clean out the oil tank at suitable intervals. The oil feed line must be suitable for the flow rate demanded by the burner. The oil feed system must also be equipped with all the necessary safety and control devices required by applicable legislation and standards. Refer to the table alongside for oil feed line characteristics. A filter must be installed in the oil feed line. Make sure that the oil return line is not kinked or blocked before starting up the boiler. Excessive back-pressure can cause the pump seal to fail. A B C H (m) L (m) Øi (8mm) Øi (0mm) 0 5 00 0,5 0 00 5 00,5 0 90 5 70 8 0,5 6 0 H = Height difference L = Maximum length of suction hose Øi = Internal diameter of hose Suction port Return By-pass screw 4 Pressure gauge fitting 5 Pressure adjuster screw 6 Vacuum gauge fitting 7 Valve 8 Auxiliary pressure measurement fitting 7 6 5 4 8 9
INSTALLATION.9 Combustion gas exhaust The flue pipe () and the connection to the stack () must be made in conformity to the laws, standards and regulations applicable in the place of installation. GITRÈ 4 LN - GITRÈ 6 LN GITRÈ 5 LN - GITRÈ 5 B/00 LN DESCRIPTION GITRÈ 4 LN GITRÈ 5 LN E G G E GITRÈ 6 LN 5 GITRÈ 5 B/00 LN E 78 mm G (flue gas exhaust fitting) 6-9 concentric Ø GITRÈ LN boilers derive their comburent air from the room in which they are installed. Suitable air vents must therefore be provided in compliance with applicable laws and standards. 00 Do not obstruct or restrict the air vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion and functioning..9. Technical specifications of stack The stack must satisfy the following requirements:: It must be constructed from materials that are impermeable to flue gases and that offer lasting resistance to mechanical stress, heat and the action of the products of combustion and condensate It must be vertical, free of restrictions and contain bends of no more than 45 It must be suitable for the specific operating conditions of the boiler and must be CE marked (EN856-, EN44) It must be of adequate dimensions to ensure draught and venting properties suitable for the needs of the boiler (EN84-) It must have adequate external insulation to prevent condensation and the cooling of flue gases the stack must have a dedicated condensate drain system at the bottom. The diameter of the stack must never be smaller than that of the flue pipe from the boiler. 9 9 In configuration B, the stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pressure at the boiler's flue gas exhaust..9. Connection to the stack The boiler must be connected to the stack using rigid flue pipes that are resistant to heat, condensate and mechanical stress. All joins must be sealed and the finished flue must be insulated. Only use materials that are suitable for this purpose, e.g. stainless steel. The near-horizontal section of flue pipe must have a slope of at least 5 towards the boiler and must also be properly insulated. In long near-horizontal sections of flue pipe (L> m), install a condensate drain system near the boiler exhaust (as shown in the figure) to drain off any condensate forming in this section of flue. The diameter of the stack must always be greater than that of the flue pipe from the boiler's exhaust fitting. To change direction, use a T section with an inspection cap to permit easy access for cleaning inside the pipe. After cleaning, always make sure that inspection caps are replaced tightly and that their seals are undamaged and efficient. Flue pipes must maintain a distance of at least 500 mm from flammable or heat sensitive construction materials. 9 9 Joins must be sealed with materials that are resistant to acid condensate and to the high temperatures of the boiler's flue gases. When installing flue pipes, always bear in mind the direction of the flue gases and of possible condensate flows. Inadequate or badly dimensioned stacks and flues can increase combustion noise, cause condensation problems and affect combustion parameters. Uninsulated flues are potentially dangerous and can cause burns. GITRÈ 5 LN and GITRÈ 5 B/00 LN boilers have diaphragms fitted inside the flue gas exhaust. Check that the diaphragm is correctly positioned and take care not to damage it during installation. 0
T T A INSTALLATION BOILER CONFIGURATIONS C - C If comburent air is drawn from outdoors, the appliances are type C "sealed" and the boiler room does not require ventilation. Connections in configuration C m m C C C C C Concentric wall vent. Twin flue pipes can also be used, but the wall through-pipes must be concentric or located close enough to be subjected to similar wind conditions. C Concentric roof vent. Outlets as for C. See the specific standard for details. A T L Adaptor Terminal Maximum straight length (This length must be reduced by metre for every 90 curve and by 0.5 metres for every 45 curve.) Concentric flue pipes (Ø 80/5) - FRANCE ONLY The boiler must be fitted with the relevant kit for use in these configurations. (See the manual provided with the kit for installation instructions). Coaxial flues can be oriented in whatever direction is most convenient for the room, provided the maximum specified lengths are respected. Description GITRÈ 4 LN GITRÈ 5 LN GITRÈ 5 B/00 LN GITRÈ 6 LN L 6.5 7.0 7.5 m Connections in configuration C L G Use of flues longer than the specified maximum leads to a loss of heat output from the boiler. Never obstruct or choke the comburent air intake pipe. A L G A G T L Adaptor Protective grille (not supplied) Terminal Maximum straight length (This length must be reduced by metre for every 90 curve and by 0.5 metres for every 45 curve.) Description GITRÈ 4 LN GITRÈ 5 LN GITRÈ 5 B/00 LN GITRÈ 6 LN L 6.5 7.0 7.5 m
INSTALLATION.0 System filling and emptying.0. Filling GITRÈ LN boilers require a filling pipe connected to the central heating circuit return pipe. Turn the mains power switch OFF and turn the control panel function selector to (0) before filling or draining the system. RI.0. Water quality requirements The heat transfer fluid (water) for the central heating circuit must conform to the quality parameters given in the following table: REFERENCE VALUES ph 6-8 Electrical conductivity less than 00 μs/cm (5 C) Chlorine ions less than 50 ppm Sulphuric acid ions less than 50 ppm Total iron less than 0. ppm Alkalinity M less than 50 ppm Total hardness less than 5 F Sulphur ions none Ammonia ions none Silicon ions less than 0 ppm Make sure that the central heating drain cock () and storage cylinder drain cock () (GITRÈ B/00 LN models) are closed before you start filling the system. Open the non-return valve () (GITRÈ B/00 LN models only) to facilitate filling (the slot in the screw must be perpendicular to the direction of flow = horizontal) GITRÈ LN If the hardness of the water exceeds the value specified in the table, it is mandatory to install a water softening system. Excessive water softening (leading to a total hardness < 5 F) can cause corrosion in metal parts (pipes and boiler components). Keep the electrical conductivity of the water under 00 µs/cm. 0 0 Do not top up the central heating circuit on a frequent or continuous basis as this can damage the boiler s heat exchanger. The use of automatic topping up systems should be avoided for this reason. GITRÈ B/00 LN
INSTALLATION GITRÈ B/00 LN 4 Close the water supply shut-off cocks; To empty the boiler, connect a rubber hose (5) (internal diameter Øint=mm) to the hose union on the boiler's drain cock (). To empty the storage cylinder, connect a rubber hose (5) (internal diameter Øint=mm) to the hose union on the storage cylinder's drain cock () (GITRÈ B/00 LN models) GITRÈ LN open 5 GITRÈ B/00 LN closed (non-return) Open the central heating circuit shut-off cocks and slowly fill the system until the pressure gauge reads out a value of.5 bar (cold). open Close the shut-off cocks opened previously and close the non-return valve () (GITRÈ B/00 LN models) NOTE The system is de-aerated automatically through the automatic vent valve (4) (GITRÈ B/00 LN models)..0. Emptying 5 NOTE Open a hot water tap to facilitate emptying the storage cylinder. Open the non-return valve () to facilitate emptying the boiler Before draining the boiler or storage cylinder: Turn the mains power switch OFF and turn the control panel function selector to (0).
INSTALLATION. Wiring diagram GITRÈ LN COM.G. B A LV LR TS Tm TR C C C C FU CO 4 5 6 7 8 9 0 COA DAI MO L N PE TA TA LPI NPI PE NC NC RE L N PE PI C N C 0V ~ 50Hz AE N X6 AE Power supply COM.G. position function selector XP6 LV Mains power indicator LR Burner lockout indicator TS Safety thermostat (0 C 0/-6) (*) TR Boiler control thermostat (55-8 C) (*) Tm Minimum temperature thermostat (50 C) (*) FU Mains power fuse 6. A-T CO-COA Multi-connectors MO Terminal strip PI Central heating pump (not supplied) DAI Automatic shut-off device (not TB supplied; only where required). The automatic shut-off device (DAI) and the relay (RE) must be suitable for a 0 VAC power supply. RE Relay (not supplied) X6 6 pin burner connector (female) (*) Homologated Yellow/Green L R N C Black Red Grey Violet K Black Blue MV M HEAT REQUESTA White BURNER CONTROLLER Black White Blue F V E C E F K MV Condenser Ignition electrodes Flame detector Thermostat for enabling start-up after pre-heating Fan motor R TB V XP6 Heating element Burner ground Fuel oil valve 6 pin burner connector (male) 4
4 4 4 5 5 4 5 6 INSTALLATION GITRÈ 5 B/00 LN COM-G. B A LV LR COM-E/I B TB TS Tm K A 5 6 TR TL TL C C C A 4 C C C C D CO 4 5 6 7 8 9 0 4 5 6 7 8 9 0 COA FU CO SPT 4 4 5 5 6 6 7 7 8 8 9 9 COA N L N PE TA TA L N PE 0V ~ 50Hz AE L LPI NPI PE N PI PE LPB NPB PE N PB PE MO AE Power supply COM.E/I Summer/Winter selector COM.G. position function selector FU Mains power fuse 6. A-T LR Burner lockout indicator LV Electric power supply signal CO-COA Multi-connectors CO-COA Multi-connectors MO Terminal strip TB Storage cylinder thermostat (0 70 C) TL Maximum temperature thermostat (8 C) (*) TL Heat dissipation thermostat (90 C) (*) TR Boiler control thermostat (55 8 C) TS Safety thermostat (0 C 0/-6) (*) Tm Minimum temperature thermostat (50 C) (*) PI Central heating pump (not supplied) PB Storage cylinder pump K Burner start relay SPT Burner total shutdown relay TA Room thermostat DAI Automatic shut-off device (not supplied; only where required). The automatic shut-off device (DAI) and the relay (RE) must be suitable for a 0 VAC power supply. RE Relay (not supplied) X6 6 pin burner connector (female) (*) Homologated C E F K MV X6 XP6 TB Yellow/Green L R N Black Red C Grey Violet K MV M HEAT REQUEST Black Blue White NC C NC N N DAI C RE BURNER CONTROLLERH Black White Blue Condenser Ignition electrodes Flame detector Thermostat for enabling start-up after preheating Fan motor R TB V XP6 F V E Heating element Burner ground Fuel oil valve 6 pin burner connector (male) 5
INSTALLATION. Electrical connections GITRÈ LN boilers are fully cabled in the factory. The only connections required for their installation are those of the mains power supply, room thermostat and central heating circuit pump. Proceed as follows to access the control panel terminals: Remove the front and top panels (A) and (B) from the boiler casing; Unscrew the fixing screw (C) and remove the protective cover (D); D C GITRÈ LN B Route the power cable (E) through the cable gland (F) and secure it in place. A H G F E GITRÈ B/00 LN B F A The terminal strip (H) can be removed to facilitate the connection of cables. Simply loosen the terminal strip fixing screws (G). 6
INSTALLATION Make the electrical connections as shown in the following diagrams; Connections to be made by the heating engineer control panel terminal strip GITRÈ LN H L N PE TA TA 4 5 L N PE TA TA 4 5 L N PE 0V 50Hz TA TA L N PE 6 7 8 9 0 PI The following is mandatory: The use of an omnipolar magnetothermic switch, line disconnecting switch in compliance with CEI-EN standards (contact opening of at least mm) Respect the connection L (line) - N (neutral). Keep the earth conductor cm longer than the power supply conductors Use cables with a section greater than or equal to.5 mm, complete with cable terminal caps Refer to the wiring diagrams in this manual for all electric operations Connect the equipment to an effective earthing system. 00 It is strictly forbidden to use pipes of any kind to ground the appliance. 00 It is prohibited to pass the power supply and room thermostat cables near hot surfaces (delivery pipes). If contact is possible with parts that have temperatures above 50 C, use a suitable type of cable. The manufacturer is not responsible for any damage caused by failure to earth connect the device and failure to comply with what is indicated in the wiring diagrams. GITRÈ B/00 LN L N PE TA TA L N PE 4 5 6 7 8 9 0 H L N PE TA TA PI PB 4 5 L N PE TA PI PB L N PE 0V 50Hz TA TA Live Neutral Earth/ground Room thermostat Central heating pump (not supplied) Storage cylinder pump The jumper (TA-TA) must be removed from the terminal strip (H) in order to connect up the room thermostat. NOTE The room thermostat connection must be dry (no voltage). On completion of the electrical connections, replace all removed components in the opposite order. 7
COMMISSIONING AND MAINTENANCE COMMISSIONING AND MAINTENANCE Open the control panel access door;. Preparing for initial startup The boiler must be started up for the first time by the manufacturer's Technical Assistance Service. Perform the following checks before starting up the boiler: Check that the fuel shut-off cock and heating system shut-off cock are open ONLY FOR MODELS GITRÈ 4 LN-GITRÈ 5 LN-GITRÈ 6 LN Turn the boiler thermostat to about the middle of the section with three lines; Check that the central heating circuit pressure gauge shows a pressure over bar with the system cold. Check also that the circuit is properly de-aerated 0 40 60 80 00 0 0 Turn the function selector to ON (I) and make sure that the green power indicator lights. Check that the expansion vessel is correctly pre-charged the electric connections have been made correctly Check that the flue and air vents are made to applicable laws and standards.. Initial startup NOTE the burner only starts up at the end of the fuel oil preheating phase. 0 40 60 80 00 0 0 Once you have completed all the checks listed above, proceed as follows to start up the boiler for the first time: Turn the boiler s mains power switch ON The boiler now starts up and the burner remains lit until the temperature setpoint is reached. Set the room thermostat to the required temperature (~ 0 C) or, if the system has a timer or timer-thermostat, make sure that this is switched ON and adjusted to the required temperature (~ 0 C).; 8
COMMISSIONING AND MAINTENANCE ONLY FOR GITRÈ B/00 LN MODELS Turn the boiler s mains power switch ON; Adjust the boiler and storage cylinder thermostats to about the middle of the section with three lines; Turn the Summer/Winter selector to (II) Winter; 40 60 80 40 60 80 0 00 0 00 0 0 0 0 Set the room thermostat to the required temperature (~ 0 C) or, if the system has a timer or timer-thermostat, make sure that this is switched ON and adjusted to the required temperature (~ 0 C).; Turn the function selector to ON (I) and make sure that the green power indicator lights. NOTE the burner only starts up at the end of the fuel oil preheating phase. Open the control panel access door; 0 40 60 80 00 0 0 The boiler now starts up and the burner remains lit until the temperature setpoint is reached... Ignition failure If any ignition errors or malfunctions occur, the burner enters LOCKOUT. This is shown by the red button light on the burner and by the warning light on the control panel. 0 40 60 80 00 0 0 9 9 If a LOCKOUT SHUTDOWN occurs, wait about 0 seconds before resetting the burner. 9
COMMISSIONING AND MAINTENANCE.. Resetting the burner and safety thermostat To restore normal startup conditions, open the protective cover over the control panel and turn the function selector to position (II) "Reset burner" for at least second before returning it to position (I). Wait for the burner to complete the entire ignition cycle again, up to the ignition of the flame. The "Summer/Winter" selector is set to (II) "Winter", the boiler thermostat is adjusted to its minimum setting and the storage cylinder temperature setpoint is changed (GITRÈ 5 B/00 LN models only). Then turn the function selector from position (I) to (0) and back; 40 60 80 40 60 80 40 60 80 0 00 0 0 0 00 0 0 0 00 0 0 If boiler temperature becomes too high, the manual reset safety thermostat trips. No warning signal is given if the safety thermostat trips, but the fact that is has tripped can be seen from the boiler temperature gauge (T>0 C). Proceed as follows to reset the safety thermostat: Wait until boiler temperature falls below 80 C; Open the control panel cover; Unscrew the cap over the safety thermostat reset button; Press the reset button; Replace the cap. The "Summer/Winter" selector is set to (I) "Summer" and the storage cylinder temperature setpoint is changed. (GITRÈ 5 B/00 LN models only). Then turn the function selector from position (I) to (0) and back; 0 40 60 80 00 0 0 0 40 60 80 00 0 0 The room thermostat or timer setting is changed; 0 40 60 80 00 0 0 Eliminate the cause of the overheating before restarting the boiler. Make sure that all the pumps in the system are free and rotate in the right direction;. Checks during and after initial start-up Once the boiler has started up, make sure that it shuts down and re-starts properly when: The boiler thermostat setting is changed; The function selector is moved from position (I) to (0) and back; Turn the mains power switch OFF and make sure that the boiler shuts down completely. 40 60 80 0 00 0 0 4 0 40 60 80 0 00 0 0 4 0 0
COMMISSIONING AND MAINTENANCE Provided all the above conditions are satisfied, start the boiler up again, then analyse the combustion fumes. The sampling hole for flue gas analysis must be located along the straight section of flue at a distance (L) from the boiler exhaust. (Refer to applicable standards before drilling). FUNCTIONING MODE Performance display When the pump is running, LED is green. The four yellow LEDs indicate the pump's instantaneous electrical power consumption as shown in the table. Nr. displayed Meaning % power LED flashing green Stand-by 0 LED green and LED yellow, both lit Low load 0-5 LED green and LEDs, yellow, all lit LED green, LEDs,, 4 yellow, all lit LED green, LEDs,, 4, 5 yellow, all lit Lowmedium load Mediumhigh load 5-50 50-75 High load 75-00 Always plug the sampling hole after analysing the flue gases... Storage cylinder pump control The pump is configured in the factory for a maximum head of 7 metres. Use the button () only to activate the button lock function as instructed below. USER INTERFACE The user interface consists of a push-button (), a red/green LED () and four yellow LEDs (). L LED LED LED LED 4 LED 5 5 The pump functions at fixed speed. Alarm display If the pump detects one or more alarm conditions, LED changes from green to red. When an alarm is active, the LEDs indicate the type of alarm as shown in the following table. If more than one alarm is active at the same time, the LEDs only show the alarm condition with the highest priority. Alarm priority follows the order of the table. When no alarm is active, the user interface automatically displays pump performance. Nr. displayed Meaning Function Action LED red and LED 5 yellow, both lit LED red and LED 4 yellow, both lit LED red and LED yellow, both lit The pump rotor is blocked Supply voltage too low Electronic controller error The pump automatically attempts to start every.5 seconds Indication only. The pump continues to function The pump has stopped because supply voltage is too low or because an error has occurred in the internal electronic controller Wait or check that the pump rotor is free to rotate Check the voltage of the power supply Check the voltage of the power supply or replace the pump Button lock/unlock function The button lock function serves to prevent improper use or accidental changes to pump settings. When the button lock is active, pressing the button has no effect. This prevents users from accidentally accessing setting mode while allowing them to use setting display mode. When the button is held down for 0 seconds, all the LEDs except the red LED flash for one second to indicate that the button lock function has been activated/deactivated.
COMMISSIONING AND MAINTENANCE.. Burner control and adjustment ADJUSTING PUMP PRESSURE Turn the adjuster screw (5) to achieve the pressure setting specified in the table. 5 4 5 0 6 Adjusting pump pressure GITRÈ 4 LN GITRÈ 5 LN GITRÈ 5 B/00 LN GITRÈ 6 LN,5 bar 4,5 bar,6 bar ADJUSTING THE AIR DAMPER The air damper can be adjusted without removing the burner cover. Use an Allen key to turn the adjuster screw () to achieve the required setting on the graduated scale () GITRÈ 4 LN GITRÈ 5 LN GITRÈ 5 B/00 LN GITRÈ 6 LN Adjusting the air damper,6,8,
COMMISSIONING AND MAINTENANCE.. Burner functioning and programming Program for functioning with heater Normal functioning HT PH K FM ID V F LED POWER ON HT PH FM ID V K F LED F LED t t Flashing green t Flashing orange ti Flame failure during functioning* Flashing green Flashing orange Signal not needed t4i ts t5i Flashing green Flashing green Green Green tpp Lockout Heat request Pre-heater Thermostat for enabling start-up after pre-heating Fan motor Ignition electrode Fuel oil valve Flame detector Colour of button LED Fast flashing red Cycle times t0 - - t t -.5 tl - 5 tp max 600 (*) t - 5 tl 5 ti - ts - 5 t4i - 0 t4l t5i - - - 0.4 - - 0.8 tr repeats tpp 60 Times are expressed in seconds. (*) independent of burner controller DESCRIPTION t0 Standby: the burner waits for a heat request Input signal standby time: reaction time, the t burner controller waits for time t Initialisation verification time: time following t startup of main power supply Check for extraneous light or false flame signal tl during t: the burner controller waits for time t then enters lockout; the motor does not start Maximum fuel oil pre-heating time: the burner tp controller waits for time tp then enters lockout Pre-purging time: the fan motor runs then the fuel t oil valve opens Check for extraneous light or false flame signal tl during pre-purging: the burner controller enters lockout after time tl ti Spark pre-ignition time ts Safety time t4i Total spark ignition time Valve deactivation reaction time following flame t4l failure t5i Spark post-ignition time - Time needed to reset controller from reset button - Time needed to reset controller from remote reset Cycle repetition: max. repeats of the complete ignition sequence if flame fails during normal tr functioning; the controller enters lockout if no flame is detected after the last ignition attempt Post-purging time: supplementary purge at the tpp end of the heat request Post-purging can be interrupted by a new heat request
COMMISSIONING AND MAINTENANCE Lockout caused by ignition failure Lockout caused by extraneous light during pre-purging POWER ON POWER ON HT HT P PH PH K FM t t t t4i K FM M t t ID ti ts t5i ID V Lockout V ts F tl Lockout LED Flashing green Flashing orange Flashing green Red F Flashing green Flashing orange Flashing green, red Red Signal not needed LED HT Heat request PH Pre-heater K Thermostat for enabling start-up after pre-heating FM Fan motor ID Ignition electrode V Fuel oil valve F Flame detector LED Colour of button LED Cycle times t0 - - t t -.5 tl - 5 tp max 600 (*) t - 5 tl 5 ti - ts - 5 t4i - 0 t4l t5i - - - 0.4 - - 0.8 tr repeats tpp 60 Times are expressed in seconds. (*) independent of burner controller 4