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TTW
FLOOR STANDING GAS FIRED CONDENSING
CIRCULATING TYPE WATER HEATER
Installation Commissioning and Maintenance
instructions
MODELS
TTW410
TTW580
Installation manual_TTW_December 2018
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Table of Contents
1.0 INTRODUCTION ........................................................................................................................................................................................ 6
1.1 ANCILLARY OPTIONS: ......................................................................................................................................................................... 6
2.0 SAFETY GUIDELINES .............................................................................................................................................................................. 7
2.1 GENERAL DESCRIPTION OF SAFETY SYMBOLS USED.................................................................................................................. 7
2.2 WHAT TO DO IF YOU SMELL GAS ...................................................................................................................................................... 8
3.0 PRINCIPLE PARTS ................................................................................................................................................................................... 8
3.1 CASING .................................................................................................................................................................................................. 8
3.2 ELECTRICAL ......................................................................................................................................................................................... 9
3.3 GAS TRAIN AND AIR INLET ................................................................................................................................................................. 9
4.0 TECHNICAL DATA .................................................................................................................................................................................. 10
4.1.1 TECHNICAL DATA........................................................................................................................................................................... 10
5.0 DIMENSIONS AND CLEARANCE .......................................................................................................................................................... 11
5.1 DIMENSIONS ....................................................................................................................................................................................... 11
5.1.1 DIMENSIONS TTW410 .................................................................................................................................................................... 11
5.1.2 DIMENSIONS TTW580 .................................................................................................................................................................... 11
5.1.3 MINIMUM CLEARANCES ................................................................................................................................................................ 11
5.2 WATER HEATER CONNECTIONS ..................................................................................................................................................... 12
5.2.1 WATER HEATER CONNECTIONS ................................................................................................................................................. 12
5.2.2 CONNECTIONS AND CONNECTION SIZES ................................................................................................................................. 12
5.3 CONDENSATE DRAIN CONNECTION ............................................................................................................................................... 13
6.0 GENERAL REQUIREMENTS .................................................................................................................................................................. 14
6.1 RELATED DOCUMENTS ..................................................................................................................................................................... 15
7.0 WATER QUALITY ................................................................................................................................................................................... 16
7.1 WATER CHEMISTRY .......................................................................................................................................................................... 16
8.0 LOCATION ............................................................................................................................................................................................... 16
8.1 PLANT ROOM REQUIREMENTS ....................................................................................................................................................... 16
8.2 GENERAL REQUIREMENTS .............................................................................................................................................................. 16
8.3 UNPACKING AND LEVELLING THE WATER HEATER .................................................................................................................... 17
8.4 CLEARANCES ..................................................................................................................................................................................... 17
9.0 GAS SUPPLY .......................................................................................................................................................................................... 18
9.1 SERVICE PIPES .................................................................................................................................................................................. 18
9.2 METERS ............................................................................................................................................................................................... 18
9.3 GAS SUPPLY PIPES ........................................................................................................................................................................... 18
9.4 BOOSTED SUPPLIES ......................................................................................................................................................................... 18
9.5 PLANT-ROOM CONTROL VALVE ...................................................................................................................................................... 18
9.6 EQUIPMENT GAS SYSTEM LEAK CHECK ....................................................................................................................................... 18
10.0 FLUE SYSTEM ........................................................................................................................................................................................ 19
10.1 FLUE SYSTEM GENERAL REQUIREMENTS .................................................................................................................................... 19
10.2 FLUE TERMINAL POSITION ............................................................................................................................................................... 20
10.3 FLUE GAS AND AIR SUPPLY SYSTEM ............................................................................................................................................. 20
10.4 APPROVED FLUE SYSTEM ............................................................................................................................................................... 20
10.5 INSTALLATION PRECAUTIONS ......................................................................................................................................................... 20
10.6 WATER HEATER CATEGORIES - TYPES OF FLUE GAS SYSTEMS. ............................................................................................ 21
10.7 TYPE C63 CERTIFIED .......................................................................................................................................................................... 23
10.8 TTW AIR INLET / FLUE GAS OUTLET CALCULATION EXAMPLES ................................................................................................ 23
10.9 TYPE C53(TWIN PIPE) FLUE SYSTEMS ............................................................................................................................................ 24
10.9.1 EXAMPLE A: TWIN PIPE SYSTEM ................................................................................................................................................. 25
10.10 GENERAL TWIN-PIPE INSTALLATION GUIDELINES ....................................................................................................................... 26
10.11 TYPE B23 (CONVENTIONAL FLUE WITH FAN ASSISTANCE) ......................................................................................................... 29
10.11.1 EXAMPLE B: SINGLE PIPE SYSTEM FOR FLUE GAS OUTLET ONLY ...................................................................................... 30
10.12 SEPARATE AIR SUPPLY AND FLUE TERMINAL FOR A PITCHED ROOF ..................................................................................... 31
10.13 COMMON FLUE SYSTEMS ................................................................................................................................................................ 32
10.14 CONDENSATE DRAIN ........................................................................................................................................................................ 32
11.0 AIR SUPPLY ............................................................................................................................................................................................ 32
11.1 AIR SUPPLY THROUGH HUMID AREAS ........................................................................................................................................... 32
11.2 PIPE HEIGHTS AND MUTUAL DISTANCES ON A FLAT ROOF. ..................................................................................................... 32
11.3 COMBUSTION VENTILATION ............................................................................................................................................................ 33
11.4 COOLING VENTILATION .................................................................................................................................................................... 33
12.0 WATER CONNECTIONS ......................................................................................................................................................................... 34
12.1 GENERAL............................................................................................................................................................................................. 34
12.2 UNVENTED SYSTEM ARRANGEMENT............................................................................................................................................. 34
12.2.1 EXPANSION VESSEL SIZING ........................................................................................................................................................ 34
12.2.2 COEFFICIENT OF EXPANSION OF WATER AT 3.5 BAR INLET PRESSURE ............................................................................ 34
12.3 CIRCULATING PUMPS ....................................................................................................................................................................... 35
12.4 PRIMARY PIPEWORK LOOP SIZING ................................................................................................................................................ 35
12.4.1 CIRCULATION REQUIREMENTS ................................................................................................................................................... 35
12.4.2 PIPEWORK HEADER SIZES FOR COMMON INSTALLATIONS .................................................................................................. 36
12.4.3 PIPEWORK SCHEMATICS ............................................................................................................................................................. 36
12.5 PRESSURE RELIEF VALVE ............................................................................................................................................................... 37
12.6 ANTI-GRAVITY LOOP ......................................................................................................................................................................... 37
12.7 AUTOMATIC AIR VENT ....................................................................................................................................................................... 37
12.8 FROST PROTECTION ......................................................................................................................................................................... 37
12.9 SYSTEM FLUSHING............................................................................................................................................................................ 37
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13.0 CONTROL OPTIONS/INSTALLATION ................................................................................................................................................... 38
13.1 VESSEL TEMPERATURE SENSOR SINGLE WATER HEATER INSTALLATION............................................................................ 38
13.1 location of flow temperature sensor (fs) on a single vessel installation ............................................................................................... 39
13.2 location of flow temperature sensor (fs) on a multiple vessel installation ............................................................................................ 39
13.3 SENSOR WIRING ................................................................................................................................................................................ 39
14.0 SCHEMATICS .......................................................................................................................................................................................... 40
14.1 SINGLE WATER HEATER WITH SINGLE STORAGE VESSEL INSTALLATION ............................................................................. 40
14.2 MULTIPLE WATER HEATERS WITH MULTIPLE STORAGE VESSELS NOT IN CASCADE .......................................................... 41
14.3 MULTIPLE WATER HEATERS WITH MULTIPLE STORAGE VESSELS IN CASCADE ................................................................... 41
15.0 ELECTRICAL INSTALLATION ............................................................................................................................................................... 42
15.1.1 ELECTRICAL SUPPLY REQUIREMENTS ...................................................................................................................................... 42
15.2 EXTERNAL CONTROLS ..................................................................................................................................................................... 42
15.3 WIRING CONNECTIONS .................................................................................................................................................................... 42
15.3.1 ACCESSING WIRING CONNECTIONS .......................................................................................................................................... 42
15.3.2 WIRING CONNECTIONS ................................................................................................................................................................ 43
15.3.3 WIRING TERMINALS ...................................................................................................................................................................... 43
15.3.4 WIRING TERMINALS ...................................................................................................................................................................... 44
15.4 MAINS SUPPLY CONNECTION – THREE-PHASE SUPPLY. ........................................................................................................... 45
15.4.1 3-PHASE ELECTRICAL SUPPLY CONNECTION .......................................................................................................................... 45
15.5 MAINS SUPPLY CONNECTION – SINGLE PHASE SUPPLY ........................................................................................................... 45
15.5.1 SINGLE PHASE ELECTRICAL SUPPLY CONNECTION ............................................................................................................... 45
15.6 FUSES .................................................................................................................................................................................................. 45
15.6.1 FUSES .............................................................................................................................................................................................. 45
15.7 WIRING DIAGRAMS ............................................................................................................................................................................ 46
15.7.1 UPPER BURNER WIRING DIAGRAM (PCB A, left) ....................................................................................................................... 47
15.7.2 UPPER BURNER CONTROL .......................................................................................................................................................... 47
15.7.3 LOWER BURNER WIRING DIAGRAM (PCB B, Right) ................................................................................................................... 49
15.7.4 LOWER BURNER CONTROL ......................................................................................................................................................... 49
15.8 SENSOR VALUES ............................................................................................................................................................................... 50
15.8.1 SENSOR VALUES ........................................................................................................................................................................... 50
16.0 CONTROL SYSTEM ................................................................................................................................................................................ 51
16.1 CONTROL PANEL ............................................................................................................................................................................... 51
16.2 CONTROL PANEL / MENU STRUCTURE .......................................................................................................................................... 52
16.3 DISPLAY DURING OPERATION ......................................................................................................................................................... 54
16.4 MONITOR SCREENS .......................................................................................................................................................................... 55
16.5 SERVICE FUNCTION .......................................................................................................................................................................... 57
16.6 SCHORNSTEINFEGER FUNCTION ................................................................................................................................................... 57
16.7 PROGRAMMING IN STANDBY MODE ............................................................................................................................................... 58
16.8 SETTING TIME & DATE ...................................................................................................................................................................... 58
16.9 SET POINTS ........................................................................................................................................................................................ 59
16.10 SETTING THE TIMER PROGRAMS ................................................................................................................................................... 59
16.10.1 STARTING THE TIMER PROGRAMS ............................................................................................................................................. 59
16.11 HOT WATER PROGRAM .................................................................................................................................................................... 60
16.12 ANTI LEGIONNAIRES’ DISEASE PROGRAM .................................................................................................................................... 61
16.13 CHECKING THE OPERATING HISTORY ........................................................................................................................................... 62
16.14 CHECKING THE FAULT HISTORY ..................................................................................................................................................... 63
16.15 SETTING THE MAINTENANCE SPECIFICATIONS ........................................................................................................................... 64
16.15.1 MAINTENANCE SETTINGS ............................................................................................................................................................ 64
16.16 SETTING THE USER LOCK ................................................................................................................................................................ 67
16.17 SETTING THE PARAMETERS BY THE DISPLAY MENU ................................................................................................................. 68
16.18 FAULT CODES DISPLAY .................................................................................................................................................................... 76
16.18.1 LOCK-OUT CODES ......................................................................................................................................................................... 76
16.18.2 BLOCKING CODES ......................................................................................................................................................................... 78
16.18.3 IMPORTANT MESSAGE ................................................................................................................................................................. 80
17.0 CONTROLLING OPTIONS AND SETTINGS .......................................................................................................................................... 80
17.1 GENERAL............................................................................................................................................................................................. 80
17.1.1 EXTRA WATER HEATER CONTROL ............................................................................................................................................. 80
17.1.2 MAX COOLING TIME ...................................................................................................................................................................... 80
17.1.3 TEMPERATURE DISPLAY ON/OFF ............................................................................................................................................... 80
17.1.4 GAS TYPE SELECTION .................................................................................................................................................................. 80
17.1.5 SOFT START OPTION .................................................................................................................................................................... 81
17.1.6 PUMP MODE (EC TECHNOLOGY) ................................................................................................................................................ 81
17.2 WATER HEATER OPTIONS................................................................................................................................................................ 82
17.2.1 0-10 VDC REMOTE FLOW TEMPERATURE SET POINT ............................................................................................................. 82
17.2.2 ANTI-LEGIONNAIRES’ DISEASE (PASTEURISATION) FUNCTION ............................................................................................ 82
17.2.3 TANK SENSOR SENSITIVITY......................................................................................................................................................... 83
17.3 CASCADE CONTROL ......................................................................................................................................................................... 84
17.3.1 PARAMETER SETTINGS FOR CASCADED WATER HEATERS .................................................................................................. 84
17.3.2 MONITOR SCREENS ...................................................................................................................................................................... 86
17.3.3 OUTPUT CONTROL AND BURNER SEQUENCE .......................................................................................................................... 86
18.0 COMMISSIONING THE WATER HEATER ............................................................................................................................................. 87
18.1 FIRST: FLUSHING THE WATER HEATER WITH WATER ................................................................................................................ 87
18.2 SECOND: FILLING & VENTING THE WATER HEATER AND THE SYSTEM ................................................................................... 87
18.3 THIRD: CHECK THE WATER FLOW .................................................................................................................................................. 87
18.4 FLOW MONITORING ........................................................................................................................................................................... 88
19.0 STARTING THE WATER HEATER ......................................................................................................................................................... 89
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19.1 GENERAL............................................................................................................................................................................................. 89
19.2 FIRING FOR THE FIRST TIME ........................................................................................................................................................... 90
20.0 ADJUSTING AND SETTING THE BURNERS ........................................................................................................................................ 91
20.1 INTRODUCTION .................................................................................................................................................................................. 91
20.1.1 ADJUSTMENT TABLES .................................................................................................................................................................. 91
20.1.2 ADJUSTMENT VALUES .................................................................................................................................................................. 91
20.1.3 PRE ADJUSTMENT SETTINGS FOR GAS VALVES ..................................................................................................................... 93
20.1.4 GAS VALVE SETTING SCREWS: DRAWING ................................................................................................................................ 93
20.1.5 HOW TO REMOVE AND MOUNT THE FLUE PLUG: .................................................................................................................... 94
20.1.6 ADJUSTMENT ACTIONS: GENERAL SCHEME ............................................................................................................................ 95
20.1.7 NOTE: CO2 MEASURING POSITION.............................................................................................................................................. 96
20.2 ADJUSTING IN CASE OF A NEW WATER HEATER, OR AFTER MAINTENANCE (CASE A) ........................................................ 96
20.2.1 GENERAL REMARK ........................................................................................................................................................................ 96
20.2.2 CHECKING AND ADJUSTING THE TOP BURNER ....................................................................................................................... 96
20.2.3 CHECKING AND ADJUSTING THE BOTTOM BURNER ............................................................................................................... 97
20.2.4 CHECKING BOTH BURNERS ......................................................................................................................................................... 97
20.3 ADJUSTING AFTER GAS VALVE REPLACEMENT OR IN CASE OF GAS CONVERSION (CASE B) ........................................... 98
20.3.1 GENERAL REMARKS ..................................................................................................................................................................... 98
20.3.2 CASE B ADJUSTMENTS ................................................................................................................................................................. 98
21.0 PUTTING THE WATER HEATER OUT OF OPERATION ...................................................................................................................... 99
22.0 FAULT CODES, BLOCKING CODES................................................................................................................................................... 100
22.1 FAULT CODES .................................................................................................................................................................................. 100
22.1.1 LOCK-OUT CODES: ...................................................................................................................................................................... 100
22.1.2 BLOCKING CODES ....................................................................................................................................................................... 108
22.1.3 MAINTENANCE ATTENTION MESSAGE ..................................................................................................................................... 112
23.0 MAINTENANCE ..................................................................................................................................................................................... 113
23.1 GENERAL........................................................................................................................................................................................... 113
23.2 MAINTENANCE REMINDER FUNCTION. ........................................................................................................................................ 113
23.3 SERVICE INTERVALS ....................................................................................................................................................................... 113
23.4 INSPECTION & MAINTENANCE ....................................................................................................................................................... 113
23.4.1 CUSTOMER COMMENTS ............................................................................................................................................................. 113
23.4.2 SERVICE HISTORY ....................................................................................................................................................................... 113
23.4.3 FLUE GAS & AIR SUPPLY ............................................................................................................................................................ 114
23.4.4 GAS SUPPLY & SAFETIES ........................................................................................................................................................... 114
23.4.5 REMOVE THE BURNER UNIT ...................................................................................................................................................... 114
23.4.6 BURNER......................................................................................................................................................................................... 114
23.4.7 IGNITION / IONISATION ELECTRODE ........................................................................................................................................ 114
23.4.8 BURNER DOOR GASKETS .......................................................................................................................................................... 114
23.5 MOUNTING THE BURNER DOOR CORRECTLY BACK ONTO THE HEAT EXCHANGER: ......................................................... 114
23.5.1 NON RETURN VALVE ................................................................................................................................................................... 115
23.5.2 FAN ................................................................................................................................................................................................. 115
23.5.3 INSULATION .................................................................................................................................................................................. 115
23.5.4 SIPHON .......................................................................................................................................................................................... 115
23.5.5 HEAT EXCHANGER AND BURNER ROOM ................................................................................................................................. 116
23.5.6 GAS/AIR RATIO ............................................................................................................................................................................. 116
23.5.7 PUMP ............................................................................................................................................................................................. 116
24.0 ErP DATA TABLE ................................................................................................................................................................................. 116
25.0 USER INSTRUCTIONS ......................................................................................................................................................................... 116
26.0 WARRANTY ........................................................................................................................................................................................... 116
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1.0 INTRODUCTION
The Lochinvar TTW is a floor standing gas-fired condensing water heater. The equipment comprises of
two stainless steel radial burner assemblies and a heat exchanger that permits fully condensing
operation.
The burners are initiated by cascaded electronic ignition sequence controls that incorporate spark
ignition and flame rectification devices for supervision of the flame.
The output from the water heater is regulated by two variable speed combustion fans and gas/air ratio
controls to maintain correct combustion at all levels of modulation. This configuration allows modulation
down to 12.5% of the rated output.
For the correct operation of the water heater, it is essential that a suitably sized pump is utilised to
maintain a constant water flow rate through the heat exchanger.
This equipment is intended for use on Group H Natural Gas (2
nd
Family) and LPG propane (3rd Family).
The information relating to propane firing is to be found in Section 15.3.This equipment MUST NOT use
gas other than that for which it has been designed and adjusted.
This equipment must be installed by a competent person, registered with a H.S.E. approved body. All
installations must conform to the relevant Gas Safety and Building Regulations. Health & Safety
requirements must also be taken into account when installing any equipment. Failure to comply with
the above may lead to prosecution.
If the equipment is to be connected to an unvented (pressurised) system, care must be taken to ensure
all extra safety requirements are satisfied should a high or low-pressure condition occur in the system.
The equipment is designed for direct connection to a flue system.
1.1 ANCILLARY OPTIONS:
Matched primary pump LM900149A
Twin pipe balanced flue assemblies Refer to TT Flueing Specification Document*.
Conventional flue assembly Refer to TT Flueing Specification Document*.
Condensate neutralisation kit LM900002
* Visit www.lochinvar.ltd.uk for additional technical documentation
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2.0 SAFETY GUIDELINES
READ AND UNDERSTAND THE INSTRUCTIONS
Read and fully understand all instructions before attempting to operate maintain or install the
unit.
Keep these instructions near the water heater for quick reference.
This equipment must be installed by a competent person, registered with the H.S.E. approved body. All
installations must conform to the relevant Gas Safety and Building Regulations. Health & Safety requirements
must also be taken into account when installing any equipment. Failure to comply with the above may lead to
prosecution
Without written approval of the manufacturer the internals of the water heater may not be changed. When
changes are executed without approval, the water heater certification becomes invalid.
Commissioning, maintenance and repair must be done by a skilled installer/engineer, according to all applicable
standards and regulations.
2.1 GENERAL DESCRIPTION OF SAFETY SYMBOLS USED
BANNED
A black symbol inside a red circle with a red diagonal indicates an action that should not be
performed
WARNING
A black symbol added to a yellow triangle with black edges indicates danger
ACTION REQUIRED
A white symbol inserted in a blue circle indicates an action that must be taken to avoid risk
ELECTRICAL HAZARD
Observe all signs placed next to the pictogram. The symbol indicates components of the unit and
actions described in this manual that could create an electrical hazard.
HOT SURFACES
The symbol indicates those components with a high surface temperature that could create a risk.
This symbol shows essential information which is not safety related
Recover or recycle material
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2.2 WHAT TO DO IF YOU SMELL GAS
Warning if you smell gas
No naked flames, no smoking!
Avoid causing sparks, do not switch on or off electrical equipment or lights
Open windows and doors
Shut off the main gas supply
Warn occupants and leave the building
After leaving the building alert the local gas supply company
Do not re-enter the building until it is safe to do so
Lochinvar Limited is not liable for any damage caused by inaccurately following these installation
instructions. Only original parts may be used when carrying out any repair or service work.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their
safety. Children should be supervised to ensure that they do not play with the appliance.
3.0 PRINCIPLE PARTS
3.1 CASING
No
Item No
Description 1 E01-000-124
SIDE PANEL 2 S01-000-337
ELECTRICAL COVER
3
S01-000-380
TOP COVER
4
E01-002-114
REAR COVER
5
E01-002-128
COVER UPPER LIMIT SWITCH
6
E01-002-129
COVER LOWER LIMIT SWITCH
7
S04-000-307
WHEEL ASSEMBLY
8
E01-000-215
FRONT PANEL
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3.2 ELECTRICAL
No
Item No
Description
1
E04-016-425
RELAY LC1D09
2
E04-016-291
CONNECTOR PLUG 2 POLE
2
E04-016-292
CONNECTOR PLUG 3 POLE
2
E04-016-293
CONNECTOR PLUG 4 POLE
2
E04-016-295
CONNECTOR PLUG 6 POLE
3
E05-001-062
RUBBER PLUG 15mm
4
S04-000-310
REPLACEMENT KIT DISPLAY
5 WATER HEATER CONTROL SLAVE-STATE TYPE AND SERIAL NO
6 WATER HEATER CONTROL MASTER-STATE TYPE AND SERIAL NO
7
S04-016-582
FUSE SET x10
3.3 GAS TRAIN AND AIR INLET
No
Item No
Description
1
S04-000-199
GAS VALVE
2
S04-000-200
COMBUSTION FAN
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4.0 TECHNICAL DATA
Model Number
TTW410
TTW580
GENERAL DATA
Product I.D. Number
CE 0063BS3806
Classification II2H3B/P
Input (gross) min-max
kW
55.4 - 444
75.5 - 611
Input (net) min-max
kW
50 - 400
68 - 550
Recovery Rate (44° ΔT)
l/hr
8168
11263
Recovery Rate (50° ΔT)
l/hr
7188
9912
Heat generator seasonal efficiency
%
95.4
95.9
Shipping Weight
kg
400
450
NOX
mg/kWh
44
41
NOX Class
6
GAS DATA G20
Nominal gas inlet pressure
mbar
20
Maximum gas inlet pressure
mbar
25
Minimum gas inlet pressure
mbar
17.5
Gas flow rate – m3/hr
m3/hr
5.3 - 42.3
7.2 - 58.2
Flue gas mass rate (@ 9.0% CO2)
g/sec
24.1 - 207.8
Gas inlet connection size
“ BSP 2 2
GAS DATA G31
Nominal gas inlet pressure
mbar
37
Maximum gas inlet pressure
mbar
45
Minimum gas inlet pressure
mbar
27
Gas flow rate – m3/hr
m3/hr
16.8
23
Flue gas mass rate (@ 9.0% CO2)
g/sec
193
265
Gas inlet connection size
“ BSP 2 2
ELECTRICAL DATA
Power consumption
W
752
829
Power supply
Single phase 230v/50Hz
Protection class
IPX0B
WATER DATA
Water content
litres
30
43
Water connections (F & R)
“ BSP
2 ½
Max. water pressure
bar 8 8
Min. water pressure
bar 1 1
Maximum water temperature
°C
70
70
4.1.1 TECHNICAL DATA
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5.0 DIMENSIONS AND CLEARANCE
5.1 DIMENSIONS
5.1.1 DIMENSIONS TTW410
5.1.2 DIMENSIONS TTW580
Minimum Side Clearance of 500mm (Advised 1000mm)
Minimum Front Clearance of 800mm
Minimum Rear Clearance of 500mm
5.1.3 MINIMUM CLEARANCES
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5.2 WATER HEATER CONNECTIONS
Rear view
5.2.1 WATER HEATER CONNECTIONS
Connection
Function
Diameter (inch/mm)
A
combustion air inlet
Ø 180 mm
B
flue outlet
Ø 180 mm
C
water flow (outlet)
R 2½ "
D
water return (inlet)
R 2½ "
E
gas connection
R 2 ”
F
condensate discharge hose
Ø 25 mm outer diameter
G
cable input
Ø 22.5 mm
5.2.2 CONNECTIONS AND CONNECTION SIZES
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5.3 CONDENSATE DRAIN CONNECTION
The condensate drain is placed at the centre and at the bottom of the water heater and has a ¾ inch hose discharge.
Connect this flexible hose to a suitable drain point.
Use only plastic parts with the condensate drain.
Blockage of this drain may damage the water heater. The drain connection is correct when the condensate can be
seen flowing away.
Any damage caused by incorrectly installing the condensate drain WILL not be covered by
warranty.
There should be an open connection of the condensate hose into the drain. A possible under pressure in the
drainage system must never be allowed to cause drain water to pull into the water heater.
When mounting the bottom part of the siphon, before commissioning the water heater and/or
after maintenance, the siphon must ALWAYS be completely filled with water.
This is a safety measure: the water in the siphon keeps the flue gases from entering the plant
room by leaving the heat exchanger via the condensate drain.
FIGURE 3.2 CONDENSATION SIPHON
Turn LEFT to open
Turn RIGHT to close
Fill with water
to the edge
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6.0 GENERAL REQUIREMENTS
The Lochinvar TTW comes with the following documents and accessories:
An installation, commissioning and maintenance instruction guide for the installer.
3 spare fuses and 3 spare nuts for the installation of the burner plate (this is attached to the front of the gas
valve).
Spare flue gas plugs
One gas conversion sticker
One Torx key T40
One allen key no. 3
Bottom part of Siphon
Lochinvar will supply a suitable shunt pump with every TTW water heater, this must be
installed with the TTW to maintain the correct flow
On delivery, immediately check that the water heater is complete and without any defects. Report any damage
immediately to Lochinvar Limited.
The Lochinvar TTW has been designed to operate trouble free for many years. These instructions should be
followed closely to obtain the maximum usage and efficiency of the equipment. PLEASE read the instructions fully
before installing or using the appliance.
NOTES
1
All water heaters are supplied as twin pipe model.
2
Using propane, butane and B/P, maximum fan speed
needs to be reduced (parameter P4BD)
3
Below a table is given in which the min. and max. gas
supply pressures are listed according to EN437:
p nominal
[mbar]
p min
[mbar]
p max
[mbar]
G25
25
20
30
G20
20
17
25
G31
30
25
35 37
25
45
G30
50
43
57
4
Emissions measured during unit certification.
5
Maximum combined resistance of flue gas and air
supply piping at high fire.
6
230 Vac is necessary for the water heater to function.
If a 400 Vac water heater pump is applied, 400 Vac
must be connected to the appliance so the power
supply for the pump can be delivered by the system.
(An optional safety switch for the pump motor must be
added externally).
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6.1 RELATED DOCUMENTS
It is law that all gas appliances are installed by competent persons, in accordance with The Gas Safety (Installation
and Use) Regulations 1998. Failure to install appliances correctly could lead to prosecution. It is in your own
interest, and that of safety, to ensure that this law is complied with.
The installation of the equipment MUST be in accordance with the relevant requirements of the Gas Safety
Regulations, Building Regulations, I.E.E. Regulations and the bylaws of the local water undertaking. The installation
should also be in accordance with any relevant requirements of the local gas distributor and local authority.
In addition the installation should follow the relevant guidance offered in the following documents. It is not
practical to list all relevant information but emphasis is placed on the following documents, as failure to comply
with the guidance given will almost certainly result in an unsatisfactory installation:
Regulation
Description
BS EN 1858: 2008 +
A1: 2011
Chimneys, Components. Concrete flue blocks.
BS 5440-1: 2008
Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family
gases). Specification for installation of gas appliances to chimneys and for maintenance of chimneys.
BS 5440-2: 2009
Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70
kW net (1st, 2nd and 3rd family gases). Specification for installation and maintenance of ventilation for gas
appliances.
BS 6644: 2011
Specification for Installation of gas-fired hot water Heaters of rated inputs between 70 kW (net) and 1.8
MW (net) (2nd and 3rd family gases).
BS EN 806 1-5
Specifications for installations inside buildings conveying water for human consumption.
BS 7671 :2008 +
A3:2015
Code of practice for low temperature hot water systems of output greater than 45 kW.
BS 7074: 1989 Parts 1
and 2
Application, selection and installation of expansion vessels and ancillary equipment for sealed systems.
BS 7671: 2008 + A1:
2011
Requirements for electrical installations, I.E.E. wiring regulations seventeenth edition.
BS 7671: Amendment
2: August 2013
BS EN
12828:2012+A1:2014
Heating systems in buildings. Design for water-based heating systems.
CP 342 (Part 2 1974):
Code of practice for centralised hot water supply-buildings other than dwellings.
Institute of Gas Engineers and Managers (IGEM) Publications
IGE/UP/1 - Edition 2:
Installation pipework on industrial and commercial premises.
IGE/UP/2 – Edition 3
Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP/4 - Edition 4
Commissioning of gas-fired plant on industrial and commercial premises.
IGE/UP/10 - Edition 4
Installation of flued gas appliances in industrial and commercial premises.
Gas Safety (Installation and Use) Regulations 1998 (England, Scotland & Wales)
CIBSE: Guide parts A, B and C
H.S.E. guidance Automatically controlled steam and hot water heaters note PM5:
Third edition of the 1956 Clean Air Act Memorandum on Chimney Heights
Manufacturer's notes must not be taken in any way as overriding statutory obligations.
Page 16
16
7.0 WATER QUALITY
7.1 WATER CHEMISTRY
Water supply quality may adversely affect the efficiency performance and longevity of Water Heaters and Hot
Water systems. Hard water may cause the formation of limescale that will reduce operating efficiency and may
cause early product failure. Please note the following: -
Maximum allowed water hardness is 205 PPM or 205 mg/L CaCO3 (= 11.5°dH)
TDS (total dissolved solids) may not exceed 350 PPM
Water hardness and TDS together may not exceed 350 PPM
The pH value of the water may not be under 6.5 and not above 7.5 (measured cold)
If TDS alone or the combined value is higher than the abovementioned, the water should be heated by
means of an indirect water-heating appliance.
Minimum water hardness = 80 PPM or 80 mg/L CaCO3 (= 4.5°dH)
Minimum TDS = 100 PPM
Water that is under these minimum values normally has a pH value, which is aggressive and corrosive.
If these values are exceeded a water treatment specialist should be consulted. Water
Softeners and Water Conditioners may be considered, but whichever method is selected, it
should be suitable for installation with Direct Gas-fired Water Heaters. A maintenance
regime will also be required for such systems
The formation of limescale or other solids can cause a blockage within the heat exchanger,
which in turn may cause premature failure. Such instances are not regarded as defects in
manufacture and will not be covered under the product warranty
8.0 LOCATION
8.1 PLANT ROOM REQUIREMENTS
The Lochinvar TTW condensing water heater can only be installed in a room that complies with the appropriate
ventilation requirements.
The Lochinvar TTW can be used as a type C13, C33, C
43, C53,
or C83 appliance. Due to its room sealed design, ventilation
allowances for combustion air are not necessary; ventilation for cooling purposes however, must be fitted. For
further guidance, please refer to Section 9: AIR SUPPLY or to BS6644.
The Lochinvar TTW can also be used as a type B23 appliance. If such a configuration is to be used, then appropriate
ventilation for cooling and combustion must be provided. For further details, please refer to Section 9: AIR SUPPLY
or to BS6644.
8.2 GENERAL REQUIREMENTS
Corrosion of the heat exchanger and vent system may occur if air for combustion contains certain chemical
vapours. Such corrosion may result in poor combustion and create a risk of asphyxiation. Aerosol propellants,
cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes and process chemicals are corrosive. Products of this sort should not be stored near the water
heater or outside by the air intake (if applicable). The fitting of this equipment in a situation where aerosols or
other chemicals may be entrained into the combustion air will invalidate the warranty.
The equipment must be installed on a level, non-combustible surface that is capable of adequately supporting its
weight (when filled with water) and any ancillary equipment. The operation of the equipment must not cause the
temperature of any combustible material in the vicinity of the equipment and its flue to exceed 65°C. If such a
situation is unavoidable, appropriate insulation should be provided.
Locate the equipment so that if the appliance or any connecting pipework should leak, water
damage will not occur. When such locations cannot be avoided, it is recommended that a suitable
drain pan be installed under the equipment. The pan should be adequately drained but must not
restrict the combustion or ventilation airflow.
Page 17
17
8.3 UNPACKING AND LEVELLING THE WATER HEATER
The water heater is mounted on a pallet with a wooden support frame around it. The water heater is wrapped in
shrink wrap before the wooden support frame is mounted. After the frame is placed the whole pallet, water heater
and frame package is shrink wrapped again. Only remove the outer packaging once the water heater has been
positioned as close as possible to the place where it will be installed. After removing the wrapping and frame the
water heater can be taken off the pallet using a fork-lift truck or suitable lifting device. The water heater is fixed to
the pallet with screws; make sure these are removed before attempting to lift the water heater from the pallet.
Once the water heater is in its final position, the inner packaging can be removed.
The water heater will now be stood on 4 adjustment bolts; ensure the water heater is level in both directions by
using these 4 bolts. There are also four legs under the appliance that can be turned outward if a positive fixing to
the floor structure is required.
8.4 CLEARANCES
The location chosen for the equipment must permit the provision for a satisfactory flue system and, where
necessary, an adequate air supply. The location must also provide adequate space for servicing and air circulation
around each unit. This includes any electrical trunking laid across the floor and to the appliance.
See 5.1.3 for dimensions/clearances. Further details regarding locations are given in BS6644.
Page 18
18
9.0 GAS SUPPLY
The Lochinvar TTW is suitable for use on second and third family gasses 2H - G20 - 20mbar and 3P - G31 - 37mbar.
Details relating to Natural Gas (2H) appear below; for details relating to Propane (3P) please refer to Section 17.1.4
GAS TYPE SELECTION.
9.1 SERVICE PIPES
The local gas distributor must be consulted at the installation planning stage in order to establish the availability
of an adequate supply of gas. An existing service pipe must not be used without prior consultation with the local
gas distributor.
9.2 METERS
The local gas distributor contractor will connect a new gas meter to the service pipe. An existing gas meter should
be checked, preferably by the gas distributor, to ensure that it is adequate to deal with the rate of gas supply
required.
9.3 GAS SUPPLY PIPES
Supply pipes must be fitted in accordance with IGE/UP/2. Pipework from the meter to the equipment must be of
adequate size. The complete installation must be purged and tested as described in IGE/UP/1. Refer to Section
17.1.4 GAS TYPE SELECTION for information on LPG installation guidance.
9.4 BOOSTED SUPPLIES
Where it is necessary to employ a gas pressure booster, the controls must include a low-pressure cut-off switch at
the booster inlet. The local gas distributor must be consulted before a gas pressure booster is fitted. For details
of how to connect a low-pressure cut-off switch, please refer to Section 15.0: ELECTRICAL INSTALLATION.
9.5 PLANT-ROOM CONTROL VALVE
A manual valve for plant-room isolation must be fitted in the gas supply line. It must be clearly identified and
readily accessible for operation, preferably by an exit.
9.6 EQUIPMENT GAS SYSTEM LEAK CHECK
An approved isolating valve and union should be installed for each unit in a convenient and
safe position and be clearly marked.
Ensure that the manual gas service valve is in the OFF position. Although the equipment receives a gas leak check
and gas train component integrity check prior to leaving the factory, transit and installation may cause disturbance
to unions, fittings and components. During commissioning, a further test for tightness should be carried out on
the equipment gas pipework and components.
Care must be taken not to allow leak detection fluid on or near any electrical parts or
connections.
Page 19
19
10.0 FLUE SYSTEM
All versions of the TTW Condensing water heater can be installed as either type B23 (fan assisted open flue) C53
(room sealed) C63 (Flue not supplied by the appliance manufacturer) appliances. Only B23,C53 Flue systems are
covered in any detail within this document, further information can be found in the TTW Flue assemblies and
ancillaries guide available at www.lochinvar.ltd.uk See the relevant section for details of each flue type and
requirements.
10.1 FLUE SYSTEM GENERAL REQUIREMENTS
Install the horizontal flue components with an angle of 3° back in the direction of the water
heater (roughly equal to five centimetres for every linear meter). Failure to install the flue
correctly will result in a build-up of condense within the flue pipework that will cause early
component failure.
When using a wall terminal, there is the possible risk of ice building-up on surrounding
parts/structures, because the condensate will freeze. This risk should be taken into account
during the design phase of the heating installation.
TTW Water heaters will produce large condense clouds especially during cold weather,
consideration must be taken as to whether this will cause a nuisance to neighbouring properties
and if so alternative flue arrangements used.
TTW Water heaters can operate with very low flue temperatures; as such the flue system used
must be suitable for use with condensing appliances made from either Polypropylene or
stainless steel and have a temperature class of T120.
Aluminium flue pipe must not be used on this appliance as it may lead to premature failure of
the heat exchanger and will invalidate the warranty.
Before installation of any flue system read the installation manual carefully for both the
appliance and flue system to be used. Information on the flue system Supplied by Lochinvar can
be found within this manual.
MODEL NUMBER
TTW410
TTW580
FLUE DATA
Appliance category
B23, C13, C33, C43, C53, C83
Nominal flue diameter – mm
180
180
Maximum flue gas temp. – °C
90
90
Page 20
20
10.2 FLUE TERMINAL POSITION
Any flue termination must be in such a position as will not cause a hazard to the health of persons who may be
nearby or a nuisance to other persons beyond the curtilage. The flue terminal must be positioned externally such
as to allow the dispersal of products of combustion and air intake. The terminal should be installed in a location
where it will not easily flood or be blocked by snow. Under certain operating and weather conditions, the TTW
may generate a plume at the terminal. Consideration should be given to the nuisance this may cause and the
terminal should be sited accordingly.
The flue terminal position is very important and must be in accordance with the recommendations found in BS6644
or IGE/UP/10. Once the terminal position has been determined the appropriate local authority should be advised
of the proposed installation. It is important that the appropriate local authority is consulted at an early stage in
the design in order to establish that the proposed flue discharge positions are acceptable and will not cause
significant local exceedances of air quality objectives.
Where agreement is reached with the local authority, this should be recorded in a reproducible format as
competent people involved at the latter stages of the project (i.e. the commissioning engineer) will ask for proof
before allowing products of combustion to be discharged in an apparently non-compliant position.
10.3 FLUE GAS AND AIR SUPPLY SYSTEM
The overall resistance of the air supply and exhaust ducts must not create a pressure drop exceeding 200 Pa. The
output of the water heater is influenced by the resistance of the air supply and discharge system therefore all flue
gas and air supply systems must be carefully considered or referred to a specialist flue design company.
Details of air inlet and exhaust locations and sizes can be found in 4.0 TECHNICAL DATA.
10.4 APPROVED FLUE SYSTEM
When used as a type C appliance, the approved, purpose designed adaptive flue system should be used. For further
details, please contact Lochinvar Limited.
When used as a Type B appliance, a suitable flue system constructed of Stainless Steel or Polypropylene with a
temperature rating in excess of 120C should be used.
10.5 INSTALLATION PRECAUTIONS
The water heater must not be operated unless the complete flue system is installed. This
includes the water heater connections, flue pipes, air ducts (if required) and terminals.
Due to the condensing nature of the water heater, long external runs should be avoided to
prevent the condensate freezing within the flue system.
During assembly, precaution should be taken to ensure that any sealing ring is seated
correctly
Due to the close tolerances in the flue system, it may be necessary to use a twisting action
to fit the joints together. No lubrication other than water should be used.
Page 21
21
10.6 WATER HEATER CATEGORIES - TYPES OF FLUE GAS SYSTEMS.
Type according EN 15502-2-1: 2012
Performance
Description
B23(P)
Open
Air supply from
room
* Roof terminal
* Without draught diverter
* Water heater room air supply.
* P = overpressure systems
Be aware: The installation room has to have sufficient air
supply vents. These vents must be open and
may not be closed or blocked.
Requirements at NEN 3028 paragraph 6.5
Use table 10.11 to select the correct flue items.
C53 Closed
Air supply from
outside
*Separate air supply duct
*Separate flue gas discharge duct.
* Air supply inlet and flue gas outlet at different air
pressure zones. But not at opposite walls.
Use table 10.9 to select the correct flue items
Flue
Outlet
Air
Inlet
Flue
outlet
Air
inlet
Vented
area
Page 22
22
C63 Closed
Air supply from
outside
* Appliance sold without flue/air-inlet ducts
* The flue gas parts are not part of the water heater. The
water heater is intended to be connected to a separately
approved and marketed system for the supply of
combustion air and discharge of combustion products.
Condensate is allowed to go to the water heater.
* Air supply inlet and flue gas outlet not at opposite walls
* Technical data:
nominal T
flue gas
85°C
nominal Q
fluegas
see 2.2
1)
maximum T
fluegas
95°C
min. load T
fluegas
35°C
min. load Q
fluegas
see 2.21)
nominal % CO2
see 2.21)
max. allowed draft
70Pa
max. pressure drop inlet-
outlet
200Pa
max T
air supply
40°C
max recirculation
10%
1) table technical specifications
See chapter: Accessories
- Fluegas and air supply parts
Flue outlet
Air inlet
Page 23
23
10.7 TYPE C
63
CERTIFIED
In general, water heaters are certified with their own flue gas material. For type B23(P), C13, C33, C43, C53 and
C83 systems, only use flue gas and air supply parts approved for use with the appliance.
If a heater is C63 certified, no specific type flue gas material has been certified in combination with the water
heater. In this case the flue gas and air supply parts should comply with the applicable European standards
(EN14989).
So, for type C63 systems flue gas and air supply parts from other suppliers can be used. It must be able to handle
the condensate forming (W) and transport, overpressure (P1) and must have a minimum temperature class of
T120. Also, it has to meet the requirements in the following chapters "air supply" and "flue terminal".
CE string
flue gas
material
European standard
Temperature
class
Pressure class Resistance to
condensate
Corrosion
resistance class Metal: liner
specifications
Soot fire resis-tance class
Distance to
combustible
material
Plastics:
location Plastics: fire
behaviour
Plastics:
enclosure
min. req. PP
EN 14471
T120
P1 W 1 O
30
I of E
C/E
L
min. req. SS
EN 1856-1
T120
P1 W 1
L20040
O
40
A few examples of flue gas material suitable for TTB water heaters:
CE String for Plastic PPs: EN14471 T120 P1 W 2 O(30) I C/E L
CE String for Stainless Steel: EN1856-1 T250 P1 W V2-L50040 O (50)
When selecting flue gas systems, be aware that the minimum requirements are met. So only select flue gas
materials having the same or better properties than this table.
Never use aluminium containing flue gas pipes in these water heaters.
Connecting diameters and tolerances:
mat d
nom
D
outside
L
insert
d
inside
L
insert
d
wall thickness
RVS 180
180 ± 0,3
50 ± 1
181,2 ± 0,3
50 +0/ -2
0,6 ± 10%
RVS 200
200 ± 0,3
50 ± 1
201,2 ± 0,3
50 +0/ -2
0,6 ± 10%
PP 200
200 +1/ -0,6
50 +20/ -2
202 +0,6/ -1
50 +20/ -2
≥ 3,5
Multiple water heaters can be connected to a common duct. These flue gas systems for multiple water heater
installations must always be engineered as zero or negative pressure systems; so as to prevent the risk of
recirculation of the flue gases. Consult the flue gas supplier for detailed information and engineering.
If the combustion air is taken from the water heater room, the inlet air must be clean and free of water. Always
use a wire mesh to prevent debris being drawn into the air inlet
10.8 TTW AIR INLET / FLUE GAS OUTLET CALCULATION EXAMPLES
The load of the water heater is influenced by the resistance of the air supply and the discharge system. The
diameter and length of both air supply and flue gas pipes needs to be designed accurately to decrease the possible
power loss of the water heater.
Calculation examples
In the following, two calculation examples are given for determining the maximum length of the flue gas and air
supply pipes.
A: Twin pipe system with separate pipes for flue gas and air supply.
Air supply roof mounted.
B: Single pipe system for flue gas outlet only.
Air supply from water heater room.
Page 24
24
10.9 TYPE C
53
(TWIN PIPE) FLUE SYSTEMS
Flue system specifications
MANUFACTURER MUELINK AND GROL (M&G)
TEMPERATURE CLASS T120
FLUE GAS MATERIAL PP
Each Twin-Pipe starter assembly includes the items shown in the tables below
TWIN-PIPE FLUE ASSEMBLY MODELS
TTW410,TTW580
COMPONENTS REQUIRED TO START INSTALLATION
VERTICAL FLUE
M70439
VERTICAL TERMINAL Ø200mm
1
LE400092
INCREASER Ø180mm TO Ø200mm FOR AIR INLET ONLY
1
LE400093
ECCENTRIC INCREASER Ø180mm - Ø200mm FOR EXHAUST
1
LE400096
VERTICAL TERMINALØ200mm (AIR INLET) - PP
1
Additional Flue Ancillary Items
Item No.
Description
Dimensions
LV310696
EXTENSION Ø200mm PP
500mm
M70402
EXTENSION Ø200mm PP
1000mm
M70404
EXTENSION Ø200mm PP
2000mm
M70411
ELBOW 90° Ø200mm PP
n/a
M70412
BEND 45° Ø200mm PP
n/a
LV310677
T PIECE WITH CONDENSATE CONNECTOR Ø200mm PP
n/a
M87198
WALL CLAMP Ø200mm
n/a
Do not reduce the pipe diameter relative to the water heater connection
Page 25
25
10.9.1 EXAMPLE A: TWIN PIPE SYSTEM
Calculation example:
The total resistance is less than 200 Pa, so this is acceptable.
Water heater type:
TTW410
Flue gas
Diameter: 200 mm.
Number
Pa
Pa total
Straight tube m¹
total
13
1,8
23,4
T-piece
outlet 1 16,7
16,7
Bend
90° 2 6,5
13
Flue outlet
Zeta=0,05
1
0,9
0,9
Total resistance flue gas outlet:
54,0
Air supply
Diameter: 200 mm.
Number
Pa
Pa total
Straight tube m¹
total 7 1,3
9,1
T-piece
inlet 1 17,5
17,5
Bend
90° 2 4,9
9,8
Air inlet
Zeta=1,0 1 14,0
14,0
Total resistance air supply:
50,4
Total resistance flue gas outlet and air supply:
104,4 Pa
INLET AIR MUST BE CLEAN
AND FREE OF WATER.
USE A WIRE MESH WHEN
THERE IS RISK OF DEBRIS
BEING DRAWN INTO THE
AIR INLET.
EXAMPLE A
8m
3m
1m
2m
2m
4m
INLET AIR MUST BE CLEAN
AND FREE OF WATER.
ALWAYS USE A WIRE MESH
TO PREVENT DEBRIS BEING
DRAWN INTO THE AIR INLET.
Page 26
26
10.10 GENERAL TWIN-PIPE INSTALLATION GUIDELINES
The images shown below may not represent the equipment supplied, images and
instructions are for general guidance only
Page 27
27
Page 28
28
Page 29
29
10.11 TYPE B
23
(CONVENTIONAL FLUE WITH FAN ASSISTANCE)
When the water heater is installed as a Type B23 appliance, the flue system should be installed in accordance with
the flue manufacturer’s specific instructions
CONVENTIONAL FLUE ASSEMBLY MODELS
TTW410,TTW580
COMPONENTS REQUIRED TO START INSTALLATION
Item No.
Description
Dimensions
M70439B
VERTICAL TERMINAL Ø200mm
1
LE400093B
ECCENTRIC INCREASER Ø180mm - Ø200mm FOR EXHAUST
1
LE400094B
AIR INLET SCREEN Ø160mm SS
1
Additional Flue Ancillary Items
Item No.
Description
Dimensions
LV310696
EXTENSION Ø200mm PP
500mm
M70402
EXTENSION Ø200mm PP
1000mm
M70404
EXTENSION Ø200mm PP
2000mm
M70411
ELBOW 90° Ø200mm PP
n/a
M70412
BEND 45° Ø200mm PP
n/a
LV310677
T PIECE WITH CONDENSATE CONNECTOR Ø200mm PP
n/a
M87198
WALL CLAMP Ø200mm
n/a
When using flue pipe supplied by Lochinvar the guidance given in section 10.10 is also applicable for B23
systems.
Page 30
30
10.11.1 EXAMPLE B: SINGLE PIPE SYSTEM FOR FLUE GAS OUTLET ONLY
Calculation example:
The total resistance is less than 200 Pa, so this is acceptable.
Water heater type:
TTW410
Flue gas
Diameter: 180 mm.
Number
Pa
Pa total
Straight tube m¹
total
8,5
3,0
25,5
T-piece
outlet 1 25,5
25,5
Bend
90° 2 9,9
19,8
Flue outlet
Zeta=1,0
1
28,3
28,3
Total resistance flue gas outlet:
99,1
Air supply
Diameter: 180 mm.
Number
Pa
Pa total
Air inlet
Zeta=1,3
1
27,7
27,7
Total resistance air supply:
27,7
Total resistance flue gas outlet and air supply:
126,8 Pa
INLET AIR MUST BE CLEAN
AND FREE OF WATER.
ALWAYS USE A WIRE MESH
TO PREVENT DEBRIS BEING
DRAWN INTO THE AIR INLET.
Page 31
31
10.12 SEPARATE AIR SUPPLY AND FLUE TERMINAL FOR A PITCHED ROOF
1
2
3
4
5
6
connection tube
pitched roof adhesive
flashing
flue gas roof terminal
air inlet roof duct
90° bend
ventilation grill
door
Page 32
32
10.13 COMMON FLUE SYSTEMS
The Lochinvar TTW can be installed on to a common flue system if required. The common flue system should be
sized to operate under a negative pressure of -0.03 to -0.10 mbar throughout the modulation range of the
appliance.
If a positive pressure common flue system is to be used, a proprietary recirculation prevention
device must be installed at the flue spigot of each water heater to prevent products of
combustion from re-entering the plant room.
10.14 CONDENSATE DRAIN
If the length of the flue system exceeds 6 metres, an additional condensate drain should be fitted. The discharge
pipework should include a suitable water trap to prevent products of combustion from entering the plant room or
drainage system.
11.0 AIR SUPPLY
If combustion air is drawn from outside the building, the water heater will operate as a room-sealed (Type C)
appliance. If combustion air is drawn in from the plant room the water heater will operate as a conventionally
flued (Type B) appliance.
The following information is based on single water heater installations only. If more than one water heater is being
used, BS6644 should be consulted to calculate the necessary requirements.
11.1 AIR SUPPLY THROUGH HUMID AREAS
When the supply duct is installed in a water heater room with humid air (for example: greenhouses), a double
wall supply duct or an insulated duct should be considered to prevent condensation on the outside of the duct.
It is not possible to insulate the internal air pipes of the water heater. Make sure that no condensate can be
formed on the internal air canals.
The air supply duct must be protected against rain, when it is installed on top of the roof.
11.2 PIPE HEIGHTS AND MUTUAL DISTANCES ON A FLAT ROOF.
Height A
This is the height of the air inlet that must have a cap to prevent rainwater entering
the system.
When in- and outlet are mounted on a flat roof, the inlet should be at least 60 cm
above the roof surface and at least 30 cm above the maximum snow level.
Example 1:
When the maximum snow level on the roof surface is 45 cm then height A should be
45 + 30 = 75 cm. This is more than 60 cm so this height should be 75 cm.
Example 2:
When the maximum snow level on the roof surface is 15 cm then height A should be
at least 15 + 30 = 45 cm. This is less than 60 cm, so the height should be 60 cm.
Height difference B
This should be at least 70 cm: the flue gas outlet should be at least 70 cm higher than
the air inlet and should be equipped with a conical outlet.
A single flue outlet on a flat roof should stick out at least 100 cm from the roof
surface.
Distance C – mutual horizontal distance at roof level
This should be at least 70 cm.
Page 33
33
11.3 COMBUSTION VENTILATION
When used as a Type C appliance, ventilation for combustion is not necessary as the combustion air is ducted
directly from outside. When used as a Type B appliance, the combustion air requirements are as follows:
MODEL
GROSS
INPUT
(KW)
NET
INPUT
(KW)
PLANT ROOM
ENCLOSURE
LOW
SUMMER USE
MEDIUM
SUMMER USE
HIGH
SUMMER USE
LOW
SUMMER USE
MEDIUM
SUMMER USE
HIGH
SUMMER
USE
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
TTW410
444
400
800
1200
1200
2000
1600
2400
2000
4000
2400
4400
2800
4800
TTW580
611
550
1100
2200
1650
2750
2200
3300
2750
5500
3300
6050
3850
6600
TABLE 9.1 COMBUSTION VENTILATION REQUIREMENTS TTW410 – TTW580
11.4 COOLING VENTILATION
When used as a type C appliance, cooling ventilation should be provided as follows:
MODEL
INPUT
(GROSS)
KW
INPUT
(NET)
KW
ENCLOSURE/COMPARTMENT
ENCLOSURE/COMPARTMENT
WATER HEATER
ROOM
(DIRECT TO OUTSIDE)
(TO INTERNAL SPACE)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
HIGH
(CM2)
LOW
(CM2)
TTW410
444
400
2000
2000
4000
4000
800
800
TTW580
611
550
2750
2750
5500
5500
1100
1100
TABLE 9.2 COOLING VENTILATION REQUIREMENTS
When used as a type B appliance, provision for cooling ventilation is included in the combustion ventilation
allowance.
Page 34
34
12.0 WATER CONNECTIONS
12.1 GENERAL
TTW water heaters require a minimum flow rate and must also be installed with separate storage vessels. Suitably
sized pumps and separate storage vessels are available from Lochinvar Limited as ancillary options.
To preserve the warranty on the appliance Lochinvar Limited insists on the use of glanded
pumps.
Recommended pipework layouts are available for different water heater and storage vessel combinations. Please
refer to www.lochinvar.ltd.uk for details.
The requirements of minimum water flow are given in Table 10.3. Recommendations for the water circulation
system are given in BS6644 and CP 342. The following notes are of particular importance.
1. When the unit is being utilised as a direct-fired water heater it is designed for use with a direct type
storage vessel. Contact Lochinvar Ltd for help in sizing the storage vessel
2. Circulating pipework not forming part of the useful heating surface should be insulated. Cisterns,
expansion vessels and pipework situated in areas exposed to freezing conditions should also be insulated.
3. Drain valves must be located in accessible positions that will permit draining of the entire system including
the unit and the storage vessel.
4. Tapping sizes for connection to the water system are detailed in Table 2.1.
5. Ideally, individual valves should be fitted to each unit to enable isolation from the system. The
arrangement must comply with the requirements of BS6644.
12.2 UNVENTED SYSTEM ARRANGEMENT
It is strongly recommended that unvented hot water systems be installed by an approved
installer.
If the Lochinvar TTW water heater is to be used in an unvented arrangement, the system should follow the guidance
given in BS6700 and must comply with Building Regulations 1992: Part G3,in England and Wales,P5 in Northern
Ireland and P3 in Scotland.. A kit of components that have been suitably sized for the unvented operation of the
appliance is available from Lochinvar Limited. For further information, please see our unvented/boosted systems
guide, available on our website.
The maximum working pressure of the water heater is 8.0 bar.
12.2.1 EXPANSION VESSEL SIZING
The following information is based on:
Working pressure of 3bar
Pressure relief valve setting of 6 bar
V V = S V * e
Expansion vessel efficiency =0.45
Where:
V V = Vessel Volume
S V = System Volume
e = Coefficient of Expansion (See Table 10.1)
FLOW
TEMP.
C
35
40
45
50
55
60
65
70
e
0.006
0.008
0.010
0.012
0.015
0.017
0.020
0.023
12.2.2 COEFFICIENT OF EXPANSION OF WATER AT 3.5 BAR INLET PRESSURE
Page 35
35
12.3 CIRCULATING PUMPS
In order to ensure the correct flow rates through the water heater, the unit requires a bronze glanded pump sized
to overcome the resistance of the TTW water heater and any primary pipework loop. Lochinvar will supply a
suitable bronze glanded shunt pump with every TTW water heater sized to overcome the resistance of the TTW
water heater plus the following primary pipework loop:
14 metres of pipe sized according to table 12.4.2
4 x 90 elbows
2 x Unions
2 x Full bore lever ball valves
2 x T fittings (cold feed and building return)
For installations with Longer Primary, pipework loops or a greater number of fittings please
contact Lochinvar Technical support before proceeding with any installation.
The specification of this type of pump ensures that the bronze body and associated parts in contact with water
are suitable for use with potable water. A glanded construction is required to ensure that any scale or deposits
within the system does not build up within the pump and cause a resistance that can lead to a loss of water flow.
Glandless (canned rotor pumps) must not be used with TTW water heaters due to the fact scale can quickly build
up on the rotor in hard water areas causing early and sudden failure not only of the pump but of the TTW water
heater as well.
The use of glandless (canned rotor pumps) will invalidate the warranty of the TTW water
heater
MATCHED PRIMARY CIRCULATION PUMP
PART NUMBER
Pump for models TTW410 & TTW580
LM900149A
12.4 PRIMARY PIPEWORK LOOP SIZING
The pipework header between the TTW water heater(s) and LST(s) buffer vessels must be
sized as per the guidance given in this section. Failure to use the correct pipework header size
will cause operational problems and potential early failure of the water heater: this will not
be covered under the water heater warranty.
If the installation is outside the scope of this guidance, please contact Lochinvar Technical
support before proceeding with the installation.
TTW410
TTW580
Minimum Water Flow
m3/hr
20.22
26.94
Pressure Loss – Heat Exchanger
m H2O
5.4
5.4
Pressure Loss – Internal Piping
m H2O
0.08
0.08
Pressure Loss – Water Flow Switch
m H2O
1.0
1.0
Pressure Loss – Total (Appliance)
m H2O
6.48
6.48
Differential Temperature – High Fire – nom.
K
17.7
18.3
Differential Temperature – High Fire – min.
K
15.6
16.2
Differential Temperature – High Fire – max.
K
19.8
20.4
12.4.1 CIRCULATION REQUIREMENTS
Using the example schematics shown in section 12.4.2 and assuming the TTW water heaters are TTW410 in both
cases the primary pipework header would be sized as:
Single unit = as there is only one TTW water heater there is no common header so all pipework should be sized as
per A blue at 76mm
Two units = the common header shown in red should be sized according to the table B-red at 108mm with the
pipework between each water heater and the header sized as per A-blue at 76mm.
Page 36
36
Model
Quantity
A-Blue
B-Red
TTW410
1
76mm
76mm
TTW410
2
76mm
108mm
TTW410
3
76mm
108mm
TTW410
4
76mm
*
TTW580
1
76mm
76mm
TTW580
2
76mm
108mm
TTW580
3
76mm
*
TTW580
4
76mm
*
* n/a contact Lochinvar Technical support for assistance
12.4.2 PIPEWORK HEADER SIZES FOR COMMON INSTALLATIONS
12.4.3 PIPEWORK SCHEMATICS
For applications outside the parameters shown, please contact Lochinvar TSG for further
guidance before proceeding with any installation.
A
A
A
B
Page 37
37
12.5 PRESSURE RELIEF VALVE
The Lochinvar TTW has no internal pressure relief valve. A pressure relief valve must be fitted in between the
water heater and any isolation valve. When multiple water heaters are installed, each water heater must have its
own pressure relief valve. It is recommended that the pressure relief valve is fitted in the T-piece supplied with
the water heater.
The lift pressure and size of the relief valve should be in accordance with BS6644
12.6 ANTI-GRAVITY LOOP
If the water heater is positioned at the highest point of the installation, the flow and return pipework must rise
500mm above the top of the heat exchanger; this will ensure water remains within the heat exchanger in the event
of water loss within the system. this will not be required if the DHW buffer vessel is fitted alongside the water
heater and is taller an automatic air vent should be installed in the top of the anti-gravity loop to ensure all airlocks in the system can be cleared.
12.7 AUTOMATIC AIR VENT
There is an automatic air vent mounted on the water heater to remove air from the water circuit. This automatic
air vent is only for releasing air trapped in the heat exchanger of the water heater. One or more external automatic
air vent(s) and air separators should be mounted in the heating system to bleed air trapped in the heating circuit.
12.8 FROST PROTECTION
The Lochinvar TTW has a built-in frost protection, automatically activating the primary pump when the water
heater return water temperature drops below 5°C. When the water heater water temperature drops to 3°C, the
burner is also ignited. The pump and/or burner will shut down as soon as the return temperature has reached 10°C.
The above-mentioned temperatures relate to the temperature measured with the inlet sensor of the water heater.
This Frost Protection provision is for the water heater only and does not protect the whole
system.
12.9 SYSTEM FLUSHING
The whole installation should always be thoroughly flushed before installing the water heater to remove any debris
that may have accumulated.
Page 38
38
13.0 CONTROL OPTIONS/INSTALLATION
13.1 VESSEL TEMPERATURE SENSOR SINGLE WATER HEATER INSTALLATION
TTW requires a flow temperature sensor that needs to be fitted between the cold feed/building return and the
storage vessel, this should be located as close as possible to the storage vessel on the return pipework to the water
heater(s)– see below drawings. This sensor is an ancillary item and should be ordered at the same time as the
water heater. If cascading the water heaters then only a single sensor is required, this sensor connects back to the
lead water heater. If not cascading the water heaters then each water heater will require a sensor – see section
14.0 Schematics.
The part number for the sensor is LE04016304
Flow Temperature Sensor Flow Temperature Sensor on pipework
Page 39
39
13.1 LOCATION OF FLOW TEMPERATURE SENSOR (FS) ON A SINGLE VESSEL
INSTALLATION
On systems with multiple storage vessels it is recommend that the water heaters only read the
temperature of a single vessel, the vessels should be balanced so they are all the same
temperature.
13.2 LOCATION OF FLOW TEMPERATURE SENSOR (FS) ON A MULTIPLE VESSEL
INSTALLATION
13.3 SENSOR WIRING
For guidance on installing the wiring for the temperature sensor, please refer to section 15.0
Page 40
40
14.0 SCHEMATICS
Lochinvar limited may provide technical advice and guidance to assist with best practice,
optimisation and installation of Lochinvar products; however, we will not be liable for any
duties as designers under construction (design and management regulations 2015). In all
cases where information is provided, the customer must assess and manage risks
associated with the technical information and advice provided.
When installing multiple units we would recommend cascading the water heaters, this will
then mean only a single flow temperature sensor is required connected back to the lead
water heater. If not cascading the water heaters then each water heater will require its own
flow temperature sensor see xxx for further information.
14.1 SINGLE WATER HEATER WITH SINGLE STORAGE VESSEL INSTALLATION
Page 41
41
14.2 MULTIPLE WATER HEATERS WITH MULTIPLE STORAGE VESSELS NOT IN
CASCADE
14.3 MULTIPLE WATER HEATERS WITH MULTIPLE STORAGE VESSELS IN CASCADE
Page 42
42
15.0 ELECTRICAL INSTALLATION
Wiring external to the equipment must be installed in accordance with the I.E.E. Regulations and any local regulations that apply.
MODEL
NORMAL SUPPLY VOLTAGE
EXTERNAL FUSE RATING
POWER CONSUMPTION
TTW410
230V AC/50 Hz
1 PH
6.0 A
752 W
TTW580
829 W
15.1.1 ELECTRICAL SUPPLY REQUIREMENTS
Warning: this appliance must be earthed
A suitably competent person MUST check wiring. Normal supply required is 230 volts AC, single phase, 50 Hz. An isolator
with a contact separation of at least 3mm in all poles should be sited close to the equipment and must only serve that
equipment. The double pole switch must be readily accessible under all conditions.
15.2 EXTERNAL CONTROLS
The TTW water heater control includes the following functions:
Cascade control for up to 6 TTW water heaters.
0-10 VDC analogue input from a BMS.
Pump control for the primary circulation pump.
Open-Therm communication for advanced temperature controllers.
The TTW water heater has connections for:
Remote fault indication from each burner
Remote “burner-on” indication from each burner.
Calorifier temperature sensor.
15.3 WIRING CONNECTIONS
15.3.1 ACCESSING WIRING CONNECTIONS
The connections are placed on top of the display panel. To access the wiring connections, the top-front control panel cover retaining screws
(located either side of the control panel) should be removed. The cover can then be lifted forward and away from the appliance. The top-rear
control panel cover can then be removed and the wiring terminals accessed.
Page 43
43
15.3.2 WIRING CONNECTIONS
The following components can be connected to the water heater; see the figure below.
For voltages from 110V to 250V use the left conduit and for low voltage use the right conduit.
15.3.3 WIRING TERMINALS
Page 44
44
TERMINAL
NUMBER
LABEL
DESCRIPTION
1-2
DO NOT USE
Do not connect any cables to these connections
3-4
TANK SENSOR
Connect the tank sensor to this connection. This external flow sensor measures the flow temperature at the
system side. The sensor must be mounted on the supply pipe at the system side, close to the tank. NOTICE:
The sensor must be used when several water heaters are cascaded with the internal cascade manager.
5-6
DO NOT USE
Do not connect any cables to these connections
7-8
GENERAL BLOCKING
This connection is used for the flow switch, a standard part for the TTW
9-10
EMPTY
N/A
11-12
EXTERNAL FLOW
WATER PRESSURE
SWITCH
A water pressure sensor is mounted in the water heater.
13-14
ON/OFF STAT,
OPEN THERM
HEATING CIRCUIT
This connection has the following options:
If 24 hour operation is required, a link wire should be fitted to terminals 13-14. The water heater will use
the set/programmed flow temperature for the heating circuit when these terminals are linked.
If an on/off thermostat and/or time programmer is to be used, they should be linked in series to these
terminals. When there is a closed circuit, the water heater will use the set/programmed flow
temperature for the heating circuit.
An OpenTherm communication bus can be used to connect to an advanced time and temperature controller
such as the Lochinvar RC Controller or EBC Controller. The controller will then communicate with the water
heater and determine the optimum flow temperature to achieve the desired room temperature. When an
external temperature sensor is connected, the water heater communicates the recorded temperature to the
controller and the compensation curve is adjusted automatically.
15-16
0 – 10 VDC
The water heater can be driven by an external control through a 0 to 10 VDC control signal. A voltage of less
than 1.4V gives no heat demand, 1.48 V gives minimum set point and 10V gives maximum set point.
NOTE: This connection is polarity sensitive therefore the 0 – 10V line must be connected to terminal 15 and
the 0V line to terminal 16. A link wire must not be connected to terminals 57 & 58 when 0 – 10V control is
used.
17-18
CASCADE
CONNECTION
The Lochinvar TTW water heater has a built in cascade management system. When two or more water heaters
are connected in a cascade, each water heater of the cascade has to be connected to the next water heater
using terminals 61 & 62. This connection is polarity sensitive (all terminals 61’s to be linked and all terminal 62’s
to be linked) and should be made using screened cable.
One water heater has to be appointed as a Master, while the other water heater(s) are the Slaves. All external
controls such as Calorifier sensor, external temperature sensor, system pumps etc. are to be connected to the
Master water heater.
For a cascade to work correctly, it is essential that an external flow temperature sensor is used.
In order for the cascade to work correctly, each connected water heater needs to be programmed with a
different address using a computer interface. For further details, please contact Lochinvar Limited.
19-20
LOCK OUT
TOP
This contact is N.O. (normally open max. 230 Vac, 0.8 A). When the unit is in lock-out this contact will close. This
contact can also be used for the switching of a pump with a separate control input connection.
21-22
BURNER RUNNING
TOP
This contact is N.O. (normally open max. 230 Vac 0,8 A). When the unit starts the burner and detects the flame,
this contact will be closed. This contact can also be used to control an external (extra) water heater. This contact
can also be used for the switching of a pump with a separate control input connection.
23-24
BURNER DEMAND
TOP
This contact is N.O. (normally open max. 230 Vac 0,8 A). When the unit receives any heat demand this contact
will close. This contact can also be used for the switching of a pump with a separate control input connection.
25-26
LOCK OUT
BOTTOM
This contact is N.O. (normally open max. 230 Vac, 0.8 A). When the unit is in lock-out this contact will close.
27-28
BURNER RUNNING
BOTTOM
This contact is N.O. (normally open max. 230 Vac 0,8 A). When the unit starts the burner and detects the flame,
this contact will be closed. This contact can also be used to control an external (extra) water heater.
29-30
BURNER DEMAND
BOTTOM
This contact is N.O. (normally open max. 230 Vac 0,8 A). When the unit receives any heat demand this contact
will close.
29-30
BURNER DEMAND
BOTTOM
This contact is N.O. (normally open max. 230 Vac 0,8 A). When the unit receives any heat demand this contact
will close.
34-35-36
DO NOT USE
Do not connect any cables to these connections
37-38-39-40
DO NOT USE
Do not connect any cables to these connections
41-42-43
POWER SUPPLY
230VAC
This connection is pre-wired and should not be altered. Where a 3-phase supply is used, the water heater
must have a 16 A fuse per phase. See Section 11.2.3: MAINS SUPPLY CONNECTION – THREE PHASE SUPPLY
or Section 11.2.4: MAINS SUPPLY CONNECTION – SINGLE PHASE SUPPLY for details on the incoming supply
connection.
15.3.4 WIRING TERMINALS
Page 45
45
15.4 MAINS SUPPLY CONNECTION – THREE-PHASE SUPPLY.
15.4.1 3-PHASE ELECTRICAL SUPPLY CONNECTION
When using a 3-Phase circulating pump, a 400 VAC/50 Hz/3 Ph/N/GND power supply should be connected to the rail-mounted terminal blocks
located to the rear of the wiring connection panel via a suitable isolator. The 230 VAC power supplies to the control panel are already connected
and should not be altered.
The 400 VAC/50 Hz/3 Ph pump should be connected to the relay adjacent to the terminal blocks. An overload protection device should be
installed in accordance with BS7671.
15.5 MAINS SUPPLY CONNECTION – SINGLE PHASE SUPPLY
15.5.1 SINGLE PHASE ELECTRICAL SUPPLY CONNECTION
When using a 1-Phase circulating pump, a 230 VAC/50 Hz/1 Ph/N/GND power supply should be connected to the rail-mounted terminal blocks
located to the rear of the wiring connection panel via a suitable isolator. The 230 VAC power supplies to the control panel are already connected
and should not be altered.
The 230 VAC/50 Hz/1 Ph pump should be connected to the relay adjacent to the terminal blocks. An overload protection device should be
installed in accordance with BS7671.
15.6 FUSES
On each PCB are 2 fuses, four fuses in total
FUSE NO.
APPLICATION
FUSED VALUE
FUSE TYPE
F1
Pump1
Pump2 / TWV
250VAC5ATH
5 AT ceramic filled fuse
F2
Switch mode supply,Gas valve
Pump3,External Ignition
250VAC5ATH
5 AT ceramic filled fuse
15.6.1 FUSES
Page 46
46
15.7 WIRING DIAGRAMS
EMPTY
CN15
A B
CASCADE
CONNECTION
1817
EXTERNAL
WPS
12111098
7
TANK
SENSOR
N.O. N.O.N.O.
LOCK-OUT
HEAT
DEMAND
242322
GENERAL
BLOCKING
1 2 3
4 5
6 13 14 15 16 19 20 21 41 42 43
On/Off Stat
or
OpenTherm
Heating
Circuit
+ 0 - 10
VDC
BURNER
BURNING
2
3
4
5
6
7816
15
14
13
12
11
10
1
91718
18179
1
Gnd
out
Gnd
out
[open] 3-way, L' (NC)
Pump 2 / 3-way, N'
Pump 2 / 3-way, L' (NO)
Pump 1, N'
Pump 1, L'
Gas Valve, L'
Gas Valve, N'
Pump 3, L'
Pump 3, N'
Flame on NO
Lock-Out NO
Flame on NO
Lock-Out NO
1413121110
9
8
765
432
1
12
11
10
9
8
7
6
5
4
3
2
1
10
11
12
13
14
15
1687
6
5
4
3
2
CN11
CN10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
34567
8
9
1011121314
CN12
CN3 CN1 CN5
flow sensor ntc (S1) 10K
return sensor ntc (S2) 10K
flue sensor ntc (S6) 10K
clixon/maximum (S7)
water thermostat 24vdc
Non Return Valve NRV
end contact
siphon pressure switch (PSW)
+24Vdc
fan Hall
fan PWM
fan control
+5V
External ignition transformer, L
Heat demand NO
CN6
display
CN7
CN8
separate ionisation
input. (always active)
ionistion and/or ignition
Heat demand NO
gas valve(s)
N
[close]
N.C.
N.C.
ref.1
internal
connections
internal
connections
FAN
24Vdc
K2
K6
K5
K5
K3
K3
K0
K0
K8
K8
K6
K6
K8
K7
K7
K4
K8
K3
K6
K8
K2
K9
K9
K9
K5
1 2 4
3 5 6
7
653
421 7
653
421
+
K4
K4
K2
K2
K2
K2
ref.1
K1
K1
K7
K8
K7
K7
K3
K5
K7
K6
K0
K8
K8
K6
K3
K6
Rear wall thermal fuse
K7
K7
TOP
K6
K2
WIRING COLORS
K0=white K6=blue
K1=yellow K7=red
K2=brown K8=black
K3=green K9=purple
K4=grey K10=yellow/green
K5=orange
not used
not used
N.C.
Burner door thermal switch
N.C.
K7
K2
flow switch
Com 1
N.O. 3
only when unit is
cascaded
to
slave
boiler
to
master
boiler
water pressure
switch
Tank sensor 10K
Heat demand
N.O.
Flame on
N.O.
Lock-out
N.O.
connection
examples
OpenTherm/
on-off thermostat
Remote temperature
setpoint or burner input
DO NOT USE
DO NOT USE
water pressure switch
water pressure sensor
connection (not used)
(Standard part of
the Senator)
Page 47
47
15.7.1 UPPER BURNER WIRING DIAGRAM (PCB A, LEFT)
15.7.2 UPPER BURNER CONTROL
40393837
A B
CASCADE
CONNECTION
1817
N.O. N.O.N.O.
LOCK-OUT
HEAT
DEMAND
242322
BURNER
BURNING
L N
[open] 3-way, L' (NC)
Pump 2 / 3-way, N'
Pump 2 / 3-way, L' (NO)
Pump 1, N'
Pump 1, L'
Gas Valve, L'
Gas Valve, N'
Pump 3, L'
Pump 3, N'
Flame on NO
Lock-Out NO
Flame on NO
Lock-Out NO
MAINS N'
MAINS L'
CN3 CN1 CN5
External ignition transformer, L
External ignition transformer, N
Heat demand NO
T2
ignition
transformer incl.
ionisation input.
CN8
separate ionisation
input. (always active)
Heat demand NO
N
[close]
CN10
boiler casing
F1F2
fuse 1
fuse 2
Room thermostat (L')
Room thermostat (in)
FAN
K7
K4
K8
K3
K6
K8
K2
K6
K2
K2
K6
K9
K5
1 2 4
3 5 6
7
653
421 7
653
421
8 9 10
CN not used
CN4
K10
K10
K10
K10
K10
230Vac mains
(internal)
cascade
connection
34 35 36
L N
DO NOT USE
K6
K2
WIRING COLORS
K0=white K6=blue
K1=yellow K7=red
K2=brown K8=black
K3=green K9=purple
K4=grey K10=yellow/green
K5=orange
INTERNAL
MAIN POWER
CONNECTOR
pump relay
K2
K6
only when unit is
cascaded
to
slave
boiler
to
master
boiler
connection
examples
POWER
SUPPLY
Heat demand
N.O.
Flame on
N.O.
Lock-out
N.O.
L1 N L2
DO NOT USE
Page 48
48
CN15
30292825 26 27
2
3
4
5
6
7816
15
14
13
12
11
10
1
91718
18179
1
[open] 3-way, L' (NC)
Pump 2 / 3-way, N'
Pump 2 / 3-way, L' (NO)
Pump 1, N'
Pump 1, L'
Gas Valve, L'
Gas Valve, N'
Pump 3, L'
Pump 3, N'
Flame on NO
Lock-Out NO
Flame on NO
Lock-Out NO
1413121110
9
8
76543
2
1
12
11
10
9
8
7
6
5
4
3
2
1
10
11
12
13
14
15
1687
6
5
4
3
2
CN11
CN10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
34567
8
9
1011121314
CN12
CN3 CN1 CN5
flow sensor ntc (S1) 10K
return sensor ntc (S2) 10K
clixon/maximum (S7)
water thermostat 24vdc
Non Return Valve NRV
end contact
+24Vdc
fan Hall
fan PWM
fan control
Heat demand NO
CN6
display
CN7
CN8
separate ionisation
input. (always active)
ionisation and/or
ignition
Heat demand NO
gas valve(s)
[close]
N.C.
internal
connections
internal
connections
FAN
24Vdc
K2
K6
K5
K5
K3
K3
K8
K7
K7
K4
K8
K3
K9
K5
1 2 4
3 5 6
7
653
421 7
421
K1
K1
K7
K6
K0
K8
bottom
230Vac mains
(internal)
cascade
connection
WIRING COLORS
K0=white K6=blue
K1=yellow K7=red
K2=brown K8=black
K3=green K9=purple
K4=grey K10=yellow/green
K5=orange
not used
N.O. N.O.N.O.
LOCK-OUT
HEAT
DEMAND
BURNER
BURNING
shielding
Rear wall thermal fuse
N.C.
Burner door thermal switch
N.C.
K7
K7
K7
Mains 230 V 1 / 400 V 3
L1 L2 L3 N
Pump connection 1 / 3 (opt.)
L1 L2 L3 N
Pump relay
(internal)
pump relay
230Vac mains
(supply)
K8
K4
K2
K2
K6
K10
K6
Heat demand
N.O.
Flame on
N.O.
Lock-out
N.O.
connection
examples
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49
15.7.3 LOWER BURNER WIRING DIAGRAM (PCB B, RIGHT)
15.7.4 LOWER BURNER CONTROL
30292825 26 27
[open] 3-way, L' (NC)
Pump 2 / 3-way, N'
Pump 2 / 3-way, L' (NO)
Pump 1, N'
Pump 1, L'
Gas Valve, L'
Gas Valve, N'
Pump 3, L'
Pump 3, N'
Flame on NO
Lock-Out NO
Flame on NO
Lock-Out NO
MAINS N'
MAINS L'
CN3 CN1 CN5
External ignition transformer, L
External ignition transformer, N
Heat demand NO
T2
ignition
transformer incl.
ionisation input.
CN8
separate ionisation
input. (always active)
Heat demand NO
[close]
CN10
boiler casing
F1F2
fuse 1
fuse 2
Room thermostat (L')
Room thermostat (in)
FAN
K7
K4
K8
K3
K6
K2
K2
K6
K9
K5
1 2 4
3 5 6
7
653
421 7
653
421
8 9 10
CN not used
CN4
K10
K10
K10
WIRING COLORS
K0=white K6=blue
K1=yellow K7=red
K2=brown K8=black
K3=green K9=purple
K4=grey K10=yellow/green
K5=orange
N.O. N.O.N.O.
LOCK-OUT
HEAT
DEMAND
BURNER
BURNING
Heat demand
N.O.
Flame on
N.O.
Lock-out
N.O.
connection
examples
connection
examples
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50
15.8 SENSOR VALUES
The following temperature sensors have been fitted in the Lochinvar TTW. Sensors S1 and S2 are located on the rear right-hand side of the heat
exchanger with one of each connected to each burner control.
S1 = Flow temperature sensor (orange wire)
S2 = Return temperature sensor (green wire)
S3 = External flow temperature sensor
S6 = Flue sensor (white wire)
(S3¹) = if terminals S3 are not connected, the average value of S1 top and S1 bottom is taken and this value will be displayed.
The sensors used in the Lochinvar TTW are NTC (Negative Temperature Control) type and should have the following values:
SENSOR 1, 2, 3, 6
TEMPERATURE
[°C]
RESISTANCE
[OHM]
0
32555
5
25339
10
19873
15
15699
20
12488
25
10000
30
8059
35
6535
40
5330
45
4372
50
3605
55
2989
60
2490
65
2084
70
1753
75
1481
80
1256
85
1070
90
915
95
786
15.8.1 SENSOR VALUES
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16.0 CONTROL SYSTEM
16.1 CONTROL PANEL
Two control panels have been placed on top of each other.
The top panel controls the burner at the top of the heat exchanger and is the “master”. This panel controls the complete water heater. Only
when a lock out / error of the top burner has occurred, the water heater can be controlled by the bottom panel of the water heater
(automatically).
COMM.
PORT
SERVICE
ON/OFF
RESET
ENTER
MENU
COMM.
PORT
MENU
ON/OFF
RESET
ENTER
SERVICE
CONTROL PANEL
DISPLAY
2 rows/ each 20 characters
Press and hold for three seconds for stand-by/program. mode
Press and hold for six seconds to switch boiler on/off.
Used as RESET and ENTER button when programming.
Connector for connecting computer cable.
Button is pushed to open MENU.
Buttons to toggle through measured temperatures.
Also used for navigating through the menus and for changing values.
Button to activate service function
(hold for three seconds).
Schornsteinfeger function (only for Germany).
Light: lights when controller detects good flame signal.
Lights when burner is burning.
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52
FIGURE 12.1 CONTROL PANEL
16.2 CONTROL PANEL / MENU STRUCTURE
BASE SCREEN : (appears during operation)
WTRHTR : No demand / Standby / burning
> > > : 1 1 8 ° C ( 1 2 5 ° C )
1. view data
press: ◄►
"MONITOR" screens
One can toggle through the measured values and
status of the heater.
Pressing "ON/OFF, RESET, ENTER" briefly will cause
the display to go back to the base menu.
When no button has been pressed for three minutes
the display will automatically go to the BASE
DISPLAY.
(This period can be set by a parameter).
Display shows 2x20 digit message for
three seconds.
Message can be set in parameters.
example:
Company name
City, Country
press: ▲
Display shows for three seconds:
- Heater type
- Time, date and day
example:
Z-FG 550 13:51 US (or EU)
06 / 01 / 2010 Wed
After this message the display shows for 3
seconds:
- Software version and
- Cascade designation
example:
Firmware : Mk 00197
Address : 0
press: ▼
These three messages will also show
when:
- Heater is connected to the power
- When heater is turned ON
- When heater is turned OFF
sequence:
The messages will show from TOP to
BOTTOM each for three seconds.
press: MENU
1
2
2. press [ON/OFF] for
± three seconds to
programme in standby mode
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53
By pressing (◄ ►) one can
toggle though the available
menus.
"USER LOCK" menu
In this menu one can lock the menu for users
0= UNLOCKED
1= LOCKED
When un-locked the user can enter the
"MENU" by pressing the menu
button and all submenus will show.
When locked the user has to push the : MENU
and simultaneously
press ▼ for 6 seconds to get access to all
submenus.
This is to prevent accidental changes!
NOTE: The parameters sub menu can always
be accessed.
"MAINTENANCE" menu
By pressing (◄ ►
) one can set the following
options:
- Maintenance reset
- Maintenance Mode
- All
- Date
- Ignition cycles
- Burning hours
- Mainten Off
"SETPOINT" menu
In this menu one can change temperature
settings without the need for a password.
- Hot water set point
Calorifier or Water heater (depends on heater
type)
- Hot water reduced
The amount of degrees diff. relative to "Hot
water set point" during night reduction.
- Local set point water heater
The temperature of the hot water supply from
the DHW appliance
to the tank is set here.
"PROGRAM" menu
In this menu one can set the DHW and Anti
Legionella program.
"OPERATING HISTORY" menu
Shows burning hours DHW, etc.
"FAULT HISTORY" menu
press:
▼ Reading last fifteen faults (only
reading!).
"TIME/DATE/DAY" menu
In this menu one can set the time and the date.
"PARAMETER" menu
In this menu one can change parameters. The
possible access
depends on the password that is used.
HOW TO CONFIRM CHANGES
When changes have been made in one of the nine menus below, the user presses
ENTER to confirm these changes.
To prevent anyone from making changes by mistake, the following happens when
changes are made:
Step 1: The user presses [ENTER] to confirm the change made
or [MENU] to exit the menu without changes.
HINT: First programme all changes
planned, then only after that, press [ENTER]
Step 2:
The display asks the user to be sure to make these changes. The user can
cancel or confirm by using the left and right arrows.
CANCEL = ◄ CONFIRM = ►
Enter password
Enter PW Level 1:
three second message
confirming access:
LEVEL 1
Enter PW Level 2:
three second message
confirming access:
LEVEL 2
parameter menu
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16.3 DISPLAY DURING OPERATION
During normal operation, the text in the display shows the status of the water heater. In the following graphs, the displays during normal
operation are explained.
Display at WATER HEATER / HOT WATER DEMAND
Heat demand type:
Actual status:
W A T R H T R : S T A N D
- B Y
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
cascade
communication indicator
temp. set point water
temp.
measured temp.control.sens.
showing the measured temp.
Can be turned off by P5 BJ
Explanation "Actual status" screen
Actual status:
B o i l e r o f f
When water heater is switched off (only text in the display during this status).
N o d e m a n d
No heat demand signal coming from the room themostat and calorifier sensor (open).
S t a n d
- b y
Room themostat & calorifier sensor/themostat detect heat demand but set point is reached.
P r e
- p u r g e
The fan is purging before a burner start attempt.
P r e
- i g n i t i o n
Ignition starts before opening of the gas valve.
I g n i t i o n
The igniter is igniting.
P o s t - p u r g e
The fan is purging after burner is switched off.
B u r n i n g 1 0 0
%
When the burner is firing, also the actual rpm% is shown.
Explanation "Cascade communication indicator"
NO CASCADE COMMUNICATION
> > >
no.1
Always showing the fixed ">>>"
CORRECT CASCADE COMMUNICATION
> >
no.1
no.2
>
Showing alternating no.1 & no.2 with 1 second interval.
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55
16.4 MONITOR SCREENS
During normal operation and stand-by, the “◄” and “►” buttons can be used to show some water heater information, including measured
temperatures, settings and data. In the following graphs is explained which values can be shown in the display. When no button is activated for
2 minutes, the display will return to its status display.
Pressing [◄] or [►] while being at the "operating screen" toggles through the screens below.
When pressing [ON/OFF, RESET, ENTER] or [MENU] at any time the display returns to the base menu.
SCREEN: 1
T 1 F l o w 1 2 3 , 9 ° C Measured value by the internal flow sensor.
T 2 R e t u r n 1 2 3 , 9 ° C Measured value by the internal return sensor.
O p e n
Shown when controller doesn’t detect this sensor.
S h o r t e d
Shown when sensor wires or sensor itself is shorted.
SCREEN: 2
T 3 E x t e r n a l 1 2 3 , 9 ° C Measured value by the external sensor.
T 4 C a l o r i f i 1 2 3 , 9 ° C Measured value by the calorifier sensor.
O p e n
Shown when controller doesn’t detect this sensor.
S h o r t e d
Shown when sensor wires or sensor itself is shorted.
SCREEN: 3
T 5 O u t d o o r 1 2 3 , 9 ° C Measured value by the outdoor sensor.
T 6 F l u e 1 2 3 , 9 ° C Measured value by the flue gas sensor.
O p e n
Shown when controller doesn’t detect this sensor.
S h o r t e d
Shown when sensor wires or sensor itself is shorted.
SCREEN: 4
d T F l o w R e t u r n 1 2 3 , 9 °
C
Temp. difference between internal flow & return
sensor.
d T F l u e R e t u r n 1 2 3 , 9 °
C
Temp. difference between flue gas & internal return
sensor.
SCREEN: 5
Temp. difference between external & internal return
(ΔT LLH).
d T E x t R e t u r n 1 2 3 , 9 ° C S i g n a l P o w e r External supplied 0-10 Volt dc signal.
S e t p o
i
"Power" = power input control or "Setpoi" = set point
control.
SCREEN: 6
F a n s p e e d 9 9 9 9 r p m Actual fan speed in rpm.
F a n s p e e d 1 0 0 % Actual fan speed % of maximum allowable fan speed.
The maximum RPM may be lower than the maximum RPM set point. The fan may not be able to reach the maximum
RPM set point due to the resistance in the unit, this is still correct according to the design of the unit.
SCREEN: 7
F l a m e s i g n a l 1 0 0 μ A Flame signal given in μA.
W a t e r P r e s s u r 1 , 0 b a r Shows water pressure when sensor is connected.
SCREEN: 8
P u m p 1 H e a t e r O f f Pump 1 (HEATER PUMP) On or Off.
P u m p 1 S i g n a l 1 0 0 % Modulating signal Pump 1 in (%).
SCREEN: 9
P u m p 2 C a l o r i O f f Shows when the calorifier pump is "ON" or "OF".
3 - w a y V a l v e H e a t i n g
Signal to the 3-way valve: "HEATING" or
"HOTWATER".
SCREEN: 10
P u m p 3 S y s t e m O f f Shows when the system pump is "ON" or "OF".
h h : m m D D / M M / Y Y Y Y D a y
hh=hour; mm=minutes; DD=day; MM=month;
YYYY=yr; Day of the week
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SCREEN: 11
C a s c D e s i g n 0 0 = MASTER, 1 ..... 11 = SLAVES
C a s I n f 0 1 2 3 4 5 6 7 8 9 A
B
Displays number, priority and state of cascade water
heaters.
DESCRIPTION "CASCINFO" Screen 11
Shows the number of water heaters connected with the Cascade. The Master/Lead water heater is designated as 0. Slave/Lag water
heaters will be designated 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B. When a “-“ is used instead of a number, than that water heater is either not
connected, or in a lockout mode and not available for the Cascade. When an “x“ is used instead of a number, than that water heater is
connected, but in lockout mode.
When a “d” is used instead of a number, than that water heater is handling a DHW demand.
When the number is flashing, then that water heater is providing heat to the cascade. When the leading water heater is changed
according to the set priority change time, than that water heater’s address will be shown first in the row of numbers.
Example 1: "3 4 5 - - - - - - 0 1 2"
There are six water heaters present and nr. 3 has priority.
Example 2: "3 4 x - - - - - - d 1 2"
There are six water heaters present and nr. 3 has priority. Water heater 0 is heating up an indirect DHW tank. Water heater 5 is present,
but in a lock-out.
SCREEN: 12
C a s c P o w e r 9 9 9 % 9 9 9 % % heat demand of total (cascade) power available (%).
D u a l B u r n e r : N o Heat exchanger equipped with two burners: "Yes" or "No".
SCREEN: 13
M a x T h e r m O p e n Status of the maximum thermostat: "Open" or "Closed".
G e n B l o c k C l o s e d Status of the general blocking contact: "Open" or "Closed".
SCREEN: 14
S i p h o n p r e s s C l o s e d Status of the siphon pressure switch: "Open" or "Closed".
N R V C o n t a c t O p e n Status of the non-return valve contact: "Open" or "Closed".
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16.5 SERVICE FUNCTION
The following graphs describe how to use the service function.
Operating screen:
W A T R H T R : S T A N D - B Y
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Press [SERVICE] and hold for 3 seconds.
The burner will start and show the display below.
Operating screen:
W A T R H T R : S e r v i c e 2 6
%
> > > 7 5 . 0 ° C ( 6 0 . 0 ° C
)
"WATRHTR": It is a water heater.
"Service": It is operating in service mode.
"26%": The burner is firing at 26%.
"75,0oC": Max. allowable water temp. during service.
"60,0oC": Actual measured water temp. (when P5BJ active).
Press [SERVICE] to exit. The unit will go to the operating screen. Press 3 s.
[ON/OFF] to exit. The unit will be switched off.
By using the [▲] & [▼] buttons the burner firing rate% can be changed.
Press [MENU] to access the main menu.
Press [MENU] to return to the service menu.
Use [◄] & [►] buttons to browse through the monitor screens.
Press [MENU] to go to the operation menu of the service mode.
Press [SERVICE] to exit the service mode.
The unit will return to the standard operation display.
16.6 SCHORNSTEINFEGER FUNCTION
For use in Germany only
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16.7 PROGRAMMING IN STANDBY MODE
Standby
Programming the settings of the water heater is done at the control panel of the top burner, this is the left panel.
Use the standby mode for modifying water heater settings without interaction with the water heater control. Changes are confirmed by leaving
standby mode.
Properties of standby mode:
Keys are active and the menu is accessible.
Burner does NOT respond to an external heat demand.
All control functions are ON: pumps, fans and cascade are operational; recirculation and frost protection are active.
How to programme the water heater:
Disconnect or shut down the DHW thermostat and/or other external controllers from the water heater. The pump and fan will stop
after a short time.
Switch the water heater in standby mode by pressing [ON/OFF] for three seconds.
The next display screen should appear:
Display message
W A T R H T R : b o i l e r o f f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Programme the water heater at the control panel (see the following sections).
Terminate programming mode by pressing [MENU], or [ENTER] and NO ◄ or YES ►.
Reactivate the water heater by pressing [ON/OFF] for three seconds again.
16.8 SETTING TIME & DATE
The following graphs describe how to program time and date of the unit.
Operating screen:
W A T R H T R : b o i l e r o f f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
) Press [MENU]
Main menu screen:
M a i n M e n u
C l o c k
The display shows "CLOCK" press [ENTER]
Setting Time and Date:
S e t t i m e / d a t e 0 8 : 3 3 3 0 / 0 3 / 2 0 1 0 T u e
The day is now blinking/selected and can be changed.
Use [▲] & [▼] to change the value.
Use [◄] & [►] to select another value.
Press [ENTER] for the confirmation screen after all changes are done.
Confirmation screen:
A r e y o u s u r e
< C a n c e l ; > C o n f i r m
Press [◄] to cancel the changes made (display goes back to operating screen).
Press [►] to confirm the changes made. The time and day will start blinking
for a few seconds. After this, the display returns to its operating screen.
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16.9 SET POINTS
The following graphs describe how to program the hot water set points.
DHW set point normal/day time: (parameter P4 AA = 1/2)
D H W s e t p o i n t
6 0 ° C
This is the water temperature set point that is active during the
programmed DHW periods (parameter P4 AA = 1/2)
DHW set point reduction: (parameter P4 AA = 1/2)
D H W R e d u c e
1 0 ° C
The reduction of the normal/day time set point. This reduction is used
outside the programmed DHW periods.
Max. set point flow temperature (parameter P4 AA = 2 and
P5 DJ&DK =1)
H e a t i n g s e t p o i n t
7 5 ° C
This parameter is the local setpoint of the water heater and is regulated
on sensor S1 (parameter P4 AA = 2, P5 DJ = 1 and P5 DK =1 ).
16.10 SETTING THE TIMER PROGRAMS
Two different programs can be set with the water heater, these are:
DHW program
Anti-Legionnaires’ disease (pasteurisation) program
16.10.1 STARTING THE TIMER PROGRAMS
Three programmed periods each day can be set (period 1, 2 and 3). During this period the unit will use the normal DHW set point. Outside the
programmed period(s) the unit will use the reduced temperature as set point. When no time is programmed for a period, it will not be used.
(Example no time programmed in period 3 on Monday > "Mon 3 --:-- ---:--").
Operating screen:
W A T R H T R : b o i l e r o f f > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Press [MENU]
Select "Timer" using [◄] & [►] and press [ENTER]
Main menu screen:
M a i n M e n u
T i m e r
Press [ENTER]
Setting CH program times:
P r o g r a m C H M o n 1 0 6 : 0 0 - 2 3 : 0 0
Press [◄] for next SCREEN
> > > Continue on next page HOT WATER program < < <
The maximum actual DHW
temperature will never exceed the
value set at heating setpoint
regardless of the DHW setpoint. If
the DHW setpoint needs to be
higher than the heating setpoint,
the heating setpoint will need to be
increased to match.
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60
16.11 HOT WATER PROGRAM
> > > From previous page < < <
Setting DHW program times:
P r o g r a m D H W
M o n 1 0 6 : 0 0 - 2 3 : 0 0
Press [►] to browse through the values that can be set at the bottom line. The
blinking value can be changed.
Press [▲] & [▼] to change the selected (blinking) value.
Press [ENTER] for confirmation screen when all settings are done.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r m
Press [◄] to cancel the changes made (unit will reset).
Press [►] to confirm the changes. The last alternation will be blinking for a
few seconds and return to base menu.
Press [MENU] to exit. The water heater will reset and go to the operating screen.
Press [◄] for next SCREEN
Copy programmed day for DHW:
C o p y f r o m : D H W M o
n
C
o p y t o : D H W T u e
Press [►] to switch between "Copy from" and "Copy to". The blinking day is selected
and can be changed.
Press [▲] & [▼] to change the selected (blinking) value.
Press [ENTER] for confirmation screen when all settings are done.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r m Press [◄] to cancel the changes made (unit will reset).
Press [►] to confirm the changes. The two days will blink for a moment.
Press [MENU] to exit. The water heater will reset and go to the operating screen.
Press [◄] for next SCREEN
> > > Continue on next page LEGIONELLA program < < <
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16.12 ANTI LEGIONNAIRES’ DISEASE PROGRAM
See the following graphs. The standard factory setting for this function is “OFF”.
> > > From previous page with HOT WATER part < < <
Setting legionella program (day and time):
P r o g r a m L e g i o n e l l a
M o n 0 9 : 5 1
Press [►] to browse through the values that can be set at the bottom
line. The blinking value can be changed.
Press [▲] & [▼] to change the selected (blinking) value.
Press [ENTER] for confirmation screen when all settings are done.
Confirmation screen:
A r e y o u s u r e
< C a n c e l ; > C o n f i r m Press [◄] to cancel the changes made (unit will reset).
Press [►] to confirm the changes. The last alternation will be blinking for
a few seconds and return to base menu.
Press [MENU] to exit. The water heater will reset and go to the operating
screen.
Press [◄] for next SCREEN
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16.13 CHECKING THE OPERATING HISTORY
The following graphs describe how to check the operating history of the water heater.
Operating screen:
W A T R H T R : b o i l e r o f f > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C )
Press [MENU]
Select "Operate" using [◄] & [►] and press [ENTER]
Main menu screen:
M a i n M e n u
O p e r a t e
Press [◄] & [►] to browse through the 5 screens.
Press [MENU] or [ENTER] to exit. The unit will return to the operating screen.
SCREEN: 1
O p e r a t i n g h i s t o r y
P o w e r O n h r s 1 3 1 4 0 0 Top line: Shows the operating history menu is activated.
Bottom line: Total hours the water heater is connected to power supply and
switched on.
SCREEN: 2
h r s C h T o t 1 0 0 0 0 0 0 h r s D h w T o t 1 0 0 0 0 0 0 Top line: Total burning hours for heating.
Bottom line: Total burning hours for domestic hot water.
SCREEN: 3
h r s C h < 5 0 % 1 0 0 0 0 0 0 h r s C h = > 5 0 % 1 0 0 0 0 0 0 Top line: Burning hours for heating while the burner was firing less than 50%.
Bottom line: Burning hours for heating while the burner was firing equal or
higher than 50%.
SCREEN: 4
h r s D h w < 5 0 % : 1 0 0 0 0 0 0 h r s D h w = > 5 0 % : 1 0 0 0 0 0 0
Top line: Burning hours for hot water while the burner was firing less than
50%.
Bottom line: Burning hours for hot water while the burner was firing equal or
higher than 50%.
SCREEN: 5
T i a 1 0 0 0 0 0 F i a 1 0 0 0 0 0 S s l 1 0 0 0 0 0 S s t 1 0 0 0 0 6
Top line: Shows Total Ignition Attempts (Tia) & Failed Ignition Attempts (Fia)
Bottom line: Shows Soft Starts last (Ssl) &
Soft Starts Total (Sst)
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16.14 CHECKING THE FAULT HISTORY
The following graphs describe how to check the fault history of the water heater.
Operating screen:
W A T R H T R : b o i l e r o f f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
) Press [MENU]
Select "Faulthist" using [◄] & [►] and press [ENTER]
F a u l t h i s t N o . 0
1
2 1 / 0 4 / 2 0 1 0 W e d 2 2 : 2 3
A
▲ blinking alternately ▼
S i p h o n S w i t c h
S v 9 9 9 / C U M 9 9 9 / R 9 9 9 9 ,
5
Press [◄] & [►] to browse through the last 10 faults.
Press [MENU] or [ENTER] to exit. The unit will return to the operating
The fault menu shows the last 10 faults. For each fault the display blinks
between the two screens shown above. The top line of the top screen
shows the fault number and the bottom line of the top screen shows the
date, day and time the fault occurred.
On the top line of the bottom screen the fault type is displayed. The
bottom line shows the following:
SV: The total amount of this fault that has occurred after the last time
that the service history was erased (after service was done).
CUM: The total amount of this fault. The total amount cannot be erased
after service, this shows the fault history of the water heater (electronics)
since the start of operation.
R: Shows the elapsed time in hrs between the moment the fault occurred
and the moment it was reset.
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16.15 SETTING THE MAINTENANCE SPECIFICATIONS
16.15.1 MAINTENANCE SETTINGS
The unit can be programmed in such a way that an automatic maintenance message is displayed.
There are three options that can be selected. A maintenance message appears after:
* A programmed date is reached.
* An amount of burning hours is reached.
* An amount of ignition cycles is reached.
One single option can be activated or all three options.
Operating screen:
W A T R H T R : b o i l e r o f f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Press [MENU]
Select "Maintenan" using [◄] & [►] and press [ENTER]
Operating screen:
M a i n t e n R e s e t
Press [▲] to reset the:
Counter for the total amount of burning hours.
Counter for the total amount of ignition cycles.
(The text will blink once briefly after resetting).
Operating screen:
M a i n t e n M o d e
Blinking second line.
What is blinking at the second line (before a selection is made) is the active maintenance
option.
Press [▲] or [▼] to change the selected
blinking option.
Screen: Selecting of all maintenance options.
M a i n t e n M o d e
A l l
Press [►] to set:
The option that is blinking can be changed using by [▲] & [▼]
* Date for the Maintenance message.
* Total amount of burning hours for the Maintenance message.
* Total amount of ignition cycles for the Maintenance message.
After selecting one of these values the water heater returns to the
maintenance operating screen.
Press [ENTER] to confirm the changes.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r
m
Press [◄] to cancel the changes or [►] to confirm the changes.
Hereafter the water heater returns to the operating screen.
Go to next page
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65
From previous page
Screen: Selecting message at certain date.
M a i n t e n M o d e
D a t e
Press [►] to set:
The date for the maintenance message.
Press [◄] to:
Return to maintenance mode selection.
Press [►] to browse through the values that can be set
at the bottom line.
The blinking value can be changed with [▲] & [▼]
Press [ENTER] to confirm the changes.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r
m
Press [◄] to cancel the changes or [►] to confirm the changes.
Hereafter the water heater returns to the operating screen.
Screen: Message after total amount of ignition cycles.
M a i n t e n M o d e
I g n i t i o n c y c l e s
Press [►] to set:
The total amount of ignition cycles for the Maintenance message.
Press [◄] to:
Return to maintenance mode selection.
The blinking value can be changed with [▲] & [▼]
Press [ENTER] to confirm the changes.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r
m
Press [◄] to cancel the changes or [►] to confirm the changes.
Hereafter the water heater returns to the operating screen.
Go to next
page
Page 66
66
From previous page
Screen: Message after total amount of burning hours.
M a i n t e n M o d e
B u r n i n g h o u r s
Press [►] to set:
The total amount of burning hours for the Maintenance message.
Press [◄] to:
Return to maintenance mode selection.
The blinking value can be changed with [▲] & [▼]
Press [ENTER] to confirm the changes.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r
m
Press [◄] to cancel the changes or [►] to confirm the changes.
Hereafter the water heater returns to the operating screen.
Screen: No maintenance message will be displayed.
M a i n t e n M o d e
M a i n t e n O f f
Press [ENTER] to confirm the changes.
Confirmation screen:
A r e y o u s u r e < C a n c e l ; > C o n f i r
m
Press [◄] to cancel the changes or [►] to confirm the changes.
Hereafter the water heater returns to the operating screen.
Note: The [MENU] button will return the display to the operating screen.
The maintenance mode function is turned OFF as standard. We offer this programmable function to the installer to use as
a reminder. As the function can be switched on and off, it cannot be used as an argument in warranty cases.
Our water heaters must be maintained every 12 months whatever the settings/working of this function.
It is and remains the responsibly of the end user to have the unit maintained every twelve months
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67
16.16 SETTING THE USER LOCK
The following graphs describe how to activate the user lock of the display. The standard factory setting for this function is “OFF”.
The "USER LOCK" menu.
In this menu the water heater can be locked for (end-)users.
0 = UNLOCKED
1 = LOCKED
When the water heater is unlocked, the user can enter the
MENU by pressing the menu button and all screens
will show up.
When the water heater is locked, the user has to push the:
[MENU] button together with the [▼] button for 5 s.
to access all menu screens.
This function is to prevent accidental changes.
NOTICE: The PARAMETER screen always accessible.
Operating screen:
H E A T I N G
:
b o i l e r o f
f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
) Press [MENU]
Select "User lock" using [◄] & [►] and press [ENTER]
User lock screen:
S e t U s e r l o c k = 0
0
The "0" is now blinking/selected and can be changed.
Use [▲] & [▼] to change the value.
0 = User lock function OFF
1 = User lock function ON
Press [ENTER] for the confirmation screen after the selection has been
made.
Confirmation screen:
A r e y o u s u r e
< C a n c e l ; > C o n f i r m
Press [◄] to cancel the changes (the unit will reset and the display returns
to the operating screen).
Press [►] to confirm the changes. The changed value will be blinking for a
few seconds. After this, the display returns to the operating screen.
NOTICE:
Using the [MENU] button during the User lock display, will reset the water
heater and the water heater will return to the operating screen. Changes will
be neglected in this case.
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16.17 SETTING THE PARAMETERS BY THE DISPLAY MENU
The functions of the controller are embedded in the electronics. The values and settings of these controlling functions are called parameters.
They can be changed by a skilled and trained service engineer with the help of a computer, the correct software and an interface cable. A
selection of these parameters can be programmed on the unit itself, without the use of a computer. Setting is easily done at the control panel
of the water heater. The following table gives a list of parameters that can be programmed at the control panel. All parameters that are shown
in the display, can be changed. NOTICE: Only the password for level 1 is issued in this manual. When other “more advanced” parameters need
to be programmed, it can only be done by a skilled and trained service engineer, who has access to level 2.
PASSWORD: 1342
MENU
SOFTW.
PARAM
DESCRIPTION
UNITS
TEX T DISPLAY
LEVEL 1
Display
Modify
HEATING
A
1
P5BE
Step modulation (1=on 0=off)
- S t e p m o d u l
yes
no 2 P5AO
Blocking offset flow temperature control
°C H E s O f f 1 3
yes
yes 3 P5AP
Proportional range temperature control
°C H E s P r b 1 3
yes
no 4 P5AL
Hysteresis CH Flow temperature control
°C H E s c D i f 1 3
yes
yes 5 P2IC
Integration time temperature control
s H E s I n t 1 3
yes
no
6
P2MI
Blocking offset System CH temperature
control
°C H E c O f f 3
yes
yes 7 P2MJ
Proportional range System CH temperature
control
°C H E c P r b 3
yes
no
8
P2MK
Integration time CH temperature control
s H E c I n t 3
yes
no 9 P5AB
Timer Contact (1=on)
- T i m e r C o n t
yes
yes
DHW
B
1
P4AB
DHW Pump Config 0=Pump 1=TWV
- D H i p m p / t w v
yes
yes 2 P5CB
Flow temperature DHW tank low
°C D H i f l o w L O
yes
yes
3
P5CK
Flow temperature DHW tank hi
°C D H i f l o w H I
yes
yes 4 P5CL
Low Flow temperature time DHW
min D H i L O t i m e
yes
yes 5 P5CD
Legionella temperature
°C L e g i o t e m p
yes
no 6 P5CI
Legionella hyst DHW tank temperature
°C L e g i o h y s t
yes
no
7
P5CJ
Legionella hold time (0=off)
min L e g i o h o l d
yes
no 8 P2KI
CH interrupt by Legionella (0=yes)(1=no)
- L e g i o i n t r
yes
no 9 P2LC
Regulation temperature offset DHWd
°C D H d s c O f f 2
yes
yes A P2LE
Proportional range DHWd modulation
°C D H d s c P r b 2 3
yes
no B P2LD
Regulation temperature hysteresis DHWd
°C D H d s c D i f 2
yes
yes C P2LF
integration time DHWd modulation
s D H d s c I n t 2 3
yes
no D P2ML
Sys temp blocking offset DHW tank
°C D H d s c O f f 3
yes
yes E P2MM
Sys temp blocking hysteresis DHW tank
°C D H d s c D i f 3
yes
yes
F
P5CA
Hysteresis DHW tank temperature
°C D H i s c D i f 4
yes
yes
G
P2KH
Gradient heat demand detect DHW tank
temperature
°C D H i d e t g r a d
yes
yes
CASCADE
C
1
P2MA
Max number extra water heaters
- M a x C a s c U n t
yes
no
2
P5DA
Bus address water heater
- B u s a d r e s s
yes
no 3 P5DC
DHW on entire cascade(0) only master(1)
- D H i c a s / m a s
yes
no 4 P5DE
Extra Water heater output enable(1)
- E x t r a u n i t
yes
yes 5 P5DF
Cascade detection (0=standalone 1=Leader)
- C a s S i / M a
yes
no
6
P5BL
Power off total cascade (1)
- P w r O f f T o C a
yes
no
7
P5DB
Number of water heaters with common flue
0=None
- C o m F l u N u m
yes
no
GENERAL
D
1
P5BB
Analogue input Config (0=off 1=temp
2=power)
- A n I n p C o n
yes
yes
2
P5AI
Minimum Temperature 0-10V input
°C 0 - 1 0 M i n T m p
yes
yes 3 P5BI
Altitude (in amounts of 100 ft.)
ft*100 A l t * 1 0 0 f t
yes
yes 4 P2LK
Max cooling time
min M a x C o o l T i m
yes
yes
5
P5BJ
Temperature display 1=on
- T e m p O n D i s p
yes
yes 6 P4AA
DHW 0=off 1=Indirect 2=Direct
- D H W 1 = i 2 = d
yes
no
7
P4AD
pressure 0=off 1=sensor and 2=switch
- c o n f i g
yes
no 8 P4BD
Gas type values 0-2
- g a s t y p e
yes
no 9 P4BE
Soft start type values 0-2
- c o n f i g
yes
no A P5BN
Pump modes 0-4
- c o n f i g
yes
no
In the parameter table shown above one can see all the parameters that can be set on the unit without the use of a laptop/computer. In the
following chapter “Controlling options and settings” the controlling options for heating, indirect hot water and cascading are explained. In the
explanation of these options there is a reference of all relevant parameters which are shown in the table above and can be set on the unit
DO NOT CHANGE the parameters P2LC, P2LD, P2ML, P2MM and P5BI; they are present in the controller for other purposes
than DHW control. Changing these parameters may affect water heater operation negatively.
Parameter screens + explanation see next pages
Page 69
69
Operating screen:
H E A T I N G : b o i l e r o f f > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C )
Press [MENU]
Select "Parameter" using [◄] & [►] and press [ENTER]
Parameter menu:
I n s t a l l e r c o d e 0 0 0 0
Enter the 4-digit code with the [◄] & [►] and the [▲] & [▼] buttons and
select [ENTER]
The code will blink a few seconds and when entered correctly, the following
parameters will be displayed.
NOTICE: These codes are user based and give access to a selected amount
of parameters, which can be changed (Installer level 1/2).
Menu A: Heating
A 1 S t e p m o d u l 1
Function to activate the step modulation:
0 = Off
1 = On
Menu A: Heating
A 2 H E s o f f 1 3 4 ° C
CH supply temperature setting. This parameter is the offset of the
programmed CH temperature.
Menu A: Heating
A 3 H E s P r b 1 3 2 5 ° C
Select the CH supply temperature control. This parameter is the
proportional range of the selected CH supply temperature.
Menu A: Heating
A 4 H E s c D i f 1 3 1 0 ° C
Select the CH supply temperature control. This parameter is the hysteresis
of the selected CH supply temperature.
Menu A: Heating
A 5 H E s l n t 1 3 6 0 S e c
Select the CH supply temperature control. This parameter is the integration
time of the selected CH supply temperature.
Menu A: Heating
A 6 H E c O f f 3 4 ° C
Select the cascaded water heaters supply temperature control.
This parameter is the offset of the selected CH supply temperature of EACH
water heater of the total cascade.
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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70
Menu A: Heating
A 7 H E c P r b 3 2 5 ° C
Select the cascaded water heaters supply temperature control.
This parameter is the proportional range of the selected CH supply
temperature of EACH water heater of the total cascade and of the external
(cascade) sensor.
Menu A: Heating
A 8 H E c l n t 3 8 0 S e c
Select the cascaded water heaters supply temperature control.
This parameter is the integration time of the selected CH supply
temperature of EACH water heater of the total cascade and of the external
(cascade) sensor.
Menu A: Heating
A 9 T i m e r C o n t 0
Function to activate "external time controller":
0 = Off
1 = On
Connect to 13-14. Contact closed = daytime setting,
Contact open = night-time setting.
Menu B: Hot water
B 1 D H i p m p / t w v 1
Hot water function of the water heater by:
0 = pump
1 = 3-way valve
Menu B: Hot water
B 2 D H i f l o w L O 2 5 ° C
Hot water function of the water heater. This parameter is the CH supply
temperature LOW level with an indirect hot water demand.
Menu B: Hot water
B 3 D H i f l o w H I 8 5 ° C
Hot water function of the water heater. This parameter is the CH supply
temperature HIGH level with an indirect hot water demand.
Menu B: Hot water
B 4 D H i L O t i m e 1 M i n
Hot water function of the water heater. This parameter is the selectable
time period after which the water heater switches from LOW to HIGH set
point with an indirect hot water demand.
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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71
Menu B: Hot water
B 5 L e g i o t e m p 8 5 ° C
Pasteurisation function of the water heater. This parameter is the selected
hot water temperature during the pasteurisation function of the water
heater.
Menu B: Hot water
B 6 L e g i o h y s t 2 ° C
Pasteurisation function of the water heater. This parameter is the selected
hysteresis during the pasteurisation function of the water heater.
Menu B: Hot water
B 7 L e g i o h o l d 2 M i n
Pasteurisation function of the water heater. This parameter is the selected
time period for the pasteurisation function of the water heater.
Menu B: Hot water
B 8 L e g i o i n t r 0
Pasteurisation function of the water heater. This parameter controls if the
CH demand can be interrupted by the pasteurisation function of the water
heater.
0 = Yes
1 = No
Menu B: Hot water
B 9 D H d s c O f f 2
4 ° C
Function for the direct hot water water heater.
This parameter is de off set of the selected HW temperature of the water
heater.
Menu B: Hot water
B A D H d s c P r b 2 3 2 0 ° C
Function for the direct hot water water heater.
This parameter is the proportional range of the selected HW temperature
of the water heater.
Menu B: Hot water
B B D H d s c D i f 2 1 0 ° C
Function for the direct hot water water heater.
This parameter is the hysteresis of the selected HW temperature of the
water heater.
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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72
Menu B: Hot water
B C D H d s c l n t 2 3 2 0 0 S e c
Function for the direct hot water water heater.
This parameter is the integration time of the selected HW temperature of
the water heater.
Menu B: Hot water
B D D H d s c O f f 3 4 ° C
Function for the cascaded direct hot water water heaters.
This parameter is the offset of the selected HW temperature of the
cascaded water heaters.
Menu B: Hot water
B E D H d s c D i f 3 8 ° C
Function for the cascaded direct hot water water heaters.
This parameter is the hysteresis of the selected HW temperature of the
cascaded water heaters.
Menu B: Hot water
B F D H i s c D i f 4 5 ° C
Function for the indirect hot water supply of the water heater (tank).
This parameter is the hysteresis of the selected HW temperature of the
calorifier/tank.
Menu B: Hot water
B G D H i d e t g r a d 3 ° C
Function for the indirect hot water supply of the water heater (tank).
This parameter detects an (an accelerated) hot water demand, when a
larger (water) amount is being used.
Menu C: Cascade
C 1 M a x C a s c U n t 1 1
Function for the cascading of the water heater(s).
This parameter sets the total amount of cascaded water heaters.
(Max. 12 water heaters).
Menu C: Cascade
C 2 B u s a d d r e s s 0
Function for the cascading of the water heater(s).
This parameter determines the address of the water heater for the total
cascading control.
Master = 0, Slave 1 = 1 etc.
Menu C: Cascade
C 3 D H i c a s / m a s 0
Function for the cascading of the water heater(s).
This parameter determines if only the Master water heater or all boil-ers
of the cascade are used for indirect hot water.
0 = All
1 = Master
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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73
Menu C: Cascade
C 4 E x t r a u n i t 0
Function for the cascading of the water heater(s).
This parameter is activated when an external (extra) water heater is
connected to the Master water heater. Connect to the Master connections
21-22.
Menu C: Cascade
C 5 C a s S i / M a 0
Function for the cascading of the water heater(s).
This parameter sets the function of the water heater at a cascade alignment
0 = Single / Slave unit
1 = Master unit
Menu C: Cascade
C 6 P w r O f f T o C a 0
Function for the cascading of the water heater(s).
This parameter determines the function of the Slave water heaters when
the Master water heater is switched off.
0 = Slave water heater(s) continue operation
1 = Slave water heater(s) switch off
Menu C: Cascade
C 7 C o m F l u N u m 0
Function for the cascading of the water heater(s).
This parameter determines the number of cascaded water heaters, that are
implemented with a common flue system.
Menu D: General
D 1 0 - 1 0 V c o n t r 0
Function for the external control of the water heater by using a 0-10 Volt
signal (Connections 15-16).
0 = No external control
1 = Control based on temperature setting
2 = Control based on power setting
Menu D: General
D 2 0 - 1 0 M i n T m p 2 0 ° C
Function for the external control of the water heater by using a 0-10 Volt
signal (Connections 15-16).
Control based on temperature (setting 1).
The minimum (desired) CH water temperature when
supplying a 1.4 Volt signal.
Menu D: General
D 3 A l t * 1 0 0 f 0
Function for setting the location height (above sea level) of the water heater.
NOTICE: dimensions in English feet. One unit = 100 ft.
Use this function only in consultation with the supplier/
manufacturer.
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
Page 74
74
Menu C: Cascade
C 4 E x t r a u n i t 0
Function for the cascading of the water heater(s).
This parameter is activated when an external (extra) water heater is
connected to the Master water heater. Connect to the Master connections
21-22.
Menu C: Cascade
C 5 C a s S i / M a 0
Function for the cascading of the water heater(s).
This parameter sets the function of the water heater at a cascade alignment
0 = Single / Slave unit
1 = Master unit
Menu C: Cascade
C 6 P w r O f f T o C a 0
Function for the cascading of the water heater(s).
This parameter determines the function of the Slave water heaters when
the Master water heater is switched off.
0 = Slave water heater(s) continue operation
1 = Slave water heater(s) switch off
Menu C: Cascade
C 7 C o m F l u N u m 0
Function for the cascading of the water heater(s).
This parameter determines the number of cascaded water heaters, that are
implemented with a common flue system.
Menu D: General
D 1 0 - 1 0 V c o n t r 0
Function for the external control of the water heater by using a 0-10 Volt
signal (Connections 15-16).
0 = No external control
1 = Control based on temperature setting
2 = Control based on power setting
Menu D: General
D 2 0 - 1 0 M i n T m p 2 0 ° C
Function for the external control of the water heater by using a 0-10 Volt
signal (Connections 15-16).
Control based on temperature (setting 1).
The minimum (desired) CH water temperature when
supplying a 1.48 Volt signal.
Menu D: General
D 3 A l t * 1 0 0 f 0
Function for setting the location height (above sea level) of the water heater.
NOTICE: dimensions in English feet. One unit = 100 ft.
Use this function only in consultation with the supplier/
manufacturer.
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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75
Menu D: General
D 4 M a x C o o l T i m 2 M i n
Function for setting the maximum overrun time of the fan
(Maximum 10 minutes).
0 = Switch off
Menu D: General
D 5 T e m p O n D i s p 1
Function to show the (measured) temperature of the water heater at the
display.
Menu D: General
D 6 D H W 1 = i 2 = d 1
Function to set up the CH and HW water heater options.
0 = CH only (direct)
1 = CH/HW function (indirect)
2 = HW only (direct)
Menu D: General
D 7
c o n f i g
Function for the setting of the water pressure.
Up to 4 bar a sensor is used, up to 6 bar a switch.
0 = off
1 = sensor
2 = switch
Menu D: General
D 8
g a s t y p e
Function to select the gas type according to EN437
0 = G20, G25
1 = G31
2 = B/P
Menu D: General
D 9
c o n f i g
Function for setting the 'soft start' option
0 = normal start-up
1 = reduced fan ramp-up speed (I)
2 = reduced fan ramp-up speed (II)
Menu D: General
D A
c o n f i g
Function: Pump mode
0 = normal
1 = relay 1, connector 19 and 20 (lock-out)
2 = relay 2, connector 21 and 22 (burner burning)
3 = relay 3, connector 23 and 24 (heat demand)
4 = relay CN10, connector 9 and 18
The screen texts on these pages are
standard part of the boiler software
and apply to CH systems and/or hot
water devices.
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76
16.18 FAULT CODES DISPLAY
The following graphs describe the lock out codes of the water heater. A lock out code can only be removed by a manual resetting of the water
heater. NOTICE: Before resetting the water heater always check the water heater, central heating system and all components corresponding to
the related lock out description. Never just reset the water heater, before analysing the possible cause of failure.
16.18.1 LOCK-OUT CODES
Having a lockout means that the water heater needs a manual reset to start operating again.
When the water heater is in lockout the backlight of the display is blinking on and off.
Explanation >
9 9 9 , 5 : h r s
= time elapsed after fault & message.
Explanation >
P u m p 1 o n
= status of the pump during fault.
Display message
F0
F l o w s e n s o r e r r o r
p u m p o n 9 9 9 , 5 h r
s
Reason
Flow sensor not detected by the water heater caused by faulty connection/sensor.
Display message
F1
F l o w h i g h T e m p
p u m p o n 9 9 9 , 5 h r
s
Reason
Flow temperature exceeds the limit as set in the parameters.
Display message
F1
R e t u r n h i g h T e m p
p u m p o n 9 9 9 , 5 h r
s
Reason
Return temperature exceeds the limit as set in the parameters.
Display message
F2
L a c k o f w a t e r
p u m p o n 9 9 9 , 5 h r
s
Reason
The general required gradient water lack has failed.
Display message
F3
R e t u r n s e n s o r e r r o r
p u m p o n 9 9 9 , 5 h r
s
Reason
Return sensor not detected by the water heater caused by faulty connection/sensor.
Display message
F5
N o n R e t u r n V a l v e
p u m p o n 9 9 9 , 5 h r
s
Reason
Contact signal of the non-return valve failed.
Display message
F6
F l u e s e n s o r e r r o r
p u m p o n 9 9 9 , 5 h r
s
Reason
Flue gas sensor not detected by the water heater caused by faulty connection/sensor.
Display message
F7
F l u e t e m p t o o h i g h
p u m p o n 9 9 9 , 5 h r s Reason
Flue gas temperature exceeds the limit which has been set in the parameters.
Display message
F8
F a i l e d b u r n e r s t a r t
p u m p o n 9 9 9 , 5 h r
s
Reason
Water heater is not starting after the programmed starting attempts.
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77
Display message
F9
F l a m e l o s t
p u m p o n 9 9 9 , 5 h r
s
Reason
Flame detected during normal operation, but was lost while running.
Display message
F10
F a l s e f l a m e s i g n a l
p u m p o n 9 9 9 , 5 h r
s
Reason
Flame signal is detected while it cannot be expected.
Display message
F11
F a n s p e e d i n c o r r e c t p u m p o n 9 9 9 , 5 h r
s
Reason
The controller does not detect a correct fan speed.
Display message
F12
p r o g r a m m i n g e n d
p u m p o n 9 9 9 , 5 h r
s
Reason
Software parameters have been programmed.
Display message
F13
P a r a m / H a r d w f a u l t p u m p o n 9 9 9 , 5 h r
s
Reason
Fault during programming of the water heater software parameters.
Display message
F14
H i g h G a s F a i l
p u m p o n 9 9 9 , 5 h r
s
Reason
Gas supply pressure is too high.
Display message
F15
C l i x o n F a
u l t p u m p o n 9 9 9 , 5 h r s
Reason
Rear wall thermostat (clixon) detects a too high temperature.
Display message
F16
F l o w R e t u r n d t f a u l t
p u m p o n 9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value.
Programmed as parameters P2 CO, P2 CR until P2 CV.
Display message
F17
W a t e r h i g h l i m i t
p u m p o n 9 9 9 , 5 h r
s
Reason
Maximum thermostat (clixon) measured a too high flow temperature.
Display message
F18
A P S s w i t c h
p u m p 1 o n 9 9 9 , 5 h r
s
Reason
Air pressure switch is activated and exceeds the fixed time period.
Or combination of NRV blocking and an F11 lock out.
Display message
F19
S i p h o n s w i t c h
p u m p o n 9 9 9 , 5 h r
s
Reason
Pressure switch detects a high pressure in the flue/siphon system.
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The following graphs describe the blocking codes of the water heater. A blocking code is only a temporary blocking of the water heater, because
of an extraordinary situation. The water heater will continue to operate after stabilisation of this situation.
16.18.2 BLOCKING CODES
The display is not blinking, but is lightened up during the blocking period.
The water heater is blocking an action because of an extraordinary situation. This action will be continued after stabilisation of this situation.
Display message
A n t i c y c l e t i m e
9 9 9 , 5 h r
s
Reason
The controller received a new heat demand too quick after the last ended demand.
Display message
F l u e t e m p h i g h
9 9 9 , 5 h r
s
Reason
Flue gas temperature has exceeded the limit, as set in the parameters.
Display message
F l o w t e m p h i g h 9 9 9 , 5 h r
s
Reason
Flow temperature has exceeded the blocking temperature, as set in the parameters, but it has not
exceeded the lock-out value.
Display message
R e t u r n t e m p h i g h 9 9 9 , 5 h r
s
Reason
Return temperature has exceeded the blocking temperature, as set in the parameters, but it has not
exceeded the lock-out value.
Display message
T 2 - T 1 h i g h
9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value which has been set in the parameters.
Display message
D e a i r a t i o n
9 9 9 , 5 h r
s
Reason
The water heater starts its deairation function and after will return to normal operation. This function can
be activated by parameter P4AJ.
Display message
D e l t a D i r e c t b l o c k
9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value, as set in the parameters P2CQ-P2CV.
Display message
H e a t e x c h a n g a t r i s k
9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value, as set in the parameters P2CQ-P2CV, more
than three times,.
Display message
G a s p r e s s u r e l o w 9 9 9 , 5 h r s Reason
Gas supply pressure is (too) low.
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79
Display message
W a t e r p r e s s u r e f a u l t 9 9 9 , 5 h r
s
Reason
Water pressure is too low or too high.
Display message
O u t d o o r s e n s o r f a i l
9 9 9 , 5 h r s Reason
Outdoor temperature has exceeded the blocking temperature which is set in the parameters.
Display message
d T B l o c k
9 9 9 , 5 h r s Reason
Temperature difference between flow and return exceeds the blocking value but not the lock out value.
Display message
C a s c a d e B l o c k
9 9 9 , 5 h r
s
Reason
One of the cascaded water heaters causes an error, because of a lock out.
Display message
A P S f a u l t 9 9 9 , 5 h r
s
Reason
The activation of the air pressure switch.
Display message
N R V o r F a n f a u l t
9 9 9 , 5 h r
s
Reason
Non return valve contact signal activated, > 15 seconds will cause a lock-out.
Display message
L i n e f a u l t 9 9 9 , 5 h r
s
Reason
Wrong electrical power supply is connected (Not 50 or 60Hz, 220-240 Volt).
Display message
G e n B l o c k 9 9 9 , 5 h r
s
Reason
The general blocking circuit is activated during operation = contact 7-8
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16.18.3 IMPORTANT MESSAGE
The following graphs describe the messages at the water heater display. Depending on the selected and activated options for the water heater,
it is possible that some messages will show up at the display of the water heater. For example a maintenance message after a certain
programmed date has been reached. The water heater will operate independently of these messages.
The display shows alternating the base screen and this message, while the backlight is blinking.
The water heater is operating, but will count the exceeding hours.
A parameter must be changed, after service, to remove this message.
Display message
N e e d s M a i n t e n a n 0 . 0 I g n i t i o n c y c l e s h r s
Reason
Maintenance option of total amount of ignition cycles has been reached.
Display message
N e e d s M a i n t e n a n 0 .
0
D a t e h r s
Reason
Maintenance option of the date has been reached.
Display message
N e e d s M a i n t e n a n 0 .
0
B u r n i n g h o u r s h r s
Reason
Maintenance option of total amount of burning hours has been reached.
Display message
N e e d s M a i n t e n a n 0 .
0
A l l h r s
Reason
One of the abovementioned maintenance options has been reached.
17.0 CONTROLLING OPTIONS AND SETTINGS
17.1 GENERAL
17.1.1 EXTRA WATER HEATER CONTROL
When all units (cascaded) are firing at their maximum, it is possible to start an extra “external” heating source. This unit can be connected to the
“Burner Burning” contacts (connection 21-22).
P5DE Extra water heater output enable (1) (display C4)
When this parameter is set at 1 the contact “Burner Burning” will close, but only when all units are firing at a certain (programmable) input
percentage. The standard factory setting for this function is “OFF”.
17.1.2 MAX COOLING TIME
The fan will cool down the heat exchanger according to the temperature settings (parameters) of the software. With this cooling parameter, the
maximum run time of the fan can be programmed.
P2LK Max cooling time (display D4) [min.]
The fan will cool the heat exchanger according to parameter P2 LJ, but the fan will never run for cooling longer than the period programmed
with this parameter P2 LK. “0” = cooling function off.
For S1 > local set point P6BA – P2LJ → fan starts after 1 minute and stops after 3 minutes
During post pump circulation, no post ventilation takes place.
17.1.3 TEMPERATURE DISPLAY ON/OFF
Selection for showing the measured temperatures in the operation display of the water heater.
P5BJ Temperature display 1=on (display D5)
The measured temperature in the operation display.
0 = not visible
1 = visible
17.1.4 GAS TYPE SELECTION
Settings for gas types: natural gas, propane or butane-propane mixture (B/P).
P4 BD Gas type (0=standard, 1=propane, 2=B/P) (display D8).
This parameter is set 0 for the common used gas types such as natural gas G20 or G25.
By setting this parameter 1 for propane, fan speed is reduced. Set this parameter 2 for B/P.
0 = standard gas (e.g.: natural gas)
1 = propane
2 = B/P
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For each setting, the relevant Soft start settings are automatically adjusted, dependent of its main setting P4BE..
In case of gas conversion, paste the corresponding
sticker at the appropriate position in the water heater
and mark the square for the used gas type. Also, mark
the square, indicating that the correct value has been set
for parameter P4BD.
In the example below, ‘propane’ and ‘P4BD = 1’ have been marked).
17.1.5 SOFT START OPTION
Start parameters can be modified to achieve better start behavior, in case of noise or other difficulties. This is done by reducing the fan rampup speed. Two reduced settings are available (I and II).
P4 BE Soft start (0=normal, 1=reduced fan ramp-up speed (I), 2= reduced fan speed ramp-up (II))
(display D9).
0 = normal start-up
1 = reduced fan ramp-up speed (I)
2 = reduced fan ramp-up speed (II)
17.1.6 PUMP MODE (EC TECHNOLOGY)
When using a pump with Electronic Commutation technology and start-stop function, with a separate control connection, this parameter
determines the relay for switching the pump on and off.
P5 BN Pump mode (0=modulating, 1=relay1, 2= relay2, 3= relay3, 4= do not use) (display DA).
Do not use the 230 Vac relay for the main power supply of the pump, but directly connect the pump to the mains of the
water heater.
Pumps with an on/off control can be switched by one of the relay connections “lock-out”, “burner burning” or “heat demand” (called 1, 2 and
3). Choose a connection which is not yet used.
0 = Normal mode.
1 = Start-stop through relay 1, connector 19 and 20 (lock-out)
2 = Start-stop through relay 2, connector 21 and 22 (burner burning)
3 = Start-stop through relay 3, connector 23 and 24 (heat demand)
4 = Do not use (reserved for future applications).
PROPANE
PROPAN
PROPANO
PROPAAN
BUTANE/PROPANE
BUTAN/PROPAN
BUTANO/PROPANO
BUTAAN/PROPAAN
P4BD = 1
P4BD = 2
G31 P
G30/G31 B/P
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17.2 WATER HEATER OPTIONS
17.2.1 0-10 VDC REMOTE FLOW TEMPERATURE SET POINT
The hot water temperature is controlled by connecting an external 0-10 VDC signal to the water heater (connections 15-16).
P5 BB Analogue input Config (0=off 1=temp 2=power) (display D1).
This parameter must be set at "1" so the supplied 0-10 V dc signal will control the temperature set point.
Possible settings are:
0 = 0-10V control off
1 = 0-10V temperature set point control active
See also the following graph for the relation between temperature and control signal.
Curve and values only for illustration purposes, programmed parameter values can deviate
17.2.2 ANTI-LEGIONNAIRES’ DISEASE (PASTEURISATION) FUNCTION
To help prevent Legionnaires’ disease the water heater (software) provides a function for heating up the hot water storage tank (once a week
or every day) to a higher water temperature than the normal active hot water set point. Also the time period, that this “higher” water
temperature function must be active, can be programmed in P7BV start time (0:00) and P7BW (8) and is standard switched off.
Also an external 0-10 Vdc signal can be used to activate the pasteurisation function. This can be done by making the 0-10 V signal higher than
10.2 V.
The standard factory setting for this (pasteurisation) function is “OFF”. To activate this Legionnaires’ disease function
some parameters must be programmed by the manufacturer/supplier. The starting day and time of this Legionnaires’
disease function can be programmed at the control panel of the water heater.
Several parameters are used for this function. Three of these parameters are shown in the following graph.
10.2
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Curve and values only for illustration purposes, programmed parameter values can deviate
The settings of these parameters P5 CI, P5 CJ and P5 CD must be programmed according to all applicable anti Legionnaires’ disease preventing
regulations.
The setting of these parameters can only be done by the manufacturer/supplier of the water heater and is possible by the display of the unit
without the use of a computer.
The use and activation of this function will not guarantee a Legionnaires’ disease free installation. The responsibility for a
legionnaire’s disease free installation remains at the end-user/owner.
17.2.3 TANK SENSOR SENSITIVITY
P2KH Gradient heat demand detection DHW tank temperature (display BG) [0.1°C]
With S3 in use as tank sensor, it is possible to detect a fast cooling down of the tank through a large DHW flow. The sensitivity of this sensor can
be set in parameter P2KH in tenths of degrees.
P5CI = 5°C
This is the bandwidth within which the Legionnaires' temperature
must stay during the programmed duration time period. In this
example the temperature is allowed to fluctuate between 65°C
and 70°C during the anti-Legionnaires’ function.
P5CJ = 80 min.
This is the duration within which the water temperature must be
between the 65°C and 70°C.
P5CD = 70 °C
This is the maximum temperature during anti
Legionnaires' disease function period.
Normal setting water
temperature.
Start of the anti-Legionnaires’ disease
program (start day and time can be
programmed)
.
Normal setting water
temperature.
Time (10 min steps)
Water temperature
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17.3 CASCADE CONTROL
Before commissioning a cascade installation, a number of parameters have to be changed. These parameters can be programmed on the unit
itself, without the use of a computer.
NB! Remember that a TTW water heater is already a cascade of two burners, so cascading TTW water heaters gives a
multiple of 2-burner cascades. Each burner will be given an address and only one burner in the whole cascade will be
designated Master.
Only a skilled commissioning/service engineer, who has had specific training for setting up the TTW range water heaters,
may carry out changes in parameters. He will be able to check whether the installation functions correctly after the
parameter change has been done.
For programming all parameters of the water heaters a laptop with the appropriate software and an interface cable for connecting the laptop
to the water heater control is required. This software is used for programming but also shows all measured temperatures and cascade behavior
during operation and service/fault history.
17.3.1 PARAMETER SETTINGS FOR CASCADED WATER HEATERS
Before programming the cascaded water heaters, make sure that all water heaters are connected (wire) with each other. Use connection 17 and
18 of each water heater.
Do not alternate these connections, so always connect 17 to 17 and 18 to 18.
After connection, every water heater must be programmed. This can be done at the control panel. Press the [MENU] button and select the
[PARAMETER] menu. See graphics below.
Operating screen:
W A T R H T R : S T A N D - B Y > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
) Press [MENU]
Main menu screen:
M a i n M e n u
S e t p o i n t s
Select "Parameter" using [◄] & [►] and press [ENTER]
After this, use the password for installer’s level 2.
Parameter menu:
I n s t a l l e r c o d e 0 0 0 0
Enter the 4-digit code with the [◄] & [►] and the
[▲] & [▼] buttons and select [ENTER]
The code will blink a few seconds and when entered
correctly, the following parameters will be displayed.
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Now on each single water heater of the cascade, on both control panels, the following two parameters must be selected and programmed
according to the above drawing.
Master:
C5 P5 DF 1
C2 P5 DA 0
Slave 1:
C5 P5 DF 0
C2 P5 DA 1
Slave 2:
C5 P5 DF 0
C2 P5 DA 2
And so on.
Menu C: Cascade
C 5 C a s S i / M a 0
Function for the cascading of the water heater(s).
This parameter sets the function of the water heater at a
cascade alignment
0 = Slave unit
1 = Single / Master unit
Menu C: Cascade
C 2 B u s a d d r e s s 0
Function for the cascading of the water heater(s).
This parameter determines the address of the water heater
for the total cascading control.
Master = 0, Slave1 = 1, etc.
When the correct parameter is set, this must be confirmed at the confirmation screen. After activation, the value will blink for a few seconds
while the parameter is programmed into the water heater.
PARAMETERS
PARAMETERS
PARAMETERS
PARAMETERS
master
slave 1
slave 2
slave 3
slave 4
slave 5
slave 6
slave 7
CASCADE
CONNECTION
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When cascade connection is programmed correctly, the water heater display will show the following.
Explanation "Cascade communication indicator"
NO CASCADE COMMUNICATION
> > >
no.1
Always showing the fixed ">>>"
CORRECT CASCADE COMMUNICATION
> >
no.1
no.2
>
Showing alternating no.1 & no.2 with 1-second interval.
17.3.2 MONITOR SCREENS
To obtain cascade information, see 16.4.
17.3.3 OUTPUT CONTROL AND BURNER SEQUENCE
The total cascade set-up will act as one single big water heater, switching on- and off burners, depending on the total load necessary to adjust
and keep the flow temperature at the calculated value.
When the heat demand rises, more burners are switched on, and when heat demand falls, one or more burners will be switched off. The burner
that was switched on last will be switched off first, see table below.
To distribute operating hours equally over all burners, the working sequence of the burners will change every hour.
Hour
Switching ON sequence
Switching OFF sequence
X
Master – Slave 1 – Slave 2 – Slave 3 – Slave 4 – Slave
5 – Slave 6 – Slave 7
Slave 7 – Slave 6 – Slave 5 – Slave 4 – Slave 3 – Slave
2 – Slave 1 – Master
X+2
Slave 7 – Master – Slave 1 – Slave 2 – Slave 3 – Slave
4 – Slave 5 – Slave 6
Slave 6 – Slave 5 – Slave 4 – Slave 3 – Slave 2 – Slave
1 – Master – Slave 7
X+4
Slave 6 – Slave 7 – Master – Slave 1 – Slave 2 – Slave
3 – Slave 4 – Slave 5
Slave 5 – Slave 4 – Slave 3 – Slave 2 – Slave 1 – Master
– Slave 7 – Slave 6
X+6
Slave 5 – Slave 6 – Slave 7 – Master – Slave 1 – Slave
2 – Slave 3 – Slave 4
Slave 4 – Slave 3 – Slave 2 – Slave 1 – Master –
Slave 7 – Slave 6 – Slave 5
………..
…………………………………………………
…………………………………………………
Table: burner sequence example of a four water heater cascade (four TTW water heaters = eight burners).
In this table a total of four water heaters (one master burner, seven slaves) is mentioned as an example, in practice the maximum number in a
cascade, without extra (external) control, is six water heaters (= twelve burners).
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18.0 COMMISSIONING THE WATER HEATER
18.1 FIRST: FLUSHING THE WATER HEATER WITH WATER
After installation of the water heater the first step, before commissioning, is to flush the water heater and the whole DHW installation with fresh
water to remove pollution, debris and other materials that might cause a blocking. This must also be done with installations, where only the
water heater is replaced.
18.2 SECOND: FILLING & VENTING THE WATER HEATER AND THE SYSTEM
After flushing the water heater and the installation the system can be filled with fresh water by opening the water supply valve of the system
and opening all the taps that are on the system. The water pressure of the system should be between a minimum of 1 bar and a maximum of 8
bar, also depending on the applied pressure safety valve fitted.
The water heater has an automatic air vent situated on top of the water heater (at the roof panel). This vent must be opened during the filling
of the water heater and the DHW system to make sure that no air/oxygen is trapped in the heat exchanger of the water heater. NOTICE: Check
that the screw cap has been loosened at least one twist.
Make sure that, during flushing and filling, no water can reach any electrical parts of the water heater.
18.3 THIRD: CHECK THE WATER FLOW
Before the water heater will be started it must be sure that the pump is functioning and that there is a water flow over the heat exchanger.
Check the electrical power supply of the water heater and when this is connected correctly, the display will show either of the following:
Display message
B o i l e r o f f
Reason
Water heater is not active. To activate the water heater press [ON/OFF] button for six
seconds.
Display message
W A T R H T R : b o i l e r o f f
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Reason
Water heater is standby. To activate the water heater press [ON/OFF] button for three
seconds.
Activate the water heater by pressing the ON/OFF button for six resp. three seconds. After this the following display will appear:
Display message
W A T R H T R : N o d e m a n d
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Reason
Water heater is active, but there is no heat demand.
When no water is present in the water heater or the water pressure is too low/high, the water heater will go into lock-out and will show a
corresponding message in the display.
Display message
W a t e r p r e s s u r e f a u l t
9 9 9 . 5 h r
s
Reason
Water pressure is too low or too high
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By pressing the [SERVICE] button of the water heater, the water heater can be started without a heating demand. The water heater will start to
fire and also the pump will start to run. Firing of the water heater without a water flow (but filled with water!) will cause the so called “boiling
noises”. Check during this “service function” operation also the flow and return temperatures of the water heater by pressing the [◄] button
once. The temperature difference of the flow and return must be at least 13°C and maximum 25°C. This temperature difference indicates that
there is a (enough) water flow over the water heater; this water flow prevents the heat exchanger of possible damage caused by a thermal
overload.
18.4 FLOW MONITORING
Another safety feature of the water heater, to make sure that there is enough water flow over the water heater, is the monitoring of the flow
and return temperatures (T2 and T1). When the temperature difference (delta T) between flow and return exceeds a certain (set) value (load
dependent), the following warning messages will be shown in the display.
Display message
T 2 - T 1 h i g h
9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value, as set in the parameters
P2CO, P2CR until P2CV.
Display message
D e l t a D i r e c t b l o c k
9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value, as set in the parameters.
When this T2-T1 value exceeds the lock-out setting, the water heater will switch off and the following lock out code will be shown at the display.
Display message
F16
F l o w R e t u r n d t f a u l t p u m p o n 9 9 9 , 5 h r
s
Reason
Temperature difference T2-T1 has exceeded the blocking value, or after three times Delta
Direct block.
When these messages appear and/or the water heater will lock out, it means that there is not enough flow over the water heater. In this case
check the functioning of the pump.
The water heater has a built in water pressure switch. If water pressure of the system drops under a certain limit, the water heater will go in a
lock-out.
During and after the commissioning of the water heater, the operation of the water heater pump must be checked, before leaving the installation
room.
NOTICE: Always check the running of the pump before firing the water heater.
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19.0 STARTING THE WATER HEATER
19.1 GENERAL
The gas input pressure for the water heater to operate properly under the correct load, must be at high fire more or equal to the minimum
gas inlet pressure for the supplied gas type, as stated in the technical specification data table on page 5.
* Gas valve screws and nipples: see picture on page 76.
The water heater has two identical gas control valves: the top burner (MASTER) and the bottom burner (SLAVE 1). Both gas valves must be
adjusted at maximum load and at minimum load.
Two burners are present in one heat exchanger. In fact, into one stainless steel casing, two heat exchangers have been built, a primary and a
secondary. The primary exchanger, moreover, consists of an upper and a lower part. The upper part in which the top burner fires, is only
transferring heat from the top burner. The lower part in which the bottom burner fires, is only transferring heat from the bottom burner. After
the flue gases have passed the primary heat exchanger, they merge in the central part. In this secondary part the remaining heat is extracted
from the flue gases of both burners, causing condensation of the gases, if cooled down sufficiently,
Measuring the CO2 percentage in the flue gas outlet outside the water heater, while both burners are burning, will result in an average CO2
value. It is possible that this average value is correct, while the CO2 setting of the top burner is too low and the CO2 setting of the bottom burner
is too high. Therefore the CO2 levels of each burner must be adjusted separately. Measurements are performed at the front, by making use of
two measuring holes. See drawing.
Top (primary) heat exchanger
Top burner
Plug for top measuring hole
Top measuring hole for
flue gas measuring
(Secondary heat exchanger)
Bottom measuring hole for
flue gas measuring
Plug for bottom measuring hole
Bottom burner
Bottom (primary) heat exchanger
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19.2 FIRING FOR THE FIRST TIME
After commissioning the water heater and avoiding any possible heat demand (remove the thermostat connection lead), the water heater
displays the following message:
Display message
H E A T I N G : N o d e m a n d
> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Reason
Water heater is active, but there is no heat demand.
The display describes:
The actual operation for heating or hot water
If a heat demand is activated
The temperature setting
The temperature measured
When mounting the bottom part of the siphon, before commissioning the water heater and/or after maintenance, the siphon
must ALWAYS be completely filled with water.
This is a safety measure: the water in the siphon keeps the flue gases from leaking into the plant room via the condensate
drain.
Turn LEFT to open
Turn RIGHT to close
Fill with water
to the edge
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20.0 ADJUSTING AND SETTING THE BURNERS
Before carrying out any adjusting of the burner, carefully read this complete chapter.
20.1 INTRODUCTION
Always adjust the burners after one of the following events:
A. - A new water heater has been installed
- As part of a service/maintenance check, in case the CO2 values prove to be incorrect
Adjustment procedures for case A are described in 20.2.
B. - A gas control safety valve has been (re)placed
- Another type of gas is applied: gas conversion
Adjustment procedures for case B are described in 20.3.
In either of the four cases described in A and B, always check the gas/air ratio of the combustion figure (CO2) at maximum and minimum input.
First adjust the water heater at maximum load and subsequently at minimum load, and repeat if necessary.
Set-up of this chapter:
First, all necessary values are given in TABLES 15.1 and 15.2 found in SECTION 20.1.1. A drawing of the gas valve(s) and setting screws is given
in 20.1.4 on the next page. 20.1.5 Shows how to operate the measuring holes. 20.1.6 is a general scheme, confirming which adjustment must
be carried out.. After that, in 20.2 and 20.3, a detailed description is given of how to proceed in cases A and B respectively.
20.1.1 ADJUSTMENT TABLES
CO2 [%]
O2 [%]
Gas type 1)
max load
min load max load
min load
G20. G25.3
9.0 – 9.2
8.8 – 9.0 4.5 – 4.8
4.8 – 5.2
Propane3) G31
10.5 – 10.7
9.8 – 10.0 4.6 – 4.9
5.7 – 6.0
B/P 3.4) G30/ G31
10.5 – 10.7
9.8 – 10.0 5.0 – 5.3
6.0 – 6.3
1
Cf. EN437.
2
All values measured without front door. The CO2 / O2 values should always be between the values set in this table. Nominal values can be
found in Technical specifications datasheet page.
3
Fan settings must be changed by altering parameter P4BD (display D8). (only by a skilled mechanic).
4
B/P: Propane/butane mixture.
Using propane or butane/propane mixtures (B/P), maximum fan speed needs to be reduced by changing parameter
P4BD
20.1.2 ADJUSTMENT VALUES
To make adjustments easier, values of table 1 are presented in the following figures.
The CO2 / O2 values should always be between the values set in this figure.
Nominal values can be found in the Technical specifications table at the beginning of this manual.
All values are measured without front door
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Figure 1:
Gas type G20
The CO2 level may never be in the hatched area.
Figure 2:
Propane G31:
The CO2 level may never be in the hatched area.
Figure 3:
B/P: propane/ butane mixture G30/ G31
The CO2 level may never be in the hatched area.
Check the setting of parameter P4BD (gas type)
0 = Standard gas; e.g.: Natural gas G20 or G25.3
1 = Propane G31
2 = Mixture of Butane/Propane, B/P (G30/G31)
Setting of the parameter is described 16.17.
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PRE ADJUSTMENT SETTINGS GAS VALVES
WATER HEATER TYPE
BURNER
NUMBER OF TURNS OPEN (COUNTER CLOCKWISE)
NAT. GAS G20 1 AND G25 1
PROPANE G31 1 AND B/P
TTW 410
top
2.5
0.75
bottom
3.0
0.75
TTW 580
top
3.5
1.0
bottom
3.5
1.0
1
In accordance with EN437
20.1.3 PRE ADJUSTMENT SETTINGS FOR GAS VALVES
20.1.4 GAS VALVE SETTING SCREWS: DRAWING
Nr.
Description
1
Removable cap
2
Adjustment at maximum load.
Use Allen key no. 3
higher: turn left (CCW)
lower: turn right (CW)
3
Adjustment at minimum load.
Use Torx T40 key
higher: turn right (CW)
lower: turn left (CCW)
4
Gas supply pressure nipple
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20.1.5 HOW TO REMOVE AND MOUNT THE FLUE PLUG:
Make sure during measurement in one measuring hole, that the other one is closed.
When several measurements are done in both holes alternately, the unused hole may be temporarily Scotch taped or closed
by means of a rubber plug.
AFTER FINISHING ALL MEASUREMENTS, CLOSE BOTH HOLES USING THE ORIGINAL PLUGS.
Removing plug from heat exchanger:
Loosen the plug:
Loosen M8 wing-nut counter clockwise
approximately 20 mm.
DO NOT UNSCREW THE NUT ENTIRELY FROM
THE BOLT.
Pull the plug out:
Pull and tilt the bolt so the metal lip can be
extracted.
Mounting the plug:
Position the plug into heat exchanger:
Insert the metal lip upwards into the hole and tilt
the bolt to a horizontal position, so the lip is
completely inside the heat exchanger.
Fasten plug:
Turn the nut clockwise by hand to fasten plug.
- DO NOT USE EXCESSIVE FORCE.
- DO NOT USE TOOLS.
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20.1.6 ADJUSTMENT ACTIONS: GENERAL SCHEME
General scheme for adjustment of the gas valve(s). Consult this scheme for an overview.
To complete all the necessary adjustments in the right order, follow case A or B top-down through the scheme (B involves a few extra steps (grey
text blocks):
GENERAL SCHEME: ADJUSTMENT STEPS
case A
new water heater or
service check
case B
valve replacement or
gas conversion
start
adjusting the top burner – upper measuring hole
top burner
go to service mode
in case of gas conversion: set parameter P4BD to the
correct gas type at the left panel (top burner)
first close screw [2] of the valve,
then open it according to table 2
go to service mode
if burner doesn’t start,
open screw [2] ¼ turn extra
1) maximum load: check and adjust
2) minimum load: check and adjust
repeat steps 1) and 2) until measurements match table 1
values within ± 0.1%
switch top burner off, proceed with bottom burner
next
adjust the bottom burner – lower measuring hole
bottom burner
go to service mode
in case of gas conversion: set parameter P4BD to the
correct gas type at the right panel (bottom burner)
first close screw [2] of the valve,
then set it in accordance with table 2
go to service mode
if burner doesn’t start,
open screw [2] ¼ turn extra
1) maximum load: check and adjust
2) minimum load: check and adjust
repeat steps 1) and 2) until measurements match table 1 values within ± 0.1%
check
check with both burners burning -
1. upper measuring hole
2. lower measuring hole
both burners
set bottom burner to 50% load, start top burner and set it to 50% load
set both burners simultanously to maximum load (▲ 2x)
1) check at maximum load. Measure 2x: top and bottom, and average
set both burners simultanously to minimum load (▼ 2x)
2) check at minimum load. Measure 2x: top and bottom, and average
If measurements 1) and 2) match table 1 values within ± 0.3%, adjustment is correct
If deviation is more than 0.3%, start all over again: check and adjust burners separately
Water heater returns to NORMAL MODE after 40 min. OR by pressing [SERVICE] button
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20.1.7 NOTE: CO2 MEASURING POSITION
This chapter describes the procedure for adjusting and checking CO2 values by measuring at the front of the water heater, using the upper
measuring hole for adjusting the top burner and the lower measuring hole for adjusting the bottom burner.
When both burners are on, a deviation from the single burner measurements occurs: the upper hole shows CO2 values higher than the nominal
value, the lower hole shows CO2 values lower than the nominal value. However, the average value of the upper and lower measurements can
be used to check the nominal CO2 percentage.
If possible, measuring CO2 in the flue gas outlet outside the water heater, at the back, is preferred. The reason is that the flue gas in the common
outlet is better mixed and measurements are less deviating, regardless of whether the top or the bottom burner is on, or both. This means that
measuring and adjusting is easier: neither change of measuring hole, nor averaging values is necessary.
For an extensive description consult the next two sections (choose which is applicable, A or B):
20.2 ADJUSTING IN CASE OF A NEW WATER HEATER, OR AFTER MAINTENANCE (CASE A)
20.2.1 GENERAL REMARK
For all adjusting steps under A the following must be applied: no adjustment is required if measured values are within the margins shown in
20.1.2
20.2.2 CHECKING AND ADJUSTING THE TOP BURNER
Start top burner.
On the left control panel (controlling the top burner), go to service mode: press [SERVICE] button for about 4 seconds. After start-up
it shows:
Display message
W A T R H T R
: S e r v i c e 3 0 %
> > > 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Water heater is activated and operates at service mode at minimum.
NB! The service mode of the water heater will be active for 40 minutes. After this the water heater will return to normal operation.
Make sure that only one burner is burning: the green LED on the other panel should be off.
Also check that the fan of the bottom burner is not running: the error message "NRV or fan fault" should not be on the display of the
right panel.
Maximum load adjustment.
Press [▲] button until maximum load is reached:
Display message
W A T R H T R
: S e r v i c e 1 0 0 %
> > > 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Water heater is activated and operates at service mode at 100% (maximum) (example).
Measure CO
2
in the upper measuring hole (top burner).
Adjust the CO2 within ± 0.1% according to figures shown in 20.1.2 using key [2]:
Decrease CO2 percentage
Turn screw [2] right (clockwise)
Increase CO2 percentage
Turn screw [2] left (counter clockwise)
CO2
[2]
CO2
[2]
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Minimum load adjustment.
Press [▼] button until minimum load is reached.
Display message
W A T R H T R
: S e r v i c e 3 0 %
> > > 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C
)
Water heater is activated and operates at service mode at minimum.
By setting screw [3], adjust the gas valve to obtain the CO
2
value shown in 20.1.2
Decrease CO2 percentage
Turn key [3] left (counter clockwise)
Increase CO2 percentage
Turn key [3] right (clockwise)
Repeat adjustments:
Check again at maximum load and adjust if necessary.
Check again at minimum load and adjust if necessary.
Repeat previous steps until measurements match shown in 20.1.2.
Switch the top burner off (press service button).
20.2.3 CHECKING AND ADJUSTING THE BOTTOM BURNER
On the right control panel, go to service mode (press [SERVICE] button for 4 seconds). Make sure that only the bottom burner is on:
the green LED on the left panel (top burner) should be off. Also check that the fan of the top burner is not running: the error message
"NRV or fan fault" should not be on the display of the left panel.
Set the load at maximum by pressing the [▲] button.
Measure CO
2
in the lower measuring hole (bottom burner).
Adjust the CO
2
within ± 0.1% according to shown in 20.1.2 using key [2].
Set the load at minimum by pressing the [▼] button.
Adjust the CO
2
within ± 0.1% according to shown in 20.1.2 using key [3].
Check again at maximum load and adjust if necessary.
Check again at minimum load and adjust if necessary.
Repeat previous steps until measurements match shown in 20.1.2 .
Switch the bottom burner off (press [SERVICE] button).
20.2.4 CHECKING BOTH BURNERS
To switch both burners on at the same time: switch to service mode, set one burner at 50% load using the [▲] and/or [▼] buttons. While this
burner is on, switch the other burner to service mode (press [SERVICE] button for 4 seconds). After start-up, set it also at 50% load.
To set both burners at maximum load, press [▲] buttons on both panels simultaneously.
Measure CO
2
in the upper measuring hole (top burner); a tolerance of -0.1 to + 0.3% of the shown in 20.1.2 value is acceptable. Note
down this value.
Measure CO
2
in the lower measuring hole (bottom burner); a tolerance of - 0.3 to +0.1% of the shown in 20.1.2 value is acceptable.
Note down this value.
Calculate the average of these two measurements: add the upper and lower values and divide by two.
If this average CO
2
at maximum matches shown in 20.1.2 within ± 0.1%, proceed with the next step: checking at minimum load. If the
deviation is larger than ± 0.1%, check and re-adjust burners separately again.
To change to minimum load, press [▼] buttons on both panels simultaneously.
Check CO
2
for the minimum load: measure CO2 in the upper measuring hole of the top heat exchanger; a deviation up to + 0.3% of the
table16.1 value is acceptable. Note down this value.
Measure CO
2
in the lower measuring hole of the bottom heat exchanger; a deviation down to - 0.3% of the shown in 20.1.2 value is
acceptable. Note down this value.
Calculate the average of these two measurements: add the upper and lower values and divide by two.
If this average CO
2
at minimum matches shown in 20.1.2 within ± 0.1%, adjustment is correct. If the deviation is larger than ± 0.1%,
check and re-adjust burners separately again.
If measurements at maximum and minimum match shown in 20.1.2 within ± 0.1%, adjustment is completed.
Switch burners off (press [SERVICE] buttons on both panels).
C O 2 [ 3 ] C O 2 [ 3
]
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20.3 ADJUSTING AFTER GAS VALVE REPLACEMENT OR IN CASE OF GAS CONVERSION (CASE B)
In case of gas conversion, apply the corresponding
sticker at the appropriate position in the water
heater and mark the square for the used gas type.
Also, mark the square, indicating that the correct
value has been set for parameter P4BD.
(In the example below, ‘propane’ and ‘P4BD = 1’
have been marked).
20.3.1 GENERAL REMARKS
As can be seen in the general scheme, the main adjusting steps in case B are the same as in case A, except for these extra steps:
set the right gas group; parameter P4BD (display D8)
a pre adjusting step, to make sure the burner will fire
All adjustments must result in CO2 percentages shown in 20.1.2
In case of gas conversion: check parameter P4BD for the correct setting.
20.3.2 CASE B ADJUSTMENTS
Pre adjusting the top burner:
Turn setting screw [2] of the upper gas valve clockwise until you feel resistance. This means that the valve is closed; do not try to
tighten the screw any further.
Now turn this screw counter clockwise (open), according to the number of turns in TABLE 14.2 for the used water heater and gas
type.
→ proceed according to steps in 20.2.2.
If the burner does not start up in service mode, turn screw [2] an extra quarter turn counter clockwise, and try again.
Pre adjusting the bottom burner:
Turn setting screw [2] of the lower gas valve clockwise until you feel resistance. This means that the valve is closed; do not try to
tighten the screw any further.
Now turn this screw counter clockwise (open), according to the number of turns in TABLE 14.2 for the used water heater and gas
type.
→ proceed according to steps in 20.2.3.
If the burner does not start up in service mode, turn screw [2] an extra quarter turn counter clockwise, and try again.
Checking both burners:
→ proceed according to steps in 20.2.4.
PROPANE
PROPAN
PROPANO
PROPAAN
BUTANE/PROPANE
BUTAN/PROPAN
BUTANO/PROPANO
BUTAAN/PROPAAN
P4BD = 1
P4BD = 2
G31 P
G30/G31 B/P
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21.0 PUTTING THE WATER HEATER OUT OF OPERATION
It is recommended to have the water heater operational all year round to prevent any frost damage during the winter and/or rotating parts
getting jammed during other times of the year (built in water heater safety features).
OUT OF OPERATION: On/off function.
To be used when the appliance must be put out of operation for a long period because of a defect or another safety risk.
Act as follows:
Disconnect or switch off the tank thermostat and/or other external controllers from the water heater. The pump and fan will stop after
a short time.
Switch off the water heater by pressing the [ON/OFF] button for six seconds.
Make sure the following display screen is visible.
Display message
B o i l e r o f f
Properties of the ‘off’ function:
The keys do NOT respond and the menu is NOT accessible.
The burner does NOT respond to an external heat demand.
The water heater CAN, however, be switched on again by pressing the [ON/OFF] button.
Pump(s), fan(s) and cascade (if applicable) are operational, and so are both recirculation protection (if applicable) and frost protection.
To reactivate the water heater, switch on the burner by pressing [ON/OFF] for six seconds again.
The frost protection module can still activate the burner(s).
To prevent this, switch off this protection or put the water heater in ‘power off’ mode.
OUT OF OPERATION: Power off.
To assure that the water heater cannot become active at all anymore, power should be cut off completely.
Act as follows:
Disconnect or switch off the tank thermostat and/or other external controllers from the water heater. The pump and fan will stop after
a short time.
Switch off the water heater by pressing the [ON/OFF] button for six seconds.
Make sure the following display screen is visible.
Display message
B o i l e r o f f
Switch off the electrical power supply of the water heater (remove connection from the wall socket, or switch off the main power).
Close the gas valve / gas supply.
In case of possible frost damage: drain both the water heater and the DHW system.
NOTICE: Before starting to drain the water heater, first start draining the DHW system and subsequently open also the two drains of
the water heater.
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22.0 FAULT CODES, BLOCKING CODES
22.1 FAULT CODES
IMPORTANT:
To avoid electric shocks, disconnect electrical supply before performing troubleshooting. To avoid burns,
allow the unit to cool before performing troubleshooting.
Be aware that a fault code is an indication that the unit or the system needs attention. When repeatedly
having faults these should not be neglected.
The first step is to check if the unit is installed according to the instructions. If not, first make sure the
installation complies with the installation manual.
Always check the fuses on the control board before replacing any major components. A blown fuse can
prevent the controller or other components from operating.
Most faults can also be caused by a bad wiring and/or connections, even if it is not specifically mentioned.
With every fault it is wise to check wiring and connections (at both ends) that connect to the safety
device/component that generates the fault.
22.1.1 LOCK-OUT CODES:
Having a lockout means that the water heater needs a manual reset to start operating again.
When the water heater is in lockout the backlight of the display is blinking on and off.
Explanation >
9 9 9 , 5 : h r s
= time elapsed after fault/message.
Explanation >
P u m p 1 o
n
= status of the pump during fault.
Display message
F0
F l o w s e n s o r e r r o r p u m p o n 9 9 9 , 5 h r
s
Reason:
Flow sensor is not detected.
Cause:
Bad wiring/connection in the flow sensor circuit.
Corrective action:
Check for loose wiring/connections in the flow sensor circuit.
Cause:
Bad temperature sensor causing a fault signal.
Corrective action:
Replace flow sensor.
Display message
F1
F l o w h i g h T e m p p u m p o n 9 9 9 , 5 h r
s
Reason:
Max. flow temperature exceeds limitation (lock-out) value.
Cause:
The water flow is restricted.
Corrective action:
Check functioning of the pump.
Check/open all valves that might restrict the water flow through the unit.
Check for an external system pump that influences flow through the unit.
Check if the system resistance exceeds the spare capacity of the unit pump.
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