Lamborghini Caloreclima Externa 30 O User manual

WALL-HUNG, GAS-FIRED,

SEALED BOILER,

FOR CENTRAL HEATING

OPERATING, INSTALLATION

AND MAINTENANCE

INSTRUCTIONS

cod. 3540T54/0 - 04/2009 (Rev. 00)

7

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

• Carefully read the warnings in this

instruction booklet, as they provide

important indications on the safety of

installation, operation and maintenan-

ce.

• The instruction booklet is an integral and

essential part of the product and must

be carefully kept by the user for future

reference.

• If the appliance is sold or transferred to

another owner, or if it is moved, always

check that the booklet accompanies the

boiler for reference by the new owner

and/or installer.

• The installation and maintenance opera-

tions must be performed according to

the standards in force, the instructions of

the manufacturerand mustbe carriedout

by professionally qualified personnel.

• Incorrect installation or poor maintenan-

ce may cause damage to people, animals

or things. The manufacturer declines all

liability for damage deriving from errors

in the installation and operation of the

appliance, and inany casefrom thefailure

to observe the instructions provided by

the manufacturer.

• Before performing any cleaning or

maintenance operations, disconnect

the appliance from the mains power

supply using the system switch and/or

the corresponding on-off devices.

• In the event of faults and/or poor ope-

ration of the appliance, it should be

deactivated. Do not attempt to repair

the appliance. Contact professionally

qualified personnel only.

• The products must only be repaired-

replaced by professionally qualified

personnel, using original spare parts

only. Failure to heed this warning may

affect the safety of the appliance.

• To ensure the correct operation of the

appliance, annual maintenance must be

performed by qualified personnel.

• This appliance must only be used for the

purposes it has specifically been desi-

gned for. All other uses are considered

improper and thus dangerous.

• After having removed the packaging,

check that the contents are intact.

• The parts of the packaging must not be

left within the reach of children, as they

are potential sources of danger.

• In case of doubt do not use the appliance

and contact the supplier.

This symbol indicates “Warning” and is placed near all warnings regarding safety.

Such provisions must be strictly adhered to so as to avoid danger and damage to

people, animals and things.

This symbol highlights a note or an important warning.

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

1. Operating instructions............................................................................4

1.1 Introduction ............................................................................................................4

1.2 Control panel ..........................................................................................................4

1.3 Ignition and shut-down...........................................................................................5

1.4 Settings ...................................................................................................................5

1.5 Maintenance............................................................................................................6

1.6 Troubleshooting......................................................................................................6

2. INSTALLATION.......................................................................................7

2.1 General instructions................................................................................................7

2.2 Place of installation .................................................................................................7

2.3 Water connections ..................................................................................................7

2.4 Gas connection .......................................................................................................9

2.5 Electrical connections .............................................................................................9

2.6 Flues ......................................................................................................................11

3. SERVICE AND MAINTENANCE............................................................12

3.1 Settings .................................................................................................................12

3.2 Commissioning......................................................................................................14

3.3 Maintenance..........................................................................................................15

3.4 Troubleshooting....................................................................................................17

4. CHARACTERISTICS AND TECHNICAL SPECIFICATIONS.....................20

4.1 Dimensions and fittings ........................................................................................20

4.2 Overall view and main components .....................................................................21

4.3 Hydraulic diagram.................................................................................................22

4.4 Technical data table..............................................................................................23

4.5 Diagrams ...............................................................................................................24

4.6 Wiring diagram .....................................................................................................25

7

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

fig. 1

1. OPERATING INSTRUCTIONS

1.1 Introduction

Dear Customer,

Thank you for having chosen the Externa 30 O, an advanced-concept LAMBORGHINI wall-hung boiler

featuring cutting-edge technology, high reliability and constructional quality. Please carefully read this

manual and keep it for future reference.

The Externa 30 O is a high efficiency heat generator for central heating systems, operating on natural

gas or LPG (the type of gas can be configured at the moment of installation) and managed by an advan-

ced microprocessor-based control system.

The boiler body is made up of a copper heat exchanger, the special shape of which guarantees high

heat exchange efficiency in all operating conditions, and an atmospheric burner featuring electronic

ignition with ionisation flame control.

The boiler is intended for outdoor installation only.

The accessories supplied with the boiler also include a variable-speed pump, expansion vessel, safety

valve, air pressure switch, water pressure switch, temperature sensors and safety thermostat.

The microprocessor-based control system means that the operation of the appliance is almost comple-

tely automatic. The central heating output is automatically regulated by the control system according

to requirements. The domestic hot water output (with external storage installed) is automatically and

continuously controlled to ensure both comfort and economical operation.

The user simply has to set the temperature required inside the home (using the optional, yet recom-

mended room thermostat) or set the system temperature and the required domestic hot water outlet

temperature. The regulation and control system will then ensure optimum operation all year round.

It MUST NOT be used for pool or spa heating.

1.2 Control panel

To access to the control panel, open the front door, unscrewing the two black knobs.

POS. DESCRIPTION

AOFF/ON/RESET switch

BCentral heating temperature

setting

CHydrometer

EClock itting

CEAB

bar

Burner on signal

Shut-down warning signal

Stand-by in central heating operation (light lashing)

Central heating request (light on)

Insu icient system pressure (light lashing)

Mains power (light on)

1234

LED

Table 1

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

1.3 Ignition and shut-down

Ignition

• Open the gas cock upstream of the boiler.

• Close or insert any switches or power plugs upstream of the boiler

• Place the main switch “A” in the ON position.

• Place knob “B” in the Winter position and set the room thermostat, if fitted, to the required tem-

perature value. At this point, the burner will ignite and the boiler will start operating automatically,

managed by its control and safety devices.

If, after having correctly performed the ignition operations, the burners do not ignite and the

shut-down warning light is on, wait around 15 seconds, then turn knob A to the RESET position

and release it. The control unit will be reset and will repeat the ignition cycle. If, after a number

of attempts, the burners do not ignite, refer to the paragraph on troubleshooting.

Shut-down

Close the gas cock upstream of the boiler, turn knob “A” to OFF and disconnect the appliance from

the mains power supply.

When the boiler is off the boiler anti-freeze protection is not active.

For extended periods of inactivity during the winter months, in order to avoid damage due to

freezing, all the water should be drained from the boiler, both the domestic hot water and the

central heating system; alternatively, drain only the domestic hot water and place the special

antifreeze fluid in the central heating system.

1.4 Settings

Summer/Winter setting and system temperature control

With knob “B” Fig. 1 in the position of the symbol (Summer), the central heating function is deac-

tivated.

Only the production of domestic hot water is activated (with the optional external hot water cylinder

installed).

With the knob “B” Fig. 1 in the position of the symbol (Winter), both the central heating function

and domestic hot water are active.

Turning the knob clockwise increases the central heating water temperature, anticlockwise decreases

it. The temperature can be set from a minimum of 35° to a maximum of 85°. It is not recommended,

however, to operate the boiler below 45°.

Setting the ambient temperature (using the optional room thermostat)

Set, using the room thermostat or remote control, the temperature required inside the rooms. Based

on the command from the room thermostat, the boiler is ignited and heats the system water to the set

central heating outlet temperature. When the required temperature inside the rooms is reached, the

boiler switches off.

If no room thermostat or remote control is available, the boiler will maintain the system at the set central

heating outlet temperature.

Domestic hot water temperature control

Set the storage temperature, using knob “D” (supplied in the optional kit).

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

Before calling the service centre, check that the problem is not due to no gas or mains power

supply.

System water pressure control

The boiler is fitted with a cock for manually filling

the central heating system. The filling pressure when

the system is cold, as read on the boiler hydrometer,

must be around 1.0 bar.

If the pressure drops during operation (due to the

evaporation of the gas dissolved in the water) to a

value lower than the minimum described above, the

User must restore the initial value using the filling

cock. Once the operation is completed, always close

the filling cock.

1.5 Maintenance

It is recommended to have annual maintenance of the heating system performed by qualified person-

nel, and at least biennial checks on the combustion device. Please refer to Chap. 3.3 in this manual for

further information.

The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp

cloth, dipped in soapy water if necessary. Do not use abrasive detergents or solvents.

1.6 Troubleshooting

Any anomalies or operating faults are signalled by the LEDs on the control panel.

The following table lists the faults that may arise due to simple problems that can be resolved by the

user.

fig. 2

bar

Table 2

Boiler shut-down

Insu icient system pressure

(light lashing)

LED

Check i the gas cocks upstream o the boiler and on the counter are

open.

Turn knob A Fig. 1 to Reset and then release it.

In the event o repeated boiler shut-downs, contact the nearest service

centre.

Fill the system when cold to 1-1.5 bar, using the cock located on the

boiler.

Close the cock a ter use.

Problem Solution

Filling cock

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

2. INSTALLATION

2.1 General instructions

This appliance must only be used for the purposes it has been specifically designed for. This

appliance is used to heat water to below boiling temperature at atmospheric pressure and must

be connected to a central heating and/or hot warm distribution system, according to its cha-

racteristics, performance and heating capacity. All other uses are considered improper.

THE APPLIANCE SHALL BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURED'S INSTALLA-

TION INSTRUCTIONS, LOCAL GAS FITTING REGULATIONS, MUNICIPAL BUILDING CODES, WATER

SUPPLY REGULATIONS, ELECTRICAL WIRING REGULATIONS, AS 5601 / AG 601 - GAS INSTALLA-

TIONS AND ANY OTHER RELEVANT STATUTORY REGULATIONS.

Incorrect installation may cause damage to people, animals and things. The manufacturer will not be

held liable in such events.

2.2 Place of installation

The appliance is intended for outdoor installation only.

The place of installation must in any case be free of dust, inflammable objects or materials and corrosive

gases.

The boiler is supplied ready for wall-hung installation. The rear frame of the appliance has a two slots

for fastening it to the wall, using screws with metal wall plugs. The fastening to the wall must provide

stable and effective support of the appliance.

Upon request a metal wall drilling template is available. This is used exclusively to trace the holes for

fastening the appliance onto the wall, and can be reused for more than one appliance.

2.3 Water connections

The heat capacity of the appliance should be established in advance by calculating of the heating re-

quirements of the building according to the standards in force. For correct operation and long-life of

the boiler, the hydraulic system must be suitably proportioned and always fitted with all the accessories

that guarantee regular operation.

In the case where the central heating outlet and inlet pipes follow paths whereby, at some points, poc-

kets of air may form, air vent valves should be installed at such points.

In addition, a drain device should be installed at the lowest point in the system, to allow complete

emptying.

If the boiler is installed at a lower level than the system, a flow-stop valve should be fitted to prevent

the natural circulation of water in the system.

The thermal head between the outlet manifold and the return inlet of the boiler should not exceed

20°C.

Do not use the water pipes as the earth for electrical appliances.

Before installation, carefully clean all the pipes in the system to remove any residues or impurities that

may affect the correct operation of the appliance.

Make the connections to the corresponding fittings, as shown in fig. 3.

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

It is recommended to fit on-off valves between the boiler and the central heating system; these allow

the boiler to be isolated from the heating system, if necessary.

Make the connections to the boiler in a way that its internal tubing is not subject to stress.

fig. 3a

The connection kit shown in fig. 4a and 4b can be supplied upon request.

In t e boiler

From t e system

In t e boiler

From t e system

In t e boiler

From t e system

C D E

FEDB CA

Connection wit cocks

Connection wit nipples

A Female pipe coupling

C OR gasket

D OT 58 stop ring

E Copper washer

F OT 58 connecting pipe

G Ball cock

A Female pipe coupling

B OT 58 nipple

C OR gasket

D OT 58 stop ring

E Copper washer

F OT 58 connecting pipe

fig. 4a

fig. 4b

Key

1CH flow, 3/4”

2Filling cock

3Gas inlet, 1/2”

4CH return, 3/4”

5Pressure relief valve discharge

46,5 95 54 223,5 141

123 4

236,5 326,5

Gas inlet

Conical

ISO 7-1

Gasket

fig. 3b

Mount threaded adapter

before installation

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

Pressure relief valve

Externa 30 O incorporates a pressure relief valve discharging at 300 kPa.

The discharge of the pressure relief valve must be connected to a collection container, to avoid

water spilling onto the ground in the event of over-pressure in the central heating circuit. The

manufacturer of the boiler will not be held liable if this warning is not heeded, and the discharge

valve intervenes and floods the room.

Characteristics of the system water

In the case of water with hardness above 25 French degrees, the water should be suitably treated,

to avoid any deposits in the boiler caused by hard water, or corrosion caused by aggressive water. It

should also be remembered that even minor deposits measuring just a few millimetres thick can cause,

due to their low thermal conductivity, significant overheating of the walls of the boiler, with consequent

serious problems.

The water must always be treated in the case of very large systems (with high water capacity) or sy-

stems with the frequent inlet of recovered water. If, in these cases, the system needs to be partially or

completely emptied, it must be refilled with treated water.

Filling the boiler and the system

The boiler is fitted with a ball cock for manually filling the central heating system. The filling pressure,

when the system is cold, must be around 1 bar. If the pressure drops during operation (due to the eva-

poration of the gas dissolved in the water) to a value lower than the minimum described above, the User

must restore the initial value using the filling cock. For correct boiler operation, the pressure, when hot,

must be around 1,5÷2 bar. Once the operation is completed, always close the filling cock.

2.4 Gas connection

Before making the connections, check that the appliance is configured for operation with the

type of fuel available, and carefully clean all the gas pipes in the system, to remove any residues

that may affect the correct operation of the boiler.

The gas connections must be made at gas inlet (see fig. 3 - key 3), with a rigid metal pipe, or a stainless

steel flexible continuous-wall pipe, fitting a gas cock between the system and the boiler. Before instal-

lation, mount the threaded adapter ISO 7-1 contained in boiler package, as shown in fig. 3b. Check that

all the gas connections for tightness.

The capacity of the gas counter must be sufficient for the simultaneous use of all the connected appliances.

The diameter of the gas pipe, which leaves the boiler, does not necessarily determine the choice of the

diameter of the pipe used between the appliance and the gas counter; this must be chosen according

to its length and the pressure drop, according to the standards in force.

Do not use the gas pipes as the earth for electrical appliances.

2.5 Electrical connections

Connection to the mains power supply

The boiler should be connected to a single-phase, 240 Volt-50 Hz electrical line.

The electrical safety of the appliance is ensured only when the appliance is correctly connected

to an effective earth system, as prescribed by the safety standards in force. Have professionally

qualified personnel check the efficiency and the rating of the earth system. The manufacturer

is not liable for any damage caused by the appliance not being correctly earthed. In addition,

make sure that the electrical system is adequately rated for the maximum power absorbed by

the appliance, indicated on the boiler rating plate, and in particular that the cross-section of the

wires is suitable for the power absorbed by the appliance.

The boiler is pre-wired and fitted with a cable for connection to the electrical line. The connections to

the mains supply must be made using a fixed connection, featuring a two-pole switch with a contact

Externa 30 O

Cod. 3540T540 - 04/2009 (Rev. 00)

Room thermostat

WARNING: THE ROOM THERMOSTAT MUST NOT HAVE LIVE CONTACTS. CONNECTING

240V TO THE ROOM THERMOSTAT TERMINALS WILL CAUSE IRREVERSIBLE DAMAGE TO

THE ELECTRONIC BOARD.

When connecting a room thermostat with a daily or weekly program, or a timer, avoid taking the

power supply to these devices from their switch contacts. Their power supply must derive from

a direct connection to the mains or using batteries, depending on the type of device.

fig. 5b

fig. 5a

opening of at least 3 mm. Max 3A fuses must be installed between the boiler and the line. The correct

polarity must be followed (PHASE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green wire) in

the electrical connections.

If the supply flexible cord is damaged or the unit needs repairs it shall only be done by a qualified

person authorised by the supplier.

If replacing the electrical power cable, use only the “HAR H05 VV-F” cable, 3x0.75 mm2, with a

maximum external diameter of 8 mm.

Accessing the electrical terminal block

Follow the indications shown in figs. 5a and 5b to access to the electrical terminal block. The layout of

the terminals for the various connections is shown in the wiring diagram, in the chapter on Technical

Specifications.

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