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1. ALIMENTAZIONE L1 L 11 ALIMENTAZIONE ELETTRICA E ELETTRICA SLAVE CU 02 N N N SLAVE CU 03 A 08 IG FI 1 1a XLL1 L1 D 49 XIN 11 hi ya 12 ms x18 X17 X16 x15 1 UNE 15 PR2 t lt 95 C p lt 3bor MOTOR FN AL Y21 Y22 Y23 Y24 va 72 Y5 2 1175 8 1002 13 x14 X2 29 X2 30 x2 32 X2 31 FN AL RS485 T 8 R1 100 ohm 0 25W IG N 2 m 0 10Vcc Analogical signal input 0 10Vcc AL Warning electrical contact BUS Connection for PC CM Control board CR Remote control on request EA Ignition electrodes ER Detector electrode F1 Power supply fuse 1 6A FN Function electrical contact GS Spark generator IG Main switch J1 6 pole connector J2 4 pole connector J3 12 pole connector J4 4 pole connector J5 16 pole connector J10 10 pole connector J18 8 pole connector U1 Boiler unit probe 1 U2 Boiler supply probe SB U3 Water heater probe on request SE U4 External temperature sensor U6 Boiler unit probe 2 U7 Flue gas temperature sensor Figure 42 Functional wiring diagram 54 U8 Return temperature sensor PB VVater heater pump PO1 Circulating pump PR No vvater pressure svvitch PR2 ISPESL safety pressure svvitch TA1 Room thermostat bridge inside boiler TA2 Room thermostat bridg
2. MOJ JO lnl M GZ yno sinyesodu9 MO Jo Aiddns pz SAJEA 399uO EZ yno Sinyesodu9 Mo Jo duind ZZ 3909 LE yno MO Josuas ln l d l l OZ n z eJn eJadwia MO 10 SAJEA 61 YUE uolsuedxz 9 1S3dSI 21 y y os 193 491 91 y lul SBD SL 0 1 5 f n TSAdSI rL deo abieuosip bpnis JHA ZL Joyesedes qqnq o9IN LL OL Josu s ujioje nB jiouu ul 6 y lul SPA 01 0 8 SAJEA NO IY 2 inss id 1S448SI 9 ener Ajajes 1S3dSI yeysouu v Ajajes 1S3dSI 7 U MHAS inss id Ajayes 1S3dSI Jazijeljneu uonesu puoo 2 3AV1S pue HILSVIN Jajiog d SNICTYNA L 1 e u pue S L S ul si l ioq jo uueiBeIp uon uuo2 OL 6 yun Buipeo l s4S 26 dund Buipeo 1 e U LE t yno aslnpesadw a uBiu W A 9 1 94 Jo 62 alnesadws ublu ala 82 2 dwng 9z Ssinyesaduu9 ypy 10 1121 UBIU 404 6 A BA J XIN ZZ noo ublu qo Ajddns 92 6 Led n3419 rH
3. uBiu JO MO7 91 Alddns Jamod S q liz Ti aqojd 6 2 1oygeied s o1jneipAy u uono uuo2 Jo ajdwexg g ainbi4 e QWEZEPLL ow XOW IVA 022 Joyesedas jqqnq oIN ZL yue uoisuedx y lul 580 ol 194905 1SddSI 6 A EA yo nys SE 1934918 3909 seo 12180 Ajajes 1934919 55 Ajayes TSddSI S 193491 7 sunssald SIUSI Ajayes TS3dSI Z seas SNAG TWN 1 g pue selnbi4 AIM uono uuo 2152 Jo lduuex3 ainbi4 04 39U XOW OWA 022 OWETETLL Ue 12 4 OPERATION GA 68 on w XOW y hno JOY 2118 4 66 YUE 4015 1 10 OSEWOG Ze Josuas LE Ajajes OF yun Buipeo l s4S 62 dund 1 9 e u 82 W JS S JZ uu s s BuneaH 92 deo abieuosip 5pnis sz uinjes walsAs BunesH Ajddns us s 4s BuneaH ez 22 JJO jnuS LZ 1Jojo uuoosip dInespAH OZ dund Bune H 61 p
4. 13 103611m0_b Elemento termico MAST 9 10 ogzi Flo 16 15 Giallo verde Rosso Verde Blu 1 Morrone 4 K1 K2 gt K3 gt K4 K5 K6 Bionco Grigio K7 K8 K9 K10 gt K11 gt K12 gt K13 K14 57 9 TECHNICAL DATA MODEL Country of delivery Type Category EC type certificate PIN Nominal heat input Q Minimum heat input Nominal output heat 80 60 P Nominal output heat 50 30 P Efficiency at 100 of load 80 60 Efficiency at nominal output heat 50 30 Minimum output heat 80 60 Minimum output heat 50 30 Efficiency at minimum output heat 80 60 Efficiency at 30 of load Efficiency at minimum output heat 50 30 Certified efficiency 92 42 EEC Chimney loss burner on 80 60 Chimney loss burner off Casing loss burner on Casing loss burner off Gas flow rate Gas supply pressure mbar Gas supply minimum pressure mbar Gas supply maximum pressure mbar Comburent air pressure Primary heat exchanger water content Primary heat exchanger weight D h w setting range with water heater Project temperature Maximum heating temperature Minimum heating tempe
5. h F i N conan D A 5 E I e lt lt 1531852 B 8 4 Cleaning the condensate conveyor trap For a correct cleaning of the trap for the collection and conveying of the combustion condensates proceed as follows in both thermal elements where not otherwise specified refer to figure 36 perform a domestic water service forcing as described in section 8 9 3 with the purpose of lowering the liquid level inside the trap A access the internal components by following the instructions in section 8 3 unscrew fitting D disconnect the cables from the ignition and burner plugs see figure 1 details 17 18 and 20 disconnect the cable from the safety sensor F see figure 37 unscrew the four nuts C extract the whole fan and burner unit detail F remembering to disconnect the fan power cable during the extraction rotate the electrical board detail C shown in figure 35 as indicated in section 8 3 and cover it with a waterproof sheet B to prevent water drops from filtering and wetting the electric components inside it loosen spring G by using pliers and push it downwards pull the condensation pipes O and N downwards by opening the special locks P and Q paying attention to their positioning in order to reassemble them once finis
6. ea cet BR te qua qaqta ataqa 8 4 3 Characteristic curves of the heating system residual head r 10 S INSTAEPEEPATION u u u ua aaa a satisqa q a sas 15 5 1 Opening zusu 15 5 2 Dimensions and minimum clearance distances ii 15 5 3 Choosing the place of installation ccccccceceeseeceeeceeneeeeeecneeeeeeeeeaeeeeseeaeeeseeccaeeeeeseneeeeessceeeeeessciseeeseneaeeees 15 54 Supply and feti ei ioni 16 5 9 Water S PD V aaa rail ba planlayan 16 5 5 1 Recommendations for the characteristics of the system 3138888833 16 5 5 2 In order to guarantee the correct operation of the system please make sure that 17 5 5 3 Water treatment in thermal systems for public use e eee eee neee iii iaase 17 5 6 Discharge of the thermal CIFCUIt see si ONEEN EENE AEAEE AKASAKA ENEE ENAT KETTE arlassal 17 S EXPANSION tanka ar ba HS ta aa ba ba Deed Saban abn sae eed evade each evaded da ya 17 5 8 Radiant panel type systems or low temperature i 17 asec aaah cls tne iii 0 0 nde nds one 0 0 18 5 10 Assembling thie ap plane i u ii ince pe u SD l u pu uuu balena ara 19 5 11 Gas and water connections narrare alata 19 5 12 Condensation discharg
7. iL Lala 52 9 9 POFC n as b aa saa 52 89 1 52 2 52 6 9 53 Minimu m and MAXIMUM ENEE Enee EAEEREN 52 8 9 4 Verifying the ionization current EEEN AAAA AAAA AEAEE NE EEES 52 8 10 Water temperature measuring probe iii 53 8 11 External temperature sensor aaa a daaa ilaria 53 8 12 Verifying the Combustion efficiency i 53 6 15 Funeuonal iwiming diagram lil a a a ease 54 8 14 Multiwire wining diagrami u alama S dr aio 56 9 TECHNICAL DATA se Peet sus RB aaa Raya radial ada YER uA auqa aupaq 58 10 EC COMPLIANCE ea 60 11 MENU FORCED BY SWITCH ili aaa 61 12 DIAGRAM OF THE CONTROL 5 RAR UNEETAN E RENANE RE ENESE ENEE 62 13 INSPECTION CERTIFICATE AATAKE TAKATA puskay suya hawaka bay 64 14 ISPESL CERTIFICATB u u u uu 0 00 000000 ayaka sawaqayaqas 65 15 WARRANTY ua DAA saa malay dita 66 15 1 General warranty conditions ana asgl Lele 66 15 2 Instructions for filling in the warranty card ii 66
8. TO BE COMPLETED BY THE SERVICE CENTRE The appliance has been verified for warranty validation purposes by qualified technicians in possession of the legally required qualifications in compliance with the instructions contained in this manual and national and or local standards in force with the following results SERVICE CENTRE Stamp POSITIVE El necative LJ Date Remarks Service Centre name and signature User signature A COSMOGAS s r l Via L da Vinci 16 47014 MELDOLA FC ITALY info cosmogas com www cosmogas com
9. p ds uey oo p elds p 1567 J Z MN DUE Ul 1 llog in m 2 d J en p ejds p 1561 J ordada une u ul 13 109 13 INSPECTION CERTIFICATE HYDRAULIC INSPECTION CERTIFICATE In accordance with the Ministerial Decree of 1st December 1975 art 17 COSMOGAS srl manufac turer of wall mounted and floor standing boilers operating with gaseous fuels that this heater was tested by means of the 6 bar hydrotest on scoring a positive result Model serial number Year of manuf Operating with gaseous fuels type G20U G25U G30U 63101 Heat rating referred to the LHV heat input kW Output heat kW Maximum operating pressure 4 bar Inspection pressure 6 bar Calibrating pressure of the safety valve 3 5 bar Alessandrini Arturo Sole Responsible 64 14 ISPESL CERTIFICATE 65 15 WARRANTY 15 1 General warranty conditions COSMOGAS guarantees that all its products are free from manufacturing and material defects for 24 months from the testing and inspection date of the first start up Moreover COSMOGAS extends warranty for TUBE amp SHELL HEAT EXCHANGER BODIES and CRR guaranteed up to 5 years PRE MIX BURNERS quaranteed up to 10 years ATMOSPHERIC BURNERS guaranteed up to 15 years Such warranty extension is valid only if COSMOGAS has received the warranty card properly filled in in every part certifying the date of first start up Within the aforementi
10. 80 0107 90 80 004 6ZS 0rZ9 50 SNNOG45 DUAL 2 34 DUAL 6 70 DUAL 8 90 DUAL 4 DUALDENS series models 3ONVN31NIVIN ANY SSN NOILVTIVLSNI ALSSVS N QMY ZM NOILVINHOANI LNV HOdINI SNIYLNOO LI SV ATINAIHVO TIVNNVIN dH1 0 3 ISVAld y SHIA 110d SVO d IVNNVIN 49NVN 1NIVI NV NOILVTIVLSNI Table of contents 1 GENERAL SAFETY WARNINGS sini enel aio aaa 4 1 1 Nationaliinstallation laWS acciai 4 2 GENERAL INFORMATIONI iaia 5 2 1 MOU CU OM ee trilli in 5 2 2 5 273 MAMUTACHUIEN es u k u aaa cae 7 5 2 seg na Da da 5 2 5 Maimenance uu ama l d r aaa aaa yaaa aa a a A dade 5 2 0 VVamaniy e RR O N O 5 MAIN COMPONENTS aiar 6 aaa ie 8 4 1 Function and intended use of the appliance nn 8 4 1 1 Fiydraulic separator uu a alayla hake BRB Ey ale ala 8 4 1 2 Connectionin serleS arri dacia 8 4 1 3 Domestic hot water production iii 8 4 1 4 Systemtypes uu u daaa aaa aaa ayka ai ya aa kasstasataSkugussa aka 8 4 1 5 ON OFF remote control arreca ai 8 4 2 Installation PreCAUUOMS airne
11. u u da dA usuyasa ai 20 5 13 Safety valve rile 20 5 14 Electrical connections General information 21 5 14 1 Connecting the power supply 1 n nasa 22 5 14 2 Choosing the room thermostat time programmable thermostat 23 5 14 3 Connecting the room thermostat time programmable 8 1 23 5 14 4 External temperature sensor i 23 5 14 5 Remote control 62101051 on request n nn s a 24 5 14 6 Communication among thermal elements rr 24 9 14 7 External thermal controller ussisenniaza iaia 24 5 14 8 Digital output WARNING contact ii 24 5 14 9 Digital output FUNCTION contact iiii 24 5 15 Connecting the boiler to a water heater sss 25 5 15 17 Antleglonellaz aaa alla ayalara AL a aa dada 25 6 Vehting SV SUING occa stains uu un ihamushasqa b asa d 26 5 16 1 System SINGOLO 80 PP polypropylene eee ee Rreee eee Rraaee 27 5 16 2 Polypropylene flue gas collector system a aaaee 28 5 16 3 Condensation discharge of the collector rasa 29 STARTUP 0000000000 000 0 0 0200100 30 6 1 sci 00000 aaa 30 6 1 s
12. 3 Burner status indicator On burner on flashing burner off 4 Domestic water service status indicator On domestic water active Off domestic water inactive 5 Decimal indicator of the displayed value 6 Heating service status indicator On heating active Off heating inactive 7 Start and heating temperature knob 8 Button to decrease parameter values 9 Button to reset shutdowns and to scroll the parameter list 10 Button to increase parameter values 11 Domestic hot water temperature and start knob 12 Main switch Figure 31 Control panel 7 2 Overview According to the architecture with which it is prepared the thermal module command and control operations can be performed as follows by using the MASTER boiler control panel see section 7 5 and 7 6 by using the remote control see section 7 4 by using an external thermoregulator via 0 10Vdc analog signal see section 5 14 7 In all above cases during normal operation the MASTER boiler display reads c followed by the supply temperature probe U2 when in heating mode d followed by the water heater temperature probe U3 when in domestic water mode water heater loading In normal operating conditions the SLAVE thermal element always displays a c followed by the boiler temperature probe U1 The thermal element is preset to standard parameters It is however possible to change or look at
13. 40 30 4 20 4 0 T T T T 20 10 10 20 30 t C Figure 41 External temperature sensor curve 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Tab sonda esterna t C 53 8 10 Water temperature measuring probe A number of sensors measuring temperature are present on the boiler s heat exchanger The electrical resistance existing between the two sensor contacts shall correspond to the values in figure 40 The temperature probes are U1 U3 U5 U6 U7 and U8 whose positioning can be verified in figures 1 42 and 43 8 11 External temperature sensor The external temperature sensor U4 can be connected to the boiler see section 5 12 5 and 7 8 The electrical resistance existing between the two sensor contacts shall correspond to the values in figure 41 8 12 Verifying the combustion efficiency According to the national laws regarding the maintenance of gas appliances combustion efficiency shall be checked regularly To do so proceed exactly as described in section 6 8 and check the CO2 as well as the combustion efficiency which shall be greater than 96 8 MAINTENANCE 8 13 Functional wiring diagram
14. its weight a When choosing the room and position for installation 2 account must be taken of the following factors 896 connection of flue gas discharge pipes connection of gas supply pipe connection to the water mains connection to the central heating system connection to the domestic hot water system N electrical connection connection of the discharge the produced tt i T condensation 35 electrical connection to the room thermostat 228 203 172 136 connection of the safety valve discharge F m connection of the external temperature sensor 4 connection of the various additional safety devices 830 410 required by the national and local standards see also section 1 1 1 1 1 2 heating supply pipe 2 1 gas pipe 3 1 1 2 heating return pipe 4 Discharge 5 Support mounts Figure 12 Boiler dimensions and connection distances 15 5 INSTALLATION 5 4 Supply and return CAUTION This boiler is supplied with safety valve set at 3 5 bar Therefore it shall not be installed with a head greater than 35 m N CAUTION COSMOGAS cannot be held responsible for any damage caused by incorrect use of additives in the heating system N CAUTION The system downstream of the appliance must be made with materials resistant to temperatures up to 97 C Otherwise e g plastic tubings it w
15. ella 66 1 GENERAL SAFETY WARNINGS If you smell gas Close the gas cock Ventilate the room Do not use any electrical appliance including telephone Immediately call a qualified technician or the gas board from another room or building Otherwise call the fire brigade If you smell combustion gases Switch off the appliance Ventilate the room e Call a qualified technician In the installation room it is forbidden to use extractor fans chimneys and any other device that may cause a pressure decrease in the room Installation modifications The installation setting or modification of the gas appliance must be carried out by qualified technicians in compliance with local and national standards and with the instructions of this manual Never leave any packaging or replaced parts within the reach of children Seal the setting devices after each setting GS It is compulsory to connect the appliance discharge to a flue gas discharge pipe Failure to observe this rule may seriously put the safety of individuals and animals at risk Flue pipes must not be modified in any way GS The user in accordance with these instructions must keep the appliance in satisfactory running order and ensure reliable and safe operation The user is responsible for employing a qualified technician to carry out maintenance work on the appliance in compliance with local and national norms and the
16. if damaged if none of the previous cases is true replace the control board Replace the control board Invert phase and neutral If the mains frequency is different from 50Hz contact the electricity distributor if the mains frequency is 50Hz replace the control board grounding If the grounding is efficient replace the control board Replace the control board Replace the control board Replace the control board Replace the control board Restore the correct system grounding If the grounding is efficient replace the control board If the selector switches are in the correct position replace the control board 8 MAINTENANCE i To access the internal components 8 1 General 8 2 Assembling of the MASTER and SLAVE modules warnings the casing control panel __ Regular annual maintenance of the Use hooks F and rotate panels G heating systems is necessary for the The standard boiler is supplied with the following reasons casing assembled To vigna cha 77 electrical eto maintain high performances x connection boar and to menage tae heating 8 3 Disassembling Unscrew screws H and remove the system efficiently with low fuel H cover 7 7 me SS To access the module control board to obtain high operating safety I to keep y and accessing Pull the tongues L to the side environmental compatibility level i then pull the access cover towards high P the internal yourself while ope
17. instructions given in section 8 3 access the electrical board of the MASTER thermal panel set SWITCH No 1 on OFF and SWITCH No 5 on ON see figure 19 CAUTION Since the 0 10Vdc signal cables are subject to extremely low safety voltage they must run through ducts different from the 230Vac power supply cables 24 5 14 8 Digital output VVARNING contact n the connection terminal board of the thermal module there are terminals 1 and 2 see detail H shovvn in figure 23 Such terminals are connected to an internal relay contact VVhen a thermal element of the module stops vvorking the contact is closed Such information can be used by the installer to remote control an alarm in a visible and or audible area 5 14 9 Digital output FUNCTION contact n the connection terminal board of the thermal module there are terminals 3 and 4 see detail G shown in figure 23 Such terminals are connected to an internal relay contact The contact is closed when a thermal element has the burner on Such information can be used by the installer to control remotely an alarm in a visible and or audible area which should be interpreted as a thermal module on 5 INSTALLATION 5 15 Connecting the boiler to a water heater The boiler can be connected to a water heater with secondary exchanger The water connection must be carried out as per figures 9 and 10 For the electri
18. repeat air bleeding operations on both the boiler and the radiators 6 5 1 Self drainage Every time the appliance is powered a 2 minute self drainage procedure is started to bleed air from the system The procedure starts and stops the pump to better remove air 31 6 6 Checking the gas supply pressure and adjusting it if necessary The gas supply pressure must match that given in the table in chapter 9 at the end of this manual To check it proceed as follows close the gas cock 6 access the boiler internal components by following the procedure in section 8 3 loosen the pressure connection D see figure 26 connect a pressure gauge with a definition of at least 0 1 mbar 1 mmH20 open the gas cock check that the pressure does not exceed the value given in the table in chapter 6 under the heading Maximum gas supply pressure turn on the boiler and generate a request for heating rotate knob 9 shovvn in figure 1 to the maximum and make sure the room thermostat is in heating call status press buttons 40 and together for more than 10 seconds until is displayed press button gt until you display Now the boiler is forced to maximum power for 10 minutes Repeat the procedure for the SLAVE thermal element check that the pressure does not drop below the Minimum gas supply pressure indicated in the table in chapter 9 at the end of th
19. replace it if necessary check the integrity of the cables of the ionization current electric circuit If the flue gas discharge is on a vertical wall protect it with a windproof grill if the flue gas discharge is on the roof check that it is not on a reflux area and that the windproof chimney cap if present is really efficient Restore water circulation or replace the control board Replace the control board If the grounding is efficient replace the control board Replace the sensor if it is not within the correct values if the boiler efficiency is below 96 and the operating parameters are correct replace the primary heat exchanger and place a filter on the intake of the heating return fitting Replace the sensor if it is not within the correct values Replace the control board Replace the control board Replace the control board Replace the control board Replace the control board Replace the control board Replace the control board Replace the control board 7 USE L code L17 L18 L19 L20 L25 L32 L33 L45 L46 L47 Lock description Temperature difference between U1 and U6 Program error Gas valve flame heard for 10 seconds after closing the valve Gas valve flame heard before opening the gas valve U1 and U6 increase their temperature too fast Program error Fan rotation error Heating circuit loading time more than 10 minutes Heating circuit load repeated 16 times
20. system 2 CORROSION Corrosion is normally favored by the presence of oxygen by contact between different metals or by the presence of chlorides 3 DEPOSITS These are insoluble organic an inorganic substances SLUDGES PROCESS RESIDUES 5 6 Discharge of the thermal circuit To avoid continuous renewal of water and subsequent oxygen and limestone it is recommended to limit as much as possible every discharge of the thermal circuit 17 5 7 Expansion tank CAUTION Fit the system with a properly sized expansion tank in compliance with the national and local installation standards 5 8 Radiant panel type systems or low temperature CAUTION When installing the boiler in a low temperature system make sure the switch 6 SWITCHES is on ON see figure 19 With this setting the boiler will adjust the supply temperature between 20 C and 45 C No adjustment carried out from the control panel not even in climate adjustment mode will be able to supply water at a temperature of more than 45 C CAUTION If the boiler is installed in a radiant panel type system with plastic piping precautions must be taken against corrosion caused by water oxygenation make sure the system is made with plastic piping having oxygen permeability not greater than 0 1 g m3 at 40 C Should the pipe not meet these characteristics it is fundamental to isolate the radiant panel circuit from the boiler by means o
21. 1 Start up Before operating the appliance carry out the following operations 6 1 1 Instructing the user Instruct the user about the correct use of the appliance and of the system in general In particular Hand over the Installation and user manual and all documentation included in the packaging Instruct the user regarding the special measures for flue gases discharge specifying that they shall not be modified Inform the user on how to check the water pressure necessary in the system and on all necessary measures for filling and bleeding air Inform the user on how to correctly adjust temperatures controls room thermostats and radiators to save energy 6 1 2 Condensation discharge trap fillin The trap located inside the boiler see figure 1 detail 21 must be filled with water in order to create the head able to prevent flue gases from bleeding out of pipe D shown in figure 22 6 1 3 Filling up of the heating system If FILL appears on the display then the thermal module is powered it means that it is necessary to fill up the heating system By using only clean water coming from the water network proceed as follows slightly open all the cocks 26 as described in figure 1 open the supply cock of the system and wait until all the air is expelled from discharge cock 26 of figure 1 close all cocks 26 as shown on figure 1 and wait for the pressure of the therm
22. 23 or 24 Figure 22 Installation of the Polypropylene flue gas discharge system insert the detail G inside P insert detail F inside G Insert detail E in F N CAUTIONI The connect C and B and then insert temperature of the discharge pipe both in E during operations may reach 110 C connect A and B Insert protective heat insulating use brackets N and O to support sheathing if it has to pass through and direct the flue gas collector walls which are vulnerable to such NOTE bracket N must be temperatures installed on the right and bracket O must be installed always on the left connect a properly calculated chimney to the C output Protect the flue gas collector from direct sunlight as it is in polypropylene Horizontal sections must always be pitched by at least 3 towards the condensation drainage system The boiler comes supplied with a condensation collector which must be fitted to a discharge pipe see N 14 detail D CAUTION Since the flue gas is in polypropylene when exposed to sunlight it must be protected from UV radiation and possibly against the risk of frostbite A Collector closing terminal with condensation discharge B Long collector with inlet tee C Short collector with inlet tee D Condensation discharge trap E Intake with inspection F Chec
23. 50 40 30 20 Head kPa RIC28 2009_D3 34 10 500 1000 1500 2000 2500 3000 Flow rate l h Figure 3 Diagram of the system residual head for model DUAL 2 34 the three curves correspond to the three circulator speeds 70 60 50 40 30 20 Head kPa RIC28 2009 D4 50 10 500 1000 1500 2000 2500 3000 Flow rate l h Figure 4 Diagram of the system residual head for model DUAL 4 50 the three curves correspond to the three circulator speeds 10 4 OPERATION 70 60 50 40 90 20 Head kPa Figure 5 Diagram of the system residual head for model DUAL 6 70 RIC28 2009_D6 70 500 1000 1500 2000 2500 3000 Flow rate l h the three curves correspond to the three circulator speeds 80 70 60 50 40 30 Head kPa 20 3500 RIC28 2009 08 90 500 1000 1500 2000 2500 3000 3500 Flow rate l h Figure 6 Diagram of the system residual head for boiler DUAL 8 90 the three curves correspond to the three circulator speeds 11 4000 4 OPERATION 2 UOI ESUBPUOD BAJEA JOIN IY ZZ JOJOBUUODSIP lineipAH 02 dund Bunesy 61 p o2 Sl s uuodq 91 Ajddns waysks 44 uu s s 6
24. Boiler internal components 37 24 V connection terminal board 38 Cabinet cover 39 Sealed chamber closure 40 Burner sealed chamber porthole 41 Cascade control board 42 Connection panel cover 43 230 V connection terminal board 44 Circulating pump 45 Gas solenoid valve 46 Heat exchanger 47 Upper cover 48 Support brackets 7 4 OPERATION 4 1 Function and intended use of the appliance This product is a gas condensing appliance for central heating production If properly connected to a water heater see fig 9 and 10 it can also be used for civil use domestic hot water production Fit the boiler to the heating system by choosing to the most suitable characteristic residual curve head see fig 3 4 5 and 6 4 1 1 Hydraulic separator If the system is to be subject to a water flow higher than that suppliable by the pump it is necessary to place an hydraulic separator between the boiler and the system see figures 8 and 9 detail 20 4 1 2 Connection in series Boilers can be connected also in series according to the scheme shown in figure 10 4 1 3 Domestic hot water production In order to produce domestic hot water itis necessary to connect a water heater following one of the schemes shown in figures 9 and 10 To set the domestic water temperature follow the procedure in section 7 5 4 1 4 System types According to the model it
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26. OFF Minimum heating pressure pressure gauge inhibited or manual system supply ON Minimum heating pressure pressure gauge engaged or automatic system supply 4 OFF MWL or EBM fan ON FIME fan 5 OFF Combined boiler heating and d h w ON Boiler for heating onl 6 OFF Heating service operating between 30 C and 80 C ON Heating service operating between 20 C and 45 C 7 OFF Appliance TYPE change service inhibited ON Appliance TYPE change service enabled 8 OFF Supply temperature limited to 80 C ON Supply temperature limited to 87 C 7 11 Timing of the 7 12 Anti freeze 7 13 Energy various functions protection Saving In order to preserve the appliance better In order to reduce the energy waste the generated comfort and increase produced by the display 7 shown in energy savings we have introduced CAUTION figure 1 it is possible to set it so that it delay timings during operation These In order for the anti freeze stays off unless errors or adjustments timings are protection to be efficient it is are to be displayed To turn it off proceed Pump postcirculation every time the necessary to leave the appliance as follows room thermostat determines the end of connected to the gas and power access the Installer menu see an heating service the pump runs for supply and to set the two knobs 8 section 7 15 further 3 minutes and 9 shown in figure 1 to OFF G Heating delay every time a domestic On reaching a boiler
27. controlled by any external temperature controller see fig 10 detail 10 with 0 10Vdc analog output By connecting the output terminals 31 and 32 of the terminal board X2 as shown in Figure 16 detail O follow polarity the Combidens thermal module is self regulated according to the demand generated by the thermal controller NOTE A 100 ohm 0 25W electrical resistance is connected to terminal 31 and 32 which is to be cut off to enable the 0 10Vdc connection Settings for the 0 10Vdc signal transmission coming from the thermal controller are simple These are 0 2 Vdc voltage the thermal module is not connected to the thermal controller and it keeps working in an autonomous way 2 to 3 Vdc voltage for the thermal module it is the stand by control i e no heating request from the thermal controller The thermal module is connected to communication with the thermal control The controls on the MASTER thermal element instrument panel are disabled automatically 3 to 10Vdc voltage the thermal module causes the variation of the supply temperature between 20 C and 87 C The thermal module is connected to the communication with the thermal controller The controls on the MASTER thermal element instrument panel will still be disabled ATTENTION Before connecting the thermal module to the thermal controller it is necessary to carry out the following operations remove the casing following the
28. external temperature and supply temperature calculated temperature corresponds to the graphs shown in figures 32 and 33 In order to adapt the line to the different houses climatic conditions it is necessary to set all adjustment parameters according to the indications in the next sections 7 USE 7 8 1 Climatic adjustment precautions when adjusting To carry out a correct automatic supply temperature setting the line setting values of figures 32 and 33 which are suggested later shall be set immediately Should these values give no satisfying result then proceed with the necessary modifications considering that each parameter is to be adjusted gradually wait at least 24 hours after each variation to see the result the closer is the adjustment line to the real building needs the more comfortable will be the building heating and higher the energy savings by means of the knob 7 shown in figure 31 you can carry out some small corrections b as shown in figures 32 and 33 i e you can shift the line parallelism upwards or downwards in steps of 1 C up to a maximum of 10 C 7 8 2 Climatic adjustment parameter setting By using the user menu see section 7 14 set n U f 1 Line angle adjustable between 0 1 and 5 0 The suggested starting values are 0 6 for low temperature systems 1 6 for high temperature systems U b Minimum heating temperature adjustable b
29. freeze function active Boiler not locked out but in warning status turn OFF the domestic hot water to restore heating Should this not solve the problem contact a qualified technician Caution system pressure too low carry out the loading see section 6 1 3 Domestic water service on Heating service on Boiler locked out Press button Resed reset Should the lock out occur frequently please contact a qualified technician Boiler faulty Contact a qualified technician Self drainage procedure on see section 6 5 1 It will end in 2 minutes Antilegionella procedure on see section 5 15 1 It will end as soon as the water inside the water heater reaches a 60 C tem perature 7 16 Diagnostics During the appliance normal operation the display 7 shown in figure 1 continuously shows the appliance working status by means of the following indications DISPLAYING ON DISPLAY 7 SHOWN IN FIGURE 1 Boiler temperature C Boiler temperature C 01 Boiler temperature C Domestic hot water active for more than 120 minutes turn OFF the domestic hot water to restore heating Make sure that no cock is leaking Should this not solve the problem contact a qualified technician 02 Interruption of the communication between in series boilers No display Domestic water temperature C Heating temperature C Lock code see section 7 16 1 for decoding Error code see section 7 16 2 for decodin
30. matters stated in this manual We highly recommend arranging a regular annual maintenance contract with a qualified technician The manufacturer cannot be held responsible for any damage to people animals or property caused by incorrect installation or inadequate maintenance Before carrying out any cleaning or maintenance operation disconnect the appliance from the mains by using the specific switches Do not obstruct the intake discharge pipe ends Explosive or highly flammable products Do not store nor use explosive or highly flammable materials such as paper solvents paints etc in the same room as the appliance In case of breakdown In the event of a breakdown and or malfunctioning of the appliance disconnect it and do not attempt to repair it in any way whatsoever Contact only qualified technicians Should any part be replaced during repair make sure that only original spare parts are used Failure to observe the above may compromise the appliance safety Qualified technician A qualified technician has specific technical skills on components for electrical systems gas burning systems and for civil heating and hot water production systems for sanitary and hot water use Such personnel must have the legally required qualifications Technical drawings All drawings included in this manual relating to the electrical hydraulic and gas installation systems are to be considered purely indicative Al
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32. temperature is adjusted automatically by the external temperature sensor according to an algorithm shown in figures 32 and 33 The supply temperature corresponds to the calculated temperature By opening the room thermostat the heating supply temperature is reduced by a fixed value The boiler pump is always on When the Calculated temperature drops below the Minimum heating temperature the heating service ends It restarts automatically as the Calculated temperature rises again above the Minimum heating temperature 37 7 7 Thermostatic adjustment The boiler is factory set with parameter to 00 i e the boiler supplies hot water to the heating system at a fixed temperature which is adjusted via the knob 7 shown in figure 31 A room thermostat would act directly on the boiler inner pump to adjust room heating In order to take full advantage of the boiler performances we suggest you to use the knob 7 shown in figure 31 to adjust the temperature at a value which is just sufficient to obtain the desired room temperature Should the season temperature become colder gradually increase the set temperature value by means of the knob 7 Proceed in reverse order as the season temperature becomes warmer 7 8 Climatic adjustment Set the at Ho 01 by means of the Installer menu The heating supply temperature is adjusted automatically by the external temperature sensor The relationship between
33. the gas board from another room or from a neighbor s house Otherwise call the fire brigade 6 3 Gas type indicated for the boiler On the front of the boiler there is a label indicating the type and supply pressure of the gas to be used for the boiler The boiler can have the following two labels 30 2H G20 20mbar METHANE meaning that the appliance is set for use with gas type H of the second family methane at a supply pressure of 20 mbar 3P G31 37mbar L P G meaning that the appliance is set for use with gas type P propane also known as LPG of the third family at a fixed supply pressure of 37 mbar 6 4 Conversion of the appliance from methane to LPG or viceversa In order to change the gas follow these instructions keeping in mind that these operations must be executed on all the thermal elements of the module disconnect from the mains supply access the instrument panel see figure 35 move the switch 7 see figure 19 from position OFF to position ON Connect the power supply to the thermal module the display shows t g followed by a number using buttons C set the values as DUAL 2 34 methane 53 DUAL 4 50 methane 50 DUAL 6 70 methane 54 DUAL 8 90 methane 58 DUAL 2 34 Ipg 65 DUAL 4 50 Ipg 52 DUAL 6 70 Ipg 57 DUAL 8 90 Ipg 60 press the button eseb disconnect from power supply move the switch 7 see figure 19 on O
34. the user exited the menu If no button is pressed for more than 60 seconds the menu will be automatically exited If not confirmed using the button any datum variation will be lost The following parameters can be modified or consulted from this menu 7 USE PARAMETER Ui Uc U3 U4 US UG Ul UB cy rt F p CH br tn L 5 PS DESCRIPTION Boiler and heating supply tem perature measured by sensor U1 Not present in this boiler model Temperature of a possible water heater measured by sensor U3 External temperature mea sured by sensor U4 Measured ionization current Boiler temperature gauged by U6 sensor Flue gas temperature measured by sensor U7 Return temperature measured by sensor U8 Type of basic setting of the control board Status of room thermostat contact Measurement of fan rotation speed Power set for heating service Operating mode of the heating service Reaction to the external tem perature variations Angle fulcrum of the climatic adjustment line Temperature reduction due to the opening of the room thermostat Boiler knobs status Energy saver of display 7 shown in figure 1 Parameter not available for this boiler model DISPLAYING ON DISPLAY 7 SHOWN IN FIGURE 1 Value in C cannot be changed Value in C cannot be changed Value in C cannot be changed Value in C cannot be changed can be displayed only if t
35. 0 E51 Lock description Wrong temperature reading Circuit of the water heater temperature sensor U3 short circuited Circuit of the boiler temperature sensor U6 short circuited E2prom memory damaged Flame with gas valve closed Replace the gas valve Phase and neutral inverted Mains frequency different from 50Hz No ground connection Have the system grounding Wrong temperature reading Wrong temperature reading Wrong temperature reading Wrong temperature reading Program error or inefficient grounding Boiler TYPE selection error Reset button pressed too often in a short time Checking Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Have the system mains frequency checked checked Restore the correct system Have the system grounding checked Check the SWITCHES as described in section 7 10 48 Solutions Replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit
36. 2 0694BR1222 69 6 90 6 0 8 0 68 0 87 8 72 4 93 6 97 8 97 50 104 104 5 9 7 9 6 2 8 32 98 99 108 2 110 10 104 106 kk kk kok ok 1 5 1 5 0 2 0 2 0 5 0 5 0 1 0 1 7 36 9 51 5 40 6 99 20 20 37 37 15 15 25 25 30 30 45 45 8 2 6 6 7 2 5 4 4 4 4 4 11 11 11 11 40 70 40 70 95 95 80 80 20 20 4 4 1 1 230 230 50 50 250 380 IPX5D IPX5D 80 80 40 40 45 curve 0 5m 90 curve 1m 15 15 ppm 15 8 5 9 0 8 5 9 0 10 10 5 10 10 5 118 152 60 60 8 7 11 4 4 98 98 10 EC COMPLIANCE DECLARATION The undersigned company COSMOGAS S r L with registered offices in Via L Da Vinci 16 47014 Meldola FC ITALY DECLARES under its own exclusive liability that the product WARRANTY No GAS BOILER MODEL MANUFACTURE DATE forming the subject matter of this declaration is compliant with the model described in the type Examination Certificate CE with reference to the table headed EC type certificate PIN in chapter 9 and in accordance with the provisions of the following Directives Gas Appliances 2009 142 EC ex 90 396 EEC Efficiencies 92 42 EEC Low Voltage 2006 95 EC Electromagnetic Compatibility 2004 108 EEC The warranty number matches the serial number This declaration is issued in accordance with that established by said Directives Meldola FC ITALY Date of manufacture 60 11 MENU FORCED BY SWITCH 7 Changing these parameters m
37. 412 Decree D M dated 12 04 96 Presidential Decree dated 21 12 99 no 551 Legislative decree dated 19 08 05 no 192 Legislative decree dated 21 12 06 no 331 Standard CEI 64 8 2 GENERAL INFORMATION 2 1 Introduction Congratulations You have effectively purchased one of the best products on the market Every single part is proudly designed built tested and assembled in the COSMOGAS factory thus guaranteeing optimum quality control Thanks to the on going research carried out by COSMOGAS this product has been conceived and is DUAL X XX now considered to be the best in its class with regards to environmental protection as it belongs to class 5 less polluting as established by the UNI EN 297 and EN 483 standard and has a high output 4 stars as per EC directive 92 42 EEC Great importance was also given to the end of the appliance life All components can be easily separated in homogeneous elements that can be fully recycled 2 2 Description of models 2 34 Boiler with modulating heat input between 2 5 and 28 kW 4 50 Boiler with modulating heat input between 4 4 and 51 kw 6 70 Boiler with modulating heat input between 6 and 69 6 kW 8 90 Boiler with modulating heat input between 8 and 90 kW Gas condensing boiler for indoor and outdoor with sealed chamber and pre mix burner for central heating 2 3 Manufacturer COSMOGAS srl Via L da Vinci 16 47014 Meldola FC It
38. FF connect to power supply checking gas supply pressure following instructions on section 6 6 set the level of CO2 following the instructions in section 6 8 press button to bring the boiler back to normal operating conditions highlight the new settings on the appliance 6 START UP C Service pressure connection D Supply gas pressure inlet E CO2 adjusting screws Maximum power F CO2 adjusting screws to maximum power Figure 26 Gas valve 6 5 Start up open the gas cock povver to the boiler if the display shows E 21 it means that the phase neutral polarity has not been observed Exchange them at start up the display shows a F for 2 minutes during which the system is bleeded If you want to bypass this phase just press the and buttons together until the F begins to flash Then press the RESET button rotate knobs 8 and 9 shown in figure 1 to the desired temperature the heating service starts only when the room thermostat calls for heating If the external temperature sensor is connected check that the calculated temperature is greater than the minimum heating temperature see figure 32 if the pump operation indicator see section 7 16 is on and the pump see figure 1 detail 44 is not running it is necessary to unlock it if the pump warning light see section 7 16 is on and the radiators do not heat up
39. Instructing4he Usef u iaia 30 6 1 2 Condensation discharge trap filling Su aa aaa asas EAEE EENES 30 6 1 3 Filling p of the heating system u a aaa 30 6 2 General warnings concerning gas SUpPplY nnkatuassuauayusciasququqaana ANRETT EERE 30 6 3 Gas type indicated for the boiler ssaa dalai ia aio ie 30 6 4 Conversion of the appliance from methane to LPG or 30 2 Table of contents 6 5 Staft 0000000800 0000 0 000 0000000 31 6 5 1 Self drainage i reina 00 0 0 31 6 6 Checking the gas supply pressure and adjusting it if necessary 31 6 7 Checking the comburent air pressure ii 32 6 8 Checking CO2 level and adjusting it if necessary a rnsssssrssssssrsssssssssssssa 33 6 9 Adlusting the heating capacity iaia etic de ya q l edo ea ly 34 35 T A Warnings 0040500000 35 2520011207 AAT 36 7 3 Precautions against freezing trti tiaina ranas i Ea ENEE NERES AEAEE AEEA KAEA ARE ETENE TE NERENN 36 TA Remote control om req est u u label aaa 37 7 S Adiusting the domestic water SySt m i uuu uuu ii 37 f 0 Adjusting the heating systemM errare dialer 37 Y ThermostaticadjUsimenti rsa ia 37 f 8 Climatic adjustment fia halia leali GG ai ee 37 7 8 1 Cli
40. KEY to figure 34 B RESET button M z A 107210m0 C Figure 34 Remote control Key to figures 32 and 33 OA Line inclination Ob Minimum heating temperature Oc Maximum heating temperature br Fixed point line angle fulcrum b Line parallel shift actionable by means of the knob on the control panel A Heating temperature knob C Domestic hot water temperature knob D Green led see section 7 4 for details E Red led see section 7 4 for details 7 USE 7 10 Thermal element settings SWITCHES The appliance can be set in different architectures by means of a single control board detail 12 in figure 1 To this purpose inside the control board there is a series of electric straddles see figure 19 detail D identified by the writing SWITCHES whose positioning ON or OFF determines the appliance operating mode CAUTION Changing these straddles may cause malfunction of the boiler and thus of the system Therefore only a qualified technician having a detailed knowledge of the appliance and of the system operation should change them SWITCHES Position Description 1 OFF Appliance with instantaneous production of D H W ON Appliance with production of D H W by means of a water heater 2 OFF Appliance with instantaneous production of D H W ON Position not available for this series of appliances 3
41. TT 2 a Q L 2 ZS 8 TO fim 1 k in i 3 ii 2 III Jy L LL I L J URL ke J 0 2 69 OVAOE QWEZOSLL vt lt gt 5 INSTALLATION 5 1 Opening the packaging The appliance is supplied in a cardboard packaging Open it up following the instructions given on the closing flaps 300 o E 2 x A N D 200 LL 5 2 Dimensions and minimum clearance distances Leave some free space around the boiler for installation or maintenance operations as shovvn in figure 11 5 3 Choosing the place of installation Figure 11 Minimum clearance distances CAUTION The appliance must always be installed with its own casing It can be installed indoor or outdoor in a partly protected place see figure 15 so that it is not directly exposed to weather agents like rain hail or snow 100 100 CLOGS 300 CAUTION 178 385 eee 267 _ If the appliance is installed in a geographic area 463 with high freeze risk the appliance shall always running T ml me H b CAUTION III The boiler must be installed exclusively on a solid vertical wall which can bear
42. al module to reach about 1 5 bar FILL appears on the display check that there is no water leaking from the fittings bleed the radiators Check the pressure gauge reading of the boiler once again If it has dropped re fill again until it reads 1 5 bar LN usan The addition of any chemical substance such as anti freeze must be carried out according to the product instructions These substances must never be inserted directly into the thermal module 6 2 Generalwarnings concerning gas suppl When starting up the boiler for the first time have a qualified technician check the following That the boiler is powered for the type of fuel it is designed for That the gas supply pressure with boiler on and boiler off is within the maximum and minimum values given in the table in chapter 9 at the end of the manual That the gas supply system is provided with all safety devices and controls required under current national and local standards That the flue gas discharge terminal and the comburent air intake terminal are free from any blockage That the connection of the condensation discharge is connected CAUTION If you smell gas A Do not use any electrical appliance including telephones or any object which might cause sparks B Immediately open doors and windows to create a current of air to rapidly clear all gas from the room C Immediately call a qualified technician or
43. aly Tel 0543 498383 Fax 0543 498393 www cosmogas com info cosmogas com 2 4 Key to symbols used CAUTION Danger electric shock failure to observe this warning may compromise the smooth running of the appliance or cause serious damage to individuals animals or property General danger Failure to observe this warning may compromise the smooth running of the appliance or cause serious damage to individuals animals or property 5 Symbol indicating activity Symbol indicating important information 2 5 Maintenance Regular annual maintenance of the appliance is recommended for the following reasons 6 to maintain high performances and manage the heating system efficiently with low fuel consumption to obtain high operating safety to keep the combustion environmental compatibility level high Offer a regular maintenance contract to your customer 2 6 Warranty See chapter 15 3 MAIN COMPONENTS 4221 4om0_2 10 11 oe S 12 13 1 One way flue gas valve 2 MASTER thermal element 3 Combustion connection for analysis 4 Burner porthole 5 SLAVE thermal element 6 Air gas collector 7 Display 8 Domestic hot water temperature and start knob active only on the master 9 Heating temperature and start knob active only on the master 10 Single thermal element switch 11 Thermal el
44. and maximum power It is possible to force the appliance operation to the minimum or maximum power both in heating and in domestic water service Proceed as follows generate a request for the service you want to force heating close the room thermostat and rotate knob 9 shown in figure 1 to the maximum domestic water rotate knob 8 shown in figure 1 to the maximum and open the hot water cock completely press buttons and together for more than 10 seconds until is displayed press button 3 until the display shows to force heating to the minimum power to force heating to the maximum power to force domestic water to the minimum power to force domestic water to the maximum power press button Reset bring the boiler back to normal operating conditions 8 9 4 Verifying the ionization current During the minimum and maximum power verifications see section 8 9 3 the display shows the letter t or S corresponding to the checked service and at the same time the ionization current value on the lower part of the display To value 30 corresponds a 1 uA current to value 99 corresponds a 5 5 uA current Such value shall always be comprised between 75 and 80 8 MAINTENANCE Tab sonda caldaia Figure 40 Water sensor curve Cc 100 5 lt x 9071 80 70 60 50
45. and water piping is not used as earth plates for the electric or telephone system This piping is completely unsuitable for this purpose and in addition could rapidly lead to serious corrosion damage to the boiler piping and radiators CAUTION The boiler has no protection against lightening strikes 21 R1 100 ohm 5 INSTALLATION 0 25W S 485 US e a eal 103611m0_c eb 5 14 1 Connecting the power supply cable To connect the remote control cable to the power supply proceed as follows refer to figure 16 use a three pole cable with double insulation and a minimum section of 1 5 mm2 disassemble the boiler casing following the instructions in section 8 3 and access the electrical terminal board lay the power cable C as shown in figure 16 strip the cable being careful to leave 1 X2 Mpa e 2 FN AL the earth wire yellow green 20 mm longer than the other 2 connect the yellow green cable to the earth terminal connect the brown cable to terminal L1 connect the blue cable to terminal N CAUTION Should the phase conductor L1 be inverted with the neutral conductor N the boiler will be locked out E21 CAUTION If the system grounding is not efficient the boiler will be locked out E23 PR2 FN AL X1 230Vac Terminal board AL Output for warning signal it activates each time that a thermal element is
46. are with the room mark holes for the wall dowel plugs and the hydraulic fittings drill the holes A and insert the wall dowel plugs C secure support bracket B by using screws D e Hang the boiler to the hooking F by means of the holes E Make the water connections 5 11 Gas and water connections The standard boiler is supplied with the fittings shown in figure 14 where A heating supply pipe 1 1 2 B gas fitting 1 C heating return pipe 1 1 2 D condensation discharge 50 Figure 14 Gas and water connections 19 5 INSTALLATION Figure 15 Example of partly protected place During installation distances A and B shall be calculated in order to prevent rain from reaching the boiler 120 5 12 Condensation discharge The boiler is fitted with a trap for condensation removal see figure 1 detail 21 and combustion residues release prevention whose end corresponds to pipe D shown in figure 14 This end must be conveyed into another odor trap to prevent smells from returning to the room In particular the condensation drainage system must for residential rooms and office rooms with more than 10 users it can be connected to the domestic drainage system by means of a special trap wit
47. at the ionization current value is greater than 60 follow the procedure in section 8 9 4 Check that the ionization current value is greater than 60 follow the procedure in section 8 9 4 Check that the flue gas discharge is properly protected to prevent obstructions caused by wind gusts Check that the pump is working Check the grounding of the appliance Check that the electrical resistance of the flue gas sensor corresponds to the graph in section 8 10 check that the boiler efficiency is greater than 96 as necessary Check that the electrical resistance of the flue gas sensor corresponds to the graph in section 8 10 45 Solutions If the supply pressure is not correct restore it by operating upstream of the appliance if the comburent air pressure is not correct remove any possible obstruction from the comburent air intake flue gas discharge circuit if current to the gas valve is not 230Vac replace the control board if the electrical resistance of the gas valve is not 0 88 Kohm and 6 59 Kohm replace the valve If the ionization current is lower than 60 check the CO2 follow section 6 8 and restore the correct value check the ionization glow plug and replace it if necessary check the integrity of the cables of the ionization current electric circuit If the ionization current is lower than 60 check the CO2 follow section 6 8 and restore the correct value check the ionization glow plug and
48. ature if possible turn the knob 11 shown in figure 31 As soon as you touch the knob flashes on display 7 shown in figure 1 and the set temperature is displayed The domestic water system temperature range is between 45 C and 70 C 7 6 Adjusting the heating system In case a thermoregulator is present refer to the relevant instructions Otherwise using the parameter in the Installer menu see section 7 15 you can select different operating modes for the heating service CH 00 Thermostatic adjustment the heating system supply temperature is adjusted manually by rotating the knob 7 shown in figure 31 By opening and closing the room thermostat the boiler pump is stopped or started accordingly in order to adjust the room temperature CH 01 Climatic adjustment the heating system supply temperature is adjusted automatically by the external temperature sensor according to an algorithm shown in figures 32 and 33 The supply temperature corresponds to the calculated temperature By opening and closing the room thermostat the boiler pump is stopped or started accordingly When the Calculated temperature drops below the Minimum heating temperature the heating service ends It restarts automatically as the Calculated temperature rises again above the Minimum heating temperature CH 02 Climatic adjustment with room compensation the heating system supply
49. ay cause malfunction of the boiler and thus of the system Therefore only a qualified technician with the necessary detailed knowledge can change them Selecting the boiler basic settings Selecting the mains frequency and voltage and the temperature unit of measurement C o F Selecting the domestic water operation with micro accumulation with water flow switch micro accumulation and water flow switch Setting the battery sequence 00 base boiler 01 master 02 slave no 1 03 slave no 2 On slave ri SWITCH 7 ON LI LIVE j 5 N cere 55 m RESET RESET W n ziz 5 r lhe 1 LL E L 2 r L I i days 2 VI m MI 103322m0_d Settings t g shall assume the values indicated in section 6 4 5 L can assume the following values 00 230Vac 50Hz C 01 230Vac 50Hz F 02 120Vac 60Hz C 03 120Vac 60Hz F d5 can assume the following values 00 Domestic water with semi accumulation 01 Domestic vvater controlled by a vvater flovv svvitch SWITCH 7 OFF 02 Domestic water controlled by a water flow switch and equipped with temperature sensor U3 on the semi accumulation f L L US can assume the following values 00 Boiler with normal operation 01 Battery master boiler the mastering boiler 02 Battery slave boiler 1 first boiler guided by the master one 03 Battery slave boiler 2 second boiler gu
50. c water temperature by 77 only It can assumo values beween 20 C anid means of the knob 8 shown in figure 1 Display only It can assume the values indicated in sec Displaying the last registered error tion 7 16 2 Display only It can assume the values indicated in sec Displaying the last block occurred tion 7 16 1 mimi 0 ca ca 41 7 USE 42 7 15 Installer menu LN caurion Changing these parameters could cause malfunction of the boiler and thus of the system Therefore only a technician having a detailed knowledge of the appliance should change them Thanks to the boiler microprocessor this parameter menu is available to the technician for the analysis of the operation and of adaptation of the appliance to the system As you access the Installer menu the parameter display 7 shown in figure 1 flashes thus indicating the successful mode switch To access the Installer menu just hold the button for 12 seconds until the parameter U is displayed by continuously pressing and releasing the button the parameter list is scrolled Once the parameter has been identified it can be Co using the button CH or i By ressing and releasing the button the modified parameter is confirmed and one passes on to the next parameter Once the end of the menu has been reached with the last the display 7 shown in figure 1 stops flashing thus indicating that
51. cal connection proceed as follows refer to figure 16 unless otherwise specified disconnect the boiler from the power supply access the internal components by following the instructions in the specific section 8 3 move switch 1 to ON see figure 19 detail D move switch 5 to OFF see figure 19 lay a bipolar electrical cable with a minimum section of 1 5mm2 which leads from the boiler to the temperature sensor of the water heater and connect it on the boiler to terminals I see figure 16 connect the other end of the cable to the temperature probe of the water heater insert the temperature sensor probe in the water heater socket lay a three pole electrical cable with a minimum section of 1 5mm2 which leads from the boiler to the water heater loading pump Figure 19 Boiler adjustment switches 25 connect the cable to the water heater pump contacts connect the other cable end to the boiler detail D shovvn in figure 16 considering that the terminal 10 is the domestic vvater control the terminal 11 is neutral CAUTIONIII Since the cables of the vvater heater temperature sensor are subject to extremely low safety voltage 24Vcc they must run through ducts different from the 230Vac diverter valve power supply cables 5 15 1 Antilegionella If the b
52. cal standards in force the running and or maintenance of the system is not carried out in compliance with these instructions and or national and or local standards in force damage to the product has been caused by voltage fluctuations damage to the product has been caused by the use of too hard too acid or over oxygenated water damage to the product has been caused by thermal shock defective chimneys and or flue gas discharge and air intake piping the product has anomalies not dependent on COSMOGAS the boiler has been tampered with due to adaptation work repair work and replacement work using non original parts the repair work has been carried out by unauthorized personnel The warranty certificate is not forwarded to COSMOGAS within 15 days from the date of 1st start up COSMOGAS cannot be held responsible for any accident including those caused by the user any compensation which does not concern boiler parts with recognized manufacturing defects being excluded Court of competent jurisdiction Forli ITALY WARRANTY CERTIFICATE FOR COSMOGAS APPLIANCES Warranty valid 24 months TO BE COMPLETED BY THE INSTALLER The appliance has been installed by qualified technicians in possession of the legally required qualifications in compliance with the instructions contained in this manual and national and or local standards in force INSTALLER Stamp Date Remarks
53. ce the remote control is connected all operations to set the temperature of the heating and domestic hot water should be carried out directly on it as specified in Chapter 7 4 To connect the remote control cable proceed as follows refer to figure 23 use a bipolar electrical cable with a minimum section of 1 5 mm2 which leads from the thermal boiler to the remote control The cable must be shielded with an earthed shield on the side of the thermal module The maximum length permitted is 100 m disassemble the boiler casing and access the electrical terminal board following the instructions in section 8 3 connect the 2 ends of the cable to terminals 27 and 28 of the terminal board X2 see figure 16 detail N connect the other two ends of the cable to terminals 3 and 4 of the remote control CAUTION Since the remote control cables are subject to extremely low safety voltage 24Vcc they must run through ducts different from the 230Vac power supply cables 5 14 6 Communication among thermal elements Thermal elements called SLAVE are controlled by the MASTER thermal element via data connection BUS VVhen a SLAVE thermal element for whatever reason loses communication with the MASTER thermal element after 15 minutes an error occurs and its display shows A 02 5 14 7 External thermal controller For better management and rational use of energy the Combidens thermal module can be
54. e manual If the supply pressure does not fall within the above values operate upstream of the appliance to bring the pressure back within the maximum and minimum range Once checked close the pressure connection D see figure 26 and verify whether there is any gas leakage 6 START UP Figure 27 Pressure connection of comburent air Figure 28 Control of comburent air pressure 32 6 7 Checking the comburent air pressure As the boiler air gas ratio is factory set the gas pressure on the burner is checked indirectly i e the comburent air pressure inside the boiler is checked and must correspond to what is indicated in the table in chapter 9 under the heading Comburent air pressure To check the pressure proceed as follows refer to figures 27 and 28 use a differential pressure gauge with a precision of at least 0 1 mbar 1 mmH20 close the gas cock remove cap B 6 loosen the pressure connection screw C insert a pipe F going from the pressure gauge to the pressure connection C passing through the opening of cap B as per figure 28 remove cap A from the pressure connection and connect the differential pressure gauge the connection shall be made as per figure 28 by meticulously observing the pressure polarity displayed on the pressure gauge reassemble the casing 39 shown in figure 1 This is fundam
55. e on remote control on request TS ISPESL safety thermostat VE Fan VG1 Gas valve V3E External diverter valve for domestic water heating 8 MAINTENANCE TAI 103611m0_a X2 25 X2 26 11 t2 BUS SLAVE CU 02 Y8 1 X2 27 X2 28 1 21351415161718 9 tol1 11 2 t 31 4115116 11 12 BUS SLAVE CU 03 A n U2 SB U3 300V fall null Holl supply 9 v Holl_sensor 300V DC 1 V3V 230VAC MAX 30W VE 1550 300V DC 55 8 MAINTENANCE 8 14 Multiwire wiring diagram TS N m x Marrone K1 00 o Nero K2 2 Rosso K3 Bianco K4 2 o Giollo verde K5 2 mi Giqllo verde s z au K6 8 g 5 28 ls o 54 8 Mel MOT Marrone K7 K8 Grigio K9 K10 K11 K12 K13 K14 Bianco Giallo Rosa Verde Rosso Marrone Blu Bianco Bianco Nero 100 ohm 0 25W Nero R1 34 33 32 31 30 29 28 27 26 25 24 23 22 21 2 For a correct reading of the vviring diagram vve SK have indicated the K references follovved by a number see example 108 2 5 the side in order to identify the correct cable continuation on the following page Key see key to figure 42 Figure 43 Multi wire wiring diagram 56 8 MAINTENANCE Elemento termico SLAVE C
56. e sliding of the pairings it is recommended to lubricate with soapy water DO NOT USE PRODUCTS OIL OR GREASE WITH HYDROCARBONS THEY CAN DESTROY THE SEAL Assemble details A B and C Insert the assembled terminal within the detail D Insert it in the detail E NOTE Detail C is 50 cm high If the thermal module is installed in a windy area it is advisable to shorten it by at least 35 cm 5 INSTALLATION 5 16 2 Polypropylene flue gas collector system The standard appliance is not supplied with fittings for connecting flue gas discharge outlets air intakes A special kit is available on request for connecting the boiler to a Polypropylene flue gas discharge system to be installed as shown in figure 22 as follows pour 100 cm3 of water in the P opening in order to fill up the trap 21 of figure 1 NOTE the flue gas discharge seals are made of EPDM rubber In order to improve the sliding of the pairings it is recommended to lubricate them with soapy water DO NOT USE PRODUCTS OIL OR GREASE WITH HYDROCARBONS THEY CAN DESTROY THE SEAL prepare the fitting E cutting it at height A according to the scheme in figure 23 or 24 depending on the side from which fumes are to be discharged respecting height A the flue gas collector is tilted by 3 and the distances of the flue gas collector will correspond to the height indicated in figure
57. e systems or the flue gas safety thermostat activates locking out the boiler L06 This may happen also in case you perform the analysis in domestic hot water mode when the domestic water flow is low or the domestic cold water temperature is very high To obviate this problem set the heating power according to the real needs of the system as indicated in the following section and carry out the test analysis of CO2 or combustion efficiency setting the above mentioned forcing to t letter t with dash or S letter S with dash for domestic water 6 START UP BOILER MODEL 103122m0_a power 2 34 4 50 6 70 8 90 88 97 84 92 80 86 76 81 72 16 68 96 70 64 89 65 60 81 59 56 74 54 52 67 49 48 95 59 43 44 85 52 38 40 75 44 32 36 65 37 27 32 55 30 22 28 92 45 22 16 24 76 35 15 11 20 60 25 7 5 16 44 15 12 28 5 8 12 Figure 30 P values to obtain the correspondent power needed by the system to be set on both thermal elements 34 6 9 Adjusting the heating capacity To best exploit the boiler potentialities we suggest to set the maximum heating power to the real needs of the system Proceed as follows access the Installer menu see section 7 15 press button until the parameter is displayed using buttons CE and set the valu
58. e to the system power needs according to the table shown in figure 30 press the button Perform the same procedure on both thermal elements Example using the radiator and heat dispersion calculation the installer realizes that the system needs only 60kW choose the column corresponding to the boiler model e g for DUAL 8 90 choose column 8 90 cross it with the Necessary power column corresponding to 60kW and you get a value of 59 set the parameter to value 59 on both thermal elements by following the above procedure 7 USE 35 7 1 Warnings for use Check the system pressure on the water gauge frequently and make sure that the indication is always between the minimum and maximum levels specified in section 9 when the system is cold Should pressure drops occur frequently ask a qualified technician to check the system for leaks GS Every time you reopen the gas cock wait a few minutes to check whether there is gas in the room If not proceed with the thermal module start up Do not touch the flue gas discharge during and after usage of the thermal module for a certain period as they may still be hot Do not wet the thermal module with water or other fluids Do not lay any object onto the thermal module Forbid use of the thermal module to children and unskilled people 7 USE 1 Parameter display 2 Display of values adopted by parameters
59. ement wiring board Figure 1 Boiler internal components 14 2 1 e DI 0 6 t 6 24 12 Thermal element control unit 13 Safety valve 14 Return temperature sensor U8 15 Spark generator 16 Start up cables 17 Left ignition glow plug 18 Right ignition glow plug 19 Burner 20 Detector glow plug 21 Condensation collection trap 22 Boiler drain cock 23 Condensation discharge pipe 24 One way valve 15 16 17 18 19 20 21 22 14 22 23 3 MAIN COMPONENTS 25 48 26 47 27 ee Z AG 28 29 45 30 44 31 o 32 33 e 34 2 Q Y li 43 35 EsMOGAS 22 36 37 41 42 38 39 40 25 Flue gas discharge connection 26 Thermal element manual air discharge 27 Flue gas safety sensor U7 28 Thermal element heating supply sensor U1 29 Heating safety sensor U6 30 Air collector 31 Blower 32 Air gas mixer cock 33 Boiler supply sensor U2 34 Pressure switch 35 Water gauge 36 Connection electrical panel Figure 1
60. ental to have a reliable reading turn on the boiler press buttons and G together for more than 10 seconds until is displayed novv the fan is forced to the maximum povver for 10 minutes vvith burner off compare the pressure value on the pressure gauge to the value indicated in the table in chapter 9 Comburent air pressure should pressure be at a lower value then check for obstructions in the comburent air flue gas discharge circuit press button to bring the boiler back to normal operating conditions after carrying out the check reassemble the unit 6 START UP Figure 29 Combustion analysis connection 40 6 8 Checking 2 level and adjusting it if necessary Under normal operating conditions and at altitudes below 1 000 m the boiler has a CO2 level carbon dioxide in flue gases which is given in the table in chapter 9 at the end of the manual A different value may lead to malfunctioning To check that value it is necessary to carry out a combustion analysis Proceed as follows connect a combustion analyzer to the special connection on the flue gas discharge connection B shown in figure 29 generate a heating request otherwise open the domestic hot water cock to the maximum press buttons 4 and together for more than 10 seconds until is displayed press button o until the display shovvs of heating re
61. ere it is partly protected from rain snow and hail such as balconies porches etc see figure 15 for an example GS Refer to figure 11 for minimum clearance distances for installation and future maintenance N CAUTION Do not expose the appliance to external temperatures below 0 C It can be exposed to temperatures down to 10 C if properly running 4 OPERATION 109218m0_p Figure 2 DUALDENS hydraulic diagram Key 1 MASTER element 2 SLAVE element 3 Comburent air intake 4 Flue gas discharge 5 Sealed chamber 6 Manual outlet valve 7 Burner 8 Fan 9 Gas valve 10 Condensation collection trap 11 Pump 14 Pressure gauge 17 Safety valve 21 Condensation discharge 22 Heating circuit supply 24 Gas supply 26 Heating circuit return 37 Check valve 44 Drain cock 45 Flue gas sensor U7 46 Thermal element supply temperature sensor U1 47 Safety temperature sensor U6 48 Return temperature sensor U8 49 Boiler supply temperature sensor U2 50 MASTER module pressure switch 51 SLAVE module pressure switch 4 OPERATION 4 3 Characteristic curves of the heating system residual head The residual head on the boiler connections is indicated in the graphs in figures 3 4 5 e 6 for the different flow rates 60
62. espond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board 7 USE E code E16 E17 E18 E19 E20 E21 E22 E23 E30 E31 E32 E33 E42 E5
63. etween 20 C and 60 C The suggested starting values are 30 C for low temperature systems 40 C for high temperature systems U C Maximum heating temperature adjustable between 30 C and 80 C The suggested starting values are 45 C for low temperature systems 80 C for high temperature systems By using the installer menu see section 7 15 set f Reaction of the supply temperature to the external temperature variations Adjustable between 1 C and 10 C A low reaction value allows you to have a constant house temperature which is however slow in reaching the heating capacity and in reacting to external temperature variations A high reaction value ensures that the heating capacity is reached fast even though temperature oscillations inside the house may occur We suggest to keep this value between 1 and 2 Fixed point is the heating supply temperature when the external temperature is 20 C It is also called Fixed point because it is the fulcrum of the line angle The suggested starting values are 33 C for low temperature systems and 50 C for high temperature systems 7 8 3 Climatic adjustment adapting to the different climatic zones The previously suggested values are valid for houses having a fair insulation and for climatic zones whose external temperature calculating the thermal requirements is 5 using these data the correspondence to t
64. f a plate heat exchanger 5 INSTALLATION 18 5 9 Gas CAUTION It is forbidden to operate the boiler with a gas type different from the stated ones CAUTION Check that the gas type and the supply pressure are those required for the boiler There are two possible situations A the gas type and the supply pressure match those of the boiler setting In this case proceed with connections B the gas type and the supply pressure do not match those of the boiler setting In this case the boiler shall be converted to the type of gas and the supply pressure matching the available ones A special conversion kit is available on request from your salesman or directly from COSMOGAS Before installation we recommend thorough flushing of the gas supply pipe an on off cock must be installed on the gas supply pipe amp to avoid damage to the appliance gas control unit carry out a leak test at a pressure of no greater than 50 mbar if testing of the gas system must be carried out at a pressure of more than 50 mbar use the cock situated immediately upstream from the boiler to isolate the same from the system Figure 12 shows the position of the appliance gas fitting The sections of piping making up the gas supply system must always provide sufficient gas to cover the required maximum 5 INSTALLATION 5 10 Assembling the appliance Refer to figure 13 ensure that the template is squ
65. g Boiler temperature C Water heater temperature C DISPLAY detail 7 shown in figure 1 2 1 Parameter display 2 Display of values adopted by parameters 3 Burner status indicator On burner on flashing burner off OO On heating active Off heating off 44 4 Domestic water service status indicator On domestic hot water active Off domestic hot water off 5 Decimal indicator of the displayed value 6 Heating service status indicator 7 USE 7 16 1 Diagnostics L locks L code L01 L02 L03 L04 105 106 107 108 109 110 112 113 114 115 116 Lock description No flame detected after three consecutive start up attempts Flame lost three times Boiler temperature exceeds 95 C Gas valve control relay Safety relay or earth inefficient Flue gas sensor exceeds 110 C Flue gas sensor electric circuit broken Spark generator relay RAM memory E2prom memory damaged E2prom memory damaged Program error Program error Program error Program error Checking Check gas supply pressure see section 6 6 sparks on the ignition electrodes see section 8 6 correct pressure of the comburent air see section 6 7 220Vac power supply to the gas valve electrical resistance of the two gas valve coils of 0 88 Kohm and 6 59 Kohm If the burner turns on and off after a start up attempt check th
66. h separation meant to prevent system pressurization trap ready inside the boiler and the return of sewer smells external trap If the office room has less than 10 users install a condensation neutralizer before the system connection to the domestic drainage check condensation acidity value and quantity in chapter 9 be made with a proper diameter pipe be installed so as to avoid fluid freezing Outdoor sections should therefore be checked discharge into gutters or downpipes is forbidden slope continuously towards the point of discharge avoid high points that may put the piping under pressure 5 13 Safety valve The thermal module is protected against overpressure by a safety relief valve set at 3 5 bar see figure 1 detail 13 The safety relief valve is connected to the condensation discharge An additional safety valve properly sized can be required by enforced national and or local regulations see figures 7 8 and 9 detail 2 5 INSTALLATION Min 200 mm 5 14 Electrical connections General information CAUTION The appliance is only electrically safe when it is correctly connected to an efficiently earthed system carried out in compliance with current safety standards This is an essential safety requirement which must be checked If in doubt have the electrical system thoro
67. he climatic adjustment is active as specified in section 7 8 Value from 0 to 99 30 corresponds to a current of 1uA 99 corresponds to a current of 5 5 uA cannot be changed Value in C cannot be changed Value in C cannot be changed Value in C cannot be changed Can be changed following the instructions in the gas change kit 00 open contact heating service off 01 closed contact heating service on Value in g 1 x100 rpm 100 cannot be changed Adjustable following to the instructions of section 6 9 Can be changed 00 thermostatic adjustment see section 7 7 01 climatic adjustment see section 7 8 02 climatic adjustment with room compensation see section 7 8 5 Can be changed from 1 to 10 active only with climatic adjustment See section 7 8 2 on how to adjust it Can be changed from 9 to 65 active only with climatic adjustment See section 7 8 2 on how to adjust it Can be changed from 1 to 20 active only with climatic adjustment with room compensation See section 7 8 5 on how to adjust it Can be changed 01 knobs present 00 knobs absent Can be changed 00 display always on any other value corresponds to the display turn off delay expressed in minutes see also section 7 13 For this boiler model it should be left at 03 43 7 USE PARAMETER p A 118310m0 DESCRIPTION Boiler in stand by or paused no heating nor domestic water request Anti
68. he graphs shown in figures 32 and 33 is ensured Should the climatic zone be different adjust the curve incline parameter W f l so as to obtain a supply temperature of 80 C 45 C in case of low temperature systems when the external temperature is that of the calculation basis of the thermal requirements 7 8 4 Climatic adjustment turning the heating service on and off The climatic adjustment service is fully automatic even as far as the turning off at the end of the season and the restarting at the beginning of the season is concerned According to the calculation algorithm if the Calculated temperature is lower than the Minimum heating temperature parameter L J the heating service turns off VVhen the Calculated temperature exceeds again the Minimum heating temperature parameter L J b the heating service reactivates f the heating service does not activate or deactivate according to one s ovvn needs it is sufficient to rotate the knob 7 shown in figure 31 to increase or reduce the calculated temperature in order to meetthe Minimum heating temperature beforehand or afterwards 38 7 8 5 Climatic adjustment with room compensation Set the parameter to 02 by using the Installer menu see section 7 15 Everything works exactly as described in the previous sections on Climatic adjustment except for the boiler pump which is always on The opening of the room ther
69. hed unscrew ring nut I pull trap A upwards paying attention because it contains condensate water that may come out as you rotate it outwards open the trap and clean its interior reassemble everything by proceeding in reverse order making sure that the seal L is put back in the proper seat and rearranging the two pipes O and N as indicated before restore the liquid level inside the trap by pouring 100 cm3 of water a glass from the flue gas discharge or from its central opening proceeding as indicated in section 6 1 2 Figure 36 Condensate collection trap papa and disassembly 8 MAINTENANCE Figure 37 Fan burner unit disassembly Figure 38 Electrode positioning on the burner 8 5 Cleaning the burner and the primary heat exchanger flue gas side To correctly clean the burner and the heat exchanger body flue gas side proceed as follows refer to figure 37 unless otherwise specified access the internal components by following the instructions in section 8 3 unscrew nut D disconnect the cables from the ignition and from the detector glow plug see figure 1 details 17 18 and 20 disconnect the cable from the safety sensor F unscrew the four nuts C extract the whole fan and burner unit detail A Clean the combustion chamber interior H by means of a cylindrical plastic bristle brush 6 remove an
70. ibitor 5 INSTALLATION 5 5 2 In order to guarantee the correct operation of the system please make sure that 1 the system is leakage free or at least that the most evident leakages have been removed 2 in case there is an automatic fill up system it has to be fitted with a liter counter in order to know exactly how much water is loss in case of leakage 3 the system filling and fill ups are made with softened water in order to reduce the global water hardness Water shall also be conditioned in order to keep the pH value within the established threshold and to avoid corrosion 4 the system is equipped with efficient impurities and air removal systems both in new and replaced systems filters micro impurity separators and micro bubbles separators 5 Avoid discharging the system water when carrying out ordinary maintenance operations even if they seem to be trifling quantities when cleaning the filter for example fit the system with proper shut off valves both upstream and downstream of the filter 6 When you suspect that the system is dirty or particularly clogged and as you refill it with treated water always carry out an analysis of the system water before opening the communication between new generator and system This analysis is meant to assess whether the chemical and physical characteristics of the water require to empty the system completely to use the water already in the system or to chemicall
71. ided by the master one On Battery slave boiler n n boiler guided by the master one 08 Battery slave boiler 7 seventh boiler guided by the master one 61 no n 08 slave no 07 Setting the battery rotation frequency 00 disabled 01 daily On every n days 07 every 7 Cr can assume the following values 00 Basic setting for single boiler 01 The boiler battery rotates the operation every day On The boiler battery rotates the operation every n days 07 The boiler battery rotates the operation every 7 days 12 DIAGRAM OF THE CONTROL MENUS JOJ Mod xew Je WO OL JOJ AOd XEU ma mm ye Jayem oL f JOJ Mod uluu ye Jayem er OL JOJ mod Xew 18 Buneoy J 40 Mod m ye 0 JOJ Mod UIU ye Bune H J uudi xew je 1 uolej do uej m 7 s6unjes N 7 Bunesedo 7 dus FE mes IE J dwa p seb n 3 L J 13S33 f duu 1 jem uuoq dwa Ajddns m J Jus 7 yoo paAejdsip 1567 J 4 Joe pafe dsip 1567 J 21 wu p Ul 39llog n _J 9172 uono s 89S suonipuo5 Aq pue s ul 13 109 14931 ounyesodwe m 21890100 I m p qm T Bunei do jewou dul 2 I Bum s emesedwe if 1 CA
72. if used must be approved The approved types of flue gas discharge outlet for the boiler are given in the table of technical features at the end of the manual under the heading type and on the boiler rating plate again under the heading type The symbols used to define the type of discharge outlet are as follows B23 comburent air intake from the environment in which the appliance is installed and flue discharge outside During operation especially in Winter again due to high efficiency white smoke maybe discharged This is a purely natural phenomenon and not a reason for concern as it is steam from the gas fumes condensing on contact with the outside air 5 INSTALLATION 105215m0 A Anti wind terminal B Lower part of terminal C Extension 980x500 in PP D Reduction 980 60 with antirain E Flue gas discharge of thermal elements Figure 21 Installation of the Singolo 80 PP system 27 5 16 1 System SINGOLO 80 PP polypropylene The appliance is supplied without fittings for connecting flue gas discharge A special kit is available on request for connecting the thermal module to a SINGOLO 80 PP system to be installed as shown in figure 21 as follows pour 100 cm3 of water in the E opening in order to fill up the 21 trap of figure 1 NOTE the flue gas discharge seals are made of EPDM rubber In order to improve th
73. ill be necessary to fit the boiler with a manual reset device locking the system as it reaches the maximum allowed temperature Thoroughly wash out the system before connecting the heating pipes to flush out any deposits hemp radiator casting residue etc which might damage the appliance Thorough flushing is also required when replacing an appliance Figure 12 illustrates the correct position of the supply and return pipes GS install a metallic mesh filter on the return pipe to prevent any system residue from returning to the boiler Do not use the appliance for adding any type of additive to the system 5 5 Water supply Have the connection to the water mains pressure checked and install a proper pressure reducer if necessary CAUTION The connection of the heating system and thus of the thermal module to the water mains shall be done by interposing a device that should prevent back flows into the drinking water system as required by the current antipollution safety standards 5 5 1 Recommendations for the characteristics of the system water Filling the heating system is an extremely delicate operation that shall never be undervalued neither in case on mere replacement of the heating generator nor in case of a new installation A wrong evaluation of the system water may even damage the system and the thermal module Systems are rarely perfectly tight so damaging water leaks and oxygen infiltra
74. in 24 hours Electric circuit of the flue gas temperature sensor U7 open for more than 60 minutes Checking Check that the electrical resistance of the two sensors corresponds to the graph in section 8 10 Check that the heating circuit flow rate is not too low f one or both sensors are not within the correct values replace them Check that the heating circuit flow rate is not too low Check that the pump is running Check that it is powered at 300 Vdc Check the calibrating pressure of the pressure switch when pressure drops below 0 6 bar the message FILL shall be displayed check that there is no water leaking from the heating system Check the calibrating pressure of the pressure switch the message FILL shall be displayed when pressure drops below 0 6 bar and disappear when pressure rises above 1 5 bar check that there is no water leaking from the heating system Check that the electrical resistance of the flue gas sensor corresponds to the graph in section 8 10 46 Solutions Should the temperature difference between U1 and U8 be greater than 13 C to maximum power and the heating circuit flow rate be low increase the flow rate Replace the control board Replace the gas valve or the control board Replace the gas valve or the control board Should the temperature difference between U1 and U8 be greater than 13 C to maximum power and the heating circuit flow rate be low increase the flo
75. inimum output heat 80 60 Minimum output heat 50 30 Efficiency at minimum output heat 80 60 Efficiency at 30 of load Efficiency at minimum output heat 50 30 Certified efficiency 92 42 EEC Chimney loss burner on 80 60 Chimney loss burner off Casing loss burner on Casing loss burner off Gas flow rate Gas supply pressure mbar Gas supply minimum pressure mbar Gas supply maximum pressure mbar Comburent air pressure Primary heat exchanger water content Primary heat exchanger weight D h w setting range with water heater Project temperature Maximum heating temperature Minimum heating temperature Maximum heating pressure PMS Minimum heating pressure Nominal power supply voltage Nominal power supply frequency Absorbed electric power Electrical protection degree Flue gas pipe diameter split Flue gas pipe max length split Curve equivalent length CO 0 O2 with methane Methane LPG Methane LPG Methane LPG Methane LPG Methane LPG NOx 0 O2 with methane class 5 EN 483 and 297 CO2 maximum power minimum power Maximum flue gas temperature at boiler outlet Flue gas mass flow Head available at discharge Maximum condensate flow Condensate average acidity degree Boiler weight C stars m h kg h mbar mbar mbar mbar mbar mbar mbar mbar kg C C C C bar bar V Hz 59 DUAL 6 70 DUAL 8 90 ITALY ITALY B23 B23 II2H3P II2H3P 0694BR122
76. is possible to create the following system types With this boiler we can create a system for central heating only see figures 7 and 8 or a system for central heating and domestic hot water production see figures 9 and 10 In both cases the central heating system can be high or low temperature see section 5 8 on how to set the boiler 4 1 5 ON OFF remote control This boiler can be connected to remote systems for heating supply temperature setting Moreover in order to improve the heating service quality the boiler is equipped with an external temperature sensor see section 5 14 4 to adjust the supply temperature automatically according to the external one in this case the room thermostat can perform either an ON OFF or a two step type room temperature compensation For further information on the Climatic thermoregulation please refer to section 7 8 4 2 Installation precautions In order to guarantee the proper operation of the appliance observe the following indications It must be connected to a heating system and possibly to a domestic hot water mains system compatibly with the appliance specifications performance and power rating GS Before installation thoroughly flush the heating system and the plumbing one if necessary in order to remove any residue or impurity which might compromise the smooth running of the boiler This appliance can be installed indoor or outdoor in a place wh
77. k valve G Reduction H Fixing nuts L Fixing bolts M Fixing collar N Left fixing bracket and height regulation O Right fixing bracket and height regulation P Flue gas discharge Q Spacers R Washers S Fixing bolts T Nuts 128 5 INSTALLATION DN160 5 16 3 Condensation discharge of the collector The condensation discharge coming F from the flue gas collector see figures 23 and 24 detail F can be conveyed to the condensation discharge collector 1310 of the thermal module In any case it shall be treated as the condensation discharge of the thermal element see section 5 12 au 160 Eos 122510m0_b Figure 23 Installation of the Polypropylene flue gas discharge system with left output DN160 1 2 b KEY figures 23 24 and 25 DI A Position vvhere fitting E should be cut in order to have a 3 tilt and the distance indicated in figure 23 and 24 70 E Flue gas discharge F Condensation discharge 1510 E e 122510m0_a Figure 24 Installation of the Polypropylene flue gas discharge system with right output 122510m0_c Figure 25 Preparation height A for component E 29 6 START UP 6
78. l safety devices ancillary parts and electrical hydraulic and gas pipe diameters must always be checked by a professionally qualified technician in order to ascertain compliancy with the applicable norms and laws This manual is an integral and essential part of the product and must be kept with care by the user for any future consultation Ensure that this manual is handed over to the new owners and or installer if the appliance is to be transferred or moved for any reason whatsoever Any kit or option added subsequently must be original Cosmogas spares 4 This appliance must only be used for the purpose it has been expressly designed for heating water for closed circuits meant for public and private places central heating sanitary and domestic hot water production for civil use The manufacturer cannot be held contractually or otherwise responsible for any damage caused by incorrect installation or use and for failure to comply with the manufacturer s instructions or applicable local and national legislation For safety reasons and to safeguard the environment all packaging must be disposed of in special sorted refuse collection centers 1 1 National installation laws Fire prevention rules issued by the fire brigade Decree D M dated 1 12 75 Decree D M dated 22 01 2008 no 37 former Law dated 05 03 1990 no 46 Law dated 09 01 91 no 10 Presidential Decree dated 26 08 93 no
79. locked out or shows an error FN Output for warning signal it activates each time that a thermal element has the burner on PR2 ISPESL safety pressure switch TS ISPESL safety thermostat PB Boiler pump N and L Power supply to the thermal module Figure 17 Electrical connections X2 Very low safety voltage terminal board SB U3 Boiler temperature sensor SE U4 External temperature sensor TA1 Room temperature thermostat contact BUS PC or remote control input RS 485 Data input not available 0 10Vcc Analogical signal input 0 10Vcc 22 5 INSTALLATION 5 14 2 Choosing the room thermostat time programmable thermostat The boiler is designed to work with any room or time programmable thermostat having contacts for the boiler cable connections and the following features open closed ON OFF clean not powered closed when heating is required electrical specifications 24Vac 1A 5 14 3 Connecting the room thermostat time programmable thermostat Install the room thermostat in a part of the house where the temperature is as near to average room temperature as possible and not in an area subject to sudden temperature changes away from outside windows or doors see figure 18 To connect the room thermostat cable proceed as follows refer to figure 16 use a bipolar electrical cable with a minimum section of 1 5 mm2 which leads from the boiler to the room thermosta
80. matic adjustment precautions when adjusting 2 38 7 8 2 Climatic adjustment parameter setting 22 i 38 7 8 3 Climatic adjustment adapting to the different climatic ZONES a r a 38 7 8 4 Climatic adjustment turning the heating service on and off r r r a 38 7 8 5 Climatic adjustment with room compensation ii 38 f 9 Turning off ario 38 7 10 Thermal element settings SWITCHES i 40 7 11 Timimg of the various functions nica 40 7 12 Antifreeze protection aree 40 GAS EMGNGY Saving ariana 40 TNA Usermenu ake ca ada a a Sneak Pagan sae a a 41 filo sinstallermenti gole alal 42 1 16 DIAGNOStCS tai 44 A01 Dlagnosties a sanan baa a laya l 45 fl0 2 Dlagnosties E erfors asini ai ia 47 B MAINTENANCE aaa 49 8 1 General wamings i canali iaia ai 49 8 2 Assembling hecas nda aan 49 8 3 Disassembling the casing and accessing the internal components 49 8 4 Cleaning the condensate conveyor trap i 50 8 5 Cleaning the burner and the primary heat exchanger flue gas side 51 8 6 Correct positioning of the ignition and ionization electrodes r 51 8 0 Pump motor replacement idilliaca ian ia 52 g 0 Empiying the applianoe
81. mostat contact will cause the line shown in figures 32 and 33 to parallely shift downwards The value by which the line can shift downwards can be adjusted on parameter n specified in the Installer menu see section 7 15 The parameter n can be set to values between 1 C and 20 C The suggested values for this parameter are 10 C for radiator type systems high temperature 3 C for radiant panel type systems low temperature Too high values for this parameter can lead to instable room temperature Too low values can make the room thermostat action useless 7 9 Turning off The thermal module shall be powered also in downtime periods as the control system performs the circulators anti freeze and anti locking functions In case of prolonged absence we suggest to disconnect the thermal module from gas and power supply and to empty it this operation shall be performed only by a qualified operator 7 USE 102322m0_c 90 Calculated temperature C 20 15 10 5 5 10 15 20 25 30 External temperature C Figure 32 Climatic adjustment graph influence of the parameter OA adjustment 102322m0_d o o 80 70 60 50 40 Calculated temperature C 30 External temperature C Figure 33 Climatic adiustment graph influence of the parameter b adiustment
82. necting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board 47 Solutions Replace the probe electrical resistance if it does not correspond repair the electric circuit if damaged if none of the previous cases is true replace the control board Replace the probe electrical resistance if it does not corr
83. ning the panel components To access the internal components of CAUTION Maintenance To access the internal parts of the the sealed chamber _ operations shall only be carried out boiler proceed as follows refer to Pull out the cover M first from the by qualified technicians figure 35 bottom towards yourself then lift A Unscrew screws A it until it comes out of the upper ing R fastening pins CAUTION Before any Pull out casing B from the bottom pulling first towards yourself and maintenance operation disconnect then downwards the appliance from the mains supply 70 access the main electrical by means of the nearby appropriate connection terminal boards switch Rotate the connection panel C downwards CAUTION Close the gas Open hook D cock before any maintenance Open the left side cover E and pull it to the right operation n M M 0 L H G G o L ae m GMs GIN C E D A F A B Figure 35 Casing assembly and disassembly and access to the internal components 49 8 MAINTENANCE lt 1 C o
84. o install it with an adequate shim or remove it before plastering To connect the cable of the external temperature sensor proceed as follows lay a bipolar electrical cable with a minimum section of 1 5mm2 which leads from the boiler to the external temperature sensor Maximum allowed length is 20 m For longer lengths up to 100 m itis necessary to use a shielded cable with an earthed shield CAUTION Since the cables are subject to an extremely low safety voltage 24Vcc they must run through ducts different from the 230Vac power supply cables connect the bipolar cable to the terminals L shown in figure 16 connect the bipolar cable to the ends of the external temperature sensor Set the boiler so that it detects the external temperature sensor as follows press down the button for 12 seconds until the display flashes and shows then press and release the button several times until the following parameter appears using buttons and change the parameter value C from 00 to 01 or 02 according to the desired type of climate thermoregulation see chapter 7 8 press button repeatedly until exiting the menu as shown by the flashing of the display 5 INSTALLATION 5 14 5 Remote control 62101051 on request The 62101051 remote control is a device which can control remotely the setting commands of the heating and domestic water of the MASTER thermal element On
85. oiler is connected to a domestic water heater a disinfection cycle against the legionella bacterium will be performed This cycle brings the water heater to a temperature of 60 C temperature at which said bacteria die at least once a week Therefore water at certain times may reach the user at a temperature higher than that set on the domestic water control When the boiler is started for the first time the disinfection cycle against the legionella bacterium is carried out even after 2 hours of operations 5 INSTALLATION TYPE B23 A Comburent air B Combustion residue C Condensation discharge Figure 20 Approved discharge intake systems 26 5 16 Venting systems CAUTION All venting systems must be connected in compliance with current national and local standards CAUTION The temperature of the fumes in this appliance can reach in certain conditions 110 C Hence pipes in plastic material able to reach such a high temperature must be used CAUTION This is an air condensing boiler To build the gas discharge system use stainless steel AISI 316L or polypropylene plastic materials in order to avoid corrosion due to the condensation acidity Remember that this type of appliance must have discharge and intake pipes supplied by the appliance manufacturer Any other types of pipes
86. oned period COSMOGAS will repair or replace any manufactured parts found to be defective excluding any defects caused by normal wear and tear during operations The warranty does not cover compensation for any type of damage which may occur to people or property The faulty materials replaced under warranty are the property of COSMOGAS and must be returned free of charge to our factory within 30 days of their replacement All COSMOGAS products are subject to reserved ownership agreement until the purchased appliance has been fully paid for 15 2 Instructions for filling in the warranty card The installer must stamp the warranty certificate Always request the intervention of one of our authorized technicians for the initial start up and for warranty validation For warranty validation the technician shall check gas pressure on the burner or comburent air pressure for pre mix and condensing boilers water leaks check gas leaks check The list of authorized technicians is enclosed with the instruction manual or can be found in the Yellow Pages under Gas boilers 66 The technician will collect the warranty certificate and forward it to COSMOGAS 15 3 Warranty limits The warranty is invalid if the appliance is installed by non qualified technicians if the appliance is not installed in compliance with COSMOGAS instructions and or those established by national and or lo
87. quest or in case of domestic hot water request Now the boiler will run for 10 minutes at maximum power wait until the CO2 level stabilizes compare the measured value with that given in the table in chapter 9 headed CO2 level If the measured value differs from the read one bring it back within the values given in the table in chapter 9 by proceeding as follows use screw E shown in figure 26 turn it clockwise to reduce the level of CO2 Turn it anti clockwise to increase the level of CO2 press button until the display shows Or 5 in case you were trying in domestic water mode Now the boiler will run for 10 minutes at minimum power Check the CO2 value it shall reduce by 0 5 as compared to the value read at maximum power Otherwise use screw F shown in figure 26 to adjust the CO2 value rotate it clockwise to increase or anti clockwise to decrease Check the CO2 level again at maximum power and further adjust it if necessary Once done seal the screws E and F shovvn in figure 26 vvith red paint or equivalent method press button eset to bring the boiler back to normal operating conditions 33 During this phase if the boiler delivered power is much greater than the system power consumption the boiler turns continuously off as itreaches the maximum allowed temperature 45 C for low temperature systems 85 C for radiator typ
88. rature Maximum heating pressure PMS Minimum heating pressure Nominal power supply voltage Nominal power supply frequency Absorbed electric power Electrical protection degree Flue gas pipe diameter split Flue gas pipe max length split Curve equivalent length CO 0 O2 with methane stars Methane m h LPG kg h Methane mbar LPG mbar Methane mbar LPG mbar Methane mbar LPG mbar Methane mbar LPG NOx 0 O2 with methane class 5 EN 483 and 297 CO2 maximum power minimum power Maximum flue gas temperature at boiler outlet Flue gas mass flow Head available at discharge Maximum condensate flow Condensate average acidity degree Boiler weight C mbar kg C C C C bar bar V Hz 58 DUAL 2 34 ITALY B23 II2H3P 0694BR1222 28 2 5 27 6 28 8 230 50 250 IPX5D 80 40 DUAL 4 50 ITALY B23 II2H3P 0694BR1222 51 44 49 4 52 0 96 8 104 4 3 4 6 97 1 108 8 230 50 250 IPX5D 80 40 45 curve 0 5m 90 curve 1m 1 ppm 8 5 9 0 10 10 5 50 60 3 8 4 98 8 13 8 5 9 0 10 10 5 84 60 6 4 98 9 TECHNICAL DATA MODEL Country of delivery Type Category EC type certificate PIN Nominal heat input Q Minimum heat input Nominal output heat 80 60 P Nominal output heat 50 30 P Efficiency at 100 of load 80 60 Efficiency at nominal output heat 50 30 M
89. t there is a limited corrosion but the high specific gravity of this oxide can lead to cloggings that are difficult to remove especially in hot areas Incrustations are due to water hardness i e to the presence of calcium and magnesium salts Calcium in the form of carbonate settles on the hottest parts of the system The magnetite often strengthens incrustations Iron oxide instead indicates 16 corrosion due to oxygen water has a reddish color Frequent losses In case of frequent losses hydrogen and or air cumulate on the upper part of the heat exchanger and of the radiators thus preventing a complete heat exchange When the galvanic corrosion process starts the water level in the system decreases and gases cumulate in the upper part of the heat exchanger and in the radiators Air presence is due to the fact that the system may not be perfectly tight A slow drop of the system pressure caused by a leakage is often difficult to detect especially when the leakage is small in winter for example the leakages on the radiators valves are sometimes not visible because they dry due to the radiator or boiler heat However these microleakages let air infiltrate into the system Microleakages mainly occur on joints and in particular on the circulator suction side air outlet valves sealings with o ring loading valves In such cases in order to prevent damage the system shall be protected using a proper corrosion inh
90. t time programmable thermostat Maximum allowed INT NTIS x s Steyn a LA oe ol zio 5 ee length is 20 m For longer lengths up to 100 m it is necessary to use a shielded cable with an earthed shield disassemble the boiler casing following the instructions in section 8 3 and access the interior part of the electrical box get the cable to pass via a free cable clamp not used by other wires strip the cable connect the 2 cable ends to the TA terminals see figure 16 CAUTION Since the cables of the room thermostat time programmable thermostat are subject to extremely low safety voltage 24Vcc they must run through ducts different from the 230Vac power supply cables Figure 18 Correct positioning of the room thermostat time programmable thermostat 23 5 14 4 External temperature sensor connection Install the external temperature sensor outside the house on a wall facing NORTH or NORTH EST at a height of between 2 and 2 5 meters from the ground on buildings with several floors install near the upper half of the second floor Do not install the sensor above doors windows or ventilation outlets nor directly under balconies or gutter pipes Do not plaster the external temperature sensor Do not install the sensor on walls without overhangs or not protected from rain If the sensor is installed on a wall still to be plastered it is necessary t
91. tat and turning the knob 9 shown in figure 1 to the minimum Wait until the temperature on the display 7 in figure 1 is at least 40 C turn off the boiler access the internal components by following the procedure in section 8 3 connect a flexible rubber hose to the discharge cock 22 see figure 1 and place the other end in a sink plughole or similar open the discharge cock 22 see figure 1 open the bleeding valves of the radiators Start from the upper radiators and continue with the lower ones After draining out all the water close the radiator bleed valves and the discharge cock 22 see figure 1 CAUTION Do not recover and or re use water drained from the heating circuit for any purpose as it could be contaminated 8 9 Forcin For the purpose of carrying out some specific verifications described throughout the manual it is possible to perform some forcing of the appliance operation 8 9 1 Self drainage The self drainage procedure can be reset by pressing the buttons and together for 10 seconds until the letter F appears on the display Then press button 8 9 2 Fan It is possible to turn on only the fan by pressing the buttons and together for 10 seconds until the letter F appears on the display Now the fan will be on for 10 minutes Press button to exit the forcing beforehand Figure 39 Pump motor replacement 52 8 9 3 Minimum
92. temperature set the parameter to a value other water service ends the systems waits 2 of 7 C the heating pump and the than zero considering that each value minutes before reactivating the heating domestic water pump if present will correspond to the display delay service automatically turns on If the expressed in minutes after entering Anti locking pump and diverter valve temperature further drops under 2 C the Energy Saving mode every 24 hours the heating pump and the burner will also turn on so as to the domestic water pump if present are protect the boiler from the effects of forced for 15 seconds freezing weather conditions Antilegionella if the boiler is connected to a domestic water heater every seven days the heater is brought to a temperature of 60 C to perform the disinfection against the legionella bacterium Start up delay In all operating modes except for the domestic water one every time the burner turns off it waits 3 minutes before restarting 40 7 USE modified parameter then pass on to La 77100 the ihe nex parameter di aan 205 Once the end of the menu has been isplay 7 shown in figure 1 starts to flash indicating the successful mode reached vvith the last RESO the display switch to the user To access the User stops flashing thus indicating that the menu just user exited the menu Reset Reset f no button is pressed for more than 60 5 7
93. the parameters via the User menu see section 7 14 While functioning the display 1 shown in figure 31 shows the status of the thermal element whereas display 2 see figure 31 shows the parameter value The different operating statuses are indicated in the table in section 7 14 Within the User menu see section 7 14 it is possible to check the latest locks or errors occurred In addition to the operating modes the instrument panel provides important information on the current functioning of the boiler via the indicators 3 4 5 and 6 shown in figure 38 In particular the indicator 3 displays whether the burner is running on or off flashing the indicator 4 displays whether the domestic water service is active or inactive the indicator 6 displays whether the thermal element pump is running on or nor off 36 118110m0_b_ 7 3 Precautions against freezing If you leave the house and turn the power and gas supplies off the appliance will not be protected against freezing Thus in case of turning off with temperatures that may possibly drop below zero you should empty the system Contact a qualified technician CAUTION It is absolutely forbidden to introduce chemical additives such as anti freeze or others into the domestic water circuit 7 USE 7 4 Remote control on request the thermal module is connected to the remote con
94. tion may occur The main parameters negatively affecting the system life are simultaneous presence of different metals copper brass steel and aluminium causing a galvanic corrosion in aqueous environment The presence of free oxygen due to air infiltrations on fittings or seals is a typical corrosion agent particularly active with temperatures between 50 and 70 C The loss of water which translates into frequent fill ups can provoke both corrosion and incrustations according to the type of water used to fill up In any case the amount of water loss and consequent fill ups shall be kept under control particularly in case of an automatic fill up system In this case we recommend you to install a counter indicating the refilled water quantity Natural or water added impurities Drinking water can often contain even high concentrations of chlorides and sulphates which can speed up corrosion of metal surfaces Further undesired components may have been introduced into the system before or during installation building material metal chips sawdust grease deposits and dirt whatsoever Even welding residues may cause corrosion in both new and modified or repaired systems In old systems designed to work with radiators having very large diameter piping the huge quantity of water more often leads to the formation of sludge and deposits Sludge and incrustations The presence of black deposits magnetite shows tha
95. trol shown in figure 35 the adjusting functions of the heating and domestic water temperatures can be performed directly from the remote control as indicated below the heating adjustment is performed directly by means of knob A shown in figure 35 the domestic water adjustment is performed directly by means of knob C shown in figure 35 Furthermore you can reset any alarm by pressing the RESET button see figure 35 detail B There are two warning lights on the remote control which have the following meaning green led on heating service running and correct communication between thermal module and remote control green led flashing every 7 seconds correct communication between thermal module and remote control red led on thermal module locked out You can reactivate it by pressing the RESET button see figure 35 detail B Should the lock out occur frequently please contact a qualified technician red led flashing thermal module lock out longer than 5 minutes contact a qualified technician red led and green led flashing low pressure to the heating system Please refer to section 6 1 3 to restore the correct pressure In order to assess the type of lock corresponding to the lit led check the error type on each thermal element and refer to sections 7 16 1 locks and 7 16 2 errors 7 5 Adjusting the domestic water system To adjust the domestic water temper
96. ughly checked by a qualified technician Have a qualified technician check that the electrical system is appropriate for the electric power indicated on the rating plate required by the appliance The appliance must be connected to the power supply by means of a mobile plug use of adapters multiple plugs extensions etc is not A allowed The appliance must be connected to the power supply by means of a three pole electrical cable with double insulation a minimum section of 1 5 mm2 and resistant to a minimum temperature of 70 C feature T To connect to the power supply 7 use a bipolar switch with a contact m opening distance of at least 3mm in compliance with current standards on the subject Respect the polarity between phase and neutral when connecting the O NMLI CDEF Figure 16 Electrical connections A Connection panel cover B Cover closing laces C Main power supply D Water heater pump connection E ISPESL safety thermostat connection F ISPESL pressure switch connection G Function contact H Warning contact L External probe M Room thermostat Water heater probe N Bus O Analogical inlet 0 10 vdc H appliance Make sure the heating
97. uriti seconds the menu will be automatically exited If not confirmed using the button press and release the button any datum variation will be lost several times until the desired ox The following parameters can be modified parameter is displayed 40 or consulted from this menu by means of the or buttons it is possible to change the value of the parameter Press the ese button to confirm the PARAMETER DESCRIPTION DISPLAYING ON DISPLAY 7 shown in figure 1 Line incline adjustment as per figures 32 and 33 n R visible only vvith active climatic adiustment See LJ section 7 8 Setting range 0 1 5 0 Minimum heating temperature adjustment vis ible only with active climatic adjustment See section 7 8 Setting range See section 7 8 2 oO Maximum heating temperature adjustment visible only with active climatic adjustment See section 7 8 Setting range See section 7 8 2 n Line parallelism adiustment as per figures 32 and 33 visible only vvith active climatic adiustment See section 7 8 Display only The adiustment is made by means of the knob 9 shovvn in figure 1 and the possible values are between 10 C and 10 C Displaying the calculated heating temperature if the climatic adiustment is active see section 7 8 or the set temperature by means of the knob 9 shovvn in figure 1 Display only It can assume values between 20 C and 80 C Displaying the set domesti
98. w rate Replace the pump or the control board Replace the control board If the fan is powered differently replace the board Replace the pressure switch if it is not properly calibrated repair any possible leaking in the system Replace the pressure switch if it is not properly calibrated repair any possible leaking in the system Replace the sensor if it is not within the correct values 7 USE 7 16 2 Diagnostics E errors E code E01 E02 E04 E07 E08 E11 E12 E13 E14 E15 Lock description Circuit of the boiler temperature sensor U1 broken Circuit of the boiler supply temperature sensor U2 broken Circuit of the heating return temperature sensor U8 broken Circuit of the water heater temperature sensor U3 broken Circuit of the boiler temperature sensor U6 broken Circuit of the boiler temperature sensor U1 short circuited Circuit of the boiler supply temperature sensor U2 short circuited Wrong temperature reading Circuit of the heating return temperature sensor U8 short circuited Circuit of the external temperature sensor U4 short circuited Checking Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables connecting the probe to the control board Check that the electrical resistance of the sensor corresponds to the graph in section 8 10 check the electrical cables con
99. y unburned residue from the combustion chamber H by means of a vacuum cleaner with the same vacuum cleaner clean the burner surface and the area around the electrodes reassemble the components by proceeding in reverse order open the gas cock 6 restore normal electrical power make sure that there are no gas leaks from the removed joints 8 6 Correct positioning of the ignition and ionization electrodes To ensure an efficient appliance operation the correct electrode positioning is fundamental please refer to figure 38 the distance between the ignition electrodes tips A and B must be between 2 and 2 5 mm the distance between the ignition electrodes and the burner surface must be between 5 and 5 5 mm the distance between the ionization electrode and the burner surface must be between 5 5 and 6 5 mm 8 MAINTENANCE 8 7 Pump motor replacement Should it be necessary to replace the circulating pump proceed as follows refer to figure 39 empty the heating circuit by following the procedure in section 8 8 access the appliance internal components by following the instructions in section 8 3 remove screws B pull the pump A outwards disconnect the electrical wires from the pump body 8 8 Emptying the appliance To empty the boiler from the heating side proceed as follows cool down the water inside the boiler by closing the room thermos
100. y wash the system with mains water and a detergent If the analysis of a sample of the water to be used for system loading has the following values 9 6 lt pH lt 10 5 if the system is in contact with aluminium the pH value is to be below 8 5 Ca Mg lt 0 5 f OH 1 2 CO from 5 to 15 f P_0 from 10 to 30 mg l Na 50 from 10 to 50 mg l then you can continue loading If the characteristics are different you should use an inhibitor 5 5 3 VVater treatment in thermal systems for public use The vvater treatment in thermal systems for public use must alvvays be carried out both in case of replacement of the generator and in case of nevv systems During the project phase according to the characteristics of the raw water all the treatment plants and the chemical conditioning components to obtain water with the following characteristics Aspect possibly limpid pH higher than 7 with radiators with aluminum elements or light alloys pH must be lower than 8 5 Conditioning components in the concentrations established by the supplier Ifthe characteristics of the water are not known the following problems are likely to occur 1 DEPOSITS 1 fr 10mg kg CaCO 30 fr 300 mg kg CaCO In a system with 1000 liters of water the content of CaCO is 300 g which will set down on the heat exchanger surface if they are not treated appropriately because it is the hottest part of the

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