Lamborghini Installation Instructions Final
Contents
1. a e e CALORECLIMA Room temperature adjustment with optional room thermostat Using the room thermostat set the personal temperature requirement for the building Room temperature adjustment with optional remote timer control Using the remote timer control set the temperature desired in the rooms The boiler unit will set the system water according to the required room temperature For information on the remote timer control please refer to its user s manual Sliding temperature When the optional external ambient sensor probe is installed the corresponding symbol detail Fig 122 is activated on the control panel display detail 5 Fig 1 The boiler control system operates with Sliding Temperature In this mode the heating system temperature is adjusted according to the outside weather conditions to ensure both high comfort and energy saving throughout the year In particular as the outside temperature increases the system delivery water temperature is decreased according to a specific compensation curve With Sliding Temperature adjustment the temperature set with the heating buttons details 3 and 4 Fig 1 becomes the maxmum system delivery temperature It is advisable to set a maximum value to allow system adjustment throughout its useful operating range The boiler must be adjusted at the time of installation by trained qualified personnel Final adjustments can be made later if requir2. d i e e CALORECLIMA FUTURIA power Sold and serviced by Hurlcon Heating 90 Hanna Street Noble Park VIC 3174 Ph 03 9554 2275 INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE 1 GENERAL INSTRUCTIONS Carefully read the instructions contained in this instruction booklet and store booklet in a safe place e After boiler installation inform the user regarding its operation and give them the instruction manual this is an integral and essential part of this product and must be kept with care for future reference e Installation and maintenance must be carried out by professionally qualified trained personnel in accordance with national installation code AS NZ 5601 and any relevant electrical and local requirements and the manufacturer s instructions Do not carry out any operation on the sealed control parts Incorrect installation or inadequate maintenance can result in damage or injury The manufacturer declines any liability for damage due to errors in installation and use or failure to follow the instructions Before carrying out any cleaning or maintenance operation disconnect the unit from the power supply using the system isolating power switch e In case of a fault and or poor operation deactivate the unit and do not attempt to repair it or directly intervene Contact professionally qualified trained personnel at Hurlcon heating Repair and replacement of the parts must only be carried out by a qual
3. L L fig 31 Connectian In cascade 42 DHW temperature sensor not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 Diverter valve not supplied A Heating phase B DHW phase C Neutral Note For valves with 2 wires and spring return use the connections B and C 130 DHW circulating pump not supplied 138 Exernal probe not supplied 139 Remote timer control not supplied 298 Cascade temperature sensor not supplied 299 Input 0 10 Vdc 300 Burner lit contact voltage free contact 301 Fault contact voltage free contact 302 Remote reset input 230 Volt 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied For connection in cascade MAX 5 MODULES 1 Connect the modules as shown in Fig 32 example with 4 modules 2 GET E m x A 1st Module B 2nd Module C 3rd Module D 4th Module 2 Carry out all the electrical connections terminals 4 to 24 on module no 1 9 On the remaining modules only connect the power supply and possible contacts for burner lit 300 fault contact 301 and remote reset input 302 4 Switch on the power to the entire cascade 5 After the FH procedure check correct operation ofthe cascade Module 1 arrow symbol at top left of the display Module 2 arrow symbol at bottom right of the display Module 3 arrow symbol at bottom right of the display Module 4
4. The hot water tank can be deactivated by the user ECO mode by pressing the eco comfort button detail 7 Fig 1 In ECO mode the display activates the symbol detail 12 Fig 1 To activate the COMFORT mode press the eco comfort button detail 7 Fig 1 again 2 3 Lighting and turning Boiler lighting Press the On Off button detail 14 Fig 1 er e FH 10 gt By Olla A ef e J J c m OS ema FH Se eS JExo fig 4 Boiler lighting For the following 120 seconds the display will show FH which identifies the heating system pre purge air venting Cycle During the first 10 seconds the display will also show the software version of the programming card A Display card software version B Top boiler shell control unit software version C Bottom boiler shell control unit software version model FUTURIA power 160 250 only Open the gas cock supply valve to the boiler When the message FH disappears the boiler is ready to operate automatically when the room thermostat is in the demand mode Turning the boiler off Press the button eco comfort detail 7 Fig 1 for 5 seconds er eeso E fig 5 Turning the boiler off When the boiler is turned off the PCB is still powered Domestic hot water with optional hot water tank installed and heating operation are disabled The antifreeze system remains activated To relight the boiler press the button e
5. PINCE s 21 Circulating pump head pressure losses Pressure losses model FUTURIA power 80 125 Pressure losses model FUTURIA power 80 125 mc O e N O A Cc C N oco d c E NE ul D va bw EN N LLLA W ML AW E EBEN a a A NEP PN a NE Oo HENT A Boiler pressure losses 1 2 3 Circulating pump speed Circulating pump head pressure losses Pressure losses model FUTURIA power 160 250 Pressure losses model FUTURIA power 160 250 mC A A Boiler pressure losses 1 2 3 Circulating pump speed 22 f e e CALORECLIMA e A e CALORECLIMA 5 6 W iring diagram DSP12C fig 64 Wiring diagram A FUTURIA power model 160 250 only A Important Before connecting the room thermostat or the remote timer control remove the jumper from the terminal block located inthe electrical box of the FUTURIA power boiler 23 5 y e CALORECLIMA Declaration of conformity Manufacturer FERROLI S p A Address Via Ritonda 78 a 37047 San Bonifacio VR Italy Declares that this unit complies with the following EU directives Gas Appliance Directive 2009 142 Efficiency Directive 92 42 Low Voltage Directive 73 23 amended by 93 68 Electromagnetic Compatibility Directive 89 336 amended by 93 68 President and Legal Representative Cav del Lavoro Dante Ferroli e CALORECL
6. bends and manifold extensions are also available for the flue connection 13 Installation examples with opposed modules Arrange the height and slope of the manifold by means of the special holes inthe brackets Fig 40 and Fig 41 A 041026X0 Starting Kt 2200 B 041027X0 Starting kt 2300 E 041030X0 Manifold Kt 2200 opposed F 041031X0 Manifold Kt 2300 opposed Fume manifold installation Fix the fume manifold support brackets in the special holes arranged in the modules see Fig 38 for side by side modules and Fig 39 for opposed modules fig 41 14 Couple together the fume manifolds and the trap cap using an appropriate o ring grease see Fig 42 fig 42 Insert the fume dampers Fig 46 loosening screw D Position the manifolds on the previously fixed brackets and correctly fit them on the fume flue manifold Then Fig 43 and fix them using the special clamps Fig 44 tighten screw D Fig 47 Fix the trap Fig 45 fig 47 3 6 Condensate drain B The boiler has an internal condensate drain trap connected to an internal condensate outlet manifold Condensate outlet connection using one Boiler 15 2 Using the special key supplied open the cabinet of the upper exchanger body 3 Detach the electrical connections from the gas valve controller 4 Loosen the gas valve e Fixing ring Fig 50 A Fig 51 fig 48 Condensate drain connection with one gener
7. menu and the boiler control panel Summer mode has priority over a possible Remote Timer Control heating demand On disabling DHW iram the Remote Timer Contro menu the boiler selects the optional hot watertank inetalled Economy mode inthis condition the button fig 1 detaH7 onthe boller panells disabled On enabling DHW from the Remate Timer Contro menu the boiler selects the Comfort mode In this condition it is possible select one cf the two modes with the button detail fig 1 Both the Remote Timer Contro and the boiler card manage Sliding Tempera ture adjustment of the two the Sliding Temperature of the boiler card has prior ity System water pressure adjustment The filling pressure with the system cold must be approx 1 0 bar If the system pressure falls to values below minimum the boiler card will activate fault F37 Fig 14 Flashing of the arrows details 18 amp 24 Fig 1 together with the error code indicates which boiler shell is in fault status a e e CALORECLIMA AAA yy panny T EMI UA T 15 ES fig 14 Low system pressure fault Illu 7 M A Once the system pressure is restored the boiler will activate the 120 second per purge air venting cycle indicated on the display by FH 3 INSTALLATION 3 1 General Instructions THE BOILER MUST ONLY BE INSTALLED BY TRAINED QUALIFIED PERSONNEL IN COMPLIANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNIC
8. of just a few mm thick causes significant overheating of the generator tube walls with consequent serious problems Water treatment is indispensable in the case of very large systems containing large amounts of water or with the frequent introduction of replenishing water to the system If partial or total emptying of the system becomes necessary in these cases it is advisable to refill with correctly treated water Gas connection The gas supply must be connected to the corresponding union with a rigid metal pipe The gas meter must be of a size adequate for the simultaneous use of all units connected to it Carry out the boiler gas connection in accordance with all current regulations The diameter of the gas pipe leaving the generator does not determine the diameter of the pipe between the unit and the supply line it must be sized according to its length and pressure loss Make sure to install a gas isolation shut off valve exernally to the boiler modules enabling the gas to be turned off even without opening the modules doors equipped with key lock closing Connection instructions Futuria Power hot water boiler is equipped inside the casing module with 3 manifolds system flow delivery system return flow gas lines and a condensate drain pipe to facilitate cascade connections and connections of a single module to the heating system The manifolds are sized for a connection in series of up to 1000 KW The boiler is sup
9. un MN un TE EA uz 2 Y ea F3 F3 F3 Ua ua a el a fig 17 Examples of opposed configurations 1 Model 160 250 2 Model 80 125 4 Safety devices and separator module oo Table 3 Opposed configurations Table 2 Configurations in line Opposed configurations fig 15 Configuration in line example with 4 modules fig 16 Opposed configurations 3 2 Place of installation The generator can be installed directly outside or in a suitable room with ventilation openings to the outside as prescribed by the current regulations If there are several burners or extraction units that can work together in the same room the ventilation openings must be sized for simultaneous operation of all the units The place of installation must be free of flammable materials corrosive gases volatile substances or dusts For positioning leave enough space around the modules for normal maintenance operations Make sure the front door opens without hindrance B The air necessary for combustion enters through special openings in the bottom and top part of the unit Make sure these air passages are not obstructed in any Way c dV fig 18 Air inlet 3 3 Gas and water connections Make the relevant connections according to the instructions given below Make the boiler connections in such a way that its internal manifold pipes are free of stress for proper operation and lon
10. 0 125 29 s 16 5 4 Technical data table The column on the right gives the abbreviation used on the data plate Max heating capacity la 750 1160 150 0 2310 Min heating capacity kW 170 25 0 120 250 Max Heat Output in heating BO 60 C kw 735 13 7 1470 2274 Min Heat Output in heating BO BO C law 1 amp 7 24 6 16 7 246 Max Heat Output in heating 50 30 kw 795 1230 159 0 2461 Min Heat Output in heating 50 2060 ki 183 26 0 18 3 260 Efficiency Prax REOT E 580 980 SR 98 0 Efficiency Pin 80 600 98 5 985 38 5 98 5 Efficiency Pmax 50 30 C E 106 106 106 106 Efficiency Pmin 50 300 107 5 107 5 107 5 107 5 Efficiency 30 a 109 108 108 109 Gas supply pressure G20 bar a 20 3 20 Max gas delivery G20 mih 784 12 38 1588 24 76 Min gas delivery G20 mih 18 i55 1B 255 Gas supply pressure O31 iba 37 37 37 37 Max gas delivery G31 ka h 587 5 08 1174 18 16 Min gas delivery G31 kgh 133 1 96 133 1 96 Efficiency class Directive 32 42 EEC A e NOx emission class 5 5 5 5 Max working pressure in heating bar 6 5 5 amp Min working pressure in heating bar n 8 a8 of a8 Max heating temperature ya 95 a5 35 85 tpa Heating water content litres 13 15 26 30 Protection rating IP X5D X5D X5D X5D Power supply voltage V Hz 230v 50Hz PI0V S0Hz NI SOHz 3hv 5oHz Electrical power input Ww 285 390 570 FBO Type otumt 7 B3 0 M
11. AL MANUAL THE PROVISIONS OF CURRENT LAWS NATIONAL AND LOCAL REGULATIONS PLUS THE RULES OF PROPER WORKMANSHIP FUTURIA power is a hot water heat generator that can be operated alone or in cascade group When two or more generators are installed in cascade with the original installation Kits following the installation requirements laid down by Lamborghini in this manual they can be considered as a single heat generator of total power equal to the sum of the powers of all the units connected in cascade All the requirements of the current standards and regulations applicable to this equivalent total heating capacity generator must be met In particular the location and place of installation safety devices and the fume exhaust system must be adequate for the total heating temperature no water or no circulation in the unit the protection devices cause the unit or units to shutdown preventing its operation The installation instructions given in the following paragraphs concern single units and connection in cascade Given below are the possible configurations for connection in cascade Table 2 Configurations in line mee i RM m Model er AE Module 3 eh dee ET l l 3 N E NA un ce MN un uU N un e Las ce Ny 5 un N s B NS S 5 a i Nm un B pm pmo w m amp pem EE NENNEN NUM I 2500 A Uo un i
12. Change parameter P 09 of the System Type Menu to 1 One direct heating circuit and one DHW circuit with diverter valve CheckChange parameter PO2 of the Transparent Parameters Menu to 6 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 Change parameter P 11 of the System Type Menu to 1 10 fig 26 Two direct heating circuits CheckChange parameter PO2 of the Transparent Parameters Menu to 4 Change parameter P 01 of the System Type Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 fig 27 Two mixed heating circuits and one direct heating circuit CheckChange parameter PO2 of the Transparent Parameters Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 For the electrical connection and the zone system settings refer to the FZ4 zone regulator handbook Two mixed heating circuits one direct heating circuit and one DHW circuit with pump CheckChange parameter PO2 of the Transparent Parameters Menu to 5 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 For the electrical connection and the zone system settings refer to the FZ4 zone regulator Handbook 3 4 Electrical connections Connection to the electrical supply B Th
13. IMA 4 E PA ROLI FERROLI S p A Via Ritonda 78 a 37047 San Bonifacio Verona ITALY www ferroll it 24
14. SET on the optional remote timer control if installed if e Check the efficiency of the flue and air fume ducts while the boiler fails to start it is necessary firstly eliminate the the boiler is working fault Other faults marked with the letter F cause temporary shutdowns that are automatically reset as soon as the value returns within the boiler s normal workng range except for fault F37 which is reset by turning the unit off and on using button 14 see Fig 1 Make sure the gas supply and water systems are tight Check the correct tightness and functionality of the condensate elimination system and trap Make sure the water is circulating properly between the boiler and the systems Table of faults Make sure the gas valve modulates correctly in both the heating and domestic hot water production phases Table 6 List of faults Check for correct boiler lighting by doing several tests feme Je TIMES turning it On amp Off with the room thermostat or remote and that the air has been eliminated from control the pipes Detectionigeation elec Check the wiring of the electrode and that Using a combustion analyser connected to the boiler imde faut PA fume flue test outlet check that the Co2 content in the isbn e Het asa Es i M ck the gas valve and replace it if nac combustion fumes with the boiler operating at max and Faulty gas valve sis min output corresponds to that given in the technical data A c
15. Safety Heating 298 Cascade temperature sensor not supplied 299 Input 0 10 Vdc 300 Burner lit contact voltage free contact 301 Fault contact voltage free contact 302 Remote reset input 230 Volt Flowswitchor pressure Greuatng pump not work E 306 Heating system circulating pump not supplied Fi ab a Check the circulating pump 307 Heating system second circulating pump not supplied Checkandif necessary modify the card parameter A Heating phase Cean the flowswitch or replace itf naces B DHW phase Bi uy C Neutral Cech desi abe dicen Note For valves with 2 wires and spring return use the connections B and C E Reconnect the external probe or disable the sliding temperature Muda UA emwer Aras m Check correct positioning and operation of 120 132 the heating sensor M Heating sensorfault ensor damaged Raplace the sensor H emen guum ases rad Cascade temperature ser 5 sor faut Check the wiring or replace the sensor Wiring disconnected Controller DMI faut Controller DEMI internal Check bi earth connection and replace emor the controller necessary No communication Controller nat connected Connect the controller to the qas valve between controller and qat valve Ab Abi A5 is Controller DEM 2 fault Hi 5 TECHNICAL DATA AND CHARACTERISTICS Key of cap 5 7 Gas inlet 10 System delivery 11 System return 14 Safety valve 16 Fan 22 Bu
16. TAT WILL IRREPARABLY DAMAGE THE ELECTRONIC CARD When connecting a remote timer control or a timer switch do not take the power supply for these devices from their cut out contacts Their power supply must be taken with a direct connection from the mains or with batteries depending on the kind of device External probe optional Connect the probe to the respective terminals The maximum permissible length of the electric cable connecting the boiler external probe is 50 m A common 2 wire cable can be used The external probe should 11 preferably be installed on the South South east wall in Australia or on the wall facing most of the main living room The probe must never be exposed to the early morning sun and in general as far as possible it should not be exposed to direct sunlight or weather protect it if necessary In any case the probe must not be installed near windows doors vents flues or heat sources that could affect the reading iF yi Y fig 30 Eleciricai terminal block Accessing the electrical terminal block The electrical terminal block is located inside a sealed box at the bottom left hand side of the cabinet Make the electrical connections as shown in the wiring diagram on sec 64 and run the cables through the special electrical cable glands supplied A B C D 25 28H I7 i 20 30 35 TE 27 28 T9 320 135 i38 27 3 20 14 z5 3H 37 28 29 30 i i E A Los ll i L las nd A i Ex rin pi L i i i Ta AL
17. arrow symbol at top right of the display If this does not occur disconnect the power and check the wiring in Fig 32 Settings All adjustments must be made on all the modules Possible faults If the electrical connection to a module is disconnected for any reason module 1 will activate fault F70 If the electrical connection of a module is disconnected for any reason the next module will activate fault F71 3 5 Flue connection Important The unit is a non room sealed appliance with combustion air drawn from the installation room and flue fumes exhausted by means of a power fan operating with flue under pressure and must be connected to one of the discharge systems indicated below Before proceeding with installation check and carefully comply with the local regulations and provisions Also comply with the provisions concerning the positioning of wall and or roof terminals and the minimum distances from windows walls ventilation openings etc Manifold ducts and flues must be suitably sized designed and made in compliance with the current standards They must be made of suitable materials i e resistant to heat and corrosion smooth on the inside and hermetic In particular joints must be condensate proof Also provide for suitable condensate drainage points connected through a trap to prevent the condensate produced inthe flues from running into the generators 12 a e CALORECLIMA B The unit is equipp
18. as system proceeding with caution and using a soapy water solution to detect any leaks in connections Check correct pre filling pressure of the expansion tank ref sec 5 4 Fill the system with water and make sure all air trapped inside the boiler and the system has been vented by opening the air vent valve in the boiler Make sure the internal circulating pump impeller is free and any automatic air vents in the system are open Fill the condensate trap with water and check the connection of the condensate elimination system e Make sure there are no water leaks in the system DHW circuits connections to the boiler Check connections of the electrical system are correct and efficiency of the earthing system Make sure the gas pressure value for heating is that required Sufficient gas supply pressure to allow the boiler to operate correctly 4 4 Troubleshooting Make sure there are no flammable liquids or materials stored in the immediate vicinity of the boiler Checks during operation CALORECLIMA Diagnostics The boiler is equipped with an advanced self diagnosis system In case of a boiler fault the display will flash together with the fault symbol detail 20 Fig 1 indicating the fault code e Turn the unit on as described in sec 2 3 There are faults that cause permanent shutdown marked with the letter A to restore operation just press the RESET button detail 8 1 for 1 second or RE
19. ator a Place the 040 pipe 1 not supplied on the side of the generator b Slide the pipe 2 towards the arrow side at least 2 3 cm in order to insert itin the pipe 1 Condensate outlet connection using two or more generators H y b H fig 49 Condensate drain connection with several generators A Place the 240 pipe 1 not supplied on the side of the generator B Slide the pipe 2 of each generator towards the arrow side at least 2 3 cm in order to insert itinthe pipe 1 4 SERVICE AND MAINTENANCE All adjustment conversion start up and maintenance operations described below must only be carried out by qualified fully trained personnel meeting the professional technical requirements prescribed by current regulations such as those of the Local After Sales Technical Service Lamborghini declines any liability for damage and or injury caused by unqualified and unauthorised persons tampering with the unit 4 1 Adjustments Gas conversion Contact the supplier first The unit can operate on both natural gas or on LPG and is factory set for use with one of these two types of gas this is clearly shown on the packing and on the data plate Whenever a gas is different from that shown on the unit a conversion kit will be required proceed as follows 1 Disconnect the power supply to the boiler 16 FJ Tz MT LL Z XN 5 Undo the two screws B and remove the fan assembly as indicated
20. ccess the card service menu Press the following heating buttons to select tS Transparent Parameters Menu In Information menu Hi History Menu rE History Menu Reset Select tS and press the RESET button The card has 29 transparent parameters also modifiable from Remote Control Service Menu Press the Heating buttons to scroll the list of parameters in increasing or decreasing order Press the DHW buttons to modify the value of a parameter the change will be automatically saved Press the Reset button to return tothe Service Menu Press the Reset button for 10 seconds to ext to the card Service Menu System Type Menu Press the Summer Winter button for 10 seconds to access the card System Type Menu The card has 21 transparent parameters Press the Heating buttons to scroll through the list of parameters inincreasing or decreasing order Press the DHW buttons to modify the value of a parameter the change will be automatically saved Press the Summer Winter button for 10 seconds to ext the card System Type Menu One direct heating circuit CheckChange parameter P 02 of the Transparent Parameters Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 One direct heating circuit and one DHW circuit with pump CheckChange parameter PO2 of the Transparent Parameters Menu to 5 Change parameter P 02 of the System Type Menu to 1
21. co comfort detail 7 Fig 1 again for 5 seconds The boiler will be immediately ready to operate whenever domestic hot water is drawn optional hot water tank installed or in case of a room thermostat demand To completely disconnect the power to the unit press the button detail 14 Fig 1B The antifreeze system will not work when the power and or gas to the unit are turned off To avoid damage caused by freezing during long idle periods in winter it is advisable to drain all water from the boiler DHW circuit and system or drain just the DHW circuit and add an approved antifreeze to the heating system complying with that prescribed insec 3 3 2 4 Adjustments Summer Winter Switchover Press the button Summer 3 Winter detail 6 Fig 1 for 1 second The display activates the Summer symbol detail 10 1 The heating function is deactivated whereas the possible production of domestic hot water with optional external hot water tank remains activated The antifreeze system remains activated To deactivate Summer mode press the button detail 6 Fig 1 again for 1 second Heating temperature adjustment Use the heating buttons details 3 and 4 Fig 1 it is possible to adjust the temperature from a min of 20 C to a max of 90 C DHW temperature adjustment with optional hot water tank installed Use the DHW buttons details 1 and 2 Fig 1 to adjust the temperature from a min of 10 C to a max of 65 C
22. e ducts EMEN Seated For each single sccm Body Table 5 Accessories Losses inm i oo O wem Dow fa 3 ew pm mw pm 2n Teed Mm SO mE swWeme fear 53 o Direct connection of 080 terminals code 041013X0 Each single module can be connected directly to the terminal kits 041013X0 as shown in fig 33 connection in bank Each flue kt comprises an 280 straight flue and flue terminal ref 3 a seal ref 1 and a centre ring not used in this model For models Futuria 160 250 modules use 2 kits and for 80 125 modules use 1 kit fig 35 A 041026X0 Starting kt 2200 B 041027X0 Starting kt 2300 C 041028X0 Manifold kit 2200 in line D 041029X0 Manifold kit 300 in line B Before installing the flues fill the trap with approx 0 5 litres of water through the flue connections B For outside installations make the seal 1 adhere perfectly to the top part of the cabinet to prevent possible infiltration of rain and atmospheric agents Connection with manifolds To connect one or more modules in bank to a single flue it is advisable to use the special manifolds option given in the table The choice of diameter must be made according to the total power of the bank of units refer to information that provided in the tables Use a starting kit for each bank containing manifold plug and trap and a suitable number of manifolds one for each 80 125 and two for each 160 250 90
23. e unit s electrical safety is only guaranteed when correctly connected to an efficient earthing system executed according to current safety standards Have the efficiency and suitability of the earthing system checked by professionally trained and qualified personnel The manufacturer is not responsible for any damage caused by failure to earth the system Also make sure that the electrical system is adequate for the maximum power absorbed by the unit as specified on the boiler data plate The boiler is prewired and provided with a 240 Volt cable and plug for connection to the electricity line The connections to the power supply must be made with a permanent connection and equipped with a bipolar switch whose contacts have a minimum opening of at least 3mm interposing fuses of max 3 amp between the boiler and brown wre NEUTRAL blue wire EARTH yellow green wire when making connections to the electrical line During installation or when changing the power cable the earth wre must be left 2 cm longer than the others The end user must never change the unit s power cable If the cable gets damaged switch the unit and have it changed solely by professionally qualified personnel If changing the electric power cable use solely HAR H05 VV F 3x0 75mm2 cable wth a maxmum outside diameter of 8 mm Room thermostat optional CAUTION The room thermostat must have clean contacts CONNECTING 230 V TO THE TERMINALS OF THE ROOM THERMOS
24. eals supplied between the flanges of the two modules Fit the bolts supplied on the flanges from inside the first module so they protrude through the flanges in the second module Partially tighten the nuts on the bolts from inside the second module Before tightening the nuts make sure all the seals are correctly positioned and the condensate drain pipes of the two modules see Fig 49 Tighten the nuts and repeat the connection operations for the U pipes and next modules Fit the blind flanges contained in the kit 042027X0 on the last module Hydraulic Safety device and separator module optional The Hydraulic Safety Device and Separator Module for series modular generators is an ISPESL certified module containing a hydraulic separator and safety protection and control devices required by R section R3A and R3B intended for use with series modular generators Every ISPESL hydraulic safety device module comprises a cabinet of the same size and appearance as the modular hot water generators FUTURIA power containing a hydraulic separator with air valve and thermal insulation the respective system delivery and return manifolds a gas manifold and a discharge manifold for the safety valve The safety devices required by R section R3A and R3B are fitted on the hydraulic manifolds and hydraulic separator body Provision is also made for the probe pocket for a possible gas shutoff valve to be installed in the system on the
25. ec table for the corresponding gas type pressure SUE aaa ack the trap and dean it if necessary e Make sure the gas consumption indicated on the gas Fame present signal with Electrodefault Lheck the ionisation electrode wiring meter matches that given in the technical data table on SERU Card faut Eun EIER WETA CI STO anc operaron pi sec 5 4 Heating sensor damaged irai daa Keerai potee i water circulation in the e Check the correct programming of the parameters and pacer system carry out any necessary customization compensation Air in the system curve power temperatures etc Fume extraction duct Fault H7 generated 3 safety deviceactivation times in the last 24 hours i5 A Fa protection activated eni generat hour consecutive No flame after ignition stage 6 times in 4 min 4 3 Maintenance Periodical check To keep the unit working and performing correctly over time it is necessary to have qualified trained personnel make an annual check that includes the following tests e The control and safety devices gas valve flow meter utes thermostats etc are functioning correctly mun The fume extraction system is operating at max Check hetrap and dean itf necessary efficient y l Flue partially obstructed or Check the efficiency of the flue fume The airtight chamber is sealed correctly insufficient extraction ducts and outlet terminal The air fume end piece and ducts must be free of Fra
26. ed by the user to improve comfort Compensation curve and curve offset Press the button RESET detail 8 Fig 1 for 5 seconds to display the actual compensation curve Fig 10 which can be modified with the DHW buttons details 1 and 2 Fig 1 Adjust the required curve from 1 to 10 according to the characteristic Fig 12 By setting the curve to 0 sliding temperature adjustment is disabled fig 10 Compensation curve Press the heating buttons details 3 and 4 Fig 1 to access parallel curve offset Fig 13 adjustable with the DHW buttons details 1 and 2 Fig 1 au 11 Fm fia 11 Curve parallel offset Press the button reset detail 8 Fig 1 again for 5 seconds to exit parallel curve adjustment mode If the room temperature is lower than the required value it is advisable to set a higher order curve and vice versa Proceed by increasing or decreasing in steps of one then check the results in the room 90 85 8 TO I 2f Li a ladra 2 10 i 10 n fig 12 Compensation curves OFFSET 20 OFFSET 40 sal 2 1 7 M a m fig 13 Example of compensation parallel curve offset A If the Remote Timer Control optional is used to set the boiler the above adjustments are managed according to that given intable 1 Adjustment can be made from the Remote Timer Control menu and the boiler control panel Adjustment can be made from the Remote Timer Control
27. ed with one Futuria power models 80 125 or two models160 250 separate 280 flue connections for the two burner exchanger units The combustion circuits of the two units are completely independent When joining the two flue outlets to a single flue or manifold in case of a single module or connection in cascade it is necessary to install a fume anti backflow valve on each outlet to prevent operation anomalies or the creation of hazardous conditions Make sure to use the optional Lamborghini kits provided with special anti backflow valves Please note Before carrying out the connection make sure to fill the condensate trap with approx 0 5 litres of water through the flue connections Connection with separate pipes Separate 280 ducts can be connected directly to the unit Insert the seal 1KWMA84A on the 280 pipes leaving the unit and make it adhere to the upper wall of the cabinet Before proceeding with installation make sure the maxmum permissible length has not been exceeded by means of a simple calculation 1 Establish the layout of the system of split Flues including accessories and outlet terminals for each of the two burner exchanger bodies 2 Consult the table 5 and identify the losses in meq equivalent metres of every component according to the installation position 3 Check that the sum total of losses is less than or equal to the maxmum permissible length in table 4 Table 4 Max length separat
28. g life of the generator The plumbing system must be sized correctly and complete with all the accessories that guarantees correct operation conditions In particular provide for all the protection and safety devices prescribed by current regulations for the complete modular generator They must be installed on the hot water circuit delivery piping immediately downstream of the last module within a distance of 0 5m with no shut devices in between A Safety Device and Circuit Breaker module equipped with internal hydraulic circuit breaker and safety units with ISPESL certification is available by request Refer to the price list or contact our sales network The unit is not supplied with an expansion tank its connection must therefore be made by the Installer A filter must also be installed on the system return piping to prevent impurities or sludge from the system clogging and damaging the heat generators The filter must be installed when installing or replacing boiler in existing systems The manufacturer declines any liability for damage caused to the unit by failure to install or inadequate installation of an appropriate line filter a e e CALORECLIMA W ater system characteristics In the presence of water harder than 25 Fr it is advised to use a suitable water treatment to avoid possible scaling within the boiler or possible corrosion caused by aggressive water Due to its low thermal conductivity scaling
29. ges and the condensate drain pipe Place the seals contained in the Kt between the flanges of the two modules Fit the bolts supplied with the kit into the flanges from the inside of the first module allowing them to protrude through the flange in the second module Partially tighten the nuts on the bolts from inside the second module Before tightening the nuts make sure all the seals are correctly positioned and the condensate drain pipes of the two modules see g 49 e Tighten the nuts and repeat the connection operations for the following modules 1 Gas inlet 2 System delivery 3 System return 4 Condensate drain 5 Blind flanges kt 042027X0 optional 7 Blind flanges kt 042027X0 optional 8 Seals and screws standard To connect several opposed modules Optional Kt code 042026X0 is available for connecting the water and gas manifolds in series The kit contains 3 flanged U pipes fig 21 Kit for connection of opposed modules A 1st Module B 2nd Module C 3rd Module D 4th Module 1 Gas inlet 2 System delivery 3 System return 5 Blind flanges 7 Drilled flanges 8 Seals and screws standard Arrange the modules according to the layout of Fig 21 Connect the module to the system and gas pipes using the flanges with pipe section and respective seals contained inthe kit 042027X0 Position the second module making sure to align the connection flanges and the condensate drain pipe Fit the s
30. ified technician using original spare parts Failure to comply with the above could affect the safety and warranty of the unit This unit must only be used for its intended purpose Any other use is considered improper and therefore hazardous Notfor use as a pool heater e After removing the packing check the integrity of the contents If in doubt do not use the unit and report this directly to the supplier Hurlcon Heating Packing materials are potentially hazardous and must not be left within the reach of children The images given in this manual are a simplified presentation of the product only 2 OPERATING INSTRUCTIONS 2 1 Introduction Dear Customer Thank you for choosing the Lamborghini FUTURIA power one ofthe latest generation in heat generators featuring advanced design and cutting edge technology Please read this manual carefully since it provides important information on safe installation use and maintenance The Lamborghini FUTURIA power condensing boiler is a high efficiency modular premix heat generator for heating with very low operating emissions running on Natural gas or LPG and can be arranged for installation in both single and cascade format if required Each module FUTURIA power is equipped with one single version 80 125 or with twin version 160 250 boiler with aluminium finned tube exchangers with steel premix burners housed in a vertical cabinet finished in epoxy powder coated steel
31. in Fig 50 for the model 80 160 and in for Fig 51 the model 125 250 fig 51 model FUTURIA power 125 250 6 Undo the screws C and remove the fan D Fig 52 model 125 250 only fig 52 model FUTURIA power 125 250 7 Undo the g screws E Fig 53 model 80 160 and Fig 54 FUTURIA power Model 125 250 and remove the gas valve fig 53 model FUTURIA power 80 160 fig 54 model FUTURIA power 125 250 8 Replace the gas nozzle F see Fig 53 for the model 80 160 and Fig 54 the model 125 250 with the one contained in the conversion kit positioning it inside the seal G Refit the parts and check their gas leaks 9 Modify the parameter for the type of gas put the boiler in standby mode press the DHW buttons details 1 and 2 Fig 1 at the same time for 10 seconds the display shows P01 flashing Press the DHW buttons details Fig 11 amp Fig 2 to set parameter OO for use with natural gas or 01 for use with LPG Press the DHW buttons details 1 and 2 Fig 1 together for 10 seconds The boiler will return to standby mode 10 Apply the label contained in the conversion kit near the data plate 11 Using a combustion analyser connected to the boiler flue fume outlet make sure the Co2 content in the fumes with the boiler operating at max and min output complies with that given in the technical data table for the corresponding type of gas TEST mode activa
32. me Tapes sckconed positibaegardopeion d obstructions and leaks the fume sensor The condensate evacuation system must be efficient with Sensor damaged no leakage or obstructions Delivery sensor 1 fault Witing shorted Check the wiring or replace the sensor e The burner and exchanger must be clean and free of pohly eet scale When cleaning do not use chemical products or wire brushes Contact the supplier The ignition electrode must be free of scale and properly positi oned f DHW sansar fault Check the gas and water systems for leaks The water pressure in the cold water system must be approxmately 1 to 1 5 bar otherwise reset to that value Fume sensor fauit Check the operation of the internal circulation pump The expansion tank must be set to the correct pressure e The gas flow and pressure must correspond to that given inthe respective tables Turne extraction and air miet ducts and ter Fume sensor position Return sensor fault Delivery sensor 2 fault Wiring disconnects A The boiler casing panel and aesthetic parts can be cleaned with a soft damp cloth possibly soaked in soapy water Do not use any abrasive detergents and solvents 18 f e e CALORECLIMA ERE E 83 196 Condensate tray a fhe kthe 3 pin connector wiring 215 Air inlet reducer Samir 220 Ignition card i ii PSOE eche pin conector wing 252 3 way drain and shut o cock nina dee ca aes 278 Double sensor
33. optional 17 z Information symbol 18 z Top boiler shell 19 z Top boiler shell system fault reset request 20 Fault 21 Circulating pump on 22 Appears on connecting the external probe optional 23 Boiler off 24 Bottom boiler shell 25 Bottom boiler shell system fault reset request model 160 250only Indication during operation heating A heating demand generated by the room thermostat or remote timer Control or 0 10 Vdc signal is indicated by activation of the circulating pump and the radiator details shown 13 amp 21 Fig 1 The display detail 11 Fig 1 shows the actual heating delivery temperature and during heating standby time the message d Activation of the arrows details 18 and 24 Fig 1 indicates which boiler module shell is in operation e ae d i5 i amp fig 2 Le HED DHW with optional hot water tank installed A potable hot water tank heating demand is indicated by activation of the circulating pump and the tap display details 9 amp 21 Fig 1 The display detail 11 Fig 1 shows the actual hot water tank sensor temperature and during heating standby time the message d Activation of the arrows details 18 and 24 Fig 1 indicates which boiler module shell is in operation Exclude hot water storage tank economy Hot water tank temperature maintaining heating can be excluded by the user If excluded domestic hot water will not be delivered
34. outside of the bank of modules The hydraulic separator contained in the module allows the hydraulic circuit of the modules primary circuit to operate independently of the hydraulic circuit of the respective heating system secondary circuit The separator is sized for correct operation up to 1000 KW and the main advantages offered are An external circulating pump for the primary circuit is not necessary In fact circulation in the primary circuit is ensured by the small integral circulating pumps contained inside the Futuria power hot water generators When the secondary pump is deactivated the circulation in the system circuit also stops the entire flow delivered by the circulating pumps contained inside the Futuria hot water generators is bypassed through the hydraulic separator The flow rate in the primary circuit can remain constant whereas the secondary circuit can function with a variable or intermittent flow rate There are no anomalous operating conditions in which the system pumps interact with the circulating pumps inside the hot water generators thus creating unwanted head and flow rate variations inthe circuits e Sizing of the system circulating pump can be carried out according to the needs of just the secondary circuit and not the boilers fig 22 Opposed configurations A 1st Module B 2nd Module 1 Gas inlet 2 System delivery 3 System return 4 Hydraulic separator The hydra
35. plied with a set of seals 2 for water manifolds 1 for the gas manifold with respective bolts and nuts found inside the cabinet to be used for connection to a subsequent module connection in cascade The optional kit code 042027X0 containing Din 6 flanges 3 blind flanges and 3 drilled flanges with respective seals and screws is available on request for connection to the system To connect a single module Connections can easily be made from both sides of the boiler After establishing which side of the boiler to make the water and gas connections connect the flanges using the joining seals supplied When connecting to the heating system pipes make sure that the special seals contained inthe kt have been installed correctly to avoid leaks e Connect a 040 pipe to the condensate drain pipe for removing the condensate produced during operation see Fig 48 Fit the blind flanges contained in the kit on the opposite side of the module placing the special seals in between the flanges 1 Gas inlet 2 System delivery 3 System return 4 Condensate drain 5 Blind flanges kt 042027X0 optional 7 Blind flanges kt 042027X0 optional To connect several modules in line Connect the first module to the system and gas pipes as described above but without fitting the blank flanges on the opposite side of the module to that of the connection Connect the second module on this side making sure to align the connection flan
36. rner 29 Fume outlet manifold 32 Heating circulating pump 36 Automatic air vent 38 Flow switch 42 DHW temperature sensor not supplied 44 Gas valve 72 Room thermostat not supplied 72b Second room thermostat not supplied 81 Ignition electrode i 82 Detection electrode 95 Diverter valve not supplied 98 Switch 114 Water pressure switch 130 DHW circulating pump not supplied LEER 138 External probe not supplied fig 56 Dimensions and connections model FUTURA power 80 125 139 Remote timer control not supplied x ESAE aati ie eddie outlet pipe 3 Heating system return 186 Return sensor 191 Fume temperature sensor 193 Trap Model FUTURIA power 160 250 282 12 380 120 tm 5 p Lb 48 fig 57 Dimensions and connections model FUTURI power 160 250 IE Gas inlet i Heating system delivery J Heating system return 20 CALORECLIMA 5 2 General view and main components Model 80 125 36 16 191 278 pr 3 mG TER ee Ey ai EE SEG wes T Ed S een ee ri is E M EIIGAR Dis i Li aso it er T PCM Geers de T l g ela TI TOM es Y fig 58 General view mode FUTURIA power B0 125 CALORECLIMA FUTURIA power model 160 250 FUTURIA power model 160 250 F IM a1 fig 59 General view model FUTURIA power 160 250 5 3 W ater circuit fig 61 Plumbing circuit model FUTURIA power 160 250 FUTURIA power model 8
37. tion Press the heating buttons details 3 and 4 Fig 1 together for 5 seconds to activate the TEST mode The boiler lights at the maximum heating power set as described in the following section 17 The heating symbol detail 13 Fig 1 and DHW symbol detail 9 Fig 1 flash on the display the heating power will be displayed alongside fig 55 TEST mode heating power T0036 To deactivate the TEST mode repeat the activation sequence The TEST mode wil automatically disable after 15 minutes Only for models FUTURIA power 160 250 In TEST mode press the button detail 7 Fig 1 to obtain the following operation Top boiler shell on bottom boiler shell off Top boiler shell bottom boiler shell on Top boiler shell on bottom boiler shell on Heating power adjustment To adjust the heating power switch the boiler to TEST mode see sec 4 1 Press the heating buttons details 3 and 4 Fig 1 to increase or decrease the power min 00 max 100 Press the reset button detail 8 Fig 1 within 5 seconds the max power will remain as that just set Exit the TEST mode see sec 4 1 4 2 Start up B Check to be made at first lighting and after all maintenance operations that involved disconnection from the systems or an operation on safety devices or parts of the boiler Before lighting the boiler Open all valves between the boiler and the systems Check the tightness of the g
38. to resist atmospheric agents 2 5 a e CALORECLIMA The plumbing circuits of the heat exchangers each equipped with its own local circulating pump combine into system Flow and return manifolds inside the module The control system has a microprocessor user interface with a large display and advanced cascade control functions 2 2 Control panel 16 17 19 18 20 23 5 y it ww ZZ mmm i O NO 24 1 MI E apod JL AS J Jeane cam 13 E ete ti mT WE SSS UT CG y EL iu fg 1 Control panel The control panel is located inside the cabinet Access is va a steel lockable front door opened with special key supplied Operation Key 12 DHW temperature setting decrease button with optional hot water tank installed 2 DHW temperature setting increase button with optional hot water tank installed 3 Heating system temperature setting decrease button 4 Heating system temperature setting increase button 5 Display 6 Summer Winter mode selection button 7 z Economy Comfort mode selection with optional hot water tank installed and unit On Off button 8 Reset button 9 DHW operation with optional hot water tank installed 10 Summer mode 11 Multifunction 12 Eco Economy mode with optional hot water tank installed 13 Heating mode 14 Unit On Off button 15 Burner On 16 Appears on connecting the Remote Timer Control
39. ulic safety devices separator module must be installed directly nex to the last module making up the modular generator The particular symmetrical shape of the module allows it to be installed on the right side and left side of the generator bank Some possible connection examples are given below fig 23 Configuration in line C 3rd Module containing the hydraulic separator 1 Gas inlet 2 System delivery 3 System return 4 Hydraulic separator Plumbing circuit examples Key of examples a e CALORECLIMA l ISPESL safety devices D Hydraulic separator 42 DHW temperature sensor not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 3 way valve with spring return at rest on DHW side not supplied 130 Hot water tank circulating pump not supplied 138 External probe not supplied 139 Remote control not supplied 298 Cascade temperature sensor not supplied 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied SM Delivery probe supplied with kt FZ4 TS oafety thermostat not supplied PZ Zone pump not supplied FZ4 Zone regulator Parameters Each system requires a different parameterisation Follow the procedure for accessing the two menus given below for the parameters tobe modified refer to the tables given alongside the plumbing diagrams Service Menu Press the Reset button for 10 seconds to a
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