thermital COROLLA PACK 1000 Series Installation, Operation And Maintenance Manual Download | Manualshive

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Electrical Connections

Figure 12

Figure 13

Contents

Sigla

N. Jumper

Description

S1

J11 (1-2)

Flow temperature probe (High)

SB

J11 (3-4)

Sanitary temperature probe

S2

J11 (5-6)

Flow temperature probe (Low)

SE

J11 (7-8)

External temperature probe

T1

J12 (9-10)

Room thermostat (High)

T2

J12 (11-12)

Room thermostat (Low)

AI

J12 (13-14)

Analogical device 0-10V

CR

J12 (15-17)

Remote control

AL

J8 (18-19)

Alarm device

VM

J9 (20-22)

Mixing valve

P3

J10 (23-24)

Low temperature circuit pump

P1

J10 (25-26)

High temp. circuit pump

P2

J10 (27-28)

Sanitary pump

Figure 14

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Summary of Contents for COROLLA PACK 1000 Series

Page 1: ...COROLLA PACK SERIE1000 ...

Page 2: ......

Page 3: ...devices 18 6 2 4 Pump Connections 18 6 2 5 Room thermostat connection on off 19 6 2 6 Outside temperature probe connection 19 6 2 7 Anti freeze protection 21 6 2 8 Connection of an external regulation 0 10v 21 6 2 9 Connection of an alarm device 21 6 2 10 Remote control 21 6 3 Emergency mode 21 6 4 Cascade installation 22 6 4 1 Power supply 22 6 4 2 Serial Connection 22 6 5 Position of the flow pr...

Page 4: ... You have chosen a technology which is the best synthesis of energy saving and functionality compliant with the strictest European safety standards For the realization of this product THERMITAL follows these European and Italian laws and standards Directive 2009 142 EC Gas Appliances Directive 92 42 EEC on efficiency re quirements for new hot water boilers fired with liquid or gaseous fuels Electr...

Page 5: ...hnical assis tance Periodically check that the condensate drain is free from obstruction Periodically check the pressure of the wa ter circuit is less than the maximum limit speci fied for the device This check has to be done with cold unit and water Otherwise contact the Technical Assistance Centre Maintenance is mandatory and shall be carried out at least once a year Please call Your local autho...

Page 6: ...cted from the main supply Do not obstruct or reduce the ventilation openings Do not put the unit outdoor if it is not a specified outdoor unit Do not leave containers of flammable substances in the room where it is installed the device Do not dump the packing material Keep out of reach of children the packing material because it can be potentially dangerous It must be disposed of as required by la...

Page 7: ...e with variable factor of heating power load so that when a certain power percentage of the first element is reached e g 30 the successive element al ready starts with the same load factor This lat ter feature allows to share the power supplied inside more than one heat exchangers with a power exchange surface ratio which is particu larly favourable for condensation latent heat 3 2 Main Advantages...

Page 8: ... safety de vices altered or excluded The replacement of safety devices should only be performed by authorized Technical As sistance Centre using only original parts Refer to Spare Parts Catalog 3 4 System Structure Corolla Serie 1000 is made up of a series of Co rolla Thermal Units installed in battery placed inside a metal casing Each thermal unit is connected to the system in parallel position a...

Page 9: ... return intercepting valve 16 Unit flue pipe 3 Pump 10 Return water manifold 17 Water Flow Manifold 4 Flue manifold with clapet 11 Gas manifoldas 18 One way valve 5 Fan 12 Gas pipe 19 Water differential pressure switch 6 Air gas mixing pipe 13 Condensate manifold 7 Gas valve 14 Condensate flexible pipe Figure 2 ...

Page 10: ...anger 11 Water differential pressure switch 19 Unit flue discharge 4 Air inlet 12 Gas valve 20 Gas manifold 5 Fan 13 Ignition electrode 21 Water flow manifold 6 Return detection tap 14 Automatic vent valve 22 Condensing manifold 7 Pump 15 Safety thermostat 23 Water return manifold 8 One way valve 16 Gas tap Figure 4 Figure 3 ...

Page 11: ...g check the integrity and completeness of delivery Keep out of reach of children the packing material because it can be potentially danger ous A tag on the front side of the electrical panel shows the following information Product name Serial number Product code CE homologation number Gas type and pressure Main supply type Heat input Qn Useful heat output Pn Efficiency in accordante with 92 42 CEE...

Page 12: ...scade according to the power required by the installation and they can reach a maximum of 32 thermal elements The grouping of more than one module allows to make some noise less thermal plants with low thermal inertia and high power in a very simple and rational way Each thermal module is equipped with the following connections which have been pre set for the connection to the system see Table 1 4...

Page 13: ...ny case make sure that same neces sary space is left for the passage of the electric supply cables of each Corolla Pack and to let the front panel open Space is also required in case of maintenance ser vices of the flue condensate and gas pipes 3 Mount the side panels of the Corolla Serie 1000 and connect the first or the only thermal group of the battery to the system use the correct connections ...

Page 14: ... of each unit and in some points of the hydraulic system specific for this purpose For more information on the characteristics of hydraulic system see Chapter 5 in which differ ent types of plant are shown 4 1 7 Exhaust Flue The chimney should be as straight as possible sealed and isolated Should not have occlusions or narrowing The overall potential of thermal groups Corolla 1000 Series is more t...

Page 15: ...15 Installation In installation with air intake from the environment both in and outside the boiler room never obstruct the passage of air under the metal cabinet Figure 7 ...

Page 16: ...chnical boiler features so it s possible to utilize in the better way boiler s efficiency and to keep the plant in good conditions for a long time In Figure 8 is shown an installation without a mixing element in Figure 9 is shown a installa tion with a mixing element Figure 8 Figure 9 ...

Page 17: ...make sure that their electrical features voltage consumption inrush currents etc are compatible with the device inputs and outputs For connection to external electrical compo nents is necessary the use of relays and or auxiliary contactors to be installed in an exter nal cabinet This solution also enables the operation of cir culators valves etc in emergency mode ie when the master board of boiler...

Page 18: ...ollowing the same in structions in the previous paragraph Furthermore the master panel must be con nected to Corolla 1000 Series through the ap propriate bus connection to be made with a twin cable Need to connect one end of the bi polar cable to the terminal on the master panel see Figure 10 and the other end to one of the terminals at the ends of the door panel control units via one of the holes...

Page 19: ... operation of the pump regardless of what the board For these reasons it must explicitly provide for the use Cable of the same type of power cable is to be used unless otherwise specified by the manu facturer of the component 6 2 5 Room thermostat connection on off Connect the high temperature system s envi ronment thermostat to terminals no 9 and 10 Figure 13 The low temperature system s thermost...

Page 20: ...1 5 6 Flow temperature probe Low SE J11 7 8 External temperature probe T1 J12 9 10 Room thermostat High T2 J12 11 12 Room thermostat Low AI J12 13 14 Analogical device 0 10V CR J12 15 17 Remote control AL J8 18 19 Alarm device VM J9 20 22 Mixing valve P3 J10 23 24 Low temperature circuit pump P1 J10 25 26 High temp circuit pump P2 J10 27 28 Sanitary pump Figure 14 ...

Page 21: ...allows to connect an outside sound or visual alarm device capable of high lighting any technical anomalies The alarm device must be connected to termi nals no 18 and 19 Figure 13 6 2 10 Remote control If the remote control is to be used it must be connected to terminals no 15 16 and 17 Figure 13 6 3 Emergency mode Corolla Pack Serie 1000 electronic manage ment system includes an operation mode cal...

Page 22: ...he ca ble pass it through the opening made in the back of the frame structure after properly re moved the rubber stoppers present and then in the provided cableguides Connect the cable to the relative wiring of the successive Pack by using the proper connector see Figure 18 The rubber cableguides placed on the structure of the equipment have not to be re moved because their purpose is to protect t...

Page 23: ...ow probe must always be installed inside the pocket placed downstream as it is shown in Figure 19 Of course in case of more than one Pack in bat tery the probe must be inserted in the pocket placed downstream on the unit closer to the system inlet The temperature difference read by the probe causes ignition switching off and modulation of all the thermal elements in cas cade Installer shall take c...

Page 24: ...e following procedure always remem bering that a block is equivalent to a pack Locate the block the slave is related to ex Block n 1 n 2 till block n 15 Locate the slave position inside each block e g position1 2 3 or 4 Supply each Corolla Pack composing the battery see par 6 4 1 All electrical maintenance and installing operation have to be made in full compliance with the applicable Law and with...

Page 25: ...ed to be configured respectively with address 1 and 2 and with relative burners to the first block with address 1 2 3 and 4 and to the second block with address 1 2 and 3 see Figure 21 JUMPER J17 4 UNITS BLOCK PACK 1 2 3 4 OFF OFF OFF OFF Emergenza OFF OFF OFF ON 1 block OFF OFF ON OFF 2 block OFF OFF ON ON 3 block OFF ON OFF OFF 4 block OFF ON OFF ON 5 block OFF ON ON OFF 6 block OFF ON ON ON 7 b...

Page 26: ...eed by using the S4 key par n 15 All the sys tem fans will work with this selected speed On the first digit on the left it s shown the selected speed H maximum speed Other two digit will show the water flow temperature example T1 80 C Regulate the combustion acting on throttle Figure 23 until you arrive to the nominal CO2 value shown in the below table NOTE To increase the gas flow rotate on the l...

Page 27: ...t of functions activated by pressing a key or combination of two keys pressed simultaneously Each key has a par ticular meaning because there are many use modes KEY FUNCTION DESCRIPTION S1 Reset button It is necessary to unblock the electronic board after a permanent block S2 Set esc It is necessary to enter into parameters and monitor mode for the singles units S3 Arrow It is necessary to display...

Page 28: ...it figures on the right display the T1 e g T1 80 C Antifreeze function is active or external probe is disconnected see also Par 6 2 7 8 3 Function values display Press S3 arrow to step forward from functioning display and to visualize the following value below listed values shall be displayed in succession by pressing the S3 button POS DISPLAYED VALUES DISPLAY 1 Flow Temperature High T1 e g T1 80 ...

Page 29: ... the display mode will be restored In the following table is shown the procedure to change the setpoint of the low temperature circuit from 50 to 40 C PROCEDURE DISPLAY 1 E g installation running with T_flow_system_high at 80 C 2 Press S3 arrow to access into the display mode press again till the value detected from T_flow_system_low is displayed e g fig 8 50 C 3 Press S2 Set esc 4 Premere S5 till...

Page 30: ...all the values that can be displayed E g value n 1 flow probe temperature 70 C E g value n 1 flow probe temperature 70 C 5 To exit monitor mode press S2 Set esc If no procedures are carried out for 5 minutes the boards automatically returns to functioning display Pressing S3 arrow the following values can be displayed for each unit POS VALUE DISPLAY 1 Flow probe e g 70 C 2 Return probe e g 50 C 3 ...

Page 31: ... T_tank_hyst_up 1 C 0 C 20 C Upper DHW differential Ex 50 C 1 C 51 C 12 T_tank_hyst_down 5 C 0 C 20 C Lower DHW differential Ex 50 C 5 C 45 C 13 Max number of burners active on DHW mode Max 60 0 60 Limit of burners that can start on dhw mode 14 CH_type_high 1 0 3 0 Fixed temperature 1 Climate with outside sensor 2 0 10 Vdc for heat output 3 0 10 Vdc for temperature 15 P_ch_max 230 1 255 Setting th...

Page 32: ...p start If after 10 minutes T1 is not over 5 C one burner starts at the maximum power until T1 20 C If af ter 10 minutes T4 is still under this value then pump run until T4 this value 36 Gas Type 1 1 7 1 NG with flue gas duct 15m 2 NG with flue gas duct 15m 3 LPG with flue gas duct 15m 4 LPG with flue gas duct 15m 5 Town Gas 6 Gas F 7 Gas G 37 T_out_min 0 C 20 C 30 C Minimum outside temperature gi...

Page 33: ...successful ignitions attempts E 33 live and neutral reversed error ni A 02 too many flame failures more than 3 flame failures E 34 reset button error A 04 internal hardware error E 35 water flow switch not closed error A 06 internal hardware error E 36 e2prom read error A 07 internal hardware error E 37 blocking flame error A 08 internal hardware error E 38 shorted flue gas sensor A 09 ram error E...

Page 34: ...34 Electrical wiring diagram 11 Electrical wiring diagram Bus cable connected to strip in master board ...

Page 35: ...35 Electrical wiring diagram ...

Page 36: ...cy ref NHV 80 C 60 C 98 6 98 6 98 6 Useful efficiency ref NHV 50 C 30 C 108 6 108 6 108 6 Useful efficiency ref NHV Tm 50 C 60 40 C 104 2 104 2 104 2 Useful efficiency at 30 ref NHV 80 C 60 C 99 2 99 2 99 2 Useful efficiency at 30 ref NHV 50 C 30 C 109 109 109 Useful efficiency at 30 ref NHV Tm 50 C 60 40 C 105 105 105 Losses through the casing Tm 70 0 1 0 1 0 1 Efficiency Class 92 42 CEE Consumpt...

Page 37: ...and at low temperature rating P1 kW 83 6 125 4 167 3 EFFICIENCY at rated thermal input and at high temperature rat ing ɳ4 88 74 88 74 88 74 at 30 of rated thermal input and at low temperature rating ɳ1 98 1 98 1 98 1 ADDITIONAL ENERGY CONSUMPTION at full load El max W 300 450 600 at partial load El min W 90 135 180 in stand by PSB W 4 6 8 OTHER PARAMETERS Heat loss in standby mode Pstby W 2272 340...

Page 38: ...NOTES ...

Page 39: ......

Page 40: ...20135201 Rev 0 05 17 ...

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