IVAR SUPERAC 93 User manual

I.VAR INDUSTRY S.r.l.
Via S. Pierino, 4 (Z.A.I.) -37060 Trevenzuolo–VERONA -Italy
Telefono 045/6680082-Telefax 045/6680051-P.IVA 02835480233
e-mail: [email protected]–Web site: www.ivarindustry.it
code: ist-Superac-ing rev.01
INSTRUCTIONS
BOOKLET
For installation, use and maintenance
HOT WATER BOILERS
SUPERAC

Dear Customer,
Thank you for choosing a boiler by IVAR INDUSTRY.
In your interest and to maintain the highest level of performance and duration
of your appliance, we recommend that you follow the instructions contained
in this booklet and have regular maintenance performed by qualified
personnel.
We would like to remind you that failure to follow the instructions contained
in this booklet may invalidate the guarantee
0085
IMPORTANT
It is possible to install on these boilers, even other
burners that are not included in the enclosed lists,
provided that the required values of furnace
thermal output and counterpressure are respected.

CONTENTS
GENERAL INSTRUCTIONS
General warnins…………….………………………………………….page 4
Basic safety rules……….....…................…........................................page 5
Boiler description ...............…….......…..…................................... page 6
Technical specifications..………………….…………………………...page 8
Identification elements...............................……………..........….….. page 9
pare part list…………………………………..………………………..page 9
USER
Start up……………………...........................................………........ page 10
Turning off...........................................................................………. page 11
Cleaning............................................................................……….... page 11
Maintenance.......................................................................………... page 11
INSTALLATION TECHNICIAN
Product receipt…............................................................…….......... page 12
Dimensions...........................................................................…….....page 13
Installation.........................................................................……........page 15
Installation premises……………………..…………………………....page 15
Discharge of combustion products....................................……..........page 15
Hydraulic connection..............................................................……....page 16
Electrical system...............................................................……..….. page 17
The condensate problem…………………………………..…………..page 17
Fuel supply…………….......................................…................……...page 19
Burner connection..........................................………........…….........page 19
Cover assembling (only SUPERAC 93 ÷ 1045)..………………….….page 20
Control panel assembly…........................................................……...page 22
ASSISTANCE AND MAINTENANCE
Preliminary operations prior to first start up……….…………….…page 23
First start up............................................................................……...page 24
First start up and further checks……….............…....................….....page 24
Maintenance........................................................…...............……....page 25
Door opening and adjustment…..............................................….......page 26
Boiler cleaning………………………..……………..………………page 26
Checks after boiler cleaning…............................................…...........page 27
Troubleshooting……..............................................................….......page 27

GENERAL WARNINGS
This instruction booklet is an integral and essential part of the product.
Should the appliance be sold or transferred to another owner, or if you move
and leave the appliance behind, always ensure that this booklet accompanies
the appliance so that the new owner and/or installation technician can consult
it.
This appliance must be used for the purpose for which it was specifically
intended.
All contractual or non-contractual responsibility of the manufacturer is
excluded in the event of damages to persons, animals 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 having removed the packaging, check the contents for breakages. If you
are in doubt do not use the appliance, contact your supplier.
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.
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
use and domestic hot water production.
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.
Any repairs to the appliance must be carried out using only original spare
parts.
If you decide 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.
FAULT: smell of gas and/or unburnt products.
REMEDY:
-check the seal of the fuel supply system (if gas fuel);
-check the hermetic seal of the smoke circuit (door, smoke box, boiler/flue
connection);
FAULT: the boiler reaches the appropriate temperature but the heating
system is cold.
REMEDY:
-check that no air is in the system and that circulaiton pumps are working
well;
-check the ambience thermostat setting.
FAULT: the safety valve of the boiler intervenes often.
REMEDY:
-check the system loading pressure;
-check the efficiency of the expansion vessel;
-check the calibration of the valve itself.
FAULT: water on the floor near the smoke box (condensate).
REMEDY:
-check that the probes have been positioned correctly, the boiler
thermostat has been regulated correctly (between 60 and 90°C) and
works well.
-verify that the discharge in the fumes box is connected with a gathering
ground;
-verify that the anticondensate pump and its regulation (if it is present)
correctly work;
-check that the temperature of the return water of the plant are not less than
50°C.
FAULT: membranes overheating due to lack of water in the boiler.
REMEDY:
Turn off the burner, do not pour water and do not open the door; wait until
the ambience temperature is restored before performing any operation.

FAULT: the burner turns on well but turns off immediately after.
REMEDY:
-check the pilot flame, the air calibration and that the burner appliance
works correctly.
FAULT: the burner is difficult to be adjusted and/or no output.
REMEDY:
-check for the cleannes of burner, boiler, boiler/flue pipes and flue;
-check the hermetic seal of the smoke circuit (door, smoke box, boiler/flue
connection);
-check that the fuel supply is flowing regularly and verify the effective
power of the burner;
-check for the presence of scale and carry out a chemical washing
FAULT: the boiler gets easily covered with soot.
REMEDY:
-check the buener regulation (smoke analysis);
-check the fuel quality;
-check the flue for clogging and the cleannes of the burner air intake (dust).
FAULT: the boiler does not reach set temperature.
REMEDY:
-check that the smoke side and water side of the boiler are clean;
-check the combination, regulation and performance of the burner;
-check the regulation of the pressure switches and that they work
correctly;
-check the position of the thermostat gauges;
-ensure that the boiler capacity is appropriate for the plant.
FAULT: the safety thermostat intervenes.
REMEDY:
-check electric wires;
-check that the gauges bulbs are positioned correctly and all thermostats are
working correctly.
GENERAL SAFETY 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.

DESCRIPTION OF THE APPLIANCE
The steel boiler from the SUPERAC range is a high performance generator for
heating systems up to 90°C. When combined with a hot water tank, this
generator can be used also for the production of domestic hot water.
This is a en-bloc pressurized combustion flame-inversion boiler. The flame
produced by the burner develops into the furnace and as it is closed on the
bottom, the fluegas returns to the anterior part, and through the cavity
obtained in the front door insulation it enters into the tube system.
Here the flugas 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 fluegas 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
maintenace 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.
CHECKS AFTER BOILER CLEANING OPERATIONS
After performing maintenance and cleaning operations, repeat the preliminary
start up inspection (see page 23), check the burner calibration and perform a
smoke analysis to ensure that the correct degree has been reached.
Check the seal of the fuel supply system. This inspection is absolutely
necessary when gaseous fuels are used.
Check the perfect seal of the smoke circuit and, if needed, replace worn seals.
Check the seal of the pipe system to avoid time-wasting water changes and
refilling which could also increase the risk of scaling.
Should the boiler inside walls be scaled, a chemical washing is needed to
remove scale. This operation must be performed by qualified companies.
The specification of the plant water should be examined and, if needed, a
treatmen system should be installed.
Never leave highly inflammable substance containers in the premises where the
boiler has been installed.
TROUBLESHOOTING
Below is the description of the most common faults and their remedy:
FAULT: the burner does not turn on.
REMEDY:
-check electric connections;
-check the regular fuel supply;
-check the integrity and the cleanness of the fuel supply system and that
no air is present;
-check that ignition sparks form regularly and the burner appliance works
correctly;
-check the boiler safety thermostat intervention with manual reset;
-check the calibration of the environment thermostat.
27

OPENING AND ADJUSTMENT OF THE DOOR
The door can be opened from both sides (except for models 2910÷4070).
The opening is normally from left to right.
To open the door, remove the fixing nuts from the left side.
To change the direction of opening of the front door with help of lifting
equipment, work as follow:
-hood the front door to the lifting equipment through the foreseen 2 holes
that are in the superior part;
-take away the 4 tightening nuts;
-unthread the front door;
-unscrew the 2 jam nuts left on the tie rods and screw them on the tie rods
on the other side;
-remount the big door having care of threading the jam nuts seat in the
front door bushes;
-screw the 4 fixing nuts.
To adjust and tighten:
-release the regulation jam nuts without let them go out from the bush seat of
the door;
-tighten the locking screw only as far as required to censure a uniform airtight
closure.
-lock the regulation jam nuts against the door bush.
Normally, at all maintenance operations the door adjustment should be
inspected.
CLEANING THE BOILER
The boiler should be cleaned at least once a year to remove carbon deposits
from the heat transfer surfaces
Open the door, open the cleaning door and take the turbolators out.
Clean the smoke tubes using a steel brush and remove the soot from the
fornace and the rear cleaning door.
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
7

MODEL
SUPERAC 93 105 150 190 230 290
345
405
Rated output 93 104.
7151. 2192 233 291
349
407 kW
Furnace thermal output 103 115.
5167 211 257 320
384
449 kW
Furnace counterpressure 0.5 0.7 1.2 1.2 1.5 2.3 3.3 4.4 mbar
Water side loading loss (∆t
15°C)4.5 5.6 11.8
6.9 10 16.3
23 31 mbar
Boiler water content 119 119 155 228 228 285
276
329 dm3
Max boiler working pressure 55566666bar
Min boiler return temperature
allowed 50 50 50 50 50 50 50 50 °C
Max boiler temperature
allowed 100 100 100 100 100 100
100
100 °C
Weight in empty conditions 270 280 340 450 460 590
630
700 kg
MODEL
SUPERAC 465 520 580 695 810 930 1045
Rated output 465 523 581 700 820 940 1060 kW
Furnace thermal output 511 577 637 771 899 1027 1156 kW
Furnace counterpressure 3.3 4.3 4.8 4.5 5.6 5.4 6mbar
Water side loading loss (∆t
15°C) 18 22 28 18 25 33 40 mbar
Boiler water content 402 402 476 697 795 733 817 dm3
Max boiler working pressure 6666666bar
Min boiler return temperature
allowed 50 50 50 50 50 50 50 °C
Max boiler temperature
allowed 100 100 100 100 100 100 100 °C
Weight in empty conditions 900 910 1000
1270 1400 1500 1650 kg
MODEL
SUPERAC 1220
1450
1860
2330 2910 3490 4070
Rated output 1240
1480
1890
2360 2960 3550 4150 kW
Furnace thermal output 1349
1606
2056
2570 3213 3855 4497 kW
Furnace counterpressure 6.5 6.8 77.2 7.5 7.8 9mbar
Water side loading loss (∆t
15°C) 36 54 45 70 64 90 120 mbar
Boiler water content 1277
1372
2010
2163 3155 3292 4839 dm3
Max boiler working pressure 6666666bar
Min boiler return temperature
allowed 50 50 50 50 50 50 50 °C
Max boiler temperature
allowed 100 100 100 100 100 100 100 °C

Weight in empty conditions 2100
2350
3450
3850 5200 5800 8000 kg