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MANUAL FOR INSTALLATION AND MAINTENANCE

Boiler with forced flue exhaust

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3 Instructions for opening the boiler 3.7 Gas connection 2. Open the door and the windows. It is necessary to close the electricity supply before any interference in the product. Call authorized service engineers to repair the appliance. Gas regulation 4.1 Conditions for boiler operation 3. It must be connected to the heating circuit and to the hot water distribution system corresponding to its purpose and output.4 The first start 3. according to the manufacturer’s instructions and by a qualified and trained worker.12 Function diagram 2. Do not block up the air or other outlets. the maintenance and any other interference must be carried out in accordance with the valid norms. close the central gas supply (at the gas meter) and call an authorized service engineer.4 Minimum distances 2.8 Protection functions 3. IN GENERAL 1.1 General information 1.5 Regulation of operation 3. 3. It is forbidden to use it for any other than the stated purposes. Prevent children and mentally ill people from using the equipment without supervision.7 Gas outlet check 3. TECHNICAL SPECIFICATIONS 2 .10 Room thermostat connection 2.13 Hydraulic diagram 1. The manufacturer is not responsible for faults caused by unsuitable. If you can smell gas. MAINTENANCE 6.2 Boiler description 2.8 Water supply 2.9 Boiler draining 4. 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.2 Control panel 3. CHANGE TO A DIFFERENT GAS TYPE 4. The notes and instructions included in this manual are to be used by the people who are going to install our product. The installation.2 Boiler placement 2. close the central gas supply as well. wrong or irresponsible use. switch the appliance off by closing the gas tap. operation and maintenance of the product.CONTENTS 1. Read the instructions in the manual carefully because there is the necessary information about the safe installation.3 Boiler dimensions 2.5 Boiler fixation 2. do not switch on any electrical appliances.9 Installation of flue exhaust and air suction 2. STARTING THE BOILER 3.1 GENERAL INFORMATION The appliance serves for room heating and domestic hot water production for home purposes.1 Change to a different gas type 5. Incorrect installation can cause harm to possessions or persons. INSTALLATION 2. phones or other appliances which can produce sparks.6 Connection to the mains 2. Use a wet cloth and soap for cleaning the appliance’s cover.6 Flue analysis 3. The manufacturer is not responsible for damages inflicted in this way. The technician installing the heating equipment must also have valid authorization by the manufacturer. Do not put any objects on the appliance. There is more information in the User’s Guide. Do not use abrasive or dissolving cleaners. Should you be away for a long time. 1.11 Wiring diagram 2. The best way is to unplug it. If there is a fault or malfunction.1 Warning before installation 2.

check which gas type is the boiler designed for (read the label on the packaging and the manual including technical specifications) . Cold water inlet E. Pump pressure switch 13. To gain the best efficiency of the boiler it is necessary to make sure that the temperature of the place where to boiler is mounted is within the temperature limits for the boiler so that the boiler is protected against atmospheric influences. as mentioned in paragraph 2. Placing of such a boiler is not limited by ventilation possibilities or room size. INSTALLATION The installation and the first putting into operation must be carried out by a qualified technician in accordance with the norms valid for installation of this kind of appliances and with the norms of local authority bodies and medical institutions.2 BOILER PLACEMENT The equipment with combustion air supply from the outside and with forced flue exhaust into the outside can be installed in any room which corresponds with the relevant local norms and standards. Primary exchanger 6.1 WARNING BEFORE INSTALLATION The appliance must be connected to the heating distribution system and to the water supply corresponding with the boiler’s purpose and output. Gas valve 24. Safety valve 3 bars 14. washing rooms or shower rooms it is necessary to follow specific relevant local norms. Ignition electrodes 12. Circulation pump 21. Motor-driven 3-way valve 22. It is also necessary to make enough free space around the boiler to make access to individual boiler parts possible. Heating water outlet B.make sure the following exhaust installation meets the valid local norms. If the boiler is to be placed in the bathroom. Through-flow sensor 19. compact so that any access to electricity at the back part is prevented. (electrical part has IP 44 cover). Expansion vessel 25.2 BOILER DESCRIPTION 2. Flue exhaust rectifier 5. De-aerating valve 23. DHW outlet C.3 BOILER DIMENSIONS Legend: 1.4. 2. Connection to flue exhaust 2. Ventilator 4. The boiler must be mounted on a solid. . 2. Refilling valve 17. Safety thermostat 7. Draining valve 20. Flue exhaust differential manostat 26. Ignition transformer Legend: A. Sockets for gas analysis 27. 2.1. (See the specifications) Before you connect the boiler it is necessary to: . Ionization electrode 11. Cold water inlet 18. Secondary exchanger 16. Temperature sensor in the DHW circuit 15. Burner lamellas 10. Combustion chamber 9.check the piping and make sure there are no impurities which could affect the boiler’s operation. Temperature sensor in the heating circuit 8. Gas supply D. Opening for separated exhaust 3. Heating return pipe 3 .

The point of gas connection in the boiler has to be equipped with a proper round closing cock.open the front cover of the control panel. and it has to be fixed to the wall with use of cramps and hooks.75mm2 – outer ∅ max 8 mm – HTO3VV-F type).connect the blue cable (neutral) to the point in the terminal connector that is marked “N”. The boiler is designed for natural gas and propane category II 2H3p combustion. Heating return pipe F.3. . which could affect the efficiency of the boiler. as stated in the chart in chapter 4 “Gas regulation”.take out the bad cable and put in a new one at the same point. . It is connected to a 230 V. Further information is to be found in the manual which goes with the hydraulic connection set and the flue exhaust set. 50 Hz (10 A) socket installed according to valid norms. Heating outlet B. If the pressure in the distribution is higher. We recommend you to clean all piping before installation and to remove possible impurities. use the cable with the same parameters (3 x 0.connect the brown cable (phase) to the point in the terminal connector that is marked “L”. Follow these rules and the above diagram for the connection: . .6 CONNECTION TO THE MAINS The manufacturer is not responsible for damages caused by wrong supply mains in the house. The boiler is connected to the supply mains by a fixed flexible line with a plug. as mentioned in paragraph 3. 2. Cold water inlet E. When dimensioning distributions and radiators the circulation pump output must be taken into consideration . 4 . . Before you connect water. Make sure the phase and neutral connection has been done according to valid norms in the socket. If you need to change the supply cable. It is therefore recommended to have the supply mains checked in certain cases. Gas supply D. following the valid norms.4 MINIMUM DISTANCES The following layout shows the minimum distances for boiler installation which are necessary for possible proper maintenance. IMPORTANT! Legend: A. 2. More detailed information on armature connection to distribution systems is to be found on the connection armature packaging. which will give you an access to the terminal connector.8 WATER SUPPLY CONNECTION TO THE BOILER 2.2 bars. Therefore it is possible to insert a thermostatic valve at the cold-water inlet to limit the maximum DHW amount (see the following picture in part 1).7 GAS CONNECTION graph (output x lift). . including the grounding cable drawing in. check if the maximum pressure in the water distribution system does not exceed 6 bars.unscrew two screws in the back window of the control panel. 2. The same applies for any possible change of the supply cable. . it is recommended to install a reduction valve.1.2. It can also be connected by a firm cable where a suitable two-pole switch must be incorporated. The minimum pressure for proper boiler functioning in the DHW mode is 0. If you need to change the boiler to another gas type. The equipment must be connected to 230 V supply mains by a triplex cable. Refilling valve G.connect the yellow-green cable (grounding) to the point that is marked by a symbol behind the back cover inside the boiler.put the grommet to the new cable. see the following The connection to the supply mains including plugging can only be carried out by a service technician. follow the instructions in 4.5 BOILER FIXATION The boiler has to be placed with the use of water level according to the minimum distances shown at the picture. Safety valve spillway There are connections to heating distribution systems. DHW outlet C. . boiler’s DHW and gas distributions and connections to the appliance in the picture.place the cable so that the insulation fits into the right place.

The boiler is equipped with an automatic by-pass. 5 . 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. which provides the right water supply into the primary exchanger in case installation with variable supply is done (heating systems with thermostatic valves etc. 2.) We recommend installing safety valve discharge piping of 3 bars of the heating circuit. connect the elbow to the outlet right to the bottom brink (Seal or insulation is not necessary). 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. cut off the outlet bottom.

C52 installation has to meet following conditions according to the diagram: 1 – The same outlet and inlet pipe diameter of 80 mm over the total length.1 ÷ 4.5 m over the roof top (where it is fixed) and it must be placed at the side opposite the side with the air inlet (this condition is not obligatory if the inlet and outlet are at the same side of the building).4 m ≈ orifice plate ∅ 43 mm • 10.0 m ≈ orifice plate ∅ 43 mm • 2.0 m ≈ no orifice plate • maximum pressure loss of the exhaust 80 Pa 6 . 3 – The flue outlet (chimney) must stick out by at least 0. 2 – If you want to insert another elbow into the inlet or outlet systems.5 ÷ 10.0 m ≈ no orifice plate maximum separate exhaust length 2x80mm • 0. adapter.Diagrams show some examples of various types of coaxial and separate exhaust systems. Recommended exhaust length maximum coaxial exhaust length 100/60mm • 0. you have to provide the equivalent length for the other side along the same rules as when counting the length. opening etc.5 ÷ 2.5 ÷ 43. The stated values of maximum outlet and inlet lengths include also the length of accessories such as roof bushing. For coaxial systems the value includes also one 90° elbow.

the ventilator ventilates the combustion chamber t max = 82o C Radiator heating system 2 min.3o with a decline in the direction from the boiler • • 90o = -75 cm 45o = -50 cm Shortening of the maximum length by an elbow: Note: The length of exhaust means the length of the inlet pipe + the outlet pipe length. For common operation!!! For TURBO installations J W CN101 7 . 2 – insert the thermostat cable in the connector and fix it.10 ROOM THERMOSTAT CONNECTION It is necessary to: 1 – open the control panel.3. Then connect both conductors to the electrical terminal connector placed at the back of the panel by removing shortening jumper. The shortening jumper substitutes the room thermostat when the room thermostat is not connected. 2.11 WIRING DIAGRAM Legend: A = Connector for remote control connecting B = Heating temperature regulation (Summer/Winter switch) C = Connector for remote control D = DHW temperature regulation E = Slow ignition regulation F = Maximum heating temperature regulation G = ON/OFF switch H = ON/OFF diode I = Insufficient flue outlet diode J = Maximum DHW temperature jumper (for floor systems) L = Wrong ignition diode M = Insufficient water diode N = Unblocking button O = Economical/comfort mode switch P = Overheating diode Q = Temperature diodes R = Transformer S = Circulation pump relay T = Ventilator relay U = Gas valve relay V = Motor-driven 3-way valve relay ZA=Jumper for postventilation function A01 = Circulation pump A02 = Ventilator A03 = Ignition transformer A04 = Gas valve A05 = Motor-driven 3-way valve A07 = Flame scan circuit (ionization electrode) A08 = Heating temperature sensor A09 = DHW temperature sensor A10 = Through-flow switch A11 = Heating through-flow switch A12 = Modulation A13 = Overheating safety thermostat A14 = Programmable clock A15 = Room thermostat COLOURS: Gr = Grey Bi = White Ro = Red Mr = Brown Bl = Blue Nr = Black R/N = Red/Black Jumper service setting: Label at the gas joint: ZA Jumper function: Ventilation of the combustion chamber by the smoke ventilator Heating temperature limitation: floor heating/radiators Anticycling time setting: Combustion chamber type: Effect at A position: Chimney version.• the angle of 0. as described in paragraph 3. 2. Just for the service setting of the boiler For atmospheric installations (chimney version) Effect at B position: Turbo version. no ventilator t max = 45o C Floor heating system 0 min.

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Gas 3/4” D. Secondary exchanger 12. Primary exchanger 3. Heating return pipe 3/4 ” A = Main switch B = DHW temperature regulation C = Mode switch and heating water temperature regulation D = ON/OFF diode (green) E = Insufficient flue outlet diode (yellow) F = Insufficient water or operation stop diode (red) G = Economical/comfort mode switch H = Unblocking button / “flue analysis” I = Safety thermostat operation diode (overheating) L = Insufficient water in the system diode (red) M = Heating water temperature diodes (yellow) N = Place for programmable clock installation O = Heating manometer 9 . Automatic by-pass 18. GAS SUPPLY Open the gas supply tap on the inlet pipe and the gas supply tap on the boiler and check the gas installation. 3. DHW temperature sensor 11. Check if the gas and its pressure. Burner 5. the mains voltage and frequency correspond with the data on the boiler’s production label. 3. Ventilator manostat A. Heating outlet 3/4 ″ B. Ventilator 2. DHW flow switch 14. 3 bars 16.2. Cold water inlet 1/2 ” E.2 CONTROL PANEL PARTS DESCRIPTION: Legend: 1. Refilling valve 15. Heating temperature sensor 8. Safety valve.1 CONDITIONS FOR BOILER OPERATION To ensure safety. Expansion vessel 20. FILLING THE BOILER Follow this procedure: release deaerating valves on the radiators. Ignition electrodes 6. proper functioning and guarantee period validity it is necessary that the installation and the first start should be carried out by a THERMONA authorized service technician. Motor-driven 3-way valve 17. Safety thermostat 4. Pressure through-flow switch 10.13 HYDRAULIC DIAGRAM 3. Pump with deaeration 19. close the boiler’s refilling valve when the pressure reaches 1 bar. slowly open the refilling valve on the boiler and close the deaerating valves on the radiators when the water starts to flow out. Ionization electrode 7. Heating manometer 9. 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. Gas valve 13. DHW outlet 1/2 ″ C. You will find any leak using water with soap.

open water taps. if the pressure is lower than 1 bar. using turning knob “B” . using turning knob “C” . which is for them more comfortable. The ignition of the main burner should come immediately.choose the economical mode -E. Leave the boiler in this mode for some time to allow complete deaeration. as described in paragraph 3. If you want to gain better access you have to lift the panel and turn it into the horizontal position. If the burner does not ignite. The economical mode is the usual boiler’s operation.4 THE FIRST START When starting the boiler for the first time you have to: 1) check that: the electricity connection was made correctly and the installation is properly grounded. the gas tap is closed. repeat the process. i. The comfortable mode is a special function.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 temperature of water for heating. 2. 2) Start the boiler by turning knob “A” to position “I” (green diode „D” lights up) and turning knob “C” to the middle position between min and max to start the boiler in the “winter” mode. To access the area where the operation can be adjusted it is necessary to open the control panel. when DHW is heated only when required by the user. 6) Unblock the boiler by pressing “H” button. unscrew the two bottom front screws. repeat the process of radiator deaeration. To unscrew the outer case you have to: 1. Releasing the control panel: Releasing the front cover 3.3. Block the leaks if necessary. It stops in an almost horizontal position. 4) Check that the ventilating holes are open. 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. Thus you gain access to the electronic panel and the following component: 1) supply cable connector 2) fuses 3) potentiometer for regulating the slow ignition. 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 .e. 7) Check the minimum and maximum value of the gas pressure on the burner and set it according to the chart in chapter 4 – REGULATION. put more water in the circuit. which is preset to position B – ventilation on – by the manufacturer 8) connector for room thermostat connecting (A 15) 10 ..the temperature of water for DHW.5 REGULATION OF OPERATION It is possible to adjust: .wiring diagram). lift the cover and remove it from the top fittings.or the comfortable mode -C. 3. the automatic deaerating valve is allowed. The boiler will signal blocking after 7 seconds. by unscrewing two screws and removing the back window. which allows the access to the inside. 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). open the refilling tap again until the pressure is 1 bar 3) Check that the outlet and inlet pipes are clear. 5) Open the gas tap and check the installation for leaks (including the burner installation) using water with soap. using switch “G”. check the circuit pressure and if it is lower. Then: release the front plug of the pump deaerating valve to prevent creation of air bubbles. which changes according to the minimum and the maximum output. The control panel swings down and it can be drawn forward on two side pins.

The block is temporary and is signalled by “E” diode lighting for 15 minutes.: . the boiler is stopped until it is repaired. it is probably because of ventilator defect or because the flue outlet pipes are blocked. O2.8 PROTECTION FUNCTIONS The boiler is equipped with the following protection-checking functions: 1 – Wrong ignition This measure signals that the burner has not ignited within 7 seconds after the spark. However. It measures the water temperature (<61°C) and checks the water temperature in the primary circuit. The spots are used for finding the harmful substances in the flue.e. 5 – Protection against frost The boiler is equipped with a special protection which activates the pump to the heating mode if the temperature falls bellow 8 °C until the temperature is 18° C. You should call an authorized service technician in this case. You can restart the boiler by pressing and releasing button “H” after you check the gas tap is open.open all cold-water and hot-water taps . This function is operational both in the heating mode and the DHW heating mode. CO2 concentration etc. 3. 3 -Overheating This measure blocks the boiler if the temperature in the primary circuit exceeds 105°C.55 mbar with the maximum heat output. 2 – Circulation pump blocking This measure blocks the boiler if the through-flow switch does not order the pump to start within 40 seconds.close the main house or flat water seal . Then the boiler starts itself if the flue exhaust has reached the usual status. drain the water from the lowest parts of the heating system.the water pressure is sufficient . which should not exceed 72°C. yellow diode E lights). 3. 3. Screw the cover with seal back to their original place and seal it properly after the flue analysis.9) connector for programmable clock connecting (if required by the customer) (A14) diodes lighting up. The boiler is blocked.the gas supply is open. If this kind of malfunction appears repeatedly. 4 – Protection against boiler scale The boiler is equipped with a device reducing limestone creation in the secondary circuit. It is possible to restart the boiler by button “H” after a few minutes. 3. switch off the boiler 2. In this case red “L” lights up. the boiler switches to the original mode after 5 minutes.7 GAS OUTLET CHECK It is possible to check the correct installation of the exhaust system and to check losses in the inlet system.9 BOILER DRAINING HEATING CIRCUIT DRAINING It is not recommended to drain the heating system very often because each water change increases the possibility of limestone inside the boiler and its circuits. which is signalled by red “F” diode. 8 –Safety operation stop Before each ignition the control electronics does a series of internal checks. It is possible to drain the boiler in the following way: 1. The block is signalled by red “I” and “F” DHW CIRCUIT DRAINING Whenever there is the danger of freezing it is necessary to drain the DHW circuit in the following way: . add anti-freeze liquid. If the boiler is not used for some longer time and it is in danger of freezing. You can restart the boiler after you refill the pressure in the system and press button „A”. To access the scanning spots you have to unscrew the front screw and remove the cover with seal. use a suitable container for the drained water.6 FLUE ANALYSIS The boiler has 2 scanning spots on the output of flue collecting pipe.the boiler is connected to the supply mains . The value measured should not be lower than 0. i. You can measure the difference of pressures ∆P with differential manometer connected to the “testing terminals” of the combustion chamber. 7 –Flue exhaust malfunctions This protection block the boiler if there is a malfunction of flue outlet. If the temperature falls bellow 3° C the burner ignites with the minimum output until the temperature is 33° C.drain the water from the lowest parts of the system 11 . If an internal malfunction is detected. by using these scanning spots and other suitable measuring equipment. The best conditions for analysis are set when the function “flue analysis” is activated (press button RESET H for 10 seconds. which are necessary for the primary circuit to cool down. 3. or it is possible to interrupt the function by ON/OFF switch (button A). open the safety valve 3 bars manually. 6 –Pump protection To protect the pump and prevent its blocking it is activated 21 hours after the last use for 20 seconds. It is possible to measure the flue temperature. the function is activated only if the boiler is in the proper operation.

check the leaks of water armatures.check of gas valve 9. repair or replace defective seals 3. The manufacturer produces boilers in the version for natural gas. If you want to do the change you have to: 1. visual check of the appliance.check of flame scan . set the ignition delay. set the slow ignition. change the main burner nozzles (see the chart in chapter 4).6 – 6.72 2. gas pressure regulation: in the ignition mode.69 37 25 0. check the correct connection to the supply mains 10.check the lamellas . 1013 mbar) Nominal connecting excess pressure Minimum connecting excess pressure Main nozzles diameter: 14 nozzles Consumption (15°C. disassembling and cleaning nozzles if necessary 5. 1013 mbar) Consumption (15°C. GAS REGULATION CATEGORY II2H3P Wobbe’s index (15°C. check the leaks of gas connection. which cannot stop working. repair or replace defective seals 2. check the proper installation of flue exhaust 12. 5. MAINTENANCE We recommend the following checks at least once a year: 1. change the production label.67 20 17 1.min NATURAL GAS G20 45. cleaning burners. 5.maximum temperature . check the efficiency of the secondary exchanger for DHW production (check the provided volume and DHW temperature) 11. 13.4. check the function and position of the flue thermostat. complete check of all boiler functions. 2.25 2.1 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. check heating safety systems: .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. 6. it can only by replaced with an original type. 4. If a replacement of this component is necessary.3 – 2. visual check of the combustion process. CATEGORY II2H3P 23 kW Recommended pressures for slow ignition (mm H2O) NATURAL GAS G20 5 PROPANE G31 12 4. check gas safety systems: . 12 .clean the exchanger if necessary 6. 1013 mbar) Pressure on gas valve outlet MJ/m3h mbar mbar mm m3/h kg/h max . regulate the maximum and the minimum boiler output (see the chart in chapter 4).75 10. set the maximum heating output.maximum pressure 8.6 35. visual check of the primary exchanger: .0 PROPANE G31 70. for the reduced and the maximum outputs 7. 3.8 1 mbar = 10. disassembling and combustion chamber cleaning if necessary 4.

2 5.3 2.8 2.8 1.0 24.6 8 / 0. 1013 mbar) (G31) Flue temperature at max.06 106 7.7 1.1 0.7 90.25 82 / 42 56 / 36 14.6. output (G20) Propane consumption at max. output with natural gas combustion CO2 volume in flues Minimum ambient temperature Pressure losses in water (max)(DT=20°C) Minimum pressure in the heating system Heating water temperature DHW temperature Hot water volume with DT=25°C Hot water volume with DT=35°C Minimum DHW consumption DHW pressure Expansion vessel volume Expansion vessel excess pressure Maximum water volume in the circuit Maximum water pressure in the heating circuit Natural gas connecting excess pressure (G20) Propane connecting excess pressure (G31) Voltage/frequency Electricity input Level of electric cover Max/min kW Max/min kW % % % % % Kg/h Pa m3/h kg/h °C % °C mbar bar max/min °C max/min °C l/min l/min l/min max/min bar l bar l bar mbar mbar V/Hz W IP 0694BO0090 26.2 7 1 130 3 20 37 230 / 50 110 24D 13 .2 10.7 93.5 / 11.8 / 9.2 2.4 51.09/2. TECHNICAL SPECIFICATIONS 23 TCA CE Certificates Heat input Nominal heat output Efficiency at maximum input Efficiency at 30% input Heat loss at the cover (D=50°C) Heat loss by draught with ignited burner Heat loss by draught with expired burner Maximum flue flow (natural gas) Minimum draught Natural gas consumption at max.1 +5 200 0. output (15°C.