PLUS COMBI - Columbia Heating
Contents
1. to the terminal block situated next to the control the jumper J in Fig 12 6 must be control panel removed Tofused spur L ce N The room thermostat must be connected bh Power supiy to the Control Terminal Block Fig 12 7 lal A la terminal joci ss 3 2 1 2 2 Q TL SSE Poom temose LIS KS Ermina seck i aae 1 120 VAC Control LN Terminal Block p S S O oO ru 1 ORO O Power supply Figure 12 6 3 Anyexternal controls and connection lines must be rated at 120 VAC but under no terminal block 2 leis External controls o O terminal block circumstances should external live volt Figure 12 7 age be connected to the room thermostat e Connect the room thermostat between link on the boiler terminals 1 and 3 as shown in Fig 12 7 12 4 Relay Panel Connection e The relay control must be connected to e Connect the dry contact switch of the re the terminal block situated next to the lay panel to the 120 VAC control terminal control panel block Fig 12 9 Generic Relay Control 120V rating To fused spur isolation switch L N d Power supply L block L e N MS 3i i 3 2 1 ere comes P X I E 4 E terminal bloc S Gy S External controls Plo pale nm Oo o terminal block KJ 2 Qj 2 Qv Figure 12 9 Connect2. Figure 17 4 17 6 Checking the combustion fan The combustion fan does not require any special maintenance Lubrication is not necessary due to the fact that the ball bearings are sealed Check that the fan operates and that the vis ible impeller fins are free of any dirt or obstructions 17 7 Checking the ue Have the integrity of the flue outlet pipe 24 on page 10 air intake pipe 25 on page 10 checked periodically the venturi device 23 on page 10 cleaned and the efficiency of the flue safety circuit checked at least once a year For all the above maintenance operations it is ad visable to call an approved Service Engineer Remove the four Phillips head screws from the vent connector on the boiler Remove the vent connector from the boiler by pulling vertically on it Remove the first elbow from the horizontal run of the exhaust to the outside Using a flashlight inspect each length of vent pipe for obstructions and dirt buildup Clean any that is found with an appropriate sized brush nspect the venture device inside the outlet of the combustion fan Make sure that it is free of any dirt build up or blockage Make sure the seals are properly seated in the female ends of the vent pipe with the fins facing the male end of the pipe Reinstall the elbow onto the horizontal run of the pipe first by simply pushing the parts together Push the vent adapter down onto the top of the boiler and reinstall the four Phi
3. This SAVIO Plus Combi has a 10 year warranty a copy of which is provided with the boiler Please be sure to return the warranty registration card as the warranty will be void without your boiler s serial numbers located on the ratings label affixed to the boiler date of installation and the name of your installer being on record in our files Thank you for purchasing our SAVIO Plus Combi If you have questions or comments please don t hesitate to contact us immediately Our goal is 10096 customer satisfaction BOYERTOWN 2 SAVIO PLUS COMBI MANUAL Table of Contents Section Title Section Number Page Number Warnings 5 6 Important Information 7 General Information 1 8 Technical Information M135 30CM 2 8 9 Parts List 3 10 Internal Piping and Parts List 4 11 Electric Diagrams 5 12 Sequence of operation 5 1 13 Installation Location 6 14 Exhaust Pipe Location 7 15 Mounting Bracket 8 16 Venting 9 17 24 Restrictor Sizing 9 1 18 Fitting the Flue System 9 2 18 Choice of Flue 9 3 19 24 Pipe Connections 10 25 Gas Pipe Connections 11 26 Electrical Connections Wiring 12 27 29 Power Connection 12 1 27 Connection to the Electricity Supply 12 2 27 Room Thermostat Connection 12 3 28 Relay Panel Control Connection 12 4 28 Zone Valve Microswitch Connection 12 5 29 Finishing 12 6 29 Circulator Sizing 13 30 Circ Cap as a Function of Flow Rate 13 1 30 Expansion Vessel 13 2 30 Piping 14 31 34 SAVIO PLUS COMBI MANUAL 3 T
4. air intake sampling point Figure 15 11 15 10 Instructing the user Hand over the User manual this Installation Operation and Service manual to the end user and explain how to use the unit in Central Heating mode Take the User step by step through the lighting instructions Show the User how to switch off the appliance quickly and indicate the position of the elec tric service switch and the boiler on off switch Explain the proper use and adjustment of all system controls this will ensure the greatest possible safety and fuel economy Explain the function and use of the function switch Explain how to turn off the appliance for both short and long periods and advise on the pre cautions necessary to prevent damage should the appliance be inoperative when freezing conditions may occur Fill in the details required on the Boiler Guarantee Certificate and hand to the User advis ing them to return the correct section for boiler Guarantee registration Finally advise the User that for continued safe and efficient operation the appliance must be serviced by a competent person at least once a year KW 12 14 16 18 20 22 24 26 Useful output BTU h 40950 47750 54600 61400 68240 75064 81900 88700 Pa 290 370 460 560 660 780 900 1040 inwc 116 148 184 224 265 3 13 3 61 4 17 Naturel m lh 176 2 00 223 246 269 291 3 14 3 36 ft h 577 656 7 31 8
5. s S Figure 18 3 Part Description Order Number A Coaxial flue kit 10999 0387 0 SAVIO PLUS COMBI MANUAL 47 19 Installer Notes System Checkout Boiler Model No Serial No Original Purchaser Installer Performance Tests GROSS STACK TEMPERATURE ROOM TEMPERATURE AMBIENT NET STACK TEMPERATURE CO2 O2 SMOKE READING COMBUSTION EFFICIENCY COMMENTS 48 SAVIO PLUS COMBI MANUAL SAVIO PLUS COMBI MANUAL 49 50 SAVIO PLUS COMBI MANUAL SAVIO PLUS COMBI MANUAL 51 17962 1519 0 2908 52A4 USA
6. the dry contact switch to termi Figure 12 8 nals 1 and 3 shown in Fig 12 9 When connecting any type of relay con trol the jumper J in Fig 12 8 must be re moved 28 SAVIO PLUS COMBI MANUAL 12 Electrical Connections Wiring Cont 12 5 Zone Valve Micro Switch Connection The zone valve micro switch must be con Vane Thaimoctit nected to the terminal block situated next to the control panel e To fused spur N L isolation swi m latior T j l I N f ower supply E terminal block N o e 4 L E I 2 UM d ET Taiamai paniei A a Ora v A Isl Is O o 120 VAC 120 VAC Control D O O Control Terminal Terminal Block Figure 12 10 Figure 12 11 e When connecting the zone valve switch e Connect the micro switch of the zone the jumper J in Fig 12 10 must be re valve to terminals 1 and 3 as shown in fig moved ure 12 11 Connect the zone valve switch to the room thermostat as shown in figure 12 11 12 6 Finishing Route the electrical supply cord and the external control cord as illustrated in Fig 12 12 prre To the external control device To the fused spur isolation switch Cio e P Figure 12 12 Lock the cords in place with the flexible cord clamps Replace the control panel reversing the steps on page 27 SAVIO PLUS COMBI MANUAL 29 13 Circulator Sizing 13 1 Circulator capacity as a function of
7. to it To ensure the remaining appliances will function properly the test procedure below should be followed At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determi
8. 07 8 82 9 54 10 30 11 02 Pa 680 860 1060 1270 1500 1740 2000 2270 inwc 145 169 225 321 434 5 62 7 06 8 95 Propane Kg h 1 3 1 5 1 7 1 9 2 0 2 2 2 3 2 5 Ib h 3 0 3 3 3 7 44 4 4 4 8 5 1 5 5 Table 15 1 40 SAVIO PLUS COMBI MANUAL 16 Gas Conversion WARNINGS Procedures to adapt the boiler to the type of gas available must be car ried out by a competent and responsible person Components used to adapt it to the type of gas available must be genuine parts only Procedures Check that the gas cock 30 on Section 4 fitted on the gas supply pipe is turned off and the appliance is switched off at the circuit breaker Remove the front and side panels of the case see the section 17 2 Annual Main tenance Dismantelling the External Panels Take off the lid of the sealed chamber Remove the front panel of the combustion chamber Figure 16 1 Loosen the screws A and remove the burner 7 Figure 16 1 Carry out the conversion for the type of gas replacing the burner injectors cor rectly Re assemble the burner the front panel of the combustion chamber and the lid of the sealed chamber Extract the control panel as explained in the section 12 1 of this manual Loosen the screws D and remove the ser vice panel figure 16 2 SAVIO PLUS COMBI MANUAL Set correctly the dip switch 2 to the cor rect position Fig 16 3 in accordance with the follow
9. 15 8 To carry out the adjustment use the adjustment device RISC with the help of a screwdriver By rotating the device clockwise the pressure increases Adjust the gas pressure at the burner to the value according to the useful c h output wanted Tab 15 1 Reassemble the service panel Close the gas valve outlet pressure test point 15 figure 15 5 Reassemble the front pannel of the case 38 SAVIO PLUS COMBI MANUAL 15 Commissioning Cont 15 8 Labels placement Figure 15 10 Warning The installation is not complete unless labels supplied are placed on the boil er as shown in Figure 15 10 All the labels supplied with the boiler are numbered for reference According to Figure 15 10 place all the labels on the boiler Use label numbered as 1 already installed in the front panel to begin the placement in the correct way SAVIO PLUS COMBI MANUAL 39 15 Commissioning Cont To check the exhaust gas 15 9 Checking the ue system and combustion Theflue system should be visually checked Reference tables are given in the Sec for soundness Check all clamps gaskets tions 2 on page 9 of this manual for proper and fixings are secure and tight CO2 levels Ensure that the flue terminal is sited cor rectly in accordance with the flue fitting instructions Alr Fl e exhaust sampling points Remove the plugs indicated Fig 15 11 Insert the analyzer probe in the exhaust gas sampling point or in the
10. HEATING Maximum pressure psif 300 Minimum pressure psif 435 ELECTRICAL Voltage 120 8 SAVIO PLUS COMBI MANUAL 2 Technical Information Cont ENERGY CAPACITY Nominal heat input 0 2000ft 16 9 Nominal heat input 2000 4500ft Mz Minimum heat input Maximum useful output 0 2000ft 102 Maximum useful output 20006000 Minimum useful output 41 6 GAS SUPPLY PRESSURE Gas Nomai Min Mex Propane inwe 1 0 80 t9 GAS PRESSURE AT BURNER Gas f Mim Mex ignition FLUE DESIGN Minimum Venturi pressure Flue pipe diameter Pf 2 25 4 Coaxial in 3 25 5 Twin split pipes 3 25 3 25 Nominal heat flow rate 0 2000ft 19 9 Nominal heat flow rate 2000 4500ft Min Exhaust temperature Max Exhaust temperature SAVIO PLUS COMBI MANUAL GAS FLOW RATE Gas Mm Mak CLEARANCE TO COMBUSTIBLES Back i 9 Em C s Bum s Flue pipe fear m 9 FLUE GAS FIGURES DOMESTIC HOT WATER Minimum temperature bemmwenm m ums D h w AT 25K D h w AT 30 K 32 8 Maximum temperature D h w AT 35 K 32 D h w AT 40K gal h 2 3 Parts List Primary Components 12 Pump Pump vent plug Automatic air purger valve Modulation gas valve Flame detecting electrode Ignition electrodes Burner Combustion chamber Primary heat exchanger 10 Fan 11 Air pressure switch 12 Air switch pres Test points 13 Safety thermostat 14 Modulat
11. I MANUAL 10 Pipe Connections The SAVIO Plus Combi is supplied with a 3 4 stainless steel gas pipe A in figure 10 1 2 3 4 copper pipe C D in figure 10 1 2 1 2 F G in figure 10 1 located in a plastic bag in the boiler package 1 o A Stainless steel gas pipe n L t B Main circuit drain cock C C h supply copper pipe eee D C h return copper pipe E C h PRV discharge copper pipe F Dhw outlet pipe B G Dhw inlet pipe H Condensate trap C E F A G D Figure 10 1 Installation Remove the protective caps off boiler connections Figure 10 1 Thoroughly clean the connections Attach the supplied components to the boiler connections see Figures 10 1 Be sure to use the proper gaskets for the pipe connections Attach the condensate trap to an appropriate drain pipe Before connecting the boiler to the heating system piping review the suggested piping dia grams in Section 4 page 11 If the c h system is above the boiler level it is advisable to install c h cocks close to the boiler for servicing operation Ahot water boiler installed above radiation level or as required by the Authority having juris diction must be provided with a low water cutoff device elther as part of the boiler or at the time of boiler installation Condensate trap The condensate trap allows the discharge of the condensate via the condensate drain pipe avoiding in the mean timethe escape of combustion pro
12. S avio PLUS COMBI WALL HUNG GAS BOILER FOR CENTRAL HEATING SUPPLY Please Read Instructions Carefully Save for Future Reference WARNING If the information in this manual is not followed exactly a re or explosion may result causing property dam age personal injury or loss of life Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance MEE TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Fol low the gas supplier s instructions If you can not reach your gas supplier call the re department e Z e a Q zx e Z Installation and service must be performed by a quali ed installer service agency or the gas supplier Manufactured by Distributed by E Boycriown Furnace qa lt i BOYERTOWN FURNACE CO PO Box 100 Z 4 a4 ea 24 e a p z Un Z p lt a4 ea p aa Sic D oo BOYERTOWN PA 19512 e 1 610 369 1450 D N CERTIFIED A US KR Dear Customer Thank you for buying a SAVIO Plus Combi The SAVIO Plus Combi is a high efficiency condensing wall mounted gas boiler which pro vides central heat supply water We realize that it is not possible to answer all questions about the SAVIO Plus Combi system in this manual Reading this installation man
13. able of Contents Section Title Section Number Page Number Primary Secondary with Zone Valves 14 2 33 Manifold Piping with Zone Valves or Circ 14 3 34 Commissioning 15 35 41 Initial Filling of the System 15 1 35 Lightning the Boiler 15 2 35 Checking the Gas Pres at the Burner 15 3 36 Adjustment of the Gas Pressure 15 4 37 Checking the Ignition Device 15 5 37 Checking the Burner Ignition 15 6 38 Adjustment of the Useful c h Output 15 7 38 Labels Placement 15 8 38 Checking the Flue System and Comb 15 9 39 Instructing the User 15 10 40 Gas Conversion 16 41 Annual Maintenance 17 42 44 Warnings 17 1 42 Dismantelling the External Panels 17 2 42 Emptying the C h System 17 3 42 Emptying the D h w circuit 17 4 43 Cleanig the Burner 17 5 43 Checking the combustion fan 17 6 43 Checking the Flue 17 7 43 Checking the press in the exp vassel 17 8 44 Visual Inspection of Appliance 17 9 44 Gas Pressures and Soundness 17 10 44 Cleanig the primary heat exchanger 17 11 44 Cleanig the domestic hot water exchanger 17 12 44 Condensate trap 17 13 44 Vent Part Spares 18 45 47 Installer Notes 19 48 4 SAVIO PLUS COMBI MANUAL WARNING Boiler is certified as an indoor appliance Do not install boiler outdoors or locate where it will be exposed to freezing temperatures WARNING If the information in this manual is not followed exactly a re or explosion may result causing property dam age personal injury or loss of life Donot store o
14. ate through the outside wall that is less than 18 thick Cut the pipe as necessary so that no more than 6 protrudes from the house Slide the exhaust pipe through the hole Slide one rubber wall trim piece on the pipe from inside and one from outside Attach each collar to the boiler with the gasket and screws provided Insert each elbow into its corresponding collar Connect each pipe to its corresponding elbow 22 SAVIO PLUS COMBI MANUAL 9 Venting Cont E Alternative separate kit Exhaust amp intake outside pi Tn E 8 Figure 9 7 Twin Pipe 3 25 in These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses Consequently it is possible to extend the flue system to a greater distance than that provided by the standard coaxial horizontal flue If either an additional 45 or 90 accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3 0 ft or 5 4 ft respectively The sum of the lenghts of the two horizontal part must be less than 49 ft Installation e Drill holes B amp C on the wall template through the outside wall Drill hole C on the wall template through the outside wall that is less than 18 thick Cut the pipes as necessary so that no more than 6 of intake pipe protrudes from the house and the exhaust pipe is a minimum of 4 inches longer than the intake pipe Slide the Intake and exhaust pipes through t
15. csa international org SAVIO PLUS COMBI MANUAL 7 l General Information The SAVIO Plus Combi is a high efficiency condensing wall mounted gas boiler which provides central heat The boiler features a gas valve which modulates the energy input from 49 476 BTU h to 116 008 BTU h The boiler is shipped fully assembled with the components listed on page 10 All units are pressure and combustion tested at the factory prior to shipping Key Features e Wall mountable saving valuable floor space Several flue options available Electronic spark ignition Safety flow switch positioned on the main circuit which monitors the flow and protects the main heat exchanger from thermal shock should there be a lack of water in the system Frost protection contains an integral frost Boiler operation recognition system should the boiler not be used for longer than 24 hours it then performs a con trolled system test to ensuring the motor ized components within the boiler do not become inoperable due to lack of use Gas valve modulation the gas input modulates based off central heating tem perature to within 2 F Diagnostic information system equipped with three LED diagnostic lights for quick error assessment protection system to prevent frost dam age which can occur in areas susceptible to very cold weather conditions 2 Technical Information M135 30CM INJ ECTORS l 30476 30 5 85 CENTRAL
16. ducts A plastic ball closes the trap out let in case that the trap is empty The condenste trap is provided with two electrodes if the drain pipe is plugged or in any case in which the condensate isn t correctly evacuated the conden sate level in the trap rises putting in contact the electrodes thus causing the boiler lock out SAVIO PLUS COMBI MANUAL 25 IM ECT T Pipe Connections Gas supply piping is to be sized and installed properly in order to provide a supply of gas suffi cient to meet the maximum demand without undue loss of pressure between the meter and the boiler Consult with the National Fuel Gas Code ANSI Z223 1 for proper sizing of gas piping for various lengths and diameters La Chaudi re doit tre isol e du syst me de la tuyauterie de la fourniture du gaz en fermant son robinet d arr t durant n importe test de pression du syst me de la tuyauterie de la fourni ture du gaz en pr sence de pressions d essai gales ou inf rieures 1 2 psi 3 5 kPa Direction of flow A Manual T handle Shutoff Valve B Pressure Gauge Port A C Flexible Gas Line to Burner D Male Union NPT E Pipe Cap F VATA TEE Note Height of valve above ground level to conform to local codes if any Massa c chusetts statecode requires gas shut off to be a tee handled gas cock E D Figure 11 1 Locate a drop pipe adjacent to but not in front of the boiler Locate a tee F in the drop pipe at the same elevation as the gas inle
17. e YES NO Air pressure switch closed Starts ignitors Opens gas valve Begins ignition timing NO Flame presence YES 4 Closes gas valve Stops fan Interrupts ignitor Boiler lockout v Interrupt igniter Gas valve open NO End of ignition period Reset push button NO YES pressed Close gas valve A ae Flame presence NO gt YES y Safety thermostat ND Opens the circuit m A L_ yes E NO SAVIO PLUS COMBI MANUAL 13 6 Installation Location The installation location chosen must Comply with all clearances listed below Provide suitable location for the exhaust and intake venting e Not be installed in an unheated space Comply with all local codes and standards Note Dimensions shown are minimums Greater clearances will simplify installation and service 3 0 in CLOSET INSTALLA TION MINIMUM PERMANANT CLEARANCE 31 6 in 18 0 in CLOSET INSTALLA TION SERVICECLEARANCE FRONTVIEW SIDE VIEW CLOSET INSTALLA TION Figure 6 1 WARNING Do not install the boiler on carpeting If the boiler is to be installed in an enclosed room with no fresh air intake the room must have proper vent louvers installed There should be two louvers place each within 12 of the ceiling and floor respectively Each vent will have a free area of 54 square inches Note For boilers in an enc
18. enght required is 2 9 ft Maximum equivalent lenght of 8 8 ft can be achieved utilising extensions This flue system can only be used to discharge horizontally it is not designed to enable termination in the vertical plane Installation Drill hole A on the wall template through the outside wall that is less than 18 thick Cutthe pipe as necessary so that a no more than 6 protrudes from the house Slide the intake and exhaust pipes through the hole Slide one rubber wall trim piece on the pipe from inside and one from outside Connect exhaust inner pipe to concentric elbow Connect intake outer pipe to concentric elbow Secure elbow to boiler using gasket and four screws provided Secure end cap on the intake pipe outside the house SAVIO PLUS COMBI MANUAL 19 9 Venting Cont B Standard separate horizontal _ue kit Exhaust amp intake outside Exhaust Pipe End Cap Intake Pipe End Cap Intake Pipe Intake Elbow Intake Collar Test Ports Figure 9 4 Twin pipe 3 25 in Various twin split pipes kits and optional accessories elbows are available to assist in the termination of the flue where the boiler is installed in a location remote to an outside wall These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses Consequently it is possible to extend the flue system to a greater distance than that provided by the standard coaxial horizontal flue If ei
19. ewspa per or similar Brush out the primary heat exchanger 9 on page 10 with a bristle paintbrush 17 12 Cleaning the domestic hot water exchanger The descaling of the domestic hot water exchanger will be evaluated by the Authorised Assis tance Centre Technician who will carry out any cleaning using specific products 17 13 Condensate trap To clean the condensate trap Remove the front and right case panels Disconnect the trap from the drain pipe Using pliers remove the spring D moving it upwards Disconnect the wirings from the trap Reassemble carrying out the removal op erations in reverse order The trap should be serviced once a year dur ing the annual service Figure 17 6 44 SAVIO PLUS COMBI MANUAL 18 Vent Part Spares For any spare parts please contact BOYERTOWN 1 610 369 1450 dd X Q Figure 18 1 Description Order Number Twin pipe kit 10999 0393 0 SAVIO PLUS COMBI MANUAL 45 18 Vent Part Cont For any spare parts please contact BOYERTOWN 1 610 369 1450 Lex AN A A P S Figure 18 2 Description Order Number Coaxial flue kit 10999 0387 0 46 SAVIO PLUS COMBI MANUAL 18 Vent Part Cont For any spare parts please contact BOYERTOWN 1 610 369 1450 f Cw _ E C Rs e N lt an lat C 2 S y N oo oe gt Sana Ns J I TT id A 2 Pd Z u
20. he respective holes Slide one rubber wall trim piece on each pipe from inside and one from outside Attach each collar to the boiler with the gasket and screws provided Insert each elbow into its corresponding collar Connect each pipe to its corresponding elbow as shown in the diagram Secure end cap on the intake and exhaust pipe outside the house SAVIO PLUS COMBI MANUAL 23 9 Venting Cont F Standard Vertical roof kit Exhaust amp intake outside max 41 Figure 9 8 vertical pipe 3 1 4 9 in This kit allows vertical termination of the flue pipe through the roof The kit is 1 2 min length Extension pieces Co axial are also available which allows the flue system to be extended to a total overall maximum permissible length Optional 45 and 90 elbows can be used to offset the flue route Each additional elbow reduces the overall acceptable length of the flue system as follows 45 reduce length by 1 6 ft 90 reduce length by 3 2 ft Installation Drill hole through the outside roof Cutthe pipe as necessary Slide the intake and exhaust pipes through the hole Slide one rubber wall trim piece on the pipe from inside and one from outside Connect exhaust inner pipe to concentric elbow Connect intake outer pipe to concentric elbow Secure elbow to boiler using gasket and four screws provided Secure end cap on the intake pipe outside the house 24 SAVIO PLUS COMB
21. ing table Position of the Gas SUpply switch 2 Natural gas On L P G Off Natural gas Figure 16 3 Close the service panel Turn on the boiler Calibrate the gas valve according to the instructions given in section 15 4 of this manual Set the correct gas pressure for central heating output required Stick on the inside of the left hand side panel adjacent to the data badge the self adhesive label included with the conver sion kit indicating the type of gas and the gas pressures to which the appliance has been set Reassemble the front and side panels of the case 41 17 Annual Maintenance 17 1 Warnings The procedures detailed in this chapter must be carried out only by a professionally qualified person Thus you are advised to contact an Authorised Service Agent For efficient and continuous operation of the boiler you are advised to have at least once a year maintenance and cleaning done by an Approved Service Person Isolate the appliance from the electricity supply by turning off the fused spur isolation switch adjacent to the appliance and turn off the gas cock before carrying out any procedures what soever for cleaning maintenance opening or dismantling boiler panels 17 2 Dismanteling the external panels Front Panel Loosen the three screws A Fig 17 1 Lift and remove the panel Side Panels Loosen the screws B Figure 17 2 Bring the bottom of the panels away from
22. ion operator 15 Gas valve outlet pres Test point 16 Gas valve inlet pres Test point 17 Central heating expansion vessel 18 Central heating temp Probe NTC 19 Central heating pressure relief valve 20 Primary circuit flow switch 21 Main circuit drain cock 10 SAVIO PLUS COMBI MANUAL o eB LOT UN SS De qom By pass valve Three way diverter valve Venturi device Flue outlet pipe Air Intake Pipe Control panel Safety thermostat probe Pressure reducing automatic fill valve Backflow preventer Gas supply line cock Water supply inlet cock Condensate trap Condensing heat exchanger Flue termostat D h w heat exchanger D h w flow switch Domestic water circuit filter D h w flow limiter Domestic hot water temp probe NTC Domestic cold water inlet valve D h w outlet pipe 4 Internal Piping amp Parts List 32 Note Pressure Relief Valve 19 should be piped to a drain or to
23. l turn and leave open permanently Figure 15 1 Open the installer supplied automatic fill valve between the cold water inlet and Central Heating System See 28 on pip ing diagrams in previous section Open each radiator air vent starting at the lower point and close it only when clear water free of bubbles flows out Purge the air from the pump by unscrewing the pump plug 2 Fig 15 2 release the pump by turning the rotor in the direction indicated by the arrow on the information plate Figure 15 2 Close the pump plug Continue filling the system The actual reading should ideally be 1 3 bar 19 psi and not less than 0 3 bar 4 3 psi Close all air release valves on the c h system Inspect the boiler and the system for water soundness and remedy any leaks discovered Cold flush the system to remove any loose particles and any system debris before starting the boiler for the first time Reassemble the front panel of the case Return fill valve to automatic position 15 2 Lighting the boiler Note If external controls are fitted e g room thermostat ensure they call for heat WARNINGS THE BOILER AND ITS GAS CONNECTION MUST BE LEAK TESTED BEFORE THE BOILER IS PLACED IN OPERATION Turn on the electricity supply to the boiler switching on the circuit breaker switch The ap pliance operation light A will flash every 4 seconds Turn the function selector B as in Fig 15 3 The appliance operation light A will f
24. lash every 2 seconds Figure 15 3 SAVIO PLUS COMBI MANUAL 35 15 Commissioning Cont The boiler will now go through an ignition sequence and the burner will light If during the ignition attempt period the boiler fails to light the full sequence control p c b will go to lockout and the lock out signal lamp E will appear To reset the boiler turn the knob C figure 15 3 on the O position and then press and release the boiler reset button D Fig 15 3 15 3 Checking the gas pressure at the burner This boiler has been tested to the highest quality control standards The maximum and minimum gas pressures are already set during this quality control process however the checking procedure must be followed to ensure maximum operat ing ef ciency from the boiler Remove the front panel of the case Take off the lid of the sealed chamber Loosen the internal screw 15 Figure 15 4 on the Outlet Pressure Test Point of the Gas Valve and connect a pressure gauge using a suitable hose Figure 15 4 Set the c h temperature control knob to its maximum position If external controls are fitted e g room thermostat ensure they call for heat Switch on the boiler Check the maximum gas pressure and com pare the value on the gauge with the value indicated in the Section 2 on page 9 gas pressures at the burner Check the maximum gas flow at the gas meter and compare the value indicated in the section 2 on page 9 ga
25. llips head screws SAVIO PLUS COMBI MANUAL 43 17 Annual Maintenance Cont 17 8 Checking the pressurization in the expansion vessel Empty the central heating system as described in section 17 3 of this chapter and check that the pressure in the expansion vessel is not less than 1 bar 14 5 psi See also section 13 2 of this manual If the pressure should be lower take steps to correct the pressure level To check the pressure at the venturi device use the test points 12 on page 11 Remove the caps of the pressure test points and connect a differential pressure gauge Switch on the boiler Compare the value on the gauge with the minimum values of venturi pressure indi cated in the Section 2 on page 9 Venturi test points Figure 17 5 17 9 Visual inspection of appliance Visually inspect all water joints seals and connections for any evidence of leakage and re tighten grease or replace them as necessary 17 10 Gas pressures and soundness Check appliance for gas soundness Recheck operational pressures and adjust as necessary as described in Section 15 4 page 37 of this manual 17 11 Cleaning the primary heat exchanger Take off the front panel of the case then the sealed chamber lid and the front panel of the com bustion chamber If you notice dirt on the fins of the primary heat exchanger 9 on page 10 cover the sloping surfaces of the burner 7 on page 10 entirely in a protective layer sheets of n
26. losed space Each opening free area 1 sq inch per 2 000 BTU h it is recommended to install a CO detector in the boiler room Figure 6 2 When choosing an installation location insure the exhaust and intake pipes comply with NFPA 54 The drawing on the next page illustrates the restrictions on exhaust locations 14 SAVIO PLUS COMBI MANUAL 7 Exhaust Pipe Location CAUTION EXTERNAL VENT SURFACES ARE HOT IT IS RESPONSABILITY OF THE HOMEOWNER TO KEEP THE VENT TERMINAL CLEAR OF SNOW AND ICE NOTE USE ONLY LISTED COMPONENTS SUPPLIED WITH THE BOILER SURFACE DISCOLORATION OF THE BUILDING MAY OCCUR DUE TO IMPROPER INSTALLATION QHT WILL NOT ACCEPT RESPONSIBILITY OR LIABILITY FOR SUCH DISCOLORATION Mechanical draft y went termination The Exhaust Hood must be installed on the leeward side of house and conform to the following guidelines 1 2 The Vent hood shall not be less than 3 feet above any forced air inlet to the house The Vent hood shall not be less than 1 foot below 1 foot horizontally or 1 foot above any door window or gravity inlet into any building 3 The Vent hood shall not be less than 2 feet from an adjacent building 4 D The Vent hood shall be not less than 7 feet above grade when located adjacent to public walkway The Vent hood shall be located so that flue gasses are not directed to jeopardize people overheat combustible structures materials or enter buildings Minimum of 4 feet h
27. n of any boiler It is the responsibility of the installing contractor to see that all controls are correctly installed and operating properly when the installation is completed This boiler is intended for use only with propane or natural gas All ammable liquids especially gasoline chemicals rags paper wood scraps debris etc should be kept away from the boiler at all times Keep the boiler area clean and free of all re hazards Please read the literature and warranties supplied by the manufacturers of the various accessory equipment This equipment is warranted by the respective manufacturers not by BOYERTOWN Each piece of equipment must be installed and used according to the recommendations of the manufacturer Codes and Regulations Installation of the boiler and related equipment must conform to national state and local regulating agencies and codes applicable to the installation of the equipment In the absence of local requirements the following codes apply A ANSI NFPA 70 National Electric Code B ANSI NFPA 211 Chimneys and Vents C ANSI NFPA Z223 1 National Fuel Gas Code C ANSI NFPA Domestic Gas Conversion Burner D CAN CGA B149 Installation Codes E ANSI ASME CSD 1 The above codes are available from National Fire Protection Association NFPA CSA International Battery March Park 8501 E Pleasant Valley Road Quincy Massachusetts 02269 Cleveland OH 44134 5575 http www nfpa org http www
28. ned that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Codes SAVIO PLUS COMBI MANUAL 17 9 Venting Cont The Riva is a mechanical draft side wall vented boiler There are two flue options available separate and coaxial The coaxial option has one configuration shown on the next page The separate option has two possible configurations shown on the following pages 9 1 Restrictor Sizing Each exhaust option is shipped standard with 3 feet of exhaust pipe 3 feet of intake air pipe There is also a restrictor kit in which there are some restrictors that must be placed in exhaust breech of fan on the top of the boiler Fig 9 1 according to the flue configuration used If additional flue piping is need for a particular application it can be ordered separately in 3 feet increments Depending on the final flue pi
29. oiler and rotate the minimum gas pressure adjustment G in Fig 15 5 until you obtain the required pressure by rotat ing clockwise the pressure increases Figure 15 5 Remove the protection cap Fig 15 7 from the mechanical pressure adjustment components levering with a flat screw driver in the slots H Start the boiler at its maximum power Turn the boiler off and re connect the wire to the modulating operator Start the boiler and check again the maxi mum gas pressure setting Turn the boiler off and disconnect the gauge Close the lid of the sealed chamber Important after the checks all of the test points must be sealed 15 5 Checking the ignition device With the burner on high flame close the gas cock After three ignition attempts within about three minutes the lock out signal lamp must appear D on Figure 15 3 To reset the boiler turn the knob B figure 15 3 on the 0 position and then press and release the boiler reset but ton C on Figure 15 3 SAVIO PLUS COMBI MANUAL 37 15 Commissioning Cont 15 6 Checking the burner ignition Turn the boiler OFF Open the gas valve outlet pressure test point 15 figure 15 5 and connect the gauge Turn the boiler ON positioning the function selector B in the position shown in figure 15 7 and ensure that the room thermostat is set to heat demand s 8 J i V a Figure 15 7 Loosen screws D and remove the service panel fig
30. oom where the boiler is installed If either an additional 45 or 90 accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3 0 ft or 5 4 ft respectively Note When utilizing this option see page 14 for room ventilation details Installation Drill hole C on the wall template through the outside wall that is less than 18 thick e Cutthe pipe as necessary so that no more than 6 protrudes from the house Slide the exhaust pipe through the hole Slide one rubber wall trim piece on the pipe from inside and one from outside Attach each collar to the boiler with the gasket and screws provided nsert each elbow into its corresponding collar Connect each pipe to its corresponding elbow SAVIO PLUS COMBI MANUAL 21 9 Venting Cont D Alternative separate kit Exhaust outside amp intake inside Figure 9 6 Twin Pipe 3 25 in This configuration of the twin pipe kit allows to discharge the exhaust gasses outside The air supply is obtained with an air intake pipe This allows to take air from the room where the boiler is installed If either an additional 45 or 90 accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3 0 ft or 5 4 ft respectively Note When utilizing this option see page 14 for room ventilation details Installation Drill hole C on the wall template through the outside wall Drill hole C on the wall tem pl
31. orizontal clearance from electric meters gas meters regulators and relief equipment All joints in system are to be sealed to prevent leakage of products of combustion in the building Avoid installing exhaust hood on the North West or the side of the house receiving the prevailing winds The vent should not be situated so that the flue gases are directed towards brickwork siding or other construction in such a manner that may cause damage from heat or condensate from the flue gases SAVIO PLUS COMBI MANUAL 15 8 Mounting Bracket After a suitable installation location is chosen verify that the mounting wall is properly braced and strong enough to support the 110 pound weight of the unit when lled with water NOTE The boiler shall be installed such that the gas ignition system components are protected from water and liquids in general dripping spraying rain etc during the appliance operation and service Use the paper template provided with the boiler to determine the location of the mounting bracket Securely mount the bracket to the wall using appropriate hardware for the particular wall construction Mounting Steps 1 2 3 Tape the paper template to the wall in the chosen location Be sure to level the template Pre drill two holes in the center of the oval slots on the mounting bracket sized for the hardware being used Mount the bracket to the wall Be sure to level the bracket by adju
32. ow rate ft of head 20 0 16 7 19 4 10 0 6 7 Figure 13 1 The hydraulic speci cation in Fig 13 1 represent the pressure available head for the central heating system as a function of the ow rate The pressure loss due to the in ternal piping in the boiler has already been substracted When determining proper piping of the heating system verify that the internal boiler circulator will overcome the head loss of the system at the designed flow rate using the graph above If the internal circulator is adequate direct system piping can be utilized See section 4 page 11 for suggested direct supply return piping If the internal circulator is inadequate a secondary circulator must be utilized See sections 14 for suggested primary secondary piping 13 2 Expansion vessels The height difference between the C h PRV 19 on page 10 and the highest point in the system may be 23 ft at most For greater differences increase the pre load pressure in the C h expansion vessel 17 on page 10 and the system when cold by 0 1 bar for additional 3 3 ft For systems with volumes greater than 154l an additional expansion vessel must be provided 30 SAVIO PLUS COMBI MANUAL 14 Piping All external piping components are to be supplied by the installer It is very important to use a Primary Secondary piping scheme when an external circulator will be used Also when the boiler is piped in a primary secondary manner it is necessa
33. pe length an alternative restrictor may be required Refer to the tables 9 1 for proper restrictor ring sizing Separate 3 25 3 25 Coaxial 2 5 4 0 Air intake adapter v T Restrictor SH Gasket Co axial ai Gasket D lt gt Figura 9 1 Separate 3 25 3 25 Restrictor Size Coaxial 2 5 4 0 Restrictor Size From 3 30 to 49 2 ft in out 45 From 0 to 2 9 ft 82 From 2 9 to 8 8 ft No restrictor Table 9 1 9 2 Fitting the flue system In general it has to be taken in consideration that the orizontal sections of the flue pipe must have an horizontal sloping not less than 1 5 degree 0 3 in per ft towards the boiler In the standard horizontal flue kit the flue pipe is angled within the air duct therefore the air duct must be horizontally installed If one or more exstensions have to be used they must be adequately supported so that there is no sag in the flue pipe and a minimum fall of 1 5 degree 0 3 in per ft over the whole lenght towards the boiler is ensured 18 SAVIO PLUS COMBI MANUAL 9 Venting Cont 9 3 Choice of ue The following flue kits are available for connecting to the boiler A Standard coaxial horizontal ue kit Exhaust amp intake outside Rubber Wall Trim Intake Air Pipe 90 Concentric Elbow Figure 9 3 Coaxial 2 4 4 0 inches nominal lenght 3 3 ft It can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow Minimum l
34. r use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your build ing Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you can not reach your gas supplier call the re department Installation and service must be performed by a quali ed installer ser vice agency or the gas supplier DANGER Caution Do not store or use ammable materials chemicals or ammable liquids especially gasoline in the vicinity of this heating appliance SAVIO PLUS COMBI MANUAL 5 6 WARNING Any appliance that burns natural gas propane gas fuel oil wood or coal is capable of pro ducing carbon monoxide CO Carbon Monoxide CO is a gas which is odorless colorless and tasteless but is very toxic CO is lighter than air and thus may travel throughout the building BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF CO OR PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY RESULT IN CARBON MONOXIDE POISONING EXPOSURE CAN BE FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT IN THE SUDDEN ONSET OF SYMPTOMS INCLUDING UNCONSCIOUSNESS Symptoms of CO poisoning include the following dizziness vision problems shortness of breath headache loss of muscle control unclear thinking nausea weakness unconsciousness The symptoms of CO poisoning a
35. re often confused with those of influenza and the highest incidence of poisoning occurs at the onset of cold weather or during flu season A victim may not experience any symptoms only one symptom or a few symptoms Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home The following signs may indicate the presence of carbon monoxide Hot gasses from appliance venting system pipes or chimney escaping into the living space Flames coming out around the appliance Yellow colored flames in the appliance Stale or smelly air The presence of soot or carbon in or around the appliance Very high unexplained humidity inside the building If any of the symptoms of CO occur or if any of the signs of carbon monoxide are present VACATE THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED HEATING SERVICE COMPANY OR THE GAS COMPANY OR THE FIRE DEPARTMENT ONLY QUALIFIED LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR SAVIO PLUS COMBI SAVIO PLUS COMBI MANUAL IMPORTANT INFORMATION Please read this page carefully ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL STATE AND LOCAL PLUMBING HEATING AND ELECTRICAL CODES AND ORDINANCES AS WELL AS THE REGULATIONS OF THE SERVING ELECTRICAL WATER AND GAS UTILITIES All systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of heating systems should attempt the installatio
36. ry to us the central heating flow restrictor supplied with the boiler The flow restrictor ensures that there will be enough back pressure to make the central heating flow switch in a low head loss piping system like primary secondary Installation of flow restrictor The flow restrictor is installed inside the pipe tail that X attaches to the boiler Place the flow restrictor into the gasket for the central heating supply pipe tail Place the gasket on the pipe tail so the flow restrictor seats into the pipe tail Then install the pipe tail onto the boiler There are two methods for accomplishing a Primary Secondary piping system The first is to use two closely spaced tees for the boiler supply and return An example is shown below in Figure 14 1 The run legs should be sized so that there is no excessive head loss on the exter nal circulator that is installed In most circumstances 1 74 piping will be the best choice When the boiler is piped in this way the external circulator will not have any hydraulic effect on the SAVIO Plus Combi This is essential to ensure that the flow switch will operate properly Boiler Boiler Supply Return Must be less than 8 lt gt System Ys System Supply Return 1w Figure 14 1 The second method is a hydraulic separator Hydraulic separators are available commercially however you can al
37. s flow rate 36 SAVIO PLUS COMBI MANUAL Switch off the boiler Disconnect the gas modulator coil by remov ing the electrical connector E Figure 15 4 Switch on the boiler Check the minimum gas pressure and com pare the value on the gauge with the value indicated in the Section 2 on page 9 gas pressures at the burner Switch off the boiler and re connect the electrical connector E to the modulator coil Switch on the boiler Check that the boiler lights up uniformly Switch off the boiler turn off the hot water taps and disconnect the pressure gauge Close the lid of the sealed chamber Important after the checks all of the test points must be sealed 15 Commissioning Cont 15 4 Adjustment of the gas pressure Remove the front panel of the case Take off the lid of the sealed chamber Open the gas valve inlet pressure test point 16 in Fig 15 5 at the valve input connect a suitable pressure gauge and check the gas pressure of the supply net work Remove the gauge and close the pres sure test point 16 Open the gas valve outlet pressure test Figure 15 6 point 15 in Fig 15 5 and connect the Ensure that the boiler is not range rated gauge Rotate the maximum gas pressure adjust ment F in Fig 15 5 until you obtain the required pressure by rotating clockwise the pressure increases Turn the boiler off and disconnect one of the two connectors E in Fig 15 5 Startthe b
38. so construct your own An example of a hydraulic separator is given in Figure 14 2 It is important that the separator be at least 2 in size to ensure proper performance Boiler supply Boiler Return No more than 8 lt gt p 1v a System supply 2 a System return cA gt At least 16 Figure 14 2 SAVIO PLUS COMBI MANUAL 31 14 Piping Cont 14 1 Primary Secondary Piping All external piping components are to be supplied by the installer It is very important to use an hydraulic separator before secondary circulators 3 d Secondary Circulators 3 io A M Boiler VEN Boiler Supply _ Return P al a M Air Elimination Hydraulic Backflow UT Preventor ond Pressure Reducing Volve Figure 14 3 32 SAVIO PLUS COMBI MANUAL 14 Piping Cont 14 2 Primary Secondary Piping with Zone Valves All external piping components are to be supplied by the in
39. staller It is very important to use a hydraulic separator before secondary circulators Zone Volves 8 say gay s d BD EBD Bj PEEL E ur upply Return J La La m La site n o I Backflow Air Elimination Hydraulic Preventor and Separator Pressure Reducing Valve P R Figure 14 4 SAVIO PLUS COMBI MANUAL 33 14 Piping Cont 14 3 Manifold Piping with Zone Valves shown conn to radiators All external piping components are to be supplied by the installer Biasi Heat F Boiler Boller Biasi Steel Supply _ lt Return Panel Radiators n A H s I NY H Bockflow Prevento Pressure Reducing Val l I I IL MIT Zone Valves Figure 14 5 34 SAVIO PLUS COMBI MANUAL 15 Commissioning 15 1 Initial lling of the system Remove the front panel of the case Unscrew the cap on the automatic air purger valve 3 Fig 15 1 one ful
40. sting the screw in the vertical slot Pre drill the remaining hole in the mounting bracket and secure the final screw Mark and drill the exhaust intake pipe holes through the house If you are using a coaxial pipe system drill the hole marked A 4 in the drawing below and on the paper template If you are using a separate pipe system drill holes marked B and C 3 25 shown below as well as on the paper template Remove paper template and hang boiler on bracket j Ko J A B C l paler T a 1 Figure 8 1 16 SAVIO PLUS COMBI MANUAL The SAVIO Plus Combi is a mechanical draft side wall vented boiler There are two side wall flue options available separate and coaxial The coaxial option has one configuration shown on the next page The separate option has two possible configurations shown on the follow ing pages There is also a vertical roof venting option Regardless of what vent kit is installed they should all conform to the Provisions for combustion and ventilation air in accordance with section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or appli cable provisions of the local building codes If the SAVIO Plus Combi replaces a boiler that was attached to a common vent system the common venting system is likely to be too large for proper venting of the appliances remaining connected
41. t connection to the boiler Extend the drop line with a nipple towards the floor and cap to form a sediment trap E Install a shut off valve A before the tee with sediment trap and a union after the tee before the combination gas valve D When installing the boiler make sure a pipe compound resistant to the action of liquefied pe troleum is used Check piping for leaks Always check leaks with a water and soap solution The boiler and its gas connection must be leak tested before placing the boiler in operation The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 75 psi 3 5 kPa WARNINGS DO NOT USE A FLAME FOR CHECKING GAS LEAKS 26 SAVIO PLUS COMBI MANUAL 12 Electrical Connections Wiring 12 1 Power Connection Removing Side Panel Move the lower part of the Remove screws B side panels figure 12 3 COND Pull the control panel When N completely pulled out the panel can rotate 45 down ward Figure 12 2 Removing Service Panel Remove screws C wA Figure 12 4 Figure 12 1 b II e Loosen screws D and remove Removing Front Panel i the service panel Fig 12 4 Remove the front panel by removing screws A and slid il ing the front panel up and away from the boiler Figure 12 3 For the electrical connection to the boiler use electric wires
42. the boiler and lift them freeing them from the top hooks Take off the front panel of the case then the sealed chamber lid and the front panel of the com bustion chamber If you notice dirt on the fins of the primary heat 9 on page 10 cover the slop ing surfaces of the burner 7 on page 10 entirely in a protective layer sheets of newspaper or similar Brush out the primary heat exchanger 9 on page 10 with a bristle paintbrush A D 2 Figure 17 2 Figure 17 1 17 3 Emptying the d h w system Close the pressure reducing automatic fill valve 28 on Section 4 Open the central heating drain cock F in Fig 17 3 Empty the c h system Close the central heating drain cock F in Fig 17 3 Open the pressure reducing automatic fill valve 28 on Section 4 42 SAVIO PLUS COMBI MANUAL Figure 17 3 17 Annual Maintenance Cont 17 4 Emptying the Domestic Hot Water circuit Close the inlet valve Open the system domestic hot water valves 17 5 Cleaning the primary heat exchanger Follow the instructions for removing the ex ternal panels from 17 2 Remove the nine screws labelled C in figure 17 4 Now you will have complete access to the combustion chamber The sloping and multi gas type burner 7 on page 10 does not need special maintenance but it is sufficient to dust it with a bristle paintbrush
43. the floor as lose as pos sible to a drain SAVIO PLUS COMBI MANUAL 11 5 Electric Diagrams Flue thermostat w gt 8 Air pressure Ignition Flame detection ot Switch electrodes electrode a oO Electric supply TO OS e terminal block n Ox ae Q c 83 es ot HE bu wh rd rd rd J gnyegy bu COM wh rd i t D h w D h w NTC Three way flow switch NO diverter Primary circuit valve flow switch C h temperature probe NTC Gas valve Pump bk black gy grey bn brown rd red Caution bu blue wh white Label all wires prior to disconnection gnye green yellow ye yellow when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 12 SAVIO PLUS COMBI MANUAL 5 Electric Diagrams Cont 5 1 Sequence of Operation ut ls primary circuit temp higher than selected temp Request for heat from thermostat Y NO YES y Circulator off Starts the circulator Ignition device off Supplies the ignition device YES Is the boiler in lockout NO NO Air pressure switch open Fan starts NO YS Pq 1 Air pressure switch closed Begin wait period NO Presence of flam
44. ther an additional 45 or 90 accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3 0 ft or 5 4 ft respectively The sum of the lenghts of the two horizontal part must be less than 49 2 ft Installation e Drill holes B amp C on the wall template through the outside wall that is less than 18 thick Cutthe pipes as necessary so that no more than 6 of intake pipe protrudes from the house and the exhaust pipe is a minimum of 4 inches longer than the intake pipe Slide the Intake and exhaust pipes through the respective holes Slide one rubber wall trim piece on each pipe from inside and one from outside Attach each collar to the boiler with the gasket and screws provided nsert each elbow into its corresponding collar Connect each pipe to its corresponding elbow as shown in the diagram Secure end cap on the intake and exhaust pipe outside the house 20 SAVIO PLUS COMBI MANUAL 9 Venting Cont C Alternative separate kit Exhaust outside amp intake inside Exhaust Pipe End Cap Uj v d J Ud Rubber Wall Trim 2X J f y Exhaust Pipe L Exhaust Elbow Air Intake Elbow Bw Air Intake Pipe Se Va Exhaust Collar NDA Air Intake Collar lt aq Test Ports Figure 9 5 Twin Pipe 3 25 in This configuration of the twin pipe kit allows to discharge the exhaust gasses outside The air supply is obtained with an air intake pipe This allows to take air from the r
45. ual does not make the reader an expert in all aspects of installation and operation and does not replace the need for a qualified licensed heating contractor We urge you to contact your installing contractor or distributor if you are in question about any aspect of your boiler s performance Our main concern is that you are satisfied with your boiler and its performance We require that your contractor complete efficiency tests using instruments The external controls and accessories listed in this manual excluding those supplied inside the boiler are intended to serve as guidelines rather than specific recommendations We re alize that other makes and models of such devices are available and can be used as suc cessfully as those we specify The installing contractor is the best judge of a system s specific requirements as well as the local availability of certain makes and models of controls and accessories The preceding does not apply however to the equipment that comes with every boiler such as the overheat control and pressure relief valves The installation of the specific devices supplied with every boiler is absolutely necessary to the safe operation of the boiler and protection of the heating system All SAVIO wall hung boilers are built in accordance with the ASME boiler and pressure vessel code and bear the H stamp The Entire range of applications for the SAVIO Plus Combi has been tested to standard CSA 4 9 and is CSA compliant
46. ure 15 8 D Figure 15 8 Watch the gauge and check to see if the ignition pressure registerd corresponds to the values given in the Technical Data Turn off the boiler and reignite it by turning the function selector B to the O position and then back to that indicated in figure 15 7 Repeat this process two to three times leaving 30 second intervals between each ignition Check the ignition pressures and visually check that the burner lights uni formly and in a controlled manner To carry out the adjustment move the function selector 3 to the OFF position Fig 15 9 and use the device ACC Figure 15 9 Adjust the gas pressure at the injectors to the value indicated in the tables of section 2 By rotating the device clockwise the pressure increases After the adjustment operations bring the selector 3 of figure 15 9 back to the nor mal position ON Reassemble the service panel Close the gas valve outlet pressure test point 15 figure 15 5 Reassemble the front pannel of the case Important after the checks all of the test points must be sealed 15 7 Adjustment of the useful c h output Turn the boiler OFF Open the gas valve outlet pressure test point 15 figure 15 5 and connect the gauge Turn the boiler ON positioning the function selector B in the position shown in figure 15 7 and ensure that the room thermostat is set to heat demand Loosen screws D and remove the service panel figure
47. which conform to local requlations The boiler when installed must be electricallybonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Elec trical Code ANSI NFPA 70 and or Canadian Electrical Code Part CSA C22 1 Electrical Code Aux tats Unis garder un espace d au moins 4 pieds horizontalement du terminal d vacuation aux compteurs du gaz compteurs de l lectricit r gulateurs et quipement d vacuation Au Canada garder un espace de 6ft entre le terminal d vacuation et ces dispositifs 12 2 Connection to the electricity supply Connect the electrical supply cable coming from the fused spur isolation switch to the power supply terminal block of the boiler as shown in figure 12 5 keeping the same connections for the live wire and the neutral wire E Ta 120 VAC AES 15 AMP BREAKER Service Man s Switch Fire O Matic To fused spur e isolation switch Li WARNING ORSIO OMO FN Power supply 3 2 1 f Kg 2 terminal block Note Do not connect live wires to r4 Y thermostat terminals 1 3 j J External controls terminal block J Figure 12 5 SAVIO PLUS COMBI MANUAL 27 12 Electrical Connections Wiring Cont 12 3 Room Thermostat Connection The room thermostat must be connected When connecting any type of external
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