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COSMOGAS MYDENS 100T, Installation, Use & Maintenance Manual, Page: 8 / 94

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COSMOGAS MYDENS 100T Installation, Use & Maintenance Manual Download Page 8

8

60T - 280T

COSMOGAS

2 - GENERAL INFORMATION

2.1 - Introduction

Congratulations! You have purchased truly one of the best products on the market.

Every single part is proudly designed, built, tested and assembled at the COSMOGAS plants, thereby ensuring 

the best quality control.

2.2 - Overview of the models

XXXXDENS XXXTXX

v = Appliance with 2-way valves

s = Appliance with stainless steel manifold

sv = Appliance with 2-way valves and stainless steel manifold

c = Appliance with carbon steel manifold

cv = Appliance with 2-way valve and carbon steel manifold

“60T” = Floor standing appliance with 60kW maximum heat output;

“70T” = Floor standing appliance with 69,9kW maximum heat output;

“100T” = Floor standing appliance with 100kW maximum heat output;

“115T” = Floor standing appliance with 115kW maximum heat output;

“140T” = Floor standing appliance with 140kW maximum heat output;

“180T” = Floor standing appliance with 180kW maximum heat output;

“210T” = Floor standing appliance with 210kW maximum heat output;

“280T” = Floor standing appliance with 280kW maximum heat output;

“MYDENS” = Indoor gas condensing boiler with low emission pre-mixed burner.

  

Summary of Contents for MYDENS 100T

Page 1: ...62403578 R01 09 12 2016_UK INSTALLATION USE AND MAINTENANCE MANUAL 60T 70T 100T 115T 140T 180T 210T 280T MYDENS FLOOR STANDING CONDENSING BOILER ...

Page 2: ...former are not available Carbon Monoxide Every year deaths and serious injuries occur due to carbon monoxide poisoning This tragedies are avoidable if certain preventative measures such as the following are undertaken Ensure that all boilers water heaters room heaters stoves and hobs which burn oil natural gas LP gas coal peat wood and wood pallets are serviced regularly Servicing is needed at lea...

Page 3: ... kept carefully by the user for possible future consultation If the appliance must be transferred or if you should move and leave the unit to another user always ensure that this manual remains with the new user and or installer Do not use homemade cures or heater patent medicines Serious damage to the heater personnel and or property may result Do not use petroleum based cleaning or sealing compo...

Page 4: ...mination 25 6 INSTALLATION Setup 26 6 1 Setup 26 6 1 1 Moving the appliance 26 6 1 2 Opening the package 26 6 1 3 Lifting the appliance 26 7 INSTALLATION Minimum distances to respect 27 7 1 Dimensions and minimum distances to respect 27 8 INSTALLATION Dimensions and centre distances Boiler 28 9 INSTALLATION Dimensions and centre distances table Boiler 29 10 INSTALLATION Hydraulic connections boile...

Page 5: ... one type of gas to another 48 15 5 Converting appliance models from 100T to 280T from one type of gas to another 49 15 6 Ignition 52 15 6 1 Boiler ignition 52 15 7 Checking the supply gas pressure and any adjustments 52 15 8 Checking the CO2 seal and any adjustments 53 15 8 1 Checking the CO2 seal and any adjustments on 60T and 70T model appliances 53 15 8 2 Checking the CO2 seal and any adjustme...

Page 6: ...r 71 17 7 Condensate drain system maintenance and cleaning 71 17 8 Connecting the Display to the other burners 72 17 9 How to move a control board 73 17 10 Emptying the appliance 75 17 11 Minimum and maximum output heat 75 17 12 Checking the ionisation current 75 17 13 Checking combustion performance 75 17 14 Temperature and water measurement probes 75 17 15 External temperature probe 76 17 16 60T...

Page 7: ...and 3rd family gases BS 6891 2005 A2 2008 Installation of low pressure gas pipework of up to 35 mm R1 1 4 in domestic premises 2nd family gas specification BS 5482 1 2005 Code of practice for domestic butane and propane gas burning installations Installations at permanent dwellings residential park homes and commercial premises with installation pipework sizes not exceeding DN 25 for steel and DN ...

Page 8: ...ppliance with carbon steel manifold cv Appliance with 2 way valve and carbon steel manifold 60T Floor standing appliance with 60kW maximum heat output 70T Floor standing appliance with 69 9kW maximum heat output 100T Floor standing appliance with 100kW maximum heat output 115T Floor standing appliance with 115kW maximum heat output 140T Floor standing appliance with 140kW maximum heat output 180T ...

Page 9: ...ing system affordably low fuel consumption to reach high work safety to keep the level of fuel environmental compatibility high Offer your customers a periodic maintenance contract 2 GENERAL INFORMATION 2 3 Included accessories The appliance is supplied with the following accessories Amount No Description Code Figure 1 60T 100T AND 115T METH GAS LP gas CONVERSION KIT 62630197 70T 140T 180T 210T AN...

Page 10: ...g not present 13 Water pressure sensor present on the MASTER burner 1 14 Spark generator 15 Ignition cables 16 Water flow rate measuring device 17 Motorised 2 way valve on request 18 Water inlet pipe 39 Air bleed valve present on all slave burners 3 MAIN COMPONENTS Figure 3 1 Components inside 60T 70T 100T 115T 140T 180T 210T and 280T models 18 17 9 7 15 16 14 5 12 39 13 1 3 4 2 020009 01 018 ...

Page 11: ...t temperature sensor 27 LH ignition electrode 28 RH ignition electrode 29 30 31 Flue gas check valve 32 Check valve magnet 33 Check valve sensor 3 MAIN COMPONENTS Figure 3 2 Components inside 60T 70T 100T 115T 140T 180T 210T and 280T models 7 21 19 27 28 23 26 18 25 020009 01 028 32 33 31 25 020009 01 028_a ...

Page 12: ...st 13 885 IF board on request 14 Electrical connections 15 16 17 Control panel 19 Upper front casing 20 Burner 1 command and control board 21 Lower front casing 24 Pressure switch against discharge clogging 25 Wiring diagram 35 Automatic air vent 36 Water supply connection 37 Water return connection 38 Drain valves 3 MAIN COMPONENTS Figure 3 3 Components inside 60T and 70T models 5 10 37 1 12 35 2...

Page 13: ...an covering 28 Flue exhaust temperature safety fuse 29 Flue exhaust temperature probe 30 Flue exhaust manifold 31 Water inlet pipe 32 33 Condensate level sensor 34 3 MAIN COMPONENTS Figure 3 4 Components inside 60T and 70T models 31 22 33 30 28 29 27 23 020014 01 024 ...

Page 14: ...16 17 Control panel 18 Burner 2 command and control board 19 Upper front casing 20 Burner 1 command and control board 21 Lower front casing 24 Pressure switch against discharge clogging 25 Wiring diagram 26 Water outlet manifold temperature sensor 35 Air bleed valve 36 Water outlet 37 Water inlet 38 Drain cock 3 MAIN COMPONENTS Figure 3 5 Components inside 100T 115T and 140T models 5 10 37 12 1 35...

Page 15: ... exhaust temperature safety fuse 29 Flue exhaust temperature probe 30 Flue exhaust manifold 31 Water inlet pipe 32 33 Condensate level sensor 34 3 MAIN COMPONENTS Figure 3 6 Components inside 100T 115T and 140T models 31 31 22 33 30 28 28 29 29 27 27 23 31 31 22 33 30 28 28 29 29 27 27 23 020014 01 004 BURNER 2 BURNER 1 Master ...

Page 16: ...ser 4 Burner 1 MASTER 5 Condensate drain pipe 6 Gas inlet pipe 7 Hot water supply pipe 8 Burner 2 3 4 SLAVE 9 Air intake 10 Electrical wire passage 11 Air intake filter 12 Flue exhaust 13 885 IF board on request 14 Electrical connections 15 16 17 Control panel 18 Burner 2 3 4 command and control board 19 Upper front casing 20 Burner 1 command and control board 21 Lower front casing 24 Pressure swi...

Page 17: ... 31 31 31 22 28 29 28 33 28 29 30 28 29 29 27 27 27 27 23 020013 01 010 BURNER 2 Not present on 180T and 210T models BURNER 1 Master BURNER 3 BURNER 4 22 Upper covering 23 Main ON OFF switch 27 Fan covering 28 Flue exhaust temperature safety fuse 29 Flue exhaust temperature probe 30 Flue exhaust manifold 31 Water inlet pipe 32 33 Condensate level sensor 34 ...

Page 18: ... safety fuse 12 Pre mixed burner 13 Ignition electrodes 14 Spark generator 15 Water inlet temperature sensor 16 Fan 17 Flue gas non return valve 20 Gas valve 22 Detection electrode 24 CRV Heat exchanger 25 Water outlet 26 Water inlet 27 Gas inlet 28 Pressure switch against discharge clogging 29 Condensate level sensor 30 Condensate drain 31 Condensate drain siphon 36 Condensate neutraliser 47 Wate...

Page 19: ...Flue exhaust temperature safety fuse 12 Pre mixed burner 13 Ignition electrodes 14 Spark generator 15 Water inlet temperature sensor 16 Fan 17 Flue gas non return valve 20 Gas valve 22 Detection electrode 24 CRV Heat exchanger 25 Water outlet 26 Water inlet 27 Gas inlet 28 Pressure switch against discharge clogging 29 Condensate level sensor 30 Condensate drain 31 Condensate drain siphon 33 Manifo...

Page 20: ...afety fuse 12 Pre mixed burner 13 Ignition electrodes 14 Spark generator 15 Water inlet temperature sensor 16 Fan 17 Flue gas non return valve 20 Gas valve 22 Detection electrode 23 Inlet and outlet manifold 24 CRV Heat exchanger 25 Water outlet 26 Water inlet 27 Gas inlet 28 Pressure switch against discharge clogging 29 Condensate level sensor 30 Condensate drain 31 Condensate drain siphon 33 Man...

Page 21: ...ty fuse 12 Pre mixed burner 13 Ignition electrodes 14 Spark generator 15 Water inlet temperature sensor 16 Fan 17 Flue gas non return valve 20 Gas valve 22 Detection electrode 23 Inlet and outlet manifold 24 CRV Heat exchanger 25 Water outlet 26 Water inlet 27 Gas inlet 28 Pressure switch against discharge clogging 29 Condensate level sensor 30 Condensate drain 31 Condensate drain siphon 33 Manifo...

Page 22: ...t This boiler must be connected to a heating and domestic hot water production system with required output heat that is compatible with the features of the appliance itself Figure 4 5 280T model appliance modulation 4 1 2 Wide range of modulation and maximum performance The appliance management program depending on the head required by the system provides for the gradual ignition of each single he...

Page 23: ...ased on the external temperature An operating example is shown as a graphic in figure 4 6 The graphic shows an example in which the supply and return temperatures are 55 C and 43 C respectively and the external temperature is 0 C The external probe controls boiler modulation progressively reducing the supply temperature and optimising output Output changes from 97 when the external temperature is ...

Page 24: ...terial damage 5 INSTALLATION Installation site ATTENTION Installing the appliance in rooms with thin floors could create resonance noise Install elements that reduce the noise ATTENTION Do not allow to much dust to accumulate on the appliance ATTENTION The appliance must only be installed on solid flooring that supports the weight and is level Before installing wash the heating system and if neces...

Page 25: ...e fans ceiling fans dryers compressors air heating units etc that can take air away from the appliance ATTENTION EXTRACTORS Extractors or similar devices to discharge air from the central heating unit can decrease the ventilation required for combustion and or cause vacuums in the ventilation system Flue exhaust leaks from the ventilation system in an inhabited room can cause very dangerous condit...

Page 26: ...s supplied in cardboard packaging secured to a pallet for transport Be careful when opening lift the cardboard box upwards after having detached it from the pallet 6 1 3 Lifting the appliance There is a bracket part A in figure 6 1 to facilitate installation that allows the appliance to be lifted remove the upper covering as per section 17 2 hook the lifting cables B in figure 6 1 to the bracket A...

Page 27: ...t around the appliance both for installation and maintenance as illustrated in figures 7 1 and 7 2 Figures 8 1 8 2 9 1 and 9 2 show the appliance connection dimensions and centre distances Figure 7 1 Minimum distances to respect for 60T 70T 100T 115T and 140T models Figure 7 2 Minimum distances to respect for 180T 210T and 280T models ...

Page 28: ... and centre distances Boiler Figure 8 1 Fitting dimensions and centre distances for 60T 70T 100T 115T and 140T models References in figure 9 1 Figure 8 2 Fitting dimensions and centre distances for 180T 210T and 280T models References in figure 9 1 ...

Page 29: ... 1 1 2 1 1 2 80 mm 80 mm 1 28mm 100T 1 1 2 1 1 2 110 mm 110 mm 1 28mm 115T 1 1 2 1 1 2 110 mm 110 mm 1 28mm 140T 1 1 2 1 1 2 110 mm 110 mm 1 28mm 180T DN65 PN16 DN65 PN16 160 mm 160 mm 1 1 4 28mm 210T DN65 PN16 DN65 PN16 160 mm 160 mm 1 1 4 28mm 280T DN65 PN16 DN65 PN16 160 mm 160 mm 1 1 4 28mm Fittings and flanges are not factory assembled Figure 9 1 Figure 8 1 and 8 2 connection diameter table ...

Page 30: ... safety valve to all the installer to choose the appropriate valve for the system service pressure check appliance operation pressure in the technical features Installation must be done so as to allow the user to check valve intervention should it open The safety valve drain the installer s responsibility must then be directed in order to avoid danger for people in the event it intervenes ATTENTIO...

Page 31: ...e of boiler connection diagram with hydraulic separator and storage tank 24 Heating system return 25 Plug for sludge drain 26 Heating system mixing valve 27 System drain 28 Storage tank loading pump 29 System loading unit 30 Storage tank safety valve 31 Hot water tank temperature sensor 32 Domestic circuit expansion tank 33 Domestic hot water supply 34 INAIL safety minimum pressure switch 36 Main ...

Page 32: ...or the 60T 70T 100T 115T and 140T models Figure 10 3 key 1 Nipple 2 Gasket 3 Manifold 4 Well for Valve probe 11 5 INAIL thermometer 6 INAIL manometer 7 INAIL safety valve 8 Connection unit 11 INAIL gas shut off valve 12 Inspection well 13 INAIL safety thermostat 14 INAIL safety pressure switch 15 INAIL safety pressure switch 16 Expansion tank connection fitting ATTENTION The valve sensor 11 figure...

Page 33: ...tal shavings sawdust grease deposits and dirt in general Welding residues can also cause corrosion both in new systems as well as in the event of modifications or repairs In old systems designed to work with radiators featuring very large pipe diameters the water content is considerable and favours the formation of sludge and deposits Sludge and scale build up Black deposits magnetite indicate tha...

Page 34: ...ated by the presence of oxygen by contact between different metals or by the presence of chlorides c DEPOSITS SLUDGE PROCESSING RESIDUES are organic and inorganic insoluble substances 10 8 Draining the boiler heating circuit In order to avoid constant water top ups and subsequent oxygen and scale it is advisable to limit draining the heating circuit as much as possible 10 9 Boiler low temperature ...

Page 35: ...rculation pump To size the pump to use the designer must consider the hydraulic resistances of the system and the hydraulic resistances of the boiler itself To this end figure 11 1 shows the hydraulic resistances of the boiler in graphic form 11 INSTALLATION Hydraulic connections boiler Figure 11 1 key A Boiler 60T and 70T B Boiler 100T and 115T C Boiler 140T D Bolier 180T and 210T E Boiler 280T ...

Page 36: ...d odours from coming back into the room In particular the condensate disposal system must be made with a pipe that has an inner diameter greater than or equal to 13 mm be installed so as to prevent the liquid from freezing therefore be aware of any sections passing outdoors Draining into gutters or drainpipes is prohibited be in continuous incline towards the drain point avoid high points that cou...

Page 37: ...l mains provide a bipolar switch near the appliance with a contact opening distance of at least 3 mm as required by the applicable standards in force Respect the polarity between phase and neutral when connecting the appliance Make sure the piping for the hydraulic heating and gas systems is not used to ground the electrical or telephone system This sort of piping is absolutely not appropriate for...

Page 38: ...be is enabled Proceed with the steps in section 16 9 1 to set the correct supply temperature adjustment values based on the external temperature 13 1 2 Choosing the room thermostat time programmable thermostat The boiler is equiped to work with any room thermostat or programmable thermostat that has a contact to connect to the cables coming from the boiler with the following characteristics open c...

Page 39: ...er the boiler must be connected to a storage tank The hydraulic connection must be done as per figure 10 2 or the like For the electrical connection proceed as follows refer to figures 13 4 and 13 5 1 disconnect power to the boiler 2 lay a bipolar electrical cable with 1 5 mm2 minimum cross section going from the boiler to the storage tank temperature sensor and connect it on the boiler to termina...

Page 40: ... the water heater to the storage tank temperature sensor and connect it on the water heater to terminals 8 and 9 Manifold temperature sensor 5 connect the other end of the cable to the storage tank temperature probe 6 put the temperature sensor probe inside the storage tank well see figure 11 1 part 42 The temperature of the water stored inside the storage tank can be selected by the user within a...

Page 41: ...60T 280T 13 INSTALLATION Electrical connections Figure 13 4 Boiler electrical connections Example of system shown in figure 10 1 41 ...

Page 42: ...60T 280T COSMOGAS Figure 13 5 Boiler electrical connections Example of system shown in figure 10 2 COSMOGAS 42 ...

Page 43: ...ce and an 885 HC cascade control see figure 13 7 must be purchased At most 8 appliances can be connected in cascade figure 13 6 show examples with 4 Follow the 885 HC control manual for instructions on connecting the appliances in cascade 885 HC Cascade sequence controller MASTER appliance 1 SLAVE appliance 2 SLAVE appliance 3 SLAVE appliance 4 up to 8 Heating module pump Heating heating circuit H...

Page 44: ...onal and or local standards must be taken C53 separated with ceiling mounted exhaust and wall mounted intake or in any case in two potentially different pressure points C63 the boiler can be jointed to approved exhaust and intake ducts of other brands ATTENTION With the C63 type exhaust the condensate coming from the chimney cannot be directed to the boiler During operation especially in the winte...

Page 45: ...ain is designed to make all the liquid produced by an individual appliance flow out Should several appliances be installed provide each with its own condensate drain The flue exhaust air intake system can be extended up to a maximum distance as instructed in section 18 Each 90 curve has a loss equivalent to what is described in section 18 ATTENTION The flue exhaust outlet must be appropriately pro...

Page 46: ...N If the boiler stays off for more than 3 months the siphon must be filled again as explained above ATTENTION Once the appliance has been started up again make sure no flue gases are escaping from plug A 15 1 3 Filling the heating system When the appliance is being powered if Err 59 appears on the display it means that the system needs to be filled Proceed as follows only use clean water from the ...

Page 47: ... unit run a seal test at a pressure no greater than 50 mbar if the gas system test must be run at pressures exceeding 50 mbar use the cock located immediately upstream of the appliance to cut if off from the rest of the system In figures 8 1 8 2 9 1 and 9 2 you can check the gas fitting positioning The sections of piping that make up the gas adduction system must always ensure sufficient gas suppl...

Page 48: ...10 Screw on fitting H in figure 15 2 11 Open the gas supply valve 12 Make sure there are no leaks from fitting H in figure 15 2 ATTENTION Run the seal test exclusively with a soap based water solution Using naked flames is absolutely prohibited 13 Switch on the appliance by turning the main switch to the ON position part T in figure 16 1 14 Completely unscrew screw E in figure 15 6 anticlockwise 1...

Page 49: ...A Connector from Burner 1 MASTER B Connector from display C Connector from Burner 2 D Connector from Burner 3 E Connector from Burner 4 Figure 15 5 Burner Position Burner 2 Burner 1 Master Burner 3 Burner 4 15 COMMISSIONING ...

Page 50: ...to 16 in section 15 4 After converting Burner 3 proceed with Burner 4 if present as described below 5 Convert Burner 4 following points 1 to 16 in section 15 4 After converting all the Burners proceed as described below 6 Check the gas inlet pressure as described in section 15 7 7 Check the appliance output heat as described in section 15 9 ATTENTION The measurements must be taken with calibrated ...

Page 51: ... 5 6 to 6 0 Methane gas CO G20 at maximum and minimum output heat ppm Less than 150 Methane gas CO2 G25 at maximum output heat from 8 5 to 9 1 Methane gas CO2 G25 at minimum output heat from 8 1 to 8 5 Methane gas O2 G25 at maximum output heat from 4 7 to 5 1 Methane gas O2 G25 at minimum output heat from 5 6 to 6 0 Methane gas CO G25 at maximum and minimum output heat ppm Less than 150 LP gas CO2...

Page 52: ...in section 17 2 3 loosen pressure plug D see figure 15 6 4 connect to a manometer with a resolution of at least 0 1 mbar 1 mmH2O For models from 115T to 280T you can use any one of the valves 5 open the gas cock 6 make sure the pressure does not exceed 45 mbar 7 position the main switch to ON part T in figure 16 1 and generate a heating demand by pressing the key until the maximum value Make sure ...

Page 53: ... output heat 5 Wait two or three minutes for the CO2 to stabilise 6 Put the CO2 value reading probe into socket F shown in figure 15 9 7 Compare the CO2 value detected with the one shown in table 15 8 Be sure to read the value for the type of gas being used If the CO2 value does not match the one in table 15 8 it must be adjusted via screw E in figure 15 10 Use a 2 5 mm hex spanner turn the screw ...

Page 54: ... 12 Set parameter 2201 to OFF 13 Repeat the operations from point 3 to point 11 on the remaining burners considering that parameter 2202 corresponds to burner 2 2203 to burner 3 and 2204 to burner 4 14 Close the combustion analysis hole in figure 15 9 with appropriate plug F as per the instructions from the drain pipe manufacturer ATTENTION Once plug H is positioned with the appliance at maximum o...

Page 55: ...y the external probe R Key to increase the temperature of the domestic hot water with storage tank and change the parameter values S Key to reduce the temperature of the domestic hot water with storage tank and change the parameter values T on off switch 16 1 Checking water pressure 16 1 1 Checking boiler water pressure If the pressure inside the heating circuit drops below 0 5 bar display N in fi...

Page 56: ...ashing burner icon Press the RESET key to restore normal operating conditions The appliance will automatically attempt another ignition ATTENTION If the appliance frequently stops because it locks up contact a qualified technician to reset normal operating conditions Once started properly the appliance will continue to work for the service requested To switch OFF the appliance proceed as follows 1...

Page 57: ... can raise or lower the calculated temperature and match the desired room temperature 16 8 2 Climatic adjustment switching the heating system on and off The climatic adjustment service is completely automatic even as far as switching off at the end of the season and reignition at the beginning of the season is concerned via parameter 2020 When the external temperature exceeds the value set in this...

Page 58: ...y temperature corresponding to the external design temperature winter Par 2023 Spring external temperature Par 2024 Supply temperature corresponding to spring external temperature Par 3016 Minimum supply temperature Par 3015 Maximum supply temperature 16 USE External temperature C Calculated temperature C Par 2021 Par 2023 Par 2020 Par 3016 Par 2024 Par 2022 Par 3015 ...

Page 59: ...e burner lost its flame No 1055 Burner 1 Number of failed burner ignitions No 1056 Burner 1 Number of hours worked h x 10 1057 Burner 1 Number of hours worked in domestic water with hot water storage tank h x 10 1059 interval of time between the last two errors Err 1 value in minutes 2 value in hours 3 value in days 4 value in weeks 1060 interval of time between the last two lock ups Loc 1062 Burn...

Page 60: ...e burner in question as described in section 17 8 ATTENTION In order to facilitate any command and control board replacements it is essential to make a note of any changes made to the parameters in the customised values column in the following table The following parameters can be edited or consulted in this menu 16 USE Parameter Parameter description U M Setting field BOILER default value WATER H...

Page 61: ...0 15 2105 Multi burner burner ignition temp delta C from 0 to 20 5 5 2106 Multi burner burner switch off temp delta C from 0 to 20 5 5 2107 Multi burner maximum temp increase with respect to calculated temp C from 0 to 20 10 4 2108 Multi burner maximum temp decrease with respect to calculated temp C from 0 to 20 20 4 2109 Multi burner Subsequent burner ignition from 1 to 100 70 70 2110 Multi burne...

Page 62: ...ontrol board are in good condition A If the electrical connections are interrupted restore them B If the connections are in good condition try replacing the gas valve or the control board Loc 4 Gas valve relay does not close Make sure the electrical connections between the gas valve and control board are in good condition A If the electrical connections are interrupted restore them B If the connec...

Page 63: ...Replace the gas valve Loc 28 Flame with gas valve closed Replace the gas valve Loc29 Interlock input A Check LWCO connection B Check flue blocked pressure switch A If LWCO intervenes try to reset it B Check if flue gas line is free from any blockage Loc 30 Software error inside command board Replace the command and control board Loc 31 Flame lost three times A Check the detection electrode B Make ...

Page 64: ...sure is greater than parameter 3022 replace the pressure measuring device Err 60 Flue exhaust tempera ture high error A Check the combustion output of the burner in error the output must be higher than 97 referring to the PCI B Make sure the flue exhaust temperature sensor resistance matches with the graphic in section 17 14 A If the output is lower than 97 try cleaning the flue gas side and the w...

Page 65: ...ontrol board Err 108 Software error inside command board Replace the command and control board Err 109 Error burner 2 3 or 4 When burner 1 MASTER goes in a general error will stops all others burner generating an Err 109 Resolve the error to burner 1 MASTER Err 110 Flapper valve not open error A Check for and if necessary remove any obstruc tions in the air intake and flue exhaust ducts B Check th...

Page 66: ...take and flue exhaust ducts have obstructions signs of corrosion physical damage water spots or signs of rust 2 Make sure the externally assembled intake grids and flue exhaust outlets have no residue and are clean 17 1 3 Checking the system water pressure 1 Make sure the system is full of water and under pressure as shown in section 18 technical features 2 Make sure there are no leaks in the hydr...

Page 67: ...A in figure 17 3 turning it clockwise then removing it towards the left 5 unscrew nut H in figure 17 4 being careful of the gasket on the connection 6 with the aid of a flathead screwdriver remove spring A in figure 17 4 7 remove the electrical plug from the gas valve 8 pull the gas valve out upwards being careful of O ring L see figure 17 4 9 Unscrew the four bolts B in figure 17 5 10 remove the ...

Page 68: ...es Only use brushes with nylon or equivalent material bristles 5 Using an extractor suction the unburnt residues inside combustion chamber H 6 using the same extractor suction the surface of the burner and around the electrodes 7 reassemble the components in reverse order 8 open the gas cock 9 restore power 10 make sure there are no gas leaks between the removed joints ATTENTION Run the seal test ...

Page 69: ...urner fan unit R H B A C T S R H B A C T S 020009 01 031 020009 01 032 ATTENTION The gasket ensures combustion chamber seal If the gasket is damaged do NOT reuse it It must be replaced along with the burner unit To replace it consult the manufacturer GASKET BURNER UNIT ...

Page 70: ...sation electrodes properly For the appliance to work well it is essential for the electrodes to be positioned properly refer to figure 17 7 the distance between ignition electrodes A and B must be between 2 0 and 2 5 mm the distance of the ignition electrodes from the burner surface must be between 5 and 5 5 mm the distance of the ionisation electrode from the burner surface must be between 5 5 an...

Page 71: ...ced to every six months or year depending on the local standards in force The neutralising content of the box must be replaced when the pH level drops below the level required by the standards in force The allowed acidity level goes from pH 5 5 to 9 5 To replace the neutraliser proceed as follows 1 Follow what is shown in section 17 2 to remove covering E in figure 17 1 2 Extract box A figure 17 9...

Page 72: ...nnector for Burner 2 dialogue D Connector for Burner 3 dialogue Only in 180T 210T and 280T models E Connector for Burner 4 dialogue Only in 280T models 2 Follow what is described in section 17 2 to access the inner components 3 Disconnect terminal B coming from the display from terminal A coming from Burner 1 Master 4 Connect terminal B to terminal C D or E depending on which burner you wish to vi...

Page 73: ...e display to connector A connector coming from Burner 1 Master 4 Disconnect all the other connectors from the Burner 1 Master control board 5 Remove the Burner 1 Master control board from the appliance 6 Follow points 3 to 5 to remove the control board from the burner positioned lower 7 Assemble the board in place of the Burner 1 Master board 8 Restore all the connections in the new Burner 1 Maste...

Page 74: ...60T 280T 17 MAINTENANCE Figure 17 12 Setting parameters 3001 3050 and selectors S4 COSMOGAS 74 Models 280T Models 180T 210T Models 100T 115T 140T Models 60T 70T ...

Page 75: ... sure the system can withstand this temperature 2 access parameter 2010 2200 for multi burner models located in the installer menu see section 16 15 3 set the parameter to the following value a LOuto force the burner or all the burners to minimum output heat b Ign to force the burner or all the burners to ignition output heat a HIgH to force the burner or all the burners to maximum output heat 4 T...

Page 76: ...must match what is shown in figure 17 13 The temperature probes are 1001 1002 1006 and 1007 Figure 17 13 Water sensor curve Figure 17 14 External temperature sensor curve 17 MAINTENANCE 17 15 External temperature probe The 1004external temperature sensor see section 13 1 4 comes standard The electrical resistance between the two sensor contacts must match what is shown in figure 17 14 ...

Page 77: ...COSMOGAS 17 16 60T and 70T models multi line wiring diagram Figure 17 15 Multi line wiring diagram part 1 continues on the following page 60T 280T 77 17 MAINTENANCE ...

Page 78: ...60T 280T 17 MAINTENANCE Figure 17 15 Multi line wiring diagram part 2 continued from the previous page COSMOGAS 78 ...

Page 79: ...COSMOGAS 17 MAINTENANCE Figure 17 16 Multi line wiring diagram part 1 continues on the following page 60T 280T 79 17 17 100T 115T 140T 180T 210T and 280T models multi line wiring diagram ...

Page 80: ...60T 280T 17 MAINTENANCE Continues Figure 17 16 Multi line wiring diagram part 2 continues on the following page COSMOGAS 80 ...

Page 81: ...81 60T 280T COSMOGAS 17 MAINTENANCE Figure 17 16 Multi line wiring diagram part 3 continued from the previous page ...

Page 82: ...asuring device 20 Gas valve 22 Detection electrode 28 Flue exhaust differential pressure switch 29 Condensate level sensor 32 Main ON OFF switch 34 Display 35 885 IF board on request Fuse F1 5x20 3A 47 Water flow rate sensor 48 Motorised two way valve on request 51 Connection diagrams Fuse F1 5x20 10A Fuse F2 5x20 10A Fuse F3 5x20 3A Fuse F4 5x20 3A Fuse F6 5x20 3A RGPR Heating circuit pump relay ...

Page 83: ...sing loss burner off 0 05 0 05 0 05 Loss at no load 0 05 0 05 0 05 Gas flow rate G20 m3 h 6 11 7 40 10 47 G25 m3 h 7 11 8 61 12 17 G30 kg h 4 55 5 52 7 80 G31 kg h 4 49 5 43 7 68 Gas supply pressure G20 mbar 20 20 20 G25 mbar 25 25 25 G30 mbar 30 30 30 G31 mbar 37 37 37 Gas supply minimum pressure G20 mbar 10 10 10 G25 mbar 10 10 10 G30 mbar 10 10 10 G31 mbar 10 10 10 Gas supply maximum pressure G...

Page 84: ... 0 5 0 5 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 05 0 05 0 05 0 05 0 05 0 05 0 05 0 05 0 05 0 05 12 22 14 80 18 30 22 20 29 61 14 22 17 22 21 32 25 83 34 43 9 11 11 03 13 66 16 55 22 06 8 97 10 87 13 50 16 30 21 73 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 37 37 37 37 37 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 12 ...

Page 85: ...1 5 9 5 1 5 9 5 1 G31 6 0 5 4 6 0 5 4 6 0 5 4 Maximum flue gas recirculation in case of wind 10 10 10 Maximum flue gas temperature at boiler outlet C 90 90 90 Minimum flue gas temperature at boiler outlet C 30 30 30 Δt temperature fumes Return at 100 of the load 80 60 C 16 17 16 Δt temperature fumes Return at 30 of the load 37 30 C 1 1 1 Flue gas mass flow rate kg h 95 115 163 Flue gas mass flow r...

Page 86: ... 2 9 8 10 2 9 8 10 2 9 8 10 2 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 8 4 9 5 9 5 1 5 9 5 1 5 9 5 1 5 9 5 1 5 9 5 1 6 0 5 4 6 0 5 4 6 0 5 4 6 0 5 4 6 0 5 4 10 10 10 10 10 90 90 90 90 90 30 30 30 30 30 16 17 17 17 17 1 1 1 1 1 190 230 284 345 460 20 7 25 4 25 4 25 4 25 4 110 110 110 110 110 40 40 40 40 40 0 9 0 9 0 9 0 9 0 9 92 92 92 92 92 50 50 50 50 50 14 4 17 4 ...

Page 87: ... domestic hot water operating mode 0 only heating 1 hot water storage tank 2 storage tank with thermostat 3 N A 4 N A 5 N A 0 0 only heating 1 hot water storage tank 0 only heating 1 hot water storage tank 0 3013 Reset Err 115 EnAb Enabled dISA Disabled Enab Enab Enab Enab 3015 Climatic adjustment heating supply maximum temperature this parameter is overwritten by parameter 3017 from 20 C to 90 C ...

Page 88: ...start up ignoring this could cause damage to persons animals or objects ATTENTION In the event of the multi burner appliances 100T to 280T models the display is always connected to burner 1 MASTER To set the parameters in the other burners the display must be connected to them as described in section 17 8 The forced menu allows the appliance to be set based on the system to serve Setting occurs by...

Page 89: ...mber the RESET and keys Press and release the key Press and release the key Parameters displayable under normal operating conditions see section 16 16 User menu parameters see section 16 14 Installer menu parameters see section 16 15 Installer menu parameters see section 16 15 User menu access see section 16 14 Installer menu access see section 16 15 Go back to normal operation Go back to normal o...

Page 90: ...mand is disa bled TA opens or the external probe is met Is the water flow rate greater than 15 l min After 3 minutes Err 114 The burners will be switched off Are all the burners operating Ignition attempt 50 of the output heat Are pressure and gas flow rate adequate Burner in opera tion Appliance with only one burner 3 minute delay The burner output heat is 70 Request for other burners to interven...

Page 91: ...S section under CE type certificate PIN and fulfils the requirements of the following Directives Gas Appliances 2009 142 EC Performance 92 42 EEC modified by EU Reg 813 2013 Low Voltage 2014 35 EU Electromagnetic Compatibility 2014 30 EU Product surveillance is done by the notified body according to form C The warranty number is the same as the serial number This declaration is issued as establish...

Page 92: ... 8 95 8 Auxiliary electricity consumption At full load elmax kW 0 14 0 14 At part load elmin kW 0 06 0 06 In standby mode Psb kW 0 005 0 005 Other items Standby heat loss Pstby kW 0 1 0 1 Ignition burner power consumption Pign kW 0 0 Annual energy consumption QHE GJ 104 130 Sound power level indoors LWA dB 70 70 Emissions of nitrogen oxides NOx mg kWh 20 20 For combination heaters Declared load pr...

Page 93: ... 6 111 7 135 8 168 2 203 7 271 6 87 3 87 3 87 3 87 3 87 3 87 3 28 7 33 5 40 7 50 5 61 1 81 5 95 8 95 8 95 8 95 8 95 8 95 8 0 28 0 28 0 28 0 42 0 42 0 56 0 06 0 06 0 06 0 06 0 06 0 06 0 01 0 01 0 01 0 015 0 015 0 02 0 2 0 2 0 2 0 3 0 3 0 4 0 0 0 0 0 0 169 195 237 288 345 452 70 70 70 70 70 70 20 20 20 20 20 20 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N...

Page 94: ...C ITALY info cosmogas com www cosmogas com H E A T I N G S O L U T I O N S L T D 01256 587 800 info gemtex co uk www gemtex co uk 65 Basepoint Business Centre Aviation Business Park Enterprise Close Christchurch BH23 6NX F o r t h e U K c o n t a c t ...

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