BLOWTHERM PACK-P AR 93 User manual

INSTRUCTIONS MANUAL FOR BOILERS MODELS:
nº1460040EN
Updated 04/2009
PACK-P AR 93 PACK-P AR 810
PACK-PAR 105 PACK-P AR 930
PACK-P AR 150 PACK-P AR 1045
PACK-PAR 190 PACK-P AR 1100
PACK-P AR 230 PACK-P AR 1250
PACK-P AR 290 PACK-P AR 1600
PACK-P AR 345 PACK-P AR 1800
PACK-P AR 405 PACK-P AR 2000
PACK-P AR 465 PACK-P AR 2500
PACK-P AR 520 PACK P-AR 3000
PACK-P AR 580 PACK P-AR 3500
PACK P-AR 695
0085

WATER STEEL BOILERS PACK-P AR MOD. PACK-P/AR
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1
Dear Customer,
Thank you for choosing a BLOWTHERM boiler of the range PACK-P AR.
This manual has been prepared to provide you with information, warnings and suggestions regarding the
installation, the correct use and maintenance of the product.
In your interest and to maintain the highest level of performance of your appliance, we recommend that you
carefully observe the instructions contained in this manual. A regular maintenance made by authorized technicians
will grant a long life of the product.
We would like to remind you that failure to follow the instructions contained in this manual may invalidate the
guarantee.

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CONTENTS
1GENERAL INFORMATION
1.1 General warnings…………………………………………………………………………………….page 3
1.2 Certification…………………………………………………………………………………………... page 4
1.3 Safety Rules…………………………………………………………………………………………… page 4
1.4 Description of the appliance……………………………………………………………………….. page 5
1.5 Dimensions and technical features………………………………………………………………… page 6
1.5.1 Dimensions and technical features PACK-P AR 93-405 …………………………………….... page 6
1.5.2 Dimensions and technical features PACK-P AR 465-1100…………………………………….. page 7
1.5.3 Dimensions and technical features PACK-P AR 1250-3500…………………………………… page 8
1.6 Identification Elements…………………………………………………………………………….... page 9
1.7 Documents delivered with the boilers…………………………………………………………….. page 9
1.8 Standard Electrical control Panel……………………………………………………………….. page 10
1.9 Standard electrical diagram……………………………………………………………………….. page 11
1.10 Electrical diagram (for 2 stages Burners)…...……………………………………………………..
page 12
2USER
2.1 Start-up Operations……………………………………………………………………………………
page 13
2.2 Turning off………………………………………………………………………………………………
page 14
2.3 Cleaning…………………………………………………………………………………………………
page 14
2.4 Maintenance………………………………………………………………………………………….. page 14
2.5 Product receipt………………………………………………………………………………………. page 14
3INSTALLER
3.1 Packaging and Handling…………………………………………………………………………… page 15
3.2 Installation-Boiler Room……………………………………………………………………………… page 15
3.3 Discharge of Combustion Products………………………………………………………………….
page 16
3.4 Hydraulic Connection………………………………………………………………………………. page 17
3.5 Water Supply page 17
3.6 Water temperature –Limit temperatures page 18
3.7 The Condensate Problem…………………………………………………………………………….page 18
3.8 Diagram of a standard heating installation……………………………………………………… page 19
3.9 Electrical System…………………………………………………………………………………….. page 20
3.10 Control Panel Installation………………………………………………………………………….. page 20
3.11 Fuel Supply………………………………………………………………………………………….. page 21
3.12 Possible Combustibles…………………………………………………………………………………
page 21
3.13 Burner Connection…………………………………………………………………………………….
page 22
3.14 Cover Assembling (only for PACK-P AR 93-1045)……………………………………………….page 23
3.15 Preliminary Operations before First Start-up……………………………………………………..
page 24
3.16 First Start-up……………………………………………………………………….…………………. page 24
3.17 First Start-up and further Checks……………………………………………………………………
page 25
4SERVICE
4.1 Warnings for the service Center…………………………………………………………………… page 26
4.1 Routine Maintenance……………………………………………………………………………….. page 26
4.2 Opening and Adjustment of the Door……………………………………………………………... page 26
4.3 Cleaning of the Boiler……………………………………………………………………………… page 27
4.4 Check after boiler cleaning operations………………………………………………………….... page 27
4.5 Troubleshooting…………………………………………………………..………………………….. page 27
4.6 Spare Parts List…………………………………………………………………………………….. page 29
4.7 Warranty………………………………………………………………………………………………. page 29

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1 GENERAL INFORMATION
1.1 GENERAL WARNINGS
This instruction manual is an integral and essential part of the product and provides important instructions for
installation, operation and maintenance.
Should the appliance be sold or transferred to another owner, or if you move and leave the appliance behind,
always ensure that this manual accompanies the appliance so that the new owner and/or installation technician
can consult it.
This appliance must only be used for the purpose it has been specifically designed for: “to heat water to a
maximum limit temperature which has to be lower than the boiling temperature at atmospheric pressure; the boiler
must be connected to an hot water distribution system”.
All contractual or non-contractual responsibility of the manufacturer is excluded in the event of damages to
persons, animals and/or things caused by errors in installation, adjustment, maintenance and improper use.
The manufacturer's responsibility is excluded for all damage to persons and/or things resulting from a clear risk for
the user which he could have avoided by taking suitable safety measures.
After the receipt of the product, after having removed the packaging, check that it has not been damaged due to
handling and transport.
Do not leave the packaging materials (wooden cage, nails, staples, plastic bags, polystyrene foam, etc.) within the
reach of children, as they are potential sources of risk.
If you are in doubt do not use the appliance, contact your supplier.
The installation must be performed in compliance with the regulations in force, following the manufacturer's
instructions, by professionally qualified personnel.
The term “professionally qualified personnel” means persons with specific technical skills in the sector of heating
systems and components for domestic/industrial use and domestic/industrial hot water production.
The installer must observe the local standards in force regarding the choice of the site of installation of the boiler,
the compliance with the required ventilation conditions, the chimney configuration, the connection to the fuel line,
the electrical system and any other safety and technical standards.
To guarantee the efficiency of the appliance and ensure correct operation, it is indispensable to have regular
maintenance performed by professionally qualified personnel, following the manufacturer's instructions.
Before performing any cleaning or maintenance operations, disconnect completely the appliance from the mains
powers supply (electrical power, fuel supply,..).
Any repairs to the appliance must be carried out using only original spare parts.
If you decide do not to use the appliance for a long period, ensure you have professionally qualified personnel to
carry out the necessary operations to preserve the generator:
-set the boiler main switch and the general switch on “off”;
-close fuel and water on-off valve;
-empty the thermal system in case of freezing conditions.
The failure to follow the instructions, suggestions and standards contained in this manual may void the warranty.
The warranty excludes all damages due to corrosion or formation of deposits caused by the use if hard or
aggressive water.

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1.2 CERTIFICATION
The EC mark attests that BLOWTHERM appliance is conform to the requirements contained in European
Directives and norms.
In particular this appliance is conform to the following EEC Directives:
-Gas Directive (90/396EEC)
-Efficiency Directive (92/42/EEC)
-Low Voltage Directive (73/23/EEC)
-Electromagnetic compatibility Directive (89/336/EEC)
The PACK-P AR boilers are made according to the European standard EN 303, part 1.
1.3SAFETY RULES
The use of any component utilising energy power, fuels and water requires that certain fundamental rules be
respected, such as:
Do not allow children or unskilled people to use the appliance;
If you notice smell of gas, do not turn on electric switches, household appliances, telephone or any other objects
that could cause sparks. If this is the case:
-open doors and windows immediately to clear the air in the room;
-turn off the fuel taps;
-contact professional qualified personnel.
Do not touch the appliance with wet or damp parts of the body and/or with bare feet.
Do not perform any maintenance and cleaning operations without having disconnected the electric power and
turned off the fuel supply tap(s).
Do not pull, disconnect, unwind electric cables coming from the boiler, even if they are disconnected from the
mains supply.
Do not block or reduce the ventilation openings in the room to prevent the formation or toxic and explosive mixtures
caused by gas leakage; it is also uneconomic and polluting because it causes bad combustion.
Do not expose the appliance to atmospheric agents.
The generator has not been designed to work outdoors and is not provided with automatic anti-freezing systems.
Keep the boiler turned on in freezing conditions.
Other important warnings to be respected:
-If the power cable of the appliance is damaged, have it replaced by professionally qualified personnel;
-do not fix (and do not allow other persons to fix) electric cables on the system pipes or near sources of heat;
-ensure that the earthing cables of the appliance are not connected to the water system;
-do not touch the hot parts of the system (in particular the door and the smoke box) as they normally remain hot
even for some time after the appliance has been turned off.
In the event of a water leak, turn off the system and contact exclusively professionally qualified personnel.

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1.4DESCRIPTION OF THE APPLIANCE
The steel boilers of the PACK-P AR range are high performance generatorsfor heating systems for temperatures
up to 95°C (on request only for Export market the boilers are delivered for max temperature 115°C).
When combined with a hot water tank, this generator can be used also for the production of domestic hot water.
This is a pressurised combustion boiler with horizontal-cylinder configuration and flame reversal in the furnace,
completely cooled.The flame produced by the burner develops into the furnace and as it is closed on the bottom,
the flue gas returns to the anterior part, and through the cavity obtained in the front door insulation it enters into the
tube system.
Here the flue gas is obliged to make a whirling run through the turbolators, which increase the convective heat
transfer.
In this way it obtains the maximum absorption of heat without harmful thermal stresses and above all it has a
useful output superior to 90%.
After the tube system, the flue gas is collected in the smoke chamber and conveyed to the chimney.
The boiler can be equipped with all the traditional liquid or gaseous burners.
The burner is installed on a hinge door; in this way the regulation and maintenance operation of the boiler and of
the burner are facilitate, it is not necessary to disassemble the burner.
The thermal insulation of the boiler body is obtained by applying a pad of highly insulating mineral wall.
Elegant pre-painted steel panels complete the outside finish
The pre-wired control panel for the boiler automatic operation is positioned on top of the boiler itself.
The electrical diagram is housed inside the control panel.
An electronic climate adjusting system can be installed on request and provides the boiler temperature adjustment
as well as many other auxiliary functions.
5 6 943
78
12
rm
v
10
s
1Boiler body
2Front door
3Support burner plate
4Pilot flam
5Smoke chamber
6Smoke exhaust
7Cleaning door
8Smokes condensate discharge
9Identification plate
10 Control panel
r Heating return
m Heating flow
v Safety valve or espansion vessel
s discharge

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1.5PACK-P/AR DIMENSIONS AND TECHNICAL FEATURES
1.5.1 PACK-P/AR 93-405
rmv
s
ef
φ
d
B1
B
H
A1
A
PACK-P/AR MODEL 93 105 150 190 230 290 345 405
Power Input KW
Kcal/h
103
88.600
115,5
99.300
167
143.600 211 181.500 257 220.600
320
275.000
384
330.200
449
386.100
Power Output KW
Kcal/h 93 80.000
104,7
90.000
151,2
130.000 192 165.000 233 200.000
291
250.000
349
300.000
407
350.000
Max Working pressure
bar
55566666
Weight of empty boiler + cover Kg 250 270 310 460 480 540 550 610
Water content litres 119 119 155 228 228 285 276 329
Water pressure drop with∆t 15°
C
mbar 4.5 5.6 11.8 6.9 10 16.3 23 31
Pressure drop Comb. Chamber mbar 0,5 0,7 1,2 1,2 1,5 2,3 3,3 4,4
HHeight mm 880 880 880 990 990 990 990 990
BTotal width mm
B1 Width of body only mm 1110 760 1110 760 1360 1010 1405 1010 1405 1010 1655 1260 1655 1260 1905 1510
ATotal length mm
A1 Length of body only mm 790 750 790 750 790 750 940 900 940 900 940 900 940 900 940 900
d Distance
hydraulic connections
mm 460 460 460 510 510 510 510 510
e
Water outlet connection position
mm 430 430 430 465 465 465 465 465
f Chimney connection height
mm
260 260 510 450 450 700 700 950
r/m Hydraulic connection DN 2” 2” 2” 65 65 65 65 65
vSafety valve or expansion vessel
DN 1 ¼” 1 ¼” 1 ¼” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½”
s Discharge
DN ¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾”
∅Chimney connection mm 200 200 200 220 220 220 220 220

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1.5.2PACK-P/AR 465-1100
rmv
s
ef
φ
d
B1
B
H
A1
A
PACK-P/AR MODEL 465 520 580 695 810 930 1045 1100
Power Input KW
Kcal/h
511
439.000
577
494.000 637 548.000 771 663.000 899 773.000
1.027
884.000 1.156 994.000 1.349 1160000
Power Output KW
Kcal/h
465
400.000
523
450.000 581 500.000 700 602.000 820 705.000
940
808.000 1.060 911.000 1.240 1066000
Max Working pressure
bar
66666666
Weight of empty boiler + cover Kg 870 890 940 1310 1380 1440 1620 2200
Water content litres 402 402 476 697 795 733 817 1277
Water pressure drop with∆t 15°
C
mbar
18 22 28 18 25 33 40 36
Pressure drop Comb. Chamber
mbar
3,3 4,3 4,8 4,5 5,6 5,4 6,0 6,5
HHeight mm 1150 1150 1150 1280 1280 1280 1280 1500
BTotal width
mm
B1 Width of body only mm 1990 1512 1990 1512 2290 1812 2345 1814 2545 2014 2545 2014 2795 2264 2950 2416
ATotal length
mm
A1 Length of body only
mm
1040
1000 1040 1000 1040 1000 1240 1200 1240 1200 1240 1200 1240 1200 1380 1380
d Distance
hydraulic connections
mm
595 595 595 640 640 640 640 810
e
Water outlet connection position
mm
625 625 625 625 625 625 625 430
fChimney connection height
mm
792 792 1092 974 1174 1174 1424 1700
r/m Hydraulic connection DN 80 80 80 100 100 100 100 125
vSafety valve or expansion vessel
DN 2” 2” 2” 65 65 65 65 80
s Discharge
DN ¾” ¾” ¾” ¾” ¾” ¾” ¾” 1” ½
∅Chimney connection mm 250 250 250 350 350 350 350 400

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1.5.3PACK-P/AR 1250-3500
rmv
s
ef
φ
d
B1
B
H
A1
A
PACK-P/AR MODEL 1250 1600 1800 2000 2500 3000 3500
Power Input KW
Kcal/h
1.606
1381000 2.056 1768000
2.282
1963000
2.570
2210000
3.213
2762000
3.855
3315000 4.497 3867000
Power Output KW
Kcal/h 1480 1273000 1.890 1625000
2.100
1806000
2.360
2030000
2960
2545000
3550
3053000 4150 3569000
Max Working pressure
bar
6666666
Weight of empty boiler + cover Kg 2770 3300 3640 3710 5280 5760 7490
Water content litres 1372 2010 2204 2163 3155 3292 4839
Water pressure drop with∆t 15°
C
mbar 54 45 68 70 64 90 120
Pressure drop Comb. Chamber mbar 6,8 7,0 7,2 7,2 7,5 7,8 9,0
HHeight mm 1500 1800 1800 1800 2000 2000 2210
BTotal width mm
B1 Width of body only mm 3200 2666 3245 2680 3535 2970 3535 2970 3955 3320 4255 3620 4790 4024
ATotal length mm
A1 Length of body only mm 1380 1380 1610 1610 1610 1610 1610 1610 1800 1800 1800 1800 2000 2000
d Distance
hydraulic connections
mm 810 965 965 965 1070 1070 1700
e Water ou
tlet connection position
mm 430 430 430 430 510 510 522
f Chimney connection height mm 1950 1440 1730 1730 1700 2000 2200
r/m Hydraulic connection DN 125 150 150 150 200 200 200
vSafety valve or expansion vessel
DN 80 100 100 100 125 125 125
s Discharge
DN 1 ½” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½”
∅Chimney connection mm 400 450 450 450 500 500 600

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1.6IDENTIFICATION ELEMENTS
The appliance can be identified through the TECHNICAL PLATE that contains the performing values and
identification data.
The plate is applied in the front right upper part.
For any servicing and spare part the correct identification of the boiler model will facilitate all operations.
IMPORTANT: ensure that the technical plate has been applied onto the boiler: if not, ask your installation
technician to apply it.
1.7DOCUMENTS DELIVERED WITH THE BOILERS
All the boilers are delivered with a plastic envelope in which there are the following documents:
-Technical Instructions manual
-Warranty Certificate
-Stickers for Warranty claim
-Construction Certificate (Certifying that the water pressure test have been passed)
-Heating Central Booklet (Document to register the start-up of the boiler and the following periodic
combustion analysis tests)
All these documents have to follow the boiler during all the life of the product.

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1.8 STANDARD INSTRUMENT PANEL
The standard electrical control panel supplied with the boiler is made from a plastic case in which there are
the control and safety devices.
The electrical protection degree is IP 40.
The main devices are:
-General switch with working lamp
-Thermal fuse
-Working Thermostat Tmax 100°c (120°C on request)
-Safety Thermostat at manual reset Tmax 100°c (120°C on request)
-Dial manometer 0/120°C
-Predisposition for Digital Controller
The control panel is completed of EC norms terminal board for the electrical connection of the burner and
other system devices.

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1.9 STANDARD ELECTRICAL DIAGRAM

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1.10 ELECTRICAL DIAGRAM (FOR 2 STAGES BURNERS)

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2 USER
2.1START-UP OPERATIONS
The boiler first start up operation must be carried out by professionally qualified personnel. Later, it will start
automatically.
The user, for instance, may need to re-start the boiler personally after a long period of inactivity.
Therefore, ensure:
-that the fuel and thermal plant water cocks are open;
-that the hydraulic system pressure when not working is over 1 bar and lower than the boiler max allowed
limit;
-that the boiler regulation thermostat is set between 60 and 90°C;
-that the environment thermostat is “ON” and set on 20°C;
-that the plant pumps are not blocked.
Turn on the main general switch and later the main switch from the control panel.
The appliance will run an ignition cycle which will last until set temperatures have been reached.
After this operation has been completed, the system will run automatically.
In case of ignition failures or malfunctioning, turn off the appliance and contact professionally qualified
personnel.
2.2 TURNING OFF
In the event of temporary periods of inactivity (week-ends, short trips, etc.) with no danger of frost, follow the
procedure below:
-turn off the main switch on the control panel (OFF);
-turn of the plant main switch.
CAUTION: if there is danger of frost, do not carry out the above operations but:
-set the ambient thermostat on approx. 10°C.
In the event of a long period of inactivity, follow the procedure below:
-turn off the main switch on the control panel (OFF)
-turn of the plant main switch.
-close fuel and thermal plant water cocks.
CAUTION: if there is danger of frost, have the thermal plant emptied by professional qualified personnel.

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2.3CLEANING
Before cleaning operations make sure that:
-the main switch on the control panel has been turned off (OFF);
-the plant main switch has been turned off.
The only part of the boiler that needs to be cleaned by the user is the outer panelling; use a wet soapy
cloth.
If the dirt is particularly difficult to remove, soak with water and denaturated alcohol.
Do not use abrasive sponges or products and do not clean with jets of water.
2.4MAINTENANCE
Periodic maintenance and measurement of the combustion efficiency are required by law and the person in
charge of the heating system must ensure that these checks are carried out by professionally qualified
personnel.
2.5PRODUCT RECEIPT
Up to mod. PACK-P AR 1045:
-boiler body without insulation (the box of the electric board, the documentation, the mineral wool
insulation and the ceramic fibre mattress to seal the fissure of the burner blast tube, is placed into the
boiler furnace)
-n°1 cardboard box containing the casing.
The PACK-P AR 1100÷3500 boilers are delivered already insulated and cased.
The box of the electric board, the documentation and the ceramic fibre mattress to seal the fissure of the
burner blast tube, is placed into the boiler furnace.
Handle the boiler body using appropriate equipment using the lifting hooks of the boiler upper part.
Due to itsheavy weight it should not be handled manually.

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3INSTALLATION
3.1 PACKAGING AND HANDLING
The boilers are supplied complete of door.
Separately we deliver the following items:
-Kit of cover panels to be assembled in the place of installation (only for models PACK-P AR the panels
are already assembled)
(this kit is delivered inside a protection cartoon box)
-Electrical control Panel
-Mineral wool insulation for boiler body
-Ceramic fibre joint for blast tube burner
(All these items are placed inside the combustion chamber)
3.2INSTALLATION –BOILER ROOM
The boiler must be installed in a room, exclusively used for this purpose, that complies with the technical
standards and legislation in force in the place of installation regarding: minimum distances from the wall
and roof, sizes of permanent ventilation openings, electrical system, fuel supply line, etc., in relation to the
type of used fuel.
The ventilation openings must be permanent, directly communicating with outside and located in both high
and low position, complying the local standards in force.
The flat surface of the boiler must be positioned horizontally.
The flat surface should be raised from the floor.
CAUTION: if the burner is supplied with combustible gas with specific weight higher than the specific weight
of air, the electric parts must be positioned above 0.5 meters from ground level.
The boiler must not be installed outside as it has not been designed for outdoor installation and is not
provided with automatic anti-freezing systems.
To assist the cleaning of the flue gas circuit, free space must be left in front of the boiler. We advise a
minimum distance correspondent to the length of the boiler and in any case not less than 1300mm.
Regarding the distance from lateral walls:
-To check that the opening of the door at 90° will be permitted. This verify has to be done considering the
burner installed.
-To check that all the maintenance operations will be permitted
-To respect local standards or requirements.

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3.3DISCHARGE OF COMBUSTION PRODUCTS
Correct burner/boiler/flue coupling drastically reduces consumption, optimises combustion with low
emission of contaminants and provides effective protection against condensation.
The FLUE must be resistant at high temperature and condensation, thermally insulated, hermetically
sealed, without bottlenecks or obstructions, as vertical as possible and sized according to current
regulations.
The flue must ensure the minimum negative pressure specified by the standards in force, considering a
pressure “0” at the fitting to the flue.
Unsuitable or incorrectly sized flues may increase the noise produced during the combustion and/or can
create combustion problems.
The CONNECTION BETWEEN THE BOILER AND THE FLUE must comply with the current regulations
and legislation and consist of rigid hermetically sealed pipes resistant to high temperatures, condensation
and mechanical stress. For sealing the joints, use materials that can withstand at least 250°C.
Badly sized and shaped flues and couplings between boiler and flue can amplify the combustion noise,
negatively affect the combustion parameters and cause condensation problems.
CAUTION: non-insulated outlet pipes are a potential source of danger.
The following diagram it is a quick selection diagram for the height of the chimney (manufactured in stainless steel)
referred to the UNI 9615 Norm.

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3.4HYDRAULIC CONNECTION
The choice and installation of the system components is the responsibility of the installer who must
operate in accordance with correct working practice and the current legislation.
Here are some recommendations that should be taken in consideration:
-the boiler fittings and the safety valves must not be strained by the weight of the system connection
pipes: this can be dangerous for the boiler and the latter must therefore be sustained and appropriately
positioned
-Cut-off devices must not under any circumstances be fitted between the boiler and the expansion vessel
and between the boiler and the safety valves.
-The expansion vessel must be correctly sized (there must be no leaks of water due to normal expansion)
and, if the expansion vessel is closed, the safety valves must open only in exceptional cases in order to
minimise any subsequent introduction of water and in any case to ensure that it is introduced and
controlled by one single point in the system.
-Ensure that the safety valve outlets are connected to an outlet funnel. If not, when the valves cut in they
will flood the room and the manufacturer will accept no liability for this.
-Ensure that the hydraulic pipes are not used as earth connections for the electrical or telephone system.
They are not suitable for this use and can rapidly deteriorate leading to serious damage.
-Before connecting up the boiler, wash all the system pipes to remove any debris that could affect correct
operation.
-After connection to the hydraulic system, ensure that the latter is completely de-aerated.
You are advised to insulate the heating system pipes to avoid heat dispersion resulting in increased fuel
consumption and environmental pollution.
3.5WATER SUPPLY
ATTENTION: To verify that the water pressure of the heating system is not bigger than the
maximum working pressure of the boiler.
ATTENTION: If the water available for filling the system is hard (> 15/20 French degrees) or
corrosive (pH < 7.2), it is recommended a treatment plant to avoid encrustation in the boiler and
permanent damages. Similar damages are out of the warranty conditions.
Note that even encrustations (result of deposit of lime scale) of only few millimetres in thickness, due to
their low thermal conductivity, can produce a considerable overheating of the sheeting of the body of the
boiler creating expansion and deformations in various points with permanent damages for sheeting and
welding.
Softened and/or demineralised water provides protection against lime scale and other deposits.
Anyway there is another phenomenon to be considered: the corrosion on water side due to the dissolution
of iron into its ions. The presence of dissolved gases, in particular oxygen and carbonic dioxide, is the
most important factor in this process. Softened and/or demineralised water is not solution for this problem.
It is necessary that the water is treated with corrosion inhibitors.
ATTENTION: If the mains water supply contains impurities, a suitable filter must be fitted.
ATTENTION: Avoid any accidental contact between the heating system water and the sanitary
water as the former is not drinkable.

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3.6 WORKING CONDITIONS TEMPERATURE
The maximum water working temperature of the boilers PACK-P AR is 95°C (on request for the export
market max 115°C).
The temperature difference (delta T) between outlet and inlet temperature should not exceed 20°C.
This differential must be maintained during normal working and during ignition phase.
Greater temperature differentials can produce serious damages to the boiler body.
3.7THE CONDENSATE PROBLEM
The condensation of the steam contained in the discharge smokes of the boiler (condensate), appears
when the boiler temperature returning in the boiler is less than 50°C and it is important above all during the
morning start up after than the boiler has been switched off all night long.
The condensate is acid and corrosive and, with the passing of time, corrodes the plates of the boiler.
To avoid the formation of condensate as much as possible, an anti-condensate pump must be installed as
describe below.
When the burner starts, a thermostat (calibrated to 55°C) which is placed on the return water pipe makes
contact, and starts the anti-condensate pump to reach the stated temperature, and the temporally
extinguishes the anti-condensate pump and switches on the unit pump.
BOILER
T
To eliminate totally the problem, it should make perfect the above mentioned design to maintaining the
temperature of the boiler (55 °C) also by night and add a further temperature limit fuse thermostat that
operate to the unit mixer valve not forward to the boiler, water not at 55 °C.
In this way it will guarantee a long life to the boiler.
The anti-condensate pump capacity is normally the 25-30% of the plant pump capacity, while the required
lift is modest because it was to overcome only the boiler and the check valve resistance.
On the smoke chamber of the PACK-PAR boiler there is a connection for the discharge of eventual
condensate that should form in the starting phase.
Do not connect directly the attach to the network of urban sewers, but to a gathering ground to control the
extent of the phenomenon.
To survey exactly the phenomenon, check that the condensate formed in the chimney does not pour in the
gathering ground.
The condensate is acid and corrosive, therefore polluting, if it is flown into the drainage system.
Therefore it is necessary, before to drain the tank into the drainage system, to restore the acidity level into
levels between pH 6,5 and 9 using neutralizer products.

WATER STEEL BOILERS PACK-P AR MOD. PACK-P/AR
1460040EN (04-2009)
19
3.8DIAGRAM OF A STANDARD HEATING INSTALLATION
1 BOILER
2 BOILER THERMOMETER
3 BOILER THERMOSTAT
4 SAFETY THERMOSTAT
5 PIT TO INSTALL THE THERMOMETER
6 FUEL CUT-OFF VALVE WITH POSITIVE ACTION
7 CUT-OFF PRESSURE SWITCH WITH HAND RESET
8 PRESSURE INDICATOR
9 DAMPING PIPE (TO KEEP THE REGULATION OF THE PRESSURE INDICATOR IN THE TIME)
10 MANOMETER HOLDING TAP
11 SAFETY VALVE
12 BASIN TO RECEIVE THE SAFETY VALVE OUTLET WATER (IF WISHED)
13 EXPANSION VESSEL
14 AUTOMATIC FEEDER WITH NON-RETURN VALVE AND MANOMETER
15 REGULATION AUTOMATIC UNIT, BALANCED WITH THE EXTERNAL TEMPERATURE, CONSISTING OF:
15A THREE-WAY VALVE, COMPLETE WITH SERVOMOTOR: TO MIX THE HOT BOILER OUTLET WATER
WITH THE COLD INLET WATER.
15B EXTERNAL SENSOR
15C DIPPING SENSOR OR CIRCUIT DELIVERY
16 HEATING CIRCUIT ELECTRICAL PUMP (ONE WORKING + A SPARE ONE)
17 PLANT FEEDING WATER PIPE
18 HEATING CIRCUIT PIPES
19 BLOWN AIR BURNER
20 AIR PURGE UNIT, INCLUDING: AUTOMATIC VALVE AND CUT-OFF
24 PRESSURE GOVERNOR + MANOMETER
26 ANTICONDENSATION ELECTRICAL PUMP