Thermona Therm 28 KD, Therm 28 KDZ, Therm 28 KDC Installation Manual
Manual for Installation
and Maintenance of
Condensing Boilers
Therm 28 KD, KDZ, KDC
2
INDEX:
INDEX:.........................................................................................................................................................................2
1. USAGE....................................................................................................................................................................3
2. GENERAL DESCRIPTION OF THERM 28 KD BOILERS .................................................................................3
3. TECHNICAL SPECIFICATIONS..........................................................................................................................5
4. PRODUCTION CHECK .....................................................................................................................................6
5. INSTRUCTIONS FOR INSTALLATION..........................................................................................................6
♦ POSITION OF THE BOILER.........................................................................................................................6
♦ BOILER HANGING .......................................................................................................................................6
♦ BOILER CONNECTION TO WARM WATER SYSTEM............................................................................6
♦ CONDENSED FLUID DRAIN.......................................................................................................................7
♦ BOILER CONNECTION TO DOMESTIC HOT WATER SYSTEM (DHW)..............................................7
♦ BOILER CONNECTION TO GAS ................................................................................................................7
♦ BOILER CONNECTION TO SUPPLY MAINS............................................................................................7
♦ FLUE EXHAUST............................................................................................................................................8
♦ HEATING SYSTEM FILLING ......................................................................................................................8
♦ CHOICE OF REGULATION AND CONTROL ELEMENTS ......................................................................8
♦ STARTING THE BOILER .............................................................................................................................9
♦ DISCONNECTING THE BOILER.................................................................................................................9
6. INSTRUCTIONS FOR OPERATION AND MAINTENANCE ............................................................................9
♦ OPERATING THE BOILER ..........................................................................................................................9
7. DIMS03-TH01 MODULATION ELECTRONICS...............................................................................................11
8. SIT 848 SIGMA GAS FITTING............................................................................................................................14
9. GUARANTEE AND LIABILITY FOR DEFECTS ..............................................................................................15
10. GRAPHS OF THE USABLE CONNECTING EXCESS PRESSURE OF THE HEATING WATER ...............16
11.WIRING CONNECT. OF THE THERM 28 KD BOILERS WITH THE DIMS03-TH01 AUTOMATICS........17
12.WIRING CONNECT. OF THE THERM 28 KDC BOILERS WITH THE DIMS03-TH01 AUTOMATICS.....18
13.WIRING CONNECT. OF THE THERM 28 KDZ BOILERS WITH THE DIMS03-TH01 AUTOMATICS .....19
14. THERM 28 KD SET ............................................................................................................................................20
15. THERM 28 KDZ SET..........................................................................................................................................21
16. THERM 28 KDC SET..........................................................................................................................................22
17. HANGING THERM 28 KD, KDZ, KDC BOILERS..........................................................................................23
18. INSTALLATION VERSIONS.............................................................................................................................24
19. RECORD OF GUARANTEE / POST-GUARANTEE REPAIRS AND YEARLY MAINTENANCE CHECKS
....................................................................................................................................................................................25
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1. USAGE
Hanging condensing boilers THERM 28 KD are modern gas appliances with a forced flue exhaust (they need no
chimney) suitable for heating in such houses whose heat losses do not exceed 28 kW. The combustion process
taking place in these appliances is based on the principles of steam condensation. The THERM 28 KDs are boilers
with maximum efficiency and minimal emissions to the air, which means that their operation is very economical
and environment friendly. Their output is adjustable ranging from 18 to 100 % and it adapts itself automatically to
the heating needs of the premises.
The high technical standard is guaranteed by the use of top components from the world’s best producers.
The engineering solutions of the THERM 28 KD boilers are the following:
THERM 28 KD – modification of the boiler used only for warming of the heating appliance (the actuating
circuits enabling external connection of a three-way valve necessary for the warming of the DHW supply tank have
been maintained)
THERM 28 KDZ – used for warming of the heating appliance and for warming of the external DHW supply
tank with a continuous output modulation in both regimes
THERM 28 KDC – for warming of the heating appliance and DHW through-flow heating with continuous
output modulation in both regimes
All boilers are provided with an expansion vessel with a capacity of 7 litres.
Warning: For the proper boiler functioning, it is necessary to keep the minimum water pressure in the heating
system at 0.8 bars (measured when the water is cold). If the boiler is connected to a system with an open expansion
vessel, the expansion vessel must be placed at least 8 m above the boiler.
2 . GENERAL DESCRIPTION OF THERM 28 KD BOILERS
The THERM 28 KD gas boiler is made up of a supporting frame to which all operative elements are attached.
In the upper part of the frame there is a stainless compact condensation device Giannoni that connects the
combustion chamber with the burner and the two-chamber exchanger. The heat-mediating surface of the
exchangers is made of circular tube plates. These must be protected against the dirt coming from the heating system
which might clog them up. Therefore, it is necessary to install a filter at the return water inlet into the boiler. The
collector at the outlet of the heating water is equipped with an automatic deaerating valve and a temperature
indicator. The removable front wall of the device is fitted with two electrodes (ignition electrode and ionizing
electrode), with a tubular burner and a modified pipiline conducting the air-gas mixture.
The approriate rationing of the air-gas mixture and its mixing is ensured by a mixer and a special gas fitting. The
latter contains a gas pressure regulator, two solenoid blocking valves and a ratio control of the outlet gas volume
with the elements for mechaical setting. The setting of synchronous ratio control is possible only if a special
instrumentation device is used. The whole system is based on the principle that the volume of the added gas is
directly proportional to the volume of air supplied by the ventilator and passing through the mixer. The boiler
output is consequently dependent on the volume of the air that is circulating in the system for the purposes of
combustion.
The running speed of the ventilator is fully controlled by means of electronic devices, which ensures a wide
output range of the boiler. The air supply for the ventilator is ensured by a modified pipeline from the connecting
set.
The exhaust of the condensed fluid from the condensation device, as well as from the pipelines of the flue exhaust
and air supply is realized through hoses conducting the condensate to a siphon trap, from where it is conducted
away, outside the boiler.
The adequate supply of combustion air as well as the forced flue exhaust outside the boiler is usually ensured by
coaxial tubes that lead either horizontally through the perimeter wall or vertically over the roof structure out into
the open space. The tubes must be installed in such a way that prevents the potential freezing of the exhaust ending
(this might happen due to the low temperature of the streaming flue). For this reason it is crucial that the vertical
tube be topped by a roof chimney while the horizontal tube must be installed with a moderate fall in the direction
from the exhaust to the boiler.
At the return water inlet there is a service pump Grundfos / Wilo that drives the water through the boiler. The
sufficient flow of the heating water is ensured by a flow-switch that is a part of the multifunctional flue collector
GRF 3. It is installed there together with a by-pass and a valve used for the refilling of the heating system from the
DHW circuit (or, where applicable, from the external connection), and the bleed valve. The flue collector is further
connected to a safety valve controlling the potential excess pressure in the boiler.
The heating water outlet of the THERM 28 KDC and KDZ boilers is fitted with a motor-driven three-way valve
by means of which the functions of DHW warming and warming of the heating appliance are kept apart.
The process of DHW warming in the THERM 28 KDC boilers takes place within the desk exchanger.
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The control panel is all made of plastic. On the front side there are the control elements (see the instructions for
operation), in the inside there is the DIMS03-TH01 automatics containing the microprocessor controlling the boiler
operations and the electric circuits participating in the ignition of the burner.
Important:
The type of supply of the ionizing current is determined by the neutral. It is therefore crucial that the neutral
and the phase are not confused in the socket that connects the boiler to the supply mains. The installation of the
socket must comply with the local valid norms. If this regulation is not followed, the boiler will not be functional.
5
3. TECHNICAL SPECIFICATIONS
units THERM 28 KD THERM 28 KDZ THERM 28 KDC
Nominal heat input:
- natural gas kW 26.4 26.4 26.4
- propane kW 23.5 23.5 23.5
Minimum heat input:
- natural gas kW 4.9 4.9 4.9
- propane kW 4.9 4.9 4.9
Nominal heat output for heating at
∆t = 80/60 °C:
- natural gas kW 26 26 26
- propane kW 23 23 23
Nominal heat output for heating at
∆t = 50/30 °C:
- natural gas kW 28 28 28
- propane kW 25 25 25
Nominal heat output for DHW heating:
- natural gas kW 26 - 26
- propane kW 23 - 23
Minimum heat output at ∆t = 50/30 °C kW 5 5 5
Gas screen hole:
- natural gas mm 6.5 6.5 6.5
- propane mm 5 5 5
Gas excess pressure on the inlet of the
appliance:
- natural gas mbar 20 20 20
- propane mbar 37 37 37
Gas consumption:
- natural gas m3.h
-1
0.5 – 2.85 0.5 – 2.85 0.5 – 2.85
- propane m
3.h-1
0.19 – 0.93 0.19 – 0.93 0.19 – 0.93
Max. heating system excess pressure bar 3 3 3
Min. heating system excess pressure bar 0.8 0.8 0.8
Max. DHW inlet pressure bar - - 6
Min. DHW inlet pressure bar - - 0.5
Max. heating water outlet temperature
o
C 80 80 80
Coaxial flue exhaust diameter mm 60/100 60/100 60/100
Average flue temperature
o
C 50 50 50
Weight flue flow:
- natural gas g.s
-1
3.1 – 14.7 3.1 – 14.7 3.1 – 14.7
- propane g.s
-1
3.4 – 17 3.4 – 17 3.4 – 17
Max. noisiness according to valid norms dB 52 52 52
Boiler efficiency % 98 - 106 98 - 106 98 – 106
Boiler NOx class 5 5 5
Nominal supply voltage / frequency V / Hz 230 / 50 230 / 50 230 / 50
Nominal electric input W 150 150 150
Nominal fuse current A 2 2 2
Level of electric components cover IP 41 (D) IP 41 (D) IP 41 (D)
Surroundings according to valid norms
basic
AA5/AB5
basic
AA5/AB5
basic
AA5/AB5
Volume of expansion vessel l 7 7 7
Expansion vessel filling excess pressure bar 1 1 1
DHW tank volume l - 40 – 200 DHW temperature kept in the tank
o
C - 65 -
DHW though-flow at ∆t = 30 oC:
- natural gas l.min
-1
- - 12
- propane l.min
-1
- - 11
Boiler dimensions: height/width/depth mm 800/450/370 800/450/370 800/450/370
Boiler weight kg 45 46 47
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4 PRODUCTION CHECK .
All boiler parts are rechecked and set by the manufacturer before they are assembled. Each boiler is tested for
water system staunchness, gas system staunchness; regulating and safety components are rechecked and set.
5 . INSTRUCTIONS FOR INSTALLATION
Boiler mounting can only be done by a qualified expert company, while this has to respect all the advice and
notes in this manual. The mounting has to be carried out in correspondence with valid local norms and regulations.
The mounting company is required to check the suitability of the chosen boiler with respect to its functional
character and customer’s requirements. Further, it is necessary to check the label on the packaging to be sure the
delivered boiler corresponds with the ordered boiler and the fuel type. When it is unpackaged it is necessary to
check if the delivery is correct and complete. In case of any doubts, inform the manufacturer or the supplier before
mounting.
♦
POSITION OF THE BOILER
The THERM 28 KD boilers may be placed both in the interior and in the non-residential areas of a house (in a
boiler room, etc.). When placing the boiler inside a flat it is recommendable to set the limitation of maximum boiler
output at the lower level of the power loss range and reduce thus the noise that the boiler makes when being
operated at a lower output level.
The boilers are equipped with IP 41 covering of electrical parts and their position in all rooms in which there is a
tub or shower or which are used for bathing, must comply with the valid local norms.
The room where the boiler is placed must be a “common basic environment” as it is defined in the valid
regulations, which means that it has to be protected against frost with ambient temperature ranging from + 5 °C to
+ 35 °C with relative humidity lower than 80 %.
According to the valid norms, there are certain objects that must not get closer to the boiler than:
100 mm for objects made of not easily flammable, heavily flammable and medium
flammable materials.
200 mm for objects made of easily flammable materials (e.g. fibreboards, cellulose materials,
polyurethane, polystyrene, polyethylene, PVC, etc.)
Important:
No flammable objects can be placed closer than at the safe distance from the boiler (the minimum distance of the
appliance from flammable materials is 50 mm in the direction of the main heat radiation and 10 mm in the other
directions).
Before you start doing anything that could possibly change the environment of the installed boiler (e.g. working
with paints, adhesive agents, etc.), you must switch the boiler off by the mode switch (pointer to the left).
♦
BOILER HANGING
Before the boiler is mounted make sure the chosen place meets the requirements for flue exhaust placement and
for minimum distances stated in the previous sections. Using the dimension scheme (see back pages in this manual)
prepare the anchorage by which the boiler will be mounted.
♦ BOILER CONNECTION TO WARM WATER SYSTEM
Since the THERM boiler is a warm-water through-flow boiler that is equipped with its own pump, it is possible to
connect it to any existing gravity circulation system or to any new technologies designed for the forced water
circulation in the heating system. With regard to the rapid temperature rise and a relatively high flexibility of the
system, it is recommendable to use small volume radiators and the least dimensioned piping in the case of a new
distribution system. The piping system has to be duly projected on the basis of hydraulic ratio calculations and total
transmitted power. In order to use the condensation regime as effectivelly and economically as possible it is
advisable to dimension the heating system for lower temperatures (∆t = 50/30 °C). If you want to achieve the
maximum output of the flue exchanger and ensure a proper functioning as well as long durability of the whole
system, it is necessary that the minimum excess pressure of the heating system be 0.8 bar.
Before the boiler is connected to the heating system it is necessary to rinse it very carefully, so that all impurities
and sediments can be removed. The heating system has to be equipped with a suitable filter and comply with the
local norms.The inbuilt expansion vessel enables the boiler to be connected to a sealed heating system.
The necessary expansion volume for the given system must be calculated according to the following formula:
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V
c
= V . ∆ v . 1.3
V
c
expansion volume (m3)
V water volume in the heating system (m
3
)
∆
v
relative increase of water volume at the increased temperature tm
(if t
m
= 80 oC then ∆ v = 0.029)
The calculated expansion volume is the smallest volume. If the calculated expansion volume is higher than the
volume of the expansion vessel in the boiler it is necessary to install another expansion vessel in the system.
♦
CONDENSED FLUID DRAIN
The boiler is equipped with a siphon trap that must be filled with circa 100 ml of water before the boiler is put
into operation. The exhaust pipe must be installed with a falling gradient of minimum 5° from the boiler to the
drainage it must not be in any way clogged (the clogging of the condensed water drain leads to resonation in the
combustion chamber of the boiler).
Analysis of the condensed fluid:
indicator Unit Value
PH - 3
Nitrites mg.l
-1
0.01
Copper(Cu) mg.l
-1
0.2
Lead (Pb) mg.l
-1
0.01
Cadmium (Cd) mg.l
-1
0.004
Zinc (Zn) mg.l
-1
0.12
♦
BOILER CONNECTION TO DOMESTIC HOT WATER SYSTEM (DHW)
The connection of the domestic water inlet must be done according to relevant norms and standards, with all the
necessary armatures. The quality of water circulating in the DHW system is critical for the prevention of
incrustation being created in the heat exchanger. Therefore it is crucial that the water meets the relevant quality
norms, mainly as far as water hardness is concerned (the sum of material concentrations of calcium and magnesium
< 2.5 mmol/l). If you have doubts or insecure parameters (e.g. if the users have their own well), we recommend
using automatic water modification equipment.
♦ BOILER CONNECTION TO GAS
The boiler must always be connected to gas by a professional company with valid certification and its
professional certified employees and according to the approved documentation for gas fitting. The gas regulator is
not to be fitted in front of the boiler, as it is inbuilt in the gas armature, which is a part of the boiler. A round gas
cock with a certificate for gas must be fitted to the boiler’s gas inlet. The gas cock must be freely accessible.
The boiler is designed for
natural gas with 9 to 10.5 kWh/m3 heating power and 20 mbar nominal pressure in the
distribution net and for
propane with 37 mbar nominal pressure in the distribution net.
Important:
If you change the boiler to another gas type it is necessary to change the gas screen, too. This is situated at the
screwed fitting between the gas outlet from the gas fitting and the mixer. Further, it is necessary to check, or where
applicable, to reset the corresponding parameters concerning the synchronous mixing on the gas fitting. The values
to be set are the amount of CO
2
contained in the flue ranging from minimum to maximum boiler output depending
on the flue analyser.
The change and resetting can only be carried out by a trained service worker certified by the manufacturer.
After the control elements are reset they have to be secured against unauthorized manipulation. The manufacturer
is not liable for any damages resulting from unauthorised setting.
♦
BOILER CONNECTION TO SUPPLY MAINS
The boilers are equipped with a triplex flexible cable with a plug. They are to be plugged in the socket nearby so
that the plug is accessible even after the boiler is mounted. The installation of the socket must comply with the
local valid norms, with the protection pin at the top and the central or neutral connected on the right from the front
view. The mains voltage must be 230 V ± 10 %. The socket installation, the connection of the room thermostat,
8
and, if applicable, the connection of the outside temperature sensor THERM Q01 for weather compensated
regulation, as well as the maintenance of the boiler’s electrical parts, can only be provided by a professional person
qualified for electro-technical work pursuant to the valid norms.
♦
FLUE EXHAUST
The boiler must be mounted with the necessary accessories (the piping for combustion air supply and flue
exhaust including the outlet, distance pieces, piping armatures) that is allotted to the particular boiler type. These
components are supplied separately depending on the installation type and the concrete installation conditions, and
the boiler must not be put into operation without them. The possible flue exhaust installation versions are shown at
the end of this manual.
The basic requirements for the flue exhaust outlet of appliances with a burner with the forced combustion air
supply and with the forced flue exhaust must follow relevant technical standards. The connection to a chimney,
where applicable, must, too, comply with the corresponding technical standards. The actual flue exhaust solution
must be designed and projected with respect to the standard regulations providing for the condensate exhaust. The
horizontal piping must be installed with a falling gradient of 2° from the ending towards the boiler so that the
escape of the condensed fluid from the exhaust ending into the adjacent area can be prevented.
The maximum pressure loss of the flue exhaust and combustion air supply system is 80 Pa.
The maximum coaxial flue exhaust lengths allowed by the manufacturer:
Horizontal piping: The shortest length is 1 m, the longest is
3 m – measured from the elbow on the appliance
to the outlet on the façade. Each another 90º elbow shortens the length by 0.75 m and each 45º elbow by 0.5 m.
Vertical piping: The shortest length is 1 m, the longest is
2.7 m – measured from the appliance to the bottom
edge of cowl collar. Each 90º elbow shortens the length by 0.75 m and each 45º elbow by 0.5 m.
When a distributor and separate piping for flue exhaust and combustion air supply with diameter Ø 80 mm are
used including the outlet, the stated maximum lengths can be doubled (i.e. horizontal piping can be up to 6 meters
long, subtraction of the elbow resistance is still valid).
♦
HEATING SYSTEM FILLING
During the time when the heating system is filled with water the boiler must be unplugged, i.e. the plug must be
out of the socket. The recommended heating water pressure ranges from 1 to 1.5 bar when the system is cold. The
heating system must be filled slowly so that the air bubbles can escape through the deaerating valves. The water
used both for the first filling and refilling must be clear, colourless, without suspended solids, oil or chemically
aggressive additives, it must not be acid (pH lower than 7), with the minimum carbonate hardness (max. 3.5 mval/l)
and it must comply with the relevant local norms. If the above mentioned requirements are not met the pump,
exchanger, or other components of the boiler can be damaged.
The manufacturer is by no means liable either for the above mentioned damages or, where applicable, for the
clogging of the exchanger, which means that the guarantee cannot be applied in such cases!
To refill the heating system an inbuilt valve can be used. It can be adjusted at the bottom of the boiler (close to
return water inlet). When the required pressure is reached the valve must be closed again.
♦ CHOICE OF REGULATION AND CONTROL ELEMENTS
The boiler is equipped with basic regulation and safety elements, as follows from the following wiring diagrams.
As further expansion, it is possible to use regulation according to the temperature in the selected reference room or
the weather-compensated regulation of the heating water, or a combined regulation.
The manufacturer offers a wide range of thermostats for the room temperature control, e.g. Digistat 3, Honeywell
CM 27, CM 67, popř. T 8360A1000, TG - TM 100/19 and others. For the weather compensated regulation there is
the outside sensor THERM Q01 offered by Thermona.
A high-quality regulation can be achieved by using a smart programmable regulator SIEMENS QAA 73.110 that
is continuously communicating with the boiler microprocessor via the IU02 interface. The data communication
that takes place in this way concerns the required temperature of the heating system in relation to the indoor and
outside temperature. It also produces information on boiler operations (nominal range of use, output, temperatures,
potential defects, possible switch-off of the DHW supply tank heating at night when the scope of use is limited,
etc.). The major characteristic of this system is the vast number of its adjustable and displayable parameters that
ensure an ideal run of the heating system with power modulation.
When you order a Therm boiler, we supply the aforementioned regulators at reduced prices.
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