Thermona Therm DUO 50 FT Manual For Installation And Maintenance
Manual for
installation and
maintenance
DUO 50 FT
2
Contents:
1. Usage ....................................................................................................................... 3
2. General description ................................................................................................. 3
3. Technical specifications ......................................................................................... 4
4. Production check ...................................................................................................... 5
5. Instructions for boiler mounting................................................................................... 5
• Position of the boiler ............................................................................... 5
• Boiler hanging .......................................................................................... 5
• Boiler connection to warm-water system ................................................. 5
• Boiler connection to gas .......................................................................... 5
• Boiler connection to supply mains ........................................................... 6
• Boiler connection to chimney .................................................................. 6
• Heating system filling ................................................................................ 6
• Choice of regulation and control elements ................................................ 7
• Starting the boiler ...................................................................................... 7
• Disconnecting the boiler ........................................................................... 8
6. Regulations for control and maintenance .................................................................. 8
• Use of the boiler ........................................................................................ 8
• LCD display ............................................................................................... 9
• Maintenance ............................................................................................. 10
7. Gas fitting SIT 845 SIGMA .................................................................................... 10
8. Boiler hanging ........................................................................................................ 11
9. Graphs for output and connecting excess pressure setting .......................................... 11
• 9.1 Graphs for usable connecting overpressure of heating water ............... 12
• 9.2 Graphs for output setting ...................................................................... 13
10. Therm DUO 50 FT sets ............................................................................................. 14
11. Wiring diagrams ...................................................................................................... 16
12. DIMS01-TH01 modulation electronics....................................................................... 17
13. Guarantee and liability for defects .......................................................................... 19
14. Installation versions .................................................................................................... 20
15. Record of repairs ..................................................................................................... 21
16. Quality certificate ...................................................................................................... 22
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1. USAGE
THERM DUO 50 FT is an advanced wall-mounted source of heat energy for premises with the
maximum heat loss of 45 kW. It can be used separately or in a cascade for large buildings. The demanded
output of the boiler room will be acquired by using more Therm Duos in a cascade, which is controlled by
its own expansion regulation including weather compensated regulation. In this easy way you can acquire
a heat source with high efficiency. The construction of boilers in a cascade lowers the operational costs
and losses compared to standard boiler rooms. The boilers are designed as appliances with maximum
efficiency and minimal emissions to the air, their operation is economical and it does not harm the
environment. The boiler output is adjustable within 50 and 100 % and it adapts itself to the current needs
depending on heat losses.
The high technical standard is guaranteed by the use of top components from the best world
producers.
Important: The boiler is designed for heating systems equipped with an open expansion vessel with
min. height of 8 m above the boiler.
2. GENERAL DESCRITPTION OF THERM DUO 50 FT
All functional parts of THERM DUO 50 FT are fixed to a metal supporting frame. There are two
copper flue exchangers in its upper part. Their surface is protected by an aluminium and silicone mixture.
Inside the tube sheet there are turbulators, which have to be protected against blocking by dirt from the
heating system. Therefore, it is necessary to install a filter at the return water inlet in the boiler. To
maintain the minimum losses of heat transfer it is essential to keep exchanger lamellas clean. The
exchanger usually gets dirty when dust particles are burned (the boiler operates in a dusty environment).
There are automatic deaerating valves on the inlet and safety contact thermostats on the outlet of the flue
exchanger.
The combustion chamber is made of aluminium plated metal sheet and it is inlaid by a heat
insulation. The front wall is removable. Above the exchangers there is an exhaust rectifier.
There is an eighteen-armed, water-cooled, low NOX gas burner in the lower part of the combustion
chamber. The burner is a product of POLIDORO. It has an advanced modular construction and it is fitted
with three electrodes. Two of them (ignition electrodes) ignite the burner; the third (ionization electrode)
checks the burning
SIT gas fitting is connected to the burner by a grommet and screwing. The fitting includes a gas
pressure regulator and two solenoid valves controlled automatically.
There is also a modulating electromagnet. The magnetic coil core of the modulator has an adjustable
lift so gas pressure into burner can be adjusted within the set range.
There is a Grundfos pump on the return water inlet. The pump drives the water through the boiler.
The sufficient through-flow is watched over by a through-flow switch. Moreover, there is a safety valve
connected to in front of the pump to protect the boiler against excess pressure.
The control panel is made of plastic. The control elements are placed on the front of the plastic
control panel (see the operational rules). There is a DIMS01-TH01 microprocessor automatics for boiler
control inbuilt inside
THERM DUO boilers work without an ignition burner and they are ignited with an electric spark,
which means greater gas savings.
The ventilator and the components engaged in gas combustion and power transformation are inbuilt
in a closing chamber. The sufficient supply of combustion air and the forced flue exhaust are usually
ensured by the coaxial tubes that go horizontally through the perimeter wall or vertically through the roof
construction out into the open space. The coaxial tubes must be installed in such a way that any
penetration of rainwater or condensed water into the boiler can be averted. It is therefore necessary that
the vertical tubes be finished with a stack, whereas the horizontal tubes must be installed with a moderate
fall in the direction from the boiler to the flue exhaust. Should these instructions be disregarded, the
components inside the closing chamber, in particular the flue ventilator, are easily liable to damage.
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The ventilator’s operation is checked by manostat. When the electric manostat contact closes the
ignition cycle starts and the burner is ignited.
GRUNDFOS 15/60 pump is used for this version. Graph for usable connecting overpressure of
heating water with max. boiler output and heat slope up to 20oC shows relatively low excess pressure for
the heating system. It is necessary to remember to use an additional system pump, mainly when a separate
boiler is installed into a heating system (especially with horizontal distribution nets).
It is necessary to use 80/125 mm flue gas ducting for this type of boiler. Proportion of outlet flue
gas ducting is 60 mm. Don´t forget to put reduction (from 60/100mm to 80/125mm) pipe directly on the
boiler flue outlet.
It is possible to use a distributor above the boiler and lead a separate pipe through which the
combustion air will be supplied and another through which the flue gas will be exhausted.
3. TECHNICAL SPECIFICATIONS
units
DUO 50 FT
Flue natural gas
Boiler category I2H
Maximum heat input kW 49
Minimum heat input kW 27,5
Maximum heat output for heating kW 45
Minimum heat output for heating kW 25
Number of burner nozzles ks 36
Nozzle drilling : mm 1
Gas excess pressure at the inlet: mbar 20
Gas pressure at burner nozzles: mbar 4 – 12
Gas consumption: m3/h 2.9 – 5.2
Max. heating system excess pressure bar 3
Min. heating system excess pressure bar 0.8
Max. heating water outlet temperature
o
C 80
Average flue temperature
o
C 100
Max. weight flue flow g.s
-1
44.7
Max. noisiness dB 53
Boiler efficiency % 92
Boiler NOx class 5
Nominal supply voltage / frequency V / Hz 230 /50
Nominal electric input W 150
Nominal fuse current A 1.6
Level of electric components cover IP 41
Surroundings according to valid norms
common
AA5/AB5
Flue exhaust diameter mm 80/125 (2x80)
Dimensions: height / width / depth mm 900/600/475
Boiler weight kg 52
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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 BOILER MOUNTING
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 and technical guidelines.
The mounting company is required to check:
− if the boiler type is the ordered one
− the choice of boiler was correct as far as the situation is concerned (gas type, heating system,
exhaust)
− the delivery is complete
In case of any doubts, inform the manufacturer or the supplier before mounting.
♦ Position of the boiler
The design and construction of THERM DUO FT boilers enable them to be used both in places of
living and other places (boiler rooms etc.). The boilers have IP 41 cover of electrical parts, which fulfils
the conditions for resistance to vertically dripping water.
The room where the boiler is placed must be a common basic surroundings AB5 protected against
frost, with ambient temperature within + 5 °C and + 40 °C with relative humidity lower than 80 %
according to valid norms. The combustion air must not contain halogen hydrocarbon or aggressive
vapours, it must not have high humidity and dustiness.
The size of the room where the boiler is installed and its airing must follow valid technical
regulations.
Important!
No flammable objects can be placed within the safe distance from the boiler (i.e. 50 mm), and within
the safe distance from the exhaust pipe and check glass (i.e. 200 mm). The wall where the boiler is
mounted must be made of inflammable material.
Before any work which could change the surroundings of the boiler starts, you have to switch off the
boiler by the mode switch (pointer to „0“).
♦ 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 chapters. If the boilers are place in a cascade
we recommend fitting them on a common supporting structure.
♦ Boiler connection to warm-water system
Boiler rooms with THERM DUO 50 FT cascades must be solved by a project according to hydraulic
ratio calculations with respect to total outputs.
The connection of boilers to heating distribution systems and gas distribution must be carried out so
that the boiler outlets are not strained.
Before the boiler is connected it is necessary to purge the heating system to remove all impurities
and sediments. The return water inlet must be fitted with a suitable filter.
The heating system must observe the relevant local norms.
Make sure the minimum excess pressure of the heating system is 0.8 mbar.
♦ 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
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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.
Important!
If you change the boiler to another gas type it is necessary to dismantle burner’s ramp, to change the
nozzles and to reset the min. and max. pressure on the gas fitting. Further, it is necessary to reset the
concerned parameters on the modulation electronics. The change and resetting can only be carried out
by a trained service worker certified by the manufacturer.
♦ 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 socket must be protected
by a neutral or an earthing, with the protection pin at the top and the 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 and the maintenance of the boiler’s electrical parts can only be provided by a
professional person qualified for electrotechnical work pursuant to the valid norms.
♦ Boiler connection to chimney
In order to exhaust the flue gas and supply enough combustion air in the boiler, a double pipeline
(80/125 mm) is usually used. These pipelines are provided by the manufacturer of the boilers and it is
possible to order them according to the concrete project’s specifications (horizontal or vertical exhaust
including gasket sleeves, o-rings, etc.). It is logically possible to use a distributor above the boiler and
lead a separate pipe through which the combustion air will be supplied and another through which the
flue gas will be exhausted. Given the wide range of possible solutions, the exhaust components are not
delivered as the standard boiler fixtures.
Connection of the boilers to solid flues must be carried out in compliance to the valid local norms. A
concrete solution of flue exhaust must be dealt with in a corresponding project that complies with the
standard rules relating to the situations when the condensed water needs to be drained or penetration of
rain water into the boiler averted.
The maximum length of the coaxial flue exhaust approved by the manufacturer:
Horizontal piping – 3 metres – measured from the elbow of the appliance to the opening on the
façade. Each 90o elbow that comes next reduces the length by 0.75 m, each 45o elbow by 0.5 m.
Vertical piping – 2.7 metres – measured from the appliance to the bottom of the room terminal.
Each 90o elbow that comes next reduces the length by 0.75 m, each 45o elbow by 0.5 m.
If you use the distributor as well as an exhaust piping and induction piping with the diameter 80 mm,
the maximum length is 6m (sum of exhaust and induction)
♦ Heating system filling
During the time when the heating system is being filled with water the boiler must be unplugged. The
recommended heating water pressure is the range of 1 ÷ 1.5 bar when the system is cold. It must be filled
slowly so that the air bubbles can escape through deaerating valves. The water used for both 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) or it must
correspond with the relevant local norms. If the water is modified because of hardness, only the agents
recommended by the manufacturer are usable.
If any of the previously mentioned conditions is not met, the guarantee does not apply to the damaged
components.
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♦ 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.
A wide range of thermostats is available at the manufacturer for the room temperature control, e.g.
SIEMENS REV 23, Honeywell CM 707, CM 67 or Electrobock PT 21, PT 30 and others. For the weather
compensated regulation Thermona offers the outside sensor THERM Q01.
There is also a high quality regulation element – intelligent programmable SIEMENS QAA 73.110,
which communicates with the boiler’s automatics microprocessor through IU02Q interface. In this way
not only information about the required heating system temperature depending on the room and outside
temperature is transmitted but also the information about the boiler’operation is displayed (mode, output,
temperatures, malfunctions, possible DHW tank heating switch off etc.). This system includes a lot of
adjustable and displayed parameters for optimal control of the heating system with boiler output
modulation.
Boiler rooms with cascades can be controlled with our unique system of communication among
individual boilers. For this purpose there is interface IU 04.10, which transports the output needs of the
boiler room calculations and information between the boilers (it influences the number of working boilers
and their outputs). For even better communication interface IU 05Q can be used for the controlling boiler.
This interface includes the features of IU 04.10 interface (communication among boilers) and features of
IU 02Q interface (communication with programmable QAA 73.110). This kind of communication offers
more programmable options and it displays the operational modes of the boiler room (modes, output,
temperatures, failures, communication failures, possible DHW tank heating switch off during night etc.).
Recommendation: We recommend controlling the actual boiler operation (without weather-
compensated regulation) at least by a basic room thermostat. The room temperature is constant and it
keeps the boiler in longer operational modes. It is also recommended to set the boiler thermostat to 60 ºC
in autumn and spring and to 80 ºC in winter. It is advisable to use the inbuilt weather-compensated
regulation either separately or with a room thermostat (see lower).
These expansion regulation types are not delivered with the boiler.
♦ Starting the boiler
Only a service technician certified by the manufacturer can start the boiler for the first time.
Before the first ignition it is necessary to carry out the following steps:
make sure the heating system is filled with water and the boiler is deaerated
make sure all valves are open
open gas tap and check the gas installation for leaks.
The procedure for first ignition:
set the output temperature knob to maximum
plug the supply in and switch on the boiler by the mode switch
when you shortly turn the mode switch to the failure unblocking mode the boiler ignites automatically
(if the gas supply is deaerated properly)
check if all the safety thermostats and control elements work correctly
check the setting of the boiler output range, adjust the setting according to the needs of the heated
building if necessary
Important:
The boiler output range setting and other parameters must follow technical specifications. In case of
overloading or improper use may result in damaging the boiler. Components damaged in such a way
are not included in the guarantee!
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