Italtherm
Інструкція Italtherm Инструкция Italtherm CITY MAX 26K 30K
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IMPORTANT! Install the gasket included in the documents bag, on the inlet/outlet flange, as shown on page 21. Instruction Handbook for: use adjustment maintenance installation CITY MAX 32 K 26 K
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Green Heating Technology 2 Table of Content Safety warnings Safety warnings symbols legend . . . . . . . . . . . . . . 4 References to Laws and Norms . . . . . . . . . . . . . . . 4 Personnel in charge of installation . . . . . . . . . . . . . . 4 Installation, use and maintenance . . . . . . . . . . . . . . . 4 User warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 First starting up and Use . . . . . . . . . . . . . . . . . . . . . . . 5 Installation, first starting up, maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Appliance booklet or central plant booklet . . . . . . . 6 Combustion checking . . . . . . . . . . . . . . . . . . . . . . . . . 6 Boiler operation and servicing . . . . . . . . . . . . . . . . . . 6 User guide The front control panel . . . . . . . . . . . . . . . . . . . . . . 7 Commands on the lower side . . . . . . . . . . . . . . . . 8 Commands outside the boiler . . . . . . . . . . . . . . . . 8 Typical use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 9 Boiler activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Temperature adjustment . . . . . . . . . . . . . . . . . . . . . 10 Anti-Legionella function . . . . . . . . . . . . . . . . . . . . 10 Incidental malfunctioning . . . . . . . . . . . . . . . . . . 11 The burner doesn’t turn on . . . . . . . . . . . . . . . . . . . 11 Shortage of domestic hot water production . . . . . . 11 Boiler inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety shut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stand-by mode with anti-frost & anti-locking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 “Ambient Anti-Frost” Function . . . . . . . . . . . . . . . . 13 Installation Law and regulation prescriptions for the installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Dimensions and connections . . . . . . . . . . . . . . . . 14 Pump capacity diagrams . . . . . . . . . . . . . . . . . . . 14 Warnings for the installation of optional kits or special systems . . . . . . . . . . . . . . . . . . . . . . . . 15 Floor heating system . . . . . . . . . . . . . . . . . . . . . . . . . 15 Specifications for inlet air . . . . . . . . . . . . . . . . . . . 15 Domestic water supply characteristics . . . . . . . . 15 Protection against freezing . . . . . . . . . . . . . . . . . 15 Siphon overflow drain . . . . . . . . . . . . . . . . . . . . . 16 Outdoor installation in a partially protected place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Positioning and fastening . . . . . . . . . . . . . . . . . . . 16 Hydraulic system (DHW and heating) . . . . . . . . . 18 Advices and suggestions to avoid vibrations and noises in the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cleaning and preservation of the systems . . . . . . . 18 Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Condense drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 System filling and pressuring . . . . . . . . . . . . . . . . 19 DHW storage tank filling . . . . . . . . . . . . . . . . . . . . . . 19 Heating system filling . . . . . . . . . . . . . . . . . . . . . . . . 19 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 21 Flue systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation of the flue inlet/outlet flange gasket . 21 General indications . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Dimensioning the inlet and outlet ducts . . . . . . . . . 23 Flue system types . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Examples of installation of inlet and outlet ducts . 25 Adjustment and Maintenance First starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Maintenance operations . . . . . . . . . . . . . . . . . . . 27 Access to the inside of the boiler . . . . . . . . . . . . 28 Venting the primary exchanger . . . . . . . . . . . . . . 29 Venting the storage coil . . . . . . . . . . . . . . . . . . . . 29 Combustion group cleaning . . . . . . . . . . . . . . . . . 30 Combustion test and adjustment . . . . . . . . . . . . 31 Max heating power adjustment . . . . . . . . . . . . . 33 Power input / display / fan rpm table . . . . . . . . . 34 Electronic settings . . . . . . . . . . . . . . . . . . . . . . . . . 35 Accessing the main board . . . . . . . . . . . . . . . . . . . . 35 Main board settings . . . . . . . . . . . . . . . . . . . . . . . . . 35 Gas conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Hydraulic settings (pump speed) . . . . . . . . . . . . . 38 Draining the heating system and the storage coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Draining the storage unit . . . . . . . . . . . . . . . . . . . 38 Alarms - boiler block . . . . . . . . . . . . . . . . . . . . . . . 39 Warnings for servicing . . . . . . . . . . . . . . . . . . . . . 44 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Boiler internal components . . . . . . . . . . . . . . . . . 48 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . 49 Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . 50 Addendum Outdoor Sensor Kit . . . . . . . . . . . . . . . . . . . . . . . . 51 Installation and setting . . . . . . . . . . . . . . . . . . . . . . . 51 Outdoor Sensor kit and Remote Control . . . . . . . . . 51 Remote Control Kit . . . . . . . . . . . . . . . . . . . . . . . . 52
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Green Heating Technology 3 Safety warnings This instructions manual is an essential and complementary part of the product and it is supplied to- gether with the boiler. Carefully read the manual, achieving all important information for a safe installation, use and servicing. f f Carefully keep the manual, together with the documentation of all the accessories of the boiler and of the system, for any further consultation you may need. f f The installation must be carried out by a qualified technician, in accordance with manufacturer in- structions and with the relevant requirements of the current issue. f f Carbon monoxide (CO) danger: the CO is a no-smelling and no-colour gas. When a forced draught boiler with air inlet from the room (appliance type B2) is installed, permanent ventilation of the installation room is mandatory and extremely important. Ventilation must be made and sized in compliance with Laws and Rules in force. Whatever manumission, closing or neutralization of the permanent ventilation could lead to very serious consequences to people in the rooms, as intoxica- tion by CO, permanent damage and death. Besides, the CO and O2 mix can be explosive. f f A qualified technician is a person with a specific technical competence in the field of the heating appliances for domestic use and domestic hot water production, in compliance with Laws and Rules in force. f f The operations that the user can do are only and exclusively the ones contained in the "USER GUIDE" section. f f The manufacturer has no contractual and extra-contractual responsibility for any damage arising from wrong installation, wrong use and non-observance of current laws and instructions given by the manufacturer himself. f f Important: this gas boiler is used to heat the water at a temperature lower than the boiling one, at atmospheric pressure; it must be connected to an heating system and/or to a domestic hot water system, in accordance with its features and power. f f Packing items (cartons, nails, plastic bags and so on) must not be left within children easy reach, as they are potentially dangerous. f f Before any cleaning or servicing operation, disconnect the boiler from the mains electrical supply by means of the main electrical switch and stop the gas supply by means of the suitable cock. f f In case of fault and/or bad operation of the appliance, disconnect it immediately and do not try to repair it by yourselves. f f Boiler servicing and repair must be carried out exclusively by qualified technicians, which will use original spare parts. Strictly observe the above requirement, avoiding any risk of compromising the appliance safety. f f If the appliance should be definitively dismissed, remove or cut off any potential dangerous item. f f When transferring the appliance (e.g. leaving it installed after a removal or a sale of the building), make always sure that the instructions manual is close to the boiler for the future use of new owners and/or installers. f f This appliance must be used for its clearly recommended utilization only. Any other utilization must be considered dangerous and incorrect. f f It is strictly forbidden to use the appliance for different purposes than the specified ones. f f This appliance must be installed exclusively to wall.
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Green Heating Technology 4 Safety warnings symbols legend Generic safety warning Electrical danger (fulguration) Physical danger (personal damage) Thermal danger (burns) General warning or advice to avoid material damage or to achieve improvements References to Laws and Norms All the references to norms and national laws mentioned in this handbook are indicative as laws and norms are subject to issues and integrations by the authorities in charge. Also comply to eventual local norms and laws (not mentioned in this handbook) in force in the territory where the installation takes place. Personnel in charge of installation Place here all necessary advices according to national rules about WORK SAFETY of Personnel in charge of installation. An example follows: Law number 192 of 19-August-2005 and further revisions “Title of the law or brief description”. Always proceed with caution when handling the boiler and carrying out installation/mainte- nance work as metal parts may cause injuries such as cuts and abrasions. Wear personal protec- tion devices (especially gloves) while doing the above mentioned operations Installation, use and maintenance Place here all necessary advices according to national rules about BOILER INSTALLATION, An example follows. Law number 412 of 26-July-1993 n°412 and further revisions “Title of the law or brief description”.
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Green Heating Technology 5 User warnings Important In case of gas smell: 1 - do not press electrical switches, use the telephone or other objects that can provoke sparks; 2 - open immediately the windows and the doors in order to cleanse the room air; 3 - close the gas supply taps; 4 - call a qualified technician. Do not obstruct the ventilation openings of the gas boiler room, in order to avoid possible dangerous situations as the creation of poisonous or explosive mixtures. First starting up and Use The first starting up and the maintenance of the boiler must be performed by a professionally qualified staff (for example the installer or the Service Centres authorized by ITALTHERM) The latter will check that: f f the label technical data of the gas boiler correspond to those of the gas available; f f the main burner regulation is compatible with the gas boiler output; f f the chimney works correctly, expelling the combustion products; f f the air supply and the combustion products evacuation work correctly, in accordance with the re- quirements in force; f f the conditions for a correct ventilation are guaranteed, also when the gas boiler is located inside a closed space (with suitable caracteristics). This boiler is designed and prepared to be supplied with Natural Gas G20 (Methane) or Com- mercial Propane G31. A qualified technician can convert it to operate with one of these two types of gas above said. It must never be used with butane gas G30 (that can be present, pure or mixed with Propane G31, in the portable gas bottles for cookers). The User must not touch sealed items nor break the seals. Only specialized technicians and the official technical service can break the seals of sealed items. The boiler is fitted with safety devices that block operation the case of problems with the boiler or related systems. These devices must never be disabled: if a device intervenes frequently, have a qualified technician located the cause, even in systems to which the boiler is connected, and in the flue inlet/outlet system that must be efficient and made according to the laws in force (see examples in paragraph "Flue systems" on page 21). If a boiler component has failed, you must only use original replacement parts When the boiler is off for a long period see the Paragraph "Boiler inactivity" on page 11 for the necessary precautions about the electrical supply, the gas supply and the protection against freezing. Do not touch the heated surfaces of the boiler, as the doors, the flue, the chimney pipe, etc., also after the boiler operation because, for a certain time, these surfaces are overheated. Any contact with them can cause dangerous scalds. It is then forbidden to let children or inexperi- enced people be close to the boiler, during its operation.
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Green Heating Technology 6 f f Do not expose the wall hung gas boiler to water or other liquids sprinklings, or to vapours directly coming from gas cookers/hobs. f f Do not obstruct the air inlet or flue outlet terminals, even momentarily or partially. f f Do not put any object on the gas boiler and don't leave any flammable liquid or solid materials, (e.g. paper, clothes, plastic, polystirene) in its proximity. f f This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervi- sion or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. (CEI EN 60335-1:2008-07 § 7.12) f f If the gas boiler is going to be definitively unused, call a qualified technician to carry out all required operations, checking in particular disconnection of gas, water and electrical supplies. f f Only for those models that draw directly from the installation room (type B appliances installed in- door): the installation of aspirators, fireplaces or similar appliances in the room where the type B ap- pliance is installed (and in adjacent rooms in case of indirect ventilation) is prohibited except in cases foreseen by rules in force and anyway the installation must be made in compliance with all specific safety measures mentioned in the rules and laws in force, even in case of modifications or additions. Installation, first starting up, maintenance and servicing All operations for installation, first starting up, maintenance, servicing and gas conversion must be car- ried out by qualified technicians, in accordance with the Norms and Laws in force. Maintenance operations must be carried out in compliance with the manufacturer prescriptions, and in compliance with the laws and rules presently in force for what is not mentioned in this handbook; we advice to perform them at least once a year to maintain the boiler’s performance. Appliance booklet or central plant booklet All appliances must have an appliance booklet (for outputs less or equal 35 kW) or a central plant book- let (for outputs more than 35 kW). All maintenance and servicing operations and combustion checks must be written on the booklet, together with the name of the person responsible for servicing. Combustion checking Combustion checking consists of a control of the boiler efficiency. Boilers that, after the checking, will have efficiency rates lower than the ones required and not changeable with suitable adjustments (that must be performed by qualified technicians), must be replaced. Boiler operation and servicing The user (owner or tenant of the flat where the boiler is installed) or the administrator of the block of flats (in case of a central heating system) are responsible for the appliance operation and servicing; they can both transfer the responsibility of the servicing and eventually of the operation to another person, which must be a qualified technician as indicated by the Laws. Even if the user or the administrator de- cide to assume personally this responsibility, ordinary servicing of the warm air heater and combustion checks must be anyway carried out by a qualified technician
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Green Heating Technology 7 User guide The front control panel 1 green Electrical Supply Indicator Light Off - boiler not electrically supplied. Blinking - boiler electrically supplied, but not active because the knob 12 is on . On - boler active. Knob 12 on , or on along the scale . Flashing with short pulses - actuated for mistake, by the user, a function reserved to the technician. Rotate immediately the knob 13 back on the scale . 2 yellow Burner Indicator Light Off - the flame in the burner is off. On - the flame in the burner is on. 3 red Alarm Indicator Light Off - no problems detected. Blinking or Flashing - see "Alarms - boiler block" on page 39. Flashing with short flashes - the user has activated, by mistake, a function reserved to the technician. Turn the knob 13 on the scale immediately. 4 service Indication, on the display, for the Technician, usually not displayed. 5 2-digit number on the display Normally it indicates, in °C, the measured temperature of the heating system flow or of the DHW storage (when the relevant symbol 6 or 7 flashes). During the adjustment of the heating system temperature (rotating the knob 12 along the scale ) or domestic hot water (rotating the knob 13 along the scale ) it shows the set value, in °C. When the knob 13 is turned on 17, it is displayed "– –". 6 - on the display Usually, they are shown in fixed mode and they indicate that the boiler is ready to supply heat to the relevant heating or DHW . When the boiler is in Summer mode , the symbol is not shown. They blink during the actual heat delivery, by the boiler, to the relevant system. 7 s e r v i c e service 8 9 10 12 13 14 15 17 16 11 3 4 6 7 5 1 2 00056 00
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Green Heating Technology 8 8 Position on which the knob 12 should be positioned to turn the boiler off or to reset a boiler block. 9 Position on which the knob 12 should be positioned to activate the boiler in Winter mode (both Heating and Domestic Hot Water functions available) (attention: only if the Remote Control Kit is not installed). 10 Scale on which the knob 12 should be positioned to adjust the Heating system tem- perature (attention: only if the Remote Control Kit is not installed). 11 Position on which the knob 12 should be positioned to activate the boiler in Summer mode (only Domestic Hot Water function available and exclusion of Heating) 12 boiler mode Knob that allows to switch the boiler in OFF mode 8, Summer 11 or Win- ter 9 and to adjust the Heating system temperature 10. If the Outdoor Sensor Kit is installed, see "Outdoor Sensor Kit" on page 51. If the Remote Control Kit is installed, see "Remote Control Kit" on page 52. 13 DHW Knob that allows to adjust the temperature of the water in the storage (along the scale 14 ). The use of the positions 15 and 16 is reserved to the technician. 14 Scale on which the knob 13 should be positioned to adjust the Domestic Hot Water temperature in the storage. 15 service Positions of the knob 13 which use is reserved to the technician. Do not turn the knob 13 on these positions. 16 17 By turning the knob 13 on this position (hot water stand-by), the storage heating is completely deactivated and "– –" is displayed. This allows a considerable gas saving, especially in medium and long term periods in which the hot water availability is not necessary. The storage anti-freeze function remains active. The anti-legionella func- tion is disabled. Commands on the lower side 18 System pressure gauge 19 System filling and pressure restoring cock 20 GAS cock Commands outside the boiler Externally the boiler, suitably positioned in the build- ing (generally by the installer or by the electrician), two devices that the user should access to, are present. The presence and the characteristics of these devices are prescribed by the regulation in force. Two-pole switch: it is located usually close to the boiler and it's for electrically insulating the boiler itself from the domestic mains power supply network. 00066_00 18 19 20
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Green Heating Technology 9 Room thermostat: it commands electrically the boiler to activate or deactivate the heating system, in order to keep the room temperature (detected by a sensor) within a value set by the user, Regulation in force prescribe its positioning, the temperature limits within the user can adjust it and the periods of heating. On trade are available programmable room thermostats: most of them allow to make a weekly programming of various temperature levels, besides special programs for various purposes. We suggest to choose original ITALTHERM accessories. Typical use Preliminary operations f f Firstly, the knob 12 should be on the position 8 . f f Make sure, by the gauge 18 that the cold-system temperature is always within 0.5 and 1.5 Bar (opti- mal: 1÷1.5 Bar). When the pressure drops below 0.5 Bar, the boiler stops working. In this case, open the system filling cock 19 up to obtain, on the gauge, a value between 1.0 and 1.5 Bar. The system pressure raises with the temperature: a too high initial cold-system pressure could lead to water drain from the 3 Bar safety valve after the system heating-up. f f Make sure that the gas cock 20 is open. f f Make sure that the boiler is electrically supplied: green light 1 blinks. Boiler activation f f Rotate the knob 12 on Summer 11 if you want to have only hot water production, or on Win- ter 9 if you need both room heating and hot water production. f f Opening a hot water cock, the burner ignites and, after a short time (that also depends on the char- acteristics of the plant externally the boiler) hot water flows from the cock. f f In Winter mode, consequently a request by the Room thermostat, the burner ignites and the produced heat is sent, by means of the system vector liquid, to the heating elements of the building. If, in the mean time, a Domestic Hot Water request takes place, this latter has the priority for the whole request time. Since the DHW requests are usually limited in time, they generally don't affect the room heating. s e r v i c e service 8 9 10 12 13 14 15 17 16 11 3 4 6 7 5 1 2 00056 00
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Green Heating Technology 10 Temperature adjustment Note: correct adjustment leads to creating the conditions for energy saving. f f Heating system adjustment: by rotating the knob 12 along the scale 10, the setting of the heating system temperature is made (the value, during the adjustment, is shown on the display 5). Generally, in the deep cold season and/or with poor building thermal insulation (or if you notice that the burner stays on for a long time, but the room temperature rises too slowly) prefer higher settings. On the contrary, if you notice that the room temperature exceeds too much, for thermal inertia, the value set on the room temperature, it's appropriate to decrease the system temperature. Note: if the Outdoor Sensor Kit is installed, see also "Out- door Sensor Kit" on page 51; if the Remote Control Kit is installed, see also "Remote Control Kit" on page 52 and the relevant instruction booklet. Note: don't make confusion be- tween the heating system temperature here de- scribed, with the temperature of the room set on the Room Thermostat. f f Domestic hot water adjustment: by rotating the knob 13 along the scale 14, the setting of the hot water temperature inside the storage, is made (the value, during the adjustment, is shown on the display 5). On this type of boiler, we suggest to set the knob in such a way to have a comfortable hot water temperature by drawing only hot water or eventually by mixing it with a little cold water. Avoid maximum values if not strictly needed, that will force to mix the hot water with bigger quanti- ties of cold water. A high storage temperature increase the limestone scale of the storage. Also gas consumption depends on the set temperature, aside from the quality of the storage thermal insulation. Remark: Because of the thermal dissipation along the pipings, it could be necessary a certain time before the temperature of the water out of the faucet gets stabilized. ATTENTION: positions service 15 and 16 are reserved to the technician. Don't turn the knob on these positions to avoid malfunctions. Should this happen by mistake, turn immediately the knob 13 on the scale 14. Anti-Legionella function With regular periodicity the boiler, in Summer or Winter mode, automatically provides for the heating of the water in the storage, so as to destroy eventual bacteria (expecially Legionella spp.) which form in quiet warm water. Remark: the Anti-Legionella function is not active when the boiler is in stand-by 8 or in "hot water Stand-by" 17 mode. Incidental malfunctioning Avoid performing personally any intervention that are job of the technician, for example the ones on the electrical circuits, on hydraulic system or on the gas system, and whatever other operation that's not mentioned in this "User Guide" section and expressly allowed to the User. Always address yourselves to qualified personnel. s e r v i c e service 8 9 10 12 13 14 15 17 16 11 3 4 6 7 5 1 2
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Green Heating Technology 11 Boilers must be always equipped with original accessories only. ITALTHERM Srl is not responsible for damages caused by the incorrect, wrong or unreasonable use of not original materials. The burner doesn’t turn on f f if the room thermostat (or programmable room thermostat, or similar) is installed, check that it is really requiring the room heating; f f check that the electrical power supply is present and that the Summer/Winter knob isn't posi- tioned on (stand-by) but on Summer or Winter . The GREEN light should be steadily ON (see details in the paragraph "The front control panel" on page 7); f f if the RED locking light was on or blinking, or if you notice an anomalous behaviour of the light indi- cators, see the paragraph "Alarms - boiler block" on page 39; f f check on the gauge that the boiler pressure is correct (1÷1.5 Bar in a cold state) or at least not below 0.5 Bar; f f let the technician to look up the notes in the paragraph "Electrical diagram" on page 49. Shortage of domestic hot water production f f check that knob is not set on a too low value or to the “service”position f f call a qualified technician to check gas valve regulation; f f call a qualified technician to check, and eventually clean, the coil of the DHW storage. Remark: where the water hardness value is too high, it is suggested the installation of a soften- ing device, in order to prevent the limestone precipitation; this operation avoids a frequent cleaning of the coil of the DHW storage. Boiler inactivity The effects of the periods of inactivity can be relevant in particular situations such as in flats used only for some months per year, most of all in cold places. The user will have to decide to put the boiler in the SAFETY SHUT OFF state disconnecting all the sup- plies, or to leave it in stand-by and use the Anti Frost Function. When there is the possibility of freezing it is convenient to chose between the advantages and the disadvantages of the SAFETY SHUT OFF and of the Stand By/Anti Freezing Way. Safety shut off f f Turn off the general switch on the Electrical Supply Line of the Boiler; f f Close the Gas Tap; When it is expected that the temperature is going to decrease under 0°C, call a technician to do the following: •• Fill the system, included the primary circuit of the storage unit and the relevant coil, with an anti-freezing solution (unless the system was already filled with said solution) otherwise it must be completely emptied. Notice that if it had been necessary to restore the pressure (because of possible loss) in an heating system already filled with an Anti freezing solution, the concentration of the solution could have decreased and it could not guarantee the Anti freezing Protection. •• let the condense collector syphon be emptied unscrewing its inferior cap.
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Green Heating Technology 12 •• completely empty the hot and cold sanitary water system, including the sanitary circuit and the tank of the domestic water storage. Remark: the boiler is equipped with a system which protects the main components from the excep- tional cases of mechanical lock, due to the inactivity in presence of water and scale. The anti- locking function can’t work in Safety shut off mode, because of the lack of electrical supply. Before re-igniting the boiler, have a technician check that the pump is not blocked due to inac- tivity (for the technician: unscrew the plug in the centre of the cap to access the rotor shaft and turn it with a screwdriver or other suitable tool). Stand-by mode with anti-frost & anti-locking function When the boiler is left in stand-by during a period of inactivity, it will be protected against freezing by several functions provided in the electronic controller, which heat the parts involved when the tempera- ture falls below factory set values. The anti-frost heating is accomplished by turning on the burner and pump. In addition, when the boiler is in stand-by, it periodically activates the main internal components to avoid rare cases of blockage due to inactivity in the presence of water and lime. This can also occur when the boiler is locked (red lamp on) provided that the system pressure is correct. In order for these systems to be active: •• the boiler must be receiving gas and electricity; •• boiler must be left in stand-by mode (Summer/Winter knob on , green lamp flashing); •• system pressure must be correct (1÷1.5 bar in a cold state, minimum 0.5 bar) In case of lack of gas, the burner won’t turn on and the boiler will go in LOCK OUT state (red lamp on or flashing). Nevertheless the pump will work, making the water circulate in the system and reducing in this way the possibility of freezing. ATTENTION: the anti-frost protections cannot intervene in the absence of electricity. If you an- ticipate this possibility, we recommend you add a good brand of anti-freeze to the heating sys- tem, following the producer’s instructions. We recommend to ask directly the installer/technician about the type of antifreeze product put in the heating system during installation. When the power comes back on, the boiler will check the temperature measured by the two probes and, if it suspects freezing verified by a particular automatic control cycle, alarm 39 will be triggered. For more details, see the relative description in the paragraph "Alarms - boiler block" on page 39. We recommend that you completely empty the hot and cold sanitary water system. The anti- frost function does not protect the sanitary circuit outside the boiler.
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Green Heating Technology 13 “Ambient Anti-Frost” Function If the building relevant to the boiler remains unoccupied during cold weather periods, you should con- sider the chance to extend the protection against freezing to the whole heating system (and therefore to the rooms) besides the boiler itself. Also for this function, the boiler must be receiving gas and elec- tricity, and the system pressure must be correct. f f if the Remote Control (original, optional kit) is installed, the anti-freeze function is automatically performed by switching the boiler in stand-by mode by means of the suitable button on the control itself. The boiler, the DHW storage, and the rooms will be kept at a minimum temperature that avoids the freezing of the liquids in them; f f if a common room thermostat or chronothermostat is installed, featuring* the “Ambient Anti- Frost” function, and you want to use it, it'is necessary to leave the boiler in Winter mode and NOT in stand-by or in Summer mode) to allow the boiler to activate when the room tempera- ture sensor requires the heating. To minimize the gas consumption, it's also advisable to lower the storage temperature by turning the DHW temperature knob to the minimum, on , otherwise the water in the storage will be uselessly kept hot. * failing this function, you can anyway set the room temperature a few degrees above zero, e.g. +5°C (if it's a chronothermostat, remember to set it to manual mode). The “Ambient Anti-Frost” function does not protect the sanitary circuit outside the boiler and, especially, in areas where the heating system doesn’t reach. For this reason, we recommend that you empty the cold and hot sanitary system, if they were at risk of freezing. Installation Law and regulation prescriptions for the installer Note for the translator/writer: Place in this paragraph all the recommendations relevant to the compli- ance with laws in the destination nation/country (if any). As an example (from Italian regulation): Characteristics of the room: as this boiler has an heat output lower than 35 kW (about 30000 Kcal/h), it is not required to install the appliance in a dedicated room, provided that the room complies with the regulation in force and that all installation rules assuring a safe and regular gas boiler operation, are strictly respected. Permanent ventilation of the installation room is mandatory and extremely important when a boiler with air draught from the installation room (B… appliance type) is installed. Ventilation must be made and sized in compliance with Laws and Rules in force. Instructing the user: at the end of the installation, the installer must: •• explain the operation of the boiler and its safety devices to the user; •• give this user this booklet and the documentation within his/her competence, duly filled in where required.
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Green Heating Technology 14 Dimensions and connections 10 53 50 250 250 ±12 50 ±12 ±12 128 90 177 76 69 70 97 60 128 90 120 52 150 60 G G L TA F F C C M M R R 600 900 425 439 68 93 210 137 880 20 11 11 150 163 265 135 G C R M F 3 1 2 SC SC TA / L 842 870 848 845 00067_00 Legend: C DHW outlet (½”) F Fresh water inlet (½”) R System return (¾”) M System flow (¾”) G Gas: connection on the boiler ¾”; on the wall, using the optional original fitting kit ½” 1 Flue outlet 2 Air inlet for coaxial system 3 Air inlet for split-pipe system TA/L Indicative position for electrical power supply and room thermostat wirings TA Room thermostat wiring L Electrical power supply wiring SC Indicative position for the condensate drain upper view front view - hydraulic connections on the boiler left side view - hydraulic connec- tions on the boiler City Max 26 K City Max 32 K front view - hydraulic connections on the wall (with optional fitting kit) Pump capacity diagrams 0 1 2 3 4 5 6 0 200 400 1000 1200 600 800 1400 00069 00 pressure (m H2O) water flow (l/h) mod. 26K mod. 32K speed 3 - 2 of the pump The graph is referred to the capacity available to the system.
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Green Heating Technology 15 Warnings for the installation of optional kits or special systems Floor heating system The safety thermostat(s) that protects the floor against overheating (that could damage the cladding, the structure or the system itself) must be installed on the flow starting end of the serpentine embedded in the floor itself. It should not installed on the system flow pipe in prox- imity of the boiler, otherwise frequent and unjustified boiler locks, caused by its triggering, are possible. Specifications for inlet air Air must be withdrawn from places free of pollutant (like fluorine, chlorine, sulfur, ammonia, alkaline or similar agents). In the event of installation of the boiler in atmospheres with not negligible presence of aggressive chemical substances (e.g. hairdressing salons, laundries) we recommend to foresee the air inlet from outdoor, choosing the type C installation. Domestic water supply characteristics The cold water inlet pressure must be lower than 8 Bar (higher pressure will lead to the storage safety valve triggering). Besides, for an optimal boiler functioning, water pressure should be more than 1 Bar. A lower pressure could make difficult to restore correctly the pressure of the heating system. In case of higher pressure it is indispensable to install a PRESSURE REDUCER upstream the boiler. The cleaning frequency of the storage coil depends on the water supply hardness. If the water hard- ness is more than 25° fr it’s required to install a softener to bring the hardness below that value. Besides, the presence of solid residuals or impurities in the water (for example in case of new systems) could compromise the correct functioning of the boiler. For DHW production systems, the regulation in force prescribes a safety filter to protect the systems. The condensing burner/exchanger assembly requires particular characteristics for the heating system liquid, more restrictive than the ones of the inlet domestic water. See the "Heating" sec- tion of the table "Technical data" on page 45. Protection against freezing Thanks to its antifreeze system, inner components could never reach a temperature lower than 5°C. This system is activated when the boiler is supplied by the electrical and gas lines, provided that the pressure in the heating system is correct. In case of boiler installation in rooms where temperature can drop down to 0°, it is advisable to fill the heating circuit (included the primary circuit of the storage unit and the relevant coil) with an antifreeze liquid specific for heating systems, propylenic glycol based, following the in- structions of its manufacturer. Pay attention to the correct product concentration: adding those substances to the heating water in incorrect dose could lead to the deformation of the seals and cause unusual noises during operation. ITALTHERM S.r.l. will not be held responsible for consequent damages. Instruct the User about the antifreeze function of the boiler and about the antifreeze product added in the heating system.
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Green Heating Technology 16 Siphon overflow drain The boiler’s siphon is equipped with a supplementary safety discharge SCD that protects the burner in the very situation in which the condense does not from correctly from the drain pipe downstream from the siphon. Since this is easily accessible from the rear of the boiler, evaluate the opportunity to use it or not before installing the boiler, by connecting to it a section of flexible hose 1 suitable for condense. On its other end, the hose 1 should be inserted, avoiding bends and kinks, in a suitable drain, such as the funnel of the condense drain or safety valve. Do not pierce the prepared hole 4. As an alternative, although NOT recommended, you could simply leave the drain SCD open. The burner will anyway be protected if the siphon gets ac- cidentally blocked, but the condense (acid) will leak into the environment and could damage surfaces it touches (such as marble). Check the seal of siphon, making sure that the caps 2, 3, 5 and 6 are properly and completely screwed/inserted. Outdoor installation in a partially protected place “City Max xx K” forced draught, condensing mod- els can be installed outdoor, but only in partially protected places. The boiler minimum and maximum working tem- peratures are mentioned in the paragraph "Tech- nical data" on page 45 and on the boiler data plate. The materials used for the boiler installation, in- cluding the devices and/or the materials used for thermal insulation, should be so to maintain their functionality within the temperature range indi- cated on the data plate. If the place where the boiler is located is converted from outdoor to indoor (e.g. veranda) it will be necessary to verify the compliance of the new configuration with the laws and rules in force, and to make the modifications required. Positioning and fastening Remark: A re-usable metal jig ( D in the figure) can be ordered separately, so as to facilitate connec- tions and fixing points positioning (when the original connection kit is used). If the metal jig and/ or the original connection kit are not used, refer to the paragraph "Dimensions and connec- tions" on page 14 for the position of the connections directly on the boiler. f f Locate the exact position of the boiler considering the sufficient clearances for maintenance and servicing: at least 50mm laterally and 300 mm on the lower side f f To fix the boiler with wallplugs (“stud” type with nut), centre the relevant wall holes as regards to A points. To hang it with open hooks, place hooks in correspondence with B points. 00004 00
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Green Heating Technology 17 f f If the metal jig is used, hang it on the wall using the same wallplugs or hooks and the holes or slots indicated in the figure ( A for the plugs and B for the open hooks). f f Fix up the connections and all ducts for heating flow and return, cold water, hot water, gas and electrical cables, predisposing them in the holes of the metal jig or respecting the measures in the paragraph "Dimensions and connections" on page 14. The upper edge of boiler’s body, used as a refer- ence in the paragraph "Flue system types" on page 24, is represented by the dotted line C in the figure. f f Remove the jig (if used) and hang the boiler to the wallplugs or hooks, using the holes or slots indicated in the figure ( A for the plugs and B for the open hooks). f f Remove the plastic caps placed to close the hydraulic connections on the boiler. f f Proceed with the hydraulic, gas, electrical and flue connections follow- ing the instructions and warnings reported in the following paragraphs. The connections of the boiler are engineered to fit plain couplings with screw ring, interposing a plain gasket of suitable size and ma- terial, that ensure a reliable seal even without excessive tighten- ing force. They are NOT suitable for hemp, teflon tape or similar materials Remark: the lower grid is spare inside packing, not assembled. We sug- gest to fix the grid only at the end of the boiler installation opera- tions. Gas (1/2”) Hot Water Outlet (1/2”) Cold Water Inlet (1/2”) Heating Flow (3/4”) Heating Return (3/4”) Electrical Power Supply Room Thermostat 50 18 10 18 564 128 90 76 60 69 70 97 177 250 250 600 20 50 880 A A A B B C D 900 20 18 20 11 9 53 A B C 00070 00
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Green Heating Technology 18 Hydraulic system (DHW and heating) Make sure that the hydraulic and heating systems ducts are not used as earth connections of the electrical system. They are absolutely NOT SUITABLE for such a use. Besides: they don't guarantee the earth dispersion; in case of electrical fault they could generate a fulguration risk; there could take place galvanic currents in the pipings and consequent corrosion and hydraulic leaks. Advices and suggestions to avoid vibrations and noises in the system f f Do not use pipes with reduced diameters; f f Do not use bends with small radius and reductions of important sections. Cleaning and preservation of the systems The efficiency, the reliability and the safety of the boilers, as all generic thermal systems and compo- nents, depend strictly on the features of the water that supply them and on their treatment. A proper treatment of the water improves the protection of the systems against corrosions (and there- fore perforations, noise, leaks, etc.) and limestone incrustations that drastically reduce the efficiency of the thermal exchange (consider that 1 mm of limestone incrustations reduces of 18% the thermal exchange of the heating element on which it has been formed). ITALTHERM guarantees its products only if the characteristics of the water comply with UNI 8065, re- ported also in laws on energy saving. Thoroughly wash the heating system with water, before connecting the boiler. This will elimi- nate residual like welding drops, slag, hemp, mastic, mud, rust and other dirt from pipes and radiators. Otherwise, these substances could enter the boiler and damage the internal compo- nents (pump etc.). f f In case of old or very dirty systems, to wash them use specific, proven efficiency products, in the suitable quantity and following the instructions of its manufacturer. f f If the water on boiler inlet is harder than 25° fr, it’s required to install a softener to bring the hardness below that value, as required by the reference regulation. f f For floor system and generally all low temperature systems, the water treatment product must have filming action (protection against corrosion and incrustation) and action against bacteria and algae. Heating system f f Connect the safety evacuation ducts of the boiler to an evacuation funnel. If safety valves are not connected to an evacuation device, their intervention could flood the room. The manufacturer can- not be held responsible for any damage arising from that situation. Condense drain Insert the flexible pipe of condense outlet inside the outlet funnel (or other inspectable connection de- vice) properly installed for this purpose, or in the outlet funnel of the safety valve, in case of the above mentioned outlet is able to receive the acid liquids of the condense as foreseen by the norms in force in matter of condensing boilers. The system must be made in order to avoid the condense freezing. Before the activation of the appliance be sure that the condense can be evacuated correctly.
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Green Heating Technology 19 System filling and pressuring Once all system connections have been carried out, proceed with the filling of the heating system and of the DHW storage. This operation should be made with care, respecting the following steps: The operations to completely purge the air from the heating system and from the storage coil, require the activation of the boiler, therefore the final purging must be performed, by qualified technicians, during the first starting up. DHW storage tank filling 1. Load the DHW expansion vessel (see "Boiler internal components" on page 48) to the aqueduct pressure; 2. open one of the hot water taps in the DHW system; 3. gradually open the hand valve 5 installed on the boiler's cold water inlet connection; 4. when only water flows out of the tap, close it. Heating system filling 1. Open the radiators venting devices; 2. Check that the plug of the automatic air vent, in- corporated in the boiler circulator, is unscrewed: if not, unscrew it and leave it unscrewed, even afterwards, for normal operation; 3. If it's required to fill the system with anti-freeze solution, do this operation, then hermetically close the connection or the valve used to put the solution in, to allow the pressurization. 4. Gradually open the filling cock 1; 5. Check the correct functioning of automatic vent- ing devices, eventually installed on the heating system; 6. Close the radiators venting devices as soon as water flows out of them; 7. Make sure, by reading the pressure gauge 2, that the pressure reaches the optimal value of 1.0 bar (max 1.5 bar); 8. Close the filling cock 1 and bleed each radiator again; 9. Without activating the boiler, cold purge the storage coil, by using its manual venting valve (item 11 on page 29) 10. Repeat the venting and pressurization operations until the air is completely purged. The complete purging needs the activation of the pump, so it's possible only during the first starting up. 00071_00 2 4 5 1 3
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Green Heating Technology 20 Gas connection Due to various installation possibilities, the gas cock 3 supplied with the original Connections Kit has a sim- ple male Ø ½” connection, facing the rear of the boiler. The gas pipe 4, upstream the gas cock 3, should be sup- plied by the installer. While connecting the gas inlet of the boiler to the gas supply piping, it is MANDATORY to insert a PLAIN GASKET, whose dimensions and material must be adequate. Connection is NOT suitable for hemp, teflon strip or simi- lar materials. Because of the type of fitting, the use of those materials does not make the suitable seal with consequent gas leaks! This boiler is designed and prepared to be supplied with Natural Gas G20 (Methane) or Com- mercial Propane G31. A qualified technician can convert it to operate with one of these two types of gas above said. It must never be used with Butane gas G30 (that can be present, pure or mixed with Propane G31, in the portable gas bottles for cookers) therefore, if the boiler is prepared for operation with commercial Propane G31, we recommend notifying the supplier of the fuel, for example, by applying the sticker provided with the boiler (or included in the G31 conversion kit), on the gas tank or in its immediate vicinity, so that it is visible to the employee when it is being refilled. Using Propane gas G31, it is absolutely necessary to install a pressure reducer upstream the boiler. Failure to do this, the gas valve of the boiler will get damaged. The gas connection, as generally the boiler installation, must be done by qualified personnel as prescribed by the regulation in force, because a faulty gas connection could lead to fire, explosion and other very serious damages to persons, animals and objects. The manufacturer cannot be held responsible for any damage arising from that situation. f f Verify what follows: •• cleaning of all system gas pipes in order to avoid the presence of work residuals that could com- promise the correct boiler functioning; •• gas line and ramp conformity with laws and rules currently in force; •• internal and external tightness of the gas system and connections; •• supply pipe must have a section greater than or equal to the boiler one; •• supply gas must correspond to the one for which the boiler has been set: otherwise, it's manda- tory to ask to qualified personnel to set the boiler for the correct gas type; •• an interception valve must be installed upstream the appliance. f f Open the meter valve and purge the air that is inside the system pipes (including all the appliances). 00071_00 2 4 5 1 3
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Green Heating Technology 21 Electrical connections The link of the room thermostat works with a safety extra low voltage (SELV); connect it to the voltage free contacts of the room thermostat/chronothermostat. On NO account must any electrical voltage be applied to these terminals. All low-voltage wirings (e.g. Room Thermostat or Chronothermostat for trade) must be kept separate from power supply cables, as to avoid boiler malfunctioning due to electrical noise. It is advisable to use separate tubes for them. The boiler must be connected to a 220÷240V - 50Hz electrical power supply. In any case, the power supply voltage must be within the range –15% ... +10% from the nominal value (230V); otherwise it may cause malfunctions or failures. It is necessary to respect the polarities L-N (Live L=brown; - Neu- tral N=blue) - otherwise the boiler may not work - and the earth connection (yellow-green cable). Place upstream the boiler a bipolar switch in compliance with the regulation currently in force. The installation must be made complying the regulation currently in force and generally with the standard craft rules. For the general electrical supply of the appliance the bipolar switch should be used. The use of adaptors, multiple taps and extensions is not allowed. If the supply cable must be replaced, use one of the following cable types: H05VVF or H05-VVH2‑F. It is mandatory the earth connection in accordance with the rules actually in force. To replace the cable, open the control panel cover, unlock its fastening device and disconnect it from the terminals. Install the new cable proceeding in the reverse way. When connecting the cable to the boiler, it’s mandatory: •• to leave the Earth wire about 2 cm longer than the other (Live and Neutral) wires; •• to lock the cable upstream the terminals by means of the suitable fastening device. Electrical safety of the appliance is only achieved when it is well connected to an efficient earth- ing system, executed as indicated by the safety rules actually in force. A qualified technician must check that the electrical system is in line with the maximum power allowed by the boiler, indicated on the data plate, with particular attention to the cables section. ITALTHERM S.r.l. declines any responsibility for damages to persons, animals or things caused by the faulty or missing connection of the boiler earthing and by failure to comply with the rules. Flue systems Installation of the flue inlet/outlet flange gasket IMPORTANT: For a correct and safe opera- tion of the boiler it’s necessary to install, on the inlet/outlet flange 2, the gasket 1 includ- ed in the boiler’s documents bag. Before inserting the flue outlet pipe it’s therefore very important to correctly place the gasket on its seating as indicated in the figure.
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Green Heating Technology 22 General indications To grant the functionality and efficiency of the appliance it is indispensable to realize inlet and outlet ducts using flue accessories specific for condensing boilers. WARNING: the specific flue accessories components for condensing boilers, especially the parts which are in touch with the flues inlet, are so projected because they are made with plastic ma- terials acids resistant, but because of their nature, they are not suitable to resist to the higher temperature of the flues of the traditional boilers. So it is not possible to use traditional flue components for the outlet ducts of the condensing boilers, neither vice versa. When installing the pipes, we recommend lubricating the inside of their gaskets exclusively with silicone lubricants since their material (EPDM peroxide) is not compatible with other types of oils or greases If it is possible, we recommend to foresee (referring to the direction of the air/flue, see examples on page 25) an upwards slope for all the inlet and outlet ducts, in order to: f f PREVENT the water or dust or other objects entrance inside the INLET duct. In case of coaxial ducts, use the special horizontal terminal, which is especially built to respect these slopes only for the first tract of the inlet duct; f f FACILITATE, in the OUTLET duct, the flowing back of the condense towards the combustion chamber, which is built to work in these conditions and to discharge the condense. If so it is not possible, or if there are some points where the condense stagnates inside the outlet duct and if it is not possible to avoid this through a modification of the slope of the ducts, these points must be drained using the specific kit of condense collector (consult the commercial catalogues of the original accessories), and ducting the condense formed towards the outlet duct as foreseen by the norms in force in matter of condensing boilers. Air inlet and flue outlet terminals should be protected by suitable approved flue accessories, to avoid environmental elements penetration. Carefully follow the indications foreseen by the specific laws in force. Respect the minimum and maximum flue length prescribed (see "Flue system types" on page 24). In case of flue outlet on wall, the positions and the distances prescribed by the regulation mist be re- spected. The outlet duct is the assembly of components that connect the boiler to the point where the flues are discharged. The outlet can be directly outdoor only in the case foreseen by the law in force and using at the end of the outlet duct a specific terminal. In case you foreseen to discharge the combustion products through a chimney (for single user) or a common flue (for multiple users) the part of the evacuation system (the chimney or the flue) to which the outlet duct of the condensing boilers is con- nected, must be declared suitable for this purpose by its producer. In case of com- mon chimney, keep in mind the laws in force regarding the typologies and rates of users. Don't lean the flue pipe into the chimney, but stop it before the inner surface of the chimney. The axis of the flue pipe must intersect the axis of the chimney or of the flue duct. In general situations the evacuation systems of the combustion products must be properly declared suitable from the producer of the same system for wet function- ing, or must be supplied by the appliance’s producer (gas boiler). If the chimney (or the flue) were not suitable, it would be indispensable, to use it, to canalise it through specific ducts, so for example through the original flue accessories. 00044 00 Flue duct or chimney NO NO YES
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Green Heating Technology 23 Dimensioning the inlet and outlet ducts In the list that follows, you will the characteristic losses of load of the original fume venting accessories, expressed as equivalence in meters (m). Se fossero previsti accessori di fumisteria originali aggiuntivi rispetto a quelli raffigurati, nel cal- colo della lunghezza totale devono essere considerate le relative perdite di carico equivalenti, espresse come equivalenza in metri (m) nell’elenco seguente. In the case where pipes are installed with non-original accessories (this is allowed by the boiler’s C6 type-approval), but, in any case, absolutely certified for condensation, the installer must consider the losses of load specified by the manufacturer of these accessories, dimensioning the suction and dis- charge system so that the total loss of load (expressed in Pa) is between the head loss values of the boiler fan specified in the paragraph "Technical data" on page 45. Original accessories for separated systems (advises even for type C6): Connector between boiler and Ø80mm inlet pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 m - 2 Pa Connector between boiler and Ø80mm outlet pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 m - 5 Pa Separate system Ø 60 mm (original accessories): Reduction from Ø80mm to Ø60mm on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 m Reduction from Ø80mm to Ø60mm on outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 m Linear section or extension Ø60mm length 0.5m on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m Linear section or extension Ø60mm length 0.5m on outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m Linear section or extension Ø60mm length 1m on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 m Linear section or extension Ø60mm length 1m on outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 m Linear section or extension Ø60mm length 2m on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 m Linear section or extension Ø60mm length 2m on outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 m 90° bend Ø60mm on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 m 90° bend Ø60mm on outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 m 45° bend Ø60mm on inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m 45° bend Ø60mm on outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 m T-shaped condense collector Ø60mm on discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 m Inlet terminal Ø60mm (length 1 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 m Horizontal outlet terminal Ø60mm (length 1 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 m Vertical outlet terminal Ø60mm (length 1 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 m Coaxial system Ø100/60mm (original accessories): Flanged coaxial connector Ø100/60mm (starting vertically). . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 m Flanged coaxial 90° bend Ø100/60mm (starting horizontally). . . . . . . . . . . . . . . . . . . . . . . . . . . 2 m Coaxial linear section or extension Ø100/60mm (length 1 m). . . . . . . . . . . . . . . . . . . . . . . . . . . 1 m 90° coaxial bend Ø100/60mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 m 45° coaxial bend Ø100/60mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m Horizontal condense collector Ø100/60mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 m Horizontal inlet + outlet coaxial terminal Ø100/60mm (length 1 m). . . . . . . . . . . . . . . . . . . . 1.5 m Vertical inlet + outlet coaxial terminal Ø125/80mm (length 1 m, connector Ø100/60mm) . . . 1 m
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Green Heating Technology 24 Flue system types Split pipe system (C43 , C53 , C83 , C93 * ) Mod. Original*** split pipe system Ø80mm AS+SC min÷max (m) SC max (m) 26 K 1 ÷ 52 51 32 K 1 ÷ 52 51 Original*** split pipe system Ø60mm 26 K 1 ÷ 15 14 32 K 1 ÷ 15 14 00046 00 SC AS Ø80 Ø60 Ø80 Ø60 153 (Ø80) 223 (Ø60)** ** 127 (Ø80) 197 (Ø60) Example of split pipe system (C53) * Remark: Split pipes allow to make also C13 and C33 flue sys- tems. ** The dimensions on the duct axis are referred to the upper edge of the boiler’s body, close to the mouth of the first 90° bend. The difference of level due to the slopes are not considered. *** IMPORTANT: this table is referred to the original flue ac- cessories. Using non-original flue accessories (certified for condensation, whose use is allowed by the boiler’s C6‑type certification) refer to paragraph "Dimensioning the inlet and outlet ducts" on page 23. Coaxial system (C13 , C33 ) 00047 00 1300 LCV Ø100 /Ø60 Ø125 00049 00 LCO Ø100 /Ø60 127 135 Example of vertical coaxial system (C33) Example of horizontal coaxial system (C13) Mod. Original*** coaxial system Ø60/100 mm LCO min÷max (m) LCV min÷max (m) 26 K 1 ÷ 10 1 ÷ 12 32 K 1 ÷ 10 1 ÷ 12 Put the outlet coaxial horizontal terminal with the outlet head UP- WARDS, as indicated in the picture, respecting the measures in the drawing. Check that the elastic sealing collar is housed in the groove and against the outside wall face.
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Green Heating Technology 25 Examples of installation of inlet and outlet ducts We give you some correct and wrong examples of installation of inlet and outlet ducts for condensing boilers (the slope are voluntarily represented in an exaggerated way). A = Inlet; S = Outlet. 1: the most functional and economic solution is to let the condense come back towards the boiler. 2-3: if an obstacle prevents to install the ducts upwards, it is necessary to install condense collectors, so as to avoid stagnations. 4: the slope upwards of the inlet ducts, for their all length or at least only for the external tract, is sufficient to prevent that the rain water reaches the combustion chamber. 5: so the inlet must not be downwards. 6: do not let the condense go out from the flue outlet terminal. 7: the coaxial inlet/outlet duct must be installed so as the flues are upwards, and so the condense discharge itself towards the boiler. The terminal tract with inlet head and outside with an outlet out axis must be horizontal placed and it is equipped with ribs which prevents the water entrance in the external inlet duct. The internal outlet duct is upwards and canalises the condense in the correct direction. 1 2 3 S S A A A+S A A S S S 00045 00 4 5 7 6
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Green Heating Technology 26 Adjustment and Maintenance WARNING: Hereby described operation can be performed by qualified technicians only. When regulation/measuring is over, remember to tighten pressure tapping point screws and to verify the absent of gas leakages only from net pressure plug (PIN, see the picture of the gas valve) and from the connection upwards the gas valve. The gas valve, exception the PIN plug and the upwards connections, works in NEGATIVE PRES- SURE. We do not recommend to use products for the detection of the gas leakages where not expressively indicated, because these products could penetrate inside the gas valve disturbing its normal functioning. Do not use free flames to detect gas leakages! The siphon is an integral part of the combustion system and it’s necessary to check its seal during every technical intervention on the boiler. Verify that both caps (upper and lower) are properly and completely screwed. Verify that the combustion products do not go out from the outlet of the condense. The condense syphon trap of the boiler is equipped with a special device which closes when dry. Anyway, the seal is guaranteed only when the syphon trap is filled with liquid. So, at the end of the first firing / commissioning operation, it is recommended to check that the syphon trap contains liquid, e.g. checking that liquid exits the condense drain of the boiler. Before firing the boiler, check that the circulator is not blocked due to inactivity: unscrew the plug in the centre of the cap to access the rotor shaft and manually rotate it using a screwdriver or other suitable tool. During the commissioning of the new boiler, it is necessary to run the burner for 30 minutes before checking the combustion because, in that period of time, any residual fabrication va- pours could cause false results in the combustion products analysis. Remark: during the first 10 minutes of electrical power supply, the re-ignition delay in heating mode might be nil (see "Electronic settings" on page 35, SW3). •• The knob on control panel has the position "service" that is used only during the regulation of the MAX heating power. •• The ignition electronics does several ignition attempts, to avoid blocking the boiler when the ignition fails sporadically. •• When the gas supply pipe is filled with air (e.g. in case of new installation) it may be necessary to repeat the ignition cycle several times. •• The boiler is factory regulated and tested. Anyway it’s advisable, during the commissioning, to check that the regulation is correct. First starting up The first ignition operations consist in verifying the correct installation and functioning, and in the even- tual regulations which are necessary: f f verify that the data of the plate correspond to those of the net supply (electrical, water, gas); f f verify the absence of the gas leakages from the connections upwards the boiler; f f verify the proper realization and the efficiency of all the boiler connections (water, gas, heating sys- tem and electrical system);
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Green Heating Technology 27 f f verify the presence of the permanent air/ventilation outlets, correctly dimensioned and working, as foreseen by the National and Local laws depending on the appliances installed; f f verify that the evacuation flue duct corresponds to the National and Local laws and that is in good and efficient conditions; f f verify the correct functioning of the system of the outlet condense, also in the external parts of the boilers, i.e. the eventual condense collector installed on the flue outlet: verify that the liquid flow is not obstructed and that there are not inlets of gaseous combustion products inside the system itself; f f verify that the passage of the air burning and the evacuations of the flues and of the condense will be made correctly accordingly to National and Local laws in force; f f verify that the conditions for the air ventilation are granted, in case of a boiler placed inside a piece of furniture; f f vent the primary exchanger and the coil of the DHW storage, proceeding as described in the para- graphs "Venting the primary exchanger" on page 29 and "Venting the storage coil" on page 29; f f verify and, if necessary, change the boiler electronic settings to adapt its work to particular system requirements (see "Electronic settings" on page 35); Before turning on the boiler, verify that the pump is not blocked due to inactivity: unscrew the cap located at the centre of the pump’s body, locate the rotor shaft behind the cap and turn it manually using a screwdriver or other suitable tool. f f verify that the combustion is correctly regulated: go on in this chapter as described in the paragraph "Combustion test and adjustment" on page 31; During the first ignition of the brand new boiler, it is necessary that burner works for at least 30 minutes, before performing combustion checks. During this time, the fumes of the eventual residual manufacturing materials are produced, and they could alter the measured values. f f verify the correct functioning of the boiler in heating and domestic hot water version; f f fill in the foreseen documentation and leave to the user the copy of his competence. Maintenance operations The periodically maintenance operations consist in cleaning the main parts of the boiler, in the further functioning proof (especially those described by the laws in force), and in the eventual regulations, which could be necessary: f f verify the absence of the gas leakages from the connections upwards the boiler; f f verify the conformity, efficiency and good conditions of the connections to the boiler (water, gas, heating and electrical system); f f verify the presence of the permanent air/ventilation outlets, correctly dimensioned and working, as foreseen by the National and Local laws depending on the appliances installed; f f vent the primary exchanger, proceeding as described in the paragraph "Venting the primary exchang- er" on page 29; f f clean the burner, the exchanger and the funnel of the condense: go on as described in the paragraph "Combustion group cleaning" on page 30; f f check that the internal parts of the boiler are in good condition and clean; f f verify that the passage of the air burning and the evacuations of the flues and of the condense will be made correctly according to National and Local laws in force;
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Green Heating Technology 28 f f verify the correct functioning of the system of the outlet condense, also in the external parts of the boilers, i.e. the eventual condense collector installed on the flue outlet: verify that the liquid flow is not obstructed and that there are not inlets of gaseous combustion products inside the system itself; f f verify that the conditions for the air inlet are granted, in case of a boiler placed inside a piece of furniture; f f when prescribed, or if it is necessary (i.e. if you find exces- sive residual in the combustion group or in the funnel of the condense), verify that the combustion is correctly regulated: go on in this chapter as described in the paragraph "Com- bustion test and adjustment" on page 31; f f verify the correct functioning of the boiler in heating and do- mestic hot water version; f f fill in the foreseen documentation and leave to the user the copy of his competence. Access to the inside of the boiler 1. Unscrew the screws 1 and remove the lower grid 2, if any; Remark: Lower grid is spare inside packing, not assem- bled. 2. Push the front panel 3 upwards and remove it, unhook- ing it from the heads of the screws 4; 3. unscrew the two screws 7 and overturn downwards the control panel 8; 4. Should the removal of the side panel(s) 9 be necassary: •• unscrew the screws 5 and remove the brackets 6; •• remove the panel 9 upwards, slightly displacing it out- wards to free it from the chassis, unhooking it from the tongues 10; 5. after the regulations (described in the following para- graphs), close the boiler repeating everything in the oth- er sense, carefully hooking (if removed) the panel(s) 9 to the tongues 10 and the front panel 3 to the screws 4.
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Green Heating Technology 29 Venting the primary exchanger When commissioning and cleaning the combus- tion unit, it is a good idea to check that there is no air in the primary circuit of the combustion unit and, if necessary, to eliminate it by opening the valve 4 located on the top of the unit. f f To avoid wetting the sealed chamber insude, use a length of flexible hose 1, with suitable diameter, on the fitting 2; f f slowly open the venting valve by manually turning the ferrule 3 counterclockwise; f f when no more air comes out, close the vent- ing valve by manually turning the ferrule 3 clockwise, without forcing excessively. Venting the storage coil 1. Put the boiler in stand-by turning the “Summer/Winter” knob on (green lamp flashing); Remark: during this procedure, that requires the activation of the boiler in DHW, it's necessary that the storage is cold or anyway at a temperature lower than the setting: if necessary, enter cold water in the storage by opening one of the hot water taps with the boiler in stand-by. 2. insert a rubber hose 12 on the hose connection of the manual venting valve 11 of the storage coil, and lead the other end of the hose to a suitable drain; 3. gradually open the manual venting valve 11: from the hose, water and air will go out (check that there are no water leaks on the hose connection side); 4. gradually open the system filling cock (located on the boiler lower side); 5. close the system filling cock and the manual venting valve 11 as soon as only water flows out of the hose; 6. adjust the system pressure to the optimal value of 1.0 bar (max 1.5 bar) by using the filling cock (to increase) or the manual vent- ing valve 11 (to decrease); 7. turn the Summer/Winter knob fully clockwise (max heating) and activate the room thermostat; 8. the boiler will start working in heating mode; wait one minute, then activate the boiler in DHW mode by turning the Hot Water knob fully clockwise to the end of the scale (max DHW temperature); 9. after a minute of working in DHW, put the boiler back in stand-by turning the “Summer/Winter” knob on (green lamp flashing) and put the storage in stand-by too by turning the Hot Water knob on ; 10. open the manual venting valve 11 again and let air and water go out from the rubber hose 12;
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Green Heating Technology 30 11. repeat steps 4. to 10. performing several working cycles and coil venting, both in heating and DHW mode, until all the air has been vented from the primary coil of the storage, and the noise caused by the air ends. 12. adjust definitely the system pressure to the optimal value of 1.0 bar (max 1.5 bar). Combustion group cleaning Switch off the boiler and discon- nect it from the electrical supply. Be sure that the parts are not hot and eventually wait the time necessary to cool them; Because some contacts with the fine dust and acid condense may occur, we recommend to wear the proper devices for the personal protection (i.e. glasses, gloves, masque) Warning: do not wash or damage the insulating coverings inside the combustion chamber. f f Open the sealed chamber; f f disconnect the two fan connectors 10; f f disconnect the connectors 12 from the ignition electrode 2 and from the flame detection electrode 13. Atten- tion: do not dismount the electrodes from the combustion group; f f unscrew the screw 6 and take away the support 5; unscrew the nut 7 which fixes the gas pipe 4 to the gas valve; pull out the gas pipe from the fan/air-gas-mixer assembly; f f unscrew the 4 nuts 1 which fix the burner group 14 (composed of fan, hose and burner) to the primary ex- changer. Remove the burner group; 9 10 11 12 13 14 1 2 3 4 5 7 8 6 00065 A 00
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Green Heating Technology 31 Do not disassemble the burner group and do not dismount the ceramic fibre plate from the bot- tom of the exchanger. f f check the integrity of the insulating coverings inside the combustion chamber; f f on the burner cover, check the integrity of the fireproof fibre gasket and of the silicone rubber one; f f check that the burner do not present deposits, foulings or excessive oxidations and that all the holes are free; f f clean softly the burner electrodes, avoiding to bend it or to move it; f f clean the cylinder of the burner ONLY IF IT IS NECESSARY and only DRY, through a NOT METALLIC brush, with movements on the burner’s axis, from cover outwards; Do not damage the insulating coverings inside the combustion chamber and don't deform the holes of the burner. If the burner works correctly, it will be of black colour but clean or in any case with few deposits, not scaled and easy to remove. f f slip off the outlet condense pipe 11 from the connection on the primary exchanger. It's advisable to plug on the connection a suitable pipe, to divert outside the boiler (and especially out of the conden- sate syphon) the dust that detaches from the primary exchanger during the cleaning; f f to clean the primary exchanger: •• prior to brushing the exchanger's coils, carefully remove, by a powerful vacuum cleaner, the solid residuals of combustion; don't use air jets; •• then clean the primary exchanger coils by a NOT METALLIC brush and remove the residuals again by using the vacuum cleaner; f f locate the lower cap 8 of the siphon (where you can access from the lower side of the boiler, behind the returned connector of the system), put a collector for liquids under it. Unscrew the cap. Let the siphon empty itself. Inside the cover a layer of residual could be present (max 1÷2mm): remove it; Remark: an excessive quantity of residual is an indicator of malfunctioning or in any case it is not a normal situation. Locate the reasons and solve the problem, so remove the siphon unscrewing the superior and lateral connectors, and the screw of its support bracket. Accurately clean the siphon and be sure that its condense inlet pipe 11 and condense outlet pipe 9 are clean and not obstructed. f f Reassemble all the components in the backwards order and opposite sense and check the combus- tion. Combustion test and adjustment Before checking the combustion, clean the burner and the exchanger as described in the para- graph "Combustion group cleaning" on page 30 (except for the case of first ignition). To check and adjust the boiler you need a flue analyser, correctly calibrated (in the condensing boiler, the precision and the correctness of the measures is particularly important). Then, through a suitable function on the panel, we ignite the burner, first with a reduced flow and then at the maximum flow, doing the measure and adjustments in both conditions. Proceed as follows: 1. Put the boiler in stand-by turning the “Summer/Winter” knob on (green lamp flashing);
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Green Heating Technology 32 2. on the flue flange, unscrew the screw 1 and move the tapping insert 2 in such a way to tap the inlet plug A only; insert the analyser sensor in the flue plug F, taking care of the seal of the connection; Remark: The device placed at the top of sensor must be placed as possible in the centre of the flow outlet: we advise you to insert well the sensor and so to extract it of 3 cm. Insert the sensor so that the protection bow of the sensor, placed at the top, is transversal (the flow must pass through it and directly touch the sensor). Generate a heating request by activating the room thermostat. Be sure that the heat produced by the boiler can be eliminated by the heating system through the radiators and/or radiant pan- els/floor systems. 3. turn the Summer/Winter knob to Summer position ; 4. turn the "Hot Water" knob on the “chimneysweeper” symbol and wait (about 5 seconds) that the display shows “SE” (SErvice) flashing (besides, the green lamp flashes with short light- nings); 5. when the display shows “SE” flashing, turn the Hot Water knob on the beginning of the scale (burner ignition at the minimum power output). The service indication appears on the display, to indicate that the function is active. Besides, the yellow lamp turns on, indicating that the burner is ignited; 6. making reference to the following table, check that the centre of the display shows the correct value for the number of revolutions per minute at Qr for the type of gas used (you are reading the number of fan revolutions per minute x100 at reduced flow capacity; for example, the value 14 means that the fan is rotating at 1400 rpm); Heat input Natural gas G20 Commercial propane G31 CO2 % Fan rpm x 100 CO2 % Fan rpm x 100 Reduced Qr 8.9 ±0.5 14 … 15 9.6 ±0.5 15 … 16 Nominal Qn 9.1 ±0.5 57 … 58 10.0 ±0.5 58 … 59 7. the burner ignites at the reduced input. Wait for the boiler to come up to full operation (about 5 minutes). If the value of CO2 in the fumes, at the reduced input Qr for the type of gas used, is within the range shown in the table, go to step 8 to check/adjust the nominal input, otherwise you will have to bring the CO2 back within the correct values, changing the offset by turning the screw P.R. ADJ. (the adjustment screw is inside the bushing, under the screw cap). ATTENTION: turn the screw 1/8 of turn at a time and then wait 1 minute to allow the CO2 value measured by the analyser to stabilize; •• If the CO2 value is HIGHER than allowed, DECREASE the off-set by turning the screw P.R. ADJ. COUNTERCLOCKwise; •• If the CO2 value is LOWER than allowed, INCREASE the off-set by turning the screw P.R. ADJ. CLOCKwise; 8. turn the Hot Water knob fully clockwise to the end of the scale (burner ignition at the maximum power output); 9. check that the centre of the display shows the correct value for the number of rpms at Qn for the type of gas used (rpm x100 at nominal flow capacity; for example, the value 57 means 5700 rpm); 10. the burner ignites at the reduced flow capacity. Wait for the boiler to come up to full operation (about 5 minutes). If the CO2 value in the fumes at nominal input Qn for the type of gas used is between the values shown in the table, turn the “Summer/Winter” knob on to quit the programming mode and turn off the boiler, otherwise you will have to adjust the gas input by turn- ing the screw R.Q. ADJ. . ATTENTION: turn the screw 1/4 - 1/2 of turn at a time, waiting 1 minute for the values measured to stabilize:
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Green Heating Technology 33 •• If the CO2 value is HIGHER than allowed, turn the screw R.Q. ADJ. CLOCKwise; •• If the CO2 value is LOWER than al- lowed, turn the screw R.Q. ADJ. COUN- TERCLOCKwise; Remark: if you have adjusted the CO2 at the nominal input, we advise you to check again the CO2 and the off-set at the reduced input (steps 3 to 7). IMPORTANT: at the end of the check or the adjustments, it is INDISPEN- SABLE: •• close, on the gas valve, the pressure plug PINT by turning the specific screw; •• close the flue plugs used, by restoring the tapping insert 2 and the screw 1, caring that the plastic surface of the flange is not damaged or worn; •• seal the screw cover of P.R. ADJ. and the screw R.Q. ADJ. if they have been used; •• check the correct flue system tightness, especially the tightness of the tapping insert 2. Max heating power adjust- ment The maximum heating power output must be set in accordance with the system require- ments (stated in the project). Power input values, corresponding fan rpms and relevant display indications are listed in the "Power input / display / fan rpm table" on page 34. The adjustment will be performed through the boiler’s controls, following a special procedure that avoids accidental activations by the User: 1. get information about the maximum heating power requirement of the heating system (reported on the project documentation of the system itself); 2. supply the boiler and turn the Summer/Winter knob to Summer position ; 3. ensure that there are NOT domestic hot water requests (no open taps); if the room thermostat is installed, make so that it requires the heating (e.g. raise the requested room temperature manu- ally); •• turn the Hot Water knob on service position: on the display will appear a flashing number from 00 to 99 that indicates the current set point of the value of heating power, where the value 00 corresponds to the minimum setting of the gas valve and the value 99 corresponds to the maximum;
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Green Heating Technology 34 •• wait (approximately five seconds) that the display shows “PO” (POwer) flashing (moreover, both the GREEN and RED indicators flash to short “pulses”). •• when the display shows “PO” flashing, within 15 seconds turn the Summer/Winter knob on the MAXIMUM value of the scale of the heating (fully clockwise). The service indication ap- pears on the display and the burner ignites to the maximum output not modulated (the yellow indicator turns on); •• on the display, the number 99 flashes, indicating the current maximum heating output setting; it’s possible to change the maximum power output by acting directly on the Summer/Winter knob within the scale of the heating ; REMARK: the value from 00 to 99 that appears on the display during the setting, is foreseen to be read at the end of the adjustment and to be eventually re-used as a quick reference to set the boiler again to the same heating power. •• do NOT move the Summer/Winter knob for about 30 seconds, until the number on the dis- play stops flashing (also the green indicator stops flashing and stays on). During this time, check that the pressure displayed on the manometer remains stabilized on the correct value. If further pressure adjustment should be needed, turn the knob and wait again 30 seconds and the end of flashing; •• to confirm and save the setting, turn the Hot Water knob on the scale ; the burner will turn off for a moment. Wait (about 5 seconds) that both the green and red indicators stay on for about 5 seconds (this is the confirmation that the burner pressure for heating is stored), then the red indicator turns off; 4. to switch off the burner, turn the Summer/Winter knob to the position. The MAX power for the heating system is now adjusted. The whole procedure should be completed within 15 minutes from the start. If you exceed this time, or in case of mistakes, the new pressure will not be stored and it will be necessary to repeat the procedure from the beginning, by turning the Summer/Winter knob on and the Hot Water knob on the scale . Power input / display / fan rpm table HEAT INPUT FAN RPM INDICATIVE DISPLAY VALUE kW kcal/h Natural gas G20 Commercial Propane G31 City Max 26 K MIN. 5.3 4558 1500 1600 0 7.45 6416 1930 2030 10 9.5 8187 2360 2460 20 11.6 9959 2790 2890 30 13.6 11730 3220 3320 40 15.7 13502 3650 3750 50 17.8 15274 4080 4180 60 19.8 17045 4510 4610 70 21.9 18817 4940 5040 80 23.9 20588 5370 5470 90 MAX. 26.2 22532 5800 5900 99
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Green Heating Technology 35 HEAT INPUT FAN RPM INDICATIVE DISPLAY VALUE kW kcal/h Natural gas G20 Commercial Propane G31 City Max 32 K MIN. 6.9 5934 1500 1600 0 9.5 8170 1930 2030 10 12.0 10320 2360 2460 20 14.5 12470 2790 2890 30 17.0 14620 3220 3320 40 19.5 16770 3650 3750 50 22.0 18920 4080 4180 60 24.5 21070 4510 4610 70 27 23220 4940 5040 80 29.5 25370 5370 5470 90 MAX. 32.1 27606 5800 5900 99 Electronic settings Accessing the main board To access the main board: Cut off the electrical supply to the boiler. Re- store the supply after having closed the contol panel rear cover. f f unscrew the screws 1 and remove the back cover of the control panel. Main board settings The boiler is equipped with a Microprocessor modulation board, featuring a 6-microswitch array (SW1÷SW6) which allow to make personalizing actions for the boiler’s functioning as described in the following table. Disconnect the power supply before approaching the microswitches. Restore the power supply only after you have closed the back cover of the control panel. Changes to microswitches status have no effect until the boiler is electrically supplied (they are red during the board startup, when the supply is connected). S1 M15 M4 M2 M16 M6 M1 S1 28 27 26 25 24 23 22 21 39 38 7 8 9 10 1 2 3 4 5 6 68 69 70 71 72 73 74 75 SW1 SW6 ON ON SW 1 ON OFF SW 2 SW 3 SW 4 SW 5 SW 6 00014 00
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Green Heating Technology 36 SW1 OFF Natural gas (G20) Functioning. ON Propane (G31) Functioning. The factory setting depends on the gas type arranged in factory for the boiler. To change the type of gas supply, it is necessary to follow the complete instructions described in the paragraph "Gas conversion" on page 36. SW2 Adjustment range for heating system flow temperature. OFF Normal setting, suitable for traditional radiators systems. It allows to select a heating system temperature within the standard range from 35°C to 78°C. Factory setting. ON Reduced setting, suitable for low temperature systems. It allows to select a heating system temperature within the reduced range from 20°C to 45°C. Remark: If the boiler supplies a mixed type system (high and low temperature) through the suitable optional kit, use the reduced range (ON) (refer also to the documentation supplied with the kit). SW3 It determines the delay of 3 minutes, before the new ignition of the burner after the over- coming of the heating set temperature. OFF delay ON (for normal radiators systems). Factory setting. ON delay OFF (for fan coil systems). SW4 It determinates the temperatures for the burner to be turned ON and OFF during the DHW work. OFF burner OFF at 75°C and burner ON at 60°C. Factory setting. ON burner OFF at the set DHW temperature (T.SET) + 3°C, and burner ON at T.SET + 2°C. SW5 Pump functioning mode during heating working. OFF intermittent for normal applications (with or without delay, see SW3). Factory setting. ON always off (external pumps are present). Remark: The pump will be anyway activated in all other circumstances, e.g. during the DHW functioning, for post-circulation (if foreseen) or for anti-freezing or anti-lockout functions. SW6 OFF In City Max "F" boilers it must be OFF. Factory setting. Gas conversion ATTENTION: the operations described below must be carried out only by qualified personnel [authorized by ITALTHERM S.r.l.]. For gas conversion, use the components supplied by boiler manufacturer only. Using Commercial Propane G31, it is absolutely necessary to install a suitable pressure re- ducer upstream the boiler. This boiler is designed and prepared to be supplied with Natural Gas G20 (Methane) or Com- mercial Propane G31. A qualified technician can convert it to operate with one of these two types of gas above said. It must never be used with Butane gas G30 (that can be present in the portable gas bottles for cookers) therefore, it's important to inform, about this, the supplier of the fuel.
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Green Heating Technology 37 1. Disconnect the boiler from the electrical supply. Remove the boiler cover as described in the paragraph "Mainte- nance operations" on page 27; 2. access the main board and switch SW1 (see also "Main board settings" on page 35) accordingly with the avail- able gas type: •• OFF for Natural gas (G20), •• ON for Propane (G31) 3. ensure that the inlet gas pressure complies with the re- quired nominal pressure (see "Technical data" on page 45) and that the gas flow is sufficient to guarantee the appliance correct work; 4. open the sealed combustion chamber; 5. slip off the silicone hose 1 from the fitting 2 of the sealed chamber compensation plug; 6. unscrew the calibrated plug 2 and replace it with the one in the conversion kit. The connector to use with Methane G20 is “silver” coloured and the one for Propane G31 is “brass” coloured; then, insert the silicone hose 1 on the sealed chamber compensation plug again; 7. open the sealed chamber, loosen the screw 5 and remove the bracket 6; 8. loosen the swivel nut 7 that connects the gas tube 4 to the gas valve, and unplug the other end of the tube 4 from the fan 3; 9. remove the diaphragm 8 by attaching a piece of adhesive tape and lifting it from its seat. NEVER USE TOOLS, espe- cially through the calibrated hole! 10. insert the diaphragm from the conversion kit, taking care that the stamped diameter is facing UPWARDS and tak- ing care to place it correctly inside the gas valve fitting: it must be flush with the edge, without projecting; Remark: see "Technical data" on page 45 for the corre- spondence between the diaphragm diameter and the gas type. 11. insert the gas tube 4 in the fan 3; reassemble the swivel nut 7 replacing the gasket; 12. remount the bracket 6 and the screw 5; close the sealed chamber; 13. check, with the burner on, that the pressure upstream from the boiler is: •• Natural gas (methane) G20 = min.17 ‑ max.25 mbar •• Commercial Propane G31 = min.35 ‑ max.40 mbar For detailed setting values, refer to the table "Technical data" on page 45.
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Green Heating Technology 38 14. check the combustion as described in the preceding paragraph "Combustion test and adjustment" on page 31 checking that the fan speed automatically change; 15. apply the label indicating the type of gas (provided with the kit) in the area provided on the “WARN- ING” plate inside the boiler; 16. in the case of liquid gas fuel, it is important that the boiler be exclusively fuelled with commercial Propane G31 and not with Butane G30. For this reason, we recommend that the supplier of the fuel be informed, for example, by applying the sticker provided in the conversion kit on the gas tank or in its immediate vicinity, so that it is visible to the employee at the time it is being filled. Hydraulic settings (pump speed) The pump has a selector which allows to reduce the speed, so as to reduce the noise produced by the too rapid circulation of the liquids in too small heating sys- tems. •• III = Maximum Speed (Factory setting) •• II = Medium Speed •• I = Minimum Speed (use only if strictly neces- sary; test the heating system, verifying that no overheating problems occur). Draining the heating system and the storage coil When it is necessary to drain the heating system, proceed as described here below: f f Connect a rubber pipe to the draining tap ter- minal 1 ; f f put the other end of the pipe in a suitable drain or sink; f f open the draining tap by turning the nut 2 counterclockwise, using a suitable spanner; f f when the pressure is COMPLETELY drained, it's possible to open the radiators venting valves, to allow the air inlet. The complete system drain is possible only draining the liq- uid from the lowest point of the system itself. f f when everything is over, close taps (turning the nut 2 clockwise) and air vents. In the primary exchanger a certain quan- tity of water of the heating system remains. If you want to remove the boiler from the wall, we advice you to close with plugs the hydraulic inlet/outlet heating system connections. Draining the storage unit f f Close the hand valve installed on the boiler's cold water inlet connection; f f connect a rubber pipe to the terminal of the storage draining tap 3; f f put the other end of the pipe in a suitable drain or sink; f f open the draining tap by turning its hand nut counterclockwise; 00016 00
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Green Heating Technology 39 f f when the draining is over, close the draining tap (turn it clockwise). Alarms - boiler block Following a malfunction, the boiler can lock-up and show a particular signalling, consisting of an alarm code on the display and of the status of the RED light indicator (and eventually of the GREEN and the YELLOW ones). In the following table, all the alarm signals are listed, their most probable causes and the suggested solutions. Each alarm code is complete of the status of the RED light indicator: = on; = blinking; = flashing with pulses; = off. Some alarms are signalled with a combination of two or more lights, in this case the light colours are explicitly reported close to the relevant status. Operations accompanied by the symbol are always reserved to the Technician. Operations with grey background are reserved to the Technician. Signal Probable causes Suggested solutions 01 Boiler just installed (air mixed to gas). Retry the ignition several times: turn the knob on the unlock position , wait the red light to turn off, then bring the knob in the previous position. The flame has extin- guished or it did not ignite Restore the boiler function by turning the knob on the unlock position , wait the red light to turn off, then bring the knob in the previous position. In case of frequent blocks, verify the correct combustion, the good state and the cleaning of the burner. Incorrect com- bustion / flame de- tachment from the burner Check that the Inlet/Outlet Ducts and the respective terminals are clean and in good condition, and that there are no leaks in them. During the installation, respect the regulation prescriptions, the slopes and the lengths (see "Flue systems" on page 21). Note for the TECHNICIAN: The burner flame is not detected by the control electron- ics because it has not turned on or it has suddenly turned off, or it has detached from the burner, because of an incorrect combustion. This can be due, in exam- ple, to combustion product reflow into inlet duct, leaks in inlet/outlet ducts or errors in sizing of ducts (ducts length out of the allowed range, and/or wrong use of the reducer on boiler’s outlet). Incorrect electrical supply Check that the electrical connections Live, Neutral and Earth are correct and efficient, and especially that the Live and the Neutral are not swapped (see "Electrical diagram" on page 49). Remark: The problem may also be caused by an incorrect electricity supply by the Electrical Agency (unbalanced Neutral). Condensate drain problem Verify and restore the correct condensate drain. Warning! DO NOT open the combustion assembly before having cleared the drain and removed the condense accu- mulated in the combustion chamber. This alarm is caused by the condensate that, after having partially filled the combustion chamber, reach- es the detection electrode and inhibits the detection of the flame ionisation. Then, check the combustion and verify that the burner is clean and in good conditions.
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Green Heating Technology 40 Signal Probable causes Suggested solutions 02 the boiler has over- heated and the Safety Thermostat has triggered Turn the knob on the unlock position until the red lamp turns off (or eventually for a longer period to make the boiler cool), then bring the knob in the previous position. If necessary, wait and try again for few times. If the lockout persists or reappears, call the Service Centre. Verify the safety thermostat functionality. Detect the causes of the overheating, e.g. an insufficient circulation in the primary cir- cuit; max gas pressure out of the limits or maximum heating power excessive for the heating system size. 03 The overheat ther- mal fuse of the combustion assem- bly has triggered (combustion assem- bly overheating) Solve the problem that caused the overheating, then replace the combustion assembly. Note for the TECHNICIAN: the condensing combustion assembly has overheated and the relevant thermal fuse has blown. This is an extreme protection that normally is anticipated by other safety thermostats. If, in case of fault, those devices should not trigger and the burner should get hotter and hotter, the thermal fuse will cause the block of the boiler to avoid damages to building and furniture, but the combustion group must be considered damaged and there- fore it must be replaced. The flue overheat thermal fuse has triggered (flue on boiler outlet too hot) Solve the problem that caused the overheating of the flue, then replace the flue thermal fuse. Note for the TECHNICIAN: the flue thermal fuse preserves the flue ducts (that are made with Polypropylene, a material suitable to the condensate acidity) from the high temperatures, that could lead to their fusion or deformation. The trig- gering of this device consists in its blowing and therefore it must be replaced. – 5 Communication be- tween display and main PCB is not cor- rect At every Power On, this alarm is showed for max 2-3 seconds; then it will disappear. If not, call the Service. Check display, main PCB and connection wire. Replace what it is needed. 05 Failure to the sys- tem flow tempera- ture probe. Check the cabling of the system flow temperature probe (primary circuit). Replacement of the system flow temperature probe. 10 Insufficient system pressure (loss of water pressure switch triggered) Restore the correct pressure as described in "Preliminary opera- tions" on page 9 or (preferibly bu the Technician) in "System filling and pressuring" on page 19. Remark: Consider that the pressure, in normal conditions, should not decrease with the progress of the time. If this happens, there is probably a loss in the heating system. Sometimes the loss is so small that it doesn’t leave evident signs, but with the progress of the time it can cause the decreasing of the pressure. Also the opening of the manual venting taps of radiators (intentional or unintentional) makes the pressure decrease. Check that this doesn’t happen. 12 Failure to the DHW storage tempera- ture probe. Check the cabling of the DHW storage temperature probe. Replacement of the DHW storage temperature probe. 15 Failure to the heat- ing system return temperature probe. Check the cabling of the system return temperature probe. Replacement of the system return temperature probe.
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Green Heating Technology 41 Signal Probable causes Suggested solutions 16 Fan failure. The burner fan is stopped or rotates at an incorrect speed. User: Restore the boiler function by turning the knob on the unlock position , wait the red light to turn off, then bring the knob in the previous position. Check the burner fan functionality. Replace it if necessary. 22 Memory-stored data not coherent. User: Disconnect the electrical supply to the boiler by operating the suitable external bipolar switch, then connect it again after a few minutes. If the lockout persists or reappears, call the Service Centre. Redo all the boiler settings ("Max heating power adjustment" on page 33 and "Electronic settings" on page 35) to update the data in the main board memory. Replace the main board (consequently, redo the "Max heating pow- er adjustment" on page 33 and "Electronic settings" on page 35). 24 Floor heating sys- tem safety thermo- stat triggering: system flow tem- perature too high; floor heating sys- tem defective, faulty or malfunc- tioning. The floor heating system and the floor cladding can be damaged by temperature shocks, so a good quality system includes one or more safety thermostats that, if necessary, trigger and lock the boiler. Turn the knob on the unlock position until the red lamp turns off (or eventually for a longer period to cool the system and restore the thermostat), then bring the knob in the previous posi- tion. If the lockout persists or reappears, call the Service Centre Remark: when this alarm is active, the hot water production is locked too. If any floor heating system was installed, check the integrity of the jumper connecting terminals 57 and 58 of M12 see "Electrical diagram" on page 49). If the floor heating system is installed, check the system flow tem- peratures on the boiler and on the low temperature system kits (if installed). Replace the faulty or out-of-tolerance thermostats. Check the correct positioning of the thermostats on the system (see "Floor heating system" on page 15). 31 Remote control* not working Data exchanged between the boiler and the Re- mote Control don't com- ply with the expected protocol. * This applies to Remote Control optional kit only, and not to third parties chrono-thermostats User: see also paragraph "Remote Control Kit" on page 52. Under these conditions, the boiler functions only in Sanitary. If the heating was neces- sary, and no spare Remote Control nor standard room thermostat were immediately available, ask the technician to temporarily make heating work manually from the boiler’s control panel (excluding the operation from the remote control). Note for the TECHNICIAN: to activate the heating in manual mode, jumper the boiler’s room thermostat input (see "Electrical diagram" on page 49); make the boiler operate in Winter mode by regulating the heating tem- perature manually from the boiler’s control panel. Show the User how to adjust the heating from the boiler’s in-built control panel, by rotating the Summer/Winter knob within the scale . 33-34 Cabling configura- tion error. Refer to the electric diagram (page 49) and check the integrity of the wirings, especially the eventual short cable jumpers between two contacts of the same connector (on the cabling connections to the electronic board).
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Green Heating Technology 42 Signal Probable causes Suggested solutions 35 RED YELLOW Unexpected flame the control elec- tronic has detected the flame on the burner when this one should be off Wait for the boiler automatic reset (5 minutes) or reset it manually by turning the knob on the unlock position , waiting the red light to turn off, then bringing the knob in the previous position. If the lockout persists or reappears, call the Service Centre Detect eventual malfunctioning of the gas valve (that does not stop fully the gas flow, so the burner remains ignited) or of the elec- tronics, flame detection section (that detects the flame presence even if it's absent). 38 Failure to the out- door temperature probe (optional). The outdoor tem- perature probe, that was recog- nized and working, now results faulty. User: Call the Service Centre. The boiler now works either in heating and in hot water, like as the external boiler had never been installed, so the heating system temperature is set by the knob , in direct way and not as a function of the outdoor temperature. The alarm is displayed to in- form that the accessory is no more efficient (consider that, on a first analysis, the boiler seems to work perfectly). Important: if the boiler is turned off and then on again, it's possible** that the alarm is no more displayed, even though the problem persists. Check the cabling of the outdoor temperature probe. Replacement of the outdoor temperature probe. ** The alarm shows again only if the resistance of the probe is out of tolerance or in short-circuit. On the contrary, if the probe or the relevant cabling is interrupted, when the electrical supply is restored the boiler will consider the external probe absent and, in Winter mode, it will work in normal mode (temperature shifting disabled). 39 Suspected freezing After a power fail- ure, the boiler de- tected tempera- tures at the Heating and DHW probes equal to, or less than, 0°C when power was restored The display shows the alarm code 39 while the boiler inhibits the ignition of the burner and activates the circulator, forcing water to circulate in the hydraulic circuits. If, during this time, the temperatures measured by the probes rise above +1°C, the alarm is reset and the boiler returns to the normal operation. Otherwise, the alarm will persist and you should suspect that water has frozen at one or more points of the hydraulic circuit of the boiler and/or system (with possible damage to the frozen parts). If the alarm persists, call a qualified technician. Find/replace the parts damaged by the freezing. 42 RED YELLOW System error Anomaly of inner boiler device(s) Mains electrical power supply out of tolerance limits Detect the fault or anomaly also referring to the technical literature reserved to the service centres.
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Green Heating Technology 43 Signal Probable causes Suggested solutions 43 Over-temperature of water on system return The water that returns to the boiler from the heating system is too hot: this may be an effect of a malfunction of the system, and any- way this can cause a too high temperature of the flue and damage the flue system. Before this happens, a suitable safety protection has triggered. Wait 20-30 minutes to let the boiler and the system cool down, then turn the knob on the unlock position until the red lamp turns off, then bring again the knob in the previous position. It is impossible to restart the boiler before the cooling of the system. If the block happens again, please call a qualified technician. 46 Cabling configura- tion error. See alarm 33. – – (??) The “Hot Water” knob is on a position reserved to the techni- cian: or service . Turn the knob back along the scale . – – (??) RED GREEN it has been started, by mistake (moreo- ver very improb- able), a procedure reserved to the Technician In order to avoid malfunctions, do the following as soon as possible: f f turn the knob on the off/unlock position; f f turn the "Hot Water" knob along the scale ; f f turn the knob on the normal working position (Summer or Winter along the scale ).
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Green Heating Technology 44 Warnings for servicing All servicing operations and gas conversions MUST BE CARRIED OUT BY QUALIFIED TECHNI- CIANS, in compliance with the norms and laws in force (see an indicative list on page 4). Moreo- ver, MAINTENANCE operations must be carried out in compliance with the manufacturer pre- scriptions and with the laws and rules presently in force, for the parts not mentioned in this handbook; we advice to perform them at least once a year to maintain the boiler’s performance. A careful servicing is always a guarantee of safety and energy saving. Normally, it will be necessary to execute the following operations: f f Remove any possible oxidization from burners and electrodes; f f Remove the scale from the exchangers; f f Cleaning and checking the exchanger, the siphon and all the parts which are in touch with the con- dense; f f Check integrity and stability of the insulating coverings in the combustion chamber and proceed eventually to substitution; f f Check and eventual substitution of the magnesium anode of the storage unit (see "Boiler internal components" on page 48); f f Check the boiler ignition, switching off and operation; f f Check the water and gas connections tightness; f f Check the gas consumption at the minimum and maximum output; f f Verify that safety devices are correctly working; f f Verify the correct functioning of control and adjusting devices; f f Verify periodically the absence of leaks of combustion products to the inner room, the correct func- tioning and the integrity of the flue outlet ducts and/or devices and of the relevant terminals and accessories; f f In case of works or servicing of the structures placed near the above mentioned ducts and /or de- vices and their accessories, switch off the boiler; f f Do not leave any inflammable tanks and/or substances in the installation room; f f If the boiler draws directly from the installation room (type B appliance installed indoor): Do not clean the room where boiler is installed, while it is working f f Clean casing with soapy water only. Do not clean casing, other painted or plastic surfaces with thin- ner. f f In any case of parts replacement, it is mandatory to use ITALTHERM original spare parts. ITALTHERM declines any responsibility in case of non-original spare parts utilization. "Once all check and servicing operations have been carried out, the technician must write a report for the user, who must countersign a copy for receipt and vision" as prescribed by the regulation in force.
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Green Heating Technology 45 Technical data TECHNICAL DATA U.M. City Max 26 K City Max 32 K Gas type G20 G31 G20 G31 CE certification 0694 CM 3400 Class II2H3P II2H3P Type B23 - B23P - C13 - C33 - C43 - C53 - C63 - C83 - C93 Working temperature range (min÷max) °C 0 ÷ +60 Max heat input kW 26.2 26.2 32.1 32.1 Min heat input kW 5.3 5.3 6.9 6.9 Max heat output 60°/80°C * kW 25.4 25.4 31.4 31.4 Min heat output 60°/80°C * kW 5.1 5.1 6.6 6.6 Max heat output 30°/50°C * kW 27.5 27.5 34.0 34.0 Min heat output 30°/50°C * kW 5.5 5.5 7.2 7.2 NOX Class 5 5 5 5 CO at 0% O2 (Qn) ppm 129.7 143.7 149.6 116.7 CO2 at nominal input % 9.2 10.2 9.2 10.1 Condense quantity at Qn (30°/50°C *) l/h 2.3 1.5 2.9 1.9 Condense quantity at Qr (30°/50°C *) l/h 0.5 0.4 0.8 0.7 Condense acidity pH 2.8 2.8 2.8 2.8 Flue temperature (Qn) °C 76.5 76.5 72.5 72.5 Flue mass flow rate (60/80°C - Qn) kg/h 42.61 43.49 52.20 53.76 EFFICIENCY Nominal efficiency at 60°/80°C * % 96.9 97.7 Efficiency at 30% load at 60°/80°C * % 100.4 100.6 Nominal efficiency at 30°/50°C * % 105.1 105.8 Efficiency at 30% load at 30°/50°C * % 107.2 107.8 * system return / flow water temperature Remark: data have been measured with horizontal coaxial flue, length = 1 m. HEATING Temperature selection range (min÷max) Main heating circuit, normal range / low temp. range °C 35÷78 / 20÷45 Temperature selection range (min÷max) Secondary heating circuit °C 20÷78 Characteristics of the heating system water (or filling liquid) ( * = if aluminium parts are present along the system) °f pH 5 ÷ 15 °f pH 7.5 ÷ 9.5 (7.5 ÷ 8.5 *) (follows)
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Green Heating Technology 46 TECHNICAL DATA (cont'd) U.M. City Max 26 K City Max 32 K Gas type G20 G31 G20 G31 Expansion vessel l 10 Expansion vessel pre-loading pressure bar 1 Loss of water pressure switch off / on pressure bar 0.5 / 0.9 (±0.2) 0.5 / 0.9 (±0.2) To allow the correct system filling, the pressure of the domestic water should be higher than the ON value of the pressure switch. Max working pressure bar 3 Max system temperature °C 83 Anti-freezing function temperature on / off °C 5 / 30 HOT WATER Storage volume l 60 Specific flow rate (EN625) l/min 16 17 DHW expansion vessel l 2 DHW expansion vessel pre-loading pressure bar 3.5 (see also "DHW storage tank filling" on page 19) Max supply pressure (storage safety valve threshold) bar 8 Storage temperature selection range (min÷max) °C 30÷60 ELECTRICAL DATA Voltage / frequency (nominal voltage) V / Hz 220÷240 / 50 (230V) Power consumption W 165 170 Level of protection IP X4D DIMENSIONS Width - Height - Depth mm see "Dimensions and connections" on page 14 Weight kg 59.5 60.0 CONNECTIONS Hydraulic and gas connections see "Dimensions and connections" on page 14 Flue: types, lengths and diameters see "Flue systems" on page 21 Fan head loss Pa 40 ÷ 150 40 ÷ 150 GAS SUPPLY PRESSURE Nominal pressure mbar 20 37 20 37 Inlet pressure (min÷max) mbar 17 ÷ 25 35÷40 17 ÷ 25 35÷40 Gas valve diaphragm diameter mm 5.5 4.0 6.4 4.6 Colour of the calibrated plug for sealed chamber compensation Grey "Silver" Yellow "Brass" Grey "Silver" Yellow "Brass" (follows)
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Green Heating Technology 47 TECHNICAL DATA (cont'd) U.M. City Max 26 K City Max 32 K Gas type G20 G31 G20 G31 GAS CONSUMPTION Qmax m³/h 2.77 3.39 kg/h 2.03 2.49 Qmin m³/h 0.56 0.73 kg/h 0.41 0.53 Notes
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Green Heating Technology 48 Boiler internal components 2 1 3 5 4 6 7 9 10 11 12 13 14 25 28 29 32 34 39 8 15 16 17 18 20 19 21 22 24 23 27 26 30 33 35 36 38 40 37 31 00077 00 1 Plug for Combustion analysis (air inlet) 2 Plug for Combustion analysis (flue) 3 Combustion assembly overheat fuse (connector) 4 Flue overheat fuse 5 Combustion assembly (burner+primary exchanger) 6 Ignition Electrode 7 Flame detection electrode 8 Sealed chamber 9 Electronic igniter 10 Gas injection pipe 11 Siphon for condense outlet 12 Temperature Sensor on system return 13 Loss of water pressure switch 14 Gas valve 15 System pressure gauge 16 Safety valve 3 bar 17 Filling valve 18 Drain valve 19 By-pass 20 Pump 21 Storage safety valve 8 bar 22 DHW filter 23 Flow limiter 24 Storage drain valve 25 Pipe for condense outlet 26 Storage inspection door 27 Storage tank 28 Motorized 3-way valve 29 Automatic Venting Device (heating circuit, incorporated in the pump) 30 DHW expansion vessel 31 Storage temperature sensor 32 Fan 33 Temperature Sensor, system flow 34 Air/Gas Mixing System 35 Safety thermostat on system flow 36 Manual venting valve (storage coil) 37 Heating system expansion vessel 38 Magnesium anode 39 Flue connection flange 40 Manual Venting Device (Combustion assembly) Remark: Depending on the model, the position and the shape of some items could slightly differ from the drawing.
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Green Heating Technology 49 Electrical diagram 46 47 M10 M4 M9 M11 M13 M5 M1 M2 M16 M15 M13 ~ 3 4 2 1 L N BN BN BN BN YE-GN BN BU BU GY BK VT VT WH WH OG OG OG NC NO GN BK BK GN YE-GN GN WH YE BN BU YE-GN BK RD RD BK BN RD WH BN BU BU BK 3 DHW 2 COM 1 HEA YE-GN BU BN GN N L 42 43 44 45 50 48 49 51 52 50 48 49 51 52 40 41 53 54 55 56 57 58 59 60 61 62 63 64 65 76 77 78 79 42 43 44 45 60 59 61 62 63 64 65 21 22 25 24 23 28 27 26 21 22 25 24 23 28 27 26 321 654 987 10 70 69 68 71 72 73 74 75 73 74 75 321 654 987 10 71 70 69 68 72 M8 M7 M12 S1 TF1 M11 M4 M1 M2 M15 M16 P1 M17 P2 TF2 M13 M5 M9 9 7 6 14 28 20 32.2 33 31 32.1 32.2 60 70 3 4 12 35 13 00079 INT 02 61 73 72 TA2 71 3 Combustion assembly overheat fuse (*) 4 Flue overheat fuse 6 Ignition Electrode 7 Flame detection electrode 9 Electronic igniter 12 Temperature Sensor on system return 13 Loss of water pressure switch (*) 14 Gas valve 20 Pump 28 Motorized 3-way valve 31 Storage temperature sensor 32.1 Fan - speed control 32.2 Fan - supply 33 Temperature Sensor, system flow 35 Safety thermostat on system flow (*) 60 Display board 61 Fuse F2A (2A fast) (*) the contacts of these components are shown in rest conditions (cold condition, no system pressure, no flow) Optional external devices: 70 Room thermostat: Voltage-free Contact for Room Thermostat or Chronothermostat (for trade) working at safety extra low voltage SELV. Closed contact = heating request. Remote control: Terminals of the original remote control device. See also page 52. To install, open the junction on the wires and connect them to the device terminals (eventually, extend the cable) 71 Connector for CH multi zones PCB kit 72 To optional floor heating system safety thermostat 73 To optional outdoor temperature sensor TA2 To optional room thermostat for zones with different temperature range Abbreviations: BK Black BN Brown BU Blue GN Green GY Grey OG Orange RD Red VT Violet WH White YE Yellow COM Common DHW DHW mode NC Normally Closed NO Normally Open HEA Heating mode
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Green Heating Technology 50 Hydraulic diagram This diagram is for information only. To make boiler hydraulic connection either see "Dimen- sions and connections" on page 14 and eventually "Positioning and fastening" on page 16. 00080 00 M M 8 55 56 51 32 54 17 18 23 22 14 10 34 11 20 16 21 30 24 31 27 13 15 58 57 52 28 29 19 C F R M SC G 53 50 40 35 33 12 37 36 8 Sealed chamber 10 Gas injection pipe 11 Siphon for condense outlet 12 Temperature Sensor on system return 13 Loss of water pressure switch 14 Gas valve 15 System pressure gauge 16 Safety valve 3 bar 17 Filling valve 18 Drain valve 19 By-pass 20 Pump 21 Storage safety valve 8 bar 22 DHW filter 23 Flow limiter 24 Storage drain valve 27 Storage tank 28 Motorized 3-way valve 29 Automatic Venting Device (heating circuit, incorporated in the pump) 30 DHW expansion vessel 31 Storage temperature sensor 32 Fan 33 Temperature Sensor, system flow 34 Air/Gas Mixing System 35 Safety thermostat on system flow 36 Manual venting valve (storage coil) 37 Heating system expansion vessel 40 Manual Venting Device (Combustion assembly) 50 Primary exchanger (condensing section) 51 Primary exchanger (combustion section) 52 Check valve 53 Flue hood 54 Condense drain in combustion assembly 55 Combustion chamber 56 Burner 57 Overflow drain of condensate trap 58 Tap for condensate trap cleaning C Hot water outlet F Cold water inlet R Heating return M Heating flow SC Condense drain G Gas inlet
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Green Heating Technology 51 Addendum Outdoor Sensor Kit Installation and setting The Outdoor Sensor manages automatically the CH flow temperature** as a function of the outdoor temperature, thus avoiding the user to adjust it manually. This function is also named "shifting tempera- ture". ** that's the temperature of the heating elements. Don't mistake it with the room temperature (managed by the room thermo- stat or by the Remote Control, but not by the boiler) that doesn't depend on the first one. The installation must be made by a profes- sionally skilled tech- nician following the instructions supplied with the kit. Refer to "Electrical diagram" on page 49 for the links to the Main Board. After the installation of the Sensor, the Sum- mer/Winter knob won't adjust directly the CH flow temperature, but the dispersion factor "kd" that's the response of the outdoor temperature, detected by the sen- sor, on the CH flow temperature (see graph). Practically, kd value should be adjusted depending on the esti- mated efficiency of the building's thermal insulation. Its range is from 01 to 30: use higher values when there is a high ther- mal dispersion and therefore a less efficient insulation (and vice versa). Because of the wide buildings typologies, it's impossible to give precise indications on kd value to set. The correct setting must be determined case by case and will have, as a result, an opti- mal comfort in all the climatic conditions requiring heating, i.e. a prompt reaching of the room temperature with cold weather and no room overheating during mild periods. Outdoor Sensor kit and Remote Control If also the Remote Control Kit is installed, its parameter P04 (modulation mode) should be set on val- ue 2 (modulating on outdoor sensor and on-off on room sensor) or 3 (modulating on both outdoor and room sensors) as described in the paragraph 5 of the instruction booklet included in the Remote Con- trol Kit. Afterwards, also the kd should be set on this latter (refer to paragraph 8.6 of the same booklet). On the Remote Control, just because of different display, the kd adjustment range is 0.1…3.0 instead of 01…30. 00178 00 35 40 45 50 55 60 65 70 75 78 MAX MIN High temperature range 35÷78 °C –20 text (°C) –15 –10 –5 0 5 10 15 20 25 27 20 25 30 35 40 45 MAX MIN Low temperature range 20÷45 °C (if available) (kd=00) kd=05 kd=01 kd=10 kd=15 kd=20 kd=25 kd=30 00177 ENG 00
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Green Heating Technology 52 Remote Control Kit This remote control is more than a simple room thermostat. Thanks to this, it is possible to manage the boiler in all its set- tings like DHW and CH temperature adjustment, boiler reset in case of boiler block, and of course it works as a room thermo- stat both in manual and weekly program mode. It’s powered by the boiler (in safety low voltage), so it doesn’t need batteries. Extract the Remote Control from its package. Keep the relevant user instruction booklet and annex it to this Manual. Nor the Remote Control neither the relevant cable coming from the boiler must not, for any reason, be connected to the 230Vac supply mains. To avoid malfunctions due to electrical noise, the Remote Control connections, as well as all low-voltage connections, should be kept separated from power supply cables, e.g. by enclosing it into separate raceways. The maximum overall cable length shouldn't exceed 50 m. 1. Cut off electricity from boiler; 2. install the device as described in the paragraph 4 of the supplied instruction booklet; 3. link the Remote Control wirings to the "Room Thermostat - Remote Control" cable coming out of the boiler, by means of a suitable bipolar terminal. See also "Electrical diagram" on page 49; Note: The Remote Control link is not polarized. 4. power supply the boiler; turn the boiler's Summer/Winter knob on Summer otherwise the Remote Control doesn't work and the boiler goes into alarm 31 described below; 5. check the correct work of the device. The electronics should recognize it automatically. Hereafter, the Summer/Winter knob should be left on Summer ; the boiler work is man- aged by the Remote Control, including the OFF, Summer and Winter modes, and the technical functions (such as several additional functions). Signal Probable causes Suggested solutions 31 Communication error between the Remote Control (if present) and the boiler Disconnect the electrical supply to the boiler for 30 seconds by op- erating the suitable external bipolar switch, turn the boiler's Sum- mer/Winter knob on Summer , then power supply the boiler. If the lockout persists or reappears, call the Service Centre. Under these conditions, the boiler works only in DHW. For the Technician: Problems on the optional Remote Control connection link (passing close to supply cables or other electromag- netic field sources; connection failure; cable length over 50 meters). CONTROLLO REMOTO EASYREMOTE MANUALE DI ISTRUZIONI
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Green Heating Technology 53 Notes
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Green Heating Technology 54 Notes
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Green Heating Technology 55 Notes
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ITALTHERM Srl Via S. D’Acquisto, snc • 29010 Pontenure (PC) - IT Tel. +39.0523.575611 • Fax +39.0523.575600 www.italtherm.it • e-mail: info@italtherm.it 960000027_03_ENG - 12/03/2015 ITALTHERM Srl declines any responsibility for eventual printing and/or transcription errors in the present manual. In order to constantly improve its products, the company has the right to change features and data written in the present manual, at any time and without notice. www.italtherm.it UNI EN ISO 9001:2008
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