Thermasis Cortina 12 S, Cortina S Series, Cortina 24 S, Cortina 18 S, Cortina 32 S Installation & User Manual

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CORTİNA

- S -

INSTALLATION / USER

MANUAL

1 DEAR CUSTOMER

 Thank you for purchasing Cortina wood pellet boiler.

 This instruction manual is intended to help you install and operate the product

safely, properlyand economically.

 Please read this instruction manual right through and take note of the

safetywarnings.Keep all documentation supplied with this unit in a safe place for future reference.

 Do not touch or interfere any part of the product other than those allowed.

 During installation and/or first start up the service engineer must carry out

thefollowing work.

 The installation has to be performed by a qualified installer.

 Please contact your authorised dealer if you have any questions.

 For efficient and low-emission operation of your heating system, only use the

fuels specified in this instruction manual. Only then can efficient, low-emission, and trouble-free operation of your heating system be guaranteed.

 Carry out maintenance and cleaning work recommended on your heating system

at regular intervals. Details can be found later in the instruction manual. By doing this, you will not only be ensuring the operational reliability of the heating system but also its efficient and low-emission operation.

• Your pellet boiler will automatically adjust its output between 30 to 100% of the boiler’s rated power. Your heating system may have a lower or higher heat demand than the boiler can deliver, for this reason we recommend a buffer tank is installed. The buffer tank ensures operational reliability of the appliance and improves heating response and energy saving. This ensures efficient and lowemission operation of your boiler.

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2 INTRODUCTION AND DELIVERY

Cortina is a welded steel boiler designed for automatic burning of wood pellets to be used in hot water heating installations. Therefore, it can not be used for direct sanitary water supply.

Main features and advantages of Cortina wood pellet boiler:

 Very compact dimensions thanks to its unique vertical design  Integrated fuel container  Adjustable boiler output  High efficiency and nature-friendly flue gas emissions  Automatic ignition of wood pellets  Automatic feeding  Stainless steel burning pot and fuel feeder  PID control ensures a stable output where it is adjusted  Exhaust fan speed modulation and speed control via encoder  User friendly electronic control board  Manual and simple burner cleaning  Manually activated smoke tube cleaning  Fuel level monitoring window  Flue thermostat  Room thermostat option  Fire protection  Buffer tank

Your boiler is delivered in one single package secured on a wooden pallet, with all accessories and external cabinet fit before leaving factory. You can reach the cleaning equipment under the ash cleaning cover of boiler.

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Main parts that are related to operation of boiler:

1 Fuel loading door 6 Flame inspection window 2 User interface (control panel) 7 Burning pot cleaning cover 3 Smoke tube cleaning lever 8 Ash cleaning cover 4 Fuel level monitoring window 9 Service / electronic board cover 5 Cleaning cover shield

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DANGER

3 SAFETY WARNINGS

3.1 Basic safety instructions

• Never get yourself into danger; give own safety the utmost priority.

• Keep children away from the boiler room and fuel storage room.

• Observe all instructions related to operation, maintenance, servicing and cleaning.

• The pellet heating system may only be installed and started up for the first time by an authorised installer. Professionalinstallation and start up are essential for safe and economical operation.

• Never make any changes to the heating system or flue gas system.

• Never close or remove safety valves.

3.2 Warning signs

Risk of poisoning

 Make sure that the pellet boiler is supplied with sufficient combustion air.  The openings in the combustion air inlet must never be partially or

completely closed.

 Ventilation systems, central vacuum cleaning systems, extractor fans, air

conditioning systems, flue gas blowers, dryers or similar equipment must never be allowed to draw air from the boiler room and cause a drop in pressure.

 The boiler must be connected tight to the chimney using a flue gas tube.  Clean the chimney and the flue gas tube at regular intervals.  The boiler room and pellet storage room must be sufficientlysupplied with

air and ventilated.

Risk of electric shock

 Switch off the system before performing work on the boiler.  THIS APPLIANCE MUST BE EARTHED !  Electrical installation of this boiler must be completed in accordance with

mandatory regulations, and codes of practice regarding the instructions given in this manual by authorized installator.

Risk of explosion

• Never burn petrol, diesel, engine oil or other explosive materials in the boiler

or storage room

• Never use liquids or chemicals to ignite the pellets.

• Switch off the heating system before filling the storage room.

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DANGER

WARNING

CAUTION

NOTICE

Risk of fire

• Do not store any flammable materials in the boiler room.

• Do not hang out any washing in the boiler room.

• Always keep all boiler doors closed

• Store the pellets in another room, or leave a minimum distance of 80 cm

between the boiler and the pellet pile.

Risk of burns

• Do not touch the flue spigot or the flue gas tube.

• Do not reach into the ash chamber.

• Do not remove service cover due to volteged components under the cover

• Do not clean the boiler until it has been allowed to cool down.

Risk of cut injuries due to sharp edges.

• Use gloves for performing all work on the boiler.

Damage to property

• Heat the Pellematic pellet heating system using pellets that comply with the

specifications below

Damage to property

• Do not use the heating system if it, or any of its components, come into

contact with water.

• If water damage occurs, have the heating system checked by your authorised

service stuff or approved technicians, and have any damaged parts replaced in case needed.

3.3 What to do in an emergency

What to do in the event of a fire

• Switch off the heating system.

• Call the fire brigade

• Use approved fire extinguishers.

What to do if you smell smoke

• Switch off the heating system.

• Close the doors leading to living areas.

• Ventilate the boiler room.

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4 TECHNICAL DATA

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Models

Cortina 12

S Cortina 18

S Cortina 24

S Cortina 32

S Cortina 40

Boiler class

Class 5 acc to EN 303/5

With fan at flue exhaust working

under pressure at

Maximum power input

15,6 19,2 24,8 32,6 42 Maximum power output

14,2 17,1 22,1 29,6 37,2 Minimum power output

4,5 5,2 6,6 8,9 11,2 Efficiency at max output

0,91 0,89 0,89 0,91 0,89 Efficiency at min output

0,89 0,86 0,85 0,87 0,87 Flue gas temperature at max

Flue gas temperature at min

New weight

160 165 185 225 250 Water content

lt 44 40 45 70 76

kg 45 55 85 95 lt 80 100 155 180 Fuel filling openning size

mmxmm

450x290

436x258

436x328

536x328

Combustion period

h 12

Minimum return temparature

°C

40 (With non

condensing working conditions)

CO emission

EN 303/5 Class5

Flue gas mass flow

g/s 16 21 25 30 Required draft at chimney

Pa 8-10 10-12 12-15

Temperature control range

°C 45-80

Max operating temperature

°C 80

Max operating pressure

bar 3 Water flow/return connections

1" (male)

Filling/draining connection

½" (male)

Burner design

Stainless steel cylindrical pot

External dimensions

H mm

1365

1490

1620

1670

W mm

730 850 900 H1 mm 1195

1235

1360

1490

1540

H2 mm

1050

1085

1210

1340

1390

H3 mm

300 325 360 L mm 520 570 620 D mm 127 Electrical supply

230V / 50Hz

Power consuption

Power consuption (igniter)

165

Wood pellets size 6 mm

Fuel specifications

Fuel parameters shall comply to EN 14961

Operation mode

power

Fuel container capacity

°C

flue gas outlet

116,4 155 150 140 120

84,6 125 120 110 100

(fan+feeder motor)

5 INSTALLATION

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75 71

NOTICE

5.1 Handling the product

Cortina is a heavy product, and care should be taken when carrying the boiler to the room where it is going to be installed. The total weight of each boiler is indicated in technical data section. Carrying equipment of the product must be of enough capacity to support that weight. To avoid damage during transport, boiler should be moved with forklift or transpalet. Use the transport feets on the wooden pallets.

Damage to property

• Do not use hard and sharp objects while removing the package around the

boiler to prevent damage of the painted jackets.

5.2 Room selection

Cortina series boilers must be installed in an individual boiler room particularly organized for heating. The boiler room should be of enough volume for installation, firing, and maintenance of the boiler. There should be enough space from the wall for easy removing the geared motor and the shaft for service intervention. For appropriate dimensions look into “clearances around boiler” section.

There should be enough fresh air circulation for combustion, the chimney design must ensure an adequate draught for related boiler type, and must comply with construction criteria given further in this manual and in mandatory regulations. Your boiler must never be installed in open spaces or balconies, in spaces occupied by people like kitchen, living room, bathroom and bedroom, in spaces where there are explosive and combustible materials.

The boiler room should have air ventilation holes through outside to let fresh air in. One air ventilation hole must be built maximum 40 cm below the level of room ceiling; the other must be built maximum 50 cm above the floor level. These ventilation holes should always be kept open. The upper hole should be at least 40x40 cm in size, the lower hole at least 30x30 cm.

All hydraulic and electrical circuits must be arranged by authorized staff in accordance with mandatory regulations specified by legal organizations.

Pellets should be stored by keeping minimum 800 mm distance from the boiler. We recommend you to keep the solid fuel in another room.

Cortina boiler should be installed on a concrete plinth made of a fireproof material. For minimum sizes of the plinth following table should be referred:

Model Cortina 12/18 / 24 Cortina 32 / 40 Plinth height (mm) 50 Plinth width (mm) 800 900

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Plinth length (mm) 600 650

5.3Clearances around boiler

At least the following clearances should be achieved around the boiler. When the boiler is placed to the boiler room enough distance should be left for easy fuel loading to bunker, easy removing the geared motor and auger and easy servicing.

5.4 Circulation pump

We recommend building a forced water circulation system accompanied with a sufficient pump. Refer to the system diagrams given further in this manual to find the right position of thepump within the hydraulic circuit.

Your boiler automatically switches the pump on and off according the program stored in its PCB. That is why circulation pump must be driven by the control panel. Wiring to the pump is supplied at the back of the boiler.

5.5 Rules for hydraulic circuit

Cortina boiler can be installed in a pressurized heating circuit with addition of a closed expension tank in respect with one of the following schemes. If heat demand of building differs from the nominal capacity of boiler, we recommend a buffer tank between primary circuit and heating installation. Hydraulic circuit should have at least the equipments listed below:

Circuit without buffer tank:

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Primary circuit pump

6 Safety valve

Heating circuit pump

2 Globe valves

(open)

7 Manometer

Buffer tank

3 Globe valves (closed)

8 Radiator

Cortina

boiler

4 Check valve

9 Expansion tank

Boiler probe

5 Strainer

Air relief valve

Buffer probe

Circuit with buffer tank

We recommend a buffer storage tank capacity of 25 to 50 litres per kW boiler output.

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11 12 13 S1 S2

NOTICE

WARNING

CAUTION

For correct sizing of closed expansion tank, refer to calculations supplied by the manufacturer. Nevertheless, the volume of closed expansion tank should not be less than:

12 liters for Cortina 12 12 liters for Cortina 18 18 liters for Cortina 24 24 liters for Cortina 32 30 liters for Cortina 40

Safety of heating circuitg

• Install a ½” safety valve with a maximum relief pressure of 3 bars.

• Install a manometer to follow and check water pressure in the system. When

water is cold, system pressure should be set at 1 – 1,5 bars.

Risk of corrosion on boiler and heating circuit

• Your boiler is quite a strong design against corrosion. However, all metal

surfaces in whole heating circuit should be protected against corrosion like piping and radiators. The oxygen in heating water will cause rust and then material loss on iron-based metal surfaces by means of oxidation.

• During the first water make-up, oxygen must be fully discharged from the

system. Generally, oxidation will not be a problem, if all measures are taken into account during first water make-up. Oxidation will take place because of fresh water addition to the system during operation of the boiler. Leak points in a system will cause oxygen to be absorbed inside the heating water. For this reason, minimum water pressure in a pressurized heating circuit must be above atmospheric pressure. Besides, pressure levelshould always be checked periodically.

For new installations

• System should be sized and designed accordingly, in order to minimize fresh

water addition. Make sure that no part of the system is made of material that is permeable to gases. The original system filling water and any toppingup water must always be filtered (using synthetic or metal mesh filters with a filtration rating of no less than 50 microns) to prevent sludge from forming and triggering deposit induced corrosion. Minimum water pressure in a pressurized heating circuit must always be kept above atmospheric pressure

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CAUTION

For a new boiler installed on an old heating circuit

• In old systems used for a long time, a protective coating (black magnetite)

has been built on all metal surfaces contact with water. This coating protects the system agains further corrosion. When a mew boiler is installed in such an old system, new parts with clean metal surfaces, particularly boiler surfaces will inevitably become sacrificial anode for the entire heating system, in other words, they come in the first place where corrosion starts. That is why, following precautions should be added to those given above, for a new boiler in an old system:

• If the old system has an open expension tank, this may be converted to

pressurized system with all necessary safety measures.

• The old system must be fully washed up from all substitutes and particules

contained on the surfaces.

• An air separator with manual vent should be installed at the heighest level of

the circuit.

5.6 Chimney connection

Cortina boiler must be connected to an individual chimney that will provide at least the minimum draught given in the technical data of boiler. The flue duct between the boiler and the chimney should be insulated using a glass wool material. The flue duct to chimney and chimney must be made of steel or an equivalent material that can beresisting at temperatures around 400oC. All connections on the flue system must be sealed in order to perform a good combustion and efficiency. The flue duct must be connected to the chimney using the shortest way and in accordance with the dimensions given in the following scheme. Horizontal connections and equipment that will increase the pressure loss such as elbows should be avoided.

At the lowest level of chimney, there should be a cleaning cover which is made of steel, and sealed for any leakage. The length of flue duct between the boiler and the chimney should not exceed ¼ height of chimney. The size of flue duct and chimney should not be less than the size of the boiler flue gas outlet connection. For the total height and the minimum internal diameter of the chimney, following diagram should be referred in respect with boiler output power, if otherwise stated in mandatory regulations.

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WARNING

The size of flue canal and chimney should not be less than the size of the boiler flue gas outlet connection. For the total height and the minimum internal diameter of the chimney, following diagram should be referred in respect with boiler output power, if otherwise stated in mandatory regulations.

5.7 Electrical installation

The boiler is fed with 230 V. A regulator must be used in installations where the power supply is below 205 V or above 230 V.

All electrical installations must be carried out by authorized persons in accordance with mandatory regulations and codes of practice. Only qualified personnel may open the control panel on the boiler. Any interference with the wiring in the control panel will invalidate the warranty.

Connecting the power cord

Control panel should be connected to a wall plug with an efficient ground system, which is placed not far more than 50 cm. to boiler with a circuit breaker which has at least 3 mm gap between contacts. Use the power cord supplied with the boiler.

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CAUTION

WARNING

If the supply cord is damaged, it must be replaced by a special cord or assembly available from the manufacturer or its service agent.

Connecting the pump

Use the socket given attached with the boiler to make the pump connection. Incorrect core termination can cause severe injuries and damage to the equipment. Take care not to interchange wires "L1" and "N". Recommended connecting cable H05VV-F3G 0.50 mm2

Boiler Control Panel Electrical Schematic

• Before doing any work on the boiler related with electricity, ensure that the

power supply cable is disconnected from the network electricity or turn off the main switch located at the back of the boiler

• Sensor wires, sensors and keyboard wires must be mounted so that they

cannot be accessed without disassembling the combustion device.

• Earth connection must be connected to the controller and to the

metal part of the combustion device.

• Some of the wires carry dangerous voltages. Disconnect the controller

from the mains power supply prior to any service or mounting operation.

• Do not exchange high voltage and low voltage connectors during the

mounting of the controller.

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Specification

Grade A1

M1735

51731)

Moisture (M)

≤10.0

≤12.0

w-%

Ash, 550°C (A)

≤0.7

w-%

Ash, 815°C

≤0.7

≤0.5

w-%

Durability (DU)

≥97.5

≥97.7

w-%

Fines (F)

≤1.0

w-%

Additives

≤2.0

w-%

Net calorific value (Q)

≥4.6 & ≤5.3

≥4.6

≥5.0

kWh/kg

Net calorific value (Q)

≥16.5 & ≤19.0

≥16.5

≥18.0

MJ/kg

Bulk density (BD)

≥600

kg/m

WARNING

6 FUELS

Wood pellets are natural wood (dried sawdust or waste from machining) that has been formed into pellets under highpressure. They have a very low moisture content and very high calorific value.

6.1 Pellet quality

We recommend using pellets certified on new normative with EN Plus-A1 grade. If this quality could not be found, the pellets must then comlpy with one of normatives given in the following table:

Standards

Parameter

ENplus-A1

CEN/TS 14961-2

Old

ÖNORM

DIN+

(DIN

Unit

6.2 Pellet size

Suitable pellet size for Cortina boiler: Diameter 6 mm; maximum lentgh 40 mm.

6.2 Storing the pellets

1. Pellets are to be stored in a place where they are kept dry all year.

2. Legislation in your country must be observed regarding building specifications for storage

rooms.

Damage to property

• Use of unproper pellets in Cortina boiler can block air entrance to burner,

can cause damage on boiler and chimney. Use of these kind fuels will make warranty of the boiler invalid.

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L1L3L4

L5L6L7

7 OPERATION

Control Panel: Use and Functions

Led

Led Fix Blinking

L1 Stabilization phase Ignition Start phase L3 Burner OFF Extinguishing phase L4 Work phase Modulation/Standby phase L5 Auger ON - L6 Igniter Resistance ON - L7 - External Thermostat open L8 Pump -

Display

Display Fix Blinking

D1 Work Combustion Power

Set

D2 Boiler Thermostat Set Combustion Power Change D3 Boiler Temperature Boiler Thermostat Change

I indicates the Pellet

Buttons

Button Click [P click] Long Pressure [P long]

P1 Display other data / Esc Pellet recipe selection P2 Set in to the Menu function Burner Start / Stop

Alarms

Safety Thermostat (boiler) HV1: always signalled Block

Safety Thermostat (pellet) HV2: always signalled Block

Extinguishing for Lack of Flame Block

Extinguishing for Water over Temperature Block

Extinguishing for Exhaust gas over Temperature Block

Encoder Error: No Encoder Signal Block

Encoder Error: Combustion Fan regulation failed Block

Failed Ignition Block

Lack of fuel Block Anomaly in probe control during Check Up phase

recipe 1

II indicates the Pellet

recipe 2

Thermostat Setting/ Increasing Value / Scroll

Combustion Power Setting/Decreasing

Value/Scroll Menu

The reset of the BLOCK Condition is done by the Long Pressure of the button P2

ESC

START

SET

STOP

Pellet Loading Correction

Manual Pellet Loading

OFF

D3D4

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User Menu - Settings Fuel or Recipe Selection

Through a long pushing of the button P1 is changed the type of receipe.

The display D4 shows the selected recipe (I=Recipe 1; II= Recipe 2)

Ignition/Exstinguishing

The Ignition and Extinguishing are activated with a long pushing of the button P2 The Ignition is signalled by the first blinking than fix led L1 The Work state is signalled by the fix led L4 The Modulation state is signalled by the blinking L4 The Extinguishing is signalled by the blinking led L3 The Extinguishing finished = OFF state is signalled by the fix led L3

Combustion Power Setting

Click button P4: the display D1 blinks Trough the click of the buttons P4 (increasing)or P3 (decreasing) the power is changed according to the values available Ex.: 1 – 2 – 3 – 4 – 5 – A (A= Automatic Combustion) After 5 seconds the new value is memorised and the display shows as normal

Work Thermostat Setting

Click button P3: the display D2 blinks Trough the click of the buttons P4 (increasing)or P3 (decreasing) the value of the thermostat is changed. After 5 seconds the new value is memorised and the display shows as normal

Manual Pellet Loading

The long pressure of button P4 activates the Pellet Manual Loading with activation of Auger in continuous way. The bottom display shows LoAd and the upper display shows the elapsed loading time. To stop the loading push any button. The loading stops automatically after 300 seconds

Pellet Loading Correction

The activation is with a long pushing of the button P3 The bottom display shows PELL, the upper display shows the blinking value With buttons P3 / P4 the blinking value increases or decreases The values are between the range– 7 ÷ 7.The default value is ‘0’ After 5 seconds the new value is memorised and the display shows as normal

Display With a click sequence of P1 tP= Buffer Probe Temperature (if present) UF= Combustion Fan Speed [RPM/Volt] tF= Exhaust temperature [°C] bA3

00.00

+ Product Code

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WARNING

7.1 Supply Voltage Lack Management

In case of power failure, the system saves the most important functioning data. When the control board is supplied again, the system evaluates the saved data and if the Burner were ON in the phases Ignition, Normal, Modulation, Standby, the system goes in Recover Ignition.

In case of functioning state of OFF or Block, the system goes back to the previous state.

7.2 START-UP

Loading the pellets

Open the fuel loading door, and fill the container with pellets. Do not put any other fuels than specified wood pellets, or any other material. Then close fuel loading door. Observe the fuel level in the container each day through the inspection window at the right hand side of boiler.

At the first loading the feed screw may be empty. So use the manual pellet loading function (look: “usermenu-settings”) to supply some pellets to the feed screw.

Switch ON the boiler

Check the boiler to be in “OFF” position (fixed led L3). Switch ON the boiler with a long pushing of the button P2. Led status when the boiler is ON:

1. The Ignition is signalled by the first blinking than fix

led L1

2. The Work state is signalled by the fix led L4

3. The Modulation state is signalled by the blinking L4

If the ignition is not succeed during the predefined time (time out) the controller will turned OFF and the error message “Err12” will be displayed.

• An odour of the paint can be felt while the boiler fired up for the first

time.

• Do not open the combustion chamber door during operation.

• Never fill the burner pot with pellets by hand. Excessive combustion

material in the burner pot means that the pellets will not be ignited optimally.

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Switch OFF the boiler

Switch OFF the boiler with a long pushing of the button P2.

Led status when the boiler is switched OFF:

1. The Extinguishing is signalled by the blinking led L3

2. The Extinguishing finished = OFF state is signalled by

the fix led L3

When the boiler is switched OFF the fan continues running until the flue gas temperature falls below the set trash hold and then the fan is turned off.

7.3 Operation Phases

Check Up

This stage allows for the cleaning of the boiler and burner before the ignition phase.

-The exhaust fan on the burner run at full power to eliminate any dust or smoke (in the event of a

hot restart) from the boiler.

-All the system sensors are checked for correct connections.

Pre-Heating

This stage brings the ignition element to the correct temperature before loading the burner with pellets.

Pre-Load

A pre-defined starting dose of pellets is given into the burner by the auger.

Variable Ignition

This stage starts the ignition process.

-The heat from the ignition element is directed at the pellets by the fan which runs at a relatively

slow speed.

-At intervals the auger introduces more pellets once the flame has begun to establish.

-The flue gas temperature probe measures the temperature in the flue.

-At the end of this stage if the flue gas temperature is over a pre-defined temperature the process

continues to the next stage (Stabilisation)

-If this variable are not satisfied then this stage continues for another minutes (second ignition

attempt) and if the variable has not reached its value by the end of the second attempt, EXTINGUISHING will occur and an Er12 (Failed Ignition) will be displayed on the screen.

Stabilisation

This stage develops the flame even further before allowing the system to enter RUN mode.

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-The auger introduces pellets more frequently into the burner.

-The combustion fan and exhaust fan increase in speed to speed up the combustion process.

-The ignition element remains on in this stage.

-At the end of this stage if the flue gas temperature is over a pre-defined temperature the process

continues to the next stage. (Run mode)

-If this variable are not satisfied then this stage continues for another minutes (second ignition

attempt) and if the variable has not reached its value by the end of the second attempt, EXTINGUISHING will occur and an Er12 (Failed Ignition) will be displayed on the screen.

Run Mode

During run mode the combustion rates are pre-set for the 5 different power levels.

-On entering this phase the system starts at Power Level 1 and after defined time intervals

increases a Power Level each time until Power 5 is reached.

-The boiler will continue to run at Power 5 until the water temperature reaches within 8°C of the

set point.

-The ignition element is off during this phase.

-The auger ON/OFF values are pre-set for each of the power levels.

-The circulation pump is activated by the controller once the water in the boiler reaches 40°C. The

pump will turn off once the temperature drops to 38°C.

-If the unlikely event that the flue gas temperature decrease below pre-set low value for a period

of time then Er13 will appear to indicate that the light has gone out. This may be due to a lack of pellets entering the combustion tube due to dust or poor quality pellets.

Modulation Mode

The modulation range has been pre-set so that the system starts reducing to a lower power level when the water temperature comes within 8°C of the set point.

Standby / Extinguishing / OFF

The system goes into STANDBY when the water in the buffer reaches its set temperature or the water in the boiler reaches its set temperature (whichever is sooner) and the system goes into an extinguishing mode.

-The auger stops feeding pellets to the burner.

-The exhaust fan will run at full power until all light in the burner has extinguished and the

temperature in the flue has decreased to a safe temperature.

-Once the flame has been extinguished the system enters its Final Cleaning stage where the

burner cleaning takes place (the fan runs in its maximum to eliminate the dust in the fire pote).

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WARNING

The system will sit in standby until the water temperature decreases to a pre-determined amount when it will restart again with the CHECK UP phase. The system will go into the OFF state when the system gets a signal from a room thermostat or if

the system is turned off manually on the controller. The shutdown procedure is the same as STANDBY. Once the extinguishing phase has been completed the boiler will remain in the OFF state until a signal is given to the boiler to start.

7.4 Shutting the boiler down (end of season)

At the end of season, before shutting down the boiler, we recommend completely removing pellets from the hopper with the use of a vacuum cleaner with an extension.

During periods of disuse, the boiler must be unplugged and placed in a dry place protected from the elements. For greater safety, especially if there are children around, we recommend removing the supply cable from the rear of the boiler.

Upon re-start, when pressing the main switch (located on the back of the boiler) does not make the control panel display light up, it could mean that the service fuse needs replacing. On the rear of the boiler there is a fuse holding compartment which is located underneath the supply socket. Use a screwdriver to open the fuse-holder compartment and if necessary replace them (5 AT delayed)

External thermostat

The external thermostat can be used to turn the combustion system on and off. In this case the controller ignores all internal temperature thresholds and is operating exclusively with the thermostat input. To configure this option:

Connect the external thermostat to IN5, S5AND and GND.

If the external thermostat is not used don’t forget to bridge the terminals

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WARNING

CAUTION

8 CLEANING

Periodic inspections

• Check your fuel supply regularly and allow suitable time for deliveries –

try not to run out of fuel

• Check fuel level in the fuel container through inspection window at the

right hand side of boiler, and refill before it is completely empty.

• Check the ash tray and empty regularly.

• Inspect chimney, flue pipes, flue pipe joints, and flue pipe seals

regularly to ensure that smoke and flue gases are not drawn into, and circulated by, your home’s air circulation system. If you observe rust or smoke leakage, replace the pipe immediately.

• Exercise the safety relief valve at least once a year.

• Check the water pressure is between 1 – 1,5 bar when boiler is cold – if

water pressure is too low top up system with fresh water.

• Check wiring to boiler and pump

• DO NOT clean heating system surfaces when the unit is hot.

8.1 Cleaning the smoke tubes

Before cleaning, let the boiler cool down completely leaving 2 hours after combustion terminated. Always wear a glove to protect your skin

Move smoke tube cleaning lever up and down a few times each day boiler is in operation to clean heat transfer surfaces of the boiler

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WARNING

8.2 Cleaning the burner pot

Remove cleaning cover shield, and open burning pot cleaning cover. Take the burner pot out, and brush its bottom and side faces to clean ash and residue.

Move ashes on the burner plate downwards onto bottom of boiler (where ashtray is loacted) using the same brush. Fit the burner pot back again it original place, paying attention to the following picture:

Burner pot should be cleaned, at least, on every other day

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WARNING

8.3 Ash removal

Open ash cleaning door, take the ashtray out, and empty it into a steel container. Ash accumulated at the bottom of boiler should wiped out

Do not take ash tray or ashes out of boiler, when they are hot

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9 MAINTENANCE

We recommend an annual maintenance contract with an authorized after sale stuff approved by your dealer in your region. Before each new heating season, at least the following inspections and maintenance should be carried out:

• Cleaning of draught fan

• Control of boiler and flue thermostat

• Control of safety thermostat for back burning protection on fuel feeder

• Inspection of the smoke tube cleaning lever

• Cleaning of ashes accumulated on top of heat exchanger (under cast iron cover)

• Inspection of sealing on front doors, and top cast iron cover

• Test of ignition electrode

• Control of burner pot and pellet feeder inside combustion chamber

• Control of all wirings

• Control of chimney connection and draught in chimney

• Control of other system components such as pump, expension tank, pipes and fittings

• Control of water pressure level, if necessary water make-up, and air vent

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10 TROUBLESHOOTING

Error Code

Cause Remedy

ER 01 Safety Thermostat Tripped

The boiler safety thermostats have tripped due to high water temperature in the boiler

ER 02 Pellet thermostat tripped

The pellet thermostat has detected heat travelling back up the drop tube into the burner

ER 03 Accidental extinguishing due to

low flame

The boiler has gone out unexpectedly!! It may have run out of fuel The pellets may be poor quality. The fire pot may be blocked

Check the boiler and heating system is full of water. Check the boiler pump is working Check that there are no valves in the boiler primary circuit that may have been closed inadvertently. Reset high limit thermostats. (remove black caps and press red button with the tip of a ballpoint pen or similar until it clicks) Reset the boiler by pressing on-off button (P2) for 3 seconds for the error to clear.

If error does not clear call your installer

Check that the exhaust fan is running Check for blockages in the flue, clear if found. Turn off power to the boiler Ensure the pellet drop tube is cool to the touch. Press the button on the pellet thermostat to reset the thermostat. Ensure that the connectors have connected with the pins on the thermostat. Turn power back on. Reset the boiler by pressing on-off button (P2) for 3 seconds for the error to clear. If error does not clear turn power off and re-check pin connectors If error does not clear call your installer

Ensure the boiler is cool Open the fire door; remove the fire pot and clear with the brush. Note what you find: (typically unburned pellets but may be char or clinkers as well). Reset the boiler by pressing on-off button (P2) for 3 seconds for the error to clear. Restart the boiler. If the boiler does not relight: Refer to ER 12 and: Check there are enough pellets in the hopper Check that the pellets are not dusty. IF the pellets are dusty the hopper and auger will need to be cleared. call your installer

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Error Code

ER 04

ER 05

ER 07

Cause Remedy Water Over Temperature

The water in the boiler has reached a temperature of 95°C

Check that the boiler is full of water by: Checking that the system is at the correct operating pressure (sealed systems only) Check the pump is working. Reset the boiler by pressing in the manual high limit thermostat. Reset the boiler by pressing on-off button (P2) for 3 seconds for the error to clear.

If error does not clear call your installer

Exhaust Over Temperature

Flue gas temperature has exceeded pre-defined value.

IF the flue temperature has reached this high level it is likely that the heat exchanger is damaged or not working. Check when the boiler was last serviced. If the boiler was serviced less than 1200 hours ago check the target board for damage. In either case call your installer

No encoder signal

The sensor is broken. Call your installer.

ER 08 Fan regulation failed

The fan is damaged. The fan is blocked.

ER 12 Ignition Failed

During the ignition cycle the

boiler has not detected a flame The ignitor has failed OR the pellets have not lit for another reason

Call your installer.

Ensure the boiler is cool Open the fire door; remove the fire pot and clear with the brush. Note what you find: (typically unburned pellets but may be char or clinkers as well). Check there are enough pellets in the hopper Check that the pellets are not dusty. IF the pellets are dusty the hopper and auger will need to be cleared. Check that the ignitor is functioning. If not call your installer.

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Thermasis Cortina 12 S, Cortina S Series, Cortina 24 S, Cortina 18 S, Cortina 32 S Installation & User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual