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Assembly
Once the boiler has been set into place, follow the
operations described below:
1 – Open the boiler door and remove the
protective cardboard from the insulating fi bre
on it. Remove all the material contained in the
combustion chamber (control panel, boiler
body insulation, cleaning brush and door
clamps).
2 – Fit the clamps (1) with their backnuts (2) in
the door. See Fig. 5.
3 – Check that the opening direction of the door
is the one required. On the other hand, if you
want to reverse it, proceed as follows:
3.1 – Make sure the door is correctly fastened
with the clamps (1) and hinge tie-rods
(3).
3.2 – Transfer the M4 bolts (4), which locked
the hinges on the side where the
clamps were initially, to the opposite
side (5) where the clamps will remain
permanently. See Figs 6 and 7.
3.3 – Exchange, diagonally, each clamp (1) for
a hinge tie-rod (3), keeping in each case
the respective backnuts. See Fig. 8.
3.4 – Tighten the two backnuts (6) on the
hinge side.
3.5 – Remove the door switch (7) and install
it on the opposite side.
4 – IMPORTANT
The door will be adjusted in this mounting
position so as to prevent fl ue gases from
leaking.
(This adjustement should be made before
fi tting the door casing panel and the burner).
To adjust the door, for making sure that it is
gas-tight, proceed as follows:
Likewise, loosen the backnut (2) on the side
of the door clamps. Fig. 25.
Tighten the two hinge tie-rods (3) in parallel
with the two clamps (1) until the whole outline
of the door sinks about 2 to 3 mm in the
sealing strip.
5 – Place the pocket (9) for the thermostat and
thermometer bulbs in the socket (10) of the
heating fl ow pipe (11).
Place the check valve (12) of the combined
temp./altitude gauge in the socket (13) of the
return pipe (14). In both cases put tefl on or
something similar on the thread to ensure
water tightness. See Fig. 9.
6 – Make the fl ow (11) and return (14) connections
from the boiler to the heating installation.
7 – Make the safety and drain connections (15)
in accordance with the type of installation:
7.1 – Sealed System Installation. Fig. 10
Where the hydraulic installation is to
be sealed and pressurised, a safety
valve (16) must be connected to the
upper tapping (17) adjacent to the fl ow
connection. Under no circumstances
must the setting of the safety valve
exceed 5 bar or the maximum pressure
allowed by the expansion vessel. The
discharge pipe should be connected
via a funnel (18) to the drain.
A tapping is provided for connection
of an expansion vessel (19) via a tube
(20) to the underside of the boiler body.
An automatic air vent (21) should be
installed to bleed the air in the tube (20).
7.2 – Open Vented Installation. Fig. 11
Where the hydraulic installation is to be
open vented, the vent pipe (22) should
be connected to the upper tapping (17)
and the cold feed pipe (23) must be
connected to the connection (20) at the
base of the boiler body.
8 – Fill the installation with water and test for water
tightness, checking that there are no leaks.
Drain/fl ush the installation to remove debris
and then refi ll.
9 – Insulate the boiler by wrapping the exterior of
the body cylinder with the 70 mm glass fi bre
insulating blanket (24). It will be necessary to
cut apertures for the various connections that
will pass through the insulation. With some
models, the blanket is in two parts, and any
excess should be overlapped at the centre of
the body.
Fix in place the insulating blanket with the
bands (25) and lock in place using the buckle
(26) as shown in the drawing.
Where the insulation is in two parts, the
central band (25) should be positioned at the
overlap of the two pieces. See Fig. 12.
10– Insert the cable grommets into the holes (26)
in the lower, front & rear boiler end panels. Left
or right hand holes should be used to match
the handing of the door.
11 – Take the control panel and the top front panel
of the casing.
Boilers with basic control panel
(one stage)
11.1 – Fix the control panel (29) to the panel (30)
with the four screws supplied.
Straighten up the capillary tubes of the
thermostats and thermometer (31),
introduce the bulbs in the pocket (9) and
fi x them with the incorporated clip.
Straighten up the capillary tube of the
pressure gauge (32) and fasten it to the
check valve (12). See Fig. 13.
Pass the electrical cables through the
cable entry (33) and wire the thermostats
to the control panel (29) in accordance
with the directions in the instructions for
the burner.
The door switch (7) must be connected in
series with the limit thermostat (35). See
Fig.4.
Boilers with basic control panel (two
stage) or digital KSF panel
11.1 – Open the control panel to gain access
to the terminal strip and to the capillary
tubes of the thermostats, thermometer
and pressure gauge.
Straighten the capillary tubes, passing
them across the base of the control panel
and through the knockouts in the top front
panel of the outer casing.
Fasten the base of the control station to
the panel with the screws provided.
In those models with a 2 stage basic control
panel (38 Fig.4) the thermostat bulbs
(39) and the bulb of the combined temp./
altitude gauge (40) will be introduced
in the pocket (9 Fig. 9) located in the
connection (10) as showed on Fig. 14;
introduce and fi x the pressure sensor of
the combined temp./altitude gauge in the
check valve (12) located in the connection
(13).
In those models equipped with KSF control
panel (70 Fig. 4), the safety thermostat
bulb (39 Fig 14a) and the temperature
sensor (78) will be introduced in the
pocked as showed on Fig. 14a, using the
spring (79) supplied with the KSF control
panel.
Introduce and fi x the pressure sensor of
the combined temp./altitude gauge in the
check valve (12) located in the connection
(13).
It is recommended that heat conducting
paste be put in the pocket beforehand.
Fix the bulbs into the pockits using the
incorporated clips.
12 – Assemble the sides of the casing which
for the moment will be suspended by the
slots in the front (41) and rear (42) tubular
plates. See Fig. 15.
13 – Put the top central panel in place and by
simple pressure it will remain fi xed to the
side panels.
14 – Put in place the top front and rear panels
which will rest on the central cover and will
remain fi xed by the side clips.
15 – Open the boiler door and check the correct
position of the turbulators (43), which
should be level with the tubes at the front
of the boiler. Both sections should be
interconnected; should they have become
separated, pull the long section out a little,
give a quarter turn to the short section and
interconnect them again.
From the CPA 345-BT upwards, each
turbulator consists of two sections: a long
one which should remain in the fi nal part of
the tube and a shorter one of stainless steel
which should be level with the tube at the
front of the boiler.
16 – Assemble the burner on the boiler door. If
the burner is not made by
you should check that the fl ame tube (44)
surpasses the ceramic fi bre (45) by at least
20 mm. See Fig. 16.
Important:
Fill with rock wool or ceramic fi bre (45) Fig. 16
the space which might remain between the fl ame
tube (44) and the insulating fi bre (45) of the door.
17 – Make the fuel connection to the burner.
18 – Electrical connection
The installation should include a circuit
breaker or other omnipolar disconnect switch
to isolate all power supply to the boiler.
The connection of external appliances should
be done through approved wiring harness
type ES-NOSW5-F.
Basic control panel (one stage
operation)
The electrical connection between the burner
and the boiler thermostats will be carried out in
accordance with the instructions for the burner.
The door switch will be connected in series with
the limit thermostat.
Basic control panel (two stage
operation)
Control panel supply voltage: 220/230 V~, 50 Hz.
The components which can be connected to the
control panel and their maximum power input are
the following:
Control
Component
Panel
Terminal
Pump
5-6
Burner
14-6
Storage cylinder
4-7
However, the total electrical load of components
must not exceed 2,800 W.
KSF digital control panel
In the manuals of the KSF panel (70 Fig.4), you
will fi nd a complete information about features and
heating installations can be managed with this
panel, which has specifi c components like fuse
(72), overtemperature lookout indicator (71) and
the control unit with LCD screen (73).
Electrical Connection Between the
Control Panel and Burner
See fi g. 17 to 23
See legend in fi g. 20
Electrical components of the Gas Train must be
connected according to burner instructions.
Legend. See Fig. 19.
19 – Burners with an air pressure test point (47)
Fig. 24 will have to be connected to the
boiler pressure test point (55) using a fl exible
silicone hose (56). The pressure test point
screw should be removed before-hand.
,
Max.
power
Input
1000 W
1000 W
2800 W
17
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