Flexiheat ThermoExtra 28 kW Instructions For Installation And Use Manual Download

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INSTRUCTIONS FOR INSTALLATION

AND

USE TMS-UT-0621-Z01-1

We reserve the right of alternations

ELECTRIC BOILERS FOR CENTRAL HEATING

INSTRUCTIONS FOR INSTALLATION AND USE

ThermoExtra

28-96kW

Summary of Contents for ThermoExtra 28 kW

Page 1: ...INSTRUCTIONS FOR INSTALLATION AND USE TMS UT 0621 Z01 1 We reserve the right of alternations ELECTRIC BOILERS FOR CENTRAL HEATING INSTRUCTIONS FOR INSTALLATION AND USE ThermoExtra 28 96kW ...

Page 2: ...INSTRUCTIONS FOR INSTALLATION AND USE TMS UT 0621 Z01 1 We reserve the right of alternations ...

Page 3: ...neral requirements 14 3 1 Contents included in delivery 14 3 2 Preliminary remarks 14 3 3 Recommendations for various installation types 15 3 4 Installation site 15 3 4 1 Position of a boiler 15 3 4 2 Power supply 16 3 5 System requirements 16 3 5 1 Pipe work 16 3 5 2 Cleansing and flushing the system 17 3 5 3 Filling and preparing heating system 17 3 5 4 Pressure relief valve 17 3 5 5 Expansion v...

Page 4: ...ng active modes 27 5 3 5 Selecting domestic hot water temperature 27 5 3 6 Temporary override heating curves Turbo Mode 28 5 3 7 Offsetting Heating curve 28 5 3 8 User menu options 28 5 3 9 Entering and navigating service menu 29 5 3 10 Reset service interval 30 5 4 Control mode 0 10V analog signal 31 5 4 1 Connection to PCB 31 5 4 2 Remote control settings 31 5 4 3 Remote control instructions 32 ...

Page 5: ...INSTRUCTIONS FOR INSTALLATION AND USE TMS UT 0621 Z01 1 We reserve the right of alternations ...

Page 6: ...they do not play with the appliance Boiler is not intended for outdoor use Technical safety instructions manufacturer Switch off main power by MCB before opening the boiler Boiler has built in frost protection When the boiler is not in use leave the main power active that protection stay active Read this document carefully before carrying out any installation adjustment or service and follow the i...

Page 7: ...t the same time the temperature in the heating elements for example in radiators convectors etc To achieve the desired room temperature the characteristic heating curve has to be chosen depending on the characteristics of the object and the heating system ThermoExtra are economical central heating boilers that may be used as an independent or additional source of heat ThermoExtra boilers offer you...

Page 8: ...temperature supplemental adjustments of the standard heating curves can be made Changing the inclination When changing the heating curve inclination is changing too and in that way the temperature of water in the boiler is changing when the external temperature is low below 5oC Level changes offset By offsetting the heating curve for the chosen value the temperature of water in the boiler is chang...

Page 9: ... has to be lower one element has to be built in such as motorized three way valve that is controlled by room thermostat thermostat valve for limiting the temperature of the return flow or something similar 1 4 5 Limiting the minimum and maximum temperature of water in the boiler 1 5 Functionality of hot domestic water 1 5 1 Availability If the heating curves and offset are selected correctly and r...

Page 10: ...ff with the previously described and programmed time delay If the central heating is off at the moment of reaching the desired domestic water temperature the desired water temperature in a boiler is set to the minimum value of water temperature in the boiler stand by At repeated request for heating the domestic water cylinder th e desired water temperature in the boiler is set to 25 C higher than ...

Page 11: ...Power supply 28 A 400 B 930 C 310 D 162 E 115 F 109 45 400V 3N 50 60 Hz 32 36 40 44 48 52 56 60 64 A 550 B 930 C 310 D 316 E 115 F 175 72 2 72 80 88 96 Power kW TECHNICAL DATA FOR THERMO EXTRA BOILERS BAR 2 5 1 F R CONNECTIONS BSP MALE Dimensions mm 2 1 Dimensions Thermo Extra 19 32 ...

Page 12: ...e type RCCB switch type 400V 3N 50 60 Hz 28 kW 40 58 A 50 A 5 x 10 mm2 32 kW 46 38 A 63 A B63 3 36 kW 52 17 A 5 x 16 mm2 40 kW 57 97 A 44 kW 63 77 A 80 A 50 kA 105 kA 5 x 25 mm2 48 kW 69 57 A 52 kW 75 36 A 100 A 56 kW 81 16 A 5 x 35 mm2 60 kW 86 96 A 64 kW 92 75 A 125 A 72 kW 104 35 A 5 x 50 mm2 80 kW 115 94 A 160 A 88 kW 127 54 A 5 x 70 mm2 96 kW 139 13 A 2 2 Hydraulic pressure drop and recommend...

Page 13: ... Electrical heaters 2 Return flow 7 Control panel 3 External boiler jacket 8 Inducers for el Connections 4 Boiler 9 Contactors 5 Heat insulation 10 Charge and discharge valve 2 5 Function elements of Thermo boilers ThermoExtra ...

Page 14: ...ntact For the exact list of parts see the figure and table below If parts are damaged or missing please consult our local sales office When connecting the appliance to the fixing wiring the means for disconnection MCB must be incorporated in fixing wiring in accordance with the local wiring rules If safety valve 2 5 Bar is not located in the existing installation a safety valve provided must be in...

Page 15: ...xisting installation Note These installation samples should not be used as the detailed installation plan Before installation observe the local regulations 3 4 Installation site 3 4 1 Position of a boiler The location must provide adequate space for servicing and air circulation around the boiler The boiler may be installed in any room although particular attention is drawn to the local regulation...

Page 16: ...s additional measures must be taken subject to the requirements of the Local Authorities Note In some cases additional measures must be taken subject to the requirements of the Local Authorities 3 5 System requirements 3 5 1 Pipe work Pipe work that is not a forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing particularly where pipes are r...

Page 17: ...t not be used for draining purposes 3 5 5 Expansion vessel ThermoExtra boilers are not equipped with an expansion vessel 3 5 6 Circulating pumps A circulation pump is not included in ThermoExtra boilers On the electrical switchboard mounted inside of ThermoExtra boilers there are terminals prepared to pump connection CH pump and or DHW pump See electrical diagram for more details The system can be...

Page 18: ... movements during a two person lift to ensure equal spread of weight of load It is recommended to wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance 4 2 Select position for boiler Refer to chapter 3 4 1 for information regarding the appliance position In general the boiler must be positioned in such manner that There is eno...

Page 19: ...on Note Observe chapter 3 5 for the system requirements before proceeding System flushing is necessary in order to prevent damage to appliance It is recommended to fit valves on flow and return pipe work in order to enable easy disconnection separation of boiler from the central heating system The following figure indicates flow and return for the central heating on ThermoExtra boilers Flow and re...

Page 20: ...ordance with the local wiring rules This device must be earthed Power connection main power terminals Note The power cable of the intersection from Ø6 mm to Ø21 mm must be connected with the bottom of the boiler with the help of a special introducetor located on the boiler All wires inside the electrical connection place must be tighted Pay attention when connecting the power cable so that the pha...

Page 21: ...nd wires from external temperature sensor must be connected protective cover External temperature sensor Label below terminals on switchboard option O Label below terminals on switchboard option V Note For connecting external temperature sensor two wire cable can be used of diameter from 0 6mm2 to 1 5 mm2 4 7 3 Connecting domestic hot water temperature sensor Domestic hot water temperature sensor ...

Page 22: ... external control unit like Danfoss TP9 Terminals 4 and 5 are linked together factory If external control unit is used this link must be removed Label below terminals on switchboard option V Note For more details see selected appendix from chapter 3 3 4 8 Filling the heating system For the heating system to operate properly the indicator of pressure gauge must be between 1 2 and 1 5 bar when the s...

Page 23: ...sure exact voltage between L1 L2 L1 L3 L2 L3 L1 N If there is no voltage between any combinations of phases one phase is missing and the heating elements inside the appliance can be damaged If the voltage between phases is 10 higher than nominal voltage of the appliance the appliance itself can be damaged Check if fixed wiring system is used and that overcurrent protection device is installed and ...

Page 24: ...t temperature in boiler 6 External temperature visible only if external temperature sensor is installed and enabled 7 Number of active heating steps 8 Boiler is running in anti frost protection mode 9 Current time 10 Current date 11 Active mode and desired temperature Radiator heating Underfloor heating Domestic hot water cylinder heating option Z 12 Cental heating pump is active ...

Page 25: ...ves enabled used to offset current curve Inside menu used for menu navigation and changing values 15 Multifunction key Home screen with heating curves disabled used to change desired temperature Home screen with heating curves enabled used to change desired temperature Inside menu used for menu navigation and changing values 16 Multifunction key Home screen press 5 seconds for user menu Inside men...

Page 26: ...select option and confirm values Press to exit either from menu or option inside menu 5 3 3 Example how to change date and time Press and hold for 5 seconds to enter user menu Press in order to navigate to Clock Set menu option Press to enter Clock Set option Press and to change value Press for next value When time and date are set press for returning to user menu ...

Page 27: ...rating modes Press and to navigate through modes Press to activate or deactivate mode Press to exit Mode Selection 5 3 5 Selecting domestic hot water temperature Available only with option V Press to enter mode Press and to set desired domestic hot water temperature Press to accept selected value or to exit without change ...

Page 28: ... temperature is reached 5 3 7 Offsetting Heating curve Available only with external temperature sensor enabled Press to enter mode Press and to set desired curve offset Press to accept selected value or to exit without change 5 3 8 User menu options Menu Language Select language for menus and messages Power Limit Limit boiler s power stages refer to table 2 3 Power stages for more details Clock Se...

Page 29: ...ds to enter service menu Enter service PIN by pressing combination of keys and Service PIN is available for Number related to each key 1 2 3 4 Press and to navigate through options and set desired value Press to select option and confirm values Press to exit either from menu or option inside menu ...

Page 30: ...t service interval When time for service declared by manufacturer expires service symbol will blink Navigate to Reset serv interval and press to reset option Choose Yes and press to reset service interval to default value ...

Page 31: ... signal 5 4 1 Connection to PCB U2 U0 input analogue signal 0 10VDC U1 output analogue signal of active U0 power steps 0 10VDC U1 U2 output analogue signal of current boiler temperature 0 10VDC 5 4 2 Remote control settings The first condition to enable remote control is connect jumper to terminals JP3 on control panels back If jumper is connected to JP2 it s necessary to move him to JP3 and JP2 m...

Page 32: ... power stages adjustment will be disabled Available modes 1 Local control remote control disabled Local control of desired temperature and power limit The input signal range 0 10VDC is approximated to desired temperature in range of 0 C to 100 C according to formula below U0 input direct voltage signal V TD desired boiler temperature O C 2 Remote temperature remote control of desired boiler temper...

Page 33: ... steps in range regarding to minimum and maximum values according to formulas below U0min minimum value of input direct voltage signal V U0max maximum value of input direct voltage signal V LD desired number of active power steps LM maximum number of power steps depending on type of boiler 3 7 or 15 Value of input signal must be in range of U0min and U0max for desired power steps In this mode boil...

Page 34: ...ed output value according to formula below U1 output direct voltage signal value V L number of active power steps LM maximum number of power steps depending on type of boiler 3 7 or 15 AO2 analog signal of current boiler temperature 0 10VDC The output signal value is approximated to current temperature in range of 0 C to 100 C Current temperature corresponding to measured output value according to...

Page 35: ...e in seconds domestic hot water pump will run after temperature in cylinder has been reached Default 60 seconds Option V Stand by Temperature Minimal temperature that will be maintained inside boiler when in standby Default 15 C All control panels CH Minimal Temperature Limit minimal temperature in boiler that can be calculated by heating curves Default for radiator heating 40 C Default for underf...

Page 36: ... necessary filled up valves and general functionality of the device should be checked Safety thermostat we recommended to check safety thermostat before every heating season by heating up the sensor with heating fan or lighter over 110 C must actuate overheating protection by switching off the main MCB or disconnection switch inside the boiler Safety valve should be checked once a year before the ...

Page 37: ...on prevents circulation vent installation boiler does not provide enough heat one phase is missing on supply a part of heater is burned through in a three phase system the three different phases are not brought to the boiler check fuses on the main panel contact authorized service personnel to resolve the problem the switcher can be heard while operating it buzzes radio and TV interferences poor v...

Page 38: ...uthorized service personnel to resolve the problem Boiler s temperature sensor is not properly connected When sensor is operational error will be automatically dismissed and boiler will continue with normal operation check sensor wiring contact authorized service personnel to resolve the problem Boiler s temperature sensor is not properly connected or short circuit is present on sensor s wiring Wh...

Page 39: ...t authorized service personnel to resolve the problem Overheating Safety thermostat is activated Wait until temperature inside the boiler drops below at least 90 C reset safety thermostat and switch on miniature circuit breaker F11 inside the boiler contact authorized service personnel Blinking of service symbol indicates that time for service declared by manufacturer has expired make service on t...

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