Strebel Ca6s Installation Manual
Contents
1. Je iog AIN JOSU9S WOOY 0L SM UJOOJ pue JOSU9S LUOO JOY snq ejeq jUeA9 9J ay JOJ SIOSUBS MOJJ 9 G p JA Zd 1S BUIXILU ay 10 Hugen 9 9 9 0 LAM Josues Je log 1M 002 Josuas apismo 2 BUIXILU JO ZOZ JA JOSUSS ZOZ IA Josues MOJJ LAA 9 8 0Z LAM Josues Jeylo Je LAS 20151891 49 OOZAV Josues episino LAV 1314110 269 e z 415 9 9 0 LAA Josues L A Z LdMIN BUIXILU jueA9 9J OU JOJ SSAJLA J9XI A 9 G p y jeuuud J9yuoJeo Ld1s Bunejnoum Jalog 2 JeuBis uns saung 779 ay JO L 6X ex jpauuo Ajddns oBejs eubis uns jeuung 129 919UM prouajos Ajddns any AW 1 Uogeieiqav Z UOISUSIXY 9 3A TVA 5 3A TVA BUIXILU ay JOJ SIOSUSS MOJ 9 S r E JA ynoJro BUIXILU jueA9 eJ ay JO 9 G g eui JO OLX UM2. BOILERS RADIATORS Ca 6s and BCa 6s 33 64 kW INSTALLATION AND OPERATING INSTRUCTIONS CONTENTS PAGE General specification 3 Dimensions for Ca6s and BCa6s boilers 4 Boiler room clearance requirements 5 Boiler block assembly 6 Boiler connections and jacket assembly 7 Diagram 8 assembly 9 BCa6s electrical connections and jacket assembly 10 Diagram 11 Instrument control panel description 12 Continued 13 Control module options 14 Control module diagrams 15 Installation of electronic control modules 16 Terminal wiring diagram 17 Schematic wiring diagram 18 Important notes amp burner connection information 19 Page 2 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s General Specifications The STREBEL Camino 6s 1s a special boiler for oil or gas fired pressure jet burner In the BICALOR construction a calorifier for the supply of hot water is built onto the boiler CSH S type calorifier are manufactured from 1 4571 high tensile steel with an incorporated heating coil of galvanised copper ribbed pipe Triple pass block of cast iron sections The first pass 1s the combustion chamber From there the flue gases pass between the rear section and the last intermediate section through the second pass to the front of the boiler They are then diverted into the third pass and flow back to the rear through the flue spigot into the chimney Flue baffles of cast iron can be introduced into the flue
3. eration for one heating circuit two mixing valves and HWS control illustration on page 7 Gamma 33B Weather compensated control for two heating cir cuits both with mixing valves This is an addi tional control module suitable only in addition to a basic electronic control module Mounting and operating instructions are sup plied with the electronic controls Page 14 31 07 00 ASSEMBLY INSTRUCTIONS FOR 6s BCa 6s Gamma B1 Control Module STAGE 1 STAGE 4 X G22K Control Module Gamma 223B control module Gamma 2233B Control Module Page 15 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s Installation of an electronic control module Gamma Bl First the blank cover on the boiler needs to be removed Use a screwdriver with light pressure turning anti clockwise the screws on the left and the right side of the blank cover Then remove the blank cover carefully as there is wiring connected to the back Remove the plugs X3 and X4 from the back of the blank cover Connect the plugs X1 X2 X3 and X4 from the boiler instrument panel to the back of the control module Insert the electronic control module into the opening and fix it by turning the two screws under light pressure clockwise by 90 The electronic control module unit is now fixed to the boiler instrument panel Page 16 If a further control module is to be added open the top metal cover of the boiler instr
4. passes in order to influence the flue gas temperature depending on chimney conditions The boiler can be used with an oil or gas burner Brief description e Corrosion resistant block of cast iron sections e Triple pass boiler with optimised use of energy e High efficiency e Built in instrument panel with multiple control possibilities and retro fit control options Easy erection and cleaning Modern design Operating conditions Boiler Maximum operating temperature up to 110 C Maximum operating pressure 4 0 bar Maximum test pressure 5 2 bar Page 3 Calorifier Maximum operating pressure 10 bar Maximum test pressure 13 bar The boiler can be delived in individual sections or as a boiler block The accessories are packed seperately There are different orders of assembly depending on the condition of supply when assembling and connecting the boiler all relevant instructions should be observed The boiler is to be erected on a base or a level floor which is capable of supporting the weight of the boiler water content and any ancillary equipment Refer to base details opposite Assembly connections and the initial set up operation should be carried out by a qualified heating engineer Min thickness 60mm Dimensions EA A jo Bo y 31 07 00 Ca 6s BCa 65 ASSEMBLY INSTRUCTIONS FOR Boiler Dimensions Combustion chamber depth LK C5H 5 ES n Lal
5. until the clearance is even again Page 6 Once assembled the boiler block is to be secured with the tie bars 2 at the top and 2 at the bottom Prior to screwing nuts up ensure the two disc springs 5 amp 6 are slotted on with concave sides facing each other The nuts can now be tightened until the disc springs flatten The burner door hinges should now be fitted on the left or right hand side of the front section depending on requirements Ensure the eyelet screws door hinge are at the same depth and when the door 1s closed it should press flat with the front section Diagram showing nipple amp borin 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s Connections and jacket assembly The diagram over the page shows the assembly of the connections and jackets The order of assembly from 1 to 24 must be observed Key to components Left hand lower insulation Right hand lower insulation Left hand jacket with insulation Right hand jacket with insulation Front bottom bracing angle Lower door jacket bracing Upper front insulation Upper front jacket panelling Calorifier blanking flange Top jacket insulation Inner rear insulation Burner connection Capillaries Top Jacket Flow header and flange Fitted eccentrically upwards 17 Return header and flange Fitted eccentrically upwards 18 Calorifier blanking flange 19 Drain cock connection 2
6. 0 Rear jacket angle joe d d M cM 3 pu Nm hh Y O 21 Outer rear insulation 22 Rear insulation retainer 23 Rear insulation retainer 24 Flue gas spigot 25 Front Jacket amp front shroud Page 7 Important points The burner door can be fitted to swing from either the left or right Fit hinge bolts accordingly and ensure there is even pressure around door seal by adjusting the depth of the eye holes for the hinge Note The burner plug must be mounted on the opposite side When assembling the floor insulation 1 amp 2 as well as the side jackets 3 amp 4 care should be taken to ensure they are in the correct position with burner cable holes facing the front The water temperature sensors 14 must be pushed with the pressure spring into the immersion sleeves max 3 per sleeve and then secured with the protective guard Note The sensor leads capillary tubes should not be kinked Cold water pressure test The assembled boiler is to be subjected to a cold water pressure test of 1 5 times the operating pressure The maximum test pressure of the boiler is 5 2 bar In addition at the time of testing for water pressure no pressure control fittings or safety fittings may be assembled which cannot be separated from the water area of the boiler Only fill slowly from the bottom via the filling and draining cock Ventilate during the filling procedure from time t
7. CSH 3055 CSH 2355 U LO I U Page 4 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s min 450 A o D min 150 min 400 Diagram showing clearances required in boiler room The clearance details shown above are required for access to the boilers for maintenance purposes Slight variations may apply depending on the specific installation Page 5 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 65 Boiler Block Assembly The boiler block is assembled by pulling up each section in turn starting from the rear section 1 All other sections 2 3 4 are mounted individually using the pulling up tools One face of the adjoining sections must have a length of mastic sealing strand placed into the mastic groove Each of the boiler nipples must be inspected to ensure there is no damage apparent The nipples and nipple ports should then be kept free from dirt and checked at each stage of assembly Particles of dirt which are not removed lead to leakage The accompanying nipple jointing oil serves as a lubricant as well as a waterproof seal and must be used Boiler nipples and nipple ports must align exactly at all stages of assembly An inclined retracted nipple leads to leakage The clearance between the sections throughout the pulling up stages should always be even If the clearance 1s uneven a flat chisel should be inserted into the narrower point and the sections pulled up
8. OLX UOISU91X9 eje ANE HOLLOJHHO A 19905 A Idd 1 gt 1414 P A 49715 49Y15 JHNIHOLIMAS 3101474 HOISIA Ctd 11915 Y3IH 4N4 THD LOO 1 JA Iv A Te A INV9D VIG IVNINA AL 31 07 00 Page 17 KFG INSTRUMENT CONTROL PANEL WIRING DIAGRAM IN TOTALCAD FILE INSERT HERE Page 18 31 07 00 ASSEMBLY INSTRUCTIONS FOR 6s BCa 6s IMPORTANT Flue gas temperatures of below 160 C can lead to sooting of the flue when entering a stone or brick chimney Where flue gas temperatures are below 160 C gross specially adapted chimneys must be available If after the burner has been set the flue gas temperature is too low the baffles from the 3rd flue pass can be taken out If necessary the 2nd flue pass baffles can also be removed NB Every change made to the flue baffles requires re commissioning of the burner settings Electrical connections must be carried out by qualified personnel in accordance with instructions supplied Electrical leads and oil pipes should never be fastened to the boiler casing In the interest of technical progress we reserve the right to undertake changes and improvements in production without notification Please refer to Operating and Maintenance information for details on baffles and control panel informatio
9. d A Summer Winter switch 1s fitted here Page 13 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s Control module options Single stage burner operation Gamma 1B HWS control temperature range 20 80 C HWS priority pump overrun of calorifier pri mary pump boiler control thermostat illustration on page 7 Gamma 2B Weather compensated control for one heating circuit and HWS control Gamma 23B Weather compensated control for one heating circuit one mixing valve and HWS control Gamma 233B Weather compensated control for one heating circuit two mixing valves and HWS control Gamma 233BS Weather compensated control for one heating circuit two mixing valves HWS control tem perature difference control for solar units and combination with solid fuel boilers Gamma 33B Weather compensated control for two heating circuits both with mixing valves This is an addi tional control module suitable only in addition to a basic electronic control module Two stage burner operation G22K Electronic two stage thermostat for constant tem perature boiler operation illustration on page 7 Gamma 22B Weather compensated control for two stage op eration for one heating circuit and HWS control Gamma 223B Weather compensated control for two stage op eration for one heating circuit one mixing valve and HWS control illustration on page 7 Gamma 2233B Weather compensated control for two stage op
10. e carried out by trol a competent person If any works are carried out the mains supply to E Burner lock out lamp red the boiler must be isolated and secured against ac cidental switching on The red lamp will illuminate when the burner has The proper function of the boiler instrument panel gone out burner fault the red lamp will go off is only guaranteed according to our general guar once the burner reset button has been pressed antee conditions and only if the installation and operation 1s carried out in accordance with these F high limit lamp orange instructions If the boiler safety limit thermostat STB 1s acti vated the orange control lamp will be illumi nated The orange lamp will go off once the STB button has been pressed and reset G Instrument panel On lamp green This will be illuminated when the instrument panel 1s switched on the main On Off switch A turned from 0 to 717 H Blank cover The standard version of the boiler instrument panels are supplied with blank covers Terminal blocks X3 and X4 connect to dummy connection pins on the rear side to prevent short circuits When using an additional electronic control module this blank cover should be removed Terminal blocks X3 and X4 should then be con nected to the replacement module along with X1 and X2 in the designated positions I Blank cover When a Gamma 1B control module 1s used this blank cover must be remove
11. n When connecting the burner make sure the length of the burner cable is such that when the burner door is opened it becomes disconnected Page 19 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s THE COMPANY RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DIMENSIONS WITHOUT NOTICE STREBEL LTD 1F Albany Park Industrial Estate Frimley Road Camberley Surrey GU16 7PB Telephone 01276 685422 Fax 01276 685405 E mail address info strebel co uk Website www strebel co uk E amp O E Page 20 31 07 00
12. o time until the water emerges If a nipple connection is leaking then drain off the water via the filling and draining cock Separate by driving flat wedges around the perimeter of the join between sections New nipples MUST be used for re assembly Assemble and repeat test 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s Fa ON E a me 21 0 Page 8 31 07 00 ASSEMBLY INSTRUCTIONS FOR 6s BCa 6s BCa7s Assembly Follow the steps below for completion of the assembly The diagram shows the calorifier connections and mounting brackets Key 1 Flow connections 2 Return connections 3 Mounting bracket 4 Calorifier primary flow connection 5 7 4 Calorifier primary return connections 6 Non return valve and charging pump 9 Drain cock connection Page 9 31 07 00 ASSEMBLY INSTRUCTIONS FOR 6s BCa 6s BCa 6s electrical connections and jacket assembly The diagram over the page shows the assembly for the including electrical connection and final jacket assembly Angled bracket with pipework slots Jacket alignment bracket Left hand side jacket Right hand side jacket Calorifier top insulation Top jacket Jacket mounting bracket Instrument control panel Calorifier door Sensor capillaries Boiler sensors Thermostat sensor Calorifier thermometer Burner cable outlet Alternative burner cable outlet depending on hinge
13. placement 16 Rear boiler insulation 17 Insulation retaining brackets 18 Lower rear calorifier insulation 19 Rear calorifier insulation 20 Rear insulation retainers 21 Flue gas spigot 22 Front calorifier insulation 23 Boiler front jacket pee A Es Ad om xvm VD A AO Note Mains connection should be made via the rear of the boiler through to the control panel It must not be connected directly to the front of the boiler via the calorifier jacket door Page 10 31 07 00 Ca 6s BCa 6s ASSEMBLY INSTRUCTIONS FOR di Page 11 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s ELECTRICAL CONNECIION Description of Controls and Operation A On Off and Operation mode switch Switch position 07 of With the switch in this position the operation of the boiler and burner 1s off Switch position 1 manual The instrument panel 1s 1n operation The burner and any boiler control pumps are operated with out any influence of any other built in control modules The dial controls the boiler operating temperature within the limits of the decreasing arrow Mixing valves must be manually adjusted The instrument panel On lamp G is illuminated Switch position a automatic In this position any built in electronic modules are in operation The boiler temperature and any other equipment connected back to the boiler 1 e pumps and mixing val
14. ument panel by removing the 6 screws Screw the terminal block X11 that 1s supplied with the additional control module onto the red marked part of the terminal rail inside the boiler instrument panel and likewise the X12 onto the blue marked part 2 9 x 19mm screws are supplied with the additional control module Connect the plugs X9 1 and X10 1 that are on the leads to the boiler instrument panel with X9 2 and X10 2 plugs and leads from the additional control module If a second extension module is used connect the clips of the second one Remove the central blank cover and connect the plugs X1 X2 X3 and X4 to the module Install the module as described above 31 07 00 eoe d sy ui 10 SIS9J suyo y 9 e eu pinoys JV Josuas CCTS89 9 710 TA4IH ALS ou yng Og ZZ 9 peny eDejs Z 9 jeuruuJe GL euro 415 GG pG L 48 LAM Josuas Bunejnour 89 L9 247 LAM Josuas 19 10g 16 2 EL ZA L 02 aaa e z S c LS 0G sjeuiuuJel 2M LAM Josuas 19 10g sJequinu 9 qeo 9 ee sjeuiuuey 2 o qeo uonoeuuoo Jeuung ze ZZ 9 qeo Jeuung sna vivi JOUING JOW J JOJ UOISIAOJd MS p
15. ves are controlled auto matically Attention The switch marked 0 off can only be reached by rotating the switch anti clockwise through the position marked 1 Switch position STB a This function is used to check the boiler safety limit thermostat This is activated by rotating the dial and holding the switch in position until the boiler safety limit thermostat functions B Boiler safety limit thermostat STB The boiler safety thermostat STB turns the boiler off 1f the boiler water temperature overheats Once the boiler water has cooled down to about 80 C the STB must be manually re set This is done by unscrewing the cover cap B and pressing the small button Once reset refit the cover cap again If the STB functions repeatedly check the water circulation through the boiler or call a heating engineer C Fuse 6 3A A fuse in the front of the instrument panel protects all the controls and any other equipment con nected back to the boiler A defective fuse must be replaced by an identical one Attention Before the fuse is replaced the in strument panel must be isolated from the elec trical power supply Page 12 31 07 00 ASSEMBLY INSTRUCTIONS FOR Ca 6s BCa 6s D Boiler thermometer Safety instructions It shows the actual boiler water temperature and Any servicing on the boiler instrument panel has no influence on the boiler temperature con wiring repairs changes should b
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