INSTRUCTIONS MANUAL FOR BOILERS MODELS:

PACK-P AR 93 PACK-P AR 810

PACK-P AR 105 PACK-P AR 930
PACK-P AR 150 PACK-P AR 1045
PACK-P AR 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

nº1460040EN
Updated 04/2009
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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

1 GENERAL 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

2 USER
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

3 INSTALLER
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

4 SERVICE
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.

1.3 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.

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1.4 DESCRIPTION OF THE APPLIANCE

The steel boilers of the PACK-P AR range are high performance generators for 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.

2 1 5 6 3 4 9 10
r m v

8 7
1 Boiler body
2 Front door
3 Support burner plate
4 Pilot flam
5 Smoke chamber
6 Smoke exhaust
7 Cleaning door
8 Smokes condensate discharge
9 Identification plate
10 Control panel
r Heating return
m Heating flow
v Safety valve or espansion vessel
s discharge
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1.5 PACK-P/AR DIMENSIONS AND TECHNICAL FEATURES

1.5.1 PACK-P/AR 93-405

e f

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φ H

d
s

B1 A1
B A

PACK-P/AR MODEL 93 105 150 190 230 290 345 405

Power Input KW 103 115,5 167 211 257 320 384 449
Kcal/h 88.600 99.300 143.600 181.500 220.600 275.000 330.200 386.100
Power Output KW 93 104,7 151,2 192 233 291 349 407
Kcal/h 80.000 90.000 130.000 165.000 200.000 250.000 300.000 350.000
Max Working pressure bar 5 5 5 6 6 6 6 6
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
4.5 5.6 11.8 6.9 10 16.3 23 31
mbar
Pressure drop Comb. Chamber mbar 0,5 0,7 1,2 1,2 1,5 2,3 3,3 4,4
H Height mm 880 880 880 990 990 990 990 990
B Total width mm 1110 1110 1360 1405 1405 1655 1655 1905
B1 Width of body only mm 760 760 1010 1010 1010 1260 1260 1510
A Total length mm 790 790 790 940 940 940 940 940
A1 Length of body only mm 750 750 750 900 900 900 900 900
d Distance hydraulic connections
460 460 460 510 510 510 510 510
mm
e Water outlet connection position
430 430 430 465 465 465 465 465
mm
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
v Safety valve or expansion vessel
1 ¼” 1 ¼” 1 ¼” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½”
DN
s Discharge
¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾”
DN
∅ Chimney connection mm 200 200 200 220 220 220 220 220

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1.5.2 PACK-P/AR 465-1100

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φ H

d
s

B1 A1
B A

PACK-P/AR MODEL 465 520 580 695 810 930 1045 1100
Power Input KW 511 577 637 771 899 1.027 1.156 1.349
Kcal/h 439.000 494.000 548.000 663.000 773.000 884.000 994.000 1160000
Power Output KW 465 523 581 700 820 940 1.060 1.240
Kcal/h 400.000 450.000 500.000 602.000 705.000 808.000 911.000 1066000
Max Working pressure bar 6 6 6 6 6 6 6 6
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
18 22 28 18 25 33 40 36
mbar
Pressure drop Comb. Chamber
3,3 4,3 4,8 4,5 5,6 5,4 6,0 6,5
mbar
H Height mm 1150 1150 1150 1280 1280 1280 1280 1500
B Total width mm 1990 1990 2290 2345 2545 2545 2795 2950
B1 Width of body only mm 1512 1512 1812 1814 2014 2014 2264 2416
A Total length mm 1040 1040 1040 1240 1240 1240 1240 1380
A1 Length of body only mm 1000 1000 1000 1200 1200 1200 1200 1380
d Distance hydraulic connections
595 595 595 640 640 640 640 810
mm
e Water outlet connection position
625 625 625 625 625 625 625 430
mm
f Chimney connection height mm 792 792 1092 974 1174 1174 1424 1700
r/m Hydraulic connection DN 80 80 80 100 100 100 100 125
v Safety valve or expansion vessel
2” 2” 2” 65 65 65 65 80
DN
s Discharge
¾” ¾” ¾” ¾” ¾” ¾” ¾” 1” ½
DN
∅ Chimney connection mm 250 250 250 350 350 350 350 400

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1.5.3 PACK-P/AR 1250-3500

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φ H

d
s

B1 A1
B A

PACK-P/AR MODEL 1250 1600 1800 2000 2500 3000 3500

Power Input KW 1.606 2.056 2.282 2.570 3.213 3.855 4.497
Kcal/h 1381000 1768000 1963000 2210000 2762000 3315000 3867000
Power Output KW 1480 1.890 2.100 2.360 2960 3550 4150
Kcal/h 1273000 1625000 1806000 2030000 2545000 3053000 3569000
Max Working pressure bar 6 6 6 6 6 6 6
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
54 45 68 70 64 90 120
mbar
Pressure drop Comb. Chamber mbar 6,8 7,0 7,2 7,2 7,5 7,8 9,0
H Height mm 1500 1800 1800 1800 2000 2000 2210
B Total width mm 3200 3245 3535 3535 3955 4255 4790
B1 Width of body only mm 2666 2680 2970 2970 3320 3620 4024
A Total length mm 1380 1610 1610 1610 1800 1800 2000
A1 Length of body only mm 1380 1610 1610 1610 1800 1800 2000
d Distance hydraulic connections
810 965 965 965 1070 1070 1700
mm
e Water outlet connection position
430 430 430 430 510 510 522
mm
f Chimney connection height mm 1950 1440 1730 1730 1700 2000 2200
r/m Hydraulic connection DN 125 150 150 150 200 200 200
v Safety valve or expansion vessel
80 100 100 100 125 125 125
DN
s Discharge
1 ½” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½” 1 ½”
DN
∅ Chimney connection mm 400 450 450 450 500 500 600

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1.6 IDENTIFICATION 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.

1.7 DOCUMENTS 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

2.1 START-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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2.3 CLEANING
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.

2.4 MAINTENANCE

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.

2.5 PRODUCT 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 its heavy weight it should not be handled manually.

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3 INSTALLATION

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)

3.2 INSTALLATION – 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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3.3 DISCHARGE 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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3.4 HYDRAULIC 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.

3.5 WATER 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.

3.7 THE 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

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-P AR 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.

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3.8 DIAGRAM 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

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3.9 ELECTRICAL SYSTEM

The electrical system must comply with the current regulations and be installed by professionally qualified
personnel..

Electrical safety of the equipment is ensured only when it is correctly connected to an efficient earth system
in compliance with the current safety regulations.
The manufacturer will not be liable for any damage caused by failure to earth the system.

Call professionally qualified personnel to check that the electrical system is suitable for the maximum
power absorbed by the equipment, ensuring in particular that the system cable sections are suitable for the
power absorbed by the equipment.

Adapters, multiple sockets and extension leads must not be used for general power supply of the
equipment from the mains.

For connection to the mains, a twin-pole switch must be provi ded in compliance with the current
regulations.

3.10 CONTROL PANEL INSTALLATION

The control panel is placed in a box inside the furnace or next to the boiler.
Voltage 220 V - 50 Hz.

Open the instrument panel by turning of the self-threading screws.

Extend the instrument gauge capillaries avoiding all damages and pass them through the hole at the
bottom of the panel.
Later, take the cover of the boiler casing, pass the gauge capillaries through the hole and fix the instrument
panel to the cover.
Lean the cover on the boiler and insert the gauges in the boiler bulbs avoiding any accidental breakage.

For mod. PACK-P AR 1100÷3500, fix the control panel in the most convenient position (upon or on the
sides of the boiler) using the bracket in outfit.

CAUTION: all capillary gauges of the panel instruments must be inserted in the boiler body bulbs next to
the flow fitting to the heating plant.

For the electrical connections, proceed according to the instructions in the attached electrical diagram.

Never fix the electrical cable to the sheet metal of the boiler body, door or smoxe box

Finally, close the panel and re-fit the cover on the boiler casing.

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3.11 FUEL SUPPLY

The fuel supply line must comply with current regulations and be laid by professionally qualified personnel.

Before installation, you are advised to thoroughly clean the inside of all the fuel supply pipes in order to
remove any debris that may affect correct operation of the boiler.

Check the internal and external seal of the fuel supply system.
If using gas, the connections must be perfectly sealed.

Check that the fuel supply system is provided with the safety and control devices prescribed by the current
regulations.

Never use the plant fuel pipes to earth electric or telephone systems.

Ensure that the boiler can be fed with the type of fuel that will be used.

3.12 POSSIBLE FUELS

The PACK P/AR 93-3500 boilers can be matched with burners firing following combustibles::

• Natural gas G20.

• Butane G30.
• Propane G31.
• Light oil, max 1.5°E a 20°C.
• Heavy oil 5-7°E a 50°C

The expected ideal combustion parameters for natural gas G 20 are following:
CO2 = 9.6%
CO< 50 ppm
NOx<100 ppm
Flue T°- Room T° = 180-200°C.

The expected ideal combustion parameters for butane G30 are following:
CO2 = 11.0%
CO< 50 ppm
NOx<100 ppm
Flue T°- Room T° = 180-200°C.

The expected ideal combustion parameters for propane G31 are following:
CO2 = 11.2%
CO< 50 ppm
NOx<100 ppm
Flue T°- Room T° = 180-200°C.

The expected ideal combustion parameters for Diesel oil are following:
CO2 = 13.0%
CO< 50 ppm
NOx<100 ppm
Bacharach < 2
Flue T°- Room T° = 180-200°C.

The expected ideal combustion parameters for Heavy oil are following:
CO2 = 12.5%
CO< 50 ppm
NOx<100 ppm
Bacharach < 2
Flue T°- Room T° = 180-200°C.
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3.13 BURNER CONNECTION

IMPORTANT NOTE:
It is possible to install on these boilers, even other burners that are not included in our official lists,
provided that the required values of furnace thermal output and drop pressure are respected.

For installation of the burner, the electrical connections and the necessary settings, consult the burner
instruction manual.
Ascertain that the correct type of burner has been chosen for the boiler, checking the technical
specifications of both.
The burner draught tube must be sized as shown below:

FIBRA CERAMICA

Boiler type Burner nozzle

PACK-P/AR min./max L mm
93÷150 220 / 280
190÷405 250 / 330
465÷1045 320 / 400
1100÷2000 350 / 420
2500÷3500 370 / 500

Secure the burner to the door by means of the fixing plate so that the flame is parallel and centred in the
furnace; if not, combustion problems can occur with the risk of seriously damaging the boiler.

IMPORTANT: after installing the burner, fill any crack between the draught tube and the hole of the door
with the material provided, resistant to 1000°C (ceramic fibre mat).

This operation prevents overheating of the door which would otherwise be permanently deformed.

If the burner is provided with an air intake connect it through a rubber hose to the intake arranged over the
flame pilot light: this way glass remains clear.
If burner has no air intake need to connect it through a rubber hose, remove the intake on the flame pilot
light and close the hole with a tap ø 1/8" GAS.

The fuel connections to the burner must be positioned in order to permit complete opening of the boiler door
with the burner fitted.

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3.14 COVER ASSEMBLING (ONLY PACK-P/AR 93-1045)

WARNING: carry out the cover assembling after finished the installation works.

Extract the mineral wool (1) from the furnace and wrap it around the planting of the boiler, starting from the
top fixing it obtaining a hole with the hands. to the inlet and outlet tubes.
Then lock it adherent to the plating with the out fit hose clamp.

Begin the assembling with the left lateral cover (3), taking care of putting first the inferior part and then the
superior part of the cover on the boiler structural angles.

Mount the right lateral cover (2) maintaining the some rules used for the left one.

Position the superior covers (4) (5) on the boiler.

Before joining them together, prepare the control panel (6) as specified below and fix it on the right superior
panel as follows: extend the feeler capillaries, make then pass through the cover hole and insert them in
the wells located near the delivery tube.
Then fix the set to the cover.

Then connect the upper covers, placing them at joint on the side covers.

5
6
4

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3.15 PRELIMINARY OPERATIONS BEFORE THE FIRST START-UP

Before starting up:

- check that the gauges of setting and control instruments have been correctly positioned in the bulbs;

- ensure that the turbolators do not protrude from the front of smoke tubes;

- check that the plant has been filled with water, de-aerated and that pressure is over 1 bar and lower than
the instrument max. allowed pressure;

- check that all control and safety devices are working efficiently and calibrated appropriately;

- check that the furnace is free from foreign matters;

- ensure that door refractory casing is not broken;

- check that the burner tube has been plugged correctly;

- check that the door has been closed correctly;

- check that the plant on-off valves are completely open and pumps turn correctly;

- ensure that fuel is available and fuel cocks are open.

- check that the water pumps work and push the water to the right way.

- check that the burner is regulated according to the capacity of the boiler combustion chamber, so that the
combustion values match with the ones specified by the maker.

- check that the safety valve in the closet vessel plants and the overflow in the open vessel plants, do not let water
out (if it happens, it’s due to a wrong sizing of the expansion vessels).

- In plants with open vessel check that there is no water circulation in this latter (if yes, fill-in and vent lines are
incorrectly executed).

- check that the boiler water temperature at normal rate working, stays between 70°C and 80°C:

- check that the temperature of the boiler inlet water, at normal rate working, does not drop below 60°C.

- check that the net flue temperature stays between 180°C and 200°C .

3.16 FIRST START UP

After performing the preliminary checks, to power on the boiler it is necessary:

- that the boiler thermostat on the control panel is set between 60 and 90°C, according to the type of
heating plant;

- that the environment thermostat is set on 20°C approx.;

- that the main switch is turned "ON";

- that the main switch is pressed from the control panel (the lighting button is lightened);

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.
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3.17 FIRST START UP AND FURTHER CHECKS

After the start up operations have been carried out, the appliance must be tested for standstill and further
start up. Therefore:

- modify the boiler thermostat setting;

- actuate the main switch from the control panel;
- modify the environment thermostat setting.

Check the seal of all gaskets on the water and smoke sides.

This operation is of fundamental importance for the gaskets of the door, of the burner plate and of the
smoke-box to prevent leakage of toxic and therefore hazardous combustion fumes into the boiler room. To
guarantee the perfect seal, warm tighten.

The weight of the overhanging burner tends to loosen the gasket of the door at the top.

It is very important to inspect the boiler/flue fitting seal because of the above reasons.

Check the pumps correct sense of direction.

Check the total standstill of the appliance by turning off the main switch.

After all conditions have been satisfied, the burner must be tested at the boiler max. output by examining
the combustion products to reach the correct combustion as well as the less polluting emissions as
possible.

Smoke temperature under normal working conditions ranges from approx. 170-200°C.

When the boiler is working, the pressure of the water contained in the system increases. Therefore, ensure
that its highest value does not exceed the boiler max pressure.

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4 SERVICE

4.1 WARNINGS FOR THE SERVICE CENTER

Periodical maintenance is essential for safety, output and the generator life span.
Furthermore, it is mandatory and it must be carried out by professional qualified personnel.

Before any servicing, it is recommended that a combustion analysis be performed to find out the operating
conditions as well as indications on how to intervene.

After the combustion analysis has been performed and before any other operations:
- power off the system by turning off the main general switch;
- close the fuel on-off cocks.

4.2 ROUTINE MAINTENANCE

A correct use and a regular maintenance are fundamental for a reliable working and the long life of the
appliance:
- Check that the boiler exchange surfaces do not show any encrustations and/or soot layers (to be eventually
removed by a vacuum cleaner).
- Check, at least once a year, the conditions of the flue turbulators; if needed replace them by new ones.
- Do not leave the boiler and the plant empty for long still periods of time; do not change the water if not necessary.
- During the plant still time, disconnect the boiler from the electrical main.
- Protect the electrical components from water spray and humidity.
- All the maintenance and cleaning operations should be carried out at the beginning of the boiler still time.
- Check periodically, at least once a year, that the burner regulation keeps being correct; following values should
be controlled: flue temperature, carbon dioxide, carbon monoxide nitrogen oxides, flue opacity, etc.

4.3 OPENING AND ADJUSTMENT OF THE DOOR

The door can be opened from both sides (except for models 2500÷3500).
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.

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4.4 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 furnace and the rear cleaning door.

4.5 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.

4.6 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.

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 cleanness 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
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FAULT: the boiler gets easily covered with soot.

REMEDY:
- check the burner regulation (smoke analysis);
- check the fuel quality;
- check the flue for clogging and the cleanness 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.

FAULT: smell of gas and/or un-combusted 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 circulation 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 anti-condensate 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.

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4.7 SPARE PART LIST

Spare parts recommended for two working years:

1 working thermostat 1 safety thermostat

1 door gasket 1 smoke box gasket
1 pilot flame glass 1 pilot flame gasket
1 burner plate gasket 1 complete set of turbolators

The following parts may also be supplied in the event of accidental damage or malfunctioning:

- thermometer
- complete control panel
- complete door
- complete smoke chamber
- complete or partial casing

4.8 WARRANTY
The exchange surfaces of the PACK P/AR boilers are guaranteed, starting from the invoice date, by a special
Guarantee Certficate delivered with each boiler. The conditions stated below, needed to have the guarantee valid,
are clearly specified in such certificate:
1) Installation complying with the existing laws.
2) Installation, putting into working, use and maintenance as per the state of the art and in accordance with
Blowtherm specifications.
3) No modifications have been brought to the product.
4) Maintenance works carried out by authorized personnel.

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BLOWTHERM S.P.A.
Via GUIDO RENI 5 – 35134 PADOVA – ITALY
Tel. +39 049 601600 – Fax. +39 049 9301471

Technical data and measurements are not binding. The Company reserves the right to
make modifications without warning. We decline any responsibility for incorrect
information contained in the present booklet 30
due to printing or copying errors.