MANUAL FOR INSTALLATION AND MAINTENANCE

Boiler with forced flue exhaust

CONTENTS
1. IN GENERAL
1.1 General information 1.2 Boiler description

2. INSTALLATION
2.1 Warning before installation 2.2 Boiler placement 2.3 Boiler dimensions 2.4 Minimum distances 2.5 Boiler fixation 2.6 Connection to the mains 2.7 Gas connection 2.8 Water supply 2.9 Installation of flue exhaust and air suction 2.10 Room thermostat connection 2.11 Wiring diagram 2.12 Function diagram 2.13 Hydraulic diagram

1. IN GENERAL
This manual is an essential and integral part of the product. It contains a thorough description of the equipment and it is to be of use for both the users and the authorized service personnel. Read the instructions in the manual carefully because there is the necessary information about the safe installation, operation and maintenance of the product. There is more information in the Users Guide.

1.1 GENERAL INFORMATION

The appliance serves for room heating and domestic hot water production for home purposes. It must be connected to the heating circuit and to the hot water distribution system corresponding to its purpose and output. It is forbidden to use it for any other than the stated purposes. The manufacturer is not responsible for faults caused by unsuitable, wrong or irresponsible use. The installation, the maintenance and any other interference must be carried out in accordance with the valid norms, according to the manufacturers instructions and by a qualified and trained worker. The technician installing the heating equipment must also have valid authorization by the manufacturer. Incorrect installation can cause harm to possessions or persons. The manufacturer is not responsible for damages inflicted in this way. Prevent children and mentally ill people from using the equipment without supervision. If you can smell gas, do not switch on any electrical appliances, phones or other appliances which can produce sparks. Open the door and the windows, close the central gas supply (at the gas meter) and call an authorized service engineer. Should you be away for a long time, close the central gas supply as well. Do not put any objects on the appliance. Do not block up the air or other outlets. It is necessary to close the electricity supply before any interference in the product. The best way is to unplug it. Use a wet cloth and soap for cleaning the appliances cover. Do not use abrasive or dissolving cleaners. If there is a fault or malfunction, switch the appliance off by closing the gas tap. Call authorized service engineers to repair the appliance. The notes and instructions included in this manual are to be used by the people who are going to install our product.

3. STARTING THE BOILER

3.1 Conditions for boiler operation 3.2 Control panel 3.3 Instructions for opening the boiler 3.4 The first start 3.5 Regulation of operation 3.6 Flue analysis 3.7 Gas outlet check 3.8 Protection functions 3.9 Boiler draining

4. CHANGE TO A DIFFERENT GAS TYPE

4. Gas regulation 4.1 Change to a different gas type

5. MAINTENANCE 6. TECHNICAL SPECIFICATIONS

1.2 BOILER DESCRIPTION

2. INSTALLATION
The installation and the first putting into operation must be carried out by a qualified technician in accordance with the norms valid for installation of this kind of appliances and with the norms of local authority bodies and medical institutions.

2.1 WARNING BEFORE INSTALLATION

The appliance must be connected to the heating distribution system and to the water supply corresponding with the boilers purpose and output. (See the specifications) Before you connect the boiler it is necessary to: - check the piping and make sure there are no impurities which could affect the boilers operation. - check which gas type is the boiler designed for (read the label on the packaging and the manual including technical specifications) - make sure the following exhaust installation meets the valid local norms.

2.2 BOILER PLACEMENT

The equipment with combustion air supply from the outside and with forced flue exhaust into the outside can be installed in any room which corresponds with the relevant local norms and standards. Placing of such a boiler is not limited by ventilation possibilities or room size. The boiler must be mounted on a solid, compact so that any access to electricity at the back part is prevented. To gain the best efficiency of the boiler it is necessary to make sure that the temperature of the place where to boiler is mounted is within the temperature limits for the boiler so that the boiler is protected against atmospheric influences. It is also necessary to make enough free space around the boiler to make access to individual boiler parts possible, as mentioned in paragraph 2.4. If the boiler is to be placed in the bathroom, washing rooms or shower rooms it is necessary to follow specific relevant local norms. (electrical part has IP 44 cover).

2.3 BOILER DIMENSIONS

Legend: 1. Connection to flue exhaust 2. Opening for separated exhaust 3. Ventilator 4. Flue exhaust rectifier 5. Primary exchanger 6. Safety thermostat 7. Temperature sensor in the heating circuit 8. Combustion chamber 9. Burner lamellas 10. Ionization electrode 11. Ignition electrodes 12. Pump pressure switch 13. Safety valve 3 bars 14. Temperature sensor in the DHW circuit 15. Secondary exchanger 16. Refilling valve 17. Cold water inlet 18. Through-flow sensor 19. Draining valve 20. Circulation pump 21. Motor-driven 3-way valve 22. De-aerating valve 23. Gas valve 24. Expansion vessel 25. Flue exhaust differential manostat 26. Sockets for gas analysis 27. Ignition transformer

Legend: A. Heating water outlet B. DHW outlet C. Gas supply D. Cold water inlet E. Heating return pipe

2.4 MINIMUM DISTANCES

The following layout shows the minimum distances for boiler installation which are necessary for possible proper maintenance.

The boiler is designed for natural gas and propane category II 2H3p combustion, as stated in the chart in chapter 4 Gas regulation. If you need to change the boiler to another gas type, follow the instructions in 4.1. The point of gas connection in the boiler has to be equipped with a proper round closing cock, following the valid norms. We recommend you to clean all piping before installation and to remove possible impurities, which could affect the efficiency of the boiler.

2.8 WATER SUPPLY

CONNECTION TO THE BOILER

2.5 BOILER FIXATION

The boiler has to be placed with the use of water level according to the minimum distances shown at the picture, and it has to be fixed to the wall with use of cramps and hooks. Further information is to be found in the manual which goes with the hydraulic connection set and the flue exhaust set.

2.6 CONNECTION TO THE MAINS

The manufacturer is not responsible for damages caused by wrong supply mains in the house. It is therefore recommended to have the supply mains checked in certain cases. The boiler is connected to the supply mains by a fixed flexible line with a plug. It is connected to a 230 V, 50 Hz (10 A) socket installed according to valid norms. It can also be connected by a firm cable where a suitable two-pole switch must be incorporated. The equipment must be connected to 230 V supply mains by a triplex cable. Make sure the phase and neutral connection has been done according to valid norms in the socket. IMPORTANT!

Legend: A. Heating outlet B. DHW outlet C. Gas supply D. Cold water inlet E. Heating return pipe F. Refilling valve G. Safety valve spillway There are connections to heating distribution systems, boilers DHW and gas distributions and connections to the appliance in the picture. More detailed information on armature connection to distribution systems is to be found on the connection armature packaging. Before you connect water, check if the maximum pressure in the water distribution system does not exceed 6 bars. If the pressure in the distribution is higher, it is recommended to install a reduction valve. The minimum pressure for proper boiler functioning in the DHW mode is 0.2 bars. Therefore it is possible to insert a thermostatic valve at the cold-water inlet to limit the maximum DHW amount (see the following picture in part 1). When dimensioning distributions and radiators the circulation pump output must be taken into consideration , see the following

The connection to the supply mains including plugging can only be carried out by a service technician. The same applies for any possible change of the supply cable. If you need to change the supply cable, use the cable with the same parameters (3 x 0.75mm2 outer max 8 mm HTO3VV-F type). Follow these rules and the above diagram for the connection: - open the front cover of the control panel, as mentioned in paragraph 3.3; - unscrew two screws in the back window of the control panel, which will give you an access to the terminal connector; - take out the bad cable and put in a new one at the same point; - put the grommet to the new cable, including the grounding cable drawing in; - place the cable so that the insulation fits into the right place; - connect the blue cable (neutral) to the point in the terminal connector that is marked N; - connect the brown cable (phase) to the point in the terminal connector that is marked L; - connect the yellow-green cable (grounding) to the point that is marked by a symbol behind the back cover inside the boiler.

2.7 GAS CONNECTION

graph (output x lift).

The boiler is equipped with an automatic by-pass, which provides the right water supply into the primary exchanger in case installation with variable supply is done (heating systems with thermostatic valves etc.) We recommend installing safety valve discharge piping of 3 bars of the heating circuit.

2.9 INSTALLATION OF FLUE EXHAUST AND AIR SUCTION ACCORDING TO TPG 800 01
Flue exhaust (outlet) and combustion air supply (inlet) can be provided by a system of coaxial pipes.

The outlet and the inlet can also be provided by a system of separate pipes according to the following procedure: If you assemble the exhaust system using separate pipes it is necessary to: 1. cut off the outlet bottom; 2. connect the elbow to the outlet right to the bottom brink (Seal or insulation is not necessary).

Diagrams show some examples of various types of coaxial and separate exhaust systems.

The stated values of maximum outlet and inlet lengths include also the length of accessories such as roof bushing, adapter, opening etc. For coaxial systems the value includes also one 90 elbow. C52 installation has to meet following conditions according to the diagram: 1 The same outlet and inlet pipe diameter of 80 mm over the total length.

2 If you want to insert another elbow into the inlet or outlet systems, you have to provide the equivalent length for the other side along the same rules as when counting the length. 3 The flue outlet (chimney) must stick out by at least 0.5 m over the roof top (where it is fixed) and it must be placed at the side opposite the side with the air inlet (this condition is not obligatory if the inlet and outlet are at the same side of the building).

Recommended exhaust length

maximum coaxial exhaust length 100/60mm 0.5 2.0 m orifice plate 43 mm 2.1 4.0 m no orifice plate maximum separate exhaust length 2x80mm 0.5 10.4 m orifice plate 43 mm 10.5 43.0 m no orifice plate maximum pressure loss of the exhaust 80 Pa

the angle of 0.3o with a decline in the direction from the boiler
90o = -75 cm 45o = -50 cm

Shortening of the maximum length by an elbow:

Note: The length of exhaust means the length of the inlet pipe + the outlet pipe length.

2.10 ROOM THERMOSTAT CONNECTION

It is necessary to: 1 open the control panel, as described in paragraph 3.3. 2 insert the thermostat cable in the connector and fix it. Then connect both conductors to the electrical terminal connector placed at the back of the panel by removing shortening jumper. The shortening jumper substitutes the room thermostat when the room thermostat is not connected.

2.11 WIRING DIAGRAM

Legend: A = Connector for remote control connecting B = Heating temperature regulation (Summer/Winter switch) C = Connector for remote control D = DHW temperature regulation E = Slow ignition regulation F = Maximum heating temperature regulation G = ON/OFF switch H = ON/OFF diode I = Insufficient flue outlet diode J = Maximum DHW temperature jumper (for floor systems) L = Wrong ignition diode M = Insufficient water diode N = Unblocking button O = Economical/comfort mode switch P = Overheating diode Q = Temperature diodes R = Transformer S = Circulation pump relay T = Ventilator relay U = Gas valve relay V = Motor-driven 3-way valve relay ZA=Jumper for postventilation function A01 = Circulation pump A02 = Ventilator A03 = Ignition transformer A04 = Gas valve A05 = Motor-driven 3-way valve A07 = Flame scan circuit (ionization electrode) A08 = Heating temperature sensor A09 = DHW temperature sensor A10 = Through-flow switch A11 = Heating through-flow switch A12 = Modulation A13 = Overheating safety thermostat A14 = Programmable clock A15 = Room thermostat

COLOURS: Gr = Grey Bi = White Ro = Red Mr = Brown Bl = Blue Nr = Black R/N = Red/Black

Jumper service setting:

Label at the gas joint: ZA Jumper function: Ventilation of the combustion chamber by the smoke ventilator Heating temperature limitation: floor heating/radiators Anticycling time setting: Combustion chamber type: Effect at A position: Chimney version, no ventilator t max = 45o C Floor heating system 0 min. Just for the service setting of the boiler For atmospheric installations (chimney version) Effect at B position: Turbo version, the ventilator ventilates the combustion chamber t max = 82o C Radiator heating system 2 min. For common operation!!! For TURBO installations

J W CN101

2.13 HYDRAULIC DIAGRAM

3. STARTING THE BOILER

IMPORTANT! It is necessary to cut off the electricity supply by turning A button to 0 position and unplugging the boiler before any operations inside the boiler.

3.1 CONDITIONS FOR BOILER OPERATION

To ensure safety, proper functioning and guarantee period validity it is necessary that the installation and the first start should be carried out by a THERMONA authorized service technician. Check if the gas and its pressure, the mains voltage and frequency correspond with the data on the boilers production label. FILLING THE BOILER Follow this procedure: release deaerating valves on the radiators; slowly open the refilling valve on the boiler and close the deaerating valves on the radiators when the water starts to flow out; close the boilers refilling valve when the pressure reaches 1 bar. GAS SUPPLY Open the gas supply tap on the inlet pipe and the gas supply tap on the boiler and check the gas installation. You will find any leak using water with soap.

3.2 CONTROL PANEL

PARTS DESCRIPTION:

Legend: 1. Ventilator 2. Primary exchanger 3. Safety thermostat 4. Burner 5. Ignition electrodes 6. Ionization electrode 7. Heating temperature sensor 8. Heating manometer 9. Pressure through-flow switch 10. DHW temperature sensor 11. Secondary exchanger 12. Gas valve 13. DHW flow switch 14. Refilling valve 15. Safety valve, 3 bars 16. Motor-driven 3-way valve 17. Automatic by-pass 18. Pump with deaeration 19. Expansion vessel 20. Ventilator manostat A. Heating outlet 3/4 B. DHW outlet 1/2 C. Gas 3/4 D. Cold water inlet 1/2 E. Heating return pipe 3/4

A = Main switch B = DHW temperature regulation C = Mode switch and heating water temperature regulation D = ON/OFF diode (green) E = Insufficient flue outlet diode (yellow) F = Insufficient water or operation stop diode (red) G = Economical/comfort mode switch H = Unblocking button / flue analysis I = Safety thermostat operation diode (overheating) L = Insufficient water in the system diode (red) M = Heating water temperature diodes (yellow) N = Place for programmable clock installation O = Heating manometer

3.3 INSTRUCTIONS FOR OPENING THE BOILER

To access the inside of the boiler it is necessary to unscrew the fixing screws at the lower part of the control panel. The control panel swings down and it can be drawn forward on two side pins. It stops in an almost horizontal position, which allows the access to the inside. If you want to gain better access you have to lift the panel and turn it into the horizontal position. To unscrew the outer case you have to: 1. unscrew the two bottom front screws, 2. lift the cover and remove it from the top fittings.

Releasing the control panel:

Releasing the front cover

3.4 THE FIRST START When starting the boiler for the first time you have to: 1) check that: the electricity connection was made correctly and the installation is properly grounded; the automatic deaerating valve is allowed; if the pressure is lower than 1 bar, put more water in the circuit; the gas tap is closed. 2) Start the boiler by turning knob A to position I (green diode D lights up) and turning knob C to the middle position between min and max to start the boiler in the winter mode. Leave the boiler in this mode for some time to allow complete deaeration. The boiler will signal blocking after 7 seconds. Then: release the front plug of the pump deaerating valve to prevent creation of air bubbles; repeat the process of radiator deaeration, open water taps; check the circuit pressure and if it is lower, open the refilling tap again until the pressure is 1 bar 3) Check that the outlet and inlet pipes are clear. 4) Check that the ventilating holes are open. 5) Open the gas tap and check the installation for leaks (including the burner installation) using water with soap. Block the leaks if necessary. 6) Unblock the boiler by pressing H button. The ignition of the main burner should come immediately. If the burner does not ignite, repeat the process. 7) Check the minimum and maximum value of the gas pressure on the burner and set it according to the chart in chapter 4 REGULATION.

3.5 REGULATION OF OPERATION

It is possible to adjust: - the temperature of water for heating, using turning knob C - the temperature of water for DHW, using turning knob B - choose the economical mode -E- or the comfortable mode -C- , using switch G. The economical mode is the usual boilers operation, when DHW is heated only when required by the user. The comfortable mode is a special function, where the water in the primary and the secondary circuits is kept pre-heated so that the user can use the hot water in shorter time, which is for them more comfortable. To access the area where the operation can be adjusted it is necessary to open the control panel, as described in paragraph 3.3, i.e. by unscrewing two screws and removing the back window. Thus you gain access to the electronic panel and the following component: 1) supply cable connector 2) fuses 3) potentiometer for regulating the slow ignition, which changes according to the minimum and the maximum output. 4) potentiometer for setting the maximum heat output (preset to 70% of the maximum heating output by the manufacturer) 5) jump switch for regulating the repeated burner ignition after burner expires (preset to 1 minute by the manufacturer). 6) Jumper for choosing the floor or the radiator system (J wiring diagram) 7) Jumper for setting the time of the combustion chamber ventilation (ZA - wiring diagram), which is preset to position B ventilation on by the manufacturer 8) connector for room thermostat connecting (A 15)

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connector for programmable clock connecting (if required by the customer) (A14) diodes lighting up. It is possible to restart the boiler by button H after a few minutes, which are necessary for the primary circuit to cool down. 4 Protection against boiler scale The boiler is equipped with a device reducing limestone creation in the secondary circuit. It measures the water temperature (<61C) and checks the water temperature in the primary circuit, which should not exceed 72C. 5 Protection against frost The boiler is equipped with a special protection which activates the pump to the heating mode if the temperature falls bellow 8 C until the temperature is 18 C. If the temperature falls bellow 3 C the burner ignites with the minimum output until the temperature is 33 C. This function is operational both in the heating mode and the DHW heating mode. However, the function is activated only if the boiler is in the proper operation, i.e.: - the water pressure is sufficient - the boiler is connected to the supply mains - the gas supply is open. 6 Pump protection To protect the pump and prevent its blocking it is activated 21 hours after the last use for 20 seconds. 7 Flue exhaust malfunctions This protection block the boiler if there is a malfunction of flue outlet. The block is temporary and is signalled by E diode lighting for 15 minutes. Then the boiler starts itself if the flue exhaust has reached the usual status. If this kind of malfunction appears repeatedly, it is probably because of ventilator defect or because the flue outlet pipes are blocked. You should call an authorized service technician in this case. 8 Safety operation stop Before each ignition the control electronics does a series of internal checks. If an internal malfunction is detected, the boiler is stopped until it is repaired.

3.6 FLUE ANALYSIS

The boiler has 2 scanning spots on the output of flue collecting pipe. The spots are used for finding the harmful substances in the flue. It is possible to measure the flue temperature, O2, CO2 concentration etc. by using these scanning spots and other suitable measuring equipment. To access the scanning spots you have to unscrew the front screw and remove the cover with seal. The best conditions for analysis are set when the function flue analysis is activated (press button RESET H for 10 seconds, yellow diode E lights); the boiler switches to the original mode after 5 minutes, or it is possible to interrupt the function by ON/OFF switch (button A). Screw the cover with seal back to their original place and seal it properly after the flue analysis.

3.7 GAS OUTLET CHECK

It is possible to check the correct installation of the exhaust system and to check losses in the inlet system. You can measure the difference of pressures P with differential manometer connected to the testing terminals of the combustion chamber. The value measured should not be lower than 0.55 mbar with the maximum heat output.

3.9 BOILER DRAINING

HEATING CIRCUIT DRAINING It is not recommended to drain the heating system very often because each water change increases the possibility of limestone inside the boiler and its circuits. If the boiler is not used for some longer time and it is in danger of freezing, add anti-freeze liquid. It is possible to drain the boiler in the following way: 1. switch off the boiler 2. open the safety valve 3 bars manually, use a suitable container for the drained water. 3. drain the water from the lowest parts of the heating system.

3.8 PROTECTION FUNCTIONS

The boiler is equipped with the following protection-checking functions: 1 Wrong ignition This measure signals that the burner has not ignited within 7 seconds after the spark. The boiler is blocked, which is signalled by red F diode. You can restart the boiler by pressing and releasing button H after you check the gas tap is open. 2 Circulation pump blocking This measure blocks the boiler if the through-flow switch does not order the pump to start within 40 seconds. In this case red L lights up. You can restart the boiler after you refill the pressure in the system and press button A. 3 -Overheating This measure blocks the boiler if the temperature in the primary circuit exceeds 105C. The block is signalled by red I and F

DHW CIRCUIT DRAINING Whenever there is the danger of freezing it is necessary to drain the DHW circuit in the following way: - close the main house or flat water seal - open all cold-water and hot-water taps - drain the water from the lowest parts of the system

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4. GAS REGULATION

CATEGORY II2H3P Wobbes index (15C, 1013 mbar) Nominal connecting excess pressure Minimum connecting excess pressure Main nozzles diameter: 14 nozzles Consumption (15C, 1013 mbar) Consumption (15C, 1013 mbar) Pressure on gas valve outlet

MJ/m3h mbar mbar mm m3/h kg/h max - min

NATURAL GAS G20 45.67 20 17 1.25 2.75 10.3 2.0

PROPANE G31 70.69 37 25 0.72 2.6 35.6 6.8

1 mbar = 10.197 mm of water column (*) The maximum gas pressure on the burner equals the connecting gas excess pressure reduced by pressure losses inside the gas valve.

CATEGORY II2H3P 23 kW Recommended pressures for slow ignition (mm H2O)

NATURAL GAS G20 5

PROPANE G31 12

4.1 CHANGE TO A DIFFERENT GAS TYPE

The boiler can be changed to use natural gas (G20) or propane (G31) by a technician from an authorized centre. The manufacturer produces boilers in the version for natural gas. If you want to do the change you have to: 1. change the main burner nozzles (see the chart in chapter 4); 2. regulate the maximum and the minimum boiler output (see the chart in chapter 4); 3. change the production label; 4. set the maximum heating output; 5. set the slow ignition; 6. set the ignition delay.

5. MAINTENANCE
We recommend the following checks at least once a year: 1. check the leaks of water armatures, repair or replace defective seals 2. check the leaks of gas connection, repair or replace defective seals 3. visual check of the appliance, disassembling and combustion chamber cleaning if necessary 4. visual check of the combustion process, cleaning burners, disassembling and cleaning nozzles if necessary 5. visual check of the primary exchanger: - check the lamellas - clean the exchanger if necessary 6. gas pressure regulation: in the ignition mode, for the reduced and the maximum outputs 7. check heating safety systems: - maximum temperature - maximum pressure 8. check gas safety systems: - check of flame scan - check of gas valve 9. check the correct connection to the supply mains 10. check the efficiency of the secondary exchanger for DHW production (check the provided volume and DHW temperature) 11. check the proper installation of flue exhaust 12. check the function and position of the flue thermostat, which cannot stop working. If a replacement of this component is necessary, it can only by replaced with an original type. 13. complete check of all boiler functions.

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6. TECHNICAL SPECIFICATIONS 23 TCA

CE Certificates Heat input Nominal heat output Efficiency at maximum input Efficiency at 30% input Heat loss at the cover (D=50C) Heat loss by draught with ignited burner Heat loss by draught with expired burner Maximum flue flow (natural gas) Minimum draught Natural gas consumption at max. output (G20) Propane consumption at max. output (15C, 1013 mbar) (G31) Flue temperature at max. output with natural gas combustion CO2 volume in flues Minimum ambient temperature Pressure losses in water (max)(DT=20C) Minimum pressure in the heating system Heating water temperature DHW temperature Hot water volume with DT=25C Hot water volume with DT=35C Minimum DHW consumption DHW pressure Expansion vessel volume Expansion vessel excess pressure Maximum water volume in the circuit Maximum water pressure in the heating circuit Natural gas connecting excess pressure (G20) Propane connecting excess pressure (G31) Voltage/frequency Electricity input Level of electric cover Max/min kW Max/min kW % % % % % Kg/h Pa m3/h kg/h C % C mbar bar max/min C max/min C l/min l/min l/min max/min bar l bar l bar mbar mbar V/Hz W IP 0694BO0090 26.5 / 11.0 24.8 / 9.7 93.7 90.7 1.2 5.1 0.4 51.8 1.3 2.8 2.09/2.06 106 7.1 +5 200 0.25 82 / 42 56 / 36 14.2 10.2 2.6 8 / 0.2 7 1 130 3 20 37 230 / 50 110 24D

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