ELLPREX 1 12 2 16 1 8 20 2 3 18 22 14 26 26739 - 01/05 rev.
WARNING When the boiler is operated with a pressure jet gas burner, because it does not belong to any of the categories among those listed in the Annex II to the Directive 97/23/CE (regarding pressure equipment) and beeing, furthermore, mentioned in the Directive 90/396/CE (Gas Appliance Directive) to which the art. 1, clause 3, paragraph 6.5 makes reference, it is excluded from the scope of the Directive.
GAS SAFETY (INSTALLATION AND USE) REGULATIONS, 1994 It is law that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with. The installation of the boiler MUST also be in accordance with the latest I.E.E.
1 CONSTRUCTIONAL-DIMENSIONAL TECHNICAL CHARACTERISTICS .................... page 1.1 1.2 1.3 2 INSTALLATION ................................................................. page 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 4 5 4 Construction of the ELLPREX boilers .................................. page Working principle ................................................................... page Dimensions and hydraulic connections ................................ page Packaging .........................
1 CONSTRUCTIONAL-DIMENSIONAL TECHNICAL CHARACTERISTICS 1.1 - CONSTRUCTION OF THE ELLPREX BOILERS The ELLPREX boilers are of horizontal type (oval till the ELL 970 and cylindrical from ELL 1100) with flame reversion in the combustion chamber and with third pass in the smoke pipes. The construction completely satisfies the requirements of the EN 303 - part 1.
1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS FOR ELLPREX 170÷630 I F A N T1 O T3 B P T2 T1-T3-T2 E D 1 T5 C M T5 4 2 3 H H G T6 T4 L T4 100 Q 1 2 3 4 Panel board Burner fixing plate Smoke chamber cleaning door Sight glass ELLPREX Nominal Output T1 T2 T3 T4 Nominal Input Water content R C.H. flow C.H. return Expansion vessel connection Boiler drain Water side pressure loss(**) Smoke side pressure loss Maximum working pressure Weight l m w. c. mm w. c.
DIMENSIONS AND HYDRAULIC CONNECTIONS FOR ELLPREX 760÷970 I F A B T1 D N O T3 E T1-T3-T2 T2 P T5 T5 C M 1 4 2 3 H H G T6 T4 L T4 200 Q R fig. 5 1 2 3 4 Panel board Burner fixing plate Smoke chamber cleaning door Sight glass ELLPREX Nominal Output Nominal Input T1 T2 T3 T4 Water content C.H. flow C.H. return Expansion vessel connection Boiler drain Water side pressure loss(**) T5 Flue socket T6 Max. burner blast tube dia.
DIMENSIONS AND HYDRAULIC CONNECTIONS FOR ELLPREX 1100÷2650 I F A B D N T3 O T1 E P T1-T3-T2 T2 1 T8 C 2 M 4 T5 T5 T6 G T7 H H 3 T4 1 2 3 4 Panel board Burner fixing plate Smoke chamber cleaning door Sight glass Nominal Output ELLPREX Model T4 L Q T1 T2 T3 T4 Nominal Input kW 200 Water content R C.H. flow C.H. return Expansion vessel connection Boiler drain T5 T6 T7 T8 Water side pressure loss(**) Smoke side pressure loss Maximum working pressure Weight fig.
DIMENSIONS AND HYDRAULIC CONNECTIONS FOR ELLPREX 3000÷3500 I F B D A N T1 E T3 O T2 P T8 T5 C M 4 2 G T6 H H T7 3 T4 1 2 3 4 Panel board Burner fixing plate Smoke chamber cleaning door Sight glass ELLPREX 145 L Q Nominal Output Nominal Input T1 T2 T3 T4 Water content R C.H. flow C.H. return Expansion vessel connection Boiler drain T5 T6 T7 T8 Water side pressure loss(**) Smoke side pressure loss Maximum working pressure Weight fig. 11 Flue socket Max.
2 INSTALLATION 2.1 - PACKAGING The ELLPREX boilers are supplied complete with door and smoke chamber already fitted, whilst the casing with the insulation matress are contained in separate cardboard packaging(s). After having removed every packing make sure the content is undamaged. In case of doubt do not use the boiler and revert your self to the supplier. The elements of the packing must not be left to the course of the children as potential sources of danger.
2.4 - CONNECTION TO THE CHIMNEY The chimney has a foundamental importance for the good operation of the boiler. Due to the low temperature of the smokes during the intermittent operation, it is necessary that the chimney is perfectly impermeable to the condensate of the combustion products and manufactured with corrosion resistant materials.
90 °C; under this aspect it it suggested to consider 100 °C. The expansion pipe connects the C.H. system to the expansion vessel. This pipe which starts from the connecting point T3 (see table DIMENSIONS), must have NO gate valve on it. 2.5.6 - SHUNT PUMP The ELLPREX boilers must always operate in forced circulation hot water systems and with a minimum return temperature of 55 °C.. So, it is suggestable to adopt a shunt pump, having also an anti-condensation purpose, 2.
2.6.3 - BOILERS “ELL 1100-ELL 3500” For all these models the hinging and the fixing of the door are made according to the schema of fig. 16. In these cases the two hinges on the L.H. side are normally used as rotating hinges (from Right to Left), whilst the two ones on the R.H. side are used as closing hinges. Exactly the contrary will happen when the door is hinged on the R.H. side and the door needs to be opened from Left to Right.
2.7 - BURNER All the burners equipping the ELLPREX boilers must be CE certificated and must conform 2.7.2 - CHOICE OF THE BURNER The correct choise and the adjustment of the burner are foundamental for the best operation of the boilerand then they shall be accurate and not underevaluated. The burner will be selected by verifying that its working diagram (fuel flow rate - pressure in the furnace) is compatible with the same features declared for the boiler. Remember that the smoke side resistance, i.e.
2.8 - CONNECTION OF THE SIGHTGLASS TO THE BURNER VIA A COOLING LINE The flame sightglass is equipped with a 1/8" threaded connection (pos. 1) on which a pressure test nipple (9mm dia.) is fitted. This can be used with a silicon pipe for the measurement of the counterpressure in the combustion chamber. At the place of this pressure test nipple, which must be held, a special microbore pipe (pos. 2) will connect the flame sightglass directly to the pressure room downstream the fan of the burner.
12 ELLPREX 170÷630 13 10 9 8 15 2 11 14 3 5 1 4 11 6 7 fig. 19 Assembly of the casing should be carried out in the following steps: Refer to diagram on fig. 19 for details A. Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. B.
3b / 4b ELLPREX 760÷970 8 14 13 12 3b 11 10 3a 2 5 15 9 7 6 4b 1 Mounting sequence (Ref. fig. 21) A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided in the accessories box, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels (3a, 3b and 4a, 4b) with the lower bend inside the bottom L profiles and hooking the upper bend to the upper L profile.
ELLPREX 1100÷2200 11 10 9 3b 8 3a 7 2 5 12 6 4b 1 Mounting sequence (Ref. fig. 22) A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. Make a covenient cut in the upper part of the insulation blanket to get easy access to the bulb holders.
ELLPREX 2650 12 11 3c 9 7 13 3b 6 8 3a 10 2 14 5 4c 4b 15 1 4a 5 fig. 23 Mounting sequence (Ref. fig. 23) A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. Make a covenient cut in the upper part of the insulation blanket to get easy access to the bulb holders.
ELLPREX 3000 - 3500 3 3 2 4 5 3 3 1 6 5 7 fig. 24 Mounting sequence (Ref. fig. 24) A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. Make a covenient cut in the upper part of the insulation blanket to get easy access to the bulb holders. B) Position the L.H.
Sequence of bulbs introduction 6 5 2 1 Introduce the sensors in the upper bulb holder(s) in the following sequence (Ref. to fig. 25): - thermometer (1) - working thermostat (2) - high limit thermostat (3) - minimum thermostat (4). We recommend that the introduction of the sensors is made up to bottom of the bulb holder(s). To get a better contact introduce also the arcuated spring (6) and secure the capillaries with the special clip (5).
3 STANDARD PANEL BOARD 3.1 - PANEL BOARD TYPE 21057 - FUNCTIONS DESCRIPTION 11 Through the main switch 11 the panel board and all the equipments connected to it will be under power. The switches 12 & 13 switch On and OFF the power to the burner and the Heating pump (via a relay, if necessary). With the thermostat 32 the working temperature of the boiler can be adjusted. This thermostat is provided with a DPDT contact, for the control of a two stage burner.
3.3 - INTRODUCTION OF THE ELECTRONIC PANEL BOARD TYPE 28735 The ELLPREX boilers can be supplied with an electronic panel board complete with a digital outer compensator with built-in microcomputer and permanent memory. The management of the boiler is made through the outer compensator which, in addition to the burner and pump control, can control also two different heating zones. The automatic operation is made on the base of the data detected by the boiler, D.H.W.
3.5 - ELECTRICAL WIRING DIAGRAM FOR SINGLE PHASE BURNER AND PUMPS 41 IG 11 TERMINAL OF KROMSCHRÖDER OUTER COMPENSATOR ..
3.6 - OUTER COMPENSATOR On how to adjust or to program the outer compensator, please refer to the instruction manual supplied with the outer compensator. In the following table we list the factory set parameters, which are "not changeable" and the parameters which are adjustable by the user according to his needs.
FACTORY SET PARAMETERS (protected by a secret code) N° 20 21 22 23 24 25 26 27 28 Parameter Introduction of the numeric code Numeric code Bus code for heating circuit 1 (HK1) Bus code for heating circuit 2 (HK2) Anti frost temperature Max. flow temperature for heating circuit 1 Max.
VII 2 1 1 1 2 1 FBR1 3 3 6 D.H.W. TANK SENSOR (SPFS) 9 8 7 2 4 I 5 KFS/SPFS VFAS AFS T1 T2 2 FLOW SENSOR 2 (VFAS) BOILER SENSOR (KFS) 10 2 T3 T4 1 M 1 2 3 4 5 IV 1 2 VI 1 9 10 8 M ROOM SENSOR 1 (FBR1) OUTER SENSOR (AFS) 2 1 V P1 P2 VFAS 2 1 1 VFAS VIII 2 1 1 2 FBR1 3 L H ROOM SENSOR 2 (FBR1) 3 4 IX + Bus III 3 2 1 2 N L1 L1' 1 2 1 VFAS 7 3 6 II 5 4 2 3 1 In the fig. 31 the typical connection of the boiler to C.H.
4 COMMISSIONING AND OPERATION 4.1 - POSITIONING OF THE TURBULATORS B The ELLPREX boilers are designed to be used in an output range to improve the seasonal efficiency and the possibility to be adopted in all the heating installations. The output must be adjusted at the commissioning stage, according to the system designer indications and, in any case, within the operation range for each boiler model shown on page 6 to 9, by the burner technician, which will determine the fuel throughput.
Turbulators removal Detail 1: Fit the brush handle extension onto the turbulator remover Withdraw the pin from turbulator. Detail 2: Fit the pin in the radial hole with a hammer. Detail 3: Screw the turbulator remover onto the turbulator. Detail 4: Turn up to unblock the turbulator. Detail 5: Withdraw the turbulator Detail 6: Turn the remover counterclockwise to release the turbulator fig. 34 The procedure from detail 3 to 6 has to be repeated for all the turbulators. 4.
4.4 - OPERATION OF THE BOILER To ascertain that the form and the dimension of the burner flame, which we estimate very important, are the correct ones for the good operation of the boiler, it is suggested to make a visual inspection of the furnace at least one month after the first lighting. The furnace cylinder shall show a homogeneous coloration for all of its length to demonstrate that the flame reverses in proximity of the blind bottom.
cleaning doors on the smoke chamber. Besides it will be necessary to verify the good operation of the protection and control devices (thermostats, thermometers) of the boiler and of the plant (manometers, flow and pressure switches, expansion vessels) and all the safety devices. In this occasion it will be necessary to notice the quantity of reinstatement water used and decide, also in base to its hardness, an intervention of preventive descaling.
AG S.P.A. 46033 Casteldario - Mantova - ITALIA - tel. ++39.0376.57001 (r.a.) - telefax ++39.0376.660556 www.unical.ag info@unical-ag.com This catalogue is purely indicative. The manufacturers reserve the right to modify technical data and any other parts of the contents.
