Technical instructions - Energie Transfert Thermique · · 2017-11-17Condensate treatment system...

É n e r g i e T r a n s f e r t T h e r m i q u e

Technical instructions for Operation & Maintenance

A different c l imateEnvironmental control solutions

July 2016

Annex: CC+ module

2

E n e r g i eT r a n s f e r tThermique

Contents

Information contained in this document has been prepared by qualified ETT specialists. We are doing our best to ensure its completeness and accuracy but it does not constitute a guarantee.This information is given in good faith, any use of the equipment not in accordance with the instructions and warnings is done at the user's own risk.

A. Equipment performance ................................................................................................................................ 3

B. Maintenance intervals ....................................................................................................................................... 3

C. Regulatory requirements ................................................................................................................................. 5

D. Commissioning procedure............................................................................................................................ 6

E. Regulator features .................................................................................................................................................. 8

F. Setting the burner .................................................................................................................................................11

G. Operating cycles and boiler safety ................................................................................................13

H. Recommendations to the user .............................................................................................................14

I. Diagnostics and troubleshooting support ...............................................................................15

J. Exploded view ..........................................................................................................................................................16

Technical instructionsfor Use & Maintenance

3

MARK-NOT_08.00-ENETT may change equipment’s data & design without prior notice.Specifications given in this document are for information only and are not contractual.

A. Equipment performance• The validity of the guarantee is conditional upon strict compliance with instructions presented in this

document.• Proper operation and maintenance:

> maintains units performance; > extends equipment service life; > reduces the risk of unit failure; > allows energy costs management; > ensures regulatory compliance (compulsory checks based on local regulations).

ETT Services is here to help you get the most out of your installation.

+33 (0)2 98 48 02 [email protected]

Contact your local ETT Services adviser.

B. Maintenance intervalsMaintenance intervals: Q (Quarterly), H (Half-yearly), A (Annually)

Operations Q S A

General control

Check visually X

Condensate treatment system control X

Electrodes and burner control X

Combustion control X

Glycol rate control X

Refrigeration circuits

Check water level and heat transport system X

Heating (if applicable)

Combustion chamber inspection X

Boilers flow rate control X

Maintenance intervals mentioned above represent minimum annual maintenance and are given for information only. Maintenance personnel shall adapt maintenance intervals as necessary.


4

MARK-NOT_08.00-ENETT may change equipment’s data & design without prior notice.

Specifications given in this document are for information only and are not contractual.

1/ General visual inspectionCheck visually the hydraulic and electrical connections of the thermal module.If a leak is detected, replace the concerned sealing.

2/ Heat transport system water level control On versions with expansion tank, turn off the boilers and wait until water temperature in the circuit falls under 30°C. Carefully open the filler cap and adjust water level.On versions with pressure regulation unit, check buffer tank level and adjust if necessary.

3/ Glycol rate controlAnalyse a heat transfer fluid sample and adjust the glycol percentage if necessary.

4/ BoilersflowratecontrolFollow the procedure described in “Boilers water flow rate control”, p. 7.Start the circulator.Check boilers flow rate.

5/ Combustion chamber inspectionCheck the combustion chamber for deposits annually. Vacuum up any deposit.Clean the exchanger with a flexible non-metallic brush if necessary.

! Caution:Do not clean the combustion chamber with acid-based or alkaline cleaning agents.

Check heat exchanger insulation, replace if necessary.Before closing the chamber, check door gasket.Replace every two years.On versions with expansion tank, turn off the boilers and wait until water temperature in the circuit falls under 30°C. Carefully open the filler cap and adjust water level.On versions with pressure regulation unit, check buffer tank level and adjust if necessary.

6/ Electrodes and burner control

Replace the electrode and the gasket if damaged.Check the ignition electrode gap (4 ±0.5 mm) and the gap between the electrodes and the burner (8 ±1 mm).If the burner is damaged (cracking, overheating), replace the burner-door assembly.


5


7/ Combustion controlThe burner must be set by a qualified professional using a combustion analyser. The procedure is described in “Setting the burner”, p. 11.Check the circuit for leakage after each operation.

8/ Condensate treatment system controlCheck the condensate treatment system regularly. If the condensate drain is clogged, condensates may end up in the combustion chamber and damage boiler insulation.Check neutralising granulate efficiency. Condensates pH must be greater than 5 before condensates are released into the sewage system.

C. Regulatory requirements

1/ Boilers rated from 4 to 400 kW capacityIn application of the French decree of 9 June 2009 on boilers rated from 4 to 400 kW capacity, such equipment must be maintained annually by a qualified professional.Maintenance operations involve:

> checking the boiler; > cleaning and setting the boiler; > measuring carbon monoxide (CO) level; > assessing boiler efficiency; > assessing boiler air pollutants (NOx); > consulting on installation management; > maintenance release.


6



D. Commissioning procedure

1/ Pre-commissioning checks

1.1/ Electrical connectionsCheck supply voltage. Supply voltage must be between 210 and 230V AC.

! Caution:Respect the phase-neutral polarity. In case of impedance-earthed neutral, use a non-polarised control box. This type of box affects ionisation signal reception and does not allow optimum modulation range. Contact the manufacturer for more information.

1.2/ Gas circuitCheck the gas circuit for leakage. Make sure that the type of gas and the supply pressure are suitable for the equipment. (50 mbar maximum, see pressure/flow rate table in “Burner settings”, p. 12) Check that the main gas valve is open and drain gas ducting.Open the shut-off valve upstream of the unit.

1.3/ Condensates evacuation

! Caution:Condensates are acidic. Condensates may need to be neutralised before being discharged. Refer to national and local regulations.

Discharge piping material must resist acid water with a pH of 3. Do not use copper or zinc plated iron piping.

Check discharge piping for leakage. Use PVC pipes of a diameter at least equivalent to equipment piping diameter. Make sure that the discharge piping is installed lower than the highest point of the siphon.Certain regulations may require condensates treatment. In that case, use a condensate neutraliser kit.

1.4/ HeattransferfluidcircuitFill the circuit while controlling the ethylene glycol rate.Operate the circulator several times to drain it. See “Circulator manual commissioning”, p. 6.

1.5/ Circulator manual commissioningProceed as follows on the regulator:

! Caution:See further explanations on pressure regulation unit operation.


7


Thermal module Circulator: OFF

Thermal moduleCirculator: auto

Thermal moduleCirculator: manual

Press , then press several times to reach the line “Circulator”.

Hold for 5 s. to select the circulator operating mode.

Press to change mode (auto/manual) then press to accept. Manual mode automatically switches back to auto mode after 2 minutes.

1.6/ BoilerswaterflowratecontrolThe water flow rate increases as heat transfer fluid temperature increases. The flow rate should not be lower than 1700 l/h for a boiler outlet temperature of 30°C. Insufficient flow rate may be due to incorrect circulator sizing, poor drainage or the heat transfer fluid circuit being too resistant.

Proceed as follows on the regulator to check the water flow rate.

1.7/ Smoke evacuationCheck duct connections.

2/ Commissioning > Start the air handling unit to cool down the exchanger. > Apply tension to the regulator input, as required to reach the desired capacity.

The regulator starts the boilers one after the other and adjusts capacity. Capacity can also be adjusted manually from the regulator. This function has a timer. After 10 min, capacity is re-adjusted based on the tension applied to the regulator terminals.

Setpoint: 000 %Returned: 000 %

Boiler 1QE : 1700 l/h

Boiler 2QE : 1,800 l/h


8



E. Regulator featuresThe regulator displays information sent to each boiler.Press the key and use the key to scroll through the menu.To display a boiler, enter its number. Some keys allow program modification. Hold for 5 seconds to access the setting menu.

! Caution:Modifications must be performed by qualified personnel.

Press to return to the main page.

+ Function Line 1 Line 2 Value 1 Value 2 Value 3 Value 4 Function

0 SetpointCapacity Setpoint returned xxx kW 5 s.

1 Statusboiler Boiler no.X Status ON OFF Fault Stop +

2 Capacityreturned Thermal module PR 00 kW

3 Circulator Thermal module Circulator 5 s.

4 Circuit pressure Thermal module Pressure 0.8 bar (12 psi) Fault

5 Burner Boiler no.X Burner ON OFF Fault

6 Speedburner Boiler no.X LV 6500 rpm Fault

7 Water flow Boiler no.X QE 2000 l/h Fault8 Outlet T°C Boiler no.X T°C out 80 °C Superheat Fault9 Inlet T°C Boiler no.X T°C in 60 °C Fault

10 Communication Boiler no.X Data link OK Fault 5 s.11 Operating time Boiler no.X Duration XX hour12 Cascade Thermal module 1-2-3-4 2-3-4-1 3-4-1-2 4-1-2-3

13 Settingburner Boiler no.X Burner

settings 5 s.

14 Glycol rate Thermal module Glycol rate 30 % 40 % 50 % 5 s.

15 Language Thermal module Language Français English Deutsch Español 5 s.

16 Boiler card version Boiler no.X Version Ch. Version

17 Version Programme R Thermal module Version Reg. Version 5 s.

18 Cascade CH + Thermal module Cascade CH + 7000 rpm

18 Cascade CH - Thermal module Cascade CH - 3000 rpm


9


1/ Indicating the number of boiler in the thermal module

2/ Stopping a boiler

0 = Stop1 = Auto <<

Thermal moduleVersion reg.

Thermal moduleVersion reg.

Press , then press several times to reach the line “Version reg.”.

Hold for 5 s. Use the keypad to enter the number of boilers and press to confirm.

Boiler 1Status

Press several times to reach the line “Status” and press to confirm.

Boiler 1Stop

Press to select the desired status.stop = unit stopped auto = automatic operation

Press to confirm and exit.


10



3/ Forcing capacity

4/ Addressing and reprogramming a boiler CTA card




Press , then press several times to reach the line “Setpoint”. Hold

for 5 s. The first line flashes. Hold for 5 s.

Use the key pad to enter the desired capacity and press to confirm. The value will be kept for 5 minutes, while the first line flashes.

Return to the “Setpoint” line and press to return capacity to normal mode.

Boiler 1Data link

Boiler 2Programming

Boiler 2Press reset

Press , then press several times to reach the line “Data link”. Hold

for 5 s.

Use the keypad to enter the number of the boiler you want to reset and press to confirm.

Press reset for the selected boiler, wait for the message “programming OK”, then press to exit.


11


F. Setting the burner

1/ Required tools > 2.5 mm hexagon key (for air-gas ratio setting High flow “4”) > 4.0 mm hexagon key (for air-gas ratio setting Low flow “5”) > Combustion analyser (O2/CO - Smokes temperature) > Gas manometer (max. pressure 50 mbar)

2/ Premix burner control and setting procedure• Calibrate the combustion analyser and place the sensor in the smoke duct.• Check gas supply pressure before start-up, when stopped and in operation (see table).• Start the module:

> Start the boiler in High flow mode (see Setting the burner on the regulator). > Check the oxygen (O2) level after 1 minute of operation. > Use screw 4 to adjust the level according to the table below. Turn the screw clockwise to lower the O2 level, turn counter-clockwise to increase the level. > Switch to Low flow mode (see Setting the burner on the regulator). > Use screw 5 to adjust the level according to the table below. > Turn the screw clockwise to increase the O2 level, turn counter-clockwise to lower the level. > Once low flow is set, exit the setting mode.

1. Burner fan2. Variable venturi3. Gas control valve4. High Flow mode5. Low Flow mode


12



3/ Setting the burner on the regulator

4/ Burner settings

Type of gas Pressure when stopped

Pressure during operation

O2 in High flowmode(screw 4)

O2 in Low flowmode(screw 5)

Maxi CO in PPM

NG LPG

G20 (natural gas) 20 to 50 mbar min. 18 mbar 5 % 6 % 160 200

G25 (natural gas) 25 to 50 mbar min. 20 mbar 5 % 6 % 160 200

G31 (LPG gas) 28 to 50 mbar min. 25 mbar 5 % 6 % 160 200

0 = Stop mode1 = Auto mode <<

Boiler 1Status: ON

Boiler 1Burner settings

Press . Press to display “Burner settings”. Select the boiler you want to set using the keys from 1 to 4.


Setting Burner 2 = HFExit = 0 LF = 1 HF = 2


Hold for 5 s. Select Low flow (1) or High Flow (2) mode.

Press 0 to exit.


13


G. Operating cycles and boiler safety

The CTA card continuously monitors sensors values. In a fault is detected, the boiler is stopped. To reset the fault, press the rest key on the CTA box of the concerned boiler. The fault and its origin are displayed on the regulator. Only “water pressure” faults must be reset on the regulator. In case of flame fault, the burner will attempt to restart 3 times.

The regulator send the start-up command

Sensors operation control

Fault report Sensor fault Sensors OK

Reset required Boilers water flow rate control

Insufficient water flow rate Water flow rate OK

Burner fan start-up

Burner fan speed control

Burner fan fault Insufficient speed Speed OK

Reset required Electrode ignition and gas solenoid valve opening

Flame control with ionisation probe

Flame fault Ionisation fault Ionisation OK

Reset required Boiler modulation according to settings

Boiler capacity (measured by the water flow and differential T°C between inlet and outlet) is adapted according to the

demand.


14



H. Recommendations to the user

1/ Safety rules• Do not block or reduce ventilation openings.• Do not block smoke evacuation and fresh air intake.• Do not change the settings made by the qualified professional.• Do not touch hot and/or moving parts of the module.• Do not put any object on the unit or hang anything from it.• Power and gas supplies must be cut before any intervention on the unit.• Do not change the type of gas used, the unit settings, the security or control systems. It may result in

hazardous situations.• Contact the maintenance technician in case of change of gas, gas pressure or supply voltage.• Disconnect power supply if the equipment is not used for an extended period of time.• It is recommended to you consult a professional to restart the equipment.• Repairs and maintenance operations must only be performed by qualified personnel.

2/ Troubleshooting

Problem Solution

Gas smell - Close the external gas valve, cut off the power supply and contact the maintenance technician.

Burner safety lock-out - Reset the burner from the control box. - If the problem persists, contact the maintenance technician.


15


I. Diagnostics and troubleshooting support

Faults Cause Solution

The equipment does not start.

- Main switch OFF - Green indicator OFF = no power supply - The optimiser reports a communication fault. - The optimiser reports a sensor fault. - The optimiser reports a burner fault. - The optimiser reports a water circuit fault. - Burner fan out of service - Wrong addressing

- Turn the switch ON. - Check power supply. - Check communication cable. - Check the sensor. Replace if necessary. - Reset the burner. - Check water level and pump. - Replace. - Check equipment addressing. - Configure the optimiser.

The burner fan starts several times with no flame.

- No gas - Air in piping - Incorrect air-gas setting - Faulty gas solenoid valve - Ignition electrode not properly installed or faulty - Faulty control box

- Check pressure. - Drain piping. - Set air-gas ratio. - Replace. - Set or replace. - Set or replace.

The burner fan operates at full speed but capacity is not at its maximum.

- Flue too long - Air intake duct or flue blocked - Incorrect burner setting - Return air temperature too high

- Reduce flue length or accept. - Unblock ducts. - Set combustion. - Room temperature too high

The burner is not modulating and the burner fan operates at full speed.

- Incorrect optimiser setting - PWM control cable disconnected - Faulty ventilation fan - Faulty electronic card

- Set. - Check connection. - Replace.

The burner starts, the flame appears and the control box switches to safety lock-out.

- Reversed phase/neutral - Power supply without neutral - Faulty ionisation probe

- Switch phase and neutral on power supply - Use an SNI inspection box. - Replace.

For versions with variable air flow. The air fan does not modulate.

- Speed variation not regulated on optimiser - Speed variation cable disconnected - Faulty motor

- Set the speed on the optimiser. - Check the cable. - Replace.


16



J. Exploded view

! Caution:Only original parts can guarantee equipment safety.Using non-original parts rules out manufacturer’s liability for any resulting damage.


17


No. Description Item code

1 Regulator HGGY 903

2 Slave card CTA 1 HGGY 904

3 Cold door with burner HGGY 905

4 Supply card IMT 1 HGGY 906

5 Burner control box HGGY 907

6 Gas control valve HGGY 908

7 Boilers outlet header HGGY 909

8 Safety valve HGGY 910

9 Boilers inlet header HGGY 911

10 Gas header HGGY 912

11 Gas pipe venturi HGGY 913

12 Water pressure sensor HGGY 914

13 Variable venturi HGGY 915

14 Burner fan HGGY 916

15 Condensates evacuation pipe HGGY 917

16 Flow meter HGGY 918

17 Outlet temperature probe HGGY 919

18 Inlet temperature probe HGGY 920

19 Condensing boiler HGGY 921

20 Smoke seal HGGY 922

21 Individual gas hose HGGY 923

22 Boiler temperature probe HGGY 924

www.ett.fr

Reference: MARK-NOT_08.00-EN56 Route de Brest - BP26 - 29830 PLOUDALMEZEAU - FranceTel: +33 (0)2 98 48 14 22 - Fax : +33 (0)2 98 48 09 12Export Contact: +33 (0)2 98 48 00 70 - ETT Services: +33 (0)2 98 48 02 22

Des

ign:

ETT

- D

ocum

ent p

rinte

d by

an

envi

ronm

enta

lly fr

iend

ly p

rinte

r usi

ng v

eget

able

bas

ed in

k on

PEF

C p

aper

cre

ated

from

sus

tain

ably

-man

aged

fore

st.

A different c l imateEnvironmental control solutions

É n e r g i e T r a n s f e r t T h e r m i q u e

Technical instructions - Energie Transfert Thermique · · 2017-11-17Condensate treatment system...

Documents

Transcript of Technical instructions - Energie Transfert Thermique · · 2017-11-17Condensate treatment system...