COSMOGAS NOVADENS 24, NOVADENS 24B, NOVADENS 24C, NOVADENS 24P, NOVADENS 34 Instruction Manual
...
INSTRUCTION MANUAL FOR INSTALLATION
AND MAINTENANCE OF GAS BOILERS
PLEASE READ THE MANUAL CAREFULLY: IT CONTAINS IMPORTANT INFORMATION
REGARDING SAFETY, INSTALLATION, USE AND MAINTENANCE OF THE APPLIANCE
62403425 - R00 07-12-2007_GB-IE
MODELES:
NOVADENS 24 - 24B
NOVADENS 24C - 24P
NOVADENS 34 - 34B
NOVADENS 34C - 34P
2
Table of contents
1 - General safety warnings............................................................................................4
1.1 - National installation legislation ..................................................................................................4
2 - GENERAL INFORMATION .......................................................................................5
2.1 - Introduction ............................................................................................................................... 5
2.2 - Description of models ............................................................................................................... 5
2.3 - Manufacturer ............................................................................................................................5
2.4 - Key to symbols used .................................................................................................................5
3 - MAIN COMPONENTS ...............................................................................................6
4 - Functions of the appliance ........................................................................................ 8
4.1 - Intended use and functions of the appliance .........................................................................10
4.2 - Characteristic curves of heating system’s residual head ........................................................ 11
4.3 - Characteristic curve of the domestic side ............................................................................... 11
5 - INSTALLATION ....................................................................................................... 12
5.1 - Opening the packaging ........................................................................................................... 12
5.2 - Dimensions and clearances for installation ............................................................................. 12
5.3 - Choosing the point of installation ............................................................................................ 12
5.4 - Supply and return .................................................................................................................... 13
5.5 - Radiant panel systems (or low temperature systems) ............................................................ 13
5.6 - Domestic hot and cold water ................................................................................................... 13
5.7 - Gas supply .............................................................................................................................. 13
5.8 - Assembling the appliance ....................................................................................................... 14
5.9 - Gas and water connections .................................................................................................... 14
5.10 - Condensation discharge ....................................................................................................... 15
5.11 - Safety relief valve .................................................................................................................. 15
5.12 - Hydraulic connections for boiler with BWR storage tank ...................................................... 16
5.13 - Softener (on request) ............................................................................................................ 16
5.14 - Electrical connections: overview ........................................................................................... 17
5.14.1 - Connecting the power supply cable ........................................................................................17
5.14.2 - Choosing the room thermostat/time-programmable thermostat ..............................................18
5.14.3 - Connecting the room thermostat/time-programmable thermostat ...........................................18
5.14.4 - Installing the outside temperature sensor (on request) ...........................................................18
5.14.5 - CR04 remote time control (optional) .......................................................................................19
5.14.6 - Installation of the CR04 remote time control on the boiler ......................................................19
5.15 - Connecting the boiler to the B70C type water heater (optional) ........................................... 20
5.15.1 - Prevention against Legionnaires disease ...............................................................................20
5.16 - Connecting the boiler to the BWR C type storage tank ....................................................... 21
5.16.1 - Prevention against Legionnaires disease ...............................................................................21
5.17 - Venting systems .................................................................................................................... 22
5.17.1 - “Split 80/80PP” system (polypropylene) ..................................................................................23
5.17.2 - “Split 80/80PP” system: available accessories ......................................................................24
5.17.3 - “Split 80/80PP” system: installation examples ........................................................................25
5.17.4 - “Coaxial 60/100PP” system (polypropylene) ..........................................................................26
5.17.5 - “Coaxial 60/100 PP” system: available accessories ................................................................27
5.17.6 - “Coaxial 60/100PP” system: installation examples ..............................................................28
6 - OPERATING ...........................................................................................................29
6.1 - Operating ................................................................................................................................ 29
6.1.1 - User instructions ........................................................................................................................29
6.1.2 - Filling of the condensation discharge trap .................................................................................29
6.1.3 - Filling the heating system ..........................................................................................................29
6.1.4 - Filling of the secondary heat exchanger of the domestic hot water ..........................................29
6.2 - General warnings concerning gas supply ............................................................................... 29
6.3 - Gas type indicated for the boiler ............................................................................................. 30
6.4 - Converting the boiler from one gas type to another ................................................................ 30
3
Table of contents
6.5 - Start-up ................................................................................................................................... 30
6.5.1 - Auto-purging ..............................................................................................................................30
6.6 - Checking and adjusting the gas supply pressure ................................................................... 30
6.7 - Checking the comburant air pressure ..................................................................................... 31
6.8 - Checking and adjusting CO2 levels ........................................................................................ 32
6.9 - Adjusting the heating capacity ................................................................................................ 33
6.10 - Domestic hot water ow rate adjustment .............................................................................. 33
7 - USE ......................................................................................................................... 34
7.1 - Adjusting the domestic hot water ........................................................................................... 34
7.2 - Adjusting the heating system .................................................................................................. 34
7.3 - Thermostatic adjustment ......................................................................................................... 34
7.4 - Climatic adjustment ................................................................................................................. 34
7.4.1 - Climatic adjustment: on which systems? ...................................................................................34
7.4.2 - Climatic adjustment: precautions when making adjustments ....................................................35
7.4.3 - Climatic adjustment: setting of the parameters .........................................................................35
7.4.4 - Climatic adjustment: adjustments of the various climatic zones ...............................................35
7.4.5 - Climatic adjustment: switching on and off the heating service ..................................................35
7.4.6 - Climatic adjustment with room compensation ...........................................................................35
7.5 - Boiler settings (SWITCHES) ................................................................................................... 37
7.6 - Timings of the various functions .............................................................................................. 37
7.7 - Pumps and switch valve blockage protection ......................................................................... 37
7.8 - Anti-freeze protection .............................................................................................................. 37
7.9 - (Empty) ...................................................................................................................................37
7.10 - Energy Saving ....................................................................................................................... 37
7.11 - “Users’ menu” ........................................................................................................................ 38
7.12 - “Installers’ menu” ................................................................................................................... 39
7.13 - Diagnostics ...........................................................................................................................41
7.13.1 - Diagnostics: “L” lock-outs ........................................................................................................42
8 - MAINTENANCE ...................................................................................................... 45
8.1 - General warnings .................................................................................................................... 45
8.2 - Disassembling the casing and accessing internal components .............................................. 45
8.3 - Cleaning of the condensation collecting trap .......................................................................... 46
8.4 - Cleaning the burner and primary heat exchanger (ue gas side) .......................................... 47
8.5 - Correct positioning of the ignition and ionization electrodes .................................................. 47
8.6 - Secondary heat exchanger for the production of d.h.w. .......................................................... 47
8.7 - Replacement of the pump motor ............................................................................................. 48
8.8 - Checking the expansion tank .................................................................................................. 48
8.9 - Dismantling the 3-way valve ................................................................................................... 49
8.10 - Draining the heating side of the appliance ............................................................................ 50
8.11 - Draining the domestic side of the appliance ......................................................................... 50
8.12 - Forcing .................................................................................................................................. 50
8.13 - Auto-purging .......................................................................................................................... 50
8.14 - Fan ........................................................................................................................................ 50
8.15 - Minimum and maximum output ............................................................................................ 50
8.16 - Checking the ionization current ............................................................................................. 50
8.17 - Water temperature gauging sensor ....................................................................................... 51
8.18 - Outside temperature sensor ................................................................................................. 51
8.19 - Functional wiring diagram ..................................................................................................... 52
8.20 - Multiwire wiring diagram ....................................................................................................... 53
9 - TECHNICAL FEATURES ........................................................................................54
10 - EC COMPLIANCE DECLARATION ......................................................................55
4
If you smell gas
Close the gas cock.
Ventilate the room.
Do not use any electrical appliances, telephone
included.
Immediately call a qualied technician or the gas board
from another room or building. If you cannot contact
them, call the Fire Brigade.
If you smell pruducts of the combustion
Switch off the appliance.
Ventilate the room.
Call a qualied technician.
Installation, modications
The installation, setting and modication of the gas
appliance must be carried out by qualied technicians,
in compliance with local and national norms and these
instructions.
Never leave any packaging or replaced parts within
the reach of children.
Seal the setting devices after each setting.
It is compulsory to connect the appliance’s discharge
pipe to a chimeney. Failure to observe this rule may
seriously risk the safety of individuals and animals.
Flue pipes must not be modied in any way.
The user, in accordance with these instructions, must
keep the appliance in satisfactory running order and
ensure reliable, safe operating.
The user is responsible for employing a qualified
technician to carry out maintenance work on the
appliance in compliance with local and national norms
and the matters stated in this manual.
We highly recommend arranging a regular maintenance
contract with a qualied technician
The manufacturer cannot be held responsible for any
damage to people, animals or property caused by
incorrect installation or inadequate maintenance.
Use the switches to disconnect the appliance from the
mains before carrying out any cleaning or maintenance
operations.
Do not obstruct the intake/discharge pipe ends.
Explosive or easily inammable products
Do not store or use explosive or easily inflammable
materials such as paper, solvents, paints, etc..., in the
same room as the boiler.
In the event of a breakdown
In the event of breakdown and/or malfunctioning of the
appliance, disconnect it, do not attempt to repair it or
intervene in any way whatsoever. Contact a qualied
technician. If repairs require parts to be replaced, only
original spares must be used. Failure to observe the above
may compromise the appliance’s safety.
Qualied technicians
Qualied technicians are personnel with specic, technical
1 - GENERAL SAFETY WARNINGS
training in the heating system component sector and with
regards to domestic hot water production for public use,
fuel gas systems and electrical systems. These individuals
must have the legally required qualications.
This booklet forms an integral and essential part of
the product and must be carefully kept by the user,
for any future consultation. Ensure that this booklet is
handed over to the new owners and/or installer if the
appliance should change hands or be moved for any
reason whatsoever.
Any optional extras or kit tted subsequently must be
original Cosmogas spares.
This appliance must only be used for the purpose it has
been expressly designed for: heating water for closed
circuit systems for centrally heating public and private
buildings, producing sanitary and domestic hot water
for civil use.
The man ufacture r cannot be held responsible,
contractually or otherwise, for any damage caused by
incorrect installation or use and for failure to comply
with the manufacturer’s instructions or applicable local
and national legislation.
For safety reasons and to safeguard the environment,
all packaging must be disposed of in special sorted
refuge collection centres.
1.1 - National installation
legislation
The installation must be carried out by a registered
compete nt person and be in accordanc e with the
relevant requirements of the current GAS SAFETY
(Installation and Use) REGULATIONS, the BUILDING
REGULATIONS (Scotland)(Consolidation), the LOCAL
BUILDING REGULATIONS, the current I.E.E. WIRING
REGULATIONS and the bye laws of the LOCAL WATER
UNDERTAKING. Where no specic instruction is given
reference should be made to the relevant BRITISH
STANDARD CODES OF PRACTICE. For Ireland install
in accordance with IS 813 “INSTALLATION OF GAS
APPLIANCES”.
B.S. Codes of Practice
BS 6891 Gas Installation.
BS 5546 Installation of hot water supplies for domestic
purposes.
BS 5449 Part 1 Forced circulation hot water systems.
BS 6798 Installation of gas red hot water boilers.
BS 5440 Part 1 Flues.
BS 5440 Part 2 Ventilation.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water central
heating systems.
5
2 - GENERAL INFORMATION
2.1 - Introduction
Congratulations!
You have effectively purchased
one of the best products on the
market.
Each single part is built, tested
and assembled, with pride, at the
COSMOGAS factories, thereby
guaranteeing optimum quality
control.
Thanks to on-going research
carried out by COSMOGAS, this
product has been conceived and
is considered to be the best in
its class with regards to respect
for the environment, since it falls
within class 5 (less polluting)
envisaged by technical norm EN
297 (and EN 483) and has an
elevated efciency, 4 star as per
EC Directive 92/42/CEE. Great
importance is also given to the
end of the appliance’s useful life.
All its components can easily
be separated into similar and
completely recyclable parts.
2.3 - Manufacturer
COSMOGAS srl
Via L. da Vinci 16
47014 - Meldola (FC) ITALY
Tel. +39 0543 498383
Fax. +39 0543 498393
www.cosmogas.com
info@cosmogas.com
2.4 - Key to symbols
used
CAUTION!!!
Risk of electric shock: failure to observe
th is war ning may co mpro mise the
smooth running of the appliance or cause
serious damage to individuals, animals
or property.
General danger!
Failure to observe this warning may
compromise the smooth running of the
appliance or cause serious damage to
individuals, animals or property.
Operation symbol
Important indication symbol
NOVADENS XXYYYY
“ “ =
Boiler with exchanger sanitary to partial accumulation;
“A” = Boiler for only heating without integrated pump;
“B” = Boiler which can be combined with BWR C series storage tank;
“C” = Boiler for only heating with integrated pump;
“P” = Boiler with exchanger secondary for D.H.W., to plates;
“0834” = Boiler for low temperature central heating systems.
24 = Boiler with maximum input heat of 25 kW
34 = Boiler with maximum input heat of 34.8 kW
Gas-red, condensing, hot water boiler, with sealed combustion chamber
and pre-mix burner, for heating and domestic hot water production.
2.2 - Description of
models
6
3 - MAIN COMPONENTS
Figure 1 - Internal components of boiler
1 - Automatic air vent
2 - Air intake and ue gas
discharge tting (venting system)
3 - NTC7 ue gas sensor
4 - Air drum
5 - Air/gas mixer
6 - Return unit
7 - 3 way valve
8 - NTC2 d.h.w. outlet sensor
9 - 3 way valve shell
10 - Heating pressure switch
11 - Heating circuit discharge
cock
12 - Safety relief valve
13 - Control board
14 - Lower cover
15 - Door to control box
16 - Casing
17 - NTC3 d.c.w. sensor
18 - Primary heat exchanger
19 - Ignition cables
20 - Door of sealed combustion
chamber
7
3 - MAIN COMPONENTS
Figure 1 - Internal components of boiler
21 - Combustion analysis tap
22 - NTC1 boiler temperature
sensor
23 - Burner window
24 - Air/gas manifold
25 - NTC6 high temperature limit
sensor
26 - Flue gas ow back
prevention valve
27 - Fan
28 - Gas valve
29 - Pressure gauge
30 - Domestic hot water control
31 - Heating control
32 - On/off power switch
33 - Cable clamp
34 - Filling cock
35 - By-pass pipe (optional)
36 - Condensation discharge pipe
37 - Secondary heat exchanger for
domestic hot water
38 - Expansion tank connection pipe
39 - Circulator pump
40 - Condensation discharge trap
41 - Expansion tank
42 - Ionization electrode
43 - Burner
44 - Right ignition electrode
45 - Left ignition electrode
46 - Spark generator
47 - Screw cap for unblocking
pump
48 - Display
49 - Electric connections board
50 - Opentherm interface board
(optional)
8
4 - FUNCTIONS OF THE APPLIANCE
Figure 2 - Hydraulic diagram
NOVADENS 24 or 24P
NOVADENS 34 or 34P
Figure 3 - Hydraulic diagram
NOVADENS 24C
NOVADENS 34C
(for settings, see section 5.5)
Figure 5 - Hydraulic diagram
NOVADENS 24 or 24P
NOVADENS 34 or 34P
connected to B70 type storage
tank
(for settings, see section 5.15)
Figure 4 - Hydraulic diagram
NOVADENS 24B
NOVADENS 34B
9
Key to gures 2, 3, 4 and 5:
1 = COSMOGAS boiler NOVADENS model
2 = automatic air vent
3 = air intake
4 = ue discharge
5 = sealed combustion chamber
6 = expansion tank
7 = burner
8 = fan
9 = gas valve
10 = condensation discharge trap
11 = circulator pump
12 = 3-way valve
13 = secondary heat exchanger for d.h.w.
14 = pressure gauge
15 = by-pass valve (optional)
16 = lling cock
17 = safety relief valve
18 = gas cock
19 = cold water inlet cock
20 = safety relief valve discharge (optional)
21 = condensation discharge
22 = heating supply pipe
23 = domestic hot water outlet
24 = gas inlet
25 = cold water inlet
26 = heating return pipe
27 = trap funnel (optional)
28 = heating system for radiators or radiant panel-type heating system (to be tted by installer)
29 = domestic hot water system (to be tted by installer)
30 = ------------------
31 = re-circulation supply pipe for water heater loading (to be tted by installer)
32 = B70 type storage tank (optional)
33 = expansion tank
34 = circulator pump
35 = safety rilief valve
36 = re-circulation return pipe for water heater loading (to be tted by installer)
37 = check valve (to be tted by installer)
38 = hydraulic safety unit complying with EN 1487 (to be tted by installer)
39 = water heater lling supply pipe (to be tted by installer)
40 = water heater lling return pipe (to be tted by installer)
41 = BWR type storage tank (optional)
42 = expansion tank
43 = safety relief valve
44 = heating system discharge cock
45 = NTC7 = ue gas sensor
46 = NTC1 = boiler temperature sensor
47 = NTC6 = high temperature limit sensor
48 = NTC3 = domestic cold water sensor/storage tank sensor
49 = NTC2 = domestic hot water outlet sensor
4 - FUNCTIONS OF THE APPLIANCE
10
4.1 - Intended use
and functions of the
appliance
This condensation-type gas appliance,
is designed to be used for central
heating and producing domestic hot
water for civil use.
Fit the boiler to the system according
to the most suitable residual curve
head (see gures 6 and 7).
The maximum output heat is always
guaranteed for the production of
domestic hot water since, on each
request, the heating service switches
off.
Follow the specic procedure in
section 9.13 for the adjustment of the
domestic hot water temperature.
Depending on the model chosen, the
following system types can be created:
A- NOVADENS -- ” “. By means of
this boiler, a system can be created
for the production of instant domestic
hot water and a heating system
with heating elements functioning at
temperatures ranging between 30°C
and 80°C. An example of this type of
system is shown in gure 2.
B- NOVADENS -- “B”. By means of
this boiler, a system can be created
for the production of domestic hot
water using a storage tank, BWR or
equivalent model and a heating system
with heating elements functioning at
temperatures ranging between 30°C
and 80°C. An example of this type of
system is shown in gure 4.
C- NOVADENS -- “C”. By means of
this boiler, a system can be created for
the only heating with heating elements
functioning at temperatures ranging
between 30°C and 80°C. An example
of this type of system is shown in gure
3.
In this model is moreover possible to
connect, also after the installation,
en storage tank model BWR lled
up through one external valve to the
boiler.
D- NOVADENS -- “P”. By means of
this boiler, a system can be created
for the production of instant domestic
hot water and a heating system
with heating elements functioning at
temperatures ranging between 30°C
and 80°C. An example of this type of
system is shown in gure 2.
All the boiler versions described
previously can be connected to a
room thermostat for the setting of
the heating. Or, so as to improve
the quality of the heating service,
it is possible to connect an external
temperature sensor (Climatic heat
adjustment) so as to automatically
set the supply temperature in relation
to the external temperature; the
room thermostat, in this case, can
make a compensation of the room
temperature. The room compensation
can be of an ON /OFF type or twostage.
For further information on the Climatic
heat adjustment, refer to section 7.4.
For take advantage of the rendering
characteristics of boiler, it is
advised to connect it to the CR04
cronothermostat, (see chapter
5.14.5), what it will regulate the
temperature of supply to the
radiators in continuous and linear
way, to maintain the temperature
environment planned.
The boiler must be connected to
a heating system and a domestic
hot water supply, with compatible
specications, performance and
power rating.
Before installation, thoroughly ush
the heating and plumbing systems
of any residue or impurities which
might compromise the smooth
running of the boiler.
This boiler is not designed for
outside installation.
Choose a sheltered place where
it is protected from atmospheric
elements including frost.
Refer to gure 9 for minimum
clearance distances for installation
and future maintenance.
4 - FUNCTIONS OF THE APPLIANCE
E- NOVADENS -- “0834”. By means
of this boiler, a system can be created
for the production of instant domestic
hot water and a heating system
with heating elements functioning at
temperatures ranging between 20°C
and 45°C. An example of this type of
system is shown in gure 2.
F- NOVADENS -- “B0834”. By means
of this boiler, a system can be created
for the production of domestic hot
water using a storage tank, BWR or
equivalent model and a heating system
with heating elements functioning at
temperatures ranging between 20°C
and 30°C. An example of this type of
system is shown in gure 4.
G- NOVADENS -- “C0834”. By means
of this boiler, a system can be created
for the only heating with heating
elements functioning at temperatures
ranging between 20°C and 45°C.
An example of this type of system is
shown in gure 3.
In this model is moreover possible to
connect, also after the installation,
en storage tank model BWR lled
up through one external valve to the
boiler.
H- NOVADENS -- “P0834”. By means
of this boiler, a system can be created
for the production of instant domestic
hot water and a heating system
with heating elements functioning at
temperatures ranging between 20°C
and 45°C. An example of this type of
system is shown in gure 2.
In all the boiler versions described
previously, connection of the domestic
hot water service is not indispensable;
if the boiler is required solely for central
heating purposes, it is sufcient to
connect the cold water pipe so as to ll
the heating system and close the tting
of the d.h.w. outlet.
All the NOVADENS -- or NOVADENS
--0834 model boilers, can also be
connected subsequently for the
installation of a B70 C series storage
tank (see gure 5)
11
4.2 - Characteristic
curves of heating
system’s residual
head
Each standard boiler is tted with its
own specic circulator pump. The
residual head at the boiler connections
is shown in graph form in gures 6.
On demande, we can supply the boiler
with a 7 m head pump (see g.7).
The diagram comprises 4 curves which
can be selected from the control panel,
in the following manner:
press the button for 12
seconds until parameter is
displayed (the display panel will start
to blinking);
continually press and release the
button in order to scroll
through the list of parameters until
the parameter is displayed;
once the parameter has been
identied, it can be changed using
the or key;
choose the desired value of the
pump speed;
Press the button in order to
conrm the modied data and exit
from the menu;
4.3 - Characteristic
curve of the
domestic side
Every boiler offers certain resistance
to the passage of the domestic water
(see graph ow/pressures of gure
8). The installer or the engineer must
take account of this in order to ensure
the correct domestic water ow to the
utilities.
Figure 6 - Curve of the pump with 6 metres head
Figure 7 - Curve of the pump with 7 metres head
Figure 8 - Curve of the of pressure for the domestic side.
4 - FUNCTIONS OF THE APPLIANCE
Pressure (bar)
Flow (l/min)
12
5.1 - Opening the
packaging
The appliance is supplied in a box. Open
it up following the instructions given on
the closing aps.
5.2 - Dimensions
and clearances for
installation
Leave an area free around the boiler for
carrying out installation or maintenance
activities, as shown in gure 9.
5.3 - Choosing the
point of installation
CAUTION!!! The boiler must
be installed exclusively on a solid,
vertical wall able to bear its weight.
The appliance must be installed
indoors, or protected from atmospheric
agents including rain, wind, sun and
especially frost.
When choosing the room and position
for installation, account must be taken
of the following factors:
- the connection of ue gas discharge/
air intake pipes;
- the connection of gas supply pipe;
- the connection to the water mains;
- connection of the system to the
central heating;
- the connection to the domestic hot
water system;
- electrical connections;
- the connection of the discharge for
condensation produced by the boiler;
- electrical connection to the room
thermostat;
- possible connection of the safety
relief valve discharge;
- possible connection of the external
temperature sensor;
Figure 9 - Minimum clearance distances
1 = 3/4” (models 24) and
1” (models 34) heating supply
2 = 1/2” domestic hot water
(absent in NOVADENS B and C models)
3 = 3/4” gas
4 = 1/2” domestic cold water
5 = 3/4” (models 24) and 1” (models 34)
heating return
10 = area for power supply cable
11 = BWR supply pipe
(present only on NOVADENS B models)
12 = BWR return pipe
(present only on NOVADENS B models)
14 = positions available for boiler support
5 - INSTALLATION
Figure 10 - Boiler dimensions and ttings’ distances
13
5.4 - Supply and
return
CAUTION!!! This boiler is
equipped with a safety relief valve
set at 3 bar. Therefore it must not be
installed with a radiator positioned
at a manometric high higher
than 30 m.
CAUTION!!! COSMOGAS
cannot be held responsible for any
damage caused by incorrect use of
additives in the heating system.
CAUTION!!! The system
downstream from the appliance
must be made of materials which
can withstand temperatures up to
97°C. Otherwise (e.g. plastic piping)
the boiler must be tted with a
device to cut out the pump when
it reaches the maximum permitted
temperature.
Thoroughly wash out the system,
before connecting the heating pipes,
to ush out any deposits (hemp,
radiator casting residue, etc.) which
might damage the appliance. Thorough
ushing is also required when
replacing an appliance.
Figure 10 illustrates the position of the
supply and return pipes.
Install a metallic mesh lter on the
return pipe to prevent any residue
from the system returning to the
boiler.
Do not use the appliance for adding
any type of additive to the system.
5.5 - Radiant
panel systems (or
low temperature
systems)
CAUTION!!! When the boiler
is installed in a low temperature
system, it is indispensable to set
the switch 6 in the ON position (see
chapter 7.5).
By means of this setting, the boiler will
set the temperature towards the supply
of a temperature between 20°C and
45°C. No setting operation from the
control panel (even by means of the
climatic setting) will be able to supply
water at a temperature higher than
45°C.
CAUTION!!! If the boiler
is installed in a radiant panel
heating system with plastic
piping, precautions must be taken
against corrosion caused by water
oxygenation: check that the system
has plastic piping with a permeability
to oxygen of no higher than 0.1 g/m3
at 40°C. If the piping does not comply
with these specications, the radiant
panel circuit must be isolated from the
boiler by a plate heat exchanger.
5.6 - Domestic hot
and cold water
CAUTION!!! If the water
hardness is greater than 25°F, we
recommend installing a softener
with lter (see section 5.13).
Figure 10 illustrates the positioning of
the domestic hot and cold water pipes.
For servicing purposes, install a cutoff cock upstream from the cold water
inlet.
Connection of the domestic hot water
service is not indispensable; if the
boiler is required solely for central
heating purposes, it is sufcient to
connect the cold water pipe so as to
ll the heating system and close the
d.h.w. outlet.
5.7 - Gas supply
CAUTION!!! It is forbidden to
use a different gas to that stated for
the boiler.
CAUTION!!! Check that the
gas type and the pressure of the
gas supplied correspond with those
required for the boiler.
There are two possible situations:
A - the gas type and the supply
pressure match those of the boiler
setting. In this case proceed with
connections;
B - the gas type and the supply
pressure do not match those of the
boiler setting. In this case, the boiler
must be converted to the type of gas
and supply pressure available.
A special conversion kit is available on
request from your salesman or direct
from COSMOGAS.
Before installation, we recommend
thorough ushing of the gas supply
pipe.
An on-off cock must be installed on
the gas supply pipe.
To avoid damaging the gas control
unit of the appliance, carry out a
leak test at a pressure of no greater
than 50 mbar.
If testing of the gas system must
be carried out at a pressure nigher
than 50 mbar, use the cock situated
immediately upstream from the
boiler, to isolate the same from the
system.
Figure 10 shows the position of the
appliance gas tting.
The sections of piping making up
the gas supply system must always
provide sufcient gas to cover the
required maximum.
5 - INSTALLATION
14
Figure 12 - Gas and water connections
5.8 - Assembling
the appliance
Refer to gure 11:
place the paper template, provided
with the appliance, against the wall;
ensure that the template is square
with the room;
mark holes for the wall dowel plugs
and the hydraulic ttings;
remove the paper template;
drill the holes “A” and insert the wall
dowel plugs “B”;
carry out the hydraulic and gas
connections for the boiler;
hang the boiler on the dowel plugs
“C”;
carry out the hydraulic connections.
5.9 - Gas and water
connections
The boiler comes supplied with the
standard ttings illustrated in gure 12,
where:
A = heating supply
B = domestic hot water
C = gas inlet
D = domestic cold water
E = gas inlet cock (EN 331
type approved)
F = domestic cold water cock
G = heating return
H = condensation discharge
pipe
5 - INSTALLATION
Figure 11 - Support dowel plugs
15
5 - INSTALLATION
Figure 13 - Connection of the discharge safety
valve “A” (pipe “A” is optional) and condensation
discharge “B”
Figure 14 - Trap funnel “F” (on request)
5.10 - Condensation
discharge
The boiler is equipped internally with a trap for
the evacuation of condensation (see gure 1,
detail 40) and so as to prevent the leakage of
combustion products, whose end corresponds
with pipe “B” shown in gure 13. This end
must be conveyed to another smell-control trap
(gure 14, detail “F”) so as to prevent the return
of bad smells in the room (the smell-control trap
“F” is supplied upon request).
In particular, the condensation disposal system
must:
for premises used for dwelling purposes or
ofce purposes with a number of occupants
greater than 10, be connected to the
domestic waste disposal system by means of
an appropriate trap with separation capable
of preventing the pressurization of the system
and preventing the return of bad smells
from the sewer (detail “F” of gure 14). If
the premises for ofce use has a number of
occupants less than 10, before connection
with the domestic waste discharge, it is
advisable to t a condensation neutralizer
(see section 10 for the acidity value of the
condensation and the quantity);
be carried out with a pipe with an internal
diameter equal to or greater than 13 mm;
be installed in such a way so as to avoid the
freezing of the liquid, therefore take care with
any external stretches; discharge into gutters
or rain collectors is forbidden;
present a continual slope towards the point
of discharge; avoid high points, which could
place the pipe under pressure;
5.11 - Safety relief valve
The boiler is protected against overpressure, by
a safety relief valve set at 3 bar (see gure 1,
detail 12).
The safety relief valve discharge must be
connected to pipe “A” (see gure 13) with a
minimum internal diameter of 13 mm; pipe “A”
must then be led to the smell-control trap (detail
“F” of gure 14). This discharge with trap must
provide protection against overpressure in the
event of the valve opening and must indicate to
the user that this intervention has taken place.
Pipe “A” shown in gure 13 and the smellcontrol trap “F” shown in gure 14 are on
request.
CAUTION!!! If the safety relief valve
is not connected to the discharge, opening
of the valve could cause harm to individuals,
animals or property.
16
Reference of Figure 17
A = Box tool’s control
B = stirrup of block
C = toward of opening
C = Cover
D = xing screws
E = Cover electrical
connexion board
F = toward of opening “E”
cover
G = Power supply cable
(not included)
H = Room thermostat cable
(not included)
Figure 16 - Softener with lter
5.12 - Hydraulic
connections for
boiler with BWR
storage tank
The NOVADENS -- B or NOVADENS -B0834 model boiler must be connected
to a storage tank for the production of
domestic hot water.
For this purpose, connection ttings to
the storage tank have been provided
for. For the preparation, operate as
follows (refer to gure 15):
mount pipe “F” to tting “A”;
mount pipe “G” to tting “B”;
mount ttings “C” and “D”
respectively to “F” and “G”;
Take care to insert the appropriate
gasket in each coupling.
5.13 - Softener (on
request)
If the boiler is to be installed in a
geographic area where the domestic
water hardness exceeds 25°F (250
mg/l), a softener must be installed on the
cold water supply (see gure 16, detail
“B”), so as to safeguard the appliance
from any blockage in the domestic water
circuit.
In order to facilitate installation, a softener
may be request to COSMOGAS, with a
specic installation kit.
5 - INSTALLATION
A = BWR return pipe
B = BWR supply pipe
C = BWR return tting
D = BWR supply tting
E = gaskets
F = service pipe
G = service pipe
Figure 15 - Hydraulic connections for boiler with BWR type
storage tank
17
5.14 - Electrical
connections:
overview
CAUTION!!! The appliance
is only electrically safe when it is
correctly connected to an efciently
earthed system, carried out in
compliance with current safety
standards.
This is an essential safety requirement
which must be checked. If in doubt,
have the electrical system thoroughly
checked by a qualied technician.
Have a qualied technician
check that the electrical system is
adequate for the electric power,
indicated on the rating plate,
required by the boiler.
The boiler must be connected to the
mains electricity by connection using
movable plug. Do not use adapters,
multiple plugs or extensions, etc.
The boiler must be connected to
5 - INSTALLATION
the mains electricity by a threepole electrical cable with double
insulation and a minimum cross
section of 1.5 mm2, resistant to
a minimum temperature of 70°C
(feature T).
To connect the boiler to the mains
electricity, use a bipolar switch with
a contact opening distance of at
least 3mm, near to the appliance, in
compliance with current standards
on the subject.
Respect the polarity between live
and neutral when connecting the
boiler.
Ensure that heating and water
piping is not used as earth plates for
the electric and telephone systems.
This piping is completely unsuitable
for this purpose and, in addition,
could rapidly lead to serious
corrosion damage to the boiler,
piping and radiators.
CAUTION!!! The boiler is
not provided with any protection
against lightening strikes.
5.14.1 - Connecting
the power supply
cable
To connect the electrical power supply
cable, proceed as follows (refer to
gure 17):
use a three-pole cable with double
insulation and a minimum cross
section of 1.5 mm2;
remove the boiler casing following
the instructions given in section 8.2;
to rotate the panel "A" toward the
front of the boiler acting on the
stirrups "B";
remove the screw “D” and open the
cover “E”;
lay the power supply cable “A” as
shown in gure 17;
strip the cable being careful to leave
the earth wire (yellow green) 20 mm
longer than the other two;
connect the yellow green cable to
the earth terminal (terminals “G”);
connect the brown cable to terminal
L1 (terminals “G”);
connect the blue cable to terminal N
(terminals “G”).
CAUTION!!! If the “L1” phase
conductor is inverted with
the neutral “N” conductor,
the boiler will lock-out,
displaying error code E21.
CAUTION!!! If the earthing
system is not efcient,
the boiler will lock-out,
displaying error codes L05,
E42 or E23 (depending
on the entity of the
inefciency).
Figure 17 - Electrical connections
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