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8/13/2019 Therm 23 Tca Angl
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MANUAL FOR INSTALLATION
AND MAINTENANCE
Boiler with forced flue exhaust
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CONTENTS
1. IN GENERAL1.1 General information
1.2 Boiler description
2. INSTALLATION2.1 Warning before installation
2.2 Boiler placement
2.3 Boiler dimensions
2.4 Minimum distances2.5 Boiler fixation
2.6 Connection to the mains
2.7 Gas connection2.8 Water supply
2.9 Installation of flue exhaust and air suction
2.10 Room thermostat connection
2.11 Wiring diagram2.12 Function diagram
2.13 Hydraulic diagram
3. STARTING THE BOILER3.1 Conditions for boiler operation
3.2 Control panel
3.3 Instructions for opening the boiler
3.4 The first start
3.5 Regulation of operation3.6 Flue analysis
3.7 Gas outlet check
3.8 Protection functions3.9 Boiler draining
4. CHANGE TO A DIFFERENT GAS TYPE4. Gas regulation
4.1 Change to a different gas type
5. MAINTENANCE
6. TECHNICAL SPECIFICATIONS
1. IN GENERAL
This manual is an essential and integral part of the product. It
contains a thorough description of the equipment and it is to be of
use for both the users and the authorized service personnel.
Read the instructions in the manual carefully because there is the
necessary information about the safe installation, operation andmaintenance of the product.
There is more information in the Users Guide.
1.1 GENERAL INFORMATION
The appliance serves for room heating and domestic hot water
production for home purposes.It must be connected to the heating circuit and to the hot water
distribution system corresponding to its purpose and output.
It is forbidden to use it for any other than the stated purposes. The
manufacturer is not responsible for faults caused by unsuitable,wrong or irresponsible use.
The installation, the maintenance and any other interference must
be carried out in accordance with the valid norms, according to themanufacturers instructions and by a qualified and trained worker.
The technician installing the heating equipment must also have
valid authorization by the manufacturer.
Incorrect installation can cause harm to possessions or persons. Themanufacturer is not responsible for damages inflicted in this way.
Prevent children and mentally ill people from using the equipment
without supervision.
If you can smell gas, do not switch on any electrical appliances,phones or other appliances which can produce sparks. Open thedoor and the windows, close the central gas supply (at the gas
meter) and call an authorized service engineer.
Should you be away for a long time, close the central gas supply aswell.
Do not put any objects on the appliance.
Do not block up the air or other outlets.
It is necessary to close the electricity supply before any interferencein the product. The best way is to unplug it.
Use a wet cloth and soap for cleaning the appliances cover. Do not
use abrasive or dissolving cleaners.If there is a fault or malfunction, switch the appliance off by closing
the gas tap. Call authorized service engineers to repair the
appliance.
The notes and instructions included in this manual are to be used by
the people who are going to install our product.
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1.2 BOILER DESCRIPTION
Legend:
1. Connection to flue exhaust2. Opening for
3
separated exhaust
he heating circuit
ber
h
he DHW circuit
nger
nsor
valve
valve
manostat
sis
. Ignition transformer
3. Ventilator
4. Flue exhaust rectifier
5. Primary exchanger6. Safety thermostat
7. Temperature sensor in t
8. Combustion cham9. Burner lamellas
10. Ionization electrode
11. Ignition electrodes12. Pump pressure switc
13. Safety valve 3 bars14. Temperature sensor in t
15. Secondary excha16. Refilling valve
17. Cold water inlet
18. Through-flow se
19. Draining valve
20. Circulation pump21. Motor-driven 3-way
22. De-aerating
23. Gas valve24. Expansion vessel
25. Flue exhaust differential
26. Sockets for gas analy
27
2. INSTALLATION
The installation and the first putting into operation must be
carried out by a qualified technician in accordance with thenorms valid for installation of this kind of appliances and with
the norms of local authority bodies and medical institutions.
2.1 WARNING BEFORE INSTALLATIONThe appliance must be connected to the heating distribution
system and to the water supply corresponding with the boilerspurpose and output. (See the specifications)
Before you connect the boiler it is necessary to:
- check the piping and make sure there are no impurities which
could affect the boilers operation.
- check which gas type is the boiler designed for (read the labelon the packaging and the manual including technical
specifications)
- make sure the following exhaust installation meets the validlocal norms.
2.2 BOILER PLACEMENTThe equipment with combustion air supply from the outside andwith forced flue exhaust into the outside can be installed in any
room which corresponds with the relevant local norms andstandards.
Placing of such a boiler is not limited by ventilation possibilities
or room size.The boiler must be mounted on a solid, compact so that any
access to electricity at the back part is prevented.
To gain the best efficiency of the boiler it is necessary to make
sure that the temperature of the place where to boiler is mountedis within the temperature limits for the boiler so that the boiler is
protected against atmospheric influences.
It is also necessary to make enough free space around the boilerto make access to individual boiler parts possible, as mentioned
in paragraph 2.4.
If the boiler is to be placed in the bathroom, washing rooms or
shower rooms it is necessary to follow specific relevant local
norms. (electrical part has IP 44 cover).
2.3 BOILER DIMENSIONS
Legend:
A. Heating water outlet
B. DHW outlet
C. Gas supply
D. Cold water inletE. Heating return pipe
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2.4 MINIMUM DISTANCES
he following layout shows the minimum distances for boilerT
installation which are necessary for possible proper maintenance.
2.5 BOILER FIXATIONThe boiler has to be placed with the use of water level according
to the minimum distances shown at the picture, and it has to be
fixed to the wall with use of cramps and hooks.
urther information is to be found in the manual whichFth
goes withe hydraulic connection set and the flue exhaust set.
en done according to valid norms in the socket.
The same applies
,
g
t is
k cover inside the boiler.
2.7 GAS CONNECTION
ble impurities, which could affect the efficiency of
ONNECTION TO THE BOILER
graph (output x lift).
2.6 CONNECTION TO THE MAINSThe manufacturer is not responsible for damages caused by
wrong supply mains in the house. It is therefore recommended to
have the supply mains checked in certain cases.The boiler is connected to the supply mains by a fixed flexible
line with a plug. It is connected to a 230 V, 50 Hz (10 A) socketinstalled according to valid norms. It can also be connected by a
firm cable where a suitable two-pole switch must be
incorporated. The equipment must be connected to 230 V supplyains by a triplex cable. Make sure the phase and neutralm
connection has be
IMPORTANT!
The connection to the supply mains including plugging can
nly be carried out by a service technician.o
for any possible change of the supply cable.
If you need to change the supply cable, use the cable with the
same parameters (3 x 0.75mm2 outer max 8 mm
HTO3VV-F type). Follow these rules and the above diagram for
the connection:- open the front cover of the control panel, as mentioned in
paragraph 3.3;
- unscrew two screws in the back window of the control panelwhich will give you an access to the terminal connector;
- take out the bad cable and put in a new one at the same point;
- put the grommet to the new cable, including the groundin
cable drawing in;- place the cable so that the insulation fits into the right place;
- connect the blue cable (neutral) to the point in the terminal
connector that is marked N;- connect the brown cable (phase) to the point in the terminal
connector that is marked L;
connect the yellow-green cable (grounding) to the point tha-
marked by a symbol behind the bac
The boiler is designed for natural gas and propane category
II 2H3p combustion, as stated in the chart in chapter 4 Gasregulation.
If you need to change the boiler to another gas type, follow the
instructions in 4.1.
The point of gas connection in the boiler has to be equipped with
a proper round closing cock, following the valid norms. Werecommend you to clean all piping before installation and to
emove possir
the boiler.
2.8 WATER SUPPLYC
Legend:
etA. Heating outlB. DHW outlet
C. Gas supply
D. Cold water inletE. Heating return pipe
. Refilling valveF
G. Safety valve spillway
There are connections to heating distribution systems, boilersDHW and gas distributions and connections to the appliance in
the picture. More detailed information on armature connection to
distribution systems is to be found on the connection armaturepackaging.
Before you connect water, check if the maximum pressure in the
water distribution system does not exceed 6 bars. If the pressure
in the distribution is higher, it is recommended to install areduction valve.
The minimum pressure for proper boiler functioning in the DHW
mode is 0.2 bars. Therefore it is possible to insert a thermostaticvalve at the cold-water inlet to limit the maximum DHW amount
(see the following picture in part 1).
When dimensioning distributions and radiators the circulation
pump output must be taken into consideration , see the following
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The boiler is equipped with an automatic by-pass, whichprovides the right water supply into the primary exchanger in
case installation with variable supply is done (heating systems
with thermostatic valves etc.)We recommend installing safety valve discharge piping of 3 bars
of the heating circuit.
2.9 INSTALLATION OF FLUE EXHAUST
AND AIR SUCTION ACCORDING TO TPG
800 01
Flue exhaust (outlet) and combustion air supply (inlet) can be
provided by a system of coaxial pipes.
The outlet and the inlet can also be provided by a system of
separate pipes according to the following procedure:
If you assemble the exhaust system using separate pipes it is
necessary to:
1. cut off the outlet bottom;
2. connect the elbow to the outlet right to the bottom brink (Seal
or insulation is not necessary).
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Diagrams show some examples of various types of coaxial and separate exhaust systems.
The stated values of maximum outlet and inlet lengths include
also the length of accessories such as roof bushing, adapter,
opening etc. For coaxial systems the value includes also one
90 elbow.C52 installation has to meet following conditions according to
the diagram:1 The same outlet and inlet pipe diameter of 80 mm over thetotal length.
2 If you want to insert another elbow into the inlet or outlet
systems, you have to provide the equivalent length for the otherside along the same rules as when counting the length.
3 The flue outlet (chimney) must stick out by at least 0.5 mover the roof top (where it is fixed) and it must be placed at theside opposite the side with the air inlet (this condition is not
obligatory if the inlet and outlet are at the same side of the
building).
Recommended exhaust length
maximum coaxial exhaust length 100/60mm
0.5 2.0 m orifice plate 43 mm 2.1 4.0 m no orifice plate
maximum separate exhaust length 2x80mm
0.5 10.4 m orifice plate 43 mm 10.5 43.0 m no orifice plate
maximum pressure loss of the exhaust 80 Pa
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the angle of 0.3owith a decline in the direction from the boilerShortening of the maximum length by an elbow:
90o = -75 cm 45o = -50 cm
Note: The length of exhaust means the length of the inlet pipe + the outlet pipe length.
2.10 ROOM THERMOSTAT CONNECTION
It is necessary to:
1 open the control panel, as described in paragraph 3.3.
2 insert the thermostat cable in the connector and fix it. Then connect both conductors to the electrical terminal connector placed at the
back of the panel by removing shortening jumper. The shortening jumper substitutes the room thermostat when the room thermostat is not
connected.
2.11 WIRING DIAGRAM
Legend:
A = Connector for remote control connecting
B = Heating temperature regulation (Summer/Winter switch)
C = Connector for remote controlD = DHW temperature regulationE = Slow ignition regulation
F = Maximum heating temperature regulation
G = ON/OFF switchH = ON/OFF diode
I = Insufficient flue outlet diode
J = Maximum DHW temperature jumper (for floor systems)
L = Wrong ignition diodeM = Insufficient water diode
N = Unblocking button
O = Economical/comfort mode switchP = Overheating diode
Q = Temperature diodes
R = Transformer
S = Circulation pump relay
T = Ventilator relayU = Gas valve relay
V = Motor-driven 3-way valve relay
ZA=Jumper for postventilation function
A01 = Circulation pumpA02 = Ventilator
A03 = Ignition transformer
A04 = Gas valve
A05 = Motor-driven 3-way valveA07 = Flame scan circuit (ionization electrode)A08 = Heating temperature sensor
A09 = DHW temperature sensor
A10 = Through-flow switchA11 = Heating through-flow switch
A12 = Modulation
A13 = Overheating safety thermostat
A14 = Programmable clockA15 = Room thermostat
COLOURS:
Gr = Grey
Bi = White
Ro = Red
Mr = BrownBl = Blue
Nr = Black
R/N = Red/Black
Jumper service setting:
Label at the gas joint: Jumper function: Effect at Aposition: Effect at Bposition:
ZAVentilation of the combustion
chamber by the smoke ventilatorChimney version, no ventilator
Turbo version, the ventilator
ventilates the combustion
chamber
JHeating temperature limitation: floor
heating/radiators
t max= 45o C Floor heating
system
t max= 82o C Radiator heating
system
W Anticycling time setting:0 min.Just for the service setting
of the boiler2 min. For common operation!!!
CN101 Combustion chamber type:For atmospheric installations
(chimney version)For TURBO installations
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2.13 HYDRAULIC DIAGRAM
Legend:
1. Ventilator2. Primary exchanger
3. Safety thermostat
4. Burner5. Ignition electrodes
6. Ionization electrode
7. Heating temperature sensor
8. Heating manometer9. Pressure through-flow switch
10. DHW temperature sensor
11. Secondary exchanger12. Gas valve
13. DHW flow switch
14. Refilling valve
15. Safety valve, 3 bars16. Motor-driven 3-way valve
17. Automatic by-pass
18. Pump with deaeration19. Expansion vessel
20. Ventilator manostat
A. Heating outlet 3/4
B. DHW outlet 1/2 C. Gas 3/4
D. Cold water inlet 1/2
E. Heating return pipe 3/4
3. STARTING THE BOILER
IMPORTANT!
It is necessary to cut off the electricity supply by turning A
button to 0 position and unplugging the boiler before any
operations inside the boiler.
3.1 CONDITIONS FOR BOILER OPERATIONTo ensure safety, proper functioning and guarantee periodvalidity it is necessary that the installation and the first startshould be carried out by a THERMONA authorized service
technician.
Check if the gas and its pressure, the mains voltage andfrequency correspond with the data on the boilers production
label.
FILLING THE BOILERFollow this procedure:
- release deaerating valves on the radiators;- slowly open the refilling valve on the boiler and close the
deaerating valves on the radiators when the water starts to
flow out;
- close the boilers refilling valve when the pressure reaches1 bar.
GAS SUPPLY
Open the gas supply tap on the inlet pipe and the gas supply tapon the boiler and check the gas installation. You will find any
leak using water with soap.
3.2 CONTROL PANEL
PARTS DESCRIPTION:
A = Main switch
B = DHW temperature regulationC = Mode switch and heating water temperature regulation
D = ON/OFF diode (green)
E = Insufficient flue outlet diode (yellow)F = Insufficient water or operation stop diode (red)
G = Economical/comfort mode switch
H = Unblocking button / flue analysis
I = Safety thermostat operation diode (overheating)
L = Insufficient water in the system diode (red)M = Heating water temperature diodes (yellow)
N = Place for programmable clock installation
O = Heating manometer
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3.3 INSTRUCTIONS FOR OPENING THE BOILER
To access the inside of the boiler it is necessary to unscrew the
fixing screws at the lower part of the control panel.
The control panel swings down and it can be drawn forward ontwo side pins.
Releasing the control panel:
It stops in an almost horizontal position, which allows the access
to the inside. If you want to gain better access you have to lift
the panel and turn it into the horizontal position. To unscrew theouter case you have to:
1. unscrew the two bottom front screws,
2. lift the cover and remove it from the top fittings.
Releasing the front cover
3.4 THE FIRST STARTWhen starting the boiler for the first time you have to:1)check that:
- the electricity connection was made correctly and theinstallation is properly grounded;
- the automatic deaerating valve is allowed;- if the pressure is lower than 1 bar, put more water in the
circuit;- the gas tap is closed.2) Start the boiler by turning knob A to position I (green
diode D lights up) and turning knob C to the middleposition between min and max to start the boiler in the winter
mode. Leave the boiler in this mode for some time to allow
complete deaeration. The boiler will signal blocking after 7
seconds. Then:- release the front plug of the pump deaerating valve to
prevent creation of air bubbles;- repeat the process of radiator deaeration,- open water taps;- check the circuit pressure and if it is lower, open the
refilling tap again until the pressure is 1 bar3)Check that the outlet and inlet pipes are clear.4)Check that the ventilating holes are open.5) Open the gas tap and check the installation for leaks
(including the burner installation) using water with soap. Block
the leaks if necessary.6)Unblock the boiler by pressing H button. The ignition of the
main burner should come immediately. If the burner does not
ignite, repeat the process.7)Check the minimum and maximum value of the gas pressureon the burner and set it according to the chart in chapter 4
REGULATION.
3.5 REGULATION OF OPERATIONIt is possible to adjust:
- the temperature of water for heating, using turning knob C- the temperature of water for DHW, using turning knob B
- choose the economical mode -E- or the comfortable mode -C- ,
using switch G. The economical mode is the usual boilers
operation, when DHW is heated only when required by the user.The comfortable mode is a special function, where the water in
the primary and the secondary circuits is kept pre-heated so that
the user can use the hot water in shorter time, which is for themmore comfortable.
To access the area where the operation can be adjusted it is
necessary to open the control panel, as described in paragraph
3.3, i.e. by unscrewing two screws and removing the backwindow.
Thus you gain access to the electronic panel and the followingcomponent:1) supply cable connector2) fuses3) potentiometer for regulating the slow ignition, which
changes according to the minimum and the maximum
output.4) potentiometer for setting the maximum heat output (preset
to 70% of the maximum heating output by the
manufacturer)5) jump switch for regulating the repeated burner ignition
after burner expires (preset to 1 minute by the
manufacturer).6) Jumper for choosing the floor or the radiator system (J
wiring diagram)7) Jumper for setting the time of the combustion chamber
ventilation (ZA - wiring diagram), which is preset toposition B ventilation on by the manufacturer8) connector for room thermostat connecting (A 15)
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9) connector for programmable clock connecting (if requiredby the customer) (A14)
3.6 FLUE ANALYSIS
The boiler has 2 scanning spots on the output of flue collecting
pipe. The spots are used for finding the harmful substances in the
flue.It is possible to measure the flue temperature, O2, CO2
concentration etc. by using these scanning spots and other
suitable measuring equipment.To access the scanning spots you have to unscrew the front
screw and remove the cover with seal.
The best conditions for analysis are set when the function flue
analysis is activated (press button RESET H for 10 seconds,yellow diode E lights); the boiler switches to the original mode
after 5 minutes, or it is possible to interrupt the function by
ON/OFF switch (button A).Screw the cover with seal back to their original place and seal it
properly after the flue analysis.
3.7 GAS OUTLET CHECKIt is possible to check the correct installation of the exhaust
system and to check losses in the inlet system.
You can measure the difference of pressures
P with differentialmanometer connected to the testing terminals of thecombustion chamber.
The value measured should not be lower than 0.55 mbar with the
maximum heat output.
3.8 PROTECTION FUNCTIONSThe boiler is equipped with the following protection-checking
functions:1 Wrong ignition
This measure signals that the burner has not ignited within 7
seconds after the spark. The boiler is blocked, which is signalledby red F diode. You can restart the boiler by pressing and
releasing button H after you check the gas tap is open.
2 Circulation pump blocking
This measure blocks the boiler if the through-flow switch does
not order the pump to start within 40 seconds. In this case redL lights up. You can restart the boiler after you refill the
pressure in the system and press button A.
3 -OverheatingThis measure blocks the boiler if the temperature in the primary
circuit exceeds 105C. The block is signalled by red I and F
diodes lighting up. It is possible to restart the boiler by button
H after a few minutes, which are necessary for the primarycircuit to cool down.
4 Protection against boiler scale
The boiler is equipped with a device reducing limestone creation
in the secondary circuit. It measures the water temperature
(
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4. GAS REGULATION
CATEGORY II2H3P NATURAL GAS G20 PROPANE G31
Wobbes index (15C, 1013 mbar) MJ/m3hNominal connecting excess pressure mbarMinimum connecting excess pressure mbar
Main nozzles diameter: 14 nozzles mmConsumption (15C, 1013 mbar) m3/h
Consumption (15C, 1013 mbar) kg/h
Pressure on gas valve outlet max - min
45.672017
1.252.75
-
10.3 2.0
70.693725
0.72-
2.6
35.6 6.8
1 mbar = 10.197 mm of water column
(*) The maximum gas pressure on the burner equals the connecting gas excess pressure reduced by pressure losses inside the gas valve.
CATEGORY II2H3P NATURAL GAS G20 PROPANE G31
23 kW
Recommended pressures for slow ignition (mm H2O) 5 12
4.1 CHANGE TO A DIFFERENT GAS TYPE
The boiler can be changed to use natural gas (G20) or propane (G31) by a technician from an authorized centre. The manufacturer
produces boilers in the version for natural gas.
If you want to do the change you have to:
1. change the main burner nozzles (see the chart in chapter 4);2. regulate the maximum and the minimum boiler output (see the chart in chapter 4);
3. change the production label;
4. set the maximum heating output;5. set the slow ignition;
6. set the ignition delay.
5. MAINTENANCE
We recommend the following checks at least once a year:
1. check the leaks of water armatures, repair or replace defective seals
2. check the leaks of gas connection, repair or replace defective seals
3. visual check of the appliance, disassembling and combustion chamber cleaning if necessary
4. visual check of the combustion process, cleaning burners, disassembling and cleaning nozzles if necessary5. visual check of the primary exchanger:
- check the lamellas- clean the exchanger if necessary
6. gas pressure regulation: in the ignition mode, for the reduced and the maximum outputs
7. check heating safety systems:
- maximum temperature- maximum pressure8. check gas safety systems:
- check of flame scan
- check of gas valve9. check the correct connection to the supply mains
10. check the efficiency of the secondary exchanger for DHW production (check the provided volume and DHW temperature)
11. check the proper installation of flue exhaust
12. check the function and position of the flue thermostat, which cannot stop working. If a replacement of this component is necessary, it canonly by replaced with an original type.
13. complete check of all boiler functions.
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6. TECHNICAL SPECIFICATIONS
23 TCA
CE Certificates
Heat inputNominal heat output
Efficiency at maximum input
Efficiency at 30% inputHeat loss at the cover (D=50C)
Heat loss by draught with ignited burner
Heat loss by draught with expired burner
Maximum flue flow (natural gas)
Minimum draughtNatural gas consumption at max. output (G20)
Propane consumption at max. output (15C, 1013 mbar) (G31)
Flue temperature at max. output with natural gas combustionCO2 volume in flues
Minimum ambient temperature
Pressure losses in water (max)(DT=20C)
Minimum pressure in the heating systemHeating water temperature
DHW temperatureHot water volume with DT=25CHot water volume with DT=35C
Minimum DHW consumption
DHW pressure
Expansion vessel volumeExpansion vessel excess pressure
Maximum water volume in the circuit
Maximum water pressure in the heating circuitNatural gas connecting excess pressure (G20)
Propane connecting excess pressure (G31)Voltage/frequency
Electricity input
Level of electric cover
Max/min kWMax/min kW
%
%%
%%
Kg/h
Pam3/h
kg/h
C
%C
mbar
barmax/min C
max/min Cl/min
l/minl/min
max/min bar
lbar
l
bar
mbar
mbarV/Hz
W
IP
0694BO0090
26.5 / 11.0
24.8 / 9.793.7
90.71.2
5.10.4
51.8
1.32.8
2.09/2.06
106
7.1+5
200
0.2582 / 42
56 / 3614.2
10.22.6
8 / 0.2
71
130
3
20
37230 / 50
110
24D
13