Lattner Boiler Company Alkon 90 Installation And Servicing Manual - General Information

Manual is about: Alkon 90 Condensing gas boiler Installation and Servicing Manual

Summary of Alkon 90

  • Page 1

    Alkon 90 00333991 - 1 st edition - 06/2012 installation and servicing manual notice: - this manual is avaible in the english and french language - in the commonwealth of massachusetts this boiler must be installed by a licensed plumber or gas fitter. Condensing gas boiler ® lattner.

  • Page 2

    2 contents 1 general information ................................................................................................................................................................................ 3 1.1 symbols used in this guide ............................................................

  • Page 3: General Information

    3 general information 1.1 - symbols used in this guide when reading this guide particular care has to be given to the parts marked with the followings symbols: 1.2 - correct use of the appliance the alkon appliance has been designed utilizing today’s heating technology and in compliance with the cur...

  • Page 4: General Information

    4 general information warning! The device should not be used by people with reduced physical, mental and sensory, experience and knowledge. These people must be well-informed and supervised during the work. Children must be supervised so they do not play with the appliance. Warning! The installation...

  • Page 5: General Information

    5 general information 1.6 data badge a sample data plate for a alkon boiler is shown in figure below. Danger smell of gas if you smell gas follow these safety indications: - do not turn on or off electrical switches - do no smoke - do not use the telephone - close the main gas tap - open all windows...

  • Page 6: General Information

    6 general information 1.7 - the following instruction must be followed - the boiler must only be used for its designated purpose, as described in the installation instructions. - each unit is fitted with a data plate. Consult the details on this plate to verify whether the boiler is compliant with i...

  • Page 7: General Information

    7 general information 1.10 - general warnings this instruction manual is an integral and indispensable part of the product and must be retained by the person in charge of the appliance. Please read carefully the instructions contained in this manual as they provide important indications regarding th...

  • Page 8: Technical Features

    8 technical features and dimensions 2.1 - technical features the alkon 90 boiler is a low water content thermal element about 2,64 gal (10 l), with a built-in premix gas burner, for heating only. It is mainly used as element for the modular boilers in casca- de (max 4 boilers). Peculiar characterist...

  • Page 9

    9 technical features and dimensions r ch system return dn 80 m ch flow system dn 80 g gas inlet dn 50 sc outlet condensate drain siphon Ø 32 2.2 - dimensions 48.4’’ (1238 mm) 4.6’’ (118 mm) 3.9’’ (100 mm) 20.2” (513 mm) 16.9’’ (430 mm) 11.2’’ (284 mm) 9.9’’ (251 mm) 5.3’’ (134 mm) 11.6’’ (295 mm) 18...

  • Page 10

    10 technical features and dimensions modulating fan condensate drain 3 way valve (flow) boiler drain cock flow manifold dn 80 gas manifold dn 50 return manifold dn 80 min. Water pressure switch 2 way valve (flow stop) return condensate sensor niveau return temperature sensor flow temperature sensor ...

  • Page 11

    11 technical features and dimensions 2.4 - boiler water circuit diagram 1 return gate valve 2 pump 3 flow gate valve (the way to the si- phon is open in order to drain the boiler) 4 ch flow temperature sensor 5 ch return temperature sensor 6 pressure switch against lack of water 7 hl thermostat 8 hl...

  • Page 12

    12 technical features and dimensions minimum heat input nominal heat input (low) (*) nominal heat input (high) (reduction for altitude) nominal heat output (ht) minimum heat output (ht) efficiency at full load (100%) efficiency at min load nominal heat output in condensing mode minimum heat output i...

  • Page 13: Instructions For

    13 instructions for the installer 3 instructions for the installer 3.1 - general warnings warning! This boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at ...

  • Page 14

    14 instructions for the installer 3.3 - packaging the alkon 90 boiler is supplied fully assembled in a strong cardboard box. After having unpacked the boiler check that it is intact and undamaged. Caution keep the packaging material (cardboard box, plastic bags, polyester protection etc.) out of the...

  • Page 15

    15 instructions for the installer - remove the packaging materials. - do not tear the packaging. - take note of the necessary space around the boiler for installation of venting system, pipework and servicing. See drawing in section 3.4 the location of the boiler can be determined by using the draw ...

  • Page 16

    16 instructions for the installer 3.5 - location of boiler inside a boiler room the boiler must be installed in accordance with the directions indicated in the most recent standards and legislations regarding boiler rooms, installation of heating and hot water systems, boiler ventilation, chimney’s ...

  • Page 17

    17 instructions for the installer • do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • never use or store any chlorinated detergents or haloge- nated hydrocarbons (e.G. In spraycans, solvents and de- tergents, paints, adhesives) in pr...

  • Page 18

    18 instructions for the installer 3.6 - connections m = ch system flow 3’’ - dn 80 r = ch system return 3’’ - dn 80 g = gas supply 2’’ - dn 50 s = condensate drain 1.25’’ - 32mm 3.7 - installation on existing heating systems kit of blind flanges - the circulation pump’s output, the head and flow dir...

  • Page 19

    19 instructions for the installer 3.8 - gas connection danger the gas connection must be carried out by a registered engineer who will have to respect and comply to the regulations in force and to the requirements indicated by the local gas supplier. An incorrect installation could cause injury to p...

  • Page 20

    20 instructions for the installer 3.9 - flow and return pipe connections warning! It is absolutely forbidden to fit on-off valves on the generator to the fore of the saftey devices warning! Before installing the boiler we recommend that the system is flushed out with a suitable product, in order to ...

  • Page 21

    21 instructions for the installer pressure losses in wc q: water flow rate gal/h pressure avaible to the system the boiler pump must have a delivery head which can ensure the water flow rate as shown in the diagram “water pressure losses”. The following table gives an indication of the pump’s flow r...

  • Page 22

    22 instructions for the installer 3.13 - connecting the expansion vessel in a single boiler system caution damage to the installation due to faulty pressure relief valve. - the expansion vessel must be of sufficient capacity. - connect the expansion tank to the boiler return. If a check valve is ava...

  • Page 23

    23 instructions for the installer c filling pipe 3.14 - condensate drain during the combustion process the boiler produces condensate which, through the “a” pipe, flows into the siphon. The condensate which forms inside the boiler has to be routed into an adequate drain by means of the pipe “b”. Dan...

  • Page 24

    24 instructions for the installer 3.15 - water treatment the chemical/physical features of the heating system’s water are fundamental for the boiler’s correct operation and safety. Among the inconvenients caused by the bad quality of the feeding water, the most frequent and the most serious is the i...

  • Page 25

    25 instructions for the installer 3.16 - combustion air and ventilation openings provisions for combustion and ventiiation air must be made in accordance with section 5.3, air for combustion and venti- lation, of the national flue gas code, ansi z223.1/nfpa 54, or sections 7.2, 7.3 or 7.4 of can/cga...

  • Page 26

    26 instructions for the installer 3.17 - installation of the exhaust and air intake system notice consult local and state codes pertaining to spe- cial building code and fire department requirements. Adhere to national code requirements. Notice observe the listed maximum lengths of vent sy- stem whi...

  • Page 27

    27 instructions for the installer when using indoor air, lattner strongly recommends the use of an indoor air filter. This boiler requires adequate combustion air for ventilation and dilution of flue gases. Failure to provide adequate combustion air can result in unit failure, fire, explosion, serio...

  • Page 28

    28 instructions for the installer l min = 39.7‘‘ (1 m) l max = 1181‘‘ (30 m) l min = 39.7‘‘ (1 m) l max = 1181‘‘ (30 m) l preliminary operations: fit the smoke evacuation (a) pipe Ø 3.94‘‘ (100 mm), supplied in the package (into the boiler), as shown in the picture. Fix the screw b. Flue outlets Ø 3...

  • Page 29

    29 instructions for the installer 3.19 - electrical connections regulations in force the electrical connections to the boiler must be made in ac- cordance with all applicable local codes and the latest revision of the nfpa 70: national electrical code installations should also conform with c22.1 - c...

  • Page 30

    30 instructions for the installer connection of the additional safety devices room thermostat e8 heating controller for the connection remove the existing jumper. Room thermostat and/or e8 heating controller connection - gain access to the y1 terminal board - for the room thermostat connection 1 and...

  • Page 31

    31 instructions for the installer 3.20 - functional flow wiring diagram csd - 1 prearrangement for the connection of the additional safety devices 2 ora n ge + bl ac k ( -) br o w n ( p w m ) bl u e ( t a c ho ) 4 5 bl ue ( n ) 1 2 br o w n ( l 1 ) 3 ri l ./r e g . Al im . 230v srr sr tl brown brown...

  • Page 32

    32 instructions for the installer 3.21 - general ladder diagram l n ac/dc cpu p f g 120 vac 15 kv fs1 flame caution high voltage spark lead spark rod a8 - 1 ig a8 - 2 ig a8 - 2 a9 - 2 a9 - 6 a6 - 6 a6 - 5 a9 - 5 a9 - 1 a8 - 1 a3-5 srr ribbon cable a3 a3 6 - a3-3 sr a3 4 - a4-6 pf a4-5 a4-4 a4-5 tl a...

  • Page 33

    33 instructions for the installer for the filling of the system it is necessary to fit a filling valve on the c.H. Return. The boiler is equipped with its own drain cock, whose position is shown in the figure of page 11. This cock never has to be used for the drain of the system, because all the dir...

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    34 instructions for the installer.

  • Page 35

    35 instructions for the installer 3.24 - initial lighting prelimiary checks caution the first ignition must be carried out by a qualified technician. Failure to do so could cause injury to persons, animals or damage to property. Lattner shall not be held liable for any injury and/or damage. Before l...

  • Page 36

    36 instructions for the installer - check that the boiler is connected to the electrical supply; the green indicator led “q” ( ) on the control panel must be illuminated. - create a request in ch by pressing key indicate. - turn the gas valve knob, in off position. - after 1sec, boiler switch off, l...

  • Page 37

    37 instructions for the installer 3.26 - burner adjustment warning! All the instructions indicated below are for the exclusive use of qualified lattner service technicians or installers. All the boilers are supplied already calibrated and tested. If it is necessary to change the calibration due to g...

  • Page 38

    38 instructions for the installer c) completion of the basic adjustments - check the c0 2 values at the minimum and maximum outlet - if necessary make the required adjustments to ensure correct operation the c0 2 values have to be adjusted with extreme care respecting the values indicated in the tab...

  • Page 39

    39 instructions for the installer 3.27 - programming of the operating parameters warning! These operations are accessible to trained installers and service engineers only for changing the parameter settings burner modulation level in ignition (ig) by pressing the yellow key you have access to the fi...

  • Page 40

    40 instructions for the installer setting of the minimum heating temperature continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: setting of the minimum heating temperature (hl). Repeat the operations a-b-c for setting the desired v...

  • Page 41: Servicing Schedule

    41 servicing schedule caution to ensure the continued safe and efficient operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary, and that only original spare parts are used. Regular attention will prolong the life of the boiler. Danger if...

  • Page 42

    42 instructions for the installer 4.2 - periodic examination of venting system 4.3 - proper procedure for cleaning flue gas passageways (after 1 year maintenance) verify that the system of flue and chimney are unobstructed. 4.4 - proper procedure for cleaning the burner the inspection of the boiler ...

  • Page 43

    43 instructions for the installer 4.5 - visual inspection of the flame 4.6 - proper reassembly and resealing of the vent-air intake system (2 and 4 year maintenance) the burner must flame evenly over the entire surface when operating correctly. The flame must burn with a clear, oran- ge, stable flam...

  • Page 44: Servicing Schedule

    44 servicing schedule 4.6 cleaning the condensate drain siphon in order to check and clean the siphon carry out the following steps: - disconnect the transparent pipe (a) check that no deposits have accumulated inside the siphon. If there are any de- posits flush them out with clean water; - reassem...

  • Page 45: Fault Finding

    45 fault finding description: failure of the heating return sensor (srr) corrective action: check the efficiency of the sensor and/or wiring description: over high temperature detected by the heating sensor (sr) >203°f (>95°c) corrective action: check the system’s water circulation 5 fault finding 2...

  • Page 46: Fault Finding

    46 fault finding description: alteration of the operating parameters caused by emc disturbances corrective action: restore the factory parameters description: flame signal detected before the ignition cycle corrective action: disconnect the detection electrode’s wire from the control board; if the e...

  • Page 47: Spare Parts

    47 spare parts 6 spare parts 25 41 24 30 29 28 23 26 49 19 17 35 14 21 47 31 20 14 47 33 15 6 45 16 4 34 3 41 9 13 32 12 11 10 27 46 37 38 42 39 43 44 40 2 7 36 18 48 5 8 1 22 24.

  • Page 48: Spare Parts

    48 spare parts pos. Code description 1 95000567 boiler sensor 2 95000610 grommet (3 pcs.) 3 95000710 sight glass 4 95251559 ignition electrode 5 95310874 fascia board 6 95000935 pcb 7 95100106 control panel 8 95212781 front casing 9 95000937 heat exchanger 10 95251588 fan seal 11 95251207 screw (8 p...

  • Page 49: Spare Parts

    49 spare parts.

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    Lattner boiler mfg. Co. 1411 9 th st. S.W. - p.O. Box 1527 - cedar rapids, ia 52404 319 - 366 - 0778 - 800 - 345 - 1527 - fax: 319 - 366-0770 www.Lattner.Com lattner declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also reserves the right to bring...