Unical ALKON 70 kW, Installation And Servicing Manual

Page 1: ...ALKON 50 INSTALLATIONAND SERVICINGMANUAL Notice This manual is avaible in the English and French language In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Condensing gas boiler LATTNER ...

Page 2: ...ller connection 31 Connection of the additional safety device 31 3 22 Wiring diagrams 32 3 23 Ladder diagrams 34 3 24 Starting up 35 3 25 Filling the system 35 3 26 Initial lighting 36 Preliminary checks 36 Ignition and switching off 36 Information to be supplied to the user 36 3 27 Testing ignition safety shut off device 38 3 28 Burner adjustment 39 3 29 Programming of the operational parameters ...

Page 3: ... resistance to lime scale it is recommended to adjust the domestic hot water temperature as near as possible to the one you really require We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found this period can be extended to two years 1 GENERAL INFORMATION CAUTION INDICATES A POT...

Page 4: ...been purged For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally authorized If the tank has not been correctly purged problems could occur during ignition If this occurs contact the liquid gas tank s supplier 1 5 SAFETY WARNINGS 1 4 INFORMATION TO BE HANDED OVER TO THE USER Go through the information in this manual with the owner operator and...

Page 5: ...se the main gas tap Open all windows and doors where the gas leakage has occurred Inform the gas society or a company specialized in installing and servicing heating systems DANGER Explosive and easily inflammable substances Do not use or leave explosive or easily inflammable material as for example petrol paint paper in the room where the appliance has been installed A sample DataPackaging for a ...

Page 6: ...ociated hazard in writing DANGER Gas is flammable and may cause an explo sion Beware if you smell gas there may be an explo sion hazard If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WARNI...

Page 7: ...ng only original spare parts Non observance of the above requirement may jeopardize the safety of the appliance To guarantee the efficiency and correct functioning of the appliance it is indispensable to have the boiler serviced annually by a qualified person If the boiler remains unused for long periods ensure that any dangerous parts are rendered innocuous Before putting again into service an ap...

Page 8: ... 1 G Gas Inlet Ø Sc Outlet condensate drain siphon from aluminium body Scf Outlet condensate drain siphon from the flue pipe SV Safety valve outlet A Air intake S Flue Outlet TECHNICAL FEATURES AND DIMENSIONS 2 2 DIMENSIONS eBUS device CH temperature selector switch 86 176 F 30 80 C Flame modulation in function of the absorbed power Pump overrun function Additional functions diagnostics of operati...

Page 9: ...E SPACER PIPE REPLACEABLE FOR MOUNTING OF OPTIONAL CIRCULATOR FLOW TEMPERATURE SENSOR RETURN TEMPERATURE SENSOR OVERHEAT THERMOSTAT IGNITION TRANSFORMER MIN WATER PRESSURE SWITCH IGNITION ELECTRODE SAFETY VALVE ALUMINIUM HEAT EXCHANGER CONDENSER CONDENSATE DRAIN Ø 1 25 mm FLUE OUTLET PIPE Ø 3 14 80 mm PIPE WITH SMOKE SAMPLING SIPHON AIR INTAKE OPENING Ø 3 14 80 mm R 1 R 1 G ...

Page 10: ...RATURE SENSOR RETURN TEMPERATURE SENSOR OVERHEAT THERMOSTAT IGNITION TRANSFORMER MIN WATER PRESSURE SWITCH IGNITION ELECTRODE SAFETY VALVE ALUMINIUM HEAT EXCHANGER CONDENSER CONDENSATE DRAIN Ø 1 25 mm FLUE OUTLET PIPE Ø 3 14 80 mm PIPE WITH SMOKE SAMPLING SIPHON DETECTION ELECTRODE AIR INTAKE OPENING Ø 3 14 80 mm R 1 R 1 G ...

Page 11: ...in siphon 5 Overheat thermostat 6 Heat exchanger 7 Burner 8 Air vent valve 9 Flue outlet Air intake 10 Fan 11 Premix 12 Room sealed chamber 13 Replaceable pipe for insertion optional pump only for ALKON 50 pump only for ALKON 70 14 Pressure switch against lack of water 15 Safety valve supplied 16 Smoke pressure switch 17 Manomètre optionelle M C H flow G Gas supply R C H return M R G 1 2 3 4 5 6 7...

Page 12: ...TORS BURNER PRESSURES DIAPHRAGMS OUTPUTS GAS CONSUMPTIONS please refer to the paragraph BURNER ADJUSTMENT Btu hr kW Btu hr kW Btu hr kW Btu hr kW Btu hr kW Btu hr kW Btu hr kW F C lb hr kg hr gal min l min psi kPa psi kPa gal L F C F C V Hz lb kg lb kg 55 800 227 500 204 750 199 000 47 700 87 45 85 50 298 600 54 000 91 46 96 7 98 4 98 3 0 22 124 20 6 20 3 IV 1 43 7 3 92 1 176 86 120 60 130 141 16 ...

Page 13: ...y after this verification has been carried out WARNING In rooms where there is the presence of aggressive vapours or dust the appliance must operate independently from the air present in the boiler s location room WARNING The appliance must be installed by a qualified engineer who complies to the technical professional requirements who under his own responsibility guarantees the compliance of the ...

Page 14: ...70 has been reviewed for compliance with the applicable sections of the following North American Standards ANSI Z21 13 CSA 4 9 Gas fired low pressure steam and hot water boilers ASME SECTION IV ASME Boiler and Pressure Vessel Code with addenda Section IV Rules for Construction of Heating Boilers SCAQMD RULE 1146 2 EMISSIONS OF OXIDES OF NITROGEN FROM LARGE WATER HEATERSAND SMALL BOILERSAND PROCESS...

Page 15: ...order to be able to securely hold and support the boiler weight with its water content Take note of the necessary space around the boiler for installation of venting system pipework and servicing See drawing in section 3 4 The location of the boiler can be determined by using the draw on page 16 Remember to account for the spacing of the plumbing kit Drill the necessary holes Install the mounting ...

Page 16: ...nd de tergents paints adhesives in proximity of the boiler The boiler must be installed in such a way that it is pro tected from water dripping spraying rain etc during operation and service circulator replacement condensa te trap control replacement etc This boiler is for intended for indoor installations only Products to avoid present in boiler room and or around combustion air intake Spray cans...

Page 17: ... scale Boiler system flushing Not Boiler heat exchanger When replacing an existing boiler the heating system should be flushed with the old boiler in place before the new boiler is added to the sy stem If the old boiler has already been removed a bypass must be piped in when the new boiler is installed in order to facilitate the flushing of the system The boiler must be valved off from the system ...

Page 18: ...estrictions The flue outlet pipe has a connection for the discharge of condensate The boiler room has a suitable outlet for the discharge of condensate produce by the boiler The electrical system has been fitted in compliance to the specific norms and the work has been carried out by a competent person ...

Page 19: ... boiler running Minimum 8 inches W C with gas flowing verify during boiler startup Ensure that the high gas pressure regulator is installed at least 6 to 10 feet upstream of the boiler Gas piping Use a gas shut off valve compatible with propane gases A sediment trap must be provide upstream of the gas con trols The boiler pipe is provided with external 3 4 M NPT thread onto which the tail piece of...

Page 20: ...tream of the dirt filter scale cartridge or y strainer When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system s components and by the configuration of the same system The route of the piping has to be conceived taking all the necessary precautions in order to avoid air locks and to facilitate the continuous purging of the ...

Page 21: ...Δ Δ Δ ΔT 27 F 15 C Max flow rate demanded in gal h l h Δ Δ Δ Δ ΔT 36 F 20 C 154 000 45 13 199 000 58 32 683 2826 513 2120 683 3927 663 2946 If determined by the installer or technical engineers must be sized according to the data of boiler and system In case of fixed raet pump is recommended to choose a circulator with flow rate and head at about 2 3 of the characteristic curve The Δ Δ Δ Δ Δt betw...

Page 22: ... or damage 3 13 CONNECTING THE EXPANSION VESSEL IN A SINGLE BOILER SYSTEM CAUTION Damage to the installation due to faulty pressure relief valve An expansion tank must be part of the central heating system The expansion tank must be appropriate to the water content of the installation The pre charge pressure depends on the installation height above the mounted expansion tank 1 R M G NOTICE The exp...

Page 23: ...re resistant to con densate if the condensate outlet of the boiler is lower than the drain a condensate pump must be used The condensate produced by the boiler has a pH value between 3 and 4 Do not drain the condensation water to the external rain gutter because of the danger of freezing and blockage of the drain Install a neutralization unit if required by the local code Condensate inlet coming f...

Page 24: ... the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the generator in time For this purpose it will be necessary to fix the following chemical physical characteristics of the water PH include between 6 5 and 8 Hardness 6 9 grains 9 15 fr Water hardness When there is a water hardness of more than 6 to 9 grains hardness a water softener m...

Page 25: ...o not store flammable materials and liquids in the immediate vicinity of the boiler All Air from inside the Building room air The closet shall be provided with two permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combi ned space shall be considered in making this determination Each opening shall have a minimum fre...

Page 26: ... can freeze causing ice formations Do not use chimney as a raceway if another boiler or fire place is vented into or through chimney EXHAUST INTAKE 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum NOTICE Terminals should be positioned as to avoid pro ducts of combustion entering openings into bu ildings or other vents NOTICE Terminals should be positioned a...

Page 27: ...h the roof The combustion air is withdrawn directly from the room where the boiler is installed The flue system must be installed in accordance with the local and national Standards Use only original LATTNER flue outlet systems which are provided from the follow manufacturer TABLE FLUE OUTLET SYSTEM Damages caused by installation errors and for non observance of the instructions given by the manuf...

Page 28: ...e total allowed linear maximum length of the smoke evacuation and air intake pipes of Ø 3 15 80 mm is 787 4 20 m including one wide radius curve and one evacuation terminal ATTENTION In the case in which danger of freezing subsists the insulation of the smoke evacuation pipe is recommended on the whole length in both cases outside or in the chimney ATTENTION For boiler have horizontal runs sloping...

Page 29: ...ut let terminals which admit fresh air to the burner and discharge the products of combustion to the outside through concentric or twin ducts The minimum distance between the inlet air duct and the flue outlet duct must be of 9 8 in and both terminals must be posi tioned within a 19 6 in square section 3 20 VENT AND AIR SUPPLY SYSTEM FOR ORIZONTAL DIRECT VENT SYSTEM Smoke evacuation by two separat...

Page 30: ... unless it is explicitly foreseen Do not permit children or inexpert people to use the appliance Mains electrical supply connection 120 V 60 Hz Power supply cord The boiler is provided complete with a power supply cord 59 1 5 m long and with a cross section area of 3 x 16 AWG The electric connections of the boiler are shown in the section named ACTUAL WIRING DIAGRAM paragraph 3 22 WARNING We remin...

Page 31: ...r the connection remove the existing jumper CDS 1 Prearrangement for the connection of the additional safety devices LIGHTBLUE LIGHTBLUE LIGHTBLUE For the connection of the E8 heating controller to remove the bridge wire existing between the terminals 1 and 2 Room thermostat and or E8 heating controller connection CAUTION Switch off and disconnect the electricity supply before carrying out any ope...

Page 32: ...NGE P BLUE BROWN YELL GREEN GREEN GREEN WHITE WHITE WHITE BROWN BLUE BROWN GREEN RED CH WHITE DHW IG VM L1 N 120 V 60 Hz SS MDV 00333986 BLUE N BROWN L E ACC TR ACC BLUE BROWN RED YEL GREEN VG YEL GREEN OR Only with BROWN BLUE BLACK WHITE TL TF B L A C K BLUE PF BLUE CDS 1 YELL GREEN BROWN BLUE P BOILER SYSTEM P 1 NC BROWN 3 C WHITE BLUE Minimum water pressure switch Ignition electrode Detection e...

Page 33: ... C WHITE BLUE BLUE CDS 1 YELL GREEN BROWN BLUE P BOILER SYSTEM P SYST Pump system Note Any accessories shown in the drawn are not available for this model of boiler Minimum water pressure switch Ignition electrode Detection electrode Power switch On Off Pump boiler CH sensor CH return sensor Limit thermostat Smoke thermostat only pre arrangement Ignition transformer Gas valve Modulating fan detect...

Page 34: ...ME CAUTION HIGH VOLTAGE SPARK LEAD SPARK ROD A8 1 IG A8 2 IG A8 2 A9 2 A9 6 A6 6 A6 5 A9 5 A9 1 A8 1 A3 5 SRR RIBBON CABLE A3 A3 6 A3 3 SR A3 4 A4 6 PF A4 5 A4 4 A4 5 TL A4 1 CDS 1 A2 3 DK A2 1 8 8 8 DISPLAY A1 4 A1 2 A1 1 A1 3 RL 4 RL 1 RL 2 RL 3 A4 4 A4 3 SL ATTENTION AUTE TENSION CÂBLE D ALLUMAGE A4 2 ...

Page 35: ...refully by obser ving the following steps boiler in Off position open the radiator bleeds and make ascertain the good operation of the automatic air vent fitted in the boiler open progressively the filling valve and make sure the automatic air vent in the system work properly close the bleeders of the radiators when water starts to come out control via manometer Optional that the water pressure ha...

Page 36: ...36 Instructions for the installer ...

Page 37: ...en filled with water DANGER Before commissioning the appliance fill the siphon and check the correct drainage of the condensate If the appliance is used with the condensate drain siphon empty there could be danger of intoxication resulting from the escape of flue gasses there are no water leaks all the necessary ventilation conditions and minimum clearance distances are guaranteed for subsequent s...

Page 38: ...n the gas valve knob in OFF position After 1sec boiler switch off LIGHT BLUE Power on by switching ON OFF switch 3 27 TESTING THE IGNITION SAFETY SHUT OFF DEVICE Lock out indicator led illuminated fault indicator led Press Reset Key will displayed the fault code LF loss of flame the boiler will retry ignition cycle 7 seconds after which if was not removed the cause of the fault gas tap the boiler ...

Page 39: ...conds the boiler will operate in the CH mode at the maximum output led 1 illuminated Check that the C02 values are within the values indicated in the table Burner pressures If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to decrease the value and in an ANTICLOCKWISE direction in order to increase it B Min output adjustment By pressing the key decrease agai...

Page 40: ...TICLOCKWISE direction in order to decrease it Type of Gas 7 1 74 11 2 74 7 1 74 11 2 74 0 038 1 07 0 015 0 42 0 038 1 07 0 015 0 42 0 173 4 91 0 067 1 90 0 156 4 42 0 060 1 71 A Natural E Propan HD A Natural E Propan HD min FL ALKON 50 9 5 10 8 9 5 10 8 92 93 82 83 24 24 24 24 0 22 5 6 0 22 5 6 0 22 5 6 0 22 5 6 9 5 10 8 9 5 10 8 Start output IG 40 50 40 50 Check the C02 levels often especially at...

Page 41: ...ting the desired value pressing the YELLOW key stores this new value in the memory Press the YELLOW key and the LIGHT BLUE key simultane ously to enter in the service mode SE and change the values of the pre set operating parameters PUMP OVERRUN Continue to change to the parameters by pressing the key decrease The successive parameter which can be changed is PUMP OVERRUN Po Repeat the operations A...

Page 42: ...BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE 3 30 VARIATION OF INPUT RANGE FOR HIGH ALTITUDE It is necessary adjust nominal heat input by reducing the fan speed Modify the parameter FH from the boiler panel board See factory parameter supplied separately and modifia ble only with access code LIGHT BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE LIGHT BLUE VIOLET YELLOW BLUE Insert C...

Page 43: ...and return pipes as well as the cold water inlet valve Remove the appliance s front panel After having carried out all the necessary maintenance work always follow these steps Open the CH flow and return valves as well as the cold inlet valve if previously closed Purge and if necessary proceed with restoring the hea ting system s pressure until a pressure of 0 8 1 bar is rea ched Open the on off g...

Page 44: ...an be found on the back page of this manual Verify that the air ventilation system air intake and air intake pipes are unobstructed After 1 year maintenance Perform cleaning of the burners only by blowing with com pressed air acting from the side flame Verify visually the state of the spot weldings of the L profiles and the burner mesh Compressed air Wash with water the combustion chamber avoiding...

Page 45: ...lame must burn with a clear ORAN GE stable flame Check the flame through the inspection glass The flame pattern should be as shown in the figures below SATISFACTORY ORANGE FLAME FLAME YELLOW CO2 HIGH NOT SATISFACTORY BLUE CO2 LOW NOT SATISFACTORY ORANGE OK SATISFACTORY After removing inspected and possibly cleaned Flue pipes and air intake replace the tubes correctly Attention to the sense of doub...

Page 46: ...G THE CONDENSATE DRAIN SIPHON In order to check and clean the siphon carry out the following steps unscrew the plastic nuts 1 and 2 and to remove the siphon Verify if there are any deposits flush them out with clean water reassemble the siphon in reverse order DANGER Before commissioning the appliance fill the siphon via the filling hole and check the correct drainage of the condensate If the appl...

Page 47: ... 3 Code Description Mains voltage 96 Vac Corrective action Check that the mains voltage is 96 Vac if the mains voltage is correct replace the control board Code Description Insufficient gas pressure Corrective action Check the pressure if the pressure is correct check the efficiency of the gas pressure switch and or the wiring Code Description Difference between the heating temperature sensor SR a...

Page 48: ...ption Flame signal detected before the ignition cycle Corrective action Disconnect the detection electrode s wire from the control board if the error code disappears replace the cable otherwise replace the control board Code Description Flame detected after burner OFF Corrective action Disconnect the gas valve s wire from the control board if the error code disappears replace the control board oth...

Page 49: ...49 Spare parts ALKON 50 13 36 37 41 39 38 3 9 33 23 31 43 20 10 32 12 1 18 2 14 16 2 25 4 22 26 4 4 4 27 28 17 8 21 6 29 7 35 6 39 11 24 42 5 15 44 44 34 40 45 ...

Page 50: ...50 Spare parts ALKON 70 13 36 37 41 39 38 3 9 33 23 31 43 20 10 32 12 1 18 2 14 16 2 25 4 22 4 27 28 17 8 21 6 6 30 39 11 24 42 5 15 4 26 4 35 44 44 34 45 40 ...

Page 51: ...eat thermostat 203 F 95 C 22 95261988 3 15 80mm seal 2 pcs 23 95261999 Cover protection switch 24 95262087 3 15 80mm seal 25 95262128 Gas valve 26 95263579 Ignition transformer 27 95263551 Fan Alkon 70 95263552 Fan Alkon 50 28 95262451 Mixer Alkon 70 95262789 Mixer Alkon 50 29 95262604 Low water switch 30 95263555 Pump GRUNFDFOS UPS 26 99 FC 31 95310239 Display case 32 95310726 Fascia board 33 953...

Page 52: ... press Also reserves the right to bring those changes that it will hold necessary to it own products or profits without jeopardizing its essential characteristi cs Lattner Boiler Mfg Co 1411 9th St S W P O Box 1527 Cedar Rapids IA 52404 319 366 0778 800 345 1527 Fax 319 366 0770 www lattner com LATTNER ...