CHAFFOTEAUX PIGMA Gal Evo Installation guide

Training manual :PIGMA Gal Evo
Training
Handbook
FAMILY: Wall-mounting gas boilers
TYPE: Conventional design
NAME: PIGMA Gal Evo PT IT RDC
TRADE MARK: CHAFFOTEAUX
Issue : 1V024.07.2012
Technical support for market

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Training manual :PIGMA Gal Evo
Up-date
l li is st t
.
1V0
24/07/12
MP
VERSION
DATE
NAME
CHANGES ENTERED

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Training manual :PIGMA Gal Evo
INDEX
1GENERAL INFORMATION..................................................................................................................................5
1.1 SIZE &DIMENSIONS........................................................................................................................ 5
SEALED CHAMBER OVERALL VIEW (FF)................................................................................................... 6
1.2 OPEN CHAMBER ASSEMBLY VIEW (CF)...................................................................................... 7
1.3 CONTROL BOARD .......................................................................................................................... 8
1.3.1 General Indications ......................................................................................................................................8
1.4 SCREEN.............................................................................................................................................. 9
1.4.1 indications on display scree..........................................................................................................................9
1.4.2 Indications of operating modes displayed on the screen ............................................................................11
2OPERATION..........................................................................................................................................................12
2.1 HEATING MODE ............................................................................................................................ 12
2.1.1 Assembly view of system in heating mode..................................................................................................14
2.2 SANITARY MODE............................................................................................................................. 15
2.2.1 Assembly view of sanitary mode .................................................................................................................17
SOLAR SENSOR SANITARY MODE .......................................................................................................... 17
3SPECIAL FUNCTIONS.........................................................................................................................................18
3.1 FLUE CLEANER”FUNCTION........................................................................................................... 18
3.2 “COMFORT”FUNCTION................................................................................................................... 20
3.3 “ANTIFREEZE”FUNCTION .............................................................................................................. 22
3.4 “WATER FLOW CHECK” ............................................................................................................... 23
3.5 AIR PURGE”FUNCTION .................................................................................................................. 26
3.6 “SELF ADAPTIVE HEATING RESTART DELAY” .......................................................................... 27
4HYDRAULIC BLOCK ..........................................................................................................................................28
4.1 RIGHT HYDRAULIC BLOCK.................................................................................................................. 29
4.2 LEFT HYDRAULIC BLOCK.................................................................................................................... 30
4.3 WAY VALVE....................................................................................................................................... 31
4.3.3-way valve motor...............................................................................................................................................31
4.4 PLATE TYPE HEAT EXCHANGER................................................................................................ 32
Temperatura limite anticalcare ................................................................................................................................32
4.5 PUMP UNIT ....................................................................................................................................... 33
4.5.1 PUMP speed check.....................................................................................................................................33
4.5.2 Post-circulation. .........................................................................................................................................34
4.6 DRAIN PORT &PLUG...................................................................................................................... 34
4.7 BY-PASS VALVE.............................................................................................................................. 35
4.8 PRIMARY HEAT EXCHANGER............................................................................................................ 35
4.9 PRESSURE PICK-UPS (FF ONLY) ................................................................................................. 35
4.10 HEATING LINE STRAINER............................................................................................................ 36
4.11 HEATING EXPANSION VESSEL................................................................................................... 37
4.12 SANITARY FLOW RATE................................................................................................................ 37
4.13 TEMPERATURE SENSORS.......................................................................................................... 39
5GAS LINE...............................................................................................................................................................40
5.1 GAS VALVE TYPE SIT SIGMA 845................................................................................................ 40
5.2 SOLENOID VALVE ELECTROPNIC CONNECTION DIAGRAM................................................... 40
5.3 GAS REGULATIONS. .................................................................................................................... 41
5.3.1 Supply pressure check.................................................................................................................................41
5.3.2 Maximum sanitary power check .................................................................................................................41
5.3.3 Minimum power check................................................................................................................................42
5.3.4 Soft ignition power checking.......................................................................................................................42
5.3.5 Clocking for heating restart aftr burner flame out .....................................................................................43
5.3.6 Control of maximum heating power............................................................................................................43
5.3.7 TABE OF GAS ............................................................................................................................................46
5.4 BURNER ........................................................................................................................................ 47
5.5 FLUE EXHAUST PORTS (SUCTION TYPE MODEL)........................................................................ 48
5.6. AIR PRESSURE SWITCH (SUCTION CAP TYPE DESIGN)...................................................................... 48
5.6 EXTRACTOR(SUCTION CAP TYPE DESIGN)....................................................................................... 49

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Training manual :PIGMA Gal Evo
5.7.1.POST-VENTILATION................................................................................................................................ 49
5.6.1 SPOTT UNIT ( MODEL CF) ......................................................................................................................50
5.7 FLUE EXHAUST /MODEL CF........................................................................................................ 50
5.8 SUCTION CUP OUTLET /SUCTION CUPS MODELS /POSSIBLE CONFIGURATIONS...................................... 51
EXHAUST SYSTEMS (SEALED CHAMBER FF)............................................................................................... 51
6ELECTRONIC PCBS ............................................................................................................................................55
MAIN CARD ................................................................................................................................................. 55
Electronic Wiring Diagram ......................................................................................................................................55
6.1.1 Diagramme électronique FF boiler ............................................................................................................56
6.1.2 Diagramme électronique CF boiler............................................................................................................58
7MENU AND SETTING..........................................................................................................................................59
7.1 USER MENU ...................................................................................................................................... 59
7.1.1 GUIDE TO NAVIGATING IN THE MENUS.............................................................................................59
7.1.2 MENUS.......................................................................................................................................................60
7.2 COMPLETE MENU ........................................................................................................................ 61
7.2.1 Menu 0 : Network .......................................................................................................................................61
7.2.2 MENU 2 : BOILER PARAMETERS............................................................................................................61
7.2.3 MENU 4 : ZONE 2 PARAMETERS ............................................................................................................63
7.2.4 MENU 5 : ZONE 2 PARAMETERS ............................................................................................................63
7.2.5 MENU 6 : ZONE 3PARAMETERS .............................................................................................................64
7.2.6 MENU 8:SERVICE PARAMETER..............................................................................................................65
8ERROR CODES.....................................................................................................................................................67
8.1 BOILER PROTECTION SYSTEMS................................................................................................ 67
8.1.1 Error codes.................................................................................................................................................67
9FIRST STARTING AT WORK............................................................................................................................69
10 PERIODICAL CHECKS..................................................................................................................................70
11 DONNEES TECHNIQUES URBIA.................................................................................................................72
11.1 PIGMA CF........................................................................................................................................ 72
11.1 PIGMA FF......................................................................................................................................... 73

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Training manual :PIGMA Gal Evo
1 GENERAL INFORMATION
1.1 SIZE & DIMENSIONS
LEGEND
A
System delivery
B
Hot water outlet
C
Gas inlet
D
Cold water inlet
E
Heating system return
PIGMA EVO
PIGMA SYTEM
EVO

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Training manual :PIGMA Gal Evo
SEALED CHAMBER OVERALL VIEW (FF)
LEGEND
1
Flue Manifold
16
Filling Tap
2
Air pressure switch
17
CH Filter
3
Air pressure switch pressure intake condensate exhaust
18
Pump
4
Main Heat Exchanger
19
Heating minimum pressure switch
6
NTC1 heating delivery temperature probe
20
NTC2 heating return temperature probe
7
Burner
21
3 Way Valve
8
Ignition electrodes
22
Detection electrode
9
Gas valve
23
Ceramic Fibers
10
Spark generator
24
Combustion Chamber
12
3 bar safety valve
25
Expansion Vessel
13
Secondary Heat Exchanger
26
Modulating Fan
14
CH draining tap
27
Combustion Analysis Test Point
15
Proportional sanitary flow meter

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Training manual :PIGMA Gal Evo
1.2 OPEN CHAMBER ASSEMBLY VIEW (CF)
LEGEND
1
Flue Manifold
14
CH draining tap
2
Flue Control Thermostat
15
Proportional sanitary flow meter
3
Flue Hood
16
Filling Tap
4
Main Heat exchanger
17
CH Filter
6
NTC1heating delivery temperature probe
18
Pump
7
Burner
19
NTC2 heating return temperature probe
8
Ignition electrodes
20
3 Way Valve
9
Gas valve
21
Detection electrode
10
Spark generator
22
Ceramic Fibers
12
3 bar safety valve
23
Combustion Chamber
13
Secondary Heat Exchanger
24
Expansion Vessel

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Training manual :PIGMA Gal Evo
1.3 CONTROL BOARD
1.3.1 General Indications
LEGEND
1 Dysplay
7 manometer
2 Start / Stop button
8 Push button for Sanitary
3 « ESC » button
9 Push button sanitary CONFORT
4 Push button for heating
10 Access to menu /validation push-button
5 Select push button for modes : summer /
winter / anti-frost l
11 Touche « Reset
1
2
4
9
6
8
7
5
3
10
11

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Training manual :PIGMA Gal Evo
6 SRA push button
1.4 SCREEN
1.4.1 indications on display scree
ICON
DESCRIPTION
Navigation
NavigationParameter
Code
Default Code
Flame and level of power
Flame error
Heating disable
Heating enable
Sanitary disable
Sanitary enable
Comfort function
Boiler OFF and Anti freeze function enable
Anti-freeze function activate
SRA activate
Solar system

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Training manual :PIGMA Gal Evo

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Training manual :PIGMA Gal Evo
1.4.2 Indications of operating modes displayed on the screen
During the working of the appliance, it’s possible to verify the status of the boiler:
ECRAN
DESCRIPTION
ETAT CHAUDIERE
Stand-By
STAND-BY. No request.
Adjustment of
heating request
Adjustment of the heating request by the button n° 4.the
number indicates the set point. They blink during 5 s
Heating mode,
burner ON and SRA
function
The radiator who symbolise the heating circuit is surrounded,
that fame is enable and there is an indication of the level
power
Heating mode,
burner OFF and
SRA function
End of the heating request, the boiler is OFF but there is a
post-circulation of 3 min (default value)
Adjustment of
sanitary request
Adjustment of the sanitary request by the button n° 8.the
number indicates the control temperature. They blink during
5 s
Sanitary tapping,
burner ON n
The tap who symbolise the sanitary circuit is surrounded,
that fame is enable and there is an indication of the level
power
Comfort mode,
burner ON
The boiler is operating an tank heating mode, the 2 numbers
indicate the control temperature for sanitary system
En puisage sanitaire
brûleur éteint.
End of the sanitary request, the boiler is OFF but there is a
post-circulation of 3 min (default value)
Anti-frost function
ON
The anti- frost function is activate, management with the
NTC1 delivery sensor.
Solar system
connected by E-Bus
Solar system is connected by E-Bus to the boiler
TEST mode
Combustion analysis
Purge mode
Air purge function

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Training manual :PIGMA Gal Evo
2 OPERATION
2.1 HEATING MODE
CONTROL
RANGE
35°C
85°C
Temperature readout can be viewed from screen 4
second long, each time heating button is
manipulated.
Pump is powered 7 seconds after the 3-way
valve, with a view at avoiding surge in system.
Request for Heating
3-Way Valve
powered
Pump powered
The request for heating can be initiated by :
- a room thermostat ,
- a room sensor,
- a programmer or
- an Expert Control
The character appears in this moment on the
screen.
The temperature read by the sensor on the
primary start can be viewed on the screen.
Sanitary mode is the rest position for the 3-way
valve.
When a heating request is active, the motor
driving the 3-way valve is energized for shifting
to heating mode.
The stem of the valve is then in « retracted »
position.
Extractor powered
Before activating the extractor, a check of
pressure switch status is carried out (contact
shall be in open position, otherwise default code
symbol 6 07 is displayed on the screen).
The extractor is power-supplied (model FF only).

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Training manual :PIGMA Gal Evo
Burner ignition
Flame detection
Ignitor and gas valve
powered
popoweredpopwerede
ntés
When pressure switch contact is set to closure, the
gas valve and the igniters are power supplied.
A permanent check of flow rate is developed with the
aid of 2 primary sensors (Forward & Return).
Flow rate Control
Gas valve is fed by the ignition power (adjustable by
parameter 2 20).
Flame detection is obtained by the ionization
electrode. In the event that the ionization sensor does
not sense any current during the ignition phase (8
seconds maximum), the boiler turns into safety state
and code symbol 5 01 is displayed on the screen.
Model FF only: a functional test of extractor is
performed by use of air pressure switch. If no signal is
detected after 20 seconds, the boiler turns to stand-by,
and code symbol 6 P1 is displayed on the screen.
Testing air pressure
switch
Flame detection enables the gas valve and the
extractor to carry out modulation of flame intensity
according to heat request.
Heating system output is adjustable by parameter 2
31 in operating ranges
Minimum output can be controlled directly by acting
on the gas valve.
Burner flame turn-off will take place at the following
T° values:
In the 1st min after flame detection:
T°off = set point T° + 8°C
In the 2nd min after flame detection
T°off = T° set point T° + 6°C
After the 3rd min after flame detection:
T°off = set point T° + 4°C
This logic of operation allows to avoid possible
occurrence of delayed ignitions and extinctions by
the burner.
Modulation of burner
flame
Overheat Control
Overheat control is provided through a thermostat
(102±4°C) located at the outlet of the primary heat
exchanger. Resetting to be effected manually from the
control panel.
Default 1 01 is shown on screen. Reset possible when
temperature reads 87°C.
Notice. Primary start sensor (NTC1) is to control that primary temperature may not exceed set value
88°C; in this occurrence, the sensor interdicts the burner to start ignition.
If flow circulation in the heating sytem is not sufficient to fulfill the purpose, an automatic by-pass valve
can open (maximum capacity = 350 l/h).

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Training manual :PIGMA Gal Evo
2.1.1 Assembly view of system in heating mode
Notice.
The primary start sensor (NTC1) checks to ensure that the primary circuit heat level
may never exceed 88°C in temperature; in this state, the sensor interdicts the burner
to start flame ignition.
When the circulation flow in the heating system is not enough to comply with the need ,
an autonatic by-pass valve can open ( maximum flow rate 350 l/h).

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Training manual :PIGMA Gal Evo
2.2 SANITARY MODE
OPERATION
RANGE
40°C
60°C
By pushing the buttons “+” o “-“,you can see on the
display (for 4 seconds) the set temperature .
HOT WATER REQUEST
FOR SANITARY
3-way valve
Heating request
ON
Heating request
OFF
Turning from
heating over to
sanitary
The 3-way valve
remains set for
sanitary
When a sanitary request is detected by the sanitary flow
meter (flow rate > 1,6 l/min), the symbol appears on
the display, together with the indication for temperature
control.
2 possibilities exist:
1. If boiler is in stand-by mode, the 3-way valve is
already set to sanitary position.
2. If boiler is in heating mode, the 3-way valve is being
fed for setting to sanitary mode.
During this change in mode, burner and pump are
both being fed.
Pump under supply
ssusupplyalimentée
The pump is under supply.
Extractor powered
Prior to imparting command signals to the extractor,
a check is made to the pressure switch (contact
must be set to open position, otherwise default code
6 07 is displayed).
Extractor remains under power supply (FF model
only).
Air pressure switch
Control
pressotat air
Checking closure of air pressure switch contact in 20
seconds, otherwise 6 P1 is displayed.
(for model FF only ).
When the pressure switch contact is closed, gas
valve and igniters are both under power supply.
Ignitor and gas valve
powered
The gas valve is supplied with ignition power input
(adjustable by parameter 2 20).
Ignition of burner
Flame detection is carried out by the ionization
electrode. In the event where for the time of the
ignition cycle (8 seconds maximum), the ionization
sensor does not detect any input power, the boiler
turns into stand-by, and code symbol 5 01 is
displayed on the screen
Burner flame
test

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Training manual :PIGMA Gal Evo
.
A permanent check of flow rate is developed with the
aid of 2 primary sensors (Start & Return).
Flow rate Control
Burner performs flow modulation from minimum
output up to maximum output (control over gas
valve).
Burner will flame out if temperature read by the
sensor for primary return NTC2
Burner Modulation
Overheat Control
Control by burner is performed over the sensor for
primary return NTC2. Burner flame goes out when
temperature reading by primary return sensor is by
4°C higher than set point value.
Temperature Control
Overheat control is provided through a thermostat
(102±4°C) located at the outlet of the primary heat
exchanger. Resetting to be effected manually from the
control panel.
Default 1 01 is shown on screen. Reset possible when
temperature reads 87°C.
If there is a bad circulation through the heating system, the
automatic by-pass can be opened (max capacity 350 l/h).

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Training manual :PIGMA Gal Evo
2.2.1 Assembly view of sanitary mode
SOLAR SENSOR SANITARY MODE
Boiler is fitted with a solar sensor.
On occasion of a sanitary water draw-off from the solar hot
water tank , the conrol of burner is accomplished in the
following manner :
the solar sensor will enable or not, the burner to operate
according to the specified sanitary temperature values
set to the Control Board (see Table on the right).
Setpoint T°for sanitary
set on Control Board
[°C]
Ignition T° read by solar
sensor
[°C]
36
36
40
39
45
43
50
47
55
50
60
54
Inlet
Eau
froid
e
Example :

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Training manual :PIGMA Gal Evo
3 SPECIAL FUNCTIONS
3.1 FLUE CLEANER” FUNCTION
This function is used to perform proper boiler combustion analysis and maximum and minimum gas
calibration.
Follow the instructions below to enable it:
PRESS
DISPLAY
The display will show this indication
Press Reset button for 5 continuous seconds
With the boiler on “Winter” mode, the 3-way valves is positioned on “heating” and the burner turns on
even without heating requested.
With the boiler on “summer” mode:
owithout sanitary demand the burner turns on in heating;
owith sanitary demand the burner turns on in sanitary.
The delivery temperature (NTC1) is checked during the “Flue cleaner” function, as follows:
“summer” mode → Off: 86°C; On: 81°C;
“winter” mode → Off: 89°C; On: 84°C.
Three different powers can be selected when the function is enabled
PRESS
DISPLAY
POWER
Turn the knob
anticlockwise
Maxi power in
heating mode
Max power in
sanitary mode
Turn the knob
anticlockwise
Minimum power

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Training manual :PIGMA Gal Evo
To exit the “Flue cleaner” function, press the RESET button. However after 30 minutes the function will be
disabled automatically.

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Training manual :PIGMA Gal Evo
3.2 “COMFORT” FUNCTION
This function allows the user either to activate or not the function « temperature holding in the sanitary water
reserve tank.
At workshop level this function remains active over a time range 24h/24h, 7days/7days. Wording
« COMFORT », is displayed at the screen bottom and it enables adapting Temperature Hold in the sanitary
reserve according to user’s needs.
To program it, comply with the directions given below :
Whit the menu 250, it’s possible to validate this function COMFORT:
0 = Disable
1 = timer
2 = Always activate
How to Program the comfort function
Workshop outgoing
configuration.
The term
« COMFORT »indicates that
temperature holding
condition is set
permanently..
Programming COMFORT
function
pressing Comfort button
allows setting this function n
L’icon « Timer » is displayed
on the screen.
Function disabling
Pressing this button for the
third time turn off completely.
The boiler is an instant
mode. The screen does not
indicate the clock symbol
any more nor working
Comfort mode