COSMOGAS MYDENS 60T, MYDENS 70T, MYDENS 180T, MYDENS 210T, MYDENS 280T Installation, Use & Maintenance Manual

...

62403578 - R01 09-12-2016_UK

INSTALLATION, USE AND MAINTENANCE MANUAL

60T

70T 100T 115T 140T 180T 210T 280T

MYDENS FLOOR ST

ANDING

CONDENSING BOILER

60T - 280T

COSMOGAS

Explosive or hi g h l y flammable products

Do not store or use explosive or highly flammable materials such as paper, solvents, paints, etc...in the same room where the appliance is installed.

If you can smell combustion products

1. - Switch the appliance off.

2. - Ventilate the room.

3. - Call a professionally qualified technician.

Qualied installer: qualied installer is an individual with specic, technical training in space heating systems, domestic hot water systems, fuel

gas systems and electrical systems. This individual must have the legally

required qualications.

Installation and Modications: Only a Qualied installer must carry out

the installation and calibration of the heater. Never modify the heater or its

ue gas carrying components in any

way. This heater must be properly vented.

Flue gas/air intake:

- You are only permitted to operate this appliance with the combustion

air/ue gas system that has been specically designed and approved.

- Do not obstruct the air intake or vent pipe terminals.

- If heater installation is provided as

replacement heater, DO NOT connect

new heater venting to an existing

vent system, if it is shared with other

appliances.

- Do not restrict or seal any air intake or outlet openings (terminals).

Hazards and Your Safety - Hot Water Can Scald! Water temperature over 125°F

(52°C) can cause severe burns instantly, or death from scalds. Children, the disabled, and the elderly are at highest

risk of being scalded; see instruction manual before setting temperature at heater! Feel water before bathing or showering.

In stall e r: Rea d all in struc tions, inc l u di n g th i s ma n ua l , be f or e

installing. Perform steps in the order given.

User: This manual is for use only by a qualied heating installer. Refer to

the User’s Information section for your reference.

Maintenance: at least once a year the user must call a Qualied installer for

routine maintenance.

If you smell gas

1. - Close the gas cock.

2. - Ventilate the room.

3. - Do not switch on any electric device, telephone included.

4. - Fr o m an o th e r r o om , ca ll a

professionally qualied technician

imm e d i a t e ly or th e ga s sup p l y company. Call the Fire Service if the former are not available.

Carbon Monoxide. Eve r y y ea r d ea t hs an d s er io us injuries occur due to carbon monoxide poisoning. This tragedies are avoidable if certain preventative measures such as the following are undertaken:

Ensure that all boilers, water heaters,

room heaters, stoves and hobs which burn oil, natural gas, LP gas, coal, peat, wood and wood pallets are serviced regularly. Servicing is needed at least once per year to ensure safety. the service person shoul d be qual ified and traine d to serv ice the sp ecif ic types of appliance

If an appliance is tted in a dwelling,

then a carbon monoxide detector

should always be tted. There are

two types available: a simple detector

works like a re alarm to emit a loud

noise and flashing light if carbon monoxide is detected or a more sophisticated version which will also switch off the appliance to provide more safety.

Defects: If you nd any defects, you

must inform the owner of the system of the defect and the associated hazard in writing.

When servicing heater, to avoid electric shock, disconnect electrical supply

before performing maintenance.

When servici ng heater, to avoid severe burns, allow heater to cool

before performing maintenance.

Label all wires prior to disconnection when serv icing controls. Wiring er r o rs can cause im p roper and dangerous operation. Verify proper operation after servicing.

Correct Use:

This heater must only be used for the purpose for which it has been

expressly designed: Heating of water

for closed circuit systems for central heating. Do not use this appliance if any part has been under water. Immediately call a licensed authorized technician to insp ect the app liance and to replace any part of the control system

and any gas control, which has been

under water. Ensure the heater and its controls are protected from dripping or spraying water during normal operation or service.

Only use the heater in the combinations and with the accessories and spares listed in this manual. Fo r sa f e ty an d env i ro n me nt al

rea s o n s , th e pa c k i n g ma t e rials

must be properly disposed of. Any replaced part or packaging should never be left within the reach of children.

SAFETY INSTRUCTIONS

WARNING!!!

FAILURE TO COMPLY WITH THESE PROVISIONS AND REQUIREMENTS MAY COMPROMISE THE SAFETY OF THE UNIT AND CAN RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

60T - 280T

COSMOGAS

Installatio n locat ion: The heater

must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower

oors of the structure. When such locations cannot be avoided, it is

recommended that a suitable drain

pan, adequately drained, be installed

under the heater. The pan must not

restrict combustion air ow.

Installation location: The heater must

not be installed on carpeting.

In the event of a breakdown and/or

malfunction of the heater, turn off the

unit and do not make any attempt to repair it. The heater must be serviced

exclusively by a Qualied installer

using original spare parts.

Installation, modications

Seal the adjustment devices after

every calibration.

In agreement with the provisions

for use, the user must keep the installation in good working order and guarantee reliable and safe operation of the appliance.

We also highlight the importance of

an annual scheduled maintenance contr a c t with a pro f e s si o n a ll y

qualied technician.

The end user must have maintenance

performed on the appliance only by

professionally qualied technicians

in accordance with this manual and in full compliance with both local and national standards.

 Before performing any cleaning

or maintenan ce, disconnect the appliance from the mains power supply.

After any cleaning or maintenance,

be f o re reconne c t ing the pow e r supply, make sure that all internal parts are properly dry.

This appliance is not intended for

use by persons (including children) with reduced physical and sensory conditions or lack of experience and knowledge, unless they have been given supervi sion or inst ruction concerning use of the appliance by a person responsible for their safety.

 This manual is an integral and

essential part of the product and must be kept carefully by the user, for possible future consultation. If the appliance must be transferred or if you should move and leave the unit to another user, always ensure that this manual remains with the new user and/or installer.

Do not use “homemade cures” or “heater patent medicines”. Serious

damage to the heater, personnel, and/

or property may result.

Do not use petroleum-based cleaning or sealing compounds in the heater system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Technical drawings

All drawings in this manual relating to electrical wiring, hydraulic and gas layou ts are purely ind icative. The external services such as electrical cable types and sizes, water pipes and gas pipes must always be checked by

a professionally qualied technician or

engineer to verify compliance with all relevant standards, Laws and codes of good practice.

NOTICE!

Local approval of the ue system and

the condensate connection to the public sewer system may be required.

The local building regulations stipulating the installation rules at the time of installation.

When calling or writing about the heater – Please have the heater model and serial number from the heater rating plate.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

The manufacturer declines all liability, contractual or otherwise (warranty included), for any damage to people, animals property or this same appliance, caused by: a) - incorrect installation; b) - failure to comply with this or any

other instruction provided by the manufacturer;

c) - failure to comply with the applicable

local and/or national regulations in

force; d) - incorrect use of this appliance e) - inadequate or incorrect service f) - inadequate or incorrect maintenance.

SAFETY INSTRUCTIONS

CAUTION!!!

FAILURE TO COMPLY WITH THESE PROVISIONS AND REQUIREMENTS MAY COMPROMISE THE SAFETY OF THE UNIT AND CAN RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

60T - 280T

COSMOGAS

INDEX

SAFETY INSTRUCTIONS ...................................................................................................................................2

1 - CODE REQUIREMENTS ................................................................................................................................7

1.1 - National laws and regulations .................................................................................................................................. 7

2 - GENERAL INFORMATION .............................................................................................................................8

2.1 - Introduction .............................................................................................................................................................. 8

2.2 - Overview of the models ............................................................................................................................................ 8

2.3 - Included accessories ................................................................................................................................................ 9

2.4 - Manufacturer ............................................................................................................................................................ 9

2.5 - Meaning of the symbols used .................................................................................................................................. 9

2.6 - Maintenance ............................................................................................................................................................. 9

3 - MAIN COMPONENTS ..................................................................................................................................10

4 - OPERATION .................................................................................................................................................18

4.1 - Operation and intended use ................................................................................................................................... 22

4.1.1 - Boiler operation and intended use ............................................................................................................ 22

4.1.2 - Wide range of modulation and maximum performance ............................................................................ 22

4.1.3 - Main circuit pump ...................................................................................................................................... 23

4.1.4 - Heating circuit pump ................................................................................................................................. 23

4.1.5 - Domestic hot water circuit pump ............................................................................................................... 23

4.1.6 - Hydraulic separator ................................................................................................................................... 23

4.1.7 - Boiler domestic hot water production ........................................................................................................ 23

4.1.8 - System types ............................................................................................................................................ 23

4.2 - Precautions when installing .................................................................................................................................... 23

4.3 - Anti-legionella ......................................................................................................................................................... 23

5 - INSTALLATION - Installation site ............................................................................................................... 24

5.1 - Choosing the installation site ................................................................................................................................. 24

5.1.1 Requirements for proper ventilation ............................................................................................................ 25

5.1.2 - Preventing combustion air contamination ................................................................................................. 25

6 - INSTALLATION - Setup ............................................................................................................................... 26

6.1 - Setup ...................................................................................................................................................................... 26

6.1.1 - Moving the appliance ................................................................................................................................ 26

6.1.2 - Opening the package ................................................................................................................................ 26

6.1.3 - Lifting the appliance .................................................................................................................................. 26

7 - INSTALLATION - Minimum distances to respect ...................................................................................... 27

7.1 - Dimensions and minimum distances to respect ..................................................................................................... 27

8 - INSTALLATION - Dimensions and centre distances - Boiler ................................................................... 28

9 - INSTALLATION - Dimensions and centre distances table - Boiler ......................................................... 29

10 - INSTALLATION - Hydraulic connections - boiler .................................................................................... 30

10.1 - Boiler gas and hydraulic connections ................................................................................................................... 30

10.2 - Boiler safety valve (installer’s responsibility) ........................................................................................................ 30

10.3 - Examples of boiler installations ............................................................................................................................ 30

10.4 - Boiler INAIL safety devices .................................................................................................................................. 32

10.5 - Expansion tank connection .................................................................................................................................. 33

10.6 - Supply and return ................................................................................................................................................. 33

10.7 - Boiler water supply ............................................................................................................................................... 33

10.7.1 - Recommendations on the characteristics of the water used in the system ............................................ 33

10.7.2 - For the system to operate properly, you must make sure that: .............................................................. 33

10.7.3 Treating water in heating systems for civil use .......................................................................................... 34

10.8 - Draining the boiler heating circuit ......................................................................................................................... 34

10.9 - Boiler low temperature (or floor) systems ............................................................................................................ 34

10.10 - Manifold probe ................................................................................................................................................... 34

11 - INSTALLATION - Characteristic curve of the boiler head loss .............................................................. 35

60T - 280T

COSMOGAS

INDEX

12 - INSTALLATION - Eliminating condensate ............................................................................................... 36

12.1 - Condensate drain ................................................................................................................................................. 36

13 - INSTALLATION - Electrical connections ................................................................................................. 37

13.1 - Electrical connections: general information .......................................................................................................... 37

13.1.1 - Connecting the power cable ................................................................................................................... 37

13.1.2 - Choosing the room thermostat/time-programmable thermostat ............................................................. 38

13.1.3 - Connecting the room thermostat/time-programmable thermostat .......................................................... 38

13.1.4 - Installing the external temperature probe ............................................................................................... 38

13.1.5 - 885 IF board connection (on request) ..................................................................................................... 39

13.1.6 - Alarm contact .......................................................................................................................................... 39

13.2 - Connecting boiler to the storage tank .................................................................................................................. 39

13.2.1 - D.H.W. production priority ....................................................................................................................... 39

13.4 - Connecting cascade appliances .......................................................................................................................... 43

14 - INSTALLATION - Air intake and flue exhaust ducts ............................................................................... 44

14.1 - Flue exhaust and combustion air intake duct ....................................................................................................... 44

14.1.1 - B23 suction/discharge type ..................................................................................................................... 45

14.1.2 - Split system ............................................................................................................................................. 45

15 - COMMISSIONING ...................................................................................................................................... 46

15.1 - Commissioning ..................................................................................................................................................... 46

15.1.1 - User instructions ..................................................................................................................................... 46

15.1.2 - Filling the condensate drain siphon ........................................................................................................ 46

15.1.3 - Filling the heating system ....................................................................................................................... 46

15.2 - General warnings on the gas power supply ......................................................................................................... 47

15.3 - Type of gas for which the appliance is regulated. ................................................................................................ 47

15.4 - Converting 60T and 70T model appliances from one type of gas to another....................................................... 48

15.5 - Converting appliance models from 100T to 280T from one type of gas to another ............................................. 49

15.6 - Ignition .................................................................................................................................................................. 52

15.6.1 - Boiler ignition .......................................................................................................................................... 52

15.7 - Checking the supply gas pressure and any adjustments ..................................................................................... 52

15.8 - Checking the CO2 seal and any adjustments ...................................................................................................... 53

15.8.1 - Checking the CO2 seal and any adjustments on 60T and 70T model appliances.................................. 53

15.8.2 - Checking the CO2 seal and any adjustments on appliance models from 100T up to 280T ................... 54

15.9 - Checking appliance output heat ........................................................................................................................... 54

15.10 - Minimum water flow rate .................................................................................................................................... 54

16 - USE ............................................................................................................................................................. 55

16.1 - Checking water pressure ..................................................................................................................................... 55

16.1.1 - Checking boiler water pressure .............................................................................................................. 55

16.2- General information ............................................................................................................................................... 56

16.3 - Display ................................................................................................................................................................. 56

16.4 - Ignition and shutdown procedure ......................................................................................................................... 56

16.5 - Boiler domestic hot water adjustment .................................................................................................................. 56

16.6 - Boiler heating adjustment ..................................................................................................................................... 56

16.7 - Thermostat type heating adjustment .................................................................................................................... 56

16.8 - Climatic adjustment .............................................................................................................................................. 57

16.8.1 - Climatic adjustment: setting the parameters ........................................................................................... 57

16.8.2 - Climatic adjustment: switching the heating system on and off ................................................................ 57

16.9 - Timing of the various functions ........................................................................................................................... 57

16.10 - Pump anti-locking ............................................................................................................................................... 57

16.11 - Antifreeze protection .......................................................................................................................................... 57

16.12 - Energy Saving .................................................................................................................................................... 57

16.13 - “User menu” ....................................................................................................................................................... 59

16.14 - “Installer menu” .................................................................................................................................................. 60

16.15 - Diagnostics ......................................................................................................................................................... 61

16.15.1 - Diagnostics: “Loc” lock .......................................................................................................................... 62

16.15.2 - Diagnostics: “E” errors .......................................................................................................................... 63

17 - MAINTENANCE .......................................................................................................................................... 66

17.1 - General warnings ................................................................................................................................................. 66

17.1.1 - Gas leak check ....................................................................................................................................... 66

60T - 280T

COSMOGAS

INDEX

17.1.2 - Making sure the air intake and flue exhaust ducts are in good conditions .............................................. 66

17.1.3 - Checking the system water pressure ...................................................................................................... 66

17.1.4 - Checking the ignition and detection electrodes ..................................................................................... 66

17.2 - Disassembling the casing and accessing the inner components ......................................................................... 67

17.3 - Disassembling the burner fan unit ........................................................................................................................ 67

17.4 - Cleaning the burner and the primary exchanger, flue gas side ............................................................................ 68

17.4.1 - Thermal insulations ................................................................................................................................. 70

17.5 - Positioning the ignition and ionisation electrodes properly ................................................................................. 70

17.6 - Cleaning the air intake filter .................................................................................................................................. 71

17.7 - Condensate drain system maintenance and cleaning ......................................................................................... 71

17.8 - Connecting the Display to the other burners ........................................................................................................ 72

17.9 - How to move a control board ............................................................................................................................... 73

17.10 - Emptying the appliance ...................................................................................................................................... 75

17.11 - Minimum and maximum output heat ................................................................................................................. 75

17.12 - Checking the ionisation current .......................................................................................................................... 75

17.13 - Checking combustion performance .................................................................................................................... 75

17.14 - Temperature and water measurement probes ................................................................................................... 75

17.15 - External temperature probe ............................................................................................................................... 76

17.16 - 60T and 70T models multi-line wiring diagram ................................................................................................... 77

17.17 - 100T, 115T, 140T, 180T 210T and 280T models multi-line wiring diagram ........................................................ 79

18 - TECHNICAL FEATURES ........................................................................................................................... 83

18.1 - TECHNICAL FEATURES MYDENS ..................................................................................................................... 83

19 - FORCED MENU .......................................................................................................................................... 87

20 - CONTROL MENU DIAGRAM ................................................................................................................... ..89

21 - BOILER OPERATION SEQUENCE ........................................................................................................ ..90

22 - CE DECLARATION OF CONFORMITY ......................................................................................................91

23 - ErP PRODUCT FICHE MYDENS ............................................................................................................... 92

60T - 280T

COSMOGAS

1 - CODE REQUIREMENTS

1.1 - National laws and regulations

- M.D. no.37 dated 22/01/2008 (former Law no.46 dated 05/03/90)

- Law no.10 dated 09/01/91

- Presidential Decree no.412 dated 26/08/93

- Presidential Decree no.551 dated 21/12/99

- Legislative Decree no.192 dated 19/08/05

- Legislative Decree no.311 dated 29.12.06

- UNI 7129 Standard

- UNI 7131 Standard

- UNI 11071 Standard

- IEC 64-8 Standard

All the gas appliances must be installed by a competent and

qualied person, in accordance with the relevant clauses of

applicable standards and recommendations. These include but may not be limited to the following:

- I.S. 813 Domestic gas installations.

- I.S. 820 Non-Domestic gas installations.

- IEE Wiring Regulations.

- BS 5546:2010 - Specication for installation and maintenance

of gas-fired water-heating appliances of rated input not exceeding 70 kW net.

- BS 5440-2:2009 - Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family

gases) specication for the installation and maintenance of

ventilation provision for gas appliances.

- BS 6644:2011 - Specification for the installation and

maintenance of gas-red hot water boilers of rated inputs

between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family gases).

- BS 6891:2005+A2:2008 - Installation of low pressure gas pipework of up to 35 mm (R1 1/4) in domestic premises (2nd

family gas) specication.

- BS 5482-1:2005 - Code of practice for domestic butane and propane gas burning installations. Installations at permanent dwellings, residential park homes and commercial premises, with installation pipework sizes not exceeding DN 25 for steel and DN 28 for corrugated stainless steel or copper.

- BS 5482-2:AMD 12046: June 2001 - Domestic butane and propane gas burning installations. Installations in caravans and non-permanent dwellings.

- BS 5482-3:2005 - Domestic butane and propane gas burning installations. Installations in boats, yachts and other vessels.

- Building regulations issued by the Department of the Environment and Building Standards Regulations.

- Gas safety (Installation and Use) Regulations current issue.

- BS 6700 - Design, installation, testing and maintenance of services supplying water for domestic use within buildings

and their cartilages - Specication.

- UK Health and safety at work Act.

- All relevant Building Regulations.

- Local Water Byelaws.

- Water Regulations.

- Health & Safety legislation.

Failure to install this appliance correctly could lead to prosecution. It is in your own interest and in the interest of safety to ensure that the law is complied with. Manufacturer’s instructions must not be interpreted as over-riding statutory obligations under any circumstances.

60T - 280T

COSMOGAS

2 - GENERAL INFORMATION

2.1 - Introduction

Congratulations! You have purchased truly one of the best products on the market. Every single part is proudly designed, built, tested and assembled at the COSMOGAS plants, thereby ensuring the best quality control.

2.2 - Overview of the models

XXXXDENS XXXTXX

v = Appliance with 2-way valves s = Appliance with stainless steel manifold sv = Appliance with 2-way valves and stainless steel manifold c = Appliance with carbon steel manifold cv = Appliance with 2-way valve and carbon steel manifold

“60T” = Floor standing appliance with 60kW maximum heat output; “70T” = Floor standing appliance with 69,9kW maximum heat output; “100T” = Floor standing appliance with 100kW maximum heat output; “115T” = Floor standing appliance with 115kW maximum heat output; “140T” = Floor standing appliance with 140kW maximum heat output; “180T” = Floor standing appliance with 180kW maximum heat output; “210T” = Floor standing appliance with 210kW maximum heat output; “280T” = Floor standing appliance with 280kW maximum heat output;

“MYDENS” = Indoor gas condensing boiler with low emission pre-mixed burner.

60T - 280T

COSMOGAS

2.4 - Manufacturer

COSMOGAS srl Via L. da Vinci 16 47014 - Meldola (FC) Italy Tel. 0543 498383 Fax. 0543 498393 www.cosmogas.com info@cosmogas.com

2.5 - Meaning of the symbols used

ATTENTION !!!

Danger of electrical shock. Failure to follow these warnings can compromise proper appliance operation or cause serious harm to persons, animals or things.

ATTENTION !!!

General danger. Failure to follow these warnings can compromise proper appliance operation or cause serious harm to persons, animals or things.

 Important instruction symbol

2.6 - Maintenance

It is advisabl e to follow scheduled annual appliance maintenance for the following reasons:

- to maintain high output and manage the heating system affordably (low fuel consumption);

- to reach high work safety;

- to keep the level of fuel environmental compatibility high;

Offer your customers a periodic maintenance contract.

2 - GENERAL INFORMATION

2.3 - Included accessories

The appliance is supplied with the following accessories:

Amount No.

Description

Code

Figure

60T, 100T AND 115T METH GAS-LP gas CONVERSION KIT. 62630197

70T, 140T, 180T, 210T AND 280T METH GAS-LP gas CONVERSION KIT. 62630198

1 10K SENSOR D6X45 L=2500 T 62110071

1 EXTERNAL PROBE 62110067

4 ADJUSTABLE FEET 60805006

1 10KG SACK OF CONDENSATE NEUTRALISER GRANULES 62801022

1P NPT - 1P GAS REDUCTION

Only in 100T, 115T and 140T models

60101290

1P1/4 NPT - 1P1/4 GAS REDUCTION

Only in 180T, 210T and 280T models

60101289

2 2P NPT - 1P1/2 GAS REDUCTION

Only in 100T, 115T and 140T models

60110053

2 EN 1092-1-13 DN65 PN16 NPT FLANGE

Only in 180T, 210T and 280T models

60338043

60T - 280T

COSMOGAS

1 - Air/gas mixing unit 2 - Gas valve 3 - Air inlet manifold 4 - Hot water safety thermostat 5 - Hot water temperature probe 6 - ---------7 - Hot water supply pipe 8 - ---------9 - Heat exchanger 10 - ----------

11 - ---------12 - Plug (not present) 13 - Water pressure sensor (present on the MASTER burner 1) 14 - Spark generator 15 - Ignition cables

16 - Water ow rate measuring device

17 - Motorised 2-way valve (on request) 18 - Water inlet pipe 39 - Air bleed valve (present on all slave burners)

3 - MAIN COMPONENTS

Figure 3-1 - Components inside 60T, 70T, 100T, 115T, 140T, 180T, 210T and 280T models

15 1614

1239 13

134 2

020009.01.018

60T - 280T

COSMOGAS

19 - Burner 20 - ---------21 - Detection electrode 22 - ---------23 - Burner warning light 24 - ---------25 - Fan

26 - Water inlet temperature sensor 27 - LH ignition electrode 28 - RH ignition electrode 29 - ---------30 - ---------31 - Flue gas check valve 32 - Check valve magnet 33 - Check valve sensor

3 - MAIN COMPONENTS

Figure 3-2 - Components inside 60T, 70T, 100T, 115T, 140T, 180T, 210T and 280T models

21 19

27 28

020009.01.028

32 33 31

020009.01.028_a

60T - 280T

COSMOGAS

1 - Adjustable feet 2 - Flue exhaust condensate drain pipe 3 - Condensate neutraliser 4 - Burner “1” (MASTER) 5 - Condensate drain pipe 6 - Gas inlet pipe 7 - Hot water supply pipe 9 - Air intake 10 - Electrical wire passage

11 - Air intake lter

12 - Flue exhaust 13 - 885 IF board (on request)

14 - Electrical connections 15 - ---------16 - ---------17 - Control panel 19 - Upper front casing 20 - “Burner 1” command and control board 21 - Lower front casing 24 - Pressure switch against discharge clogging 25 - Wiring diagram 35 - Automatic air vent 36 - Water supply connection 37 - Water return connection 38 - Drain valves

3 - MAIN COMPONENTS

Figure 3-3 - Components inside 60T and 70T models

7 4

3 2

11 14

020014.01.023

60T - 280T

COSMOGAS

22 - Upper covering 23 - Main ON/OFF switch 27 - Fan covering 28 - Flue exhaust temperature safety fuse 29 - Flue exhaust temperature probe

30 - Flue exhaust manifold 31 - Water inlet pipe 32 - ---------33 - Condensate level sensor 34 - ----------

3 - MAIN COMPONENTS

Figure 3-4 - Components inside 60T and 70T models

020014.01.024

60T - 280T

COSMOGAS

1 - Adjustable feet 2 - Flue exhaust condensate drain pipe 3 - Condensate neutraliser 4 - Burner “1” (MASTER) 5 - Condensate drain pipe 6 - Gas inlet pipe 7 - Hot water supply pipe 8 - Burner “2” (SLAVE) 9 - Air intake 10 - Electrical wire passage

11 - Air intake lter

12 - Flue exhaust 13 - 885 IF board (on request) 14 - Electrical connections

15 - ---------16 - ---------17 - Control panel 18 - “Burner 2” command and control board 19 - Upper front casing 20 - “Burner 1” command and control board 21 - Lower front casing 24 - Pressure switch against discharge clogging 25 - Wiring diagram 26 - Water outlet manifold temperature sensor 35 - Air bleed valve 36 - Water outlet 37 - Water inlet 38 - Drain cock

3 - MAIN COMPONENTS

Figure 3-5 - Components inside 100T, 115T and 140T models

3 2

11 14

3 2

11 14

020014.01.003

60T - 280T

COSMOGAS

22 - Upper covering 23 - Main ON/OFF switch 26 - Water general outlet temperature sensor 27 - Fan covering 28 - Flue exhaust temperature safety fuse 29 - Flue exhaust temperature probe

30 - Flue exhaust manifold 31 - Water inlet pipe 32 - ---------33 - Condensate level sensor 34 - ----------

3 - MAIN COMPONENTS

Figure 3-6 - Components inside 100T, 115T and 140T models

020014.01.004

BURNER 2

BURNER 1

(Master)

60T - 280T

COSMOGAS

3 - MAIN COMPONENTS

Figure 3-7 - Components inside 180T, 210T and 280T models

020013.01.001

1 - Adjustable feet 2 - Flue exhaust condensate drain pipe 3 - Condensate neutraliser 4 - Burner “1” (MASTER) 5 - Condensate drain pipe 6 - Gas inlet pipe 7 - Hot water supply pipe 8 - Burner “2”-”3”-”4” (SLAVE) 9 - Air intake 10 - Electrical wire passage

11 - Air intake lter

12 - Flue exhaust 13 - 885 IF board (on request) 14 - Electrical connections

15 - ---------16 - ---------17 - Control panel 18 - Burner “2”-”3”-”4” command and control board 19 - Upper front casing 20 - Burner “1” command and control board 21 - Lower front casing 24 - Pressure switch against discharge clogging 25 - Wiring diagram 26 - Water outlet manifold temperature sensor 35 - Air bleed valve 36 - Water outlet 37 - Water inlet 38 - Drain cock

60T - 280T

COSMOGAS

3 - MAIN COMPONENTS

Figure 3-8 - Components inside 180T, 210T and 280T models

020013.01.010

BURNER 2

(Not present on 180T and 210T models)

BURNER 1

(Master)

BURNER 3

BURNER 4

22 - Upper covering 23 - Main ON/OFF switch 27 - Fan covering 28 - Flue exhaust temperature safety fuse 29 - Flue exhaust temperature probe

30 - Flue exhaust manifold 31 - Water inlet pipe 32 - ---------33 - Condensate level sensor 34 - ----------

60T - 280T

COSMOGAS

4 - OPERATION

Figure 4-1 key: 1 - Air intake 2 - Flue exhaust 3 - Air bleed valve 4 - Sealed chamber 6 - Water outlet temperature safety thermostat 7 - Water outlet temperature sensor 8 - Water pressure measuring device 9 - Flue exhaust temperature probe 10 - Flue exhaust temperature safety fuse 12 - Pre-mixed burner 13 - Ignition electrodes 14 - Spark generator 15 - Water inlet temperature sensor 16 - Fan 17 - Flue gas non-return valve 20 - Gas valve 22 - Detection electrode 24 - CRV Heat exchanger 25 - Water outlet 26 - Water inlet 27 - Gas inlet 28 - Pressure switch against discharge clogging 29 - Condensate level sensor 30 - Condensate drain 31 - Condensate drain siphon 36 - Condensate neutraliser

47 - Water ow rate measuring device

Figure 4-1 - 60T and 70T model functional hydraulic diagram

60T - 280T

COSMOGAS

4 - OPERATION

Figure 4-2 - 100T, 115T and 140T model functional hydraulic diagram

Figure 4-2 key: 1 - Air intake 2 - Flue exhaust 3 - Air bleed valve 4 - Sealed chamber 6 - Water outlet temperature safety thermostat 7 - Water outlet temperature sensor 8 - Water pressure measuring device 9 - Flue exhaust temperature probe 10 - Flue exhaust temperature safety fuse 12 - Pre-mixed burner 13 - Ignition electrodes 14 - Spark generator 15 - Water inlet temperature sensor 16 - Fan 17 - Flue gas non-return valve 20 - Gas valve 22 - Detection electrode 24 - CRV Heat exchanger 25 - Water outlet 26 - Water inlet 27 - Gas inlet 28 - Pressure switch against discharge clogging 29 - Condensate level sensor 30 - Condensate drain 31 - Condensate drain siphon 33 - Manifold outlet temperature sensor 36 - Condensate neutraliser

47 - Water ow rate measuring device

48 - Motorised 2-way valve (on request)

60T - 280T

COSMOGAS

4 - OPERATION

Figure 4-3 - 180T, 210T model functional hydraulic diagram

Figure 4-3 key: 1 - Air intake 2 - Flue exhaust 3 - Air bleed valve 4 - Sealed chamber 6 - Water outlet temperature safety thermostat 7 - Water outlet temperature sensor 8 - Water pressure measuring device 9 - Flue exhaust temperature probe 10 - Flue exhaust temperature safety fuse 12 - Pre-mixed burner 13 - Ignition electrodes 14 - Spark generator 15 - Water inlet temperature sensor 16 - Fan 17 - Flue gas non-return valve 20 - Gas valve 22 - Detection electrode 23 - Inlet and outlet manifold 24 - CRV Heat exchanger 25 - Water outlet 26 - Water inlet 27 - Gas inlet 28 - Pressure switch against discharge clogging 29 - Condensate level sensor 30 - Condensate drain 31 - Condensate drain siphon 33 - Manifold outlet temperature sensor 36 - Condensate neutraliser

47 - Water ow rate measuring device

48 - Motorised 2-way valve (on request) 50 - Drain cocks

60T - 280T

COSMOGAS

4 - OPERATION

Figure 4-4 - 280T model functional hydraulic diagram

Figure 4-4 key: 1 - Air intake 2 - Flue exhaust 3 - Air bleed valve 4 - Sealed chamber 6 - Water outlet temperature safety thermostat 7 - Water outlet temperature sensor 8 - Water pressure measuring device 9 - Flue exhaust temperature probe 10 - Flue exhaust temperature safety fuse 12 - Pre-mixed burner 13 - Ignition electrodes 14 - Spark generator 15 - Water inlet temperature sensor 16 - Fan 17 - Flue gas non-return valve 20 - Gas valve 22 - Detection electrode 23 - Inlet and outlet manifold 24 - CRV Heat exchanger 25 - Water outlet 26 - Water inlet 27 - Gas inlet 28 - Pressure switch against discharge clogging 29 - Condensate level sensor 30 - Condensate drain 31 - Condensate drain siphon 33 - Manifold outlet temperature sensor 36 - Condensate neutraliser

47 - Water ow rate measuring device

48 - Motorised 2-way valve (on request) 50 - Drain cocks

60T - 280T

COSMOGAS

4.1 - Operation and intended use

4.1.1 - Boiler operation and intended use

This is a gas condensing appliance intended to generate centralised heating. It can also be used for domestic hot water production for civil use, but it must be appropriately

connected to a storage tank (see g. 10-2). Any other use is

prohibited. Maximum domestic hot water service output heat is always guaranteed as the appliance give priority to said service. Follow the procedure described in section 16.6 to adjust the domestic hot water temperature. The heating system can be created with heat elements that work at a temperature range from 30°C to 80°C. The boiler can be connected to a room thermostat, an external probe or a 0-10Vdc analogue input. This boiler must be connected to a heating and domestic hot water production system with required output heat that is compatible with the features of the appliance itself.

Figure 4-5 - 280T model appliance modulation

4.1.2 - Wide range of modulation and

maximum performance

The appliance management program, depending on the head required by

the system, provides for the

gradual ignition of

each single heating element at minimum output (see figure

4-5). After which, if the head required by the system increases, all the heating elements progressively increase output. This achieves modulated output heat that goes from a minimum of 14kW to a maximum corresponding to the architecture of the appliance (figure 4-5 shows a 280T

module with 4 heating elements), with maximum efficiency consequently maintained for the entire modulation range.

When the boiler is connected to an external probe, it always works at maximum output (see section 16.9).

4 - OPERATION

60T - 280T

COSMOGAS

Figure 4-6 - Example of output diagram / supply and return temperature / external temperature, for a

home in a very cold area and radiator system.

4.1.7 - Boiler domestic hot water

production

A storage tank must be connected for domestic hot water

production following the diagram referred to in

gure 10-2.

The domestic hot water temperature is adjusted following the

specific procedure in section 16.6.

4.1.8 - System types

The following types of systems can be created with this appliance:

- Only centralised heating system (see gure 10-1)

- Only domestic hot water production system (see gure 11-1)

- Centralised heating and domestic hot water production

system (see gure 10-2).

4.2 - Precautions when installing

For proper appliance operation, respect the following instructions:

It must be connected to a heating system and, if necessary,

to a domestic hot water distribution mains, compatibly with the features, performance and output of the appliance itself.

Check gures 7-1 and 7-2 regarding the minimum distances

to respect for installation and future maintenance.

4.3 - Anti-legionella

Boiler (when connected to a

storage tank) have no antilegionella protection: It is the installer’s responsibility to keep the storage tank temperature no lower than 60°C to disinfect it or adopt equivalent systems.

4 - OPERATION

This system allows the supply temperature to be managed automatically based on the ex ter nal tem per ature. An

operating example is shown as a graphic in gure 4-6. The

graphic shows an example in which the supply and return temperatures are 55°C and 43°C respectively and the external temperature is 0°C. The external probe controls boiler modulation, progressively reducing the supply temperature and optimising output. Output changes from 97% when the external temperature is -15°C to 105,8% with 0°C external temperature and up to 109° with 20°C external temperature.

4.1.3 - Main circuit pump

he appliance is specically built without an inner pump

to give installers the option of connecting it to any pump, even a modulating one. The main circuit pump is part “36”

in gures 10-1 and 10-2. To choose this pump, the designer

must check what is described in section 10.11 as well as the system features.

4.1.4 - Heating circuit pump

The heating circuit pump, part “19” in gures 10-1 and 10-2,

is not supplied to give the installer the option of connecting it to any pump, even a modulating one. To choose this pump, the designer must check the system features.

4.1.5 - Domestic hot water circuit pump

The domestic hot water circuit pump, part “28” in gure 10-2 and part “36” in gure 11-1, is not supplied to give the installer

the option of connecting it to any pump, even a modulating one. To choose this pump, the designer must check the system features.

4.1.6 - Hydraulic separator

If the system needs to be served by a higher water ow rate

than what the pump is able to dispense, a hydraulic separator

must be put between the boiler and the system (see gures

10-1 and 10-2, part “20”).

60T - 280T

COSMOGAS

020010.01.011

020010.01.012

Figure 5-1 - Disassembling transport pallet screws

5.1 - Choosing the installation site

ATTENTION !!! Do not store any ammable

material in the immediate vicinity of the appliance.

ATTENTION !!! Do not install the appliance on

carpeting.

ATTENTION !!! The appliance must be installed

in a room in which it can be supplied with air for

ventilation and combustion, whether that air is taken

from the outside (sealed combustion) or the inside (combustion in ventilated chamber).

ATTENTION !!! Insufcient appliance ventilation

can cause high air temperatures.

ATTENTION !!! Make sure the intake and

exhaust openings are appropriately sized and that there are no obstructions or clogs. If the problem is not

resolved, do not start the appliance. Please keep these restrictions in mind, as well as the dangers they can

present to the operator.

ATTENTION !!! LP gas Liqueed Petroleum

gas - Installation requires special attention: LP gas appliances must not be installed in pits, cellars or similar locations where the gas, which is heavier than air, could stagnate. Appliances with this kind of fuel

must not be installed in spaces under the level of the

oor or cellars. Failure to respect this precaution could cause explosions and serious harm to people, death or

enormous material damage.

5 - INSTALLATION - Installation site

ATTENTION !!! Installing the appliance in rooms

with thin oors could create resonance noise. Install

elements that reduce the noise.

ATTENTION !!! Do not allow to much dust to

accumulate on the appliance.

ATTENTION !!! The appliance must only be

installed on solid ooring that supports the weight and

is level.

 Before installing, wash the heating system and, if

necessary, the domestic hot water system thoroughly in order to remove any residues or impurities that could compromise proper appliance operation.

This appliance is not made to be installed in the open.

It must not be exposed to temperatures below zero or above 50°C. Choose a location inside the home or, in any case, sheltered from elements like rain, wind, sun and, especially, frost.

This device must be installed in this sort of location so

that any water leaks coming from it, from the connections between the pipes or from potential safety valve drainage cannot damage materials or things underneath it.

Establish the appropriate room and position for installation, keeping the following factors in mind:

- ue exhaust/air intake duct connection;

- gas adduction duct connection;

- water supply connection;

- centralised heating system connection;

- domestic hot water system connection (if present);

- electrical connection;

- connection of the condensate drain generated by the

boiler;

- room thermostat electrical connection;

- safety valve discharge connection;

- any external temperature sensor connection;

- room ventilation.

60T - 280T

COSMOGAS

Figure 5-2 Example of ventilation with methane gas appliance

Figure 5-3 Example of ventilation with LP gas appliance

CENTRAL HEATING UNIT

VENTILATION OPENING

METHANE GAS APPLIANCE

5.1.1 Requirements for proper ventilation

The utility room MUST have a properly sized ventilation opening. To ensure proper ventilation for combustion in compliance with the national and local standards in force, abide by the following: At least one direct opening to the outside is required for combustion, which must have a minimum area of 3000 cm2 of 5000 cm2 if the appliance runs on LP gas. Said opening must be positioned less than 30 cm from the ceiling if the appliance

runs on METHANE gas (see g 5-2) or along the oor if it runs on LP gas (see g 5-3).

The openings must communicate directly with the outside. The requisites described above refer to one appliance; in rooms

where there are several appliances, greater free oor space is

required to provide adequate ventilation for the combustion of all the appliances.

ATTENTION !!!

In no case must the central

heating unit be in a negative pressure state. Therefore, consider the presence of any discharge fans, ceiling fans, dryers, compressors, air heating units, etc. that can take

air away from the appliance.

ATTENTION !!!

EXTRACTORS: Extractors or

similar devices to discharge air from the central heating

unit can decrease the ventilation required for combustion

and/or cause vacuums in the ventilation system. Flue exhaust leaks from the ventilation system in an inhabited room can cause very dangerous conditions that must be corrected immediately.

5.1.2 - Preventing combustion air contamination

Do not position air intake and/or ue exhaust outlets in rooms

where combustion air can be contaminated.

ATTENTION !!! Contaminated combustion air

can damage the appliance

Make sure the combustion air does not contain any of the following contaminating agents.

Products that can contaminate combustion air:

- Permanent wave solutions;

- Chlorinated waxes/cleaning products;

- Chlorine-based pool chemical products;

- Calcium chloride used for defrosting;

- Sodium chloride used to soften water;

- Coolant leaks;

- Solutions to remove paint or varnish;

- Hydrochloric acid/muratic acid;

- Cements and adhesives;

- Antistatic softeners used in dryers;

- Chloro-type bleaches, detergents and cleaning solvents

found in laundry rooms for home use;

- Adhesives used to secure construction products and other

COSMOGAS MYDENS 60T, MYDENS 70T, MYDENS 180T, MYDENS 210T, MYDENS 280T Installation, Use & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual