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Operation and Installation manual

for authorized technicians only

Trigon XXL

09/2016

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Summary of Contents for TRIGON XXL EVO 1000

Page 1: ...Operation and Installation manual for authorized technicians only Trigon XXL 09 2016 ...

Page 2: ...he boiler 13 Commissioning Water and hydraulic system 15 Gas supply 16 Condensate connection 16 Flue and air intake connections 16 Prepare boiler for first startup 17 Combustion analysis 20 Air pressure switch 21 Check water flow 22 Check functionality of safety devices 23 Commissioning protocol 24 Maintenance Checklist 25 Replacing the electrodes 25 Cleaning the condensate receptacle 26 Cleaning ...

Page 3: ...ctive 89 336 EEC EMC directive EN 656 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 70 kW but not exceeding 300 kW EN 15417 Gas fired central heating boilers Specific requirements for condensing boilers with a nominal heat input greater than 70 kW but not exceeding 1000 kW EN 13836 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 3...

Page 4: ...oiler adapts the modulation ratio automatically to the heat demand re quested by the system This is done by controlling the speed of the fan As a result the Whirlwind mixing system will adapt the gas ratio to the chosen fan speed in order to maintain the best possible combustion figures and there with the best efficiency The flue gases created by the combustion are trans ported downwards through T...

Page 5: ...tity max min m3 h 969 242 1076 307 1258 359 1424 407 1590 454 1756 502 CO2 level main burner natural gas H E L LL max min 10 0 9 3 10 0 9 3 CO2 level main burner liguid gas P max min 11 0 11 0 11 0 11 0 CO2 level pilot burner natural gas H E L LL max min 10 0 10 2 CO2 level pilot burner liguid gas P max min 11 0 11 2 NOx level max min mg kWh 32 3 18 8 11 5 19 5 CO level max min mg kWh 8 2 10 9 27 ...

Page 6: ...27 B mm 1330 1130 1130 1330 1330 B1 mm 1210 1003 1053 1203 1253 B2 mm 665 565 565 665 665 B3 mm 120 127 77 127 77 B4 mm 1146 946 946 1146 1146 B5 mm 65 115 65 115 65 D mm 300 350 350 400 400 W1 DN DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16 G R R 2 R 2 R 2 DN65 PN16 DN65 PN16 600 1958 595 700 108 1355 970 1230 1110 615 120 1046 100 300 DN65 PN16 R 2 D1 mm 250 250 300 300 355 355 W2 DN DN65 P...

Page 7: ...2 level main burner liguid gas P max min 11 0 11 0 CO2 level pilot burner natural gas H E L LL max min 10 0 10 2 CO2 level pilot burner liguid gas P max min 11 0 11 2 NOx level max min mg kWh 61 4 22 0 CO level max min mg kWh 9 8 3 3 Max permissible flue resistance max min Pa 150 Water volume l 123 Water pressure max min bar 8 1 Max water temperature High limit thermostat ºC 100 Maximum temperatur...

Page 8: ...Technical data Dimensions Trigon XXL EVO 1700 7 ...

Page 9: ...Component Pcs Package R3400 R3500 R3600 Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border sealed in PE foil Adjustable feet 4 Cardboard box on top of boiler on R3407 R3410 already fitted to boiler Syphon for condensate connection 1 Cardboard box on top of heatexchanger under casing Operation and Installation manual 1 Map attached to back panel of the boiler Wiring dia...

Page 10: ...0 135 1010 1150 420 140 1010 1310 500 210 1420 1010 500 215 1420 1110 500 220 1420 1210 500 225 1420 1310 500 1st Heat exchanger m kg L mm W mm H mm 120 1010 1150 160 120 1030 1150 150 135 1010 1310 160 180 1420 1010 160 185 1420 1110 160 190 1420 1210 160 195 1420 1310 160 2nd Heat exchanger m kg L mm W mm H mm 135 1010 1150 160 135 1030 1050 150 150 1010 1310 160 200 1420 1010 160 200 1420 1110 ...

Page 11: ... mm H mm 200 1510 1425 150 325 2050 1250 150 330 2050 1350 150 335 2050 1450 150 2nd Heat exchanger m kg L mm B mm H mm 220 1510 1425 150 365 2050 1250 150 370 2050 1350 150 375 2050 1450 150 Frame m kg L mm B mm H mm 80 2010 1466 510 120 2525 1266 515 120 2525 1466 515 120 2525 1466 515 Condensate m kg L mm B mm H mm 40 2075 1175 350 55 2600 975 350 55 2600 1075 350 55 2600 1175 350 ...

Page 12: ...on Removing the casing 11 Boiler transport Remove the casing before transporting the boiler in order to avoid damage to the casing parts during transportation Removing the casing is done as follows 1 3 5 4 2 5 4 ...

Page 13: ...r is in the correct position the wooden blocks 1 should be removed and the adjustable feet 2 with vibration absorption dampers should be adjusted to the right height Water and gas connections should be done after mounting the feet as they effect the exact height of all connections 12 800 1000 The R3407 R3410 are not supplied on wooden blocks but on wheels After positioning the boiler the adjustabl...

Page 14: ...lic connections The boiler should always be connected in such a way that water flow through the boiler can be ensured at all times Connect the flow 3 and return 1 connection of the system tension free to the boiler connections If the boiler is used in a system with two return circuits only R3600 series the com mon return becomes the low tempera ture return the 2nd return connection is the high tem...

Page 15: ...ion ac cording to the national regulations Construct the flue gas system as short as possible for maximum length see planner documentation Construct horizonal ways with a mini mum angle of 3º Air intake connection 3 When using the boiler roomsealed The air intake can be connected if the boiler was ordered as roomsealed The diameter should be calculated according to the national regulations togethe...

Page 16: ...d out by authorized personnel only Failure to respect this condition makes the guarantee void A protocol of the commissioning should be filled out see end of this chapter for example of commissioning protocol This chapter explains the commissioning of the boiler with the standard boiler controller When an additional system controller is installed please refer to its manual for commissioning the co...

Page 17: ...now for which gas type the boiler should be commissioned Condensate connection Remove the syphon 2 from the condensate connection Fill it with water and place it back in the original position Make sure the syphon is filled before starting the boiler in order to prevent flue gases discharging through the condensate connection Flue and air intake connections Check whether the flue and air intake sys...

Page 18: ...fort sun 24 7 heating in comfort mode Reduction moon 24 7 heating in re duced mode Standby heating off frost protection activated Display L Info mode G Display possibility of following info wit hout influence on boiler control temperatures operation mode Heating DHW error code Room temperature control C for changing room comfort tempe rature for changing settings when pro gramming Deaeration mode ...

Page 19: ...nu with ESC button Commissioning Expert choose user level confirm with OK button choose menu confirm with OK button choose parameter confirm with OK button change value with wheel confirm with OK button return to main menu with ESC button Programming Select turn left right Quit menu Reset Press OK 1x Press OK 1x Press INFO 4 sec Default mode buttons Heating to comfort setpoint Info level activated...

Page 20: ... Winter automatic switching activated ECO functions activated Safety mode on with Heating off Temperature by frost protection Safety functions activated Controller Stop mode Press button 3 sec Press button 3 sec again 304 Controller Stopp mode insert setpoint after 3 sec Main menu appears Info display Press button 1x Press button 1x again Press button 1x again Press button 1x INFO Segment displaye...

Page 21: ...d for full load The combu stion settings for the pilot burner can be adjusted using the adjustment screw on the pilot gas valve 6 The combustion settings for the main burner can be adjusted using the adjustment screw N on the main gas valve 7 Combustion check at 50 load An additional reference check of combustion values at 50 load is recommended in order to check if the gas valve is set in such wa...

Page 22: ...d be 0 8 mbar Turn the dial on the switch 2 counter clockwise until the end Reduce the setting on parameter P17 step by step until the pressure differential is 0 4 mbar Slowly turn the dial on the switch clockwise until the boiler goes to lockout Set P17 back to its original setting Reset the lockout Restart the boiler and check if the switch contact closes at 0 4 mbar indicator at DW in display o...

Page 23: ... 20K and must be at least between 15K and 25K for secure boiler operation An indication of the actual flow rate can be found with the following calculation see Technical data for nominal data p measurement Check the pressure difference over the boiler p flow return when the boiler pump is running burner on is not required The nominal p for each boiler type can be found in the table below actual p ...

Page 24: ...n a standard boiler are a water flow tem perature sensor water flow switch minimum gas pressure switch and ionisation electrode These devices can be checked as described below Ionisation electrode 6 Remove electrical connection from the ionisation electrode while the boiler is running the boiler will go in lockout no 5 The boiler will try to restart With the electrical connection removed the resta...

Page 25: ...h checked Min gas pressure switch setting mbar Ignition time burner sec Combustion analysis 100 load 50 load Min load Gas consumption m3 h m3 h m3 h Gas pressure mbar mbar mbar CO2 pilot burner O2 pilot burner CO pilot burner ppm ppm ppm NOx pilot burner ppm ppm ppm Tatmospheric ºC ºC ºC Tfluegas ºC ºC ºC Twater flow ºC ºC ºC Twater return ºC ºC ºC Ionisation current µA µA µA pfan mbar mbar mbar p...

Page 26: ... ignition and ionisation electrodes Clean the condensate receptacle Clean and refill the syphon Check the water pressure of the system Check the water quality of the system water as well as supply water Check the water flow rate through the boiler Check correct the combustion values at full and mimimum load with a combustion analyzer Check the gas pressure to the boiler Check the tightness of all ...

Page 27: ...led information Combustion analysis Check the combustion at full load and minumum load correct the settings if necessary An additional reference check at 50 load is recommended Consult the chapter commissioning combustion analysis for more detailed information Gas pressure Check the dynamic pressure of the gas supply to the boiler when the boiler is running at full load In case of a boiler cascade...

Page 28: ...ion time burner sec Combustion analysis 100 load 50 load Min load Gas consumption m3 h m3 h m3 h Gas pressure mbar mbar mbar CO2 Pilot burner O2 Pilot burner CO Pilot burner ppm ppm ppm NOx Pilot burner ppm ppm ppm Tatmospheric ºC ºC ºC Tfluegas ºC ºC ºC Twater flow ºC ºC ºC Twater return ºC ºC ºC Ionisation current µA µA µA pfan mbar mbar mbar ptop panel mbar mbar mbar pcombustion chamber mbar mb...

Page 29: ...e 1 sensor error 65 Room temperature 2 sensor error 70 Buffer storage tank temperature 1 sensor error 71 Buffer storage tank temperature 2 sensor error 72 Buffer storage tank temperature 3 sensor error 73 Collector temperature 1 sensor error 74 Collector temperature 2 sensor error 82 LPB address collision 83 BSB wire short circuit 84 BSB address collision 85 BSB RF communication error 91 EEPROM er...

Page 30: ...rging temperature sensor error 324 BX same sensors 325 BX extension module same sensors 326 BX mixing group same sensors 327 Extension module same function 328 Mixing group same finction 329 Extension module mixing group same function 330 Sensor BX1 no function 331 Sensor BX2 no function 332 Sensor BX3 no function 333 Sensor BX4 no function 334 Sensor BX5 no function 335 Sensor BX21 no function EM...

Page 31: ...or 349 Buffer return valve Y15 not available 350 Puffer address sensor 351 Primary controller system pump address error 352 Pressureless header address error 353 Common flow sensor B10 not available 371 Flow temperature 3 heating circuit 3 supervision 372 Limit thermostat heating circuit 3 373 Extension module 3 error collective error 386 Fan speed has lost valid range 388 DHW error no function 42...

Page 32: ...Electrical ...

Page 33: ...kits The diagrams contain average values as all sensors are liable to tolerances When measuring the resistance values the boiler should always be switched off Measure close to the sensor in order to avoid value deviations Water flow and fluegas temperature sensor 5kΩ NTC DHW outside and header temperature sensor 1kΩ PTC ...

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