Bulex Thema Condens AS 48-A Manual Download Page 39

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MAKSİCONDENSE 48-65

Notes

03/2020

EKNİK EĞİTİM VE DESTEK

Primary heat exchanger cross-sections

PWT 7-coil cross-section

PWT 9-coil cross-section

Summary of Contents for Thema Condens AS 48-A

Page 1: ...DEM RD K M MAKS CONDENSE 48 65...

Page 2: ......

Page 3: ...n 17 2 3 1 Boiler circulation water heater 17 2 4 Design 18 2 4 1 Functional diagram 18 2 4 2 Hydraulic connection 20 2 5 Electronics box 24 2 5 1 Control panel 24 2 5 2 Unit display AI 25 3 Component...

Page 4: ...Basic system diagrams and wiring diagrams 123 5 4 1 Basic system diagrams 123 6 Installation start up 131 6 1 Installation checklist 131 6 2 Detailed installation notes 132 6 2 1 Hydraulic connection...

Page 5: ...8 4 2 Gas consumption relating to nominal load 191 8 5 System checklist 192...

Page 6: ......

Page 7: ...and underfloor heating as well as peak load boilers Space heater unit types Space saving installation in the central utility room for the modernisation and new construction of non residential buildin...

Page 8: ...MAKS CONDENSE 48 65 Notes 01 2018 2 Training 0020260859_00 The new SDBG 48 65 kW condensing WHB is a compact robust and technically proven system boiler...

Page 9: ...rcuit 1 x non regulated heat ing circuit DHW supply 1 x MiPro 2 x MiPro remote 1 x RED 5 and MiLink Internet gateway Area of application Single occupancy house apartment office building Remote access...

Page 10: ...ply 1 x MiPro 1 x MiLink Area of application Single occupancy house Remote access via MiConnect MiPortal New For 7 coil and 9 coil heat exchangers 48 kW 65 kW Additional software function for the dire...

Page 11: ...rigs Back to back Around corner layout Accessories range to manage single boiler installation as well as various cascade layouts Hanging rig Fumes Hydraulic Insulation System management High efficien...

Page 12: ...MAKS CONDENSE 48 65 Notes 01 2018 6 Training 0020260859_00...

Page 13: ...ording to the number of boilers This wider ratio implies a higher efficiency and comfort while reducing wear on components High operating reliability If one boiler goes down the others continue provid...

Page 14: ...ErP A possible with class VI control 1 Cost savings 2 Satisfaction 3 Save energy and reduce boiler wear 4 Energy saving and environmentally friendly Easy installation and start up 1 Light and compact...

Page 15: ...formity 3 Save energy and reduce boiler wear 4 Energy saving and environmentally friendly Easy installation and start up 1 Light and compact design 2 Automatic pipe length adjustment supply air flue p...

Page 16: ...tending the unit s service life Easy installation and start up 1 Light and compact design 2 Automatic pipe length adjustment supply air flue pipework 3 Automatic partial load adjustment 4 Simplified r...

Page 17: ...mily from the SDBD brands The units are introduced with outputs of 48 kW and 65 kW Special features 108 standard efficiency Hi 50 30 dT Modulation up to 1 5 It can be installed without a low loss head...

Page 18: ...product Vertical pipe connections on the underside of the unit provide unhindered access when the unit is being installed New 7 coil primary heat exchanger from the A project with additional manual p...

Page 19: ...dens AS 65 A Circulation water heater Thema Condens 48 SB A Thema Condens 65 SB A Circulation water heater Panther Condens 48 KKO A Circulation water heater 2 2 1 1 Description explanation of the nome...

Page 20: ...gory I II 2 3 H L P E S K Meaning x One usable gas category x Two usable gas categories x Second gas family natural gases x Third gas family liquid gases x Group H gas high gas x Group L gas x Group P...

Page 21: ...H HU HU 06 2018 II2H3P Saunier Duval Thema Condens 48 SB A H IT Thema Condens 65 SB A H IT IT 03 2018 II2H3P Hermann Saunier Duval Thermomaster Condens AS 48 A H ES Thermomaster Condens AS 65 A H ES...

Page 22: ...ic connections for flow and return distribution Condensate hose Drain hose for precipitation discharge Documentation Different hydraulic accessories depending on the market 2 2 4 1 Scope of delivery o...

Page 23: ...MAKS CONDENSE 48 65 Notes 03 2020 17 TEKN K E T M VE DESTEK 2 3 Product design 2 3 1 Boiler circulation water heater 48 65 kW boiler...

Page 24: ...DENSE 48 65 Notes 01 2018 18 Training 0020260859_00 2 4 Design 2 4 1 Functional diagram Space heater 65 kW Key Motor Impeller sensor Pump Valve NTC sensor Service valve Expansion re lief valve Pressur...

Page 25: ...MAKS CONDENSE 48 65 Notes 03 2020 19 TEKN K E T M VE DESTEK Space heater 48 kW Key Motor Impeller sensor Pump Valve NTC sensor Service valve Expansion re lief valve Pressure sensor...

Page 26: ...t pipe for the cutting ring connector Additional connection for precipitation discharge from the annular gap of the concentric flue system Additional outlet for drop water connection of the air separa...

Page 27: ...ACE HEATER VM 41 48 kW 7 coil SAP 0020258498 Installation set with 4 bar expansion relief valve and filling and drain cock VC SPACE HEATER VM 65 kW 9 coil SAP 0020258502 Installation set with 4 bar la...

Page 28: ...MAKS CONDENSE 48 65 Notes 01 2018 22 Training 0020260859_00...

Page 29: ...Hydraulic accessories for new build and replacement Connection set for existing safety valve and expansion vessel of the predecessor boiler Hydraulic connection with pipe group and extension for repla...

Page 30: ...uttons below the display are required to adjust the temperatures and to set unit specific and system specific parameters The display lighting switches on segments are illuminated If you switch the boi...

Page 31: ...ode heat demand burner anti cycling time ac tive Flashing Heating mode active Display off Summer mode active or terminal 24V RT open or flow temper ature target value 20 C On boilers Permanently on Ti...

Page 32: ...ted To achieve this different codes are stored On the one hand there is the level installer that is used to configure the unit during initial start up You can access this level using code 96 On the ot...

Page 33: ...ts used and the overall function of the unit The overall function is divided into Standard functions Special functions Safety functions 3 1 Overview of the components 3 1 1 Hydraulic module Space heat...

Page 34: ...ator Air separator housing with automatic float air vent separation plate 3 1 1 2 48 65 kW manometer Manometer with two operating pressure ranges Outer pressure range for the 65 kW unit output up to 4...

Page 35: ...installed Grundfos UPMM 25 85 is a glandless circulation pump with cast iron pump housing It features an EC motor with automatic output adjustment The connection to the PCB is effected via a three pi...

Page 36: ...lls 0 5 bar Switching off the unit and flashing fault message 0 0 bar The pump does not start fault message F 22 System pressure falls 0 5 bar Pressure display 0 0 and the bar symbol flashes burner do...

Page 37: ...or optional DHW cylinder charging mode C1 C2 contact NTC sensor C1 C2 contact plug in coupling The plug in couplings for optional cylinder charging via the unit electronics can be found on the left of...

Page 38: ...ate non condensing level The flue gas that has already been cooled then heats the elements 1 or 2 downstream of the insulating plate Cross flow heat ex changing principle The advantages include very e...

Page 39: ...MAKS CONDENSE 48 65 Notes 03 2020 33 TEKN K E T M VE DESTEK Primary heat exchanger cross sections PWT 7 coil cross section PWT 9 coil cross section...

Page 40: ...is equipped with a manual purging valve The purging valve is located at the highest point of the heat exchanger in order to fully purge it during start up and maintenance work so that no air remains i...

Page 41: ...exchanger and is constructed from plastic up to the air flue pipe connection Here the entirety of the condensate that occurs and the proportional rain water from the flue pipework on the collector dra...

Page 42: ...e Mixture pipe Gas valve assembly The compact module is a further development of the pneumatic gas air mixture The essential changes are The gas valve assembly Honeywell The connection to the Venturi...

Page 43: ...hape of the electrode ensures that the flame is detected for all required gas qualities A mixing cylinder that is inserted inside the burner evenly distributes the burner gas air mixture This achieves...

Page 44: ...MAKS CONDENSE 48 65 Notes 01 2018 38 Training 0020260859_00...

Page 45: ...lectrical connection The ignition transformer is no longer a component on the PCB instead it is now attached to the gas valve assembly with a support plate As described in the detailed view the transf...

Page 46: ...e maximum speed can be decreased under diag nostics code D 051 and the minimum speed can be increased under diagnostics code D 050 Changing the factory setting is only required in exceptional cases Th...

Page 47: ...ing the CO2 adjusting screw on the left hand side of the compact thermal module which is covered by a yellow sticker as supplied This system is not designed to let you adjust the minimum load The inle...

Page 48: ...ervo system and into the gas pressure regulator 3 via the opened second gas valve This amount of servo gas then moves the main gas valve 4 upwards thereby opening the main gas route As soon as the mai...

Page 49: ...gned to let you adjust the minimum load The inlet pressure is checked at the test nipple for gas connection pressure and gas flow pressure The gas pressure regulator servo pressure regulator must neve...

Page 50: ...o system and into the gas pressure regulator 3 via the opened second gas valve This amount of servo gas then moves the main gas valve 4 upwards thereby opening the main gas route As soon as the main g...

Page 51: ...int for the air pressure switch with warning label The new supply air pipe is equipped with an additional test point for an air pressure switch An additional borehole is located on the sleeve to the g...

Page 52: ...Thanks to this correlation blocks in the flue pipework or overly long flue pipe works are detected If the flue gas system resistance is too high the unit is switched off with an operating block Possi...

Page 53: ...units are equipped with a water drain collector in order to collect and drain precipitation from the flue system s annular gap In addition on the right of the unit underside floor plate the drain hos...

Page 54: ...t necessarily have to be filled with water during start up Function If the condensate now reaches the siphon and the condensate level increases the internal float is raised and the condensate drips ov...

Page 55: ...he display All important data is saved on the PCB The functions of the flame sequence control the electronic monitoring the power supply the fan monitoring and the fan control are stored on the PCB Th...

Page 56: ...interruption D 016 0 Pink eBUS External eBUS control Grey Optional External 230 V actuators e g ext heating pump Select with D 026 Blue Fan Internal fan 230 V AC Green CH pump Internal heating pump 2...

Page 57: ...ic installation set The hydraulic set consists of 4 bar 7 coil 4 bar later 6 bar 9 coil expansion relief valve Drainage nipple 2 x 1 distributor connection gas cutting ring nipple 1 x filling and drai...

Page 58: ...ewage system The hose has a rubber connector which is placed on the unit siphon s drain connection Please comply with the national regulations regarding the draining of condensate The units have a nom...

Page 59: ...s this level using code 96 On the other hand there is the level expert that is used to configure the unit after components have been replaced You can access this level using code 35 The code for the i...

Page 60: ...ng the or side of the button 3 The changed value is automatically saved after three seconds 3 2 1 4 Selecting diagnostics parameters To change the diagnostics parameter press the or side of the button...

Page 61: ...he display is blank Switch cylinder charging on or off If a domestic hot water cylinder is connected you can switch off cylinder charging without switch ing off the heating mode Press the button 1 rep...

Page 62: ...at any time in order to receive information about the current unit status It also provides diagnostics support in the event of a unit block To select the status press and hold each side of buttons 2 a...

Page 63: ...ton 3 at the same time for three sec onds Check programmes Section 7 contains the list of check programmes To select a check programme use the or side of button 2 Then use button 1 to switch the funct...

Page 64: ...t messages in the unit history To select the unit history press and hold the side of button 2 and the side of button 3 for 3 seconds Fault message history To delete the fault messages press and hold t...

Page 65: ...48 65 Notes 03 2020 59 TEKN K E T M VE DESTEK 3 3 Functional description 3 3 1 Functional description of the pneumatic gas air mixture Set RPM Air Power Volume Gas Volume Air Modulation set Electronic...

Page 66: ...signal The burner is now always modulated by modifying the air flow PWM signal of the fan The gas volume follows the air flow in a predefined ratio through the pneumatic gas air mixture as both variab...

Page 67: ...etected the ignition speed of the fan both gas valves control valve and main gas valve are opened A lined air gas intake spigot annular gap is fitted on the intake side of the fan This creates a sucti...

Page 68: ...ernal flow temperature control see symbol If the aforementioned and conditions are met a pump start up time occurs before the burner goes into operation The heating water here circulates for 30 second...

Page 69: ...d heating mode target values This prevents the living rooms from overheating Special features After switching off the burner the pump overrun and burner anti cycling time are started 1 The pump overru...

Page 70: ...in the first minute Due to the large time constants involved for a dwelling or a building no comfort bottlenecks are expected in heating mode At the end of this time the theoretical modulation target...

Page 71: ...switch from flow temperature control to return temperature control under diagnostics code D 017 Return temperature control is preferred for use in directly fed underfloor systems with out a low loss...

Page 72: ...o determine the heat curve the regional surface contact temperature for the system temperature must be determined The base point setting is set to 20 C room temperature at the factory This parameter c...

Page 73: ...sor is related to a modulating thermostat function due to this switching the base point automatically shifts and therefore optimises the heat curve If a weather compensated control e g MiPro is used t...

Page 74: ...etting selected depends on the heat demand of the flat or building The default setting for the partial heat load is Auto the manual adjustment range depends on the unit variant The partial heat load c...

Page 75: ...ial load heating mode After mains power Off On and Reset the adaptive partial heat load is recalcu lated After a regular shutdown and reactivation by an external heating control the most recently save...

Page 76: ...et flow temperature and the maximum burner anti cycling time that is set Domestic hot water mode being on during the burner anti cycling time does not influence the timing element The timing element c...

Page 77: ...der charging mode To avoid long cylinder charging times e g when heating a large cylinder volume a time limit is applied to cylinder charging mode because long cylinder charging times can have a negat...

Page 78: ...nder must be switched off so that it has reached the exact cylinder target value shortly after the end of cylinder charging To ensure this the cylinder must be switched off before the cylin der temper...

Page 79: ...ting pump switches on and The flow temperature control receives the fixed target value set in the diagnostics system diag nostics code D 078 factory setting 80 C and the prioritising diverter valve mo...

Page 80: ...in 125 l hr and max 500 l hr dependent on burner modulation and the stored modulation limitation delta T The modu lation limitation delta T is dependent on the actual volume flow circulation water vol...

Page 81: ...ulation water volume HFR Modulation is enabled for a delta T of 30 K maximum output Pmax That corresponds to a volume flow 350 l hr per heat exchanger coil The burner now operates without modulation l...

Page 82: ...is therefore enabled and the boiler starts and modulates within the temperature limitation of 65 C 3 Zone High circulation water volume HFR The temperature target value is enabled for a max Temperatu...

Page 83: ...flow measurement and response via PWM The volume flow analysis is also used for sophisticated pump fault indication Under the parameter D 149 in the diagnosis display five different messages with a d...

Page 84: ...remaining pump head Note New For the Space heater unit there are now two separate setting parameters for the unit pump s remaining feed head in different operating modes D 122 remaining feed head in...

Page 85: ...d New If the minimum volume flow LFR is not reached the electronics switch the pump mode to constant control and raise the remaining pump head to the stored value of the max Remaining feed head under...

Page 86: ...1900 l hr If the volume flow is below 500 l hr 0 volume flow zone OFR Zero Flow Rate heating mode is not possible If there is a heat demand in this condition the unit electronics check the current vo...

Page 87: ...nd delta T relative to the volume flow according to Proklima 48 kW unit Output kW delta T C T volume flow Maximum T volume flow Delta T Permitted output in kW Volume flow l h High flow rate HFR No flo...

Page 88: ...MAKS CONDENSE 48 65 Notes 01 2018 82 Training 0020260859_00 Note on D 014 If the parameter D 014 is set inside 1 5 the responsible planner must calculated and ensure the volume flow on site...

Page 89: ...e flow No circulation water volume heating circuit closed Volume flow 0 l hr S 85 6 No volume flow No circulation water volume Pump blocked No following three unsuccessful attempts F 75 1 7 No volume...

Page 90: ...ing pressure in the primary circuit rises above 0 5 bar for 30 seconds start up an auto matic purging function starts The function starts repeatedly if the system pressure has fallen below 0 3 bar for...

Page 91: ...MAKS CONDENSE 48 65 Notes 03 2020 85 TEKN K E T M VE DESTEK Flow chart for automatic purging 30 s min Start purging 0 5 bar 0 3 bar Activate purging threshold Time Pres sure...

Page 92: ...ravity is used to separate large air bubbles from the medium heating water Aggregation zone collecting zone In this zone a fine filter mesh catches small air bubbles and diverts them to the top Above...

Page 93: ...and a stabilisation time of 3 seconds starts During this time period the flame must be permanently visible Fault shutdown during start up If at the end of the safety period of 5 5 seconds or within t...

Page 94: ...onitoring Dry fire protection with flow and return sensors Dry fire protection with volume flow measurement pump PWM response 3 3 6 4 Pressure monitoring with water pressure sensor 1 Minimum pressure...

Page 95: ...ange evaluation Water pressure sen sor 0 5 bar Increase water pressure No Set prioritising di verter valve to heat ing mode pump ON for 10 seconds Yes Five further attempts with pump 10 s ON pump 7 5...

Page 96: ...ased again 3 3 6 7 Low water pressure protection Temperature rise too rapid If the flow temperature or return temperature rises quicker than 10 K s the unit cuts out for 10 minutes and then attempts t...

Page 97: ...and volume flow test successful Fault message F 75 No Boiler standby reached Yes Heat demand Yes Unit ignites Pump pressure change recognised Volume flow LFR Yes Fault message F 75 D 149 detailed de...

Page 98: ...If the flue gas system resistance is too high the unit is switched off with an operating block Possible status and fault messages are S 33 F 33 The unit always starts with the last measured rotational...

Page 99: ...cific planning information and price lists 4 1 Overview of accessories 4 1 1 Electrical accessories Accessory modules for installation in the unit electronics box Accessories Description Benefits Mult...

Page 100: ...oom temperature control eBUS Optimise the boiler Combined with outdoor sensor on the boiler Time programmes Auto adaptive heat curve netATMO An intelligent room temperature control as a 1 cir cuit con...

Page 101: ...detached houses with solar systems heat pumps or multi ple zone systems etc Can be used with MiPro R Extension to up to two regulated heating circuits Extension to a solar control for domestic hot wa...

Page 102: ...its MiPro remote R Can be used with MiPro R Remote control with room temperature control Setting the target room temperature Room air humidity measurement with activated cooling function MiGo Intellig...

Page 103: ...s heating sys tem on site Access to millions of units on the market Diagnosis and analysis of fault messages and status messages Assistance with the commissioning of new systems Optimisation of units...

Page 104: ...mum amount of energy to be saved while also offering a compact external diameter fits through a standard door Carrying aid and adjustable feet with anti noise function installed at the factory Heat ex...

Page 105: ...re not compatible due to the noise class The valve enables switch ing between domestic hot water and heating mode External installation in the heat generator s installa tion hydraulics Flue gas adapte...

Page 106: ...Training 0020260859_00 Other accessories Description Benefits Condensate lifting unit with neutrali sation Up to 200 kW output Neutralisation Up to 450 kW Condensate lifting unit with neutrali sation...

Page 107: ...MAKS CONDENSE 48 65 Notes 03 2020 101 TEKN K E T M VE DESTEK 4 1 3 Overview of the different accessories New May vary in the different markets...

Page 108: ...ts New Rig installation Improved frame for ground in stallation Installation of boiler cascades if wall mounting is not pos sible available space statics New Low loss header Improved low loss header f...

Page 109: ...awing is not the final cross section 4 2 1 2 Water softening cartridge with water meter and accessories Water softening cartridge fixed installation The water softening cartridge treats the top up wat...

Page 110: ...MAKS CONDENSE 48 65 Notes 01 2018 104 Training 0020260859_00...

Page 111: ...lay 1 is programmed with the diagnostics parameter D 027 Relay 2 is programmed with the diagnostics parameter D 028 Display Meaning Display values adjustable values D 027 Switchover of relay 1 on the...

Page 112: ...heating pump Connecting the external heating pump The external pump is only actuated if The internal pump is actuated mandatory condition The prioritising diverter valve is in the heating position A d...

Page 113: ...he VRT 370 f VRC 700 control 4 2 1 7 Operating and fault display Connecting the operating and fault display Closing contact Fault message grey Opening contact Operating display black The operating dis...

Page 114: ...return flap is actuated in the event of a heat requirement by the temperature control in the event of a hot water demand in cylinder charging mode and in the 90 seconds after the lapse of the heat re...

Page 115: ...ping each heat generator with a coupler The first unit in cascades can also work without an eBUS coupler but here the polarity must be checked to to The second unit is assigned the bus address 2 the t...

Page 116: ...derfloor heating and as a post heating installation Space heater unit types in heat pump installations with a buffer cylinder with or without solar support Space saving installation for new builds and...

Page 117: ...00 mm clearance for unit maintenance that is required to open the front of the unit No clearance is required between the unit and components made of combustible parts because the temperature at the un...

Page 118: ...ns 48 65 kW dimension drawing Key 1 Condensate siphon 6 Flue connection template 2 Heating flow 7 Unit wall mounting 3 Gas connection 8 Gas connection pressure measuring point 4 Heating return 9 Flue...

Page 119: ...led before the flue system is installed Otherwise this may lead to operating faults In this case a double walled system flue gas air mixture should be used Particularly in hairdressing salons paint sh...

Page 120: ...0 Pump diagram for Grundfos UPMM 25 105 9 heat exchanger coils Key 1 Volume flow range without unit operation 4 P constant 2 Volume flow range in limited temperature and modulation mode A Volume flow...

Page 121: ...installation room must be ventilated C 33 Air flue pipe through roof in the same pressure range C 33x DE if the flue system has no x approval the installation room must be ventilated C 43 Connection t...

Page 122: ...MAKS CONDENSE 48 65 Notes 01 2018 116 Training 0020260859_00...

Page 123: ...ding to the different markets Market Flue gas certification HU C13 C33 C53 C83 C93 B23 B23 P B33 B53 B53 P ES PT C13 C33 C53 C83 C93 B23 B23 P B33 B53 B53 P IT C13 C33 C53 C63 C83 C93 B23 B23 P B33 B5...

Page 124: ...MAKS CONDENSE 48 65 Notes 01 2018 118 Training 0020260859_00 C43P C53 C83 C83P C93 C63...

Page 125: ...50 to 200 2 1 5 0 02 Guideline values for heating water Water hardness Heating water characteristics Unit Low in salt Saline Electrical conductivity at 25 C S cm 100 100 1500 Appearance Free of sedim...

Page 126: ...x Superconcentrate Boiler Noise Silencer Fernox Superconcentrate Central Heating Leak Sealer Fernox Hawk White Jeanaqua 100 Jeanaqua 110 Adey MC1 Sentinel X 100 Sentinel X 200 You must always observe...

Page 127: ...3 in the heating instal lation return is recommended It is advisable to combine the use of a line strainer with a magnetite separator Heating installations must be flushed before starting up the unit...

Page 128: ...se sludge to form which in turn is offset by ferrous metals Since the high efficiency pumps use a magnetic drive for the inner impeller there is the immediate risk that the ferrous metals may accumula...

Page 129: ...hermostatic motorised 3a Swimming pool circulation pump 3b Cooling circuit pump 9b Zone valve 3c Cooling circuit pump 9c Flow regulator valve 3d Well pump 9d Bypass valve 3e Circulation pump 9e DHW ge...

Page 130: ...ly company switching contact 12f Wiring centre FS Flow temperature sensor swimming pool sen sor 12g eBUS bus coupler MA Multi function output 12h Solar control ME Multi function input 12i External con...

Page 131: ...owing hydraulic plans are a selection for the product start Deviations may be possible in individual markets Contact MX MCP for any questions 5 4 1 1 Hydraulic plan 0020253234 41 65 kW hydraulic plan...

Page 132: ...MAKS CONDENSE 48 65 Notes 01 2018 126 Training 0020260859_00 Hydraulic plan 0020253234 wiring Connection diagram 0020253234...

Page 133: ...MAKS CONDENSE 48 65 Notes 03 2020 127 TEKN K E T M VE DESTEK 5 4 1 2 Hydraulic plan 0020253237 41 65 kW hydraulic plan cylinder function unit low loss header...

Page 134: ...MAKS CONDENSE 48 65 Notes 01 2018 128 Training 0020260859_00 Hydraulic plan 0020253237 wiring Connection diagram 0020253237...

Page 135: ...MAKS CONDENSE 48 65 Notes 03 2020 129 TEKN K E T M VE DESTEK 5 4 1 3 Hydraulic plan 0020259028 41 65 kW hydraulic plan cylinder function unit low loss header...

Page 136: ...MAKS CONDENSE 48 65 Notes 01 2018 130 Training 0020260859_00 Hydraulic plan 0020259028 wiring Connection diagram 0020259028...

Page 137: ...allations The gas and water connections must only be connected to the boiler once all of the required soldering work has been completed on the pipelines The heat conduction that this creates destroys...

Page 138: ...tions for flow return gas connection condensate connec tion see next figure Open the press connection A Insert the gas connection B into the press connection Secure the connection on the gas connectio...

Page 139: ...c connection Installing the union nut in accordance with steps A to D Installing the heating circuit return 11 to 17 Installing the heating flow 1 to 10 Heating return stopcock seal 19 Installing the...

Page 140: ...valve 1 on the heating flow Installing the condensate discharge 2 on connection 1 The condensate discharge must always be laid frost free and with a downward gra dient of at least 48 mm per metre The...

Page 141: ...ace heater 41 65 kW PCB BMU all markets 6 2 2 1 Connecting the control Red Room or weather compensating eBUS control White 24 V room thermostat Blue Temperature cut out e g underfloor heating As deliv...

Page 142: ...nsor and C1 C2 on the unit cable harness 6 2 2 4 X41 plug in the boiler s scope of delivery Item Description Item Description OT Sensor earth AF outdoor temperature DCF Germany only Radio signal recei...

Page 143: ...3 Air and flue gas accessories 48 65 kW units are fitted with an 80 125 mm diameter air flue gas spigot as standard Observe the supplementary information in the flue gas accessory catalogue Top view...

Page 144: ...rget flow temperature Setting the maximum target flow temperature in heating mode to 30 C 85 C Setting via the display Domestic hot water temperature Preselecting the maximum DHW temperature 35 C 65 C...

Page 145: ...he end user on how to inspect the filling pressure of the system and on topping up or purging the heating installation Instruct the end user on the correct economi cal settings for temperature control...

Page 146: ...MAKS CONDENSE 48 65 Notes 01 2018 140 Training 0020260859_00...

Page 147: ...e 3 Open the water supply 4 Open the thermostatic valves 5 Open the service valves 6 Slowly open the filling drain cock 1 7 Open the purging nipple 3 and wait until the water escapes without bubbles T...

Page 148: ...r other causes during servicing maintenance After filling the installation the purging starts if 0 5 bar has been exceeded for at least 30 seconds The function cannot be stopped even by the competent...

Page 149: ...4 4 Maximum heat output The maximum unit output can be restricted in this parameter D 071 6 3 4 5 Additional relay factory delivery D 026 Definition of the actuator connected to connection terminal X...

Page 150: ...best to do this using the Live Monitor since this allows you to read all of the main operating modes 1 Use a screwdriver to loosen the screw plug 1 2 Connect the manometer to the test nipple 1 3 Open...

Page 151: ...onitor since this allows you to read all of the main operating modes 1 Use a screwdriver to loosen the screw plug 1 2 Connect the manometer to the test nipple 1 3 Open the gas valve 4 Check the gas co...

Page 152: ...check programme P 01 3 Keep the unit in operation for five minutes un til it reaches its operating temperature 4 Use a flue gas measuring instrument to meas ure the CO2 content on test opening 1 on th...

Page 153: ...load Check programme P1 Is the flow pressure within the permissible range Decommissioning the unit No Is the CO2 value within the tolerance range 0 3 Adjust to value specified in CO2 ta ble Turn cloc...

Page 154: ...01 front casing open 9 0 3 9 1 0 3 9 1 0 3 9 0 3 9 9 0 3 vol Permissible CO2 content after five minutes at full load with P 01 front casing closed 9 2 0 3 9 3 0 3 9 3 0 3 9 1 0 3 10 1 0 3 vol 6 3 5 6...

Page 155: ...n Value G20 to G25 G25 3 to G20 G20 to G27 G20 to G31 7 coil 1 5 rotations clockwise 1 rotation anti clockwise 2 25 rotations clockwise 2 5 rotations anti clockwise 9 coil 3 5 rotations anti clockwise...

Page 156: ...MAKS CONDENSE 48 65 Notes 01 2018 150 Training 0020260859_00 6 4 Regional legislation...

Page 157: ...inspection Air flue pipe for leak tightness and correct fastening Not blocked or damaged Unit for water condensed water and flue gas leaks Vacuum chamber for dirt Electrical plug connections and conn...

Page 158: ...ether the electrical plug connections and other connections are fitted tightly adjust if necessary x 8 Check that the gas lock and service valves are functioning correctly x 9 Check the pre charge pre...

Page 159: ...tion Maintenance of the integral condensation heat exchanger The spiral immersion heaters of the integral con densation heat exchanger must only be cleaned with a soft brush or using household cleanin...

Page 160: ...forget to install the non return device Cleaning the automatic air separator The air separator should be cleaned once a year To do this drain the unit and open the air separa tor housing Remove and cl...

Page 161: ...from the gas valve 8 Loosen the four fixing screws 7 9 Remove the fastening bracket 8 for the supply air pipe 10 Remove the gas air mixture 9 from the heat exchanger For assembly carry out the steps i...

Page 162: ...0 7 2 1 3 Dismantling cleaning the air separator 1 Pull off the clip 1 2 Remove the connection pipe 2 3 Loosen the fixing screws 1 4 Remove the housing 2 from the air separator 5 Clean the filter 3 us...

Page 163: ...lower section of the siphon with water up to 10 mm below the upper edge Install the siphon in reverse order After cleaning the condensate siphon do not forget to insert the internal float 3 for assemb...

Page 164: ...MAKS CONDENSE 48 65 Notes 01 2018 158 Training 0020260859_00 7 2 2 Recommended tools Basic tool set Electronic manometer Quick response thermometer Flue gas analyser Electronic leak detector...

Page 165: ...at demand S 20 Domestic hot water requirement S 01 Heating mode Fan start up S 21 DHW mode Fan start up S 02 Heating mode Pump prerun S 22 DHW mode Pump prerun S 03 Heating mode Ignition S 23 DHW mode...

Page 166: ...art up fan speed deviation S 85 Service message Insufficient circula tion water volume product in waiting period for one to five minutes S 34 Frost protection mode active S 96 Return temperature senso...

Page 167: ...verrun Heating 2 60 min 5 min D 002 Max anti cycl time Heating at 20 C flow temperature 2 60 min 20 min D 004 Cylinder temperature actual value For Space heater Cylinder sensor in C D 005 Heating flow...

Page 168: ...50 C 65 C D 022 Cylinder charging requirement through in ternal cylinder control C1 C2 impeller sensor or actoSTOR On 1 off 0 D 023 Heating mode status Released 1 Blocked 0 D 024 Status of the air pre...

Page 169: ...flame 400 No flame 800 D 047 Outdoor temperature with weather com pensated boiler control Actual value in C D 050 Offset min speed 0 to 3000 rpm Unit dependent factory setting D 051 Offset max speed 9...

Page 170: ...300 D 084 Maintenance in number of hours until next service Adjustment range 0 to 3000 hrs and for deactivated D 085 Minimum output anti sooting kW D 090 Status of eBUS control Recognised 1 Not recog...

Page 171: ...etailed description of fault F 75 If the fault message F 75 appears a defined indication for fault analysis can be evaluated here 0 No fault 1 Pump blocked 2 Electrical pump fault 3 Dry fire 4 Alarm p...

Page 172: ...tallations with low loss header as the minimum volume flow is easily reached Diagnostics code D 029 New The current pump volume flow in l min can be read here The value is measured via the pump s PWM...

Page 173: ...en cable harness and product incorrect Flow or return NTC defective loose connec tion Stray spark via ignition cable ignition plug or ignition electrode F 22 Safety switch off Water deficiency dry fir...

Page 174: ...in eBUS eBUS overload or Two power supplies with different polarities on eBUS F 61 Fault Fuel valve actuation Short circuit short to earth in cable harness for gas valves Gas valves defective short to...

Page 175: ...ater in unit check external bypass External expansion vessel connected on flow line D 149 1 Pump blocked alarm Clean the pump replace the pump D 149 2 Electrical pump fault Check supply voltage replac...

Page 176: ...posi tioned correctly on the pipe F 84 Fault NTC temp diff implausible Flow and return temperature sensors report implausible values Flow and return temperature sensors not cor rectly installed F 85 F...

Page 177: ...breaker No 2 A micro fuse defec tive fan or pump short circuit PCB de fective Yes Carry out trouble shooting as per the fault list Eliminate all faults Is there a fault mes sage in the display Yes Ye...

Page 178: ...the tar get value according to customer requirements No D 22 1 Cylinder sensor con nected and plausible Yes Check the switching movements of the motor Remove the motor and observe the func tion PCB de...

Page 179: ...0 C e g the external control is blocking the heating mode Settings D 5 external requirement D 47 outdoor temperature Status display S 0 to S 8 External prioritising di verter valve or charging pump st...

Page 180: ...5 bar If the heating pressure in the primary circuit rises above 0 5 bar for 30 seconds start up an automatic purging function starts The function starts repeatedly if the system pressure has fallen...

Page 181: ...MAKS CONDENSE 48 65 Notes 03 2020 175 TEKN K E T M VE DESTEK 7 3 3 Measurement points and measured values 7 3 3 1 Internal circuit diagram...

Page 182: ...MAKS CONDENSE 48 65 Notes 01 2018 176 Training 0020260859_00...

Page 183: ...M for the heating circuit pump 4 Flow sensor 13 D 026 optional relay 5 Return sensor 14 3 way valve DHW charging pump power sup ply 6 Air pressure switch 15 230 V fan power supply 7 Fan control signal...

Page 184: ...AKS CONDENSE 48 65 Notes 01 2018 178 Training 0020260859_00 7 3 3 2 New Honeywell gas valve assembly Honeywell VK 8205 VE V Resistance measurement at the gas coils Between contact 1 3 blue socket 114...

Page 185: ...gnition transformer ecoTEC xx6 5 5 ignition transformer Ignition transformer circuit diagram Step 230 V S1 Status measured value 0 No actuation Off Resistance between 3 and 4 100 Mohm 1 Actuation On O...

Page 186: ...rner off Block contact e g for limit thermostat condensate pump 9 230V Power supply 230 V 3 24V Contact for 24 V room thermostat with potential free switching 10 X 12 Optional 2 in 7 module power sup...

Page 187: ...81 TEKN K E T M VE DESTEK 7 3 3 5 NTC VR 11 sensor measured values Temperature C Resistance k Image VR 11 NTC flow and return 15 16 20 12 7 25 10 1 10 K 30 8 2 35 6 6 40 5 4 48 4 4 50 3 6 55 3 60 2 5...

Page 188: ...ble of optional cylinder sensor resistance values Temperature C Resistance k 10 5 39 15 4 24 20 3 37 25 2 70 30 2 17 35 1 75 40 1 43 48 1 17 50 0 96 55 0 80 60 0 66 65 0 55 70 0 47 75 0 39 80 0 33 85...

Page 189: ...th components The unit variant only has to be programmed if replacing both components otherwise fault message F 70 appears Using the correct display is particularly important when programming the DSN...

Page 190: ...e heater Gas G20 G20 Gas category II2H3P II2H3P Dimensions Height mm 720 720 Width mm 440 440 Depth mm 405 473 Weight without packaging kg 37 8 47 2 G31 CO2 minimum output front closed 9 4 9 6 G31 CO2...

Page 191: ...AS 48 A H HU 1 Thema Condens AS 48 A E BE 1 Thema Condens AS 65 A H HU 2 Thema Condens AS 65 A E BE 2 Thermo Master Condens AS 48 A H ES 1 Panther Condens 48 KKO A H CZ 1 Thermo Master Condens AS 65 A...

Page 192: ...MAKS CONDENSE 48 65 Notes 01 2018 186 Training 0020260859_00 8 3 ErP data Data sheet that is enclosed with the product...

Page 193: ...MAKS CONDENSE 48 65 Notes 03 2020 187 TEKN K E T M VE DESTEK...

Page 194: ...calculation Pressure factor Value System pressure bar Static height bar Expansion relief valve pressure set ting bar Expansion volume Expansion volume Expansion coefficient water 4 System volume Expan...

Page 195: ...adiator height 0 80 The following therefore applies In the case of a self contained central heating system with no height difference the pre charge pres sure on the expansion vessel is pre set to at l...

Page 196: ...MAKS CONDENSE 48 65 Notes 01 2018 190 Training 0020260859_00...

Page 197: ...e in MAG W Nominal volume of MAG W 8 4 2 Gas consumption relating to nominal load Heat output setting the energy demand for gas units Set value input l min Nominal input kW Lower net calorific value k...

Page 198: ...instructions 2 Electrical wiring as per installation instructions 3 Water composition as per installation instructions 4 Flue gas system as per planning information 5 Gas connection pressure 6 Gas fl...

Page 199: ...reproduction in whole or in part in written or electronic form For the installation always observe the installation and maintenance instructions enclosed with the unit Planning examples are no substit...

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Summary of Contents for Thema Condens AS 48-A

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Summary of Contents for Thema Condens AS 48-A

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