Cosmogas MYDENS 60T/70T/100T/115T/140T/180T/210T/280T INSTALLATION, USE AND MAINTENANCE MANUAL (62403578 - R01 09-12-2016_UK)

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Page 1

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

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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.

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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.

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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

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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

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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

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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.

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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.

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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

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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

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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

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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

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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

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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

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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)

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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

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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 - ----------

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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

Page 19

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)

Page 20

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

Page 21

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

Page 22

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

Page 23

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”).

Page 24

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.

Page 25

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

similar products;

CENTRAL HEATING UNIT

VENTILATION OPENING

LP GAS APPLIANCE

5 - INSTALLATION - Installation site

Page 26

60T - 280T

COSMOGAS

Figure 6-2 - Levelling feet

Figure 6-1 - Lifting system

6 - INSTALLATION - Setup

6.1 - Setup

To correctly and easily install the appliance, the following steps must be followed scrupulously.

6.1.1 - Moving the appliance

ATTENTION !!! Use appropriate forklifts for the

type of appliance to move it. Failure to respect this could cause enormous damages.

Position the appliance in the area chosen for installation, handling it with the pallet on which it is secured, making sure to keep it upright without making any sudden movements that could cause it to overturn. To free the appliance from the pallet, unscrew the front (part

“C” in gure 5-1) and rear (part “D” in gure 5-1) xing screws.

6.1.2 - Opening the package

The appliance is supplied in cardboard packaging secured to a pallet for transport. Be careful when opening, lift the cardboard box upwards after having detached it from the pallet.

6.1.3 - Lifting the appliance

There is a bracket (part “A” in gure 6-1) to facilitate installation

that allows the appliance to be lifted.

remove the upper covering as per section 17.2;  hook the lifting cables, “B” in gure 6-1, to the bracket, “A”

in gure 6-1, and lift the heating module;

ATTENTION !!! The lifting cables and system

must be suitable to the purpose. In particular, they must resist the weight of the appliance, which you can

check in section 18.

install the adjustable feet “A” to level the appliance as per

gure 6-2.

Once the appliance has been positioned properly, the lifting

cables (part “B” in gure 6-1) must be removed before applying

the upper covering.

020010.01.013

MIN 0 MAX 0,39 " (10 mm)

020010_01_030

B = Locking nut

020021.01.009

BAB

020021.01.010

Page 27

60T - 280T

COSMOGAS

7 - INSTALLATION - Minimum distances to respect

7.1 - Dimensions and minimum distances to respect

Free space must be left around the appliance both for

installation and maintenance, as illustrated in gures 7-1

and 7-2. Figures 8-1, 8-2, 9-1 and 9-2 show the appliance connection dimensions and centre distances.

Figure 7-1 - Minimum distances to respect for 60T, 70T, 100T, 115T and 140T models

Figure 7-2 - Minimum distances to respect for 180T, 210T and 280T models

Page 28

60T - 280T

COSMOGAS

8 - INSTALLATION - Dimensions and centre distances - Boiler

Figure 8-1 - Fitting dimensions and centre distances for 60T, 70T, 100T, 115T and 140T models (References in figure 9-1)

Figure 8-2 - Fitting dimensions and centre distances for 180T, 210T and 280T models (References in figure 9-1)

Page 29

60T - 280T

COSMOGAS

9 - INSTALLATION - Dimensions and centre distances table - Boiler

MODEL

SUPPLY

RETURN

AIR INTAKE4FLUE EXHAUST

GAS

CONDENSATE

DRAIN

60T 1”1/2 1”1/2 80 mm 80 mm 1” 28mm

70T 1”1/2 1”1/2 80 mm 80 mm 1” 28mm

100T 1”1/2 * 1”1/2 * 110 mm 110 mm 1” 28mm

115T 1”1/2 * 1”1/2 * 110 mm 110 mm 1” 28mm

140T 1”1/2 * 1”1/2 * 110 mm 110 mm 1” 28mm

180T DN65 PN16 * DN65 PN16 * 160 mm 160 mm 1”1/4 28mm

210T DN65 PN16 * DN65 PN16 * 160 mm 160 mm 1”1/4 28mm

280T DN65 PN16 * DN65 PN16 * 160 mm 160 mm 1”1/4 28mm

* Fittings and anges are not factory assembled

Figure 9-

1 - Figure 8-1 and 8-2 connection diameter table

Page 30

60T - 280T

COSMOGAS

10 - INSTALLATION - Hydraulic connections - boiler

10.1 - Boiler gas and hydraulic connections

ATTENTION !!! 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.

To identify the position of the ttings, see gures 8-1 and 8-2.

Gas connection

The gas connection must be done at the corresponding

tting with a rigid metal pipe. The gas counter ow rate must be sufcient for simultaneous use of all the gas appliances

connected to it. Connect the gas to the appliance according to the standards in force. The diameter of the gas pipe coming out of the generator does not determine the choice of the diameter of the pipe between the appliance and the counter; the latter must be chosen based on its length and head loss.

ATTENTION !!! Remember to install a gas shut-

off valve right before the appliance in order to be able to shut off the gas supply.

ATTENTION !!! Supplying the boiler with a different type of gas than those provided for is prohibited.

10.2 - Boiler safety valve (installer’s responsibility)

The appliance is supplied without an overpressure safety valve to all the installer to choose the appropriate valve for the system service pressure (check appliance operation pressure in the technical features). Installation must be done so as to allow the user to check valve intervention, should it open. The safety valve drain (the installer’s responsibility) must then be directed in order to avoid danger for people in the event it intervenes.

ATTENTION !!! If the safety valve is not directed,

it could harm persons, animals or objects should it

intervene.

10.3 - Examples of boiler installations

Figure 10-1 - Example of boiler connection diagram

Figure 10-1 KEY

1 Boiler 60T-280T model boiler 2 INAIL safety valve 3 INAIL manometer 4 INAIL thermometer 5 INAIL maximum safety pressure switch 6 INAIL safety thermostat 7 Gas cock 8 INAIL gas shut-off valve 9 INAIL well 10 Gas inlet 11 Expansion tank 12 Micro-bubble separator 13 External probe 14 Filter 15 Electrical power supply

16 Low or high temperature heating system 17 System loading unit 18 Domestic cold water 19 Heating circuit pump 20 - Hydraulic separator 21 Air bleed valve 23 ---------24 INAIL minimum safety pressure switch 36 Main circuit pump 37 Room thermostat or equivalent system 56 Balancing valve (necessary if there is a motorised valve,

part “17” in gure 3-1, on the appliance and the pump, “36”,

is NOT the modulating type) 57 Drain cock (Mandatory in the 60, 70, 100, 115, 140 models ) 58 Manifold sensor

Page 31

60T - 280T

COSMOGAS

1 Boiler 60T-280T series appliance

2 INAIL safety valve

3 INAIL manometer

4 INAIL thermometer

5 INAIL safety maximum pressure switch

6 INAIL safety thermostat

7 Gas cock

8 INAIL gas shut-off valve

9 INAIL well

10 Gas inlet

11 Expansion tank

12 Micro-bubble separator

13 External probe

14 Filter

15 Electrical power supply

16 ----------

17 Air bleed valve

18 Domestic cold water

19 Heating circuit pump

20 - Hydraulic separator

21 Shut-off valve

22 Check valve

23 Heating system supply

Figure 10-2 - Example of

boiler connection diagram

with hydraulic separator and

storage tank

24 Heating system return

25 Plug for sludge drain

26 Heating system mixing valve

27 System drain

28 Storage tank loading pump

29 System loading unit

30 Storage tank safety valve

31 Hot water tank temperature sensor

32 Domestic circuit expansion tank

33 Domestic hot water supply

34 INAIL safety minimum pressure switch

36 Main circuit pump

37 Room thermostat or equivalent system

56 Balancing valve (necessary if there is a motorised valve, part

“17” in Figure 3-1, on the appliance and the pump, “36”, is NOT the

modulating type)

57 Drain cock (Mandatory in the 60, 70, 100, 115, 140 models )

58 Manifold sensor

10 - INSTALLATION - Hydraulic connections - boiler

Page 32

60T - 280T

COSMOGAS

Figure 10-3 - 60T to 140T INAIL KIT

Figure 10-4 - 180T to 280T INAIL KIT

86 8

020014.01.011

020014.01.012

10.4 - Boiler INAIL safety devices

The appliance comes standard supplied without the INAIL safety devices.

ATTENTION !!! All appliances over 35 kW of

output heat must, under the installer’s responsibility, be equipped with safety devices as provided by Rule “R” issued by the National Institute for Insurance

against Accidents at Work (INAIL).

ATTENTION !!! Installing shut-off elements between the appliance and the safety valve (part “7” in

g. 10-3 and “15” in gure 10-4) is prohibited.

To facilitate installation, COSMOGAS provides,on request, INAIL kits complete with the required devices and a special pipe to install them. Figure 10-3 shows the kit for the 60T, 70T, 100T, 115T and 140T models. Figure 10-3 key 1 = Nipple 2 = Gasket 3 = Manifold 4 = Well for Valve probe “11” 5 = INAIL thermometer 6 = INAIL manometer 7 = INAIL safety valve 8 = Connection unit 11 = INAIL gas shut-off valve 12 = Inspection well 13 = INAIL safety thermostat 14 = INAIL safety pressure switch 15 = INAIL safety pressure switch

16 - Expansion tank connection tting

ATTENTION !!! The valve sensor “11” (gure 10-

3) goes into the probe carrier well “4” and secured with

the specic anti-slip locking screw.

Figure 10-4 shows the kit for the 180T, 210T and 280T models Figure 10-4 key 1 = Fixing nuts and bolts 2 = Gasket 3 = INAIL safety pressure switch 4 = INAIL safety pressure switch 5 = Connection unit 6 = INAIL safety thermostat 7 = Manifold 10 = INAIL gas shut-off valve 11 = Well for Valve probe “10” 12 = Inspection well

13 - Expansion tank connection tting

14 = INAIL manometer 15 = INAIL safety valve 16 = INAIL thermometer

ATTENTION !!! The valve sensor “10” (gure

10-4) goes into the probe carrier well “11” and secured

with the specic anti-slip locking screw.

10 - INSTALLATION - Hydraulic connections - boiler

Page 33

60T - 280T

COSMOGAS

10.5 - Expansion tank connection

ATTENTION !!! The appliance does not have

an expansion tank. Provide the system with an

appropriately sized expansion tank as required by the

national and local installation standards.

10.6 - Supply and return

ATTENTION !!! COSMOGAS is not liable for any damage caused by incorrect use of additives in the heating system.

ATTENTION !!! The system downstream of the appliance must be built with materials that resist temperatures up to 97°C and 11 bar of pressure.

Otherwise (i.e. plastic piping), the system must be equipped with appropriate protection and safety

devices.

Before making the hydraulic connections, wash the system thoroughly to remove any slag (hemp, radiator foundry sands, etc.) that could damage the appliance. The system must also be washed if an appliance is replaced. You can check the positioning of the supply and return

ttings in gures 8-1 and 8-2.

Install a metal mesh lter with a 1 mm

opening on the return pipe in order to stop any system residues before they go back into the appliance.

Do not use the appliance to introduce any type of

additives into the system.

10.7 - Boiler water supply

ATTENTION !!! The system (and, therefore,

the appliance) must be connected to the water mains interposing a device to prevent backwash into the

potable water system, as required by the pollution

prevention safety standards in force.

10.7.1 - Recommendations on the

characteristics of the water used in the system

Filling the heating system is an extremely delicate operation that must not be underestimated, both when simply replacing the heat generator as well as for new installations. A mistaken assessment of the system water characteristics can, in certain cases, lead to damages to the system and heating module. A system is almost never perfectly sealed; at times, there can be water leaks or oxygen inlets. Both of these phenomena are harmful. Of the parameters that can negatively impact the life of a system, the main ones are:

- The simultaneous presence of different metals (copper, brass, steel and aluminium) that, in a watery environment, lead to galvanic corrosion.

- The presence of free oxygen, due to air leaks that form near

ttings or gaskets, is a typical corrosive agent, particularly

active at temperatures between 50 and 70°C.

- Water loss, leading to frequent top-ups, can lead both to corrosion as well as scale build-up, depending on the type of water available for the top-ups. In any case, the extent of the leaks (and corresponding top-ups) must be kept under control,

especially when an automatic lling system is installed. In this

case, installing a counter indicating the amount of water that is reintegrated is highly recommended. Natural or additional impurities in the water. Many types of drinking water can contain even considerable concentrations of chlorides and sulphates that can increase how quickly the metal surfaces corrode. Other undesirable components could have got into the system before or during installation (construction materials, metal shavings, sawdust, grease, deposits, and dirt in general). Welding residues can also cause corrosion, both in new systems as well as in the event

of modications or repairs. In old systems designed to work

with radiators, featuring very large pipe diameters, the water content is considerable and favours the formation of sludge and deposits. Sludge and scale build-up Black deposits (magnetite) indicate

that corrosion is limited. However, the high specic gravity of this oxide can create clogs that are difcult to remove,

especially in the hotter areas. Scale build-up is due to water hardness, that is, the presence of calcium and magnesium minerals. Calcium, in the form of carbonate, falls on the hotter areas of the system. Magnetite often contributes in intensifying the scale build-up. Iron oxide (the water has a reddish colour), instead, is a sign of oxygen corrosion. Frequent leaks. In the event of frequent leaks, hydrogen and/ or air accumulates on the high part of the exchanger and the radiators, preventing complete heat exchange. When the electrolytic corrosion process begins, the water level in the system goes down, gases accumulate in the high part of the heat exchanger and on the radiators. The presence of air is caused by the fact that the system might not be perfectly sealed. Slow system pressure loss due to a leak

is often difcult to nd, especially when the breach is very

small (during winter, leaks on the radiator valves are often not visible as the heat generated by the radiator or the boiler dry them). However, these micro-leaks allow air to get into the system. The main points that can lead to micro-leaks are found in the joints and, in particular, on the circulator intake side (air bleed valve, seals with o-rings, loading valves). In these cases, to avoid damage, the system must be protected with an appropriate corrosion inhibitor.

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

1) the system has no leaks or, at the least, the most evident leaks have been removed;

2) if there is an automatic lling system, a litre counter must

have been installed in order to accurately know the extent of any leaks;

3) system lling and top-ups are done with softened water to

reduce the overall hardness. The water must also be treated in order to keep the pH within the required threshold to prevent corrosion;

4) Both in new systems and for replacements, the system

must be equipped with efcient devices that eliminate air and impurities: lters, micro-impurity separators and micro-air

bubble separators;

5) Avoid draining system water during scheduled maintenance,

even seemingly insignicant amounts: for example, to clean the lters, equip the system with specic shut-off valves upstream and downstream of the lter itself;

6) Always an alyse the sys tem water bef ore opening communication between the new generator and the system to establish whether the chemical and physical characteristics of the water indicate you should completely drain the system, use the water already in the system, or chemically wash the system using water from the mains plus a cleaning solution when there is the suspicion that the system might be dirty or

10 - INSTALLATION - Hydraulic connections - boiler

Page 34

60T - 280T

COSMOGAS

particularly clogged. Then ll it with new treated water. If the analysis of a sample of water that will be used to ll the

system shows the following values:

- Hardness from 12°F to 20°F

- 7,5 < pH < 9,5

then you can proceed with loading. If the characteristics are different, an inhibitor must be used.

10.7.3 Treating water in heating systems for civil use

Water must always be treated in heating systems for civil use, both when replacing the generator and in the event of a new system. The design stage, based on the characteristics of the raw water, must provide for all the treatment and chemical conditioning systems needed to obtain water with the following characteristics:

- Appearance: clear, colourless and non-foamy;

- pH: from 7,5 a 9,5;

- Hardness from 12°F to 20°F;

- Conditioners: present within the concentrations prescribed by the supplier. If the water characteristics are unknown, there is a very high probability of encountering the following typical setbacks:

a. SCALE BUILD-UP

30° fr = 300 mg/kg CaCO

In a system containing 1000 litres of water at 30°CF, the CaC0

content is equal to 300 g. If not appropriately treated, it will deposit on the surface of the heat exchanger as that is the hottest point of the system, creating concentrated increases in temperature and leading to the heat exchanger breaking.

b. CORROSION

Corrosion is usually facilitated by the presence of oxygen, by contact between different metals or by the presence of chlorides.

c. DEPOSITS

SLUDGE, PROCESSING RESIDUES are organic and

inorganic insoluble substances.

10.8 - Draining the boiler heating circuit

In order to avoid constant water top-ups and subsequent oxygen and scale, it is advisable to limit draining the heating circuit as much as possible.

10.9 - Boiler low temperature

(or oor) systems

ATTENTION !!! If the boiler is installed in a oor

system built with plastic piping, all precautions against corrosion due to water oxygenation must be taken:

make sure the system is built with plastic piping with an oxygen permeability no greater than 0,1 g/m3 at 40°C. Should the pipe not meet these features, the boiler radiant panel circuit must be isolated using a plate heat exchanger that can resist the corrosion caused by the oxygen dissolved in the water.

10.10 - Manifold probe

The manifold probe (part 26 in gure 3-5 and 3-7) is factory

installed on the boiler manifold. However, that position may not be correct in some systems where there is a hydraulic

separator or plate exchanger (see gures 10-1 and 10-2).

It is advisable to move the probe from the boiler manifold to

the hydraulic separator as shown in gures 10-1 and 10-2,

part “58”.

ATTENTION !!! For the system to work properly,

the manifold sensor must be positioned in a point

of the hydraulic separator/plate exchanger, able to

detect the correct supply temperature and able to

be inuenced by the secondary circuit water ow

temperature

10 - INSTALLATION - Hydraulic connections - boiler

Page 35

60T - 280T

COSMOGAS

Figure 11-1 - Boiler “60T-280T” model hydraulic resistances

Head loss (kPa)

Water ow rate (m3/h)

11 - Characteristic curve of the boiler head loss

The boiler are not equipped with a circulation pump. To size the pump to use, the designer must consider the hydraulic resistances of the system and the hydraulic resistances of

the boiler itself. To this end, figure 11-1 shows the hydraulic

resistances of the boiler in graphic form.

11 - INSTALLATION - Hydraulic connections - boiler

Figure 11-1 key

A = Boiler 60T and 70T B = Boiler 100T and 115T C = Boiler 140T

D = Bolier 180T and 210T

E = Boiler 280T

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COSMOGAS

Figure 12-3 - Proper condensate drain pipe installation

Figure 12-1 - Condensate neutraliser

C ADB EC ADB E

020010.01.029

Figure 12-2 - Condensate drain

12.1 - Condensate drain

Inside the appliance, there is a siphon and condensate

neutraliser system to evacuate condensate (see gures 3-3,

3-5 and 3-7, parts”2”-”3”) and to prevent the combustion exhaust from escaping, the outlet of which corresponds to

duct “5” referred to in gures 3-3, 3-5 and 3-7. This outlet

must be directed into another anti-odour siphon (installer’s responsibility) in order to prevent bad odours from coming back into the room.

In particular, the condensate disposal system must:

be made with a pipe that has an inner diameter greater

than or equal to 13 mm;

be installed so as to prevent the liquid from freezing;

therefore, be aware of any sections passing outdoors. Draining into gutters or drainpipes is prohibited;

be in continuous incline towards the drain point; avoid

high points that could put the duct under pressure; Figure 12-2 shows how a condensate disposal system must be made downstream of the appliance.

12 - INSTALLATION - Eliminating condensate

YES

Figure 12-2 key A = Condensate drain duct start plug; B = Condensate inlet; C = Plugs for duct inspection; D = Anti-odour siphon system; E = Atmospheric connection (duct bleed); F = Condensate drain; G = Condensate drain pipe;

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COSMOGAS

13 - INSTALLATION - Electrical connections

13.1 - Electrical connections:

general information

ATTENTION !!! Disconnect power before doing

any operations inside the appliance.

ATTENTION !!! During maintenance, label all the

wires involved in the operation before disconnecting.

ATTENTION !!! The appliance is only electrically

safe when it is properly connected to an efcient grounding system built as required by the safety

standards in force.

This fundamental safety requirement must be checked.

In you have any doubts, ask a professionally qualied

electrician to check the electrical system thoroughly.

Have a professionally qualied electrician make sure

that the electrical system is appropriate to the electrical power required by the appliance, shown on the plate.

The appliance must be connected to the electrical mains

with a mobile plug connection. Using adapters, power strips, extension cords, etc. is not allowed.

The appliance must be connected to the electrical mains

with a double insulated tri-rated cable with appropriate cross-section.

To connect to the electrical mains, provide a bipolar

switch near the appliance with a contact opening

distance of at least 3 mm, as required by the applicable

standards in force.

Respect the polarity between phase and neutral when

connecting the appliance.

Make sure the piping for the hydraulic, heating and gas

systems is not used to ground the electrical or telephone

system. This sort of piping is absolutely not appropriate

for this purpose. In addition, the appliance, the piping

and the radiators can suffer serious corrosion damage in

a short time.

ATTENTION !!! The appliance has no protections

against the effects of lightning.

13.1.1 - Connecting the power cable

To connect the electrical power cable, proceed as follows

(refer to gure 13-1):

1.- use a double insulation tri-rated cable

2.- access the electrical connection terminal board following

the specic instructions in section 17.2;

3.- lay the power cable using the cable gland near contacts

“101”, “102” and “PE”;

6.- strip the cable, taking care to keep the grounding cable

(green yellow) 20 mm longer than the other two;

7.- connect the green-yellow cable to the ground terminal

(“PE”)

8.- connect the brown cable (Phase) to terminal “101”

9.- connect the blue cable (Neutral) to terminal “102”

Key

A = Electrical wire sheath; B = Line; C = Neutral; D = Earth.

Figure 13-1 - Electrical connections

Page 38

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COSMOGAS

13 - INSTALLATION - Electrical connections

13.1.4 - Installing the external temperature probe

Install the external temperature probe outside the building on a wall facing NORTH or NORTH-EAST at a height from the ground of between 2 and 2,5 metres. On buildings with several storeys, install it at about the upper half of the second storey. Do not install it above windows, doors or air vents, nor directly underneath balconies or gutters. Do not plaster the external temperature probe. Do not install the sensor on walls without overhangs, that is, that are not protected from the rain. Should the sensor be installed on a wall that still needs to be plastered, it must be installed with an appropriate spacer or remove it before plastering. To connect the external temperature sensor cable, proceed as follows:

1.- lay a bipolar electrical cable with 1,5 mm2 minimum cross-

section going from the boiler to the external temperature

sensor. The maximum allowed length is 100 metres; use

a shielded cable with shield grounding;

ATTENTION !!! As the cables are subjected to

extremely low safety voltage (24Vdc), they must run in

different ducts than 230Vac power cables.

2.- connect the bipolar cable to terminals “14” and “15”

shown in gures 13-4 and 13-5;

3.- connect the bipolar cable to the ends of the external

temperature sensor.

Set the boiler to recognise the external temperature sensor as follows:

4.- access the “installer menu” as described in section 16.15

and set the parameter

2003 = 1.

The

icon on the display conrms that the external probe

is enabled. Proceed with the steps in section 16.9.1 to set the correct supply temperature adjustment values based on the external temperature.

13.1.2 - Choosing the room thermostat/ time-programmable thermostat

The boiler is equiped to work with any room thermostat or programmable thermostat that has a contact to connect to the cables coming from the boiler, with the following characteristics:

- open/closed (ON/OFF);

- clean (not powered);

- closed when heat is required;

- electrical characteristic of 24Vac, 1A.

13.1.3 - Connecting the room thermostat/ time-programmable thermostat

Install the room thermostat in a part of the room in which the temperature is as close as possible to the typical temperature in the house and, in any case, in an area that is not subject to sudden drastic temperature changes, away from windows or doors that lead directly outdoors (see

gure 13-2).

To connect the room thermostat cable, proceed as follows

(refer to gures 13-4 and 13-5):

1.- use a bipolar cable with 1,5 mm2 minimum crosssection than goes from the boiler to the room thermostat/ programmable thermostat. The maximum allowed length is 100 metres; use a shielded cable with shield grounding;

2.- disassemble the boiler casing following the specic

instructions in section 17.2;

3.- lay the electrical cable using the cable gland near contacts “10” and “11”;

4.- use a free cable gland that is not used by other conductors;

5.- strip the cable;

6.- connect the 2 ends of the cable to terminals “10” and

“11” (see gures 13-4 and 13-5).

ATTENTION !!! As the room thermostat/

programmable thermostat cables are subjected to

extremely low safety voltage (24Vdc), they must run in

different ducts than 230Vac power cables.

Figure 13-2 - Correct room thermostat/controllable thermostat positioning

Page 39

60T - 280T

13 - INSTALLATION - Electrical connections

1.0 1.5

2 3 4 5 6 7 8 9

OFF ON

Figure 13-3 - 0-10 Vdc analogue input operating rules

COSMOGAS

13.1.5 - 885 IF board connection (on

request)

The 885 IF board is supplied on request for all models (see

part “13” in gures 3-3, 3-5 and 3-7).

The board allows:

1.- the appliances to be controlled via 0-10Vdc analogue signal;

2.- the appliances to be controlled via MODBUS communication digital signal;

3.- up to 8 appliances to be connected in cascade (see section

13.4)

0-10 Vdc type dialogue (on request)

The 885 IF board allows the appliance to be controlled via 0-10 Vdc dialogue, proceeding as follows:

1.- Install the board as per the instructions provided;

2.- Access the “installer menu” as described in section 16.15 and set the parameter 2003 = 4.

3.- The appliance can now be controlled via 0-10 Vdc signal

according to the rules in gure 13-3;

MODBUS type dialogue (on request)

The 885 IF board allows the appliance to be controlled via MODBUS dialogue, proceeding as described on the instructions provided on request.

13.1.6 - Alarm contact

Alarm contact works only in presence of the 885 IF board

(see gures 3-3, 3-5, 3-7 item “13”). Alarm contact does not

react in case a dependent module (burner 2, 3 or 4) is in error.

Maximum supply temperature (Par.3017)

Minimum supply temperature (Par.3018)

ON/OFF hysteresis

Voltage

13.2 - Connecting boiler to the storage tank

In order to generate domestic hot water, the boiler must

be connected to a storage tank.

The hydraulic connection must be done as per gure 10-2

or the like. For the electrical connection, proceed as follows (refer to

gures 13-4 and 13-5):

1.- disconnect power to the boiler;

2.- lay a bipolar electrical cable with 1,5 mm2 minimum cross-section going from the boiler to the storage tank temperature sensor and connect it on the boiler to terminals “12” and “13” (SB);

3.- connect the other end of the cable to the storage tank temperature probe;

4.- put the temperature sensor probe inside the storage tank

well (see gure 10-2, part “31”).

5.- set parameter 3012 to “1” (see section 19)

6.- electrically connect the storage tank pump to terminals 107

and 108 of the boiler (see gures 13-4 and 13-5).

The temperature of the water stored inside the storage tank can be selected by the user within a 40-60°C range.

ATTENTION !!! A water temperature exceeding

51°C can cause even permanent harm to persons,

animals and objects.

Above all, children, the elderly and the disabled must

be protected against the potential risk of scalds by putting in devices that limit the temperature of domestic hot water use to the domestic utilities.

13.2.1 - D.H.W. production priority

The boiler comes out of the factory set with total priority given to domestic hot water production. This means that the boiler works in domestic mode until the required temperature in the connected storage tank is reached. For this reason, said setting could lead to cooling of the room that needs to be heated. Once the domestic hot water demand is met, the appliance automatically goes back to working for the heating circuit.

Page 40

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COSMOGAS

13 - INSTALLATION - Electrical connections

13.3 - Connecting water heater

to the storage tank

The water heater must be connected to a storage tank.

The hydraulic connection must be done as per gure 11-1.

For the electrical connection, proceed as follows (refer to

gure 13-6):

1.- disconnect power to the boiler;

2.- Access the connection electrical terminals;

3.- Disconnect the manifold temperature sensor from terminals “8” and “9”;

4.- use the storage tank probe supplied with the water heater and connect to terminals “8” and “9”.

lay a bipolar electrical cable with 1,5 mm2 minimum cross-

section going from the water heater to the storage tank temperature sensor and connect it on the water heater to terminals “8” and “9” (Manifold temperature sensor);

5.- connect the other end of the cable to the storage tank temperature probe;

6.- put the temperature sensor probe inside the storage tank

well (see gure 11-1, part “42”).

The temperature of the water stored inside the storage tank can be selected by the user within a 40-80°C range

using the o heating temperature adjustment controls, as described in section 16.5.

ATTENTION !!! A water temperature exceeding

51°C can cause even permanent harm to persons, animals and objects. Above all, children, the elderly and the

disabled must be protected against the potential risk of scalds by putting in devices that limit the temperature of domestic hot water use to the domestic utilities.

Page 41

60T - 280T

13 - INSTALLATION - Electrical connections

Figure 13-4 - Boiler electrical connections (Example of system shown in gure 10-1)

Page 42

60T - 280T

COSMOGAS

Figure 13-5 - Boiler electrical connections (Example of system shown in figure 10-2)

COSMOGAS

Page 43

60T - 280T

13 - INSTALLATION - Electrical connections

Figure 13-6 Boiler appliances in cascade connection conceptual diagram

COSMOGAS

13.4 - Connecting cascade appliances

Connecting cascade appliances is done as shown in the

diagrams in figure 13-6 (boiler). Preemptively, an 885 IF board (part “13” in figure 3-3, 3-5 and 3-7) must be installed in each appliance and an 885 HC cascade control (see figure 13-7) must be purchased. At most 8 appliances can be connected in cascade (figure

13-6 show examples with 4). Follow the 885 HC control manual for instructions on connecting the appliances in cascade.

885 HC Cascade sequence controller

MASTER appliance

SLAVE

appliance

SLAVE

appliance

SLAVE

appliance

#4 up to #8

Heating module pump

Heating heating circuit

Hydraulic

separator

Cascade

general

sensor

Check

valve

Check

valve

Check

valve

Check

valve

Heating module pump

Page 44

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COSMOGAS

14.1 - Flue exhaust and combustion air intake duct

ATTENTION !!! This appliance must be

connected to a ue exhaust system that can bring the ue gas into the open air outside of the building.

ATTENTION !!! The ue exhaust duct and

combustion air intake must be connected in compliance with the national and local standards in force.

ATTENTION !!! This appliance has ue gas

temperatures that can reach 90°C under certain

conditions. Therefore, use ue exhaust ducts in plastic

that can resist said temperature.

ATTENTION !!! This appliance is “condensing”.

To realise a ue exhaust, use materials in AISI 316L

stainless steel or polypropylene plastic materials to prevent corrosion due to condensate acidity.

To this end, remember that this type of appliances must have exhaust and intake ducts supplied by the manufacturer of the appliance itself. Other types of ducts, if used, must be approved for such intended use. The types of exhaust for which the appliance is approved are shown on the technical features table at the end of the manual,

under the “type” heading and on the plate afxed to the

Figure 14-1 - Exhaust/intake systems

14 - INSTALLATION - Air intake and ue exhaust ducts

C53

B23

boiler, again under the “type” heading.

The symbols used to dene the type of exhaust are shown

below:

- B23, room intake and wall or ceiling mounted ue exhaust.

ATTENTION !!! If you install an appliance with

a B23 type exhaust, it will extract air for combustion from the room in which it is located. Therefore, all the precautions regarding room ventilation required by

national and/or local standards must be taken.

- C53, separated with ceiling-mounted exhaust and wallmounted intake or, in any case, in two potentially different pressure points.

- C63, the boiler can be jointed to approved exhaust and intake ducts of other brands.

ATTENTION !!! With the C63 type exhaust,

the condensate coming from the chimney cannot be directed to the boiler.

During operation, especially in the winter, it is possible for

white smoke to come out of the appliance ue exhaust due

to high output. This is solely a natural phenomenon and no

cause for worry as it is the water vapour in the ue gases

that condense in contact with the external air.

14.1.1 - B23 suction/discharge type

In the event of B23 type combustion air intake/ue exhaust, it is

essential that at least as much air as is required for combustion

and room ventilation can ow through the room where these

appliances are installed. As such, it is a good idea to remember that the combustion of 1m3 of gas requires 11m3 of air.

The natural inow of air must be direct through permanent

openings to the outside on the walls of the room to ventilate, away from sources of pollution like: roof vents of dubious origin, industrial air exhausts, etc. (see section 5.1.1).

The vents must meet the following requisites:

have net passage cross-sections of at least 0,3 m

;

be made so that the vent openings both on the inside

and outside of the wall cannot be obstructed;

be protected, by example with grids, metal netting, etc.

The net passage cross-section must not be reduced by these systems;

be located at a height near the level of the oor and such

not to interfere with proper ue exhaust device operation;

should this position not be possible, the ventilation opening cross-section must be increased by 50%.

Page 45

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COSMOGAS

020014.01.007

020014.01.006

14 - INSTALLATION - Air intake and ue exhaust ducts

14.1.2 - Split system

The appliance is standard supplied with ttings to connect to the ue exhaust and air intake. To install, proceed as shown in gure 14-2.

1.- put duct “D” in tting “A” and secure it using the tightening clamp in tting “A”;

2.- reducer “C” is standard assembled on tting “B”;

3.- put duct “E” into reducer “C”, being sure that the gasket in reducer “C” is positioned correctly;

It is mandatory to install polypropylene ducts that are

more resistant to condensate formation on the “B” ue

exhaust side.

Take particular care in installing the ducts in the parts

that cross the wall towards the outside; it must always be possible to do normal maintenance operations. Therefore, install the pipes in a sheath in order to be able to slide them out.

The horizontal sections must always have a slope of at

least 2% towards the condensate drain devices.

The appliance is already equipped with a condensate

collector, which must be joined to an exhaust pipe (see section 12).

ATTENTION !!! This condensate drain is

designed to make all the liquid produced by an individual appliance ow out. Should several appliances be installed, provide each with its own

condensate drain.

The ue exhaust/air intake system can be extended up to

a maximum distance as instructed in section 18. Each 90° curve has a loss equivalent to what is described in section

18.

ATTENTION !!! The ue exhaust outlet must be

appropriately protected against the effects of the wind.

ATTENTION !!! Mechanically secure the

joints between the various exhaust and intake duct

components using xing or equivalent systems. See gure 14-4.

ATTENTION !!! The temperature of the exhaust

pipe during operation can reach 90°C. If they cross

through walls that are sensitive to these temperatures,

put in a protective heat insulating sheath.

ATTENTION !!! If the air intake and ue exhaust

outlets are positioned on the same wall, they must be

at least 1 metre away from each other.

ATTENTION !!! The exhaust and intake ducts

must be appropriately supported via rigid brackets positioned no more than 1 m from each other. The brackets must be secured to rigid walls that can support the weight of the duct itself.

Figure 14-4 Securing exhaust and intake ducts

Figure 14-2 - Split system installation

Figure 14-3 - Assembled system

Air Inlet

Flue exhaust

Air Inlet

Flue exhaust

Page 46

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COSMOGAS

15 - COMMISSIONING

15.1 - Commissioning

Before commissioning the appliance, the following operations must be done.

15.1.1 - User instructions

Instruct the user on how to properly use the appliance and the entire system in general. In particular:

Give the user the use and installation manual and all the

documents contained in the packaging.

Teach the user about the special measures for the ue

exhaust, informing them that they must not be modied.

Inform the user of the necessary water pressure control

in the system and of the necessary measures to ll and

bleed air.

Inform the user about properly adjusting temperatures,

control units/room thermostats and radiators for energy saving.

15.1.2 - Filling the condensate drain siphon

The siphon located inside the appliance must be lled with water to create the stop that can prevent ue gases from escaping out of duct “5” in gures 3-3, 3-5 and 3-7.

To this end, proceed as follows:

(refer to gure 15-1)

1.- unscrew and remove plug “A” shown in the gure;

2.- put a rubber hose into opening “S” and position a funnel at the other end of the hose;

3.- slowly pour about 5 litres of water though the funnel;

4.- reassemble everything in reverse order.

15-1 - Filling the condensate drain siphon

ATTENTION!!! If the boiler stays off for more than

3 months, the siphon must be lled again as explained

above.

ATTENTION!!! Once the appliance has been

started up again, make sure no ue gases are escaping

from plug “A”.

15.1.3 - Filling the heating system

When the appliance is being powered, if Err 59 appears on the display, it means that the system needs to

be lled. Proceed as follows:

only use clean water from the water mains.

ATTENTION!!! Chemicals like antifreeze must

be added as per the instructions on the product. In any

case, said substances must not be put directly into the

boiler.

ATTENTION!!! for water heaters, adding

chemicals like antifreeze is absolutely prohibited. Failure to follow this provision could cause serious harm to human health or even death.

1.- open the air bleed valve (part “35” in gure 3-7)

2.- open the lling device provided for by the installer upstream of the appliance and ll the system until the

manometer detects a pressure of 1,5 bar, shown on the

display (part “M” in gure 16-1) (Err 59 appears on the display); If you wish to increase the lling pressure

level, parameter 3022 must be set to the desired value (see section 19);

2.- make sure no water leaks from the ttings;

3.- close the lling device provided for by the installer

upstream of the appliance;

4.- bleed the heating elements;

5.- check the pressure on the display again (part “M” in

gure 16-1). If it has gone down, ll the system to 1,5 bar

again (or up to the set value).

020014.01.010

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60T - 280T

COSMOGAS

15.2 - General warnings on the gas power supply

For the rst commissioning of the appliance, run the

following checks:

That it is powered for the type of fuel for which it is

equipped.

That the gas supply pressure (with the operating

appliance stopped) is within the maximum and minimum values shown in the table in section 18.

That the gas adduction system is equipped with all the

safety and control parts required by the national and local standards in force.

That the ue exhaust outlet and the combustion air

intake outlet are free of any obstructions.

That the ue exhaust and combustion air intake outlets

are positioned outside the building.

That the condensate drain connection is connected.

ATTENTION !!! Supplying the appliance with

a different type of gas than those provided for is prohibited.

ATTENTION !!! Make sure the gas and supply

pressure are those for which the appliance is regulated.

The appliance is equipped with the specic gas conversion

kit.

Before installation, it is advisable to thoroughly clean the

inside of the gas adduction pipe;

it is mandatory to always install a shut-off cock on the

gas adduction pipe;

to prevent damaging the appliance gas control unit, run

a seal test at a pressure no greater than 50 mbar;

if the gas system test must be run at pressures

exceeding 50 mbar, use the cock located immediately upstream of the appliance to cut if off from the rest of the system.

In gures 8-1, 8-2, 9-1 and 9-2, you can check the gas tting positioning. The sections of piping that make up the gas adduction system must always ensure sufcient gas

supply to cover the maximum required.

ATTENTION!!! If you smell gas:

A - Do not activate any electrical appliances,

including telephones or any objects that could create sparks;

B - Immediately open the doors and windows to

create an air current to quickly rid the room of

gas;

C - From another room or from a neighbour’s

if there is no other room, immediately call a professionally qualied technician or the gas supply company. If they are unavailable, call the

Fire Brigade.

15.3 - Type of gas for which

the appliance is regulated.

There is a label on the front of the appliance bearing the gas supply type and pressure for which the appliance is regulated. The appliance can have the following 2 phrases:

2H-G20-20mbar METHANE

it means the appliance is regulated to work with type H second family gas (methane) at a supply pressure of 20 mbar.

3P-G31-37mbar L.P.G.

it means the appliance is regulated to work with type P third family gas (propane, also known as LP gas) at a supply pressure of 37 mbar.

15 - COMMISSIONING

Page 48

60T - 280T

COSMOGAS

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

ATTENTION !!! Read these instructions carefully

before changing the gas:

- The gas equipment must be installed, calibrated or modied by specialised personnel according to the

terms of the law;

- Check and be sure that the type of gas that is supplying the appliance is compatible with the regulation kit you have;

- Do not supply the appliance with a different type of gas than those provided for.

Figure 15-4 - Gas nozzle replacement

Figure 15-3 - Gas valve lifting

Figure 15-2 - Gas valve disassembly

A H

020010.01.020

020010.01.019

Contents:

The Kit (standard supplied with the appliance) is made up of

- label bearing the new type of gas, a gas nozzle for each burner and an instruction sheet; To change the gas, proceed as follows: 1 - Switch off the appliance by turning the main switch to

the OFF position (part “T” in gure 16-1);

2 - Close the gas supply cock; 3 - open the boiler casing as described in section 17.2;

4 - Unscrew tting “H” in gure 15-2; 5 - With the help of a screwdriver, remove fork “A” in gure

15-2;

6 - Remove the gas valve with tting “C” as in gure 15-3

(being careful of OR “L” in gure 15-3);

7 - Replace nozzle “G” in gure 15-4 with the one in the kit,

checking table 15-8 to make sure the diameter corresponds;

8 - Reinstall the gas valve, taking care to correctly position

OR “L” in gure 15-3 and the gasket of tting “H” in gure

15-2;

9 - Reposition fork “A” in the locking seat;

10 - Screw on tting “H” in gure 15-2;

11 - Open the gas supply valve;

12 - Make sure there are no leaks from tting “H” in gure

15-2;

ATTENTION !!! Run the seal test exclusively

with a soap-based water solution. Using naked

ames is absolutely prohibited.

13 - Switch on the appliance by turning the main switch to

the ON position (part “T” in gure 16-1);

14 - Completely unscrew screw “E” in gure 15-6

anticlockwise;

15 - Check the gas pressure, following section 15.7; the

minimum pressure must not be less than 10 mbar, while the maximum must not exceed 45 mbar;

16 - Check and regulate the CO2 following the procedure

referred to in section 15.8 and checking the value in

gure 15-8;

ATTENTION !!! The measurements must be

taken with calibrated, guaranteed instruments

that ensure an accurate reading.

17.- Check the appliance output heat following section 15.9;

18.- on the front casing of the appliance, in the place of the label identifying the old adjustment status, apply the self-adhesive plate (see gure 15-7), bearing the new adjustment status of the appliance, as follows: apply label “B” if the appliance was converted from methane to LP gas; apply label “A” if the appliance as converted from LP gas to methane.

ATTENTION !!! If you smell gas:

A - Do not activate any electrical appliances,

including telephones or any objects that could create sparks;

B - Immediately open the doors and windows to

create an air current to quickly rid the room of

gas;

C - From another room or from a neighbour’s

if there is no other room, immediately call a professionally qualied technician or the gas supply company. If they are unavailable, call the

Fire Brigade.

15 - COMMISSIONING

020010.01.021

020022.01.008

YES

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COSMOGAS

A - Connector from Burner 1 (MASTER) B - Connector from display C - Connector from Burner 2 D - Connector from Burner 3 E - Connector from Burner 4

Figure 15-5 - Burner Position

Burner 2

Burner 1 (Master)

Burner 3

Burner 4

15 - COMMISSIONING

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

Appliances from 100T to 280T are multi-burners, which means that the type of gas must be converted on every burner.

ATTENTION !!! Read these instructions carefully

before changing the gas:

- The gas equipment must be installed, calibrated or modied by specialised personnel according to the

terms of the law;

- Check and be sure that the type of gas that is supplying the appliance is compatible with the regulation kit you have;

- Do not supply the appliance with a different type of gas than those provided for.

Contents:

The Kit (standard supplied with the appliance) is made up of

- label bearing the new type of gas;

- a gas nozzle for every burner;

- an instruction sheet;

To change the gas, proceed as follows:

1 - Convert “Burner 1” (MASTER). See gure 15-5 to

identify “Burner 1” (MASTER);

2 - Convert “Burner 1” (MASTER), following points 1 to 16

in section 15.4;

After converting “Burner 1”, proceed with “Burner 2” as described below:

3 - Convert “Burner 2”, following points 1 to 16 in section

15.4;

After converting “Burner 2”, proceed with “Burner 3” (if present) as described below:

4 - Convert “Burner 3”, following points 1 to 16 in section

15.4;

After converting “Burner 3”, proceed with “Burner 4” (if present) as described below:

5 - Convert “Burner 4”, following points 1 to 16 in section

15.4;

After converting all the Burners, proceed as described below:

6 - Check the gas inlet pressure as described in section

15.7;

7 - Check the appliance output heat as described in section

15.9;

ATTENTION !!! The measurements must be

taken with calibrated instruments that ensure an accurate reading.

8.- on the front casing of the appliance, in the place of the label identifying the old adjustment status, apply the self-adhesive plate (see gure 15-7), bearing the new adjustment status of the appliance, as follows: apply label “B” if the appliance was converted from methane to LP gas; apply label “A” if the appliance as converted from

LP gas to methane.

ATTENTION !!! If you smell gas:

A - Do not activate any electrical appliances,

including telephones or any objects that could create sparks;

B - Immediately open the doors and windows to

create an air current to quickly rid the room of

gas;

C - From another room or from a neighbour’s

if there is no other room, immediately call a professionally qualied technician or the gas supply company. If they are unavailable, call the

Fire Brigade.

15 - COMMISSIONING

D - Gas inlet pressure plug. E - CO2 adjustment screw. F - Factory default adjustment screw (do not touch).

Figure 15-6 - Gas valve

020010.01.022

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Figure 15-7 - Label bearing the new adjustment status of the appliance

Figure 15-8 - Settings for the various operating gases

15 - COMMISSIONING

U.M 60T 70T 100T 115T 140T 180T

210T

280T

Gas supply minimum pressure mbar 10

Gas supply maximum pressure mbar 45

Nozzle diameter for Methane gas (G20) mm 8,9 9,5 8,9 8,9 9,5 9,5 9,5

Nozzle diameter for Methane gas (G25) mm N.P. N.P. N.P. N.P. N.P. N.P. N.P.

Nozzle diameter for LP gas (G31) mm 6,2 6,5 6,2 6,2 6,5 6,5 6,5

Nozzle diameter for LP gas (G30) mm 5,7 6,0 5,7 5,7 6,0 6,0 6,0

Methane gas CO2 (G20) at maximum output heat % from 8,4 to 9,0

Methane gas CO2 (G20) at minimum output heat % from 8,3 to 8,7

Methane gas O2 (G20) at maximum output heat % from 4,7 to 5,1

Methane gas O2 (G20) at minimum output heat % from 5,6 to 6,0

Methane gas CO (G20) at maximum and minimum output heat ppm Less than 150

Methane gas CO2 (G25) at maximum output heat % from 8,5 to 9,1

Methane gas CO2 (G25) at minimum output heat % from 8,1 to 8,5

Methane gas O2 (G25) at maximum output heat % from 4,7 to 5,1

Methane gas O2 (G25) at minimum output heat % from 5,6 to 6,0

Methane gas CO (G25) at maximum and minimum output heat ppm Less than 150

LP gas CO2 (G31) at maximum output heat % from 9,9 to 10,5

LP gas CO2 (G31) at minimum output heat % from 9,6 to 10,0

LP gas O2 (G31) at maximum output heat % from 5,2 to 5,6

LP gas O2 (G31) at minimum output heat % from 5,8 to 6,2

LP gas CO (G31) at maximum and minimum output heat ppm Less than 250

LP gas CO2 (G30) at maximum output heat % from 10,3 to 10,9

LP gas CO2 (G30) at minimum output heat % from 9,9 to 10,3

LP gas O2 (G30) at maximum output heat % from 4,9 to 5,3

LP gas O2 (G30) at minimum output heat % from 5,7 to 6,1

LP gas CO (G30) at maximum and minimum output heat ppm Less than 250

Page 52

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15 - COMMISSIONING

15.6 - Ignition

15.6.1 - Boiler ignition

1.- open the gas cock;

2.- power the appliance and position the main switch to ON

(part “T” in gure 16-1);

3.- the appliance only switches on when the temperature required by the room thermostat is higher than the current supply temperature. Adjust the desired temperature for

heating service using the

and keys. If the external probe is connected (see section 13.1.4), make sure that the calculated temperature (see section 16.14,

parameter

1012

or parameter

1107

for appliances from 115T to 280T) is higher than the current exchanger temperature and that the external temperature (see section

16.14 parameter

1004

) is lower than the external

temperature that switches off the heating (see section 16.15

parameter

2020

);

4.- if the appliance is connected to a storage tank (see section

13.2), press the

and keys to select the

desired temperature of the domestic hot water.

5.- if the display shows a low water pressure error (see section

16.16.2), bleed the air again.

15.7 - Checking the supply gas pressure and any adjustments

The gas supply pressure must correspond with what is in the table in section 18. To check it, proceed as follows:

1.- close the gas cock;

2.- access the inner components of the appliance by following the procedure in section 17.2;

3.- loosen pressure plug “D” (see gure 15-6);

4.- connect to a manometer with a resolution of at least 0,1 mbar (1 mmH2O). For models from 115T to 280T you can use any one of the valves;

5.- open the gas cock;

6.- make sure the pressure does not exceed 45 mbar;

7.- position the main switch to ON (part “T” in gure 16-

1) and generate a heating demand by pressing the

key until the maximum value. Make sure the room thermostat is being called and the system is in the conditions to dissipate the heat generated;

8.- Set parameter

2200

HIGH

(in the 60T and 70T

models, use parameter

2010

). The burners will now

work at maximum output heat for 20 minutes;

9.- with the appliance at maximum ow rate, make sure that

the gas supply pressure does not drop below 10 mbar (100 mmH2O). If the pressure is lower, do not attempt to adjust the appliance; you must work upstream to reset

proper pressure and gas ow rate.

ATTENTION !!! Do not touch screws “E” and

“F” in gure 15-10. They are factory set for proper gas ow rate and supply pressure.

After having made sure the gas pressure is correct:

1.- Bring parameter

2200

back to

OFF

(in the 60T and

70T models, use parameter

2010

2.- close the gas cock;

3.- disconnect the manometer and close pressure plug “D” again;

4.- check for and gas leaks from pressure plug “D” (gure

15-6);

Do not force the pressure plug locking screws to avoid

damaging the gas valve.

ATTENTION!!! Run the seal test exclusively with

a soap-based water solution. Using naked ames is

absolutely prohibited.

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15 - COMMISSIONING

Figure 15-9 - Combustion analysis socket

Figure 15-10 - Gas valve

D - Gas inlet pressure plug. E - CO2 adjustment screw. F - Factory default adjustment screw (do not touch).

020010.01.016

020010.01.022

15.8 - Checking the CO2 seal and any adjustments

Table 15-8 shows the correct CO2 values for an appliance working in normal conditions at an altitude of less than 1000 metres. Values differing from those shown can cause malfunctions. To check and, if necessary, adjust said value a combustion analysis must be done. Proceed as follows

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

ATTENTION!!! If, during this procedure, a CO

value greater than 1000 ppm is detected, stop the

appliance and contact the retailer.

1. - If there isn’t one already, a hole must be made for combustion analysis positioned about 200 mm from the

ue exhaust tting (see gure 15-9 near the plug, part “F”).

2.- Switch on the appliance and open the bridge between terminals “10” and “11”;

3.- Make sure that the required temperature is higher than the boiler/water heater temperature;

4.- Access the installer menu (see section 16.15) and set parameter 2010 to HIGH. The appliance will now work

for 20 minutes at maximum output heat;

5.- Wait two or three minutes for the CO2 to stabilise;

6.- Put the CO2 value reading probe into socket “F” shown in

gure 15-9;

7.- Compare the CO2 value detected with the one shown in table 15-8. Be sure to read the value for the type of gas being used. If the CO2 value does not match the one in table

15-8, it must be adjusted via screw “E” in gure 15-10. Use

a 2,5 mm hex spanner (turn the screw clockwise to reduce the CO2 value and anticlockwise to increase it). Make small turns, always waiting for the CO2 value to stabilise before continuing, until you reach the desired value.

8.- Once the correct CO2 value as per table 15-8 has been reached, seal the screw with red paint or a similar system to discourage tampering.

9.- Set parameter 2010 to

LOu

The appliance will now work

for 20 minutes at minimum output heat.

10.- Wait two or three minutes for the CO2 to stabilise;

11.- Compare the CO2 value read with the one in table 15-8. Be sure to read the value for the type of gas being used. The CO2 value must be within the values shown; if not, stop the appliance and call the manufacturer.

12- Set parameter 2010 to

OFF

to bring the appliance back

to normal operation.

13.- Close the combustion analysis hole in gure 15-9 with

appropriate plug “F” as per the instructions from the drain pipe manufacturer.

ATTENTION!!! Once plug “F” is positioned with

the appliance at maximum output heat, make sure there are no ue gas leaks.

F - Combustion analysis socket

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15 - COMMISSIONING

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

ATTENTION!!! If, during this procedure, a CO

value greater than 1000 ppm is detected, stop the

appliance and contact the manufacturer.

1. - If there isn’t one already, a hole must be made for combustion analysis positioned about 200 mm from the

ue exhaust tting (see gure 15-9 near the plug, part “F”).

2.- Put the appliance in stand-by, shutting down all heating demands (remove the room thermostat bridge, if any, or

adjust the heating service to off using the

key).

3.- Make sure that the required temperature is higher than the boiler/water heater temperature;

4.- Access the installer menu (see section 16.15) and set

parameter

2201 to HIGH. The MASTER burner will now

work for 20 minutes at maximum output heat;

5.- Wait two or three minutes for the CO2 to stabilise;

6.- Put the CO2 value reading probe into socket “F” shown in

gure 15-9;

7.- Compare the CO2 value detected with the one shown in table 15-8. Be sure to read the value for the type of gas being used. If the CO2 value does not match the one in table 15-8,

it must be adjusted via screw “E” in gure 15-10. Use a 2,5

mm hex spanner (turn the screw clockwise to reduce the CO2 value and anticlockwise to increase it). Make small turns, always waiting for the value to stabilise before continuing, until you reach the desired value.

8.- Once the correct CO2 value as per table 15-8 has been reached, seal the screw with red paint or a similar system to discourage tampering.

9.- Set parameter 2201 to

LOu

. The MASTER burner will

now work for 20 minutes at minimum output heat;

10.- Wait two or three minutes for the CO2 to stabilise;

ATTENZION!!! The C02 reading, at low re,

could be affected by the natural draught of the chimney (negative pressure inside the chimney). If

this is the case, take the CO2 reading removing the correspondent ue gas sensor.

12.- Set parameter 2201 to

OFF

13.- Repeat the operations from point “3” to point “11” on the

remaining burners, considering that parameter

2202

corresponds to burner 2, 2203 to burner 3 and 2204 to burner 4.

14.- Close the combustion analysis hole in gure 15-9 with

appropriate plug “F” as per the instructions from the drain pipe manufacturer.

ATTENTION!!! Once plug “H” is positioned with

the appliance at maximum output heat, make sure there are no ue exhaust leaks, which could cause damage.

15.9 - Checking appliance output heat

The appliance has a factory set air/gas mixture ratio. The gas pressure to the burner is indirectly controlled by the fan. The only way to check the appliance output heat is to directly use the gas counter. Proceed as follows:

1. Switch the appliance on by turning the main switch to ON

(part “T” in gure 16-1)

and send a heating demand, bring

the requested temperature to the maximum value via the

key, making sure that the system is able to dissipate

all the heat generated.

2. For the 60T and 70T models, set parameter

2010

HIGH

. For the other models, set parameter

2200

HIGH

. The appliance will now work for 20 minutes at

maximum output heat

3. Measure the gas ow rate to the counter. The value obtained

must be compared with the value given in section 18 under

“Gas ow rate” with a tolerance of + or - 10%.

4. If the ow rate is lower, make sure: a) That there are no obstructions in the air intake and ue

exhaust ducts;

b) That the lengths of the air intake and ue exhaust ducts

correspond to what is described in section 18;

c) That the air intake lter (part “11” in gures 3-3, 3-5 and

3-7) is clean;

5. If the gas ow rate is within the tolerance, set parameter

2200 to

OFF. In 60T and 70T model appliances,

set

parameter 2010 to

OFF

to bring the appliance back to

normal operation.

6. If the gas ow rate is greater, repeat the procedure in section

15.9.

15.10 - Minimum water ow rate

The appliance has a protection system against low water ow rate. The water ow rate measuring device (part “16” in gure 3-1) continuously measures the ow rate on each exchanger. If the ow rate drops below the “Minimum operating water ow

rate” referred to in section 18, the appliance automatically

switches off and, if the ow rate does not increase after three

minutes, the corresponding error appears on the display.

Page 55

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16 - USE

Figure 16-1 - Control panel

FIGURE 16-1 KEY

A - Key to reduce water temperature B - Multifunction key: Key to Reset and access the “user

menu” and the “installer menu” C - Key to increase water temperature D - Burner state

Icon off = burner off Icon on = burner on E - State of heating or domestic service

Icon off = Service off

Icon on = Service active but not working

Flashing

icon = Service active and working

F - State of domestic service with accumulation:

Icon off = Service off

Icon on = Service active but not working

Flashing

icon = Service active and working G - “Installer menu” access icon H - Unit of measurement of the displayed pressure L - Burner unit indicator

 = Burner 1 (master)  = Burner 2  = Burner 3  = Burner 4

M - Water pressure or indicator of the different parameters

in the various menus

N - Heating or domestic hot water temperature or indicator

of the values assumed by the various parameters O - Unit of measurement of the displayed temperature P - Heating service adjusted by the external probe R - Key to increase the temperature of the domestic hot

water with storage tank and change the parameter

values S - Key to reduce the temperature of the domestic hot water

with storage tank and change the parameter values T - on/off switch

16.1 - Checking water pressure

16.1.1 - Checking boiler water pressure

If the pressure inside the heating circuit drops below 0,5 bar, display “N” in gure 16-1 displays Err 59 to

show that correct pressure needs to be restored. To do so, proceed as follows:

1.- open the device provided for by the installed upstream of the appliance to load the system;

2.- check the pressure on view “M” in gure 16-1; it must

reach a pressure of 1,5 bar (the Err 59 warning must disappear);

3.- close the lling device provided for by the installer

upstream of the appliance.

ATTENTION !!! During normal operation the device provided for by the installer upstream of the appliance to load the system must always remain in the closed position.

If, over time, the pressure goes down, restore the correct

value. In the rst month of operation, it might be necessary

to repeat this operation several times to remove any air bubbles in the system.

020010.01.023

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16 - USE

16.2- General information

The appliance leaves the factory set with standards parameters. However, you can consult or make a series of changes to the parameters through the “user menu” (section 16.14) and the “installer menu” (section 16.15). During operation, the display shows the appliance operating status in addition to other information as described in section 16.16 (Diagnostics).

16.3 - Display

During normal operation, you can consult further parameters through the “User menu” (see section 16.14) that are helpful in understanding appliance operation and check the latest blocks or errors that have occurred. After 5 minutes of normal operation, the display switches off completely to save energy. Simply press any key to switch it back on. In the event of any anomaly, the display switches

back on automatically. This function can be modied by

following section 16.13 (Energy saving).

16.4 - Ignition and shutdown procedure

To switch ON the appliance, proceed as follows:

1.- open the gas cock;

2.- power the appliance;

3.- If the display shows Err 65, it means that phase and

neutral polarity were not respected (call customer service

to solve the problem without attempting to x it yourself).

4.- adjust the domestic hot water temperature, if any, and the heating temperature respectively as per sections 16.5,

16.6 and 16.7.

The command and control equipment will ignite the burner. If ignition is unsuccessful within 3 minutes, the appliance

automatically attempts ignition ve times, after which, if it

continues not to switch on, it locks up and the display will

show

Loc 1 along with the icon and the corresponding

ashing     burner icon. Press the RESET key

to restore normal operating conditions. The appliance will automatically attempt another ignition.

ATTENTION!!! If the appliance frequently stops

because it locks up, contact a qualied technician to reset

normal operating conditions.

Once started properly, the appliance will continue to work

for the service requested. To switch OFF the appliance, proceed as follows:

1.- Use switch “T” in gure 16-1 to cut power;

2.- close the gas cock;

16.5 - Boiler domestic hot water adjustment

If the appliance is installed for double service (heating and domestic hot water production), adjust the domestic hot water

temperature using the and keys (see gure

16-1). When the keys are pressed, the display, part “N” in

gure 16-1, shows the requested D.H.W. temperature. The

temperature adjustment ranges goes from 40°C to 60°C.

ATTENTION!!! Domestic water temperature over

51°C can cause scalding. Children, the disabled and

the elderly are at high risk for scalds. Check the water temperature before getting into a bath or shower.

16.6 - Boiler heating adjustment

Adjust the appliance heating temperature using the or

keys (see gure 16-1). The room thermostat switches

on the circulation pump in order to meet heating requests.

16.7

- Thermostat type

heating adjustment

The boiler is standard adjusted with parameter 2003 at 0, that is, the boiler supplies the heating system with hot water

at a temperature adjusted using the and keys, Any room thermostats enable or disable the heating function to adjust the temperature of the rooms. To take full advantage of boiler performance, it is advisable to adjust the heating temperature to a value that is just enough to obtain the desired room temperature. If the season grows colder, progressively increase the heating temperature value. Do the opposite when the season grows milder.

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16 - USE

16.8 - Climatic adjustment

Adjust parameter 2003 to 1 using the “Installer menu”. The heating supply temperature is related to the external

temperature sensor according to the algorithm refered to in

gure 16-2. To adapt the calculation line to the various rooms/

climatic conditions, all the adjustment parameters must be set according to the following sections.

16.8.1 - Climatic adjustment: setting the

parameters

Through the “Installer menu” (see section 16.15), set:

- 2020 = “External heating switch-off temperature”,

adjustable between 0 and 35°C. When the external temperature reaches the value set in this parameter, the heating switches off automatically. When the external temperature drops below that value again, the heating automatically switches back on. The recommended start value is 22°C.

- 2 02 1 = “External design temperature (winter)”,

adjustable between -20 and 5°C. This is the external design

temperature used to dene the output heat the system

requires. The recommended start value for a typical home is -5°C;

- 2022 = “Supply temperature corresponding to the external

design temperature (winter)”, adjustable between 0 and 80°C. The supply temperature takes on the value set in this parameter when the external temperature correspond

with what is set in parameter 2021. The recommended

start values are: 40°C for low temperature systems (oor

heating); 70°C for high temperature systems (radiators);

- 2023 = “Spring external temperature”, adjustable

between 0 and 30°C. This is the external temperature at which you wish the heating to reach its minimum supply temperature. The recommended start value is 18°C.

- 2024 = “Supply temperature corresponding to spring

external temperature”, adjustable between 0 and 40°C. The supply temperature takes on the value set in this parameter when the external temperature correspond with what is set

in parameter 2023. The recommended start values are:

30°C for low temperature systems (oor heating); 42°C for

high temperature systems (radiators);

- In addition, you can set the minimum and maximum heating

temperature, using respective parameters 3016 and

3015 in section 19.

If, for some reason, the heating service does not correspond to the load, using parameters 2022 (Supply temperature

corresponding to the external design temperature (winter)), you can raise or lower the calculated temperature and match the desired room temperature.

16.8.2 - Climatic adjustment: switching the

heating system on and off

The climatic adjustment service is completely automatic, even as far as switching off at the end of the season and reignition at the beginning of the season is concerned, via parameter

2020. When the external temperature exceeds the value

set in this parameter, the heating switches off automatically. When the external temperature drops below the value set in this parameter, the heating switches back on automatically.

16.9 - Timing of the various functions

To protect the lifespan of the appliance, improve the comfort generated and increase energy savings, timers were put in during operation. These timers are:

- Pump post-circulation: every time the room thermostat detects the end of a heating service, the pump continues to work for 4 minutes;

- Pump anti-lock: every 24 hours, the heating pump and the domestic hot water pump (if present) are forced;

- Ignition delay: In all operating modes, every time the burner switches off, it waits 3 minutes before switching back on.

16.10 - Pump anti-locking

During the summertime, the circulator switches on once every 24 hours for 15 seconds to prevent any limescale build-ups from clogging it. At the same time, the diverter valve and the hot water tank pump (if present) are activated for the same reason.

16.11 - Antifreeze protection

ATTENTION !!!

In order for the antifreeze protection to be effective, the

appliance must be left with the power and gas supply on and the two services (domestic water and heating)

in the OFF position.

ATTENTION !!!

The antifreeze protection provided by the appliance cannot ensure antifreeze protection for the heating

system, the domestic water system, nor for the building

being served or parts of it.

Once the boiler temperature of 10°C is reached, the heating pump automatically switches on. If the temperature drops further below 5°C, the burner also switches on in order to protect the appliance from the effects of frost. If you do not use the appliance for a long period of time (over a year), we recommend draining it,

following the procedure

in section 17.10.

16.12 - Energy Saving

To reduce display energy consumption (gure 16-1), it switches

off automatically 5 minutes after the last operation done. You can disable this function or edit the time via parameter 2100

in the “installer menu” (section 16.15). If you set the parameter to 0, the display will remain on constantly.

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Figure 16-2 - Climatic adjustment graphic

Par. 2020 = External heating switch-off temperature Par. 2021 = External design temperature (winter) Par. 2022 = Supply temperature corresponding to the external design temperature (winter) Par. 2023 = Spring external temperature Par. 2024 = Supply temperature corresponding to spring external temperature Par. 3016 = Minimum supply temperature Par. 3015 = Maximum supply temperature

16 - USE

External temperature (°C)

Calculated temperature (°C)

Par. 2021

Par. 2023

Par. 2020

Par. 3016

Par. 2024

Par. 2022

Par. 3015

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16 - USE

16.13 - “User menu”

Pressing the RESET key for 2 seconds accesses the “user

menu”. Display “M” in gure 16-1 begins to show parameter

1001 to tell the user that the mode has changed.

Using the

and keys, you can scroll through the parameters in the menu. To exit the menu, simply press the RESET key again for 2 seconds.

Parameter Parameter description U.M. 1001 Burner 1 - Water supply temperature °C 1002 Hot water storage tank temperature (if present) °C 1004 External temperature (visible when an external temperature sensor is installed) °C 1006 Burner 1 - Flue gas temperature °C 1007 Burner 1 - Return temperature °C 1008 Burner 1 - Ionisation current uA 1009 Burner 1 - Main circuit pump and motorised valve status ON/OFF 1010 Heating circuit pump status ON/OFF 1011 Domestic hot water circuit pump status ON/OFF

1012

Calculated heating setpoint (with external probe enabled) (only for 60T and 70T models. See Parameter 1107 for the other models)

°C

1040 Burner 1 - Current fan rotation speed rpm 1041 Burner 1 - Fan rotation speed at ignition rpm 1042 Burner 1 - Fan rotation speed at minimum output heat rpm 1043 Burner 1 - Fan rotation speed at maximum output heat rpm 1051 Burner 1 - Last recorded lock-up (Loc) (see section 16.16.1) (255 means no block) / 1052 Burner 1 - Last recorded error (Err) (see section 16.16.2) (255 means no error) / 1053 Burner 1 - Number of times the burner lost its ame No. 1055 Burner 1 - Number of failed burner ignitions No. 1056 Burner 1 - Number of hours worked h x 10 1057 Burner 1 - Number of hours worked in domestic water with hot water storage tank h x 10

1059

* interval of time between the last two errors (Err)

1 value in minutes; 2 value in hours;

3 value in days; 4 value in weeks;

1060

* interval of time between the last two lock-ups (Loc)

1062 Burner 1 - Water ow rate l/min 1101 Multi-burner: Number of burners on No. 1102 Multi-burner: Manifold temperature °C 1103 Multi-burner: Number of burners locked (Loc) No. 1104 Multi-burner: Number of burners in Error (Err) No. 1106 Multi-burner: Appliance in emergency Yes/No

1107

Multi-burner: Calculated heating setpoint only 100T, 115T, 140T, 210T and 280T models) (see Parameter 1012 for the other models)

°C

1120 Multi-burner: Burner 1 modulation level % 1121 Multi-burner: Burner 2 modulation level % 1122 Multi-burner: Burner 3 modulation level % 1123 Multi-burner: Burner 4 modulation level %

If no keys are pres sed for more than 60 seconds, it automatically exits the menu. For models from 100T to 280T, all the parameters indicated as “Burner 1” refer to the appliance Master Burner. To display the same parameters for the other burners, you must connect the display to the burner in question as described in section 17.8. The following parameters can be accessed in this menu:

* How to read the values of parameters 1059 and 1060: i.e.: If it shows 1:29, it means 29 minutes; i.e.: If it shows 2:12, it means 12 hours; i.e.: If it shows 3:15, it means 15 days; i.e.: If it shows 4:26, it means 26 weeks.

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16.14 - “Installer menu”

ATTENTION !!! Editing these parameters

could cause the appliance and, therefore, the system to malfunction. For this reason, only

technicians with in-depth knowledge and awareness of the appliance can edit them.

The appliance command and control board makes this parameter menu available to technicians for operating and appliance adaptation to the system analyses. To access the “installer menu”, proceed as follows:

1.- hold down the RESET and

keys at the same

time for 5 seconds until parameter 2001 is displayed.

The

symbol appears at the centre of the display to

show access to the “installer menu”.

2.- you can use the

and keys to scroll

through the parameters in the menu;

3.- once the parameter you are interested in is displayed, you can edit it as follows: a.- press the RESET key to access the parameter

(display “N” in gure 16-1 will begin ashing);

b.- edit the parameter value using the

and

keys;

c.- press the RESET key to conrm the edited data and

go back to the list of parameters;

4.- To exit the “installer menu”, hold down the RESET key

for 5 seconds until the

symbol disappears from the

display.

If no keys are pres sed for more than 60 seconds, it automatically exits the menu. Any data changes that are not

conrmed with the RESET key will be lost.

For 100T to 280T models, the parameters indicated as “Burner 1” refer only to Burner 1 (Master). To display or edit the same parameters for the other burners, you must connect the display to the burner in question as described in section 17.8.

ATTENTION !!! In order to facilitate any

command and control board replacements, it is

essential to make a note of any changes made to the parameters in the “customised values” column in the following table.

The following parameters can be edited or consulted in this menu:

16 - USE

Parameter Parameter description U.M. Setting eld BOILER

default value

WATER HEATER default value

Customised values

2001 Minimum output heat level % From 1 to 50 1 1

2002 Maximum output heat level % From 1 to 100 100 100

2003 Heating operating mode nn 0 = With room thermostat

1 = External probe with TA 2 = External probe closing TA reduce of 2027 3 = Permanent heating closing TA reduce of 2027 4 = With 0-10 Volt input 5 = N/A

00 00

2004 Stand-by time after differential maximum sec From 10 to 30 30 30

2005 Heating pump post-circulation sec From 10 to 260 240 240

2010 Burner 1 - Burner forcing / Off = No forcing

Low = Minimum output heat Ign = Ignition output heat High = Maximum output heat

OFF OFF

2011 Main circuit pump and motorised 2-way valve forc-

ing (Burner 1)

/ On or OFF

OFF OFF

2012 Heating circuit pump forcing / On or OFF OFF OFF

2013 Domestic hot water circuit pump forcing / On or OFF OFF OFF

2014 Icon test on the display. All the icons on the display

come on by pressing the RESET key. The display goes back to normal function by pressing the RESET key again.

/ /

2020 Climatic adjustment: external heating switch-off

temperature

°C From 0 to 35

22 N/A

2021 Climatic adjustment : external design temperature

(winter)

°C From -20 to 5

-5 N/A

2022 Climatic adjustment: supply temperature correspond-

ing to the external design temperature (winter)

°C From 0 to 80

80 N/A

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16 - USE

2023 Climatic adjustment : spring external design

temperature

°C From 0 to 30

20 N/A

2024 Climatic adjustment: supply temperature

corresponding to the spring external temperature

°C From 0 to 40

40 N/A

2027 Nighttime Reduction °C From 0 to 50 10 N/A

2040 N/A N/A N/A N/A N/A

2041 N/A N/A N/A N/A N/A

2042 Burner 1 - Protection against frequent ignitions: time sec From 10 to 900 180 180

2043 Burner 1 - Protection against frequent ignitions:

temperature differential

°C From 0 to 20

16 5

2062 Domestic water pump post-circulation sec From 10 to 255 240 240

2063 Maximum D.H.W. priority time min From 1 to 60 30 N/A /

2067 D.H.W. production priority / 0 = The priority lasts the amount

of time set in parameter 2063; 1 = OFF, domestic water does not have priority over heating; 2 = ON, domestic water always has priority over heating;

2 N/A

2100 Display energy saving min From 0 to 30 = delay to switch-

off in minutes.

5 5

2101 Multi-burner: emergency mode / Yes or No Yes Yes

2102 Multi-burner: Emergency temperature adjustment °C from 20 to 65 45 45

2103 Multi-burner: ignition delay sec from 1 to 900 180 15

2104 Multi-burner: switch-off delay sec from 1 to 900 180 15

2105 Multi-burner: burner ignition temp. delta °C from 0 to 20 5 5

2106 Multi-burner: burner switch-off temp. delta °C from 0 to 20 5 5

2107 Multi burner: maximum temp. increase with respect

to calculated temp.

°C from 0 to 20

10 4

2108 Multi burner: maximum temp. decrease with

respect to calculated temp.

°C from 0 to 20

20 4

2109 Multi-burner: Subsequent burner ignition % from 1 to 100 70 70

2110 Multi-burner: Subsequent burner switch-off % from 1 to 100 10 10

2111 Multi-burner: Burner rotation dd from 0 to 9 6 6

2113 Multi-burner: Modulation start delay min from 0 to 60 5 0

2114 Burner 1: Main circuit pump shutdown time sec from 0 to 255 240 240

2200 Forcing: All the Burners together. \ Off, Low, Ign, High OFF OFF

2201 Forcing: Burner 1 (Master). \ Off, Low, Ign, High OFF OFF

2202 Forcing: Burner 2. \ Off, Low, Ign, High OFF OFF

2203 Forcing: Burner 3. \ Off, Low, Ign, High OFF OFF

2204 Forcing: Burner 4. \ Off, Low, Ign, High OFF OFF

N/A = Not Applicable

16.15 - Diagnostics

During normal appliance operation, display “N” in gure 16-1

continuously shows the appliance work status via the following indications:

Parameter Parameter description Display on display “N” in gure 16-1

AFro

Antifreeze function active Boiler temperature (°C)

Domestic hot water with storage tank operating status Domestic hot water temperature (°C)

Heating or instantaneous domestic hot water operating status Supply temperature (°C)

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16 - USE

16.15.1 - Diagnostics: “Loc” lock

Lock-upLock-up description Checks Solutions

Loc 1 No ame detected after

5 consecutive ignition attempts.

A - Supply gas pressure (see section 15.7); B - Sparks on the ignition electrodes (see section

17.5); C - Correct gas pressure and CO2 value (see sections 15.7 and 15.8); D - 230Vac power supply to the gas valve; E - 0,88 Kohm and 6,59 Kohm electrical resistance of the two gas valve coils

F - If the burner ignites and goes out at the end of the ignition attempt, make sure: that the ionisation current value is greater than 4 (follow the procedure in section 17.12)

A - If the pressure is incorrect, it must be restored upstream of the appliance; B - Check and correct electrode positions (section

17.5); C - Remove any obstructions in the air intake and

ue exhaust ducts;

D - If the supply current to the gas valve is not 230 Vac, replace the control board; E - If the resistance does not match, replace the gas valve; F - If the ionisation current does not match, check the CO2 as per section 15.8. Make sure the detection electrode is in good condition and, if necessary, replace it. Make sure the detection electrode connection cable is in good condition and, if necessary, replace it.

Loc 2 (*) Gas valve not supplied

during ignition attempts

A - Check whether the supply safety thermostat has tripped;

B - Check whether the ue exhaust safety fuse has

tripped;

ATTENTION !!! If the ue exhaust temperature safety fuse trips, you must contact the appliance manufacturer to avoid serious damage to the exchanger.

Loc 3 Gas valve loses power

during operation

Make sure the electrical connections between the gas valve and control board are in good condition;

A - If the electrical connections are interrupted, restore them; B - If the connections are in good condition, try replacing the gas valve or the control board;

Loc 4 Gas valve relay does not

Make sure the electrical connections between the gas valve and control board are in good condition;

A - If the electrical connections are interrupted, restore them; B - If the connections are in good condition, try replacing the gas valve or the control board;

Loc 5 (*) Gas valve circuit A - Check whether the supply safety thermostat has

tripped;

B - Check whether the ue exhaust safety fuse has

tripped;

ATTENTION !!! If the ue exhaust temperature safety fuse trips, you must contact the appliance manufacturer to avoid serious damage to the exchanger.

Loc 6 Safety relay opening

error

Replace the command and control board

Loc 7 Safety relay closing error Replace the command and control board

Loc 11 Locking error exceeding

20 hours

Press the RESET key to see the type of error (Err) and proceed accordingly;

Loc 12 Fan error A - Check the 230Vac power supply to the fan;

B - Check the PWM connection to the fan;

A - If the power supply does not match, replace the control board; B - If there is no fan PWM dialogue, replace the control board; C - Try replacing the fan;

Loc 13 Software error inside

command board

Replace the command and control board

Loc 14 Software error inside

command board

Replace the command and control board

Loc 15 Software error inside

command board

Replace the command and control board

Loc 16 Software error inside

command board

Replace the command and control board

Loc 17 Software error inside

command board

Replace the command and control board

Loc 18 Software error inside

command board

Replace the command and control board

Loc 19 Software error inside

command board

Replace the command and control board

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16 - USE

Loc 20 Flame lost three times Make sure: that the ionisation current is at a value

higher than 4 (follow the procedure in section 17.12)

Make sure: that the flue exhaust is appropriately protected from obstructions caused by gusts of wind

If the ionisation current is not over 4, you must check the CO2 (follow section 15.8) and restore the proper value. Check the ionisation glow plug and, if necessary, replace it. Make sure the ionisation current electrical circuit cables are intact.

If the ue exhaust is positioned on a vertical wall, it must be protected by a windproof grid. If the ue

exhaust is positioned on the roof, make sure it is not

in a reux area and that the windproof chimney, if any, is actually efcient.

Loc 21 Software error inside

command board

Replace the command and control board

Loc 22 Software error inside

command board

Replace the command and control board

Loc 23 Software error inside

command board

Replace the command and control board

Loc 24 Software error inside

command board

Replace the command and control board

Loc 25 (*) Gas valve circuit A - Check whether the heating supply safety thermostat

has tripped;

B - Check whether the ue exhaust temperature safety

fuse has tripped;

ATTENTION !!! If the ue exhaust temperature safety fuse trips, you must contact the appliance manufacturer to avoid serious damage to the exchanger.

Loc 26 Software error inside

command board

Replace the command and control board

Loc 27 Flame with gas valve

closed

Replace the gas valve

Loc 28 Flame with gas valve

closed

Replace the gas valve

Loc 29 (*) Interlock input A - Check LWCO connection;

B - Check ue blocked pressure switch;

A - If LWCO intervenes, try to reset it.

B - Check if ue gas line is free from any blockage

Loc 30 Software error inside

command board

Replace the command and control board

Loc 31 Flame lost three times A - Check the detection electrode;

B - Make sure that the ue exhaust is appropriately

protected from obstructions caused by gusts of wind.

C - Check for any ue exhaust recirculation

A - Try replacing the detection electrode. B - Check for and, if necessar y, rem ove any

obstructions from the air intake and ue exhaust ducts; C - Find the cause of the ue exhaust recirculation

Loc 32 Software error inside

command board

Replace the command and control board

Loc 33 Software error inside

command board

Replace the command and control board

Loc 34 Software error inside

command board

Replace the command and control board

Loc 35 Software error inside

command board

Replace the command and control board

Loc 36 Software error inside

command board

Replace the command and control board

Loc 37 Software error inside

command board

Replace the command and control board

Loc 38 The ue exhaust sensor

temperature does not rise when the burner ignites

a-make sure the ue gas sensor meets the requirement in section 17.14.

b - Make sure that the ue gas sensor (parameter

1006) increases the temperature when the burner ignites.

a-If the ue gas sensor does not meet section 17.14,

it must be replaced.

b - If the temperature does not rise, replace the ue gas

temperature sensor or the command and control board.

* This error stops all the burners

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16 - USE

16.15.2 - Diagnostics: “E” errors

Error Error description Checks Solutions

Err 0 A sensor is out of the

measurement range

Make sure all the temperature sensors are in a plausible measurement range

Replace any sensors that are not in the proper temperature range or replace the main board

Err 45 Software error inside

command board

Replace the command and control board

Err 46 Software error inside

command board

Replace the command and control board

Err 47 Software error inside

command board

Replace the command and control board

Err 48 Software error inside

command board

Replace the command and control board

Err 49 Software error inside

command board

Replace the command and control board

Err 50 Software error inside

command board

Replace the command and control board

Err 51 Software error inside

command board

Replace the command and control board

Err 52 Software error inside

command board

Replace the command and control board

Err 53 Software error inside

command board

Replace the command and control board

Err 54 Flame detected at a time

in which it should not be

Replace the command and control board

Err 55 Low water pressure error Check the state of the pressure measuring device Replace the pressure measuring device.

Err 56 Low water pressure error Check the state of the pressure measuring device Replace the pressure measuring device.

Err 57 Low water pressure error Check the state of the pressure measuring device Replace the pressure measuring device.

Err 58 Low water pressure error Check the state of the pressure measuring device Replace the pressure measuring device.

Err 59 (*) Low water pressure error Check the system pressure and, if necessary,

increase it.

If the detected pressure is greater than parameter 3022, replace the pressure measuring device.

Err 60 Flue exhaust tempera-

ture high error

A - Check the combustion output of the burner in error; the output must be higher than 97% (referring to the PCI).

B - Make sure the ue exhaust temperature sensor

resistance matches with the graphic in section

17.14.

A - If the output is lower than 97%, try cleaning

the ue gas side and the water side of the heat

exchanger. B - If the sensor does not match, it must be replaced.

Err 61 Return temperature

greater than supply temperature

Make sure the return sensor electrical resistance matches with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 62 (*) Condensate level sensor

error

A - Make sure the condensate exhaust duct is not obstructed; B - Check the state of the condensate neutraliser;

A - Free the condensate exhaust duct of any obstructions; B - Replace the product contained in the condensate neutraliser;

Err 64 Frequency signal error

or WD communication error

A - Check the signal frequency. It must be between 55 and 65 Hz. B - Make sure the grounding and the neutral are at 0 volt

A - If the frequency does not fall within the values, ask the electrical service provider. Otherwise, try replacing the control board. B - If the neutral is not at zero, restore the correct electrical power supply. If the neutral is at 0 volt, try replacing the board.

Err 65 Polarity inverted

between phase and neutral.

Check proper polarity between phase and neutral. Invert the polarity between phase and neutral.

Err 66 Frequency signal error A - Check the signal frequency. It must be between

55 and 65 Hz. B - Make sure the grounding and the neutral are at 0 volt

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16 - USE

Err 67 Grounding error Make sure the appliance is correctly grounded. Restore correct appliance grounding.

Err 68 Watchdog communica-

tion error

Replace the command and control board

Err 72 Supply sensor open Make sure the sensor electrical resistance matches

with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 73 Return sensor open Make sure the sensor electrical resistance matches

with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 76 D.H.W. sensor open Make sure the sensor electrical resistance matches

with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 80 Supply sensor in short

circuit

Make sure the sensor electrical resistance matches with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 81 Return sensor in short

circuit

Make sure the sensor electrical resistance matches with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 84 D.H.W. sensor in short

circuit

Make sure the sensor electrical resistance matches with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 86 Flue exhaust sensor in

short circuit

Make sure the sensor electrical resistance matches with the graphic in section 17.14.

If the sensor does not match, it must be replaced.

Err 87 RESET key error RESET key pressed too many times in 60 seconds

Err 93 Appliance selection error Check the 3000 parameters list (section 19)

Err 107 Software error inside

command board

Replace the command and control board

Err 108 Software error inside

command board

Replace the command and control board

Err 109 Error burner 2,3 or 4 When burner 1 (MASTER) goes in a general error,

will stops all others burner generating an Err 109

Resolve the error to burner 1 (MASTER)

Err 110 Flapper valve not open

error

A - Check for and, if necessary, remove any obstruc-

tions in the air intake and ue exhaust ducts; B - Check the apper valve (part 31 g 3-2)

Err 111 Flapper valve not closed

error

Check the apper valve (part 31 g 3-2)

Err 112 Flapper inlet error Make sure parameter 3005 is set to 0 or 4 If parameter 3005 is 0 or 4, replace the command

board.

Err 113 Software error inside

command board

Replace the command and control board

Err 114 Water ow rate too low Check the ow rate to the burner (parameter 1062),

it must be greater than parameter 3035.

A - Increase the water ow rate to the system;

B - Check for and, if necessary, remove any obstructions from the system.

Err 115 Master board error Reset via parameter 3013.

Err 116 (*) Multiple burner commu-

nication failure

A - BUS communication interrupted B - A burner is not powered

A - Check the BUS connection. B - Restore power to all the burners

NO CONN

Microprocessor locked upA - Make sure that the pressure measuring device

wires are not short circuiting B - Make sure that the supply measuring device wires are not short circuiting C - Check display wires are connected to the burner 1 (MASTER)

A - If it is not short circuiting, replace the pressure measuring device (or disconnect it via menu 3000). B - If it is not short circuiting, replace the supply measuring device (or disconnect it via menu 3000). C - If the display is not connected to burner 1 (MASTER) shows “NO CONN”. D - If it is none of the above cases, replace the control board and/or the display.

* This error stops all the burners

Page 66

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COSMOGAS

17.1 - General warnings

This section must be brought to the installer’s attention, highlighting the tasks to maintain proper system operation; The installer is also obligated to inform the user that failure to take care of and service this appliance could cause malfunctions.

It is advisable to follow scheduled annual system maintenance for the following reasons:

- to keep appliance output high, thereby saving fuel;

- to keep a high level of working safety;

- to keep the level of fuel environmental compatibility high;

ATTENTION!!! The appliance must only be

serviced by a professionally qualied technician.

ATTENTION!!! Before any maintenance

operations, disconnect the appliance from the electrical mains using the specic switch located nearby.

ATTENTION!!! Close the gas cock before any

maintenance operations

The box below shows the operations to do at every maintenance session.

17 - MAINTENANCE

17.1.1 - Gas leak check

1.- Make sure there are no gas leaks in the system;

2.- Check for gas leaks using a leak detector (with bubbles or the like) or an equivalent system, thoroughly checking the entire gas route from the counter to the appliance.

ATTENTION!!! Do not carry out these checks in

the presence of naked ames.

17.1.2 - Making sure the air intake and ue

exhaust ducts are in good conditions

1. - Check whether the air intake and ue exhaust ducts

have obstructions, signs of corrosion, physical damage, water spots or signs of rust.

2. - Make sure the externally assembled intake grids and

ue exhaust outlets have no residue and are clean.

17.1.3 - Checking the system water

pressure

1.- Make sure the system is full of water and under pressure as shown in section 18 technical features.

2.- Make sure there are no leaks in the hydraulic connections.

ATTENTION!!! Repair any system or appliance

leaks. Continuously adding new water leads to

increased minerals that reduce the ow cross-section,

decreasing heat exchange and causing the heat exchanger to overheat. All of this leads to failures and reduced appliance life.

17.1.4 - Checking the ignition and

detection electrodes

1.- Remove the burner fan unit (as shown in section 17.3).

2.- Clean any operating material build-up from the electrodes.

3.- Make sure the electrodes are in the correct position as shown in section 17.5.

MAINTENANCE PROTOCOL

- Make sure there are no gas leaks (Follow section 17.1.1.);

- Make sure the air intake and ue exhaust system is in good conditions

(Follow section 17.1.2);

- Make sure the system water pressure is correct (Follow section 17.1.3.);

- Check the ignition and detection electrodes (Follow section 17.1.4.);

- Clean the burner and the ue gas side main exchanger and make sure

the heat insulators are in good condition (Follow section 17.4.);

- Clean the air intake lter

(Follow section 17.6.);

- Clean the condensate exhaust system (Follow section 17.7.).

- Check appliance performance (Follow section 17.13.);

Page 67

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COSMOGAS

Figure 17-1 - Disassembling the casing and opening the control panel

17.2 - Disassembling the casing and accessing the inner components

To disassemble the casing, proceed as follows (refer to

gure 17-1):

1.- Lift cover “A”;

2.- Unscrew screws “B”;

3.- Lower front casing “C”;

4.- Remove lower casing “E”;

5.- Open panel “D” by unscrewing the xing screw located on the left and turning it as shown in the gure.

6.- Unscrew screw “G”;

7.- Lift cover “F”;

17.3 - Disassembling the burner fan unit

To disassemble the burner fan unit, proceed as follows:

1.- close the gas adduction cock and disconnect power;

2.- access the inner components following section 17.2;

3.- disassemble spark generator “A” in gure 17-2, unscrewing screws “D” in gure 17-2 and disconnecting it

from the ignition glow plugs.

020009.01.008

17 - MAINTENANCE

4.- disassemble air manifold “A” in gure 17-3, turning it

clockwise then removing it towards the left;

5.- unscrew nut “H” in gure 17-4, being careful of the

gasket on the connection;

6.- with the aid of a athead screwdriver, remove spring “A” in gure 17-4;

7.- remove the electrical plug from the gas valve;

8.- pull the gas valve out upwards, being careful of O-ring

“L” (see gure 17-4);

9.- Unscrew the four bolts “B” in gure 17-5;

10.- remove the fan/burner unit (part “C” in gure 17-5).

Reassembling the fan/burner unit

To reassemble the burner/fan unit, work backwards compared to the disassembly operations and adopt the following precautions:

a - replace gasket “M” in gure 17-4, taking care to

thoroughly clean the seat of said gasket, as well as the support seat.

b - check the state of the gasket of nut “H” and Oring “L” in

gure 17-4. If they are ruined, they must be replaced.

c - Once everything has been reinstalled, open the gas

supply and run a seal test on nut “H” in gure 17-4.

ATTENTION!!! Run the seal test exclusively with

a soap-based water solution. Using naked ames is

absolutely prohibited.

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17 - MAINTENANCE

Figure 17-3 - Air manifold disassembly

Figure 17-4 - Gas valve disassembly

020009.01.012

BE C A

020009.01.014

Figure 17-2 - Spark generator disassembly

17.4 - Cleaning the burner and the

primary exchanger, ue gas side

To properly clean the burner and the exchanger body (ue gas side), proceed as follows (refer to gure 17-5 when not otherwise specied):

1.- access the inner components following section 17.2;

2.- disassemble the fan burner unit following section 17.3;

4.- Run a cylindrical brush with nylon bristles inside combustion chamber “H”

ATTENTION !!! DO NOT use metallic brushes. Only

use brushes with nylon or equivalent material bristles.

5.- Using an extractor, suction the unburnt residues inside combustion chamber “H”;

6.- using the same extractor, suction the surface of the burner and around the electrodes;

7.- reassemble the components in reverse order;

8.- open the gas cock;

9.- restore power.

10.- make sure there are no gas leaks between the removed joints;

ATTENTION !!! Run the seal test exclusively with

a soap-based water solution. Using naked ames is

absolutely prohibited.

ATTENTION !!! Every time you clean the burner

and the main exchanger, you must rst make sure heat insulators “R” and “S” are in good condition (see gure 17-5). If necessary, replace them along with burner gasket “T” (see gure 17-5), requesting the specic kit, code

62632006.

A H

020010.01.020

020010.01.021

020022.01.008

YES

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COSMOGAS

17 - MAINTENANCE

Figure 17-5 - Disassembling the burner fan unit

020009.01.031

020009.01.032

ATTENTION !!!

The gasket ensures combustion chamber seal. If the gasket is damaged, do

NOT reuse it. It must be replaced along with the burner unit. To replace it, consult the manufacturer.

GASKET

BURNER UNIT

Page 70

60T - 280T

COSMOGAS

17 - MAINTENANCE

17.4.1 - Thermal insulations

Thermal insulations must be checked every year and replaced if they are cracked or damaged. See Figures below where the thermal insulations (items “C” and “E”) are showned already disassembled from heat exchanger and burner. For replacement information see the spare parts section.

Figure 17-7 - Positioning electrodes on the burner

A - LH ignition electrode B - RH ignition electrode C - Detection electrode

020022.01.009

Figure 17-6 - Thermal insulations

17.5 - Positioning the ignition and

ionisation electrodes properly

For the appliance to work well, it is essential for the

electrodes to be positioned properly (refer to gure 17-7):

- the distance between ignition electrodes “A” and “B” must be between 2,0 and 2,5 mm;

- the distance of the ignition electrodes from the burner surface must be between 5 and 5,5 mm;

- the distance of the ionisation electrode from the burner surface must be between 5,5 and 6,5 mm.

To accurately position the electrodes, it is a good idea to

use a vernier caliper to respect the tolerances shown in

gure 17-7.

A = Fixing screw B = Washer C = Thermal Insulation D = Stainless steel tube E = Thermal Insulation F = White thermal insulation G = Burner H = Gasket L = Ignition electrodes M = Screws N = Detection Electrode Q = White thermal insulation R = Gasket S = Gasket

Page 71

60T - 280T

COSMOGAS

17 - MAINTENANCE

Figure 17-8 - Air intake lter disassembly

020010.01.018

17.6 - Cleaning the air intake lter

The air lter must be cleaned for the appliance to work properly. Refer to gure 17-8 and proceed as follows:

1.- access the inner components of the appliance by

following section 17.2;

2.- slide out the lter, part “A”, as shown in the gure;

3.- clean the lter with compressed area until the surface is

cleaned;

4.- reassemble the lter and the appliance casing.

17.7 - Condensate drain system

maintenance and cleaning

During appliance maintenance, the condensate drain pipe (part

“5” in gures 3-3, 3-5 and 3-7) must be disassembled and any

residue cleaned. Reassemble the clean pipe and

restore the liquid level in the siphon as per section 15.1.2.

Check the pH level every three years for the rst year. To run the test, you can use specic litmus test strips or a specic electronic instrument that allows for more accurate measurement (access the box via plug “E” in gure 12-1). The

subsequent frequency of these checks can be reduced to every six months or year, depending on the local standards in force. The neutralising content of the box must be replaced when the pH level drops below the level required by the standards in force. The allowed acidity level goes from pH 5,5 to 9,5. To replace the neutraliser, proceed as follows:

1. Follow what is shown in section 17.2 to remove covering

“E” in gure 17-1;

2. Extract box “A” (gure 17-9);

ATTENTION !!! When removing the box, take care

to tilt it in order to prevent the liquid from spilling, which

could cause damage

3. Open cover “C” (gure 17-9) upwards;

Make sure the box is in good condition;

5. Make sure the neutralising material is in good condition and, if necessary, add or replace it;

6. Fill it with fresh water until the water begins to ow out of

the drain;

7. Reposition the box in the correct seat;

ATTENTION !!! The neutralisation box must be

lled with water to prevent gas from leaking out of the

drain during unit operation.

8. Open the gas supply;

9. Restore power to the appliance.

ATTENTION !!! Follow gure 17-9 carefully to

but box “A” back in the right position.

After the above

maintenance, restore the liquid level in the siphon as per

section 15.1.2.

020010.01.014

Figure 17-9 - Disassembling and opening the condensate neutraliser box

Page 72

60T - 280T

COSMOGAS

17 - MAINTENANCE

17.8 - Connecting the Display to the other burners

In 100T to 280T appliances, being multi-burners, the display

in gure 16-1 is always connected directly to “Burner 1

(Master)”. All the parameters that can be consulted on the display (sections 16.14, 16.15 and 19) that refer to Burner 1 (Master) exclusively concern this burner. If you wish to see/ change the same parameters for the other burners, you must move the display connection from “Burner 1 (Master)” to the burner you wish you view/edit; proceed as follows:

(refer to gure 17-10):

1. Disconnect power to the appliance;

Figure 17-10 Connecting the display in the other burners

A = Connector for Burner 1 (Master) dialogue B = Connector from display C = Connector for Burner 2 dialogue D = Connector for Burner 3 dialogue (Only in 180T, 210T and 280T models) E = Connector for Burner 4 dialogue (Only in 280T models)

2. Follow what is described in section 17.2 to access the inner components;

3. Disconnect terminal “B” (coming from the display) from terminal “A” (coming from “Burner 1 (Master)”);

4. Connect terminal “B” to terminal “C”, “D” or “E”, depending on which burner you wish to view or edit, considering that: terminal “C” is for “Burner 2”; terminal “D” is for “Burner 3” and terminal “E” is for “Burner 4”

5. Once the terminal is connected to the burner to be checked, repower the appliance and switch it on;

6. The display will now show all the information regarding the

connected burner. Make all consultations or modications

following what is described in sections 16.14, 16.15 and 19.

7. Once the check is complete, reconnect terminal “B” to terminal “A” as it was previously.

Burner 2

Burner 1 (Master)

Burner 3

Burner 4

Page 73

60T - 280T

COSMOGAS

17 - MAINTENANCE

Figure 17-11 - Command board

17.9 - How to move a control board

100T to 280T model appliances are congured to be managed

by a control board (Burner 1 Master). All the devices are connected on this board: room thermostat, external probe, pump controls, external safety devices and all the internal safety devices: condensate level sensor, flue exhaust differential pressure switch, etc. If the Burner 1 control board has an error, the appliance stops working. If the technician does not have spares to replace the board, he/she can temporarily replace it with one of the boards from another burner in the appliance so that the latter can be restarted. To this end, proceed as follows:

(when not otherwise specied, refer to gure 17-10)

1. Turn off the main switch and disconnect power;

2. access the inner components following what is described in section 17.2;

3. Disconnect connector “B” (connector coming from the display) to connector “A” (connector coming from “Burner 1 (Master)”);

4. Disconnect all the other connectors from the Burner 1 (Master) control board;

5. Remove the Burner 1 (Master) control board from the appliance;

6. Follow points 3 to 5 to remove the control board from the burner positioned lower;

7. Assemble the board in place of the Burner 1 (Master) board;

8. Restore all the connections in the new Burner 1 (Master) board;

020009.01.010_a

OFF

S4 SELECTOR

9. Move selector “S4” as shown in gure 17-11 from the OFF

position to the new ON position;

10. Be very careful with the connectors from the board that was removed. They must be insulated to avoid short circuiting and damage;

11. Electrically insulate each of these connections;

12. Replace the appliance casing;

13. Reconnect power and turn on the appliance main switch;

14. Access the forced menu, follow section 19 and set all the parameters as per the “Burner 1 (Master)” column.

Parameter 3050 must be reduced by a unit compared to the previous state, as the appliance now has one less Slave Burner.

15. Cut power;

16. Repower the appliance; The new Burner 1 control board now controls the appliance;

Page 74

60T - 280T

17 - MAINTENANCE

Figure 17-12 Setting parameters 3001, 3050 and selectors S4

COSMOGAS

Models 280T

Models 180T-210T

Models 100T-115T-140T

Models 60T-70T

Page 75

60T - 280T

COSMOGAS

17.10 - Emptying the appliance

1.- generate a heating demand by increasing the domestic hot water and heating temperature (also close any room thermostat bridges in the boiler version);

2.- wait for the burner to ignite (in the multi-burner versions, wait for all the burners to ignite) (make sure as many

corresponding “L” icons in gure 16-1 as burners are on);

3.- switch off the appliance. This way, any motorised valves stay open);

4.- close the system loading cock provided for by the installer;

5.- connect a exible rubber hose to the drain cocks “38” in gures 3-3, 3-5 and 3-7, and direct it to the drain in a sink

or the like;

6.- wait for the water inside the appliance to cool to below about 40°C;

7.- open the drain cocks slowly;

8.- open the heating element bleed valves. Start from the higher heating elements and continue with the lower ones.

9.- once all the water has been drained, close the bleed valves on the heating elements and the drain cocks provided for by the installer.

ATTENTION!!! Recovering and/or reusing the

water leaving the heating circuit for any purpose is

prohibited, as it could be polluted.

17.11 - Minimum and

maximum output heat

It is possible to force operation to your own minimum, maximum or ignition output heat. Proceed as follows:

1.- make sure the heat generated by the appliance can be dissipated by the system;

ATTENTION!!! During forcing, the supply

temperature automatically goes to 93°C to allow the heat generated by the appliance to be assimilated as much as possible. Make sure the system can withstand this temperature.

2.- access parameter 2010 (2200 for multi-burner models) located in the “installer menu” (see section 16.15);

3.- set the parameter to the following value: a) LOu to force the burner, or all the burners, to minimum

output heat;

b) Ign to force the burner, or all the burners, to ignition

output heat;

a) HIgH to force the burner, or all the burners, to

maximum output heat;

4.- To end forcing, bring parameter 2010 (2200 for multi- burner models) back to 0FF and press the RESET key.

ATTENTION!!! If, during forcing, the output heat

dispensed by the appliance is much greater than the

output heat absorbed by the system, the appliance

switches off continuously to reach the maximum allowed temperature (93°C).

The same procedure above can also be applied to 100T to 280T model multi-burner appliances but consider that only one burner can be forced at a time, moving the display from one burner to another, as described in section 17.8.

17.12 - Checking the ionisation current

At any operating state, even during maximum and minimum output heat checks as per section 17.11, it is possible to see

the ionisation current value on parameter 1008 in the “user menu” (section 16.14). This value must be between 4 and 7 uA (microamperes).

Being that parameter 1008 on multi-burner appliances (models from 100T to 280T) corresponds to Burner 1 (Master), in order to check the other burners, you must refer to section

17.8.

17.13 - Checking combustion performance

Based on national laws on gas appliances, combustion performance must be checked periodically; To this end, do exactly what is described in section

15.8 and, along with the output heat, check combustion performance, which must be greater than 96%.

17 - MAINTENANCE

Page 76

60T - 280T

COSMOGAS

17.14 - Temperature and water measurement probes

There are various temperature sensors on the exchanger body. The electrical resistance between the two sensor

contacts must match what is shown in gure 17-13.

The temperature probes are: 1001, 1002, 1006 and

1007

Figure 17-13 - Water sensor curve

Figure 17-14 - External temperature sensor curve

17 - MAINTENANCE

17.15 - External temperature probe

The 1004 external temperature sensor (see section 13.1.4) comes standard. The electrical resistance between the two

sensor contacts must match what is shown in gure 17-14.

Page 77

COSMOGAS

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

Figure 17-15 - Multi-line wiring diagram part 1 - continues on the following page

60T - 280T

17 - MAINTENANCE

Page 78

60T - 280T

17 - MAINTENANCE

Figure 17-15 - Multi-line wiring diagram part 2 - continued from the previous page

COSMOGAS

Page 79

COSMOGAS

17 - MAINTENANCE

Figure 17-16 - Multi-line wiring diagram part 1 - continues on the following page

60T - 280T

17.17 - 100T, 115T, 140T, 180T 210T and

280T models multi-line wiring diagram

Page 80

60T - 280T

17 - MAINTENANCE

Continues

Figure 17-16 - Multi-line wiring diagram part 2 - continues on the following page

COSMOGAS

Page 81

60T - 280T

COSMOGAS

17 - MAINTENANCE

Figure 17-16 - Multi-line wiring diagram part 3 - continued from the previous page

Page 82

60T - 280T

COSMOGAS

17 - MAINTENANCE

Figures 17-15 and 17-16 wiring diagram key

6 - Water outlet safety thermostat 7 - Water outlet temperature sensor 9 - Flue exhaust temperature probe 10 - Flue exhaust temperature safety fuse 11 - Command and control board Fuse - F1 5x20 3A 13 - Ignition electrodes 14 - Spark generator 15 - Water inlet temperature sensor 16 - PWM modulating fan

17. Flapper valve 19 - Water pressure measuring device 20 - Gas valve 22 - Detection electrode 28 - Flue exhaust differential pressure switch 29 - Condensate level sensor 32 - Main ON/OFF switch 34 - Display 35 - 885 IF board (on request)

Fuse - F1 5x20 3A

47 - Water ow rate sensor

48 - Motorised two-way valve (on request) 51 - Connection diagrams

Fuse - F1 5x20 10A Fuse - F2 5x20 10A Fuse - F3 5x20 3A Fuse - F4 5x20 3A Fuse - F6 5x20 3A

RGPR - Heating circuit pump relay RGPS - Domestic hot water circuit pump relay RPP1 - Burner 1 (MASTER) main circuit pump relay RPP2 - Burner 2 main circuit pump relay RPP3 - Burner 3 main circuit pump relay RPP4 - Burner 4 main circuit pump relay

Page 83

60T - 280T

COSMOGAS

TECHNICAL FEATURES MYDENS UM 60T 70T 100T

Destination country UK; IE UK; IE UK; IE

Type (Flue exhaust/air intake type) B23; C43 ; C53 ; C63; C83

Category II2H3P II2H3P II2H3P

CE-type Certicate (PIN) 0476CR1272 0476CR1272 0476CR1272

Range Rated Certicate APPROVED APPROVED APPROVED

Maximum heating input heat “Q” kW 57,8 69,9 99,0

Minimum heating input heat kW 12,0 14,7 12,0

Maximum output heat (80/60) “P” kW 55,8 67,9 95,6

Efciency at 100% load (80/60) % 97 97 97

Minimum output heat (80/60) kW 11,5 14,1 11,5

Efciency at minimum output heat (80/60) % 96 96 96

Maximum output heat (50/30) kW 61,2 74,0 104,7

Efciency at maximum output heat (50/30) % 106 106 106

Minimum output heat (50/30) kW 12,8 15,6 12,8

Efciency at minimum output heat (50/30) % 107 106 107

Efciency at 30% load (80/60) % 106 106 106

Chimney loss burner on (80/60) % 1 1 1

Chimney loss burner on at minimum output heat % 0,5 0,5 0,5

Chimney loss burner off % 0,1 0,1 0,1

Casing loss burner on % 0,1 0,1 0,1

Casing loss burner off % 0,05 0,05 0,05

Loss at no load % 0,05 0,05 0,05

Gas ow rate

G20 m

/h 6,11 7,40 10,47

G25 m3/h 7,11 8,61 12,17

G30 kg/h 4,55 5,52 7,80

G31 kg/h 4,49 5,43 7,68

Gas supply pressure

G20 mbar 20 20 20

G25 mbar 25 25 25

G30 mbar 30 30 30

G31 mbar 37 37 37

Gas supply minimum pressure

G20 mbar 10 10 10

G25 mbar 10 10 10

G30 mbar 10 10 10

G31 mbar 10 10 10

Gas supply maximum pressure

G20 mbar 45 45 45

G25 mbar 45 45 45

G30 mbar 45 45 45

G31 mbar 45 45 45

Main exchanger water content It 6,34 7,57 12,68

Minimum operating water ow rate with motorised valve l/h 1620 1620 1620

Minimum operating water ow rate without motorised valve l/h 1620 1620 3240

D.H.W with storage tank adjustment range °C 40 - 60 40 - 60 40 - 60

Maximum temperature for safety intervention °C 95 95 95

Heating maximum temperature °C 80 80 80

Heating minimum temperature °C 20 20 20

“PMS” heating maximum pressure bar 11 11 11

Heating minimum pressure bar 1 1 1

Rated power supply voltage V 230 230 230

Rated power supply frequency Hz 50 50 50

Absorbed electrical power W 110 150 220

Degree of electrical protection IP20 IP20 IP20

18 - TECHNICAL FEATURES

18.1 - TECHNICAL FEATURES MYDENS

Page 84

60T - 280T

COSMOGAS

115T 140T 180T 210T 280T

UK; IE UK; IE UK; IE UK; IE UK; IE

B23; C43 ; C53 ; C63; C83

II2H3P II2H3P II2H3P II2H3P II2H3P

0476CR1272 0476CR1272 0476CR1272 0476CR1272 0476CR1272

APPROVED APPROVED APPROVED APPROVED APPROVED

115,6 140,0 173,4 210,0 280,0

12,0 14,7 14,7 14,7 14,7

111,7 135,8 168,2 203,7 271,6

97 97 97 97 97

11,5 14,1 14,1 14,1 14,1

96 96 96 96 96

122,3 148,0 183,3 222,0 296,0

106 106 106 106 106

12,8 15,6 15,6 15,6 15,6

106 106 106 106 106

1 1 1 1 1

0,5 0,5 0,5 0,5 0,5

0,1 0,1 0,1 0,1 0,1

0,05 0,05 0,05 0,05 0,05

12,22 14,80 18,30 22,20 29,61

14,22 17,22 21,32 25,83 34,43

9,11 11,03 13,66 16,55 22,06

8,97 10,87 13,50 16,30 21,73

20 20 20 20 20

25 25 25 25 25

30 30 30 30 30

37 37 37 37 37

10 10 10 10 10

45 45 45 45 45

12,68 15,14 22,70 22,71 30,28

1620 1620 1620 1620 1620

3240 3240 4860 4860 6480

40 - 60 40 - 60 40 - 60 40 - 60 40 - 60

95 95 95 95 95

80 80 80 80 80

20 20 20 20 20

11 11 11 11 11

1 1 1 1 1

230 230 230 230 230

50 50 50 50 50

220 300 430 430 590

IP20 IP20 IP20 IP20 IP20

18 - TECHNICAL FEATURES

18.1 - TECHNICAL FEATURES MYDENS

Page 85

60T - 280T

COSMOGAS

18 - TECHNICAL FEATURES

TECHNICAL FEATURES MYDENS UM 60T 70T 100T

Burner electrical power W 110 150 220

Electrical power absorbed by the pump W N.A. N.A. N.A.

Air intake and ue exhaust duct diameter (split) mm 80 80 110

Max. ue exhaust duct length (split) m 10 10 10

Max. air intake duct length (split) m 10 10 10

Equivalent length of one curve m 4 4 4

Weighted CO (0% O2) G20 ppm 15 15 15

Weighted NOx (0% O2) (EN 483 class 5) G20 ppm 15 15 15

CO2 (%) at minimum / maximum output heat

G20 % 8,5 / 8,7 8,5 / 8,7 8,5 / 8,7

G25 % 8,3 / 8,8 8,3 / 8,8 8,3 / 8,8

G30 % 10,1 / 10,6 10,1 / 10,6 10,1 / 10,6

G31 % 9,8 / 10,2 9,8 / 10,2 9,8 / 10,2

O2 (%) at minimum / maximum output heat

G20 % 5,8 / 4,9 5,8 / 4,9 5,8 / 4,9

G25 % 5,8 / 4,9 5,8 / 4,9 5,8 / 4,9

G30 % 5,9 / 5,1 5,9 / 5,1 5,9 / 5,1

G31 % 6,0 / 5,4 6,0 / 5,4 6,0 / 5,4

Maximum ue gas recirculation in case of wind % 10 10 10

Maximum ue gas temperature at boiler outlet °C 90 90 90

Minimum ue gas temperature at boiler outlet °C 30 30 30

Δt temperature fumes/Return (at 100% of the load) (80/60) °C 16 17 16

Δt temperature fumes/Return (at 30% of the load) (37/30) °C 1 1 1

Flue gas mass ow rate kg/h 95 115 163

Flue gas mass ow rate at minimum output heat kg/h 20,7 25,4 20,7

Head available at exhaust Pa 110 110 110

Maximum combustion air temperature °C 40 40 40

Maximum CO2 content in combustion air % 0,9 0,9 0,9

Maximum over-heating ue gas temperature °C 92 92 92

Max. admissible vacuum in the ue exhaust/intake system Pa 50 50 50

Maximum condensate ow rate l/h 7,2 8,7 12,0

Condensate average degree of acidity PH 4 4 4

Operating ambient temperature °C 0 ; + 50 0 ; + 50 0 ; + 50

Boiler weight (empty) kg 96 98 142

18.1 - TECHNICAL FEATURES MYDENS

Page 86

60T - 280T

COSMOGAS

115T 140T 180T 210T 280T

220 300 430 430 591

N.A. N.A. N.A. N.A. N.A.

110 110 160 160 160

10 10 10 10 10

4 4 4 4 4

15 15 15 15 15

8,5 / 8,7 8,5 / 8,7 8,5 / 8,7 8,5 / 8,7 8,5 / 8,7

8,3 / 8,8 8,3 / 8,8 8,3 / 8,8 8,3 / 8,8 8,3 / 8,8

10,1 / 10,6 10,1 / 10,6 10,1 / 10,6 10,1 / 10,6 10,1 / 10,6

9,8 / 10,2 9,8 / 10,2 9,8 / 10,2 9,8 / 10,2 9,8 / 10,2

5,8 / 4,9 5,8 / 4,9 5,8 / 4,9 5,8 / 4,9 5,8 / 4,9

5,9 / 5,1 5,9 / 5,1 5,9 / 5,1 5,9 / 5,1 5,9 / 5,1

6,0 / 5,4 6,0 / 5,4 6,0 / 5,4 6,0 / 5,4 6,0 / 5,4

10 10 10 10 10

90 90 90 90 90

30 30 30 30 30

16 17 17 17 17

1 1 1 1 1

190 230 284 345 460

20,7 25,4 25,4 25,4 25,4

110 110 110 110 110

40 40 40 40 40

0,9 0,9 0,9 0,9 0,9

92 92 92 92 92

50 50 50 50 50

14,4 17,4 21,5 26,1 34,8

4 4 4 4 4

0 ; + 50 0 ; + 50 0 ; + 50 0 ; + 50 0 ; + 50

142 147 211 211 249

18 - TECHNICAL FEATURES

18.1 - TECHNICAL FEATURES MYDENS

Page 87

60T - 280T

COSMOGAS

19 - FORCED MENU

Boiler parameters

Ref. Parameter description Adjustment range Default

value

Individual burner

(mod. 60T and

70T)

Burner 1 (Master)

(mod. 100T,

115T, 140T, 180T,

210T and 280T)

Burners from

2 to 4

(mod. 100T,

115T, 140T, 180T,

210T and 280T)

Individual burner

(mod. 60T and

3001 Burner operation address 0 = Not in cascade

1 = Burner 1 (Master), 2 to 4 = Burner from 2 to 4 (slave burners)

2 0 1 from 2 to 4

3002 Fan adjustment range from 0 to 4

60 = 0 70 = 2

100 and 115 = 0 140, 180, 210 and 280 = 2

3003 Display unit of measurement C = °C and bar;

F = °F and PSI;

C C C C

3004 Water pressure switch 0 = Disabled; 1 = Enabled;

2 = N/A; 3 = N/A

1 1 1 0

3005 Burner apper valve 0 = Disabled; 4 = Enabled;

8 = N/A; 12 = N/A

4 0 4 4

3006 Water ow rate sensor 0 = Disabled; 16 = N/A;

32 = N/A; 48 = Enabled

48 48 48 48

3007 Condensate level sensor EnAb = Enabled;

dISA = Disabled

Enab Enab Enab dISA

3008 Combustion gas sensor type SEnS = Sensor; StCH = Switch

SEnS SEnS SEnS SEnS

3009 External sensor type 10 = 10kohms; 12 = 12kohms;

10 10 10 10

3010 Other sensor type 10 = 10kohms; 12 = 12kohms;

10 10 10 10

3011 pump mode 0 = main c pump; 1 = N/A;

2 = N/A; 3 = N/A;

0 0 0 0

3012 domestic hot water operating mode 0 = only heating;

1= hot water storage tank; 2 = storage tank with thermostat; 3 = N/A; 4 = N/A; 5 = N/A

0 = only heating; 1= hot water storage tank;

3013 Reset Err 115 EnAb = Enabled;

dISA = Disabled

Enab Enab Enab Enab

3015 Climatic adjustment: heating supply

maximum temperature (this parameter is overwritten by parameter 3017)

from 20°C to 90°C

82°C 82°C 82°C 82°C

3016 Climatic adjustment: heating supply

minimum temperature

from 20°C to 90°C

20°C 20°C 20°C 20°C

3017 Supply maximum temperature (this

parameter takes priority with respect to parameter 3015)

from 20°C to 90°C

82°C 82°C 82°C 82°C

3018 Minimum supply temperature from 20°C to 90°C

32°C 32°C 32°C 32°C

3020 Water ow rate sensor type 0 = N/A; 1 = DN8;

2 = DN 10; 3 = DN 15; 4 = DN 20; 5 = DN 25

3 4 4 4

3022 Water minimum pressure from 0 to 5 bar

1 1 1 1

3035 Minimum water ow rate from 0 to 100 l/min

27 27 27 27

3050 Slave burner number from 0 to 3

3 3

100, 115 and

140 = 1 210 = 2 280 = 3

3085 Modbus address 0 to 126

1 1 1 1

3086 Number of Stopbits 1 or 2

1 1 1 1

3100 Material selection ABS; CPVC; PVC; SST; PP.

PVC PVC PVC PVC

3101 Nation Selection US, CA

US US US US

Switch “S4”

Switch “S4” position (see g 17-11 and

17-12)

On or Off

On On On Off

N/A = Not Applicable

Page 88

60T - 280T

COSMOGAS

Water heater parameters

Individual burner

(mod. 60T and

70T)

Burner 1 (Master) (mod. 100T, 115T,

140T, 180T, 210T

and 280T)

Burners from

2 to 4

(mod. 100T, 115T,

140T, 180T, 210T

and 280T)

Customised

values

0 1 from 2 to 4

60 = 0 70 = 2

100 and 115 = 0 140, 180, 210 and 280 = 2

C C C

1 1 0

0 4 4

48 48 48

Enab Enab dISA

SEnS SEnS SEnS

10 10 10

0 0 0

0 = only heating; 1= hot water storage tank;

0 for instantaneous domestic hot water; 1 per hot water storage tank.

Enab Enab Enab

N/A N/A N/A

82°C 82°C 82°C

32°C 32°C 32°C

4 4 4

1 1 1

27 27 27

100, 115 and

140 = 1 210 = 2 280 = 3

1 1 1

PVC PVC PVC

US US US

On On Off

ATTENTION!!! Editing these parameters

could cause the appliance and, therefore, the system to malfunction. For this reason, only professionally qualied technicians with in-depth knowledge and

awareness can edit them.

ATTENTION!!! When accessing the forced

menu, it is possible for the appliance to start up; ignoring this could cause damage to persons, animals

or objects.

ATTENTION!!! In the event of the multi-burner

appliances (100T to 280T models), the display is always connected to burner 1 (MASTER). To set the parameters in the other burners, the display must be connected to

them as described in section 17.8

The forced menu allows the appliance to be set based on the system to serve. Setting occurs by adjusting the available parameters (shown in the table). To access the forced menu, proceed as follows:

1.- Power off the appliance by turning the main switch to the OFF position;

2.- Holding down the RESET and

keys at the same

time, turn the main switch to the ON position;

3.- Wait for the word “INIT” or the 3000 parameters to appear on the display.

4.- Using the

and keys, scroll through the

list of 3000 parameters;

5.- Navigate the menu using the

and

keys. Once you have selected the parameter, press

the RESET key to make it editable via the

and

keys;

6.- Press the RESET key to save the changes;

7.- Wait 10 seconds;

8.- Power off the appliance;

9.- Repower the appliance to exit the forced menu and go back to its normal operation.

19 - FORCED MENU

Page 89

60T - 280T

COSMOGAS

20 - CONTROL MENU DIAGRAM

Symbol Description

Press and release the RESET key

Hold down the reset key for 2 seconds

Hold down the reset key for 5 seconds

Hold down at the same time for a time in seconds,

indicated by the number, the RESET and keys

Press and release the key

Parameters displayable under normal operating conditions (see section 16.16)

User menu parameters (see section 16.14)

Installer menu parameters (see section 16.15)

User menu access (see section 16.14)

Installer menu access (see section 16.15)

Go back to normal operation

Figure 20-1 - Command menu diagram

Page 90

60T - 280T

COSMOGAS

21 - BOILER OPERATION SEQUENCE

OPEN

CLOSED

operation sequence

power the appli-

ance

is the electrical

frequency 60Hz?

was the neutral

phase polarity

followed?

external safety

device (contacts 103

and 104)

Heating demand (present/absent)

contacts 12

and 13

Motorised valve (if

any) open and main

circuit pump on

Err 64

Err 66

Err 65

Loc 02

Err 59

Stand by

Is the supply temperature

rising?

Is the supply temperature

near the demand

temperature?

Every burner re-

duces output heat

The burner output

heat is less than

10%

After 3 minutes, the

corresponding motorised

valve (if any) is closed

Is the supply temperature decreasing?

The appliance output

heat is equal to the load

demanded

The heating demand is disa-

bled: TA opens or the external

probe is met

Is the water ow

rate greater than

15 l/min?

After 3 minutes

Err 114

The burners will

be switched off

Are all the burners

operating?

Ignition attempt

(50% of the output

heat)

Are pressure and

gas ow rate

adequate?

Burner in opera-

tion

Appliance with

only one burner?

3 minute delay

The burner output

heat

is >70%

Request for other burners

to intervene

Check fan speed

After 5 ignition at-

tempts Lock 01

No demand or other burners

After 1 minute

Lock 12

The pumps and motorised valves (if any) will be switched off after a

post-circulation time

Stand by

The burners keep

working

The burners keep

working

The burners keep

working

YES

Is the water pressure greater than

1 bar?

OPEN

CLOSED

Is the heating tem-

perature

higher than the

manifold temperature?

Burner off

YES

Page 91

60T - 280T

COSMOGAS

The undersigned company, CSOSMOGAS S.r.L., with registered ofce in via L. Da Vinci no. 16 - 47014 Meldola (FC) ITALY,

DECLARES

under its own responsibility that the product:

subject of this declaration, is compliant with the model described in the

type Test Certicate, issued by the notied body Kiwa Cermet Italia S.p.A.,

whose references are shown in the table in the TECHNICAL FEATURES

section under “CE-type certicate (PIN)” and fulls the requirements of

the following Directives: Gas Appliances, (2009/142/EC), Performance,

(92/42/EEC modied by EU Reg. 813/2013), Low Voltage, (2014/35/EU),

Electromagnetic Compatibility,

(2014/30/EU).

Product surveillance is done by the notied body according to form “C”.

(The warranty number is the same as the serial number)

This declaration is issued as established by the aforementioned Directives.

Meldola (CFC) ITALY, (Date of manufacture).

MANUFACTURE

SERIAL NO.

MODEL

22 - CE DECLARATION OF CONFORMITY

________________________

Arturo Alessandrini

Sole Project Manager

Page 92

60T - 280T

COSMOGAS

23 - ErP PRODUCT FICHE MYDENS

The name or brand of the supplier COSMOGAS

Reference of the model given by the supplier

MYDENS

60T 70T

Condensing boiler YES YES

Low temperature boiler NO NO

B1 Boiler type NO NO

Cogeneration space heater NO NO

Combination heater NO NO

Equipped with supplementary heater NO NO

Energy efciency class A A

Item Symbol Unit

Rated heat output Pn kW 56 68

Seasonal space heating energy efciency ηs % 91 91

Useful heat output at rated heat output and high-temperature regime (*) P4 kW 55,8 67,9

Useful efciency at rated heat output and high-temperature regime (*) η4 % 87,3 87,3

Useful heat output at 30 % of rated heat output and low-temperature regime (**)

P1 kW 16,7 20,4

Useful efciency at 30 % of rated heat output and low-temperature

regime (**)

η1 % 95,8 95,8

Auxiliary electricity consumption

At full load elmax kW 0,14 0,14

At part load elmin kW 0,06 0,06

In standby mode Psb kW 0,005 0,005

Other items

Standby heat loss Pstby kW 0,1 0,1

Ignition burner power consumption Pign kW 0 0

Annual energy consumption QHE GJ 104 130

Sound power level, indoors LWA dB 70 70

Emissions of nitrogen oxides NOx mg/kWh 20 20

For combination heaters

Declared load prole N/A N/A

Water heating energy efciency ηwh % N/A N/A

Daily electricity consumption Qelec kWh N/A N/A

Annual electricity consumption AEC kWh N/A N/A

Daily fuel consumption Qfuel kWh N/A N/A

Annual fuel consumption AFC GJ N/A N/A

According commission delegated regulation (EU) No 811/2013 and No 813/2013. N/A = Not applicable. (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

Page 93

60T - 280T

COSMOGAS

24 - ErP PRODUCT FICHE MYDENS

COSMOGAS

MYDENS

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

YES YES YES YES YES YES

NO NO NO NO NO NO

- - - - - -

96 112 136 168 204 272

91 91 91 91 91 91

95,6 111,7 135,8 168,2 203,7 271,6

87,3 87,3 87,3 87,3 87,3 87,3

28,7 33,5 40,7 50,5 61,1 81,5

95,8 95,8 95,8 95,8 95,8 95,8

0,28 0,28 0,28 0,42 0,42 0,56

0,06 0,06 0,06 0,06 0,06 0,06

0,01 0,01 0,01 0,015 0,015 0,02

0,2 0,2 0,2 0,3 0,3 0,4

0 0 0 0 0 0

169 195 237 288 345 452

70 70 70 70 70 70

20 20 20 20 20 20

N/A N/A N/A N/A N/A N/A

Page 94

COSMOGAS s.r.l.

Via L. da Vinci 16 - 47014

MELDOLA (FC) ITALY

info@cosmogas.com

www.cosmogas.com

HEATING SOLUTIONS LTD

01256 587 800

info@gemtex.co.uk

www.gemtex.co.uk

65 Basepoint Business Centre Aviation

Business Park

Enterprise Close

Christchurch

BH23 6NX

For the UK contact:

Cosmogas MYDENS 60T/70T/100T/115T/140T/180T/210T/280T INSTALLATION, USE AND MAINTENANCE MANUAL (62403578 - R01 09-12-2016_UK)

Specifications and Main Features

Frequently Asked Questions

User Manual