Therm 23 Tca Angl

8/13/2019 Therm 23 Tca Angl

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MANUAL FOR INSTALLATION

AND MAINTENANCE

Boiler with forced flue exhaust

1


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CONTENTS

1. IN GENERAL1.1 General information

1.2 Boiler description

2. INSTALLATION2.1 Warning before installation

2.2 Boiler placement

2.3 Boiler dimensions

2.4 Minimum distances2.5 Boiler fixation

2.6 Connection to the mains

2.7 Gas connection2.8 Water supply

2.9 Installation of flue exhaust and air suction

2.10 Room thermostat connection

2.11 Wiring diagram2.12 Function diagram

2.13 Hydraulic diagram

3. STARTING THE BOILER3.1 Conditions for boiler operation

3.2 Control panel

3.3 Instructions for opening the boiler

3.4 The first start

3.5 Regulation of operation3.6 Flue analysis

3.7 Gas outlet check

3.8 Protection functions3.9 Boiler draining

4. CHANGE TO A DIFFERENT GAS TYPE4. Gas regulation

4.1 Change to a different gas type

5. MAINTENANCE

6. TECHNICAL SPECIFICATIONS

1. IN GENERAL

This manual is an essential and integral part of the product. It

contains a thorough description of the equipment and it is to be of

use for both the users and the authorized service personnel.

Read the instructions in the manual carefully because there is the

necessary information about the safe installation, operation andmaintenance of the product.

There is more information in the Users Guide.

1.1 GENERAL INFORMATION

The appliance serves for room heating and domestic hot water

production for home purposes.It must be connected to the heating circuit and to the hot water

distribution system corresponding to its purpose and output.

It is forbidden to use it for any other than the stated purposes. The

manufacturer is not responsible for faults caused by unsuitable,wrong or irresponsible use.

The installation, the maintenance and any other interference must

be carried out in accordance with the valid norms, according to themanufacturers instructions and by a qualified and trained worker.

The technician installing the heating equipment must also have

valid authorization by the manufacturer.

Incorrect installation can cause harm to possessions or persons. Themanufacturer is not responsible for damages inflicted in this way.

Prevent children and mentally ill people from using the equipment

without supervision.

If you can smell gas, do not switch on any electrical appliances,phones or other appliances which can produce sparks. Open thedoor and the windows, close the central gas supply (at the gas

meter) and call an authorized service engineer.

Should you be away for a long time, close the central gas supply aswell.

Do not put any objects on the appliance.

Do not block up the air or other outlets.

It is necessary to close the electricity supply before any interferencein the product. The best way is to unplug it.

Use a wet cloth and soap for cleaning the appliances cover. Do not

use abrasive or dissolving cleaners.If there is a fault or malfunction, switch the appliance off by closing

the gas tap. Call authorized service engineers to repair the

appliance.

The notes and instructions included in this manual are to be used by

the people who are going to install our product.

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1.2 BOILER DESCRIPTION

Legend:

1. Connection to flue exhaust2. Opening for

3

separated exhaust

he heating circuit

ber

h

he DHW circuit

nger

nsor

valve

valve

manostat

sis

. Ignition transformer

3. Ventilator

4. Flue exhaust rectifier

5. Primary exchanger6. Safety thermostat

7. Temperature sensor in t

8. Combustion cham9. Burner lamellas

10. Ionization electrode

11. Ignition electrodes12. Pump pressure switc

13. Safety valve 3 bars14. Temperature sensor in t

15. Secondary excha16. Refilling valve

17. Cold water inlet

18. Through-flow se

19. Draining valve

20. Circulation pump21. Motor-driven 3-way

22. De-aerating

23. Gas valve24. Expansion vessel

25. Flue exhaust differential

26. Sockets for gas analy

27

2. INSTALLATION

The installation and the first putting into operation must be

carried out by a qualified technician in accordance with thenorms valid for installation of this kind of appliances and with

the norms of local authority bodies and medical institutions.

2.1 WARNING BEFORE INSTALLATIONThe appliance must be connected to the heating distribution

system and to the water supply corresponding with the boilerspurpose and output. (See the specifications)

Before you connect the boiler it is necessary to:

- check the piping and make sure there are no impurities which

could affect the boilers operation.

- check which gas type is the boiler designed for (read the labelon the packaging and the manual including technical

specifications)

- make sure the following exhaust installation meets the validlocal norms.

2.2 BOILER PLACEMENTThe equipment with combustion air supply from the outside andwith forced flue exhaust into the outside can be installed in any

room which corresponds with the relevant local norms andstandards.

Placing of such a boiler is not limited by ventilation possibilities

or room size.The boiler must be mounted on a solid, compact so that any

access to electricity at the back part is prevented.

To gain the best efficiency of the boiler it is necessary to make

sure that the temperature of the place where to boiler is mountedis within the temperature limits for the boiler so that the boiler is

protected against atmospheric influences.

It is also necessary to make enough free space around the boilerto make access to individual boiler parts possible, as mentioned

in paragraph 2.4.

If the boiler is to be placed in the bathroom, washing rooms or

shower rooms it is necessary to follow specific relevant local

norms. (electrical part has IP 44 cover).

2.3 BOILER DIMENSIONS

Legend:

A. Heating water outlet

B. DHW outlet

C. Gas supply

D. Cold water inletE. Heating return pipe


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2.4 MINIMUM DISTANCES

he following layout shows the minimum distances for boilerT

installation which are necessary for possible proper maintenance.

2.5 BOILER FIXATIONThe boiler has to be placed with the use of water level according

to the minimum distances shown at the picture, and it has to be

fixed to the wall with use of cramps and hooks.

urther information is to be found in the manual whichFth

goes withe hydraulic connection set and the flue exhaust set.

en done according to valid norms in the socket.

The same applies

,

g

t is

k cover inside the boiler.

2.7 GAS CONNECTION

ble impurities, which could affect the efficiency of

ONNECTION TO THE BOILER

graph (output x lift).

2.6 CONNECTION TO THE MAINSThe manufacturer is not responsible for damages caused by

wrong supply mains in the house. It is therefore recommended to

have the supply mains checked in certain cases.The boiler is connected to the supply mains by a fixed flexible

line with a plug. It is connected to a 230 V, 50 Hz (10 A) socketinstalled according to valid norms. It can also be connected by a

firm cable where a suitable two-pole switch must be

incorporated. The equipment must be connected to 230 V supplyains by a triplex cable. Make sure the phase and neutralm

connection has be

IMPORTANT!

The connection to the supply mains including plugging can

nly be carried out by a service technician.o

for any possible change of the supply cable.

If you need to change the supply cable, use the cable with the

same parameters (3 x 0.75mm2 outer max 8 mm

HTO3VV-F type). Follow these rules and the above diagram for

the connection:- open the front cover of the control panel, as mentioned in

paragraph 3.3;

- unscrew two screws in the back window of the control panelwhich will give you an access to the terminal connector;

- take out the bad cable and put in a new one at the same point;

- put the grommet to the new cable, including the groundin

cable drawing in;- place the cable so that the insulation fits into the right place;

- connect the blue cable (neutral) to the point in the terminal

connector that is marked N;- connect the brown cable (phase) to the point in the terminal

connector that is marked L;

connect the yellow-green cable (grounding) to the point tha-

marked by a symbol behind the bac

The boiler is designed for natural gas and propane category

II 2H3p combustion, as stated in the chart in chapter 4 Gasregulation.

If you need to change the boiler to another gas type, follow the

instructions in 4.1.

The point of gas connection in the boiler has to be equipped with

a proper round closing cock, following the valid norms. Werecommend you to clean all piping before installation and to

emove possir

the boiler.

2.8 WATER SUPPLYC

Legend:

etA. Heating outlB. DHW outlet

C. Gas supply

D. Cold water inletE. Heating return pipe

. Refilling valveF

G. Safety valve spillway

There are connections to heating distribution systems, boilersDHW and gas distributions and connections to the appliance in

the picture. More detailed information on armature connection to

distribution systems is to be found on the connection armaturepackaging.

Before you connect water, check if the maximum pressure in the

water distribution system does not exceed 6 bars. If the pressure

in the distribution is higher, it is recommended to install areduction valve.

The minimum pressure for proper boiler functioning in the DHW

mode is 0.2 bars. Therefore it is possible to insert a thermostaticvalve at the cold-water inlet to limit the maximum DHW amount

(see the following picture in part 1).

When dimensioning distributions and radiators the circulation

pump output must be taken into consideration , see the following

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The boiler is equipped with an automatic by-pass, whichprovides the right water supply into the primary exchanger in

case installation with variable supply is done (heating systems

with thermostatic valves etc.)We recommend installing safety valve discharge piping of 3 bars

of the heating circuit.

2.9 INSTALLATION OF FLUE EXHAUST

AND AIR SUCTION ACCORDING TO TPG

800 01

Flue exhaust (outlet) and combustion air supply (inlet) can be

provided by a system of coaxial pipes.

The outlet and the inlet can also be provided by a system of

separate pipes according to the following procedure:

If you assemble the exhaust system using separate pipes it is

necessary to:

1. cut off the outlet bottom;

2. connect the elbow to the outlet right to the bottom brink (Seal

or insulation is not necessary).

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

The stated values of maximum outlet and inlet lengths include

also the length of accessories such as roof bushing, adapter,

opening etc. For coaxial systems the value includes also one

90 elbow.C52 installation has to meet following conditions according to

the diagram:1 The same outlet and inlet pipe diameter of 80 mm over thetotal length.

2 If you want to insert another elbow into the inlet or outlet

systems, you have to provide the equivalent length for the otherside along the same rules as when counting the length.

3 The flue outlet (chimney) must stick out by at least 0.5 mover the roof top (where it is fixed) and it must be placed at theside opposite the side with the air inlet (this condition is not

obligatory if the inlet and outlet are at the same side of the

building).

Recommended exhaust length

maximum coaxial exhaust length 100/60mm

0.5 2.0 m orifice plate 43 mm 2.1 4.0 m no orifice plate

maximum separate exhaust length 2x80mm

0.5 10.4 m orifice plate 43 mm 10.5 43.0 m no orifice plate

maximum pressure loss of the exhaust 80 Pa

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the angle of 0.3owith a decline in the direction from the boilerShortening of the maximum length by an elbow:

90o = -75 cm 45o = -50 cm

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

2.10 ROOM THERMOSTAT CONNECTION

It is necessary to:

1 open the control panel, as described in paragraph 3.3.

2 insert the thermostat cable in the connector and fix it. Then connect both conductors to the electrical terminal connector placed at the

back of the panel by removing shortening jumper. The shortening jumper substitutes the room thermostat when the room thermostat is not

connected.

2.11 WIRING DIAGRAM

Legend:

A = Connector for remote control connecting

B = Heating temperature regulation (Summer/Winter switch)

C = Connector for remote controlD = DHW temperature regulationE = Slow ignition regulation

F = Maximum heating temperature regulation

G = ON/OFF switchH = ON/OFF diode

I = Insufficient flue outlet diode

J = Maximum DHW temperature jumper (for floor systems)

L = Wrong ignition diodeM = Insufficient water diode

N = Unblocking button

O = Economical/comfort mode switchP = Overheating diode

Q = Temperature diodes

R = Transformer

S = Circulation pump relay

T = Ventilator relayU = Gas valve relay

V = Motor-driven 3-way valve relay

ZA=Jumper for postventilation function

A01 = Circulation pumpA02 = Ventilator

A03 = Ignition transformer

A04 = Gas valve

A05 = Motor-driven 3-way valveA07 = Flame scan circuit (ionization electrode)A08 = Heating temperature sensor

A09 = DHW temperature sensor

A10 = Through-flow switchA11 = Heating through-flow switch

A12 = Modulation

A13 = Overheating safety thermostat

A14 = Programmable clockA15 = Room thermostat

COLOURS:

Gr = Grey

Bi = White

Ro = Red

Mr = BrownBl = Blue

Nr = Black

R/N = Red/Black

Jumper service setting:

Label at the gas joint: Jumper function: Effect at Aposition: Effect at Bposition:

ZAVentilation of the combustion

chamber by the smoke ventilatorChimney version, no ventilator

Turbo version, the ventilator

ventilates the combustion

chamber

JHeating temperature limitation: floor

heating/radiators

t max= 45o C Floor heating

system

t max= 82o C Radiator heating

system

W Anticycling time setting:0 min.Just for the service setting

of the boiler2 min. For common operation!!!

CN101 Combustion chamber type:For atmospheric installations

(chimney version)For TURBO installations

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2.13 HYDRAULIC DIAGRAM

Legend:

1. Ventilator2. Primary exchanger

3. Safety thermostat

4. Burner5. Ignition electrodes

6. Ionization electrode

7. Heating temperature sensor

8. Heating manometer9. Pressure through-flow switch

10. DHW temperature sensor

11. Secondary exchanger12. Gas valve

13. DHW flow switch

14. Refilling valve

15. Safety valve, 3 bars16. Motor-driven 3-way valve

17. Automatic by-pass

18. Pump with deaeration19. Expansion vessel

20. Ventilator manostat

A. Heating outlet 3/4

B. DHW outlet 1/2 C. Gas 3/4

D. Cold water inlet 1/2

E. Heating return pipe 3/4

3. STARTING THE BOILER

IMPORTANT!

It is necessary to cut off the electricity supply by turning A

button to 0 position and unplugging the boiler before any

operations inside the boiler.

3.1 CONDITIONS FOR BOILER OPERATIONTo ensure safety, proper functioning and guarantee periodvalidity it is necessary that the installation and the first startshould be carried out by a THERMONA authorized service

technician.

Check if the gas and its pressure, the mains voltage andfrequency correspond with the data on the boilers production

label.

FILLING THE BOILERFollow this procedure:

- release deaerating valves on the radiators;- slowly open the refilling valve on the boiler and close the

deaerating valves on the radiators when the water starts to

flow out;

- close the boilers refilling valve when the pressure reaches1 bar.

GAS SUPPLY

Open the gas supply tap on the inlet pipe and the gas supply tapon the boiler and check the gas installation. You will find any

leak using water with soap.

3.2 CONTROL PANEL

PARTS DESCRIPTION:

A = Main switch

B = DHW temperature regulationC = Mode switch and heating water temperature regulation

D = ON/OFF diode (green)

E = Insufficient flue outlet diode (yellow)F = Insufficient water or operation stop diode (red)

G = Economical/comfort mode switch

H = Unblocking button / flue analysis

I = Safety thermostat operation diode (overheating)

L = Insufficient water in the system diode (red)M = Heating water temperature diodes (yellow)

N = Place for programmable clock installation

O = Heating manometer

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3.3 INSTRUCTIONS FOR OPENING THE BOILER

To access the inside of the boiler it is necessary to unscrew the

fixing screws at the lower part of the control panel.

The control panel swings down and it can be drawn forward ontwo side pins.

Releasing the control panel:

It stops in an almost horizontal position, which allows the access

to the inside. If you want to gain better access you have to lift

the panel and turn it into the horizontal position. To unscrew theouter case you have to:

1. unscrew the two bottom front screws,

2. lift the cover and remove it from the top fittings.

Releasing the front cover

3.4 THE FIRST STARTWhen starting the boiler for the first time you have to:1)check that:

- the electricity connection was made correctly and theinstallation is properly grounded;

- the automatic deaerating valve is allowed;- if the pressure is lower than 1 bar, put more water in the

circuit;- the gas tap is closed.2) Start the boiler by turning knob A to position I (green

diode D lights up) and turning knob C to the middleposition between min and max to start the boiler in the winter

mode. Leave the boiler in this mode for some time to allow

complete deaeration. The boiler will signal blocking after 7

seconds. Then:- release the front plug of the pump deaerating valve to

prevent creation of air bubbles;- repeat the process of radiator deaeration,- open water taps;- check the circuit pressure and if it is lower, open the

refilling tap again until the pressure is 1 bar3)Check that the outlet and inlet pipes are clear.4)Check that the ventilating holes are open.5) Open the gas tap and check the installation for leaks

(including the burner installation) using water with soap. Block

the leaks if necessary.6)Unblock the boiler by pressing H button. The ignition of the

main burner should come immediately. If the burner does not

ignite, repeat the process.7)Check the minimum and maximum value of the gas pressureon the burner and set it according to the chart in chapter 4

REGULATION.

3.5 REGULATION OF OPERATIONIt is possible to adjust:

- the temperature of water for heating, using turning knob C- the temperature of water for DHW, using turning knob B

- choose the economical mode -E- or the comfortable mode -C- ,

using switch G. The economical mode is the usual boilers

operation, when DHW is heated only when required by the user.The comfortable mode is a special function, where the water in

the primary and the secondary circuits is kept pre-heated so that

the user can use the hot water in shorter time, which is for themmore comfortable.

To access the area where the operation can be adjusted it is

necessary to open the control panel, as described in paragraph

3.3, i.e. by unscrewing two screws and removing the backwindow.

Thus you gain access to the electronic panel and the followingcomponent:1) supply cable connector2) fuses3) potentiometer for regulating the slow ignition, which

changes according to the minimum and the maximum

output.4) potentiometer for setting the maximum heat output (preset

to 70% of the maximum heating output by the

manufacturer)5) jump switch for regulating the repeated burner ignition

after burner expires (preset to 1 minute by the

manufacturer).6) Jumper for choosing the floor or the radiator system (J

wiring diagram)7) Jumper for setting the time of the combustion chamber

ventilation (ZA - wiring diagram), which is preset toposition B ventilation on by the manufacturer8) connector for room thermostat connecting (A 15)

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9) connector for programmable clock connecting (if requiredby the customer) (A14)

3.6 FLUE ANALYSIS

The boiler has 2 scanning spots on the output of flue collecting

pipe. The spots are used for finding the harmful substances in the

flue.It is possible to measure the flue temperature, O2, CO2

concentration etc. by using these scanning spots and other

suitable measuring equipment.To access the scanning spots you have to unscrew the front

screw and remove the cover with seal.

The best conditions for analysis are set when the function flue

analysis is activated (press button RESET H for 10 seconds,yellow diode E lights); the boiler switches to the original mode

after 5 minutes, or it is possible to interrupt the function by

ON/OFF switch (button A).Screw the cover with seal back to their original place and seal it

properly after the flue analysis.

3.7 GAS OUTLET CHECKIt is possible to check the correct installation of the exhaust

system and to check losses in the inlet system.

You can measure the difference of pressures

P with differentialmanometer connected to the testing terminals of thecombustion chamber.

The value measured should not be lower than 0.55 mbar with the

maximum heat output.

3.8 PROTECTION FUNCTIONSThe boiler is equipped with the following protection-checking

functions:1 Wrong ignition

This measure signals that the burner has not ignited within 7

seconds after the spark. The boiler is blocked, which is signalledby red F diode. You can restart the boiler by pressing and

releasing button H after you check the gas tap is open.

2 Circulation pump blocking

This measure blocks the boiler if the through-flow switch does

not order the pump to start within 40 seconds. In this case redL lights up. You can restart the boiler after you refill the

pressure in the system and press button A.

3 -OverheatingThis measure blocks the boiler if the temperature in the primary

circuit exceeds 105C. The block is signalled by red I and F

diodes lighting up. It is possible to restart the boiler by button

H after a few minutes, which are necessary for the primarycircuit to cool down.

4 Protection against boiler scale

The boiler is equipped with a device reducing limestone creation

in the secondary circuit. It measures the water temperature

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4. GAS REGULATION

CATEGORY II2H3P NATURAL GAS G20 PROPANE G31

Wobbes index (15C, 1013 mbar) MJ/m3hNominal connecting excess pressure mbarMinimum connecting excess pressure mbar

Main nozzles diameter: 14 nozzles mmConsumption (15C, 1013 mbar) m3/h

Consumption (15C, 1013 mbar) kg/h

Pressure on gas valve outlet max - min

45.672017

1.252.75

-

10.3 2.0

70.693725

0.72-

2.6

35.6 6.8

1 mbar = 10.197 mm of water column

(*) The maximum gas pressure on the burner equals the connecting gas excess pressure reduced by pressure losses inside the gas valve.

CATEGORY II2H3P NATURAL GAS G20 PROPANE G31

23 kW

Recommended pressures for slow ignition (mm H2O) 5 12

4.1 CHANGE TO A DIFFERENT GAS TYPE

The boiler can be changed to use natural gas (G20) or propane (G31) by a technician from an authorized centre. The manufacturer

produces boilers in the version for natural gas.

If you want to do the change you have to:

1. change the main burner nozzles (see the chart in chapter 4);2. regulate the maximum and the minimum boiler output (see the chart in chapter 4);

3. change the production label;

4. set the maximum heating output;5. set the slow ignition;

6. set the ignition delay.

5. MAINTENANCE

We recommend the following checks at least once a year:

1. check the leaks of water armatures, repair or replace defective seals

2. check the leaks of gas connection, repair or replace defective seals

3. visual check of the appliance, disassembling and combustion chamber cleaning if necessary

4. visual check of the combustion process, cleaning burners, disassembling and cleaning nozzles if necessary5. visual check of the primary exchanger:

- check the lamellas- clean the exchanger if necessary

6. gas pressure regulation: in the ignition mode, for the reduced and the maximum outputs

7. check heating safety systems:

- maximum temperature- maximum pressure8. check gas safety systems:

- check of flame scan

- check of gas valve9. check the correct connection to the supply mains

10. check the efficiency of the secondary exchanger for DHW production (check the provided volume and DHW temperature)

11. check the proper installation of flue exhaust

12. check the function and position of the flue thermostat, which cannot stop working. If a replacement of this component is necessary, it canonly by replaced with an original type.

13. complete check of all boiler functions.

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6. TECHNICAL SPECIFICATIONS

23 TCA

CE Certificates

Heat inputNominal heat output

Efficiency at maximum input

Efficiency at 30% inputHeat loss at the cover (D=50C)

Heat loss by draught with ignited burner

Heat loss by draught with expired burner

Maximum flue flow (natural gas)

Minimum draughtNatural gas consumption at max. output (G20)

Propane consumption at max. output (15C, 1013 mbar) (G31)

Flue temperature at max. output with natural gas combustionCO2 volume in flues

Minimum ambient temperature

Pressure losses in water (max)(DT=20C)

Minimum pressure in the heating systemHeating water temperature

DHW temperatureHot water volume with DT=25CHot water volume with DT=35C

Minimum DHW consumption

DHW pressure

Expansion vessel volumeExpansion vessel excess pressure

Maximum water volume in the circuit

Maximum water pressure in the heating circuitNatural gas connecting excess pressure (G20)

Propane connecting excess pressure (G31)Voltage/frequency

Electricity input

Level of electric cover

Max/min kWMax/min kW

%

%%

%%

Kg/h

Pam3/h

kg/h

C

%C

mbar

barmax/min C

max/min Cl/min

l/minl/min

max/min bar

lbar

l

bar

mbar

mbarV/Hz

W

IP

0694BO0090

26.5 / 11.0

24.8 / 9.793.7

90.71.2

5.10.4

51.8

1.32.8

2.09/2.06

106

7.1+5

200

0.2582 / 42

56 / 3614.2

10.22.6

8 / 0.2

71

130

3

20

37230 / 50

110

24D

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Documents

Therm 23 Tca Angl