CHAFFOTEAUX PIGMA Gal Evo Training Handbook
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CHAFFOTEAUX PIGMA Gal Evo Training Handbook

Pigma gal evo pt it rdc
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Training manual :PIGMA Gal Evo
Technical support for market
Training
Handbook
Wall-mounting gas boilers
FAMILY:
Conventional design
TYPE:
PIGMA Gal Evo PT IT RDC
NAME:
CHAFFOTEAUX
TRADE MARK:
Issue : 1V0 24.07.2012

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  • Page 1 Training manual :PIGMA Gal Evo Technical support for market Training Handbook Wall-mounting gas boilers FAMILY: Conventional design TYPE: PIGMA Gal Evo PT IT RDC NAME: CHAFFOTEAUX TRADE MARK: Issue : 1V0 24.07.2012...
  • Page 2 Training manual :PIGMA Gal Evo Up-date 24/07/12 VERSION DATE NAME CHANGES ENTERED Page. 2 of 73...

  • Page 3: Table Of Contents

    Training manual :PIGMA Gal Evo INDEX GENERAL INFORMATION ..........................5 & DIMENSIONS ........................5 SIZE SEALED CHAMBER OVERALL VIEW (FF) ....................6 OPEN CHAMBER ASSEMBLY VIEW (CF) ..................7 CONTROL BOARD .......................... 8 1.3.1 General Indications ............................8 .............................. 9 SCREEN 1.4.1...
  • Page 4 Training manual :PIGMA Gal Evo 5.7.1.P ..........................49 VENTILATION 5.6.1 SPOTT UNIT ( MODEL CF) ........................50 FLUE E / MODEL CF ......................50 XHAU 5.8 S CONFIGURATIONS ........51 UCTION CUP OUTLET SUCTION CUPS MODELS POSSIBLE EXHAUST SYSTEMS ( FF) ....................

  • Page 5: General Information

    Training manual :PIGMA Gal Evo 1 GENERAL INFORMATION SIZE & DIMENSIONS PIGMA EVO PIGMA SYTEM LEGEND System delivery Hot water outlet Gas inlet Cold water inlet Heating system return Page. 5 of 73...

  • Page 6: Sealed Chamber Overall View (Ff)

    Training manual :PIGMA Gal Evo SEALED CHAMBER OVERALL VIEW (FF) LEGEND Flue Manifold Filling Tap Air pressure switch CH Filter Air pressure switch pressure intake condensate exhaust Pump Main Heat Exchanger Heating minimum pressure switch NTC1 heating delivery temperature probe...

  • Page 7: Open Chamber Assembly View (Cf)

    Training manual :PIGMA Gal Evo OPEN CHAMBER ASSEMBLY VIEW (CF) LEGEND Flue Manifold CH draining tap Flue Control Thermostat Proportional sanitary flow meter Flue Hood Filling Tap Main Heat exchanger CH Filter NTC1heating delivery temperature probe Pump Burner NTC2 heating return temperature probe...

  • Page 8: Control Board

    Training manual :PIGMA Gal Evo CONTROL BOARD 1.3.1 General Indications LEGEND Dysplay manometer Start / Stop button Push button for Sanitary « ESC » button Push button sanitary CONFORT Push button for heating Access to menu /validation push-button Select push button for modes : summer / Touche «...

  • Page 9: Screen

    Training manual :PIGMA Gal Evo SRA push button 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...
  • Page 10 Training manual :PIGMA Gal Evo Page. 10 of 73...

  • Page 11: Indications Of Operating Modes Displayed On The Screen

    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 Adjustment of the heating request by the button n° 4.the heating request number indicates the set point.

  • Page 12: Operation

    Training manual :PIGMA Gal Evo 2 OPERATION HEATING MODE 35°C 85°C CONTROL Temperature readout can be viewed from screen 4 RANGE second long, each time heating button manipulated. The request for heating can be initiated by : - a room thermostat ,...
  • Page 13 Training manual :PIGMA Gal Evo Model FF only: a functional test of extractor is performed by use of air pressure switch. If no signal is Testing air pressure detected after 20 seconds, the boiler turns to stand-by, switch and code symbol 6 P1 is displayed on the screen.

  • Page 14: Assembly View Of System In Heating Mode

    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.

  • Page 15: Sanitary Mode

    Training manual :PIGMA Gal Evo SANITARY MODE 40°C 60°C OPERATION By pushing the buttons “+” o “-“,you can see on the RANGE display (for 4 seconds) the set temperature HOT WATER REQUEST When a sanitary request is detected by the sanitary flow meter (flow rate >...

  • Page 16: Temperature Control

    Training manual :PIGMA Gal Evo A permanent check of flow rate is developed with the Flow rate Control aid of 2 primary sensors (Start & Return). Burner performs flow modulation from minimum output up to maximum output (control over gas Burner Modulation valve).

  • Page 17: Assembly View Of Sanitary Mode

    Training manual :PIGMA Gal Evo 2.2.1 Assembly view of sanitary mode Inlet froid SOLAR SENSOR SANITARY MODE Setpoint T°for sanitary Ignition T° read by solar Boiler is fitted with a solar sensor. set on Control Board sensor [°C] [°C] On occasion of a sanitary water draw-off from the solar hot...

  • Page 18: Special Functions

    Training manual :PIGMA Gal Evo 3 SPECIAL FUNCTIONS 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 ...
  • Page 19 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. Page. 19 of 73...

  • Page 20: Comfort" Function

    Training manual :PIGMA Gal Evo “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 «...
  • Page 21 Training manual :PIGMA Gal Evo The operating range is variable and depends on the temperature set for the sanitary mode: TEMP. SET FOR SANITARY MODE OFF TEMPERATURE ON TEMPERATURE Page. 21 of 73...

  • Page 22: Antifreeze" Function

    Training manual :PIGMA Gal Evo “ANTIFREEZE” FUNCTION This function is enabled only if the ON/OFF selector is turned on position ON. It is operated by means of the temperature detected by the heating delivery probe (NTC1). CONDITION EVENTS TIME - The PUMP is supplied on speed III...

  • Page 23: Water Flow Check

    Training manual :PIGMA Gal Evo “WATER FLOW CHECK” What happens Check When 1. Immediate safety shutdown - 10sec of post-circulation Check always with the - 10 sec of post-ventilation Gradient Tman > 7°C/sec flame on, except during The boiler restarts after 10sec.
  • Page 24 Training manual :PIGMA Gal Evo Evolvement of start T° > 7°C/sec >7°C/sec Evolvement <7°C/sec 10 sec 10 sec 10 sec Extractor 20 sec (post-vent.) Pump 60 sec (post-circ.) Burner 255 sec Times 1 P1 1 P1 1 03 Evolvement of start T° or return T°...
  • Page 25 Training manual :PIGMA Gal Evo Start T° or Return T° > 55°C Check also 7 seconds after each burner shut down >55°C StartT°-RetT° <55°C 10 sec 10 sec 10 sec Extractor 20 sec (post-vent.) Pump 60 sec (post-circ.) Burner 255 sec...

  • Page 26: Air Purge" Function

    Training manual :PIGMA Gal Evo Return T° > Start T° + 30°C >startT°+30°C RetT° <ReturnT°+30°C Extractor 20 sec (post-vent.) Pump 60 sec (post-circ.) Burner 1 07 AIR PURGE” FUNCTION This function can be activated by the installer by the parameter...

  • Page 27: Self Adaptive Heating Restart Delay

    Training manual :PIGMA Gal Evo “SELF ADAPTIVE HEATING RESTART DELAY” With the parameter 2 35 it is possible chose the heating restart delay type:  0: manual;  1: automatic. MANUAL: with the parameter 2 36 it is possible set the heating restart delay between 0 and 7 min.

  • Page 28: Hydraulic Block

    Training manual :PIGMA Gal Evo 4 HYDRAULIC BLOCK LEGEND Expansion vessel Retuyrn heating sensor Delivery heating sensor Primary heat exchanger Sanitary plate heat exchanger No back-flow valve 3 bar safety valve and by-pass Filling tap 3 way valve Deareator Sanitary flow meter...

  • Page 29: Right Hydraulic Block

    Training manual :PIGMA Gal Evo RIGHT HYDRAULIC BLOCK Composite block with integrated functions : CH and DHW filter Electrical diverter valve All components fitted by clips Pump unit with deareator valve and Heating pressure switch Brass connectors for installation Primary filling system...

  • Page 30: Left Hydraulic Block

    Training manual :PIGMA Gal Evo LEFT HYDRAULIC BLOCK By Composite module for CH and domestic hot water outlet. Components integrated in the block : CH safety valve 3bar Automatic by-pass Brass connections All copper pipes connected by clips LEGEND 1. 3 bar safety valve and by-pass 3.

  • Page 31: Way Valve

    Training manual :PIGMA Gal Evo WAY VALVE Boiler is fitted with a 3-way valve, 230 volts motor-driven, installed on the return line. When no operating, it is set to sanitary mode. PARTS DESIGNATION 1. 3-way valve motor 2. Motor hanging clip 3.

  • Page 32: Plate Type Heat Exchanger

    Training manual :PIGMA Gal Evo PLATE TYPE HEAT EXCHANGER The sanitary plate type heat exchanger is secured to the hydraulic assemblies, right side and left side, by 2 screws, that are accessible from the front side. Plates made from stainless steel are deep-drawn fabricated parts and welded one to the others. Tightness is ensured by 4 seal lip joints.

  • Page 33: Pump Unit

    Training manual :PIGMA Gal Evo PUMP UNIT Pump type:  Wilo INMTSL 15/5 HE-2: ( 24 28 kW);  Wilo INTMTSL 15/6.7 HE-2: ( 32 kW). The P.C.B. controls modulation of the circulation pump at two different speeds V2 (55w) and V3 (80w).

  • Page 34: Post-Circulation

    Training manual :PIGMA Gal Evo 4.5.2 Post-circulation. 3 way valve Post-circulation after: Time of post circulation Speed pump position Switching off due to: 3 min Room thermostat opening Heating (set by parameter 237 beetwen 0 e 15’) 3 min Heating Off by Summer/Winter...

  • Page 35: By-Pass Valve

    Training manual :PIGMA Gal Evo BY-PASS VALVE The boiler is equipped with an automartic by-pass valve allowing protection from the occurrence of a poor flow rate from the system, which may be originated for instance from some closures of the thermostatic cocks.

  • Page 36: Heating Lin Estrainer

    Training manual :PIGMA Gal Evo 4.10 HEATING LINE STRAINER A heating filter is placed in the hydraulic assembly, on the right (see picture below) on the return line from the heating flow circuit. strainer mesh measures 1,5 mm in cross-section.

  • Page 37: Heating Expansion Vessel

    Training manual :PIGMA Gal Evo 4.11 HEATING EXPANSION VESSEL Expansion vessel consists of two distinct parts assembled, made from metal sheet 1,8 mm thick. Inside, the tank is separated through a SBR rubber membrane (see, pictures shown below). The expansion vessel is located in the frame behind the boilere. Inflating pressure is 1 bar. Maximum capacity of the system is about 175 litres.
  • Page 38 Training manual :PIGMA Gal Evo DESIGNATION 1. Sanitary Flow Rate 2. Hold Clip for flkow meter inside the hydrauylic assembly Flow rate limiter Flow meter casing Turbine Plug with sanitary filtre incorpoorated Disassembly and re-assembly of sanitary flow meter are made...

  • Page 39: Temperature Sensors

    Training manual :PIGMA Gal Evo 4.13 TEMPERATURE SENSORS To check the delivery and return temperature use the two contact sensor. To read the sanitary water temperature the NTC1 heating delivery is used. IMPORTANT!!!! Do not use conducting paste for the contact sensors because they alter the resistance value.

  • Page 40: Gas Line

    Training manual :PIGMA Gal Evo 5 GAS LINE GAS VALVE TYPE SIT SIGMA 845 The gas valve installed in the boiler is type SIT 845 SIGMA embodying 2 solenoid safety valves supplied from a 230 Vac source and a pressure modulation valve, 24 Vdc, for control of flow to the burner.

  • Page 41: Gas Regulations

    Training manual :PIGMA Gal Evo GAS REGULATIONS. 5.3.1 Supply pressure check. Fig. A Loosen screw “1” (fig. A) and insert the pressure gauge fitting pipe in the pressure intake. Put the boiler on maximum operating power (hot water tap open). The supply pressure must correspond with the one foreseen for the type of gas for which the boiler has been prearranged (refer to table below).

  • Page 42: Minimum Power Check

    Training manual :PIGMA Gal Evo 5.3.3 Minimum power check. To check the minimum power loosen screw “2” (fig.B) and insert the pressure gauge fitting pipe in the pressure intake. Disconnect the compensation pipe of the air chamber (fig.B). Have the boiler work on minimum power and disconnect a cable from the modulator (fig.D).

  • Page 43: Clocking For Heating Restart Aftr Burner Flame Out

    Training manual :PIGMA Gal Evo 5.3.5 Clocking for heating restart aftr burner flame out Control measure acted by parameter 2 36  It is possible to set up a clocking between 0 and 7 min in the time interval between burner shut off and the following re-ignition .
  • Page 44 Training manual :PIGMA Gal Evo PIGMA 28 CF Pressure Pressure Pressure Pressure Setting Setting Setting Setting POWER kW mbar mbar mbar mbar 11,2 13,0 34,0 48,0 10,1 56,0 14,0 37,0 51,0 11,7 59,0 15,0 39,0 54,0 13,5 63,0 16,0 41,0...
  • Page 45 Training manual :PIGMA Gal Evo PIGMA 30 FF Pressure Pressure Pressure Pressure Setting Setting Setting Setting POWER kW mbar mbar mbar mbar 11,6 13,0 34,0 48,0 51,0 14,0 36,0 51,0 54,0 15,0 38,0 53,0 10,4 58,0 16,0 41,0 57,0 11,8...

  • Page 46: Tabe Of Gas

    Training manual :PIGMA Gal Evo 5.3.7 TABE OF GAS 25 CF 30 CF Lower Wobbe index (15°C 1013 mbar) 45,7 80,6 70,7 45,7 80,6 70,7 (Mj/m Nominal pressure gas mbar 28/30 28/30 Maximal pressure sanitary mbar 27,8 35,6 12,4 27,5...

  • Page 47: Burner

    Training manual :PIGMA Gal Evo BURNER Technology used : Multiple gas burner model POLIDORO, installed in rack frame in the combustiin chamber. The burner assembly is equipped with : one multiple-gas type burner one a storage tank fitted with own injectors secured by screws...

  • Page 48: Flue Exhaust Ports (Suction Type Model)

    Training manual :PIGMA Gal Evo FLUE EXHAUST PORTS (SUCTION TYPE MODEL) On the boiler top there is installewd an outlet socket (60/100) for connection with suction type exhaust pipes . Two pressure ports allow measuring quality of combustion during the COMBUSTION ANLYSIS mode as well as 2 pressure taps are provided for pressure switch tests.

  • Page 49: Extractor (Suction Cap Type Design)

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO Pressure Pressure FAN ON FAN OFF tap(+) tap (-) Connector CN 22 Connector CN 22 (brackets 11 and 12) of (brackets 11 and 12) of electronic PCB electronic PCB EXTRACTOR (SUCTION CAP TYPE DESIGN)

  • Page 50: Spott Unit ( Model Cf)

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 5.6.1 SPOTT UNIT ( MODEL CF) The SPOTT unit is to control the flue stack for a good thermal draught. This valve is located in the anti- backflow device. This is a sort of thermal contact that opens when temperature is 75±3°C Its opening causes the burner to flame out, and it brings the boiler to stop;...

  • Page 51: Suction Cup Outlet / Suction Cups Models / Possible Configurations

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 5.8 SUCTION CUP OUTLET / SUCTION CUPS MODELS / POSSIBLE CONFIGURATIONS EXHAUST SYSTEMS (SEALED CHAMBER FF) The boiler is arranged for both coaxial smoke exhaust 60/100mm and for the split 80/80mm (two ways to connect the intake pipes).
  • Page 52 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Pag. 52 de 73...
  • Page 53 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Length (L) TYPE OF DIAPHRAME EXHAUST [mm] from [m] to [m]  0,75 Ø44 60/100 C12,C32,C42, COAXIAL  SYSTEMS 0,75  0,75 Ø44 80/125 C12,C32,C42, COAXIAL  SYSTEMS  0,5 / 0,5 9 / 9 Ø44...
  • Page 54 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Length (L) TYPE OF DIAPHRAME EXHAUST [mm] from [m] to [m]  0,75 Ø46 60/100 C12,C32,C42, COAXIAL  SYSTEMS 0,75  Ø46 80/125 C12,C32,C42, COAXIAL  SYSTEMS  0,5 / 0,5 9 / 9 Ø46...

  • Page 55: Electronic Pcbs

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 6 ELECTRONIC PCBs MAIN CARD The boiler uses a GAL2EVO ATM electronic card for complete checking of the boiler and one users interfaces display LCD; The GAL2EVO ATM electronic card is protected by two 2A, 250 VAC fuses and a VDR protects the card against supply voltage peaks up to 275VAC.

  • Page 56: Diagramme Électronique Ff Boiler

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 6.1.1 Diagramme électronique FF boiler Pag. 56 de 73...
  • Page 57 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Pag. 57 de 73...

  • Page 58: Diagramme Électronique Cf Boiler

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 6.1.2 Diagramme électronique CF boiler Pag. 58 de 73...

  • Page 59: Menu And Setting

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 7 Menu and setting USER MENU To adjust and control the different existing parameters, 8 distinct menus are assigned to the boiler. N° de Pour Pour le Contenu l’utilisateur menu technicien Réseau E-Bus connecté...

  • Page 60: Menus

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 7.1.2 MENUS Access Code MENU Complete menu 0 Bus 02 Bus Network 04 Display Boiler 2 Boiler Parameter 20 DHW Set point temperature 22 General set point boiler 23 Central Heating Zone 1...

  • Page 61: Complete Menu

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO COMPLETE MENU 7.2.1 Menu 0 : Network Default Function Range setting BUS NETWORK Network presence in the bus (only visualization) USER INTERFACE Backlight time (min) 1 ÷ 10 ; 24h Thermoregulation button...
  • Page 62 Training manual :PIGMA Gal Evo Manuale Didattico – ACO 0 ÷ 15 Heating post-circulation (min) CO: non stop Pump modulation on heating Not active ΔT for pump modulation (°C) Not active CENTRAL HEATING-2 0: 5 sec Heating post-ventilation 1: 3 min 0 ÷...

  • Page 63: Menu 4 : Zone 2 Parameters

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 7.2.3 MENU 4 : ZONE 2 PARAMETERS Default Function Range setting SETPOINT Temperature setpoint zone 1 Par 425 ÷ Par 426 ZONE 1 SETTING 0: fixed delivery temperature 1: basic thermoregulation...

  • Page 64: Menu 6 : Zone 3Parameters

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 20 (par. 520=0) Zone 2 minimum heating 20 ÷ 45 (par. 520=0) 35 (par. 520=1) temperature (°C) 35 ÷ 82 (par. 520=1) DIAGNOSTICS (only OFF: no Heating request by zone 2...

  • Page 65: Menu 8:Service Parameter

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 7.2.6 MENU 8:SERVICE PARAMETER Default Function Range setting BOILER STATISTICS Hours burner on in heating (h x (only visualization) Hours burner on in sanitary (h x (only visualization) Number of flam lifts...
  • Page 66 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Last 10 errors SI: push button “OK” Reset error list NO: push button “ESC” MENU TIME (Non accessible lorsque l’Expert Control est connecté) HEURE DATE Jour Mois Année TIMER 06:00 – 22:00 Prog1 06:00 –...

  • Page 67: Error Codes

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 8 ERROR CODES BOILER PROTECTION SYSTEMS. There are two types of errors for malfunctions: - Shutdown (solved by resetting); - Safety stop (No Reset: the boiler will start working again properly when the cause is removed).
  • Page 68 Training manual :PIGMA Gal Evo Manuale Didattico – ACO 4.12 Room Sensor not available Z2 4 13 Room Sensor not available Z3 No Reset IGNITION AND DETECTION 5 01 Flame missing Reset 5 02 Flame detected with gas valve closed...

  • Page 69: First Starting At Work

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 9 FIRST STARTING AT WORK 3.Verify gas 1.Check plug 2. Verify type of gas (make changes by using connection and connectioins. proper tooling kit if electric power supply. necessary). Validated …………………….

  • Page 70: Periodical Checks

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 10 PERIODICAL CHECKS Plate-type heat exchanger for sanitary system When : every year Commentary : by mesuring DT at different sanitary flow rates. By pass & 3-way Valve When : every year...
  • Page 71 Training manual :PIGMA Gal Evo Manuale Didattico – ACO Air Pressure Switch When : each year How : Visual aspect / Property of tube and the recovery / measurement of DP as a function of the values specificed in Training Handbook.

  • Page 72: Donnees Techniques Urbia

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 11 Données techniques URBIA 11.1 PIGMA CF 25 CF 30 CF Modèle PIGMA Certification CE (pin) 1312BR4794 1312BR4923 Type chaudière 11bs 11bs Nominal heat input max/min (60/80°C) (Hi) 25,8/11 29,5/13 Nominal heat input max/min (60/80°C) (Hs)

  • Page 73: Page. 3 Of

    Training manual :PIGMA Gal Evo Manuale Didattico – ACO 11.1 PIGMA FF 25 FF 30 FF 35 FF Modèle URBIA 1312BR47 1312BR47 1312BR49 Certification CE (pin) Type chaudière Nominal heat input max/min (60/80°C) (Hi) 25,8/11 30/13 34,5/15 Nominal heat input max/min (60/80°C) (Hs)

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