Ca7s Installation Manual
Contents
1. Ca 7s and BCa 7s 61 235 kW INSTALLATION AND OPERATING INSTRUCTIONS 23 03 01 CONTENTS PAGE Dimensions for Ca7s and BCa7s boilers 3 amp 4 General specification 5 Boiler room clearance requirements 6 Boiler block assembly 7 Pulling up the sections 8 Boiler block assembly amp connections 9 Ca7s Jacket assembly 10 Calorifier assembly 11 BCa7s Jacket assembly 12 Continued 13 Electrical connection and Instrument control panel 14 Continued 15 Control module options 16 Control module diagrams 17 Installation of electronic control modules 18 Terminal wiring diagram 19 Schematic wiring diagram 20 Important notes amp burner connection information 21 Page 2 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s General Specifications The STREBEL Camino 7s is a special boiler for oil or gas fired pressure jet burner In the BICALOR construction a calorifier for the supply of hot water is built onto the boiler CSH S type calorifiers are manufactured from 1 4571 high tensile steel with an incorporated heating coil of galvanised copper ribbed pipe Triple pass block of cast iron sections The first pass is the combustion chamber From there the flue gases pass between the rear section and the last intermediate section through the second pass to the front of the boiler They are then diverted into the third pass and flow back to the rear through the flue spigot into the chimney Flue baffles of cast iron can b2. BCa 7s Boiler Dimensions Ca 7s Dimensions KEY 1 1 Boiler Flow 130mm NW65 2 1 Boiler Return 130mm NW65 35 1 Boiler Drain 3 4 Boiler ILK m T Kee Ca7s 4 Ca7s 5 101 Boiler _ We Ca7s 4 Ca7s 5 116 Ca7s 7 Ca7s 8 Ca7s 9 Page 4 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s dt BCa 7s Dimensions 1 1 Boiler flow 130mm NW65 35 2 HWS drain off ya 2 1 Boiler return 130mm NW65 38 HWS water connection flow La 2 10 Primary pump 1x230V 11 4 39 Cold water connection LS 2 33 Primary connection pipe LATE 1 40 Circulation connection SCH 34 Return connection pipe LATE Lei 44 1 Non return valve 35 Air vent 3 8 f Avallable for calorifier CSH 240S 35 1 Boiler drain off SCH LK Calorifier Type CSH Boiler 240S 300S 360S 500S LK mm o e EE aa SH cares me ms as cares mes ms w cars 436 5 4625 2075 _ cares ws 465 205 cares ws 22 Cat wes Sid 2078 Page 5 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s min 450 Or Q sx o 3 el min 150 min 400 Diagram showing clearances required in boiler room The clearance details shown above are required for access to the boilers for maintenance purposes Slight variations may apply depending on the specific installation Page 6 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s Boiler Bloc
3. age 1 burner operation DIN 4791 Additional Weiland Connector Provision for Remote Switching of Burner 4 way for use with Hi Low Burners terminals 8a amp 8b N lt z RON gt Page 17 23 03 01 Ca 7s BCa 7s ASSEMBLY INSTRUCTIONS FOR we al s LN Jad ri N OPO N laqlzr i itty er N 3ql2 podeoy orieel6 Irelocirciogleel e L LN lal ole LN ad A IA ER IA pa er em w e em 4 e em ak a ees ml lo a a ll Lo w aw Kess Trick Veg tcl due mun ZI due mo 3907 1aumg OTI BIN jeuondo D 01 12 Oongiad0o 103 WROL HUT ASS pII Ieuondo z 9881S Zulte Jo duonbal Gel Z IBLIS IOW UNY SImOH 6T Ieuondo 3881S Zulte Jo duonbaJ Ga I 938IS IOW UNY SImOH QI Z ARIS ISOWI L Jaitog oi 938 S sowy ojog I J6ISOULISY L HUT rog pI YOUMS IOLALSUWITYSIH CI YAS IUI Jaune TI HAO NO YUMS Jon TI puoso WBISVIG SULHAA EUU UE 0 900 u oum sul d Za Page 18 23 03 01 Ca 7s BCa 7s ASSEMBLY INSTRUCTIONS FOR L r IN a Se ES P ES ad tojo9 d N ad pret N adhoc N f3alzL t vtile N l3alz bodeod olecle lecloclvcloeleel e Ivl aelc LN 3d IN lt Ka ze ges I a H Gef well V cC 9 snd due mut YstH due mo 3907 J3umg tc Ic I Oc I 2 9 xo jeuondo D 01 1 12 uongiodo 103 ye S0ULI9Y WUT JO 1Og jeuondo z 3881S SUIYOMS Jo A
4. e 60 C Max M Control Thermostat Stage 1 N Control Thermostat Stage 2 O Boiler Safety Limit Thermostat STB Manual reset Used when the boiler water temperature overheats The water in the boiler must cool to around 80 C to enable reset refer to point C above P Fuse 6 3A Protection for all the controls and any ancillary equipment connected back to the control panel A defective fuse MUST be replaced with an identical one ATTENTION Before a fuse is replaced the instrument control panel must be isolated Page 14 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s B2B Panel The diagrams opposite shows connections to the instrument control panel Burner Cables Power Supply Connection Stage 1 amp Stage 2 Thermostat Sensor amp boiler Thermometer Sensor Pockets K2B Panel Calorifier Thermostat Sensor Pocket Calorifier Thermometer Sensor Pocket Page 15 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s K2B Connections 230V 50 Hz A K2B Electrical Connections egine fe Pain le leteo felelete Lelee fif Ee eE I Eh L l 1 21 3 4115 6 4 3 2 1 LIPE N T1 T2 S3 B4 T6 T8 B5 B I I u U DIN 4791 DIN 4791 Supply 230V 50Hz Lesend Instrument Control Panel Separate Calorifier Control Separate Calorifier Circulating Pump Boiler Shunt Pump Flue Gas Damper Power Supply 230V 50Hz Burner Connections Plug and Socket Looms Boiler Circu
5. e boiler is 5 2 bar In addition at the time of testing for water pressure no pressure control fittings or safety fittings may be assembled which cannot be separated from the water area of the boiler Only fill slowly from the bottom via the filling and draining cock Ventilate during the filling procedure from time to time until the water emerges If a nipple connection is leaking then drain off the water via the filling and draining cock Separate by driving flat wedges around the perimeter of the join between sections New nipples MUST be used for re assembly Assemble and repeat test 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s The order of assembly from 1 to 13 must be observed Important points When assembling the floor insulation 1 as well as the side jackets 2 care should be taken to ensure they are in the correct position with burner cable holes facing the front The water temperature sensors 9 must be pushed with the pressure spring into the immersion sleeves max 3 per sleeve and then secured with the protective guard Note The sensor leads capillary tubes should not be kinked Page 10 The jacket assembly should be in the following order Insulation under the boiler both left and right Boiler side jackets left and right Rear bottom bracing angle Front bracing bracket Rear inner insulation Position burner cable according to door hinging Position instrume
6. e introduced into the flue passes in order to influence the flue gas temperature depending on chimney conditions The boiler can be used with an oil or gas burner Brief description Corrosion resistant block of cast Iron sections Triple pass boiler with optimised use of energy High efficiency Built in instrument panel with multiple control possibilities and retro fit control options Easy erection and cleaning Modern design Operating conditions Boiler Maximum operating temperature up to 110 C Maximum operating temperature up to 120 C depending on technical safety of the equipment Maximum operating pressure 4 0 bar Maximum test pressure 5 2 bar Page 3 Calorifier Maximum operating pressure 10 bar Maximum test pressure 13 bar The boiler can be delived in individual sections or as a boiler block The accessories are packed seperately There are different orders of assembly depending on the condition of supply when assembling and connecting the boiler all relevant instructions should be observed The boiler is to be erected on a base or a level floor which is capable of supporting the weight of the boiler water content and any ancillary equipment Refer to base details opposite Assembly connections and the initial set up operation should be carried out by a qualified heating engineer Min thickness 60mm Dimensions E MA E 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s
7. elet screws door hinge are at the same depth and when the door is closed it should press flat with the front section Diagram showing nipple amp borin 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s Brass nut amp Pulling up 2 x M20 Pulling up M20 Steel nut Pulling up Bars Pulling up flange Spanner gt parallel st Intermediate lt section Pulling up Brass pas Tie bar M20 fe Kr y Ri 4 L E P j Cast lug for tie bar he Tie bar M12 Blanking Flange Once the boiler block is pulled up use the tie bars to secure as shown Page 8 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s The order of assembly from 1 to 7 must be observed Important points e When fitting the long injection tube 1 only fitted to boilers with 7 sections or more care should be taken to ensure that the holes for the direction of water are facing upwards e The boiler flow 3 must be assembled with the connection facing upwards eccentrically e The boiler return 2 must be assembled with the connection facing downwards eccentrically e It is possible to hinge the door to swing from either side of the front section Car should be taken to ensure the burner plug is mounted accordingly Page 9 Cold water pressure test The assembled boiler is to be subjected to a cold water pressure test of 1 5 times the operating pressure The maximum test pressure of th
8. h that when the burner door is opened it becomes disconnected Page 20 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s THE COMPANY RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DIMENSIONS WITHOUT NOTICE STREBEL LTD 1F Albany Park Industrial Estate Frimley Road Camberley Surrey GU16 7PB Telephone 01276 685422 Fax 01276 685405 E mail address info strebel co uk Website www strebel co uk E amp O E Page 21 23 03 01
9. k Assembly The boiler block is assembled by pulling up each section in turn starting from the rear section 1 All other sections 2 3 4 are mounted individually using the pulling up tools One face of the adjoining sections must have a length of mastic sealing strand placed into the mastic groove Each of the boiler nipples must be inspected to ensure there is no damage apparent The nipples and nipple ports should then be kept free from dirt and checked at each stage of assembly Particles of dirt which are not removed lead to leakage The accompanying nipple jointing oil serves as a lubricant as well as a waterproof seal and must be used Boiler nipples and nipple ports must align exactly at all stages of assembly An inclined retracted nipple leads to leakage The clearance between the sections throughout the pulling up stages should always be even If the clearance is uneven a flat chisel should be inserted into the narrower point and the sections pulled up until the clearance is even again Page 7 Once assembled the boiler block is to be secured with the tie bars 2 at the top and 2 at the bottom Prior to screwing nuts up ensure the two disc springs 5 amp 6 are slotted on with concave sides facing each other The nuts can now be tightened until the disc springs flatten The burner door hinges should now be fitted on the left or right hand side of the front section depending on requirements Ensure the ey
10. lating Pump Interlock Flue Gas Damper Interlock Safety Solenoid Valve Interlock Safety Solenoid Valve Calorifier Thermostat Interlock High Limit Thermostat Provision for Remote High Temperature Limit Calorifier Control Thermostat Indication Calorifier Instrument Control Panel Connection Calorifier Circulating Pump Connection NX KER DD OU Se DIN 4791 Weiland Connector 7 way for stage 1 burner operation DIN 4791 Additional Weiland Connector Provision for Remote Switching of Burner 4 way for use with Hi Low Burners terminals 8a amp 8b Ka Page 16 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s B2B Instrument Control Panel Connections 230V B2B Electrical Connections ACA FARA EECHER 2 3 4 5 6 4 13 12 LIPE N T1 T2 S3 B4 T6 T7 T8 I l l l N DIN 4791 DIN 4791 Supply 230V 50Hz Legend Instrument Control Panel Calorifier Circulating Pump I Boiler Shunt Pump where applicable 26 Flue Gas Damper where applicable 28 Safety Solenoid Valve where applicable 29 High Limit Indication 30 Calorifier Control Thermostat Power Supply 230V 50Hz Burner Connections Plug and Socket Looms Calorifier Primary Circulating Pump Boiler Circulating Pump Interlock Flue Gas Damper Interlock Safety Solenoid Valve Interlock Calorifier Thermostat Interlock Provision for Remote High Temperature Limit DIN 4791 Weiland Connector Indication 7 way for st
11. nt control panel Mount control panel to mounting bracket Mount sensors in sensor pockets Top jacket Outer rear insulation Fit insulation retainer Fit flue over cast spigot on rear section using rubber mallet and block of wood Se Ee E s RR U N e 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s Calorifier assembly and connections l Injector tubes Note Ensure the holes for the direction of water are facing upwards Header for the return connection to calorifier Header for the flow connection to the calorifier Calorifier mounting bracket Calorifier Pipework to calorifier flow Pipework to calorifier return Blank flange for return connection Blank flange for flow connection Reflector plate Injector tube al ae et See HO CEO GE Page 11 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s BCa7s Jacket assembly Follow the steps below for completion of the jacket assembly Page 12 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s The jacket assembly is completed by following the steps below e The sensors 4 must be pushed into the sensor pockets at the rear of the boiler max of 3 per pocket Note e The calorifier control thermostat sensor 5 must be pushed into the lower sensor pocket with the retaining spring Mains connection should be made via the rear of the boiler e The calorifier thermometer 6 m
12. ouoNbaly Z IBLIS IJN UNY SINOH jeuondo 3881S SUIYOMS Jo duonba14 938 8 1919JA UNY SINOH JeJSOUIDY IIOL Z IBLIS JLISOWULIOY 110g 1 938 S ysowy 19109 Jejsounoul UNT 910g YMS S L 4 LS HUNT ysiy U9JLAS IOUT Jaune HHO NO YUMS JIm mod puoso WBISVIG SULIAA EUU US 0 900 u oum sul q q Pl 6 1 6l eg I 8 Ll 91 Page 19 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s IMPORTANT Flue gas temperatures of below 160 C can lead to sooting of the flue when entering a stone or brick chimney Where flue gas temperatures are below 160 C gross specially adapted chimneys must be available If after the burner has been set the flue gas temperature is too low the baffles from the 3rd flue pass can be taken out If necessary the 2nd flue pass baffles can also be removed NB Every change made to the flue baffles requires re commissioning of the burner settings Electrical connections must be carried out by qualified personnel in accordance with instructions supplied Electrical leads and oil pipes should never be fastened to the boiler casing In the interest of technical progress we reserve the right to undertake changes and improvements in production without notification Please refer to Operating and Maintenance information for details on baffles and control panel information When connecting the burner make sure the length of the burner cable is suc
13. ust be pushed into the through to the control panel It upper sensor pocket must not be connected directly to the front of the boiler via e All sensor leads capillary leads must not be kinked the calorifier jacket door Page 13 23 03 01 ASSEMBLY INSTRUCTIONS FOR Ca 7s BCa 7s Instrument Control Panel Description Power On Off switch B Burner lock out indicator RED The red lamp will illuminate if the burner has gone to lock out C High limit indicator ORANGE Illuminates if the high limit thermostat is activated Has to be manually reset by removing cap from STB reset and press button D High Limit Test Switch STB Overrides the control thermostat to enable limit thermostat test E Boiler Thermometer Shows the actual boiler water temperature and has no influence on boiler temperature control F HWS Thermometer Shows temperature of the HWS calorifier B2B version only G Hours Run Meter blanked as standard Burner Stage 1 Shows running time of the stage 1 burner operation H Hours Run Meter blanked as standard Burner Stage 2 Shows running time of the stage 2 burner operation I Frequency of Switching Meter for Stage 1 blanked as standard J Frequency of Switching Meter for Stage 2 blanked as standard K Summer Winter Switch For switching boiler between modes to supply HWS only In the summer period L Calorifier Control Thermostat Set for the required hot water temperatur
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