Airfel ECOFEL KB1-24CE, Service Manual

Page 1: ...ADVANCED CLIMATE TECHNOLOGIES ECOFEL KB1 24CE BOILER SRVICE MANUAL PUBLICATION NO K05 08 Revision Date 29 02 2008 No 0 ...

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Page 3: ... 11 6 19 Safety Valve 12 6 20 Thermo manometer 12 7 Operation in Heater Mode 13 8 Operation in Usage Water Mode 13 9 Control Panel 15 9 1 Product Label 16 10 Installation Instructions 16 10 1 Installation Location and Conditions 13 10 2 Installation 17 10 3 Flue Kit Installation 17 10 4 Homocentric Flue Kit Application 18 10 5 Installation of Hydraulic Systems 18 10 6 Natural Gas LPG Conversion 19...

Page 4: ... MANUAL 1 Product Identification ECOFEL Code Expansion ECOFEL Code Expansion 2 Revision Date 29 February 2008 Rev No 0 Name of the wall type appliance Conventional boiler Heat exchanger type Version Capacity 24 kW Exhaust gas type Integrated hot usage water ...

Page 5: ...d hot water demands 3 For heating and hot usage water it has full flame modulation reducing the flame length and providing fuel economy 4 Provides easy diagnosis by the user and service through 9 different failure codes delivered by the LED light system on the control panel 5 Airfel boilers provide easy transportation and installation thanks to their contemporary design lower connection kit suspen...

Page 6: ...r Natural gas G 20 mm 1 35 Injector Diameter LPG G 31 mm 0 77 Heater Circuit System Operational Pressure Bars 1 5 Min Max Operational Pressure Bars 0 5 3 Max Min Water Temperature C 82 35 Expansion Tank Capacity l 7 Expansion Tank Pre Pressure Bars 1 Usage Water Circuit Operational Pressure Max Min Bars 10 0 5 Min Operational Flow l min 2 7 Max Min Water Temperature C 55 35 Dimensions Dimensions H...

Page 7: ...ts surface or the flame goes out due to any reason and the user is warned via the failure code 4 6 Safety Valve 3 bars Protects the heater system and boiler against probable high pressure 4 7 Automatic Air Purger Provides the discharge of the air in heater system and prevents air compression within the system 4 8 Frost Safety System It is developed for preventing the heater system and boiler again...

Page 8: ...ansion tank 15 Limit thermostat 16 Ionization electrode 17 3 bars safety valve 18 Automatic air purger 19 Circulation pump 20 Flow control sensor 21 Filler valve A Filler Valve B Flow Control Switch C 3 Bars Safety Valve D Circulation Pump E Automatic Air Purger F Expansion Tank G Pressure Switch H Hermetic Flue Kit I Fan J Heater Circuit Sensor K Limit Thermostat L Main Heat Exchanger M Burner N ...

Page 9: ...priate distance between them The gas coming from the valve passes through the injectors thus entering the venturi of the burner and here it is mixed with primary air It then gets out through the numerous holes on the pipes and start burning The air drawn from the combustion chamber is used as the secondary air The quantity of primary air is self adjusted according to the diameter of the injectors ...

Page 10: ... volume This expansion pressurizes the nitrogen in the tank and compresses the nitrogen with the help of diaphragm The excess pressure thus formed in the system is absorbed by the expansion tank and system pressure is continuously kept stable Care must be taken for anti freeze products to be added to the water in closed system against freezing should not be harmful for the rubber diaphragm The fun...

Page 11: ...l occur between stream and return of heater piping and water coming out the heat exchanger will be mixed with returning water 6 10 Ignition and Ionization Electrode It is located in front of the burner at right and left foremost position Inside of the electrodes are metal Outer surface is coated with ceramic material which functions as electrical insulator The ignition electrode is mounted such th...

Page 12: ...the voltage value of the gas valve coil providing modulation To sum up when there is an increase in water temperature voltage value of the gas valve coil falls down and gas valve reduces the gas pressure in burner through modulation Heater NTC Sensor Usage water NTC Sensor 6 13 Flow Control Switch and Mechanism Its function is to sense usage water demand It will start to rotate a wheel according t...

Page 13: ...cted by direct contact with the flame of the burner It provides the transfer of heat generated on the surface of the burner fully to the face of heat exchanger 6 17 Main Card The functions and components of the boiler are controlled by the main card Display card allows adjusting the user settings and display of failure codes and water temperatures 6 18 Water Pressure Pressure Switch The pressure s...

Page 14: ... is reduced In this case the boiler should be shut down and water pressure should be reduced to 1 5 bars by opening the discharge valve after the water in the system cools down Safety valve should not be used for discharging the piping water 6 20 Thermo manometer Thermo manometer measures the boiler outlet water temperature with the capillary tube connected to the heating water heat exchanger outl...

Page 15: ... set by the user by applying the pre set partial load gas pressure from the gas valve to the burner As it approaches closer to the desired temperature main card performs modulation by reducing the voltage transmitted to the gas valve and when the heating water in the system reach 5ºC above the desired temperature main card puts out the flame by cutting the energy transmitted to the gas valve Burne...

Page 16: ...es strength generated by the effect of the flame to the main card Main card detects the flame formation on the burner By comparing the desired usage water temperature with the temperature it measures from the usage water sensor the main card increases or decreases the voltage it transmits to the mod ulation coil At 8ºC above the desired temperature the burner shuts down Constant hot water comfort ...

Page 17: ...led indicating that usage water is operating When the boiler is in summer mode this led is on continuously When the tap is turned on the led starts to blink indicating that the boiler is operating in the hot usage water mode 5 Red led indicating the failures during operation In any failure in the boiler due to any reason this led lights and warns the user The boiler shall be restarted by turning t...

Page 18: ...kW Max 26 2kW Nominal Power P Min 9 02 kW Max 24 3 kW Electrical Power 220V 50Hz 110W Electrical Protection Class IPX4D Usage Water Flow ΔT 30ºC 10 l min Usage Water Max Operational Pressure 10 bars Heater Circuit Max Operational Pressure 3 bars Usage Water Circuit Temperature ºC 35 55 Heater Circuit Temperature ºC 35 82 Destination Country TR Manufactured in AIRFEL Production Facilities AIRFEL HE...

Page 19: ...made of appropriate material then the flue kit should be coated with insulating material at least 20 mm thick Do not pass flue kit pipes through the ceiling If passing through the ceiling is indispensable the flue kit pipe should be coated with insulating material at least 20 mm thick The space between the flue kit pipe and the wall it is passing should not be filled with hard material such as con...

Page 20: ... loss i e it can be assumed that for each elbow installed 1m pipe is added to the system 10 5 Installation of Hydraulic Systems Fasten water inlet and outlet pipes as defined below Heater system and usage water system connections are described below Heater stream piping Usage hot water outlet Gas Inlet City Water Inlet Heater Return Piping On the radiator return line strainer and on the top and bo...

Page 21: ...ater per hour there will not be adequate heating in some portion of the radiators and the boiler shall operate inefficiently If the capacity requirement of the house is lower and the capacity of the boiler can be adjusted to the requirement of the house it will be observed that the radiators are heated better after capacity adjustment For example If in a house requiring 12 KW 10320 kcal heat the h...

Page 22: ...er clockwise it decreases and adjust the required gas pressure according to the maximum gas pressure table figure STM P0040 See maximum gas pressure table Adjusting the Minimum Gas Pressure Remove one of the modulation coil cables figure STM P0041 Hold the bolt nr 3 fixed and by means of a No 5 flat spanner turn the bolt nr 4 at the inner side clockwise it increases and adjust the required gas pre...

Page 23: ... terminals located in the electrical box the one with the bridge is room thermostat connection terminal The other is 220V room thermostat or timer connection terminal 21 Revision Date 29 February 2008 Rev No 0 AC 220V FAN NEUTRAL GAS VALVE MODULATION HEATER WATER TEMPERATURE SENSOR ROOM THERMOSTAT PRESSURE SWITCH LIMIT THERMOSTAT EXHAUST GAS SWITCH HEATER CIRCUIT PRESSURE USAGE WATER FLOW TURBINE ...

Page 24: ...AC 4 7 KΩ GAS VALVE REGULATOR VALVES P2 SOCKET ENDS NO 1 2 10 2V DC 47 Ω AIR PRESSURE SWITCH P3 SOCKET ENDS NO 1 5 SHORT CIRCUIT 0 Ω WATER PRESSURE PRESSURE SWITCH P3 SOCKET ENDS NO 4 7 SHORT CIRCUIT 0 Ω LIMIT THRMOSTAT P3 SOCKET ENDS NO 2 6 SHORT CIRCUIT 0 Ω ROOM THERMOSTAT P2 SOCKET ENDS NO 5 6 0 Ω TURBINE Hz P5 SOCKET ENDS NO 2 3 MAX 120 MIN 18 HZ NTC Sensor Heater P2 socket 3 4 Usage water P5 ...

Page 25: ...an be changed Parameter adjusting shall remain active for 2 minutes Parameter programming menu can be exited by applying the access method or by cutting the power of the appliance After the parameter value is changed the new value will be saved to the card processor in 5 seconds When saving is realized Leds blink for 2 seconds 23 Revision Date 29 February 2008 Rev No 0 Parameter Led Explanation Op...

Page 26: ...nds Leave the button in any usage water temperature When Test Mode starts 3 leds start to blink Test mode shall operate the boiler at maximum capacity for 15 minutes During this operation maximum minimum gas pressure adjustment can be done Test mode can be exited by performing the accessing steps When there is usage water demand test mode is suspended 24 Revision Date 29 February 2008 Rev No 0 ...

Page 27: ...N L ON L Call authorized service Usage water temperature sensor failure ON L ON L OFF Call authorized service Improper ionization ON L ON ON L Call authorized service Boiler configuration error 1 1 1 Call authorized service Pump blockage ON ON ON Normal operation Flue kit mode Test mode ON L ON L ON L Used by authorized service Heater system demand OFF OFF ON L Normal operation Usage water demand ...

Page 28: ...he Main card P2 ends no 3 4 If the same values cannot be read connection cable is replaced or repaired If it can be read main card is replaced If there is still limit thermostat interference temperature of the environment in which limit thermostat exists is checked If the temperature is below 75ºC limit thermostat contacts are measured In case 0Ω closed circuit is not obtained limit thermostat is ...

Page 29: ...ensor Failure It means hot usage water sensor is short circuited or operating improperly In this case and leds blink together Solution Hot usage water NTC heat sensor is checked If 10ºC 15 kΩ 20ºC 12 Ω 40ºC 5 7 kΩ 60ºC 3 kΩ values are not read heat sensor is replaced In case these values are read measurement at main card P5 ends no 1 6 is made If the value cannot be read connection cable is replac...

Page 30: ...0830009 10 Terminal Sheet Single 7022330005 11 Lower Bracket Sheet Painted 7020100005 12 Right Side Cover Assembly 7022040005 13 Gas Valve 7020920016 14 Gas Valve Pipe Y 7020910006 15 Cable Passage Rubber D4 Y 7021210005 16 Cable Passage Rubber D15 Y 7021210003 17 Combustion Chamber Insulation Set 7022510012 18 Combustion Chamber 7022510010 19 Pressure Switch Passage Rubber 7020010235 20 Hermetic ...

Page 31: ...ev No 0 ECOFEL BOILER KB1 24CE BURNER GROUP PICTURE NO PART NAME PART CODE 1 Ignition Electrode 7020180010 2 Ionization Electrode 7021190006 3 Burner 7020450014 4 Gas Valve Pipe Passage Rubber 7020930004 5 NG Conversion Set 7020700015 6 LPG Conversion Set 7021510012 ...

Page 32: ... 4 Usage Water Inlet Pipe and Passage Rubber 7021460009 5 Surface Type NTC Sensor Y T7335D1123 7021630014 6 Surface Type NTC Sensor Y T7335D1081 7021630012 7 Thermo manometer Clip 7021170009 8 Heating Water Inlet Pipe and Passage Rubber 7021180010 9 Heating Water Outlet Pipe and Passage Rubber 7021180008 10 Pipe Clip 18 MM G MPMM18 7021370051 11 Limit Thermostat Y 2455R 01000077 7021500008 12 1 9x...

Page 33: ...Pump CESAO 3 PUMP 15 50 7021890013 4 Bypass Valve 7020520005 5 By pass Pipe 7020540006 7 Brass Part Clip 7021370062 8 Clip Between Water Inlet Hydraulic Block and Pump 21mm 7021370061 9 Flow control switch 7020860002 10 Water Inlet Hydraulic Block and Filler Tap 7020680003 11 Heating Water Outlet Block 7021180005 12 By Pass Pipe Assembly Clip 18mm 7021370053 13 1 90x4 30x11 30 mm Klingerite Gasket...

Page 34: ...E NO PART NAME PART CODE 1 Water Inlet Hydraulic Block Spare Inner Group 7022020008 2 Water Inlet Hydraulic Block Flow Limiter 7022280007 3 Water Inlet Hydraulic Block Filter 7022020007 4 Aluminum Shim 18x14 2 Sp 1 5 B0020 7020090002 5 Filler Tap Spare Shaft 10 0051 7020690002 6 Filler Tap Spare Head 10 0157 7020660003 ...

Page 35: ...UP PICTURE NO PART NAME PART CODE 1 Panel Front Cover H Type 7020750011 2 Potentiometer Button 7020200009 3 BMBC Electronic Card 7020130014 4 Panel Body 7020740005 5 Panel Back Cover 7020760011 6 Thermo manometer IMIT D40 7021170006 7 Panel Bracket Feeder 7022610002 8 Panel Bracket Pin Bearing 7022620002 ...

Page 36: ...ILER KB1 24CE CABLE GROUP PICTURE NO PART NAME PART CODE 1 Grounding cables group 7022350010 2 P9 Connector cable group 7021220014 3 P7 Connector cable group 7021220013 4 P5 Connector cable group 7021220012 5 P3 Connector cable group 7021220011 6 P2 Connector cable group 7021220010 ...

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Page 38: ...ADVANCED CLIMATE TECHNOLOGIES ECOFEL KB1 24CE BOILER SRVICE MANUAL PUBLICATION NO K05 08 Revision Date 29 02 2008 No 0 ...