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Italtherm 35 K Installation Manual Download Page 49

Green Heating Technology

49

Boiler internal components

16

18

17

19

15

14

13

21
20

22

23

24

25

27

12

26

29

28

30

5

1

4

3

2

6

8
9
10
11

7

00365 00

1 

Flue connection flange

2 

Plug for Combustion analysis (air intake)

3 

Plug for Combustion analysis (flue)

4 

Expansion Vessel

5 

Water drain pipe from air intake flange

6 

Fan

7 

Air/Gas Mixing device

8 

Temperature Sensor on system return

9 

Automatic Venting Device

 

(heating circuit, incorporated in the pump)

10 

Safety valve 3 bar

11 

Pump

12 

Pipe for condense outlet

13 

Drain valve

14 

Priority flow switch (with filter)

15 

Loss of water pressure switch

16 

Gas valve

17 

DHW temperature sensor

18 

System pressure gauge

19 

Filling valve

20 

By-pass (in-built in the 3-way valve 

hydraulic assembly)

21 

DHW exchanger

22 

Motorized 3-way valve

23 

Siphon for condense outlet

24 

Manual Venting Device (Combustion 

assembly)

25 

Temperature Sensor, system flow

26 

Safety thermostat on system flow

27 

Air intake hose

28 

Flame ignition/detection electrode

29 

Combustion assembly (primary 

exchanger)

30 

Flue overheat fuse

Summary of Contents for 35 K

Page 1: ...use installation adjustment maintenance Handbook instruction ENG 25 k 30 K 35 K Green Heating Technology IMPORTANT Install the gasket includ ed in the documents bag on the intake outlet flange as shown on page 21 ...

Page 2: ...n a partially protected place 15 Positioning and fastening 16 Hydraulic system DHW and heating 17 Advices and suggestions to avoid vibrations and noises in the system 17 Cleaning and preservation of the systems 17 Heating system 17 Condense drain 18 Heating system filling and pressuring 18 Gas connection 19 Electrical connections 20 Flue systems 21 Intake outlet flange 21 Installation of the flue ...

Page 3: ...d extra contractual responsibility for any damage arising from wrong installation wrong use and non observance of current laws and instructions given by the manufacturer himself f f Important this gas boiler is used to heat the water at a temperature lower than the boiling one at atmospheric pressure it must be connected to an heating system and or to a domestic hot water system in accordance with...

Page 4: ...h them All the references to norms and national laws mentioned in this handbook are indicative as laws and norms are subject to issues and integrations by the authorities in charge Also comply to eventual local norms and laws not mentioned in this handbook in force in the territory where the installation takes place Personnel in charge of installation Always comply with national and or local regul...

Page 5: ...Methane It can be set just by means of electronic settings but always by a qualified technician to operate with Commercial Propane G31 It must never be used with butane gas G30 that can be present pure or mixed with Propane G31 in the portable gas bottles for cookers The User must not touch sealed items nor break the seals Only specialized technicians and the official technical service can break t...

Page 6: ...intenance and servicing All operations for installation first starting up maintenance servicing and gas conversion must be car ried out by qualified technicians in accordance with the Norms and Laws in force Maintenance operations must be carried out in compliance with the manufacturer prescriptions and in compliance with the laws and rules presently in force for what is not mentioned in this hand...

Page 7: ...emark in the descrition of symbol Burner ON It indicates the presence of the flame in the burner DHW mode indication If flashing it means that the boiler is functioning to produce hot water If both and symbols flash at the same time a Technician reserved function has been activated In this case turn immediately the boiler off and then turn it on again by means of the button Two digit display under...

Page 8: ... on page 52 Commands on the lower side 1 System pressure gauge 2 System filling and pressure restoring cock 3 GAS cock Commands outside the boiler Externally the boiler suitably positioned in the build ing generally by the installer or by the electrician two devices that the user should access to are present The presence and the characteristics of these devices are pre scribed by the regulation in...

Page 9: ... as DHW does not last for long this priority does not affect the CH efficiency in the system Temperature adjustment Note correct adjustment leads to creating the conditions for energy saving Note if a Low Temperature Kit or an Outdoor Probe Kit are installed refer to the relevant documen tation for what concerns the heating system temperature adjustment Note don t make confusion between the heatin...

Page 10: ...l materials The burner doesn t turn on f f if the room thermostat or programmable room thermostat or similar is installed check that it is really requiring the room heating f f be sure the boiler is set on winter or summer mode not in OFF The reference symbols must be shown on the display see The front control panel on page 7 f f in case the display shows or or in case the boiler seems to be worki...

Page 11: ...including the sanitary circuit and the boiler s sanitary exchanger Remark the boiler is equipped with a system which protects the main components from the excep tional cases of mechanical lock due to the inactivity in presence of water and scale The anti locking function can t work in Safety shut off mode because of the lack of electrical supply Before re igniting the boiler have a technician chec...

Page 12: ...sanitary circuit outside the boiler and especially in areas where the heating system doesn t reach For this reason we recommend that you empty the cold and hot sanitary water from the parts of the system that are at risk of freezing Installation Law and regulation prescriptions for the installer Always comply with national and or local regulation about BOILER INSTALLATION Always comply with nation...

Page 13: ...al fitting kit F Fresh water inlet R System return TA L Indicative position for electrical power supply and room thermostat wirings TA Room thermostat wiring L Electrical power supply wiring SC Indicative position for the condensate drain front view hydraulic connections on the wall with optional fitting kit see also page 16 upper view front view hydraulic connections on the boiler left side view ...

Page 14: ... floor against overheating that could damage the cladding the structure or the system itself must be installed on the flow starting end of the serpentine embedded in the floor itself It should not installed on the system flow pipe in prox imity of the boiler otherwise frequent and unjustified boiler locks caused by its triggering are possible Specifications for intake air Air must be withdrawn fro...

Page 15: ... by the electrical and gas lines provided that the pressure in the heating system is correct If some part s of the system external to the boiler could be subject to freezing risk it is advis able to fill the heating circuit with instead of water an antifreeze liquid specific for heating systems propylenic glycol based following the instructions of its manufacturer Pay attention to the correct prod...

Page 16: ...e fixing devices and the holes or slots A or B f f Fix up the connections and all ducts for heating flow and return cold wa ter hot water gas and electrical cables predisposing them in the holes of the metal jig or as an alternative respecting the measures in the paragraph Dimensions and connections on page 13 The upper edge of boiler s body used as a reference in the para graph Flue system types ...

Page 17: ...of the systems against corrosions and there fore perforations noise leaks etc and limestone incrustations that drastically reduce the efficiency of the thermal exchange consider that 1 mm of limestone incrustations reduces of 18 the thermal exchange of the heating element on which it has been formed ITALTHERM guarantees its products only if the characteristics of the water comply with UNI 8065 re ...

Page 18: ...ng and pressuring Once all system connections have been carried out proceed with system filling This operation should be made with care respecting the following steps f f Open the radiators venting devices f f Check that the plug of the automatic air vent incorporated in the boiler circulator is unscrewed if not unscrew it and leave it unscrewed even afterwards for normal operation f f If it s req...

Page 19: ...ity so that it is visible to the employee when it is being refilled Using Propane gas G31 it is absolutely necessary to install a pressure reducer upstream the boiler Failure to do this the gas valve of the boiler will get damaged The inlet gas pressure must be compliant with the one specified in Technical data on page 47 The gas connection as generally the boiler installation must be done by qual...

Page 20: ...plying the regulation currently in force and generally with the standard craft rules For the general electrical supply of the appliance the bipolar switch should be used The use of adaptors multiple taps and extensions is not allowed If the supply cable must be replaced use one of the following cable types H05VVF or H05 VVH2 F It is mandatory the earth connection in accordance with the rules actua...

Page 21: ...d safe op eration of the boiler it s necessary to install on the intake outlet flange 2 the gasket 1 included in the boiler s docu ments bag Before inserting the flue out let pipe it s therefore very important to correctly place the gasket on its seating as indicated in the figure General indications To grant the functionality and efficiency of the appliance it is indispensable to realize intake a...

Page 22: ...ct the minimum and maximum flue length prescribed see Flue system types on page 25 In case of flue outlet on wall the positions and the distances prescribed by the regulation mist be re spected The outlet duct is the assembly of components that connect the boiler to the point where the flues are discharged The outlet can be directly outdoor only in the case foreseen by the law in force and us ing ...

Page 23: ... prevent the rain water to reach the burner s fan 5 so the intake must not be downwards 6 do not let the condense go out from the flue outlet terminal 7 the coaxial intake outlet duct must be installed so as the flues are upwards and so the condense discharge itself towards the boiler The terminal tract with intake head and outside with an outlet out axis must be horizontal placed and it is equipp...

Page 24: ...r from Ø80mm to Ø60mm 0 3 m 2 Pa 0 8 m 2 Pa Connector from boiler to Ø80mm outlet pipe or to adapter from Ø80mm to Ø60mm 0 7 m 5 Pa 2 0 m 5 Pa Separate system original accessories Adapter from Ø80mm to Ø60mm on intake 0 4 m Adapter from Ø80mm to Ø60mm on outlet 1 7 m Linear section or extension length 0 5m on intake 0 5 m 0 5 m Linear section or extension length 0 5m on outlet 0 5 m 0 5 m Linear s...

Page 25: ...considered IMPORTANT this table is referred to the original flue ac cessories Using non original flue accessories certified for condensation whose use is allowed by the boiler s C6 type certification refer to paragraph Dimensioning the intake and outlet ducts on page 24 Coaxial system C13 C33 00047 00 1300 LCV Ø100 Ø60 Ø125 00049 00 LCO Ø100 Ø60 127 135 Example of vertical coaxial system C33 Examp...

Page 26: ...ind conditions C33 Coaxial system to roof Ducts can start sepa rate from the boiler but outlets must be co axial or close each other within 50 cm as to be subject to similar wind conditions C43 Separated outlet and inlet in shared chim neys subjected to similar wind conditions natural draught chimney The condense flow towards the appliance is not allowed C53 Separated outlet and inlet to wall or r...

Page 27: ...ure that the circulating pump is not blocked due to inac tivity in the middle of the cap there is a hole should there be a cap remove it that gives access to the rotor shaft push and turn it using a suitable tool usually a Phillips screwdriver During the commissioning of the new boiler it is necessary to run the burner for 30 minutes before checking the combustion because in that period of time an...

Page 28: ...cate the rotor shaft behind the cap and turn it manually using a screwdriver or other suitable tool f f verify that the combustion is correctly regulated go on in this chapter as described in the paragraph Combustion test on page 35 During the first ignition of the brand new boiler it is necessary that burner works for at least 30 minutes before performing combustion checks During this time the fu...

Page 29: ... the funnel of the condense verify that the combustion is correctly regulated go on in this chapter as described in the paragraph Combustion test on page 35 f f verify the correct functioning of the boiler in heating and domestic hot water version f f if necessary vent the primary exchanger proceeding as described in the paragraph Venting the primary exchanger on page 30 f f fill in the foreseen d...

Page 30: ...sure and if needed the concentration of additive liquid Combustion group cleaning and check Switch off the boiler and disconnect it from the electrical supply Be sure that the parts are not hot and eventually wait the time necessary to cool them Because some contacts with the fine dust and acid condense may occur we recom mend to wear the proper devices for the personal protection i e glasses glov...

Page 31: ... air jets now then clean the primary exchanger coils by a NOT METALLIC brush and remove the residuals again by using the vacuum cleaner if necessary clean the coils using compressed air vacuum clean the residues from the condense pipe 9 f f locate the lower cap 7 of the siphon and put a collector for liquids under it Unscrew the cap Let the siphon empty itself Pour water into the combustion unit t...

Page 32: ...ns and within the low temperature range Remark in case of mixed plants with high and low temperature thanks to optional kit set low range value 1 please also refer to documentation provided with the kit 03 It indicates the CH boiler power during the soft ignition phase We recom mend to leave the factory setting unchanged 04 0 99 It indicates the CH boiler power according to the maximum nominal boi...

Page 33: ...er work rimember to reset this parameter to value 0 1 burner ignition at maximum output 2 burner ignition at minimum output Remark During this phase the delay between burner ignitions is zero so if flow temperature is close to maximum frequent re ignitions of the burner could take place 17 20 80 TA2 input setting flow temperature during a CH request from the Secondary Room Thermostat only The boil...

Page 34: ...ording to its use to affect the boiler behaviour 0 Safety thermostat of Floor plant When thermostat opens open circuit boiler blocks and shows a specific alarm Both this parameter and no 22 are factory set to 0 so practically AUX input is ignored 1 DHW Storage tank thermostat Don t use because this function is not allowed on this boiler Information purpose only in models with DHW storage with clos...

Page 35: ...otection bow of the sensor placed at the top is transversal the flow must pass through it and directly touch the sensor 3 set the boiler in a status different from e g in Winter mode 4 generate a heating request by activating the room thermostat or by opening a DHW faucet consist ent with the boiler s status Be sure that the heat produced by the boiler can be eliminated by the heating system throu...

Page 36: ... caring that the plastic surface of the flange is not damaged or worn check the correct flue system tightness especially the tightness of the tapping insert 2 Power adjustment tables HEAT INPUT Value of par 4 kW kcal h City Class 25 K MIN 2 50 2150 00 4 61 3965 10 6 75 5805 20 9 25 7955 30 11 87 10208 40 14 14 12160 50 16 50 14190 60 18 75 16125 70 20 00 17200 78 20 75 17845 80 23 20 19952 90 MAX ...

Page 37: ...llowing options depending on the parameter 49 see page 34 AUTOMATIC this calibration is made during boiler production on the field it should not be done unless components linked to combustion have been replaced main PCB Gas Valve Fan Primary exchanger Burner Electrode At the end of this procedure it is not allowed any change at val ues stored but boiler can work property with correct combustion va...

Page 38: ...lectrical supply to the boiler Restore the supply after having closed the control panel rear cover f f unscrew the screws 1 and release the latches 2 f f remove the back cover of the control panel An incorrect or not complete closure of the electronic box voids the IP grade of protection of the appliance Ensure that all closing items are correctly used and that all cables pass through the suitable...

Page 39: ...let gas pressure complies with the required nominal pressure see Technical data on page 47 and that the gas flow is sufficient to guarantee the appliance correct work with burner ON 4 we suggest to clean the burner and exchanger as described in the paragraph Combustion group cleaning and check on page 30 except for the case of first ignition new burner 5 carry out the AUTOmatic combustion calibrat...

Page 40: ...Remark The complete system draining can be achieved only by drain ing the system from its lowest point f f when everything is over close taps turning the nut 2 clockwise and air vents In the primary exchanger a certain quantity of water of the heat ing system remains If you want to remove the boiler from the wall we advice you to close with plugs the hydraulic inlet outlet heating system connectio...

Page 41: ... the 5 reset possibilities are over to have 5 more it s possible to switch off the electrical supply to the boiler for 30 seconds by using the purposed external switch The flame has extin guished or it did not ignite Restore the boiler function by using the button In case of frequent blocks verify the correct combustion the good state and the cleaning of the burner Incorrect com bustion flame de t...

Page 42: ... reset many times This proves that the boiler has a problem so call the Service Centre User To attempt an interim restore disconnect the electrical sup ply to the boiler by operating the suitable external bipolar switch then connect it again after a few minutes E08 Max number of boiler alarms reached for no flame detection Combustion or burner has a recursive problem Flame detection has been lost ...

Page 43: ... parameters settings technician menu on page 31 to update the data in the main board memory Replace the main board by carefully following the instructions in cluded in the spare part kit See also Main board replacement on page 38 E24 Floor heating sys tem safety thermo stat triggering f f system flow temperature too high f f floor heating system defec tive faulty or malfunctioning The floor heatin...

Page 44: ...water like as the external boiler had never been installed so the heating system temperature is set directly and not as a function of the outdoor temperature The alarm is displayed to inform that the acces sory is no more efficient consider that on a first analysis the boiler seems to work perfectly Important if the boiler is turned off and then on again it s possible that the alarm is no more dis...

Page 45: ...an effect of a malfunction of the system and any way this can cause a too high temperature of the flue and damage the flue system Before this happens a suitable safety protection has triggered Wait 20 30 minutes to let the boiler and the system cool down then reset it manually by using the button It is impossible to re start the boiler before the cooling of the system If the block hap pens again p...

Page 46: ...Check the boiler ignition switching off and operation f f Check the water and gas connections tightness f f Check the gas consumption at the minimum and maximum output f f Verify that safety devices are correctly working f f Verify the correct functioning of control and adjusting devices f f Verify periodically the absence of leaks of combustion products to the inner room the correct func tioning ...

Page 47: ... 3 0 3 0 4 0 4 Condense acidity pH 2 8 2 8 2 8 2 8 2 8 2 8 Flue temperature Max C 61 5 60 80 Qr 61 5 60 80 Qr 69 0 60 80 Qn 69 0 60 80 Qn 64 0 60 80 Qn 64 0 60 80 Qn Flue temperature Min C 41 0 30 50 Qr 41 0 30 50 Qr 47 0 30 50 Qr 47 0 30 50 Qr 38 0 30 50 Qr 38 0 30 50 Qr Flue mass flow rate 60 80 C Qn kg h 41 11 41 86 48 31 49 32 54 60 54 41 Flue mass flow rate 60 80 C Qr kg h 3 94 4 22 4 83 4 89...

Page 48: ... 0 2 0 2 0 2 Max supply pressure bar 6 6 6 Temperature selection range min max C 30 55 30 55 30 55 Flue temperature average DHW T 25 C C 54 59 56 Flue temperature average DHW T 30 C C 57 62 59 ELECTRICAL DATA Voltage frequency nominal voltage V Hz 220 240 50 230V 220 240 50 230V 220 240 50 230V Power consumption W 135 142 150 Level of protection IP X5D IP X5D IP X5D DIMENSIONS Width Height Depth m...

Page 49: ... incorporated in the pump 10 Safety valve 3 bar 11 Pump 12 Pipe for condense outlet 13 Drain valve 14 Priority flow switch with filter 15 Loss of water pressure switch 16 Gas valve 17 DHW temperature sensor 18 System pressure gauge 19 Filling valve 20 By pass in built in the 3 way valve hydraulic assembly 21 DHW exchanger 22 Motorized 3 way valve 23 Siphon for condense outlet 24 Manual Venting Dev...

Page 50: ...system flow 28 Ignition and flame detection Electrode 30 Flue overheat fuse 41 Fuse F2A 2A fast the contacts of these components are shown in rest conditions cold condition no system pressure no flow Optional external devices TA Room thermostat or Chronothermostat SELV simple contact Closed contact heating request or Remote control original accessory only SE To optional outdoor temperature sensor ...

Page 51: ...including automatic venting device 13 Drain valve 14 Priority flow switch with filter 15 Loss of water pressure switch 16 Gas valve 17 DHW temperature sensor 18 System pressure gauge 19 Filling valve 20 By pass in built in the 3 way valve hydraulic assembly 21 DHW exchanger 22 Motorized 3 way valve 23 Siphon for condense outlet 24 Manual Venting Device Combustion assembly 25 Temperature Sensor sys...

Page 52: ...he CH flow temperature as shown in the following graph 35 40 45 50 55 60 65 70 75 78 MAX MIN High temperature range 35 78 C 20 text C 15 10 5 0 5 10 15 20 25 27 20 25 30 35 40 45 MAX MIN Low temperature range 20 45 C if available kd 00 kd 05 kd 01 kd 10 kd 15 kd 20 kd 25 kd 30 00177 ENG 00 Practically kd value should be adjusted depending on the estimated efficiency of the building s ther mal insu...

Page 53: ...ould be kept separated from power supply cables e g by enclosing it into separate raceways The maximum overall cable length shouldn t exceed 50 m 1 Cut off electricity from boiler 2 install the device as described in the paragraph 1 of the supplied instruction booklet 3 connect the terminals OT nr 1 2 of the Remote Control to the TA Room Thermostat Remote Control cable coming out of the boiler by ...

Page 54: ...Green Heating Technology 54 Notes ...

Page 55: ...Green Heating Technology 55 Notes ...

Page 56: ...ts products the company has the right to change features and data written in the present manual at any time and without notice 960000128_01 20180119 ITALTHERM Srl Via S D Acquisto 10 29010 Pontenure PC IT Tel 39 0523 575611 Fax 39 0523 575600 www italtherm it e mail info italtherm it www italtherm it Green Heating Technology UNI EN ISO 9001 2015 ...

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