Beretta Ciao C.A.I Manuale utente

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CiaoC.A.I. - C.S.I.

Service Manual

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1 GENERAL

1.1 GENERAL INSTRUCTIONS

Make sure the supplied goods are intact and comple-

te after unpacking them and contact the boiler sales

point if there are any problems of nonconformity.

The boiler must be installed by BERETTA Servicing

Centre.

The boiler must be used for the purpose for which the

factory expressly designed it. The factory shall not be

held liable either contractually or non-contractually

for damages caused to persons, animals or objects,

caused by erroneous installation, regulation,

maintenance and improper use.

Should any water leak out, turn off the water supply

and contact BERETTA Servicing Centre.

Regularly check that the water system working

pressure is between 1 and 1.5 bar, if not, contact

BERETTA Servicing Centre.

The following operations should at least be done if the

boiler is not going to be used for a long time:

- Turn the main switch of the appliance and the general

switch of the system to “off”

- Turn off the fuel and water taps of the heating system

- Empty out the heating and sanitary systems if there is

any risk of freezing.

The boiler should be overhauled at least once a year.

1.2 BASIC RULES FOR SAFETY

We would remind you that some basic rules for safety must

be followed with products using combustible substances,

electricity and water such.

Childrenandunassisteddisabledpersonsareforbidden

to use the boiler.

It is forbidden to work with devices or electrical

appliances such as switches, domestic appliances etc.

if there is a smell of fuel or unburned fuel.

In this is the case:

- Air the room by opening doors and windows

- Switch off the fuel on/off switch

It is forbidden to touch the boiler with bare feet or if

some parts of the body are wet.

No cleaning operations must be done before

disconnecting the boiler from the main electricity

supply, turning the main system switch to “off”.

It is forbidden to modify the safety or control devices

without permission and instructions from the boiler

manufacturers.

It is forbidden to tug, pull out and twist wiring coming

out of the boiler even if the latter is disconnected from

the main electricity supply.

It is forbidden to seal up or reduce the size of vents in

the installation premises, if existing. Vents are

indispensable for correct combustion and for safety.

It is forbidden to leave inflammable containers and

substancesinthepremises wheretheboiler is installed.

It is forbidden to expose the boiler to atmospheric

agents. It has not been designed for the open air and

does not have adequate anti-freeze systems.

It is forbidden to discard or leave packing material

within the reach of children, as it could be a potential

source of danger.

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1.3 GENERAL GUARANTEECONDICTIONS

The guarantee covers all the parts making up the products. It

covers repairs and eventually replacing any of the parts that the

supplier considers as having production defects, free of charge.

A qualified authorized person should ignite the boiler the first

time and then make out a certificate, signed for acceptance by

the customer.

The guarantee shall terminate if:

- the cause of defect has nothing to do with the product itself;

- non-original components, spare parts or wear materials have

been used;

- repair and servicing work has been done by non-authorized

persons;

- environmental or installation conditions differ from those

specified in section 7 page 71.

The guarantee does not cover quick wearing materials: filters,

gaskets, dials, etc.

1.4 IDENTIFICATION OF BOILER MODEL

Boilers can be identified through the Serial number plate:

Showing technical data and working characteristics.

Badhandling,removal,missingserialnumberplates

orany other preventingreliable identification ofthe

product,complicatesanyinstallationormaintenance

operation.

Fig. 1.1

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1.5 IDENTIFICATION OF MAIN

COMPONENTS

(APPENDIX - A page 77)

INDEX

• Burner page 3

• Combustion chamber page 3

• Circulator page 3

• Igniter/control electrode page 4

• Flowmeter page 4

• Flow limiter page 4

• Water pressure switch page 4

• Safety pressure switch (C.S.I. only) page 4

• Filling tap page 5

• Bithermal exchanger page 5

• Air box (C.S.I. only) page 5

• Electronic control panel page 5

• NTC temperature control probes page 6

• Fumes thermostat (C.A.I. only) page 6

• Limit thermostat page 6

• By-pass valve page 6

• Gas valve page 6

• Safety valve page 7

• Expansion tank page 7

• Fan (C.S.I. only) page 7

• Venturi and Pitot tube page 7

1.5.1 Burner

(POS. 1 APPENDIX - A page 77)

The burner is installed underneath the combustion chamber

(Sect. 1.5.2 page 3) and serves to create the correct mixture of

air and gas for the combustion process.

Itconsists ofa series ofperforated rampsin stainlesssteel, linked

together and adequately spaced one from the other.

The gas flowing from the valve (Sect. 1.5.17 page 6) enters the

burner Venturi and mixes with primary air; the mixture then

comes out of the numerous openings made on the upper parts

of the ramps and ignites, thanks to the secondary air sucked

into the combustion chamber.

1.5.2 Combustion chamber

(POS. 2 APPENDIX - A page 77)

The combustion chamber is located at the centre of the boiler

and combustion occurs inside it.

It consists of a steel plate structure adequately folded to be

able to insert slabs of insulating material made of ceramic

fibre with normal working temperature of about 1200°C

and a melting point of about 1700°C.

1.5.3 Circulator

(POS. 3 APPENDIX - A page 77)

The circulator is installed on the return side of the boiler

water circuit and it facilitates the water circulation while

heating is on when the room thermostat signals a drop in heat.

The circulator is made of composite material with incorporated

degasser.

The current must be higher than that of the main power supply

at ignition to push the water into the central heating system;

this is why it is necessary for the condenser discharge to be

housed inside the connector box.

Water in the pump is circulated and pushed towards the

bi-thermal exchanger (Sect. 1.5.10 page 5) by the blades.

At the same time a vacuum is created inside the pump,

sucking other water from the system and triggering off the

circulation of primary fluid.

Fig. 1.2

Fig. 1.3

Fig. 1.4

Automatic air

vent bottle

Connection cover

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Ball cock

Filter

Segments

1.5.4 Igniter/control electrode

(POS. 4 APPENDIX - A page 77)

The electrodeis located near the centre rampof theburner(Sect.

1.5.1 page 3) and its job is to strike up the spark for ignition and

to control the presence of the flame.

The igniter plug consists of a metallic core and is coated on the

outside with ceramic material for electric insulation. The end

of the metal part is free from ceramic insulation and is located

at about 3 mm from the burner.

1.5.5 Flowmeter

(POS. 5 APPENDIX - A page 77)

The flowmeter is connected to the inlet on the sanitary side

of the boiler; the device is designed to control the water flow

with a ball cock consisting of a teflon spear valve, with a

magnetized sector on the upper part.

The ball cock is in stand-by position at the initial phase and the

internalcontactis open.Itrisesas thewaterflowsthrough making

thetwosegmentscometogether,theflowmetercontact thencloses

releasing electricity to the water in the boiler.

There is a filter at the cold water inlet to save the flowmeter

from passing impurities.

1.5.6 Flow limiter

The flow limiter is located at the inlet of sanitary water on the

bi-thermal exchanger (Sect. 1.5.10 page 5) and has the work

of reducing the sanitary water level to a maximum value of

101/min.

1.5.7 Water pressure switch

(POS. 6 APPENDIX - A page 77)

The water pressure switch is located on the right hand side of

the water heating unit; it is a device for controlling whether

there is a pressure or not in the primary system. Operating levels

are:

- ON system pressure > 0.45 bar;

- OFF system pressure < 0.45 bar.

1.5.8 Safety pressure switch (C.S.I only.)

(POS. 7 APPENDIX - A page 77)

The safety pressure switch is located on the upper part of

the air box (Sect. 1.5.11 page 5) and controls that the fan

(Sect. 1.5.20 page 7) and flues are working properly.

It consists of a double shell containing a silicone rubber

membrane. The membrane works a microswitch when the

difference in pressure indicated by the Venturi and the Pitot

tube (Sect. 1.5.21 page 7) falls to below the safety limit,

blocking the gas supply.

Fig. 1.5

Fig. 1.6

Fig. 1.7

Fig. 1.8

Fig. 1.9

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Compensating

outlet

Analysis

of outlets

Primary

water

flowing

Secondary

water

flowing

Turbo propeller

1.5.9 Filling tap

(POS. 8 APPENDIX - A page 77)

The filling tap is located at the sanitary inlet in the boiler and

hasthe job of connecting up the sanitarysystem withthe heating

system for filling or topping up (Sect. 7.4 page 72) .

1.5.10 Bi-thermal exchanger

(POS. 9 APPENDIX - A page 77)

The bi-thermal exchanger is located on the upper part of the

combustion chamber (Sect. 1.5.2 page 3) and is the part used

by the primary water (heating) and secondary (sanitary) water

for heating up by effect of heat generated in combustion.

It consists of a coil with two oval shaped tubes, one inside

the other, all fitted inside a commutator core which is

designed to increase the area of heat exchange. The entire

exchanger is coated with aluminium alloy to protect it from

corrosion.

The outside part of the coil is reserved for the flow of primary

fluid, flowing against the current of the secondary fluid.

The inside part is reserved for the flow of secondary water;

the coil has septum inside - turbo propeller - to increase

performance and to avoid temperature stratification.

1.5.11 Air box ( C.S.I. only)

(POS. 10 APPENDIX - A page 77)

The air box is at the centre of the boiler and serves to isolate all

components involved in the combustion process (burner,

combustion chamber, electrode, safety pressure switch,

exchanger and fan) from the domestic environment.

It is made up of four units in aluminised metal sheets with

neoprene sealing.

There is a compensation outlet connected to the gas valve

pressure regulator, at the bottom of the box. The outlet stabilizes

the membrane inside the regulator through a small tube.

The air box is designed to be able to analyse combustion

parameters without having to remove the case.

Measurements are taken through two pockets located on

the upper part, which are used to house probes for measuring

air temperature andpolluting fumes are inserted, after

removing the screw caps.

1.5.12 Electronic control panel

(POS. 11 APPENDIX - A page 77)

The electronic control panel is housed inside the control panel

and is designed to control the entire appliance.

It contains terminals for connecting up the boiler electrically

and for connecting a eventualy room thermostat (Sect. 7.3

page 71).

Fig. 1.10

Fig. 1.11 Fig. 1.13

Fig. 1.12

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1.5.13 NTC temperature control probes

(POS. 12 APPENDIX - A page 77)

NTC probes, Negative Temperature Control, are located at the

exchanger outlet (Sect. 1.5.10 page 5) on the heating side and

on the outlet ramp of the exchanger on the sanitary side

respectively; they measure the temperature of primary and

secondary water for the electronic control panel.

These are thermistors where the value of the heating element

drops as the temperature rises.

The instantaneous comparison between effective temperature of

the water and the one set by the User causes a change in the

current sent to the gas valve modulator coil (Sect. 1.5.10 page 5).

1.5.14 Fumes thermostat (C.A.I. only)

(POS. 13 APPENDIX - A page 77)

The fumes thermostat is located on the upper right hand side of

the hood; it is a device for controlling correct evacuation of

combustion products.

Combustion products will be discharged through slits on the

side of the hood if the flue should be obstructed, heating up the

thermostat so that it starts working.

1.5.15 Limit thermostat

(POS. 14 APPENDIX - A page 77)

The limit thermostat is on the heating side of the exchanger

(Sect. 1.5.10 page 5) and serves to prevent the boiler from

boiling.

It is an automatically set contact device, which will interrupt

the flame detection electrical circuit, should it work at a

temperature of about 110°C.

1.5.16 By-pass valve

The automatic by-pass is installed inside the duct

connecting the system’s delivery to CH return. Its job is to

guarantee primary water re-circulation in the boiler in

systems with high load loss.

The spring inside the by-pass valve is gauged to 530 gr. This

should be replaced with another one with increased capacity

if a high-headed circulator is used.

1.5.17 Gas valve

(POS. 15 APPENDIX - A page 77)

The gas valve is located under the combustion chamber (Sect.

1.5.2 page 3) and is the part designed to supervise burner

ignition, regulation and control operations.

The valve is made up of an aluminium pressofusion with two

solenoid valves, mechanically in series but parallel electrically.

The modulator is an integral part of the gas valve; the operator

modulates by changing the current to the coil to let the right

quantity of gas to flow to the burner. These configuration ensure

Fig. 1.14

Fig. 1.15

Fig. 1.16

Fig. 1.17

Heating

sensor

Sanitary

sensor

0 20 40 60 80 100

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

22000

24000

26000

28000

30000

32000

34000

RESISTANCE (ohm)

NOMINAL RESISTANCE

MINIMUM RESISTANCE

MAXIMUM RESISTANCE

TEMPERATURE (°C)

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Solenoid valves

Modulator

that gas flowing to the burner is stopped very quickly under

any faulty condition.

The modulator is an integral part of the gas valve; the operator

modulates by changing the current to the coil to let the right

quantity of gas to flow to the burner (Sect. 1.5.1 page 3).

1.5.18 Safety valve

(POS. 16 APPENDIX - A page 77)

The safety valve is located underneath the circulator (Sect. 1.5.3

page 3) and has the job of protecting water circulation from

eventual over pressure caused, for example, by an increase in

the volume of primary fluid due to heating effect. The valve is

gauged to an operating pressure of 3 bar.

1.5.19 Expansion tank (POS. 17 APPENDIX - A page 77)

The expansion tank is located between the two uprights of the

framework and has the job of compensating the increased

volume of primary fluid from heating effect, thanks to the work

done by a rubber membrane loaded with nitrogen beforehand

at 1 bar.

It has been scaled to meet with all engineering solutions

normally used in domestic central heating units. The current

production expansion tank has a capacity of 8 l. and is adequate

for a system containing about 100 l. It may eventually be

integrated with an auxiliary if it should prove to be insufficient.

1.5.20 Fan (C.S.I. only)

(POS. 18 APPENDIX - A page 77)

The fan is located above the combustion chamber (Sect. 1.5.2

page 3) and serves to expel combustion products from the air

box (Sect. 1.5.11 page 5).

Specifically designed for this kind of application, it has the

characteristic of being absolutely silent with top performance.

1.5.21 Venturi and Pitot tube (C.S.I. only)

(POS. 19 APPENDIX - A page 77)

TheVenturi andPitottube areinstalledon the fanscrewconveyor

(Sect. 1.5.20 page 7) and continuouslycorrect scavenging of

products of combustion.

The first device has the job of signalling static pressure value

as combusted gas flows through, while the second measures

thetotal pressure.The differenceinpressure workson thesafety

pressure switch membrane (Sect. 1.5.8 page 4), through two

small tubes, switching on the microswitch.

Fig. 1.19

Fig. 1.20

Fig. 1.21

Fig. 1.22

Fig. 1.18

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DHW

OUT IN

1.6 DESCRIPTION OF OPERATING

PRINCIPLES

1.6.1 Hydraulic operating principle in DHW

(Fig. 1.23)

When service water taking cock (1) is opened, system water

flows back to DHW input (2), through capacity regulator (3)

and the flow-meter (4). Water getting through the flow-meter,

exceeding a 2,5 l/min capacity, pushes float, located inside it,

upward. This movement allows closing the electric contact,

located in a device out of the flow-meter. By a connection ramp

(5), water flows from flow-meter to flow limiting device (6)

and then into bi-thermal exchanger (7).

1.6.2 Electric operating principle in DHW

(see APPENDIX - E pages 81, 82)

In order to get hot water ready only, in summer, set function

selector on « » DHW symbol. When hot water cock is

opened and capacity exceeds 2,5 l/min, the flow-meter,

measuring water flowing through the circuit, check pressure

switch closing by electric enabling; the pressure switch starts

ignition sequence:

- C.A.I. version:

When activated, water pressure switch enables ignition; gas

valve operating devices are fed.

- C.S.I. version:

When activated, water pressure switch feeds the fan, while

gas valve operating devices are fed.

Under temperature request condition, the burner switches on

and gas solenoid valve proportionally opens shutter to allow

slow burner ignition- automaticallyadjusted bymicroprocessor

- then maximum power is reached until temperature set on

selector is obtained.

According to taking capacity, burner flame automatically fits

hot water requests.

Both temperature selector and sensor provide for a resistance

value to board integrated component, which, at the beginning

(cold) controls burner maximum operation, until temperature

read on secondary by NTC sensor, compared by main board

integrated component, with resistance set on DHW temperature

selector, approaches temperature set: then minimum level is

reached in modulation phase.

The burner switches off 5°C after temperature set and switches

on 1°C below.

Finally, when DHW cock is opened, the operating sequence is

the following:

C.A.I. version

Flow-meter

Water pressure switch check

Burner

C.S.I. version

Flow-meter

Water pressure switch check

Quiescent safety pressure switch

Fan

Safety pressure switch enabled

Burner

1.6.3 DHW temperature adjustment

To adjust DHW temperature (bathrooms, shower, kitchen, etc.)

to adjust CH temperature, remove function selector and act on

right potentiometer (Fig. 1.24).

Fig. 1.23

Fig. 1.24

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