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thermital SUNDAY 30/130 B Installation And Maintenance Manual

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INSTALLATION AND
MAINTENANCE MANUAL
SUNDAY 30/130 B

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  • Page 1 INSTALLATION AND MAINTENANCE MANUAL SUNDAY 30/130 B...
  • Page 2 CONFORMITY THERMITAL SUNDAY 30/130 B boilers conform to the following directives: • Directive 92/42/EEC on efficiency requirements • Directive 2009/142/EC - Gas Appliances • Low Voltage Directive 2014/35/EU • Electromagnetic Compatibility Directive 2014/30/EU • Ecodesign Directive 2009/125/CE for energy-related products •...
  • Page 3 Dear heating engineer, THERMITAL boiler. You have selected a SUNDAY 30/130 B Congratulations on having chosen a modern, quality product that is designed to give dependable, efficient and safe service and to pro- vide comfort in the home for many years to come. This manual provides information that is essential to the installation of the appliance.

  • Page 4: Table Of Contents

    CONTENTS General General safety information " Precautions " Product description " Safety devices " Identification " Layout " Technical specifications " Water circuit " Location of sensors " Pump " Wiring diagram " Control panel " Installer Unpacking the product "...

  • Page 5: General Safety Information

    - Drain the central heating circuit if there is any risk laws and standards. of freezing. This SUNDAY 30/130 B boiler must be used only The boiler must be serviced at least once a year. for the proper purpose for which it is designed and made.

  • Page 6: Product Description

    PRODUCT DESCRIPTION SUNDAY 30/130 B condensing boilers are high efficiency, The main technical characteristics of SUNDAY 30/130 B low temperature boilers for the production of hot water boilers are: for central heating, and also for domestic hot water in - electronic burner ignition and ionisation flame control conjunction with a 137 litre storage cylinder.

  • Page 7: Identification

    IDENTIFICATION SUNDAY 30/130 B boilers are identified by two plates: - Data plate This lists the appliance’s technical specifications and performance data. Categoria: Combustibile: Combustible: Categorie: Brennstoff: Brandstof: Kategorie: RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.thermital.it...

  • Page 8: Layout

    LAYOUT 40 60 80 1 Cover panel 2 BAG control card 3 Automatic vent valve 4 Direct zone pump 5 Bleed manifold 6 Mixed zone pump 7 Mixer valve 8 Drain cock for delivery group 9 Delivery group 10 Mixing column drain cock 11 Top front panel 12 Mixing column/storage cylinder pump 13 Deviator valve and by-pass...

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS Description SUNDAY 30/130 B condensing boiler for mixed heating B23P-B53P-C13-C13x-C23-C33-C33x- Type of boiler C43-C43x-C53-C53x-C63-C63x-C83- C83x Fuel G20 - G31 Class of boiler II2H3P Furnace heat output ref. PCS (PCI) 33,2 (30) Furnace heat output ref. PCS (min) 6,7 (6) Useful heat output (nominal) Rated heat output 60-80°C (P4)
  • Page 10 Description SUNDAY 30/130 B Standby PSB P sb (*) Calculated with one 90°curve, 24 x 1 metre extensions and a 1 metre horizontal collector. Description SUNDAY 30/130 B Type of storage cylinder Vitrified Cylinder layout Vertical Heat exchanger layout Vertical...

  • Page 11: Water Circuit

    WATER CIRCUIT CH flow CH return CH flow CH return CH flow CH return DHW outlet Cold water inlet 1 Primary heat exchanger 20 Non-return valve 2 CH flow temperature sensor 21 Deviator group and bypass 3 Safety thermostat 22 Automatic bypass 4 Fan 23 Deviator valve 5 Gas valve...

  • Page 12: Location Of Sensors

    LOCATION OF SENSORS CONDENSATE NTC FLUE GAS SENSOR (located inside sealed chamber) TEMPERATURE SENSOR THERMOSTAT WATER SAFETY (located on CH circuit flow 40 60 80 pipe inside sealed chamber) NTC CH FLOW PRIMARY CIRCUIT SENSOR (located on CH circuit flow pipe inside sealed chamber) 40 60 80 STORAGE...

  • Page 13: Pump

    PUMP TECHNICAL SPECIFICATIONS CIRCOLATORE SANITARIO/RISCALDAMENTO DESCRIPTION ERP ready 2015 Electrical consumption EEI Part 3 (*) ≤ 0,20 P L,Avg (**) ≤ 24 Minimum pressure at pump suction inlet Energy efficiency index according to ERP 2015 (Commission regulations 641/2009 and 622/2012) (**) Average annual electricity consumption according to ERP 2015 (Commission regulations 641/2009 and 622/2012) PUMP CURVE - DIRECT ZONE [kPa]...
  • Page 14 PUMP CURVE - MIXED ZONE [kPa] 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4 Q [m³/h] Flow-rate 1,0 Q [l/s] 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4 Q [m³/h] Curves are referred to a water density of 983.2 Kg/m , a temperature of +20°C, and a kinematic...
  • Page 15 ADJUSTING THE PUMP Display Meaning % power LED 1 flashing green Stand-by (only The boiler's pump is ErP 2015 Ready, and suitable for use with PWM control) in central heating only/domestic hot water applications. LED 1 green and LED 2 Low load 0-25 The pump can be controlled by an external PWM signal...
  • Page 16 Display Meaning Function Action LED 1 red and LED 5 yellow, The pump rotor is blocked. pump automatically Wait or check that the pump both lit attempts to start every 1.5 rotor is free to rotate. seconds. LED 1 red and LED 4 yellow, Supply voltage too low.

  • Page 17: Wiring Diagram

    WIRING DIAGRAM MAIN BOILER CONTROL CARD Power supply 230 VAC OPE OPE 1 2 3 4 pink black brown blue yellow/green blue brown brown blue black 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 white F1 F2 pink...
  • Page 18 CH CIRCUIT CONTROL CARD (BAG) CI Mix 2 (*) VMix 2 (*) Alimentazione 230 VAC CI Dir CI Mix 1 VMix 1 JUMPER di fase L - Sez. 0,75 mmq Ground connection plate BAG CARD SMix 2 (*) TS Mix 2 (*) JP3A JP3B JP3C...

  • Page 19: Control Panel

    CONTROL PANEL 40 60 80 Set to SUMMER Set to MINIMUM 1 Storage cylinder temperature gauge Displays domestic hot water temperature. 2 Boiler pressure gauge Displays the pressure in the central heating circuit. Å Storage cylinder temperature selector Adjusts domestic hot water temperature. When the boiler is used with the rec- ommended remote control accessory (REC 07/08), DHW temperature must be adjusted directly from the remote control.
  • Page 20 NOTES ON FUNCTIONING The CH circuit (BAG) control card functions in conjunction with the main boiler control card to control: - The anti-seize function that opens and closes the mixer - The overtemperature dispersal function, which ensures valve (if fitted) and the circuit pump for 10 seconds, at a uniform system temperature and disperses excess intervals determined by the setting of the "ANTI-SEIZE heat towards the direct CH circuit that made the last...

  • Page 21: Unpacking The Product

    The instruction manuals are integral parts of the boiler. Once located, read them thoroughly and keep them safe. DIMENSIONS AND WEIGHT SUNDAY 30/130 B boilers are designed and made for installation in combined central heating and domestic hot water production systems. Description...

  • Page 22: Handling

    HANDLING Once you have removed the packaging, proceed as fol- lows to handle and move the boiler. - Unscrew the 4 screws (A) shown in the figure and remove the boiler from the pallet - Remove the front panel (1) to facilitate handling and movement of the boiler TILT - Grip the boiler at points (B) and tilt it backwards, then grip...

  • Page 23: Place Of Installation

    PLACE OF INSTALLATION SUNDAY 30/130 B boilers can be installed in any indoor When installing the boiler, allow sufficient space around it to access all safety and control devices location provided the flue gases are adequately removed and to permit easy maintenance.

  • Page 24: Installation In Older Systems And Systems Requiring Modernisation

    INSTALLATION IN OLDER SYSTEMS AND SYSTEMS REQUIRING MODERNISATION When installing SUNDAY 30/130 B boilers in old systems or systems requiring modernisation, always perform the fol- lowing checks: - Make sure that the flue is able to withstand the temper- - Make sure that the central heating circuit has been...
  • Page 25 WATER IN CENTRAL HEATING SYSTEMS: INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF CENTRAL HEATING SYSTEMS 1. Chemical and physical characteristics of water The chemical and physical characteristics of water used in central heating systems must conform to the requirements of EN 14868 standard and to the following tables: ALUMINIUM BOILERS ALUMINIUM BOILERS...
  • Page 26 2.2 Reconditioning old central heating systems If a boiler has to be replaced, do not refill the entire central heating circuit if the quality of water in it conforms to requi- rements. If the quality of water fails to conform to requirements, either recondition the old water or separate the water circuits (water in the boiler circuit must conform to requirements).

  • Page 27: Water Connections

    WATER CONNECTIONS Before installing the boiler, thoroughly flush out all the pipes of the central heating circuit. Connect the boiler to the water supply with a shut-off cock upstream. Connect the condensate drain pipe to a clean domestic water drain in compliance with the relevant standards. The water fittings have the following specifications: Gas supply 3/4"...
  • Page 28 Condensate collection Locate the corrugated condensate drain pipe (S) at the rear of the burner and connect it to a domestic water drain in compliance with the relevant standards. The connection to the waste water drain must be made in compliance with national and local legisla- tion and standards.

  • Page 29: Electrical Connections

    ELECTRICAL CONNECTIONS All the boiler’s internal electrical connections have been pre-wired and tested in the factory. Only the following connections are needed for installation: - Connect the boiler to the mains power supply (single phase 230V-50Hz); - The room thermostats (TA Dir and TA Mix1) or remote controls (REC 07/08 Zone Dir and REC 07/08 Zone Mix);...
  • Page 30 OUTDOOR TEMPERATURE SENSOR - Access the CH circuit (BAG) control card as instructed above - Connect up the outdoor temperature sensor (SE) as shown in the figure alongside. 40 60 80 The boiler is configured in the factory to function with an OUTDOOR TEMPERATURE SENSOR CONNECTED, and with the flow temperature of all CH circuits regulated to suit outdoor tem-...

  • Page 31: Outdoor Temperature Sensor

    OUTDOOR TEMPERATURE SENSOR Correct positioning of the outside temperature sensor is essential to proper indoor temperature control. The sensor must be installed outside the building to be heated, about 2/3 of the way up a NORTH or NORTH-WEST facing wall, well clear of any flues, doors, windows and out of direct sunlight.

  • Page 32: Fuel Connections

    FLUE GAS OUTLET AND COMBURENT AIR INTAKE SUNDAY 30/130 B boilers are type C sealed boilers, and must therefore have a sealed flue gas vent pipe and comburent air intake pipe, both of which must terminate outdoors.
  • Page 33 boiler is installed. Flue gas vent via horizontal or vertical flues designed to operate at positive pressure, with air ventilation to room. Concentric wall vent. Twin flue pipes can also be used, but the wall through-pipes must be concen- tric or located close enough to be subjected to 40 6080 40 6080 40 6080...
  • Page 34 Coaxial flues (Ø 80/125) An adapter kit must be used in order to install this size of Maximum straight length of Pressure drop (m) flue. Coaxial flues can be oriented in whatever direction coaxial flue Ø 80/125 45° bend 90° bend is most convenient for the room, provided the maximum lengths specified alongside are respected.
  • Page 35 FORCED/OPEN INSTALLATION (TYPE B23P/ B53P) Boiler gas vent flue (Ø 80) The vent flue can be oriented in whatever direction is most convenient for the room. In this configuration, a Ø Maximum length of flue gas Pressure drop (m) 60-80 mm adapter must be fitted in order to connect the vent pipe (Ø...

  • Page 36: Filling And Draining The System

    FILLING AND DRAINING THE SYSTEM SUNDAY 30/130 B boilers incorporate a CH system fill cock. Make sure that the system filling cock (3) is closed before you start to fill or drain the system. FILLING THE STORAGE CYLINDER - Make sure that the storage cylinder drain cock (2) is closed - Open a DHW user tap.
  • Page 37 DRAINING Switch the electricity supply OFF at the control panel and at the system’s main switch before starting to drain the boiler or storage cylinder. DRAINING THE CENTRAL HEATING SYSTEM - Make sure that the CH system fill cock (1) is closed. - Close the shut-off cocks for the central heating and domestic hot water circuits.

  • Page 38: Preparing For Initial Start-Up

    PREPARING FOR INITIAL START-UP Initial start-up must be performed by an authorised and qualified heating engineer from a THERMITAL Technical Assistance Centre. Remove the front panel from the boiler and perform the following checks before switching the boiler on or testing any of its functions.
  • Page 39 Every time electrical power is switched on, the boiler performs an automatic venting cycle that lasts about 12 minutes. Two dashes flash on the display in an alternating manner dur- ing automatic venting. At the end of the automatic venting cycle, check the pressure on the gauge (1) again.
  • Page 40 SETTING CENTRAL HEATING WATER TEMPERATURE USING THE OUTDOOR TEMPERATURE SENSOR Since an outdoor temperature sensor is installed, the sys- tem automatically adjusts the temperature of the central heating flow to bring room temperature rapidly to a level JP3C determined on the basis of outdoor air temperature. To increase or decrease room temperature with respect to the automatic setting calculated by the BAG control card, turn the trimmers on the BAG card clockwise to increase...
  • Page 41 STARTING UP THE BOILER If a timer or room thermostat is installed, these must be switched on and adjusted to a temperature higher than current room temperature before the boiler can start up. The boiler will remain in stand-by mode until the burner ignites following a request for heat.

  • Page 42: Shutdown

    SHUTDOWN If you are going away for a short period of time like a weekend or a short holiday, etc., turn the function selector to “ “ OFF/RESET. É The digital display reads out the message shown alongside. 40 60 80 Because electrical power and the gas supply to the boiler both remain on, the boiler is protected by the following systems:...

  • Page 43: Warning Leds And Errors

    WARNING LEDS AND ERRORS THE MAIN CONTROL PANEL Green LED (2) Off = boiler in stand-by, burner out On = burning lit, boiler functioning normally. Red LED (3) Safety shutdown: an error code flashes on the display. Burner lockout: the red LED lights and an error code flashes on the display.
  • Page 44 Dealing with error AL41 Check the pressure on the control panel pressure gauge; if it is below 0.5 bar, proceed as follows. - Turn the function selector to “ ” É - Remove the top front panel from the boiler by pulling it forwards.

  • Page 45: Automatic Temperature Control

    AUTOMATIC TEMPERATURE CONTROL Automatic temperature control only works with the outdoor temperature sensor connected. As soon as you install the outdoor temperature sensor, connect it immediately to the relevant terminals on the CH circuit (BAG) control card (see page 30). The boiler will now be able to function with AUTOMATIC TEMPERATURE CONTROL.
  • Page 46 HEATING CURVE CORRECTION To increase or decrease room temperature with respect to the automatic setting calculated by the BAG control card, turn the trimmers on the BAG card clockwise to increase temperature or anti-clockwise to reduce it. JP3C The available adjustment range is between -5 and +5 comfort levels.
  • Page 47 CONTROL OF THE FLOOR CURING FUNCTION (only from a PC running dedicated software) Proceed as follows to enable the “floor curing" function. - Disconnect power to the system. - Fit a jumper between pins 4 and 5 of the ST2 programming connector on the CH circuit (BAG) control card. - Power the system on again.

  • Page 48: Settings

    SETTINGS All settings have already been made in the factory. If the boiler needs new settings after repairs have been made, the gas valve changed, or after a conversion from methane to LPG, proceed as follows. The settings for minimum fan speed, maximum CH fan speed, maximum DHW fan speed, and ignition slow fan speed must be made in the sequence given and must only be made by qualified personnel.
  • Page 49 When supplied, the boiler is configured with the settings shown in the table below. These settings can be changed if necessary to comply with specific system requirements or regional emission control legislation. Refer to the following graphs to adjust the settings. 30/130 B Heating curve (Qnheating) –...

  • Page 50: Conversion From One Gas Type To Another

    - Check the CO content. If the value is not as speci- MAXIMUM FAN SPEED fied in the table, adjust the gas valve minimum screw METHANE PROPANE accordingly (G20) (G31) - Turn the Max CH trimmer anticlockwise until minimum 30/130 B x 1000 rpm speed is reached (see table) MINIMUM FAN SPEED...

  • Page 51: Maintenance

    MAINTENANCE Hints for bleeding air out of the cen- To maintain maximum functionality and efficiency, and to comply with the relevant legislation, have the boiler tral heating circuit and burner group inspected at regular intervals. When performing maintenance, always follow the precau- Perform the following operations during installation and tions listed in the “GENERAL SAFETY INFORMATION”...
  • Page 52 Checking combustion parameters Proceed as follows to perform combustion analysis: - Pull off the function selector knob (7) from the control panel and press the combustion analysis button - Remove the screw (A) and the combustion analysis cap (40) and insert the combustion analysis probe into the air box 40 60 80 - Check that the values for CO...

  • Page 53: Troubleshooting

    TROUBLESHOOTING CAUSE SOLUTION FAULT Leaks from the gas supply Check that all joints are tight and There is a smell of gas. circuit. that the pressure measurement points are closed. There is a smell of Check: Leaks from the flue gas circuit combustion fumes.
  • Page 54 CAUSE SOLUTION FAULT The boiler does not reach its Burner dirty. Clean the combustion chamber. temperature set point. Insufficient air/fuel flow to burner. Check and adjust the burner. Incorrect temperature setting. Adjust the temperature setting and check on correct functioning. Verify the temperature setting.
  • Page 55 CAUSE SOLUTION FAULT Reduced supply of domestic Supply pressure is too high. Fit a pressure reducer. hot water. Lime scale and/or sludge in Check and clean. storage cylinder. Flow rate too high. Fit a flow reducer. Check functioning circuit pump. Check positioning of sensors.
  • Page 56 RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.thermital.it As part of the company’s ongoing commitment to perfecting its range of products, the appearance, dimensions, technical data, equipment and accessories may be subject to variation.

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