USER MANUAL AND INSTRUCTIONS
Contents
1. C ANSI NFPA Z223 1 National Fuel Gas Code C ANSI NFPA Domestic Gas Conversion Burner D CAN CGA B 149 Installation Codes E ANSI ASME CSD 1 The above codes are available from National Fire Protection Association NFPA CSA International Battery March Park 8501 E Pleasant Valley Road Quincy Massachusetts 02269 Cleveland OH 44134 5575 http www nfpa org http www csa international org 6 SAVIO FP USER MANUAL 1 General Information The SAVIO FP is a high efficiency non condensing wall mounted gas boiler which pro vides central heat The boiler features a gas valve which modulates the energy input from 49 476BTU h to 122 837 BTU h The boiler is shipped fully assembled All units are pressure and combustion tested at the factory prior to shipping Key Features e Wall mountable saving valuable floor space Several flue options available Electronic spark ignition Safety flow switch positioned on the main circuit which monitors the flow and protects the main heat exchanger from thermal shock should there be a lack of water in the system Frost protection contains an integral frost Boiler operation recognition system should the boiler not be used for longer than 24 hours it then performs a con trolled system test to ensuring the motor ized components within the boiler do not become inoperable due to lack of use Gas valve modulation the gas input modulates based off central heating tem2. page 9 has gone down e It is necessary to fill up the appliance with water again so as to raise the pressure to an adequate level as described in the section 5 2 of this manual If filling up with water has to be done very frequent have the system checked for leaks 16 SAVIO FP USER MANUAL 6 Useful Advice Cont If water comes out of the pressure relief valve pipe 3 in Fig 6 3 e Check on the temperature and pressure gauge figure 5 1 on page 11 that the pressure in the central heating circuit is not close to 3 bars 43 5 psi In this case temperature rise in the circuit can cause the pressure relief valve to open e So that this does not happen and to de crease the pressure to a normal value it is advisable to vent some of the water in the appliance through the bleed valves present in the heating system Figure 6 3 If water should occasionally leak from the boiler e Close the cocks connected to the inlet gas pipe and to the supply cold water inlet pipe under the boiler and call an Authorised Service Person In case of problems other than those mentioned here switch off the boiler as described in Section 5 5 on page 13 and call a competent and responsible service person SAVIO FP USER MANUAL 17 Warranty For SAVIO Residential Wall Hung Gas Boilers FIRST 2 YEARS WARRANTY FOR SAVIO SERIES RESIDENTIAL HOT WATER BOILERS BOYERTOWN warrants that itswall hung boiler and casing are free from defects in material and
3. up check that no air is present in it and E 0 that its valve is open e Ifthe ambient temperature is too high do not alter the radiator valves Reduce the JE central heating temperature instead by means of the room thermostat and the knob C in Fig 6 1 Figure 6 1 6 2 Frost Protection The built in antifreeze system and any additional system protect the boiler from possible damages due to the icing e This system doesn t guarantee the protection of the whole central heating system e In the case that the external temperature may be lower than 32 F it is suggested to leave the system running setting the room thermostat at a low temperature When the boiler is completely switched off for a long period it is recommended to empty completely central heating circuit 6 3 Periodic Maintenance e For efficient and continuous operation of the boiler it is advisable to arrange maintenance and cleaning by an Authorised Service Person at least once a year e During the service the most important components of the boiler will be inspected and cleaned This service can be part of a maintenance contract In particular you are advised to have the following checks carried out e primary heat exchanger burner e exhaust fume duct and flue e pressurization of the expansion vessel e filling up of the central heating circuit e bleeding of air from the central heating system e general check of the app
4. workmanship for 2 years from the date of installation If any part on the boiler is found to be defective within this period BOYERTOWN will replace the part free of charge FIRST 10 YEARS WARRANTY FOR SAVIO SERIES RESIDENTIAL HOT WATER BOILERS SAVIO war rants that the copper tube heat exchanger of the SAVIO boilers are free from defects in material and workman ship for 5 years from the date of installation If the cop per tube heat exchanger is found to be defective within the first 5 years after installation BOYERTOWN and SAVIO will replace the copper tube heat exchanger These warranties are subject to the condition that a heating contractor whose principal occupation is the sale and installation of heating equipment must have installed the boiler PARTS WHICH ARE COVERED consists of all materials supplied by SAVIO identified by BOYERTOWN s part numbers in its literature Other parts supplied by the installer carry their own warranty and each manufacturer has responsibility for its own products NOTE ANY PART WHICH IS REPLACED UNDER WARRANTY CARRIES ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY OWNER RESPONSIBILITIES 1 Provide for proper installation which includes pres sure relief and pressure reducing valves and high limit safety controls on closed systems 2 Provide qualified periodic service to prolong proper operation and service 3 Insure that boiler is installed in accordance with all codes and ord
5. Savio FP WALL HUNG GAS BOILER FOR CENTRAL HEATING SUPPLY Please Read Instructions Carefully Save for Future Reference WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property dam age personal injury or loss of life Donotstore or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Fol low the gas supplier s instructions If you can not reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Manufactured by Distributed by ES Bovertown Furnace Caldaie a Gas BOYERTOWN FURNACE CO PO Box 100 T Z O O cc l 0 Q Z lt mua lt Z lt cr Lu 0 gt PEN AS BOYERTOWN PA 19512 SA 9 4 Y 1 610 369 1450 j c us Ei NEHA SAVIO FP USER MANUAL Dear Customer Thank you for buying a SAVIO FP Boiler System The SAVIO FP is a high efficiency non condensing wall mounted gas boiler which provides central heat and domestic hot water We realize that it is not possible to answer all questions about the SAVIO boiler system in this manual Reading this installation manual doe
6. an air and thus may travel throughout the building BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF CO OR PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY RESULT IN CARBON MONOXIDE POISONING EXPOSURE CAN BE FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT IN THE SUDDEN ONSET OF SYMPTOMS INCLUDING UNCONSCIOUSNESS Symptoms of CO poisoning include the following The symptoms of CO poisoning are often confused with those of influenza and the highest incidence of poisoning occurs at the onset of cold weather or during flu season A victim may not experience any symptoms only one symptom or a few symptoms Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home The following signs may indicate the presence of carbon monoxide Hot gasses from appliance venting system pipes or chimney escaping into the living space Flames coming out around the appliance Yellow colored flames in the appliance Stale or smelly air The presence of soot or carbon in or around the appliance Very high unexplained humidity inside the building If any of the symptoms of CO occur or if any of the signs of carbon monoxide are present VACATE THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED HEATING SER VICE COMPANY OR THE GAS COMPANY OR THE FIRE DEPARTMENT ONLY QUALIFIED LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR SAVIO FP SAVIO FP USER MANUAL 5 IMPORTANT INFORMATION Please read this page care
7. causing property dam age personal injury or loss of life Donot store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your build ing Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you can not reach your gas supplier call the fire department Installation and service must be performed by a qualified installer ser vice agency or the gas supplier DANGER Caution Do not store or use flammable materials chemicals or flammable liquids especially gasoline in the vicinity of this heating appliance Caution Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Caution Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water SAVIO FP USER MANUAL WARNING Any appliance that burns natural gas propane gas fuel oil wood or coal is capable of pro ducing carbon monoxide CO Carbon Monoxide CO is a gas which is odorless colorless and tasteless but is very toxic CO is lighter th
8. ed in cold weather with consequent risk of freezing do not switch off the boiler at the circuit breaker or close the gas inlet cock e When you expect not to use the boiler for a long period follow the instructions given in sec tion 5 6 on page 14 5 2 Refilling procedure e Isolate the boiler from the electrical sup ply at the circuit breaker The boiler should have been installed with an automatic fill valve external to the unit Open the cold water supply to the auto matic fill valve e The pressure should be 1 1 5 bar 14 5 22 psi e The automatic fill valve should maintain Figure 5 1 this pressure but not exceed it Air introduced into the boiler during this filling process will vent through the automatic air purger fitted to the boiler You may also find it necessary to vent air from your heating circuit using the installed vents however be aware that excessive venting will cause the pressure in the system to drop Always ensure that the pressure gauge is set at the required pressure SAVIO FP USER MANUAL 11 5 Instructions For Use Cont 5 3 Lighting Operating Instructions Warnings Do not attempt to start the boiler unless all cleanout doors are secured and sealed Do not attempt to light the burner by hand 1 Check that the cocks connected to the gas inlet pipe and to the supply cold wa ter inlet pipe see section 3 3 for pipes are open Turn on the electricity supply to the boiler switching on t
9. fully ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL STATE AND LOCAL PLUMBING HEATING AND ELECTRICAL CODES AND ORDINANCES AS WELL AS THE REGULATIONS OF THE SERVING ELECTRICAL WATER AND GAS UTILITIES All systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of heating systems should attempt the installation of any boiler It is the responsibility of the installing contractor to see that all controls are correctly installed and operating properly when the installation is completed This boiler is intended for use only with propane or natural gas All flammable liquids especially gasoline chemicals rags paper wood scraps debris etc should be kept away from the boiler at all times Keep the boiler area clean and free of all fire hazards Please read the literature and warranties supplied by the manufacturers of the various accessory equipment This equipment is warranted by the respective manufacturers not by BOYERTOWN Each piece of equipment must be installed and used according to the recommendations of the manufacturer Codes and Regulations Installation of the boiler and related equipment must conform to national state and local regulating agencies and codes applicable to the installation of the equipment In the absence of local requirements the following codes apply A ANSI NFPA 70 National Electric Code B ANSI NFPA 211 Chimneys and Vents
10. he circuit breaker The appli ance operation light A figure 5 2 will flash every 4 seconds stand by condition TLS no Figure 5 2 3 If the boiler is to be used for c h position the function selector C as in figure 5 2 The appliance operation light A will flash every 2 seconds operating boiler If the appliance will not operate follow the extinguishing instructions on page 13 and call your service technician or gas supplier 5 4 Central Heating Circuit Temperature The output temperature of c h water is adjustable from a minimum of about 100 F to amaximum of about 176 F Figure 5 3 by turning the knob B Adjustment of the boiler temperature al ters the gas flow at the burner according to the thermal demand in the system So it is usual to see the burner lit at the mini mum level for more or less long periods Adjustment of central heating output on the boiler is automatic The greatest out put is factory pre set however it can be reduced according to actual system re quirements These adjustments must be carried out by a qualified person there fore we advise you to contact your install er or Service Agent 12 SAVIO FP USER MANUAL Figure 5 3 5 Instructions For Use Cont Adjustment e In order to achieve optimal settings for e The temperature and pressure gauge Fig economy and comfort we recommend 5 1 on page 11 will allow you to check adjusting the operating
11. ig 5 6 Minimum Maximum Figure 5 7 Figure 5 6 Adjustment of the d h w temperature is completely separate from that of the c h circuit The adjustment system integrated within the boiler automatically controls the flow of gas to the burner in order to keep the temperature of d h w delivered constant between the limits of maximum and minimum output Where the demand is at a low level or with the temperature set to the minimum it is normal to see a cycle of lighting and extinguishing of the burner when running Regulate the domestic hot water temperature to a value suitable for your requirements Reduce the need to mix the hot water with cold water In this way you will appreciate the characteristics of automatic regulation If the water is particularly hard we recommend regulating the boiler at a temperature lower than 120 F fig In these cases we nevertheless recommend the installation of a water softener on the domes tic hot water system If the maximum flow rate of the domestic hot water is too high for a sufficient temperature to be reached it is advisable to have a suitable flow rate limiter installed by an Authorised Assistance Technician 14 SAVIO FP USER MANUAL 6 Useful Advice 6 1 Central Heating e For reasonably economical service install C a room thermostat e Never shut off the radiator in the area where the room thermostat is installed e Ifa radiator or a convector does not heat
12. inances 4 This warranty does not apply to boilers which are subject to misuse abuse neglect alteration accident excessive temperature excessive pressure or corro sive water or atmosphere 5 Owner will be responsible for return of faulty compo nents to BOYERTOWN PA freight pre paid BOYERTOWN and SAVIO will not be responsible for 1 Components that are part of the heating system but were not manufactured by SAVIO or BOYERTOWN as part of the boiler 2 The workmanship of the installers of SAVIO boilers Furthermore this warranty does not assume any liabil ity for unsatisfactory performance caused by improper installation 3 Any costs for labor to remove or replace the faulty component 4 Improper boiler application or adjustments control settings care or maintenance 5 Any damage associated with corrosion or leakage due to the use of non barrier plastic pipe in the heat ing system IMPLIED WARRANTIES OF FITNESS FOR A PAR TICULAR PURPOSE AND MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE EXPRESSED WARRANTY SAVIO AND BOYER TOWN EXPRESSLY DISCLAIM AND EXCLUDE ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACH OF ANY EXPRESSED OR IMPLIED WARRANTY THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE For prompt warranty service notify the installer who in turn will notify the distributor from whom the boiler was purcha
13. is SAVIO boiler has a 2 year warranty on the boiler and 10 years on the heat exchanger a copy of which is provided with the boiler Please be sure to return the warranty registration card as the warranty will be void without your boiler s serial numbers located on the ratings label affixed to the boiler date of installation and the name of your installer being on record in our files Thank you for purchasing our SAVIO FP boiler If you have questions or comments please don t hesitate to contact us immediately Our goal is 100 customer satisfaction BOYERTOWN 2 SAVIO FP USER MANUAL Table of Contents Section Title Section Number Page Number Warnings 4 5 Important Information 6 General Information 1 7 Technical Information 2 7 8 Appliance Description 3 9 Operation Lights 4 10 Instructions for Use 5 11 14 Warnings 5 1 11 Refilling Procedure 5 2 11 Lighting Operation Instruction 9 3 12 Central Heating Circuit Temp 5 4 12 13 Extinguishing Instructions 5 5 13 Domestic hot water 5 6 14 Useful Advice 6 15 17 Central Heating 6 1 15 Frost Protection 6 2 15 Periodic Maintenance 6 3 15 External Cleaning 6 4 16 Operational Faults 6 5 16 17 Warranty 18 SAVIO FP USER MANUAL 3 WARNING Boiler is certified as an indoor appliance Do not install boiler outdoors or locate where it will be exposed to freezing temperatures 4 WARNING If the information in this manual is not followed exactly a fire or explosion may result
14. liance s operation SAVIO FP USER MANUAL 15 6 Useful Advice Cont 6 4 External Cleaning e Before performing any cleaning disconnect the appliance from the electrical mains using the dedicated circuit breaker or serviceman s switch located adjacent to the appliance e To clean the external panels use a cloth soaked in soapy water Do not use solvents abra sive powders or sponges Do not carry out cleaning of the appliance and or its parts with readily flammable substanc es for example petrol alcohols naphtha etc 6 5 Operational Faults If the lock out signal lamp comes on e This indicates that the safety lock out 1 A C Fig 6 2 has stopped the boiler e To re start the boiler it is necessary to turn the function selector B in the position 2 and then press the boiler reset button 2 Fig 6 2 e For the first light up and following main tenance procedures for the gas supply it may be necessary to repeat the resetting Figure 6 2 operation several times so as to remove the air present in the pipework If noises due to air bubbles are heard during operation e You should check that the pressure on the temperature and pressure gauge Fig 5 1 on page 11 is not below the correct setting e If required fill up the system correctly as described in the section 5 2 of this manual e Bleed any air present in the radiators if necessary If the pressure on the temperature and pressure gauge Figure 5 1 on
15. op 3 im _ 8 Sides in 2 Bottom in 8 Flue pipe free air in 0 FLUE GAS FIGURES DOMESTIC HOT WATER Menmu presne psi 15 Minimum pressure psi 235 3 Appliance Description 3 1 Overview 1 Case front panel 2 Control panel 3 Control panel cover 3 2 Control Panel 4 Central heating circuit temperature and pressure gauge Lock out signal lamp Boiler reset button Function selector knob and radiator temperature control 8 Domestic hot water temperature control knob 9 Appliance operation lights NOOO gt po E 5 r yi gt NA LY 69 ee AR owy eA a op 9 8 7 6 5 Figure 3 2 3 3 Piping Connections a ny Gas inlet pipe e i Main circuit drain cock C h supply copper pipe C h return copper pipe C h PRV discharge copper pipe D h w hot water outlet D h w cold water inlet llill Ill QO7m7mMvgagW gt y gt E C F A G D B Figure 3 3 SAVIO FP USER MANUAL 9 4 Operation Lights Three lights 8 in Fig 3 2 give detailed indication regarding the operation of the boiler The following table gives the relationship between each of the possible light combinations and their meaning Ashort pulse every 4 seconds stand by condition Function selector in 2 position Anti freeze system active 1 second pulse every 2 seconds normally operating boiler Function selector in on position Central heating operation Frost pro
16. perature to within 2 F Diagnostic information system equipped with three LED diagnostic lights for quick error assessment protection system to prevent frost dam age which can occur in areas susceptible to very cold weather conditions 2 Technical Information M130 30CM GENERAL INJ ECTORS No Size 4 Poon a o CENTRAL HEATING Maximum pressure psi 200 Minimum pressure psif 435 Max nead oss at 44 GPM A 99 ELECTRICAL Frequency Hz 60 SAVIO FP USER MANUAL 7 2 Technical Information Cont ENERGY CAPACITY Nominal heat input 0 2000ft MBH 1228 Nominal heat input 2000 4500ft CECA mO Minimum heat input Maximum useful output 0 2000ft jf er 10057 Maximum useful output 2000 4500ft Minimum useful output useful Minimum useful output 37 0 GAS SUPPLY PRESSURE cas Nomai Min Max Propane inwe 7 0 80 190 GAS PRESSURE AT BURNER Gas f min Max lation Natural mue 08 53 24 Propane inwe 14 90 52 FLUE DESIGN Minimum Venturi pressure inwc me 288 Flue pipe diameter pipe Flue pipe diameter 25 4 Coaxial 3 25 5 Twin split pipes 3 25 3 25 Nominal heat flow rate 0 2000ft leet Nominal heat flow rate 2000 4500ft Moe Min Exhaust temperature Max Exhaust temperature 8 SAVIO FP USER MANUAL GAS FLOW RATE ces mn Max CLEARANCE TO COMBUSTIBLES Front in 18 Bak in 0 T
17. s not make the reader an expert in all aspects of installation and operation and does not replace the need for a qualified licensed heating contractor We urge you to contact your installing contractor or distributor if you are in question about any aspect of your boiler s performance Our main concern is that you are satisfied with your boiler and its performance We require that your contractor complete efficiency tests using instruments The external controls and accessories listed in this manual excluding those supplied inside the boiler are intended to serve as guidelines rather than specific recommendations We re alize that other makes and models of such devices are available and can be used as suc cessfully as those we specify The installing contractor is the best judge of a system s specific requirements as well as the local availability of certain makes and models of controls and accessories The preceding does not apply however to the equipment that comes with every boiler such as the overheat control and pressure relief valves The installation of the spe cific devices supplied with every boiler is absolutely necessary to the safe operation of the boiler and protection of the heating system All SAVIO wall hung boilers are built in accordance with the ASME boiler and pressure vessel code and bear the H stamp The Entire range of applications for the SAVIO FP has been tested to standard CSA 4 9 and is CSA compliant Th
18. sed If this does not result in corrective ac tion contact SAVIO through BOYERTOWN Hydronic Technologies Address Below with details in support of the warranty claim All claims must be processed through proper trade channels Contact with SAVIO di rectly is not recommended for rapid claim settlement BOYERTOWN Furnace Co PO Box 100 Boyertown PA 19512 1 610 369 1450 www boyertownfurnace com SAVIO BOILER WARRANTY REGISTRATION IMPORTANT Registration required To gain complete warranty Protection fill in and mail this card within 1 year of installation to the address listed below NAME ADDRESS CITY STATE ZIP BOILER SERIAL NO DATE OF INSTALL NAME OF INSTALL CO ADDRESS CITY STATE ZIP RETURN TO BOYERTOWN FURNACE Co PO Box 100 BOYERTOWN PA 19512 1 610 369 1450 18 SAVIO FP USER MANUAL SAVIO FP USER MANUAL 19 17962 1512 0 2908 20A4 ma N LOIL
19. tect operation Faulty central heating temperature probe NTC Faulty primary circuit no water or absence of flow Lack of burner ignition no ignition signal from the full se Ignition gas pressure adjustment Minimum gas pressure adjustment Flashing lamp alone Flashing lamp al Lamp OFF or simultaneously ternate with another with another lamp lamp 10 SAVIO FP USER MANUAL 5 Instructions For Use 5 1 Warnings In order to guarantee safety and correct operation it is essential that all the tests are carried out by a competent and responsible licensed service person before lighting up the boiler e The tests are described in the installation operation and service instructions manual in Sec tion 15 Commissioning Ensure that the Central Heating circuit is regularly filled with water checking that the pres sure indicated on the temperature and pressure gauge 4 on figure 3 2 is not lower than 1 bar 14 5 psi as shown on figure 5 1 e Ifthe pressure reading on the pressure gauge is below 1 bar 14 5 psi then the system will require filling An automatic filling valve is normally provided by the installer for this pur pose If you are in any doubt regarding this procedure you are advised to contact your In staller or an Approved Service Person e This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 41 F e Therefore when the boiler is not lit or us
20. temperature of that the set temperature is obtained the central heating water according to the From 41 to 59 F Between 23 and 41 F outside temperature positioning the knob as in figure 5 4 e Your installer may have installed addi tional energy saving equipment and will be able to recommend the most suitable adjustment for your system Lower than 23 F Figure 5 4 5 5 Extinguishing Instructions To turn the boiler off set the function se A E lector C to the position shown in the Fig ure 5 5 e The appliance operation light A figure5 2 will flash every 4 seconds stand by mode e Turn off electric power to the appliance at the circuit panel of boiler serviceman s switch Figure 5 5 When you expect not to use the boiler for a long period e Switch off the electricity supply to the boiler by means of the circuit breaker Shut off the gas supply cock connected to the gas inlet pipe and the cock connected to the supply cold water inlet pipe see section 3 3 for pipes e Empty the water circuit if necessary as shown in the installation operation and service instructions manual in the maintenance section SAVIO FP USER MANUAL 13 5 Instructions For Use Cont 5 6 Domestic hot water temperature The temperature of the domestic hot water coming out from the boiler can be regulated from a minimum of approximately 95 F to a maximum of approximately 131 F by turning the control shown in f
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