thermital SUNDAY 200 SOL Series Installation And Maintenance Manual
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thermital SUNDAY 200 SOL Series Installation And Maintenance Manual

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INSTALLATION AND
MAINTENANCE MANUAL
SUNDAY 200 SOL

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  • Page 1 INSTALLATION AND MAINTENANCE MANUAL SUNDAY 200 SOL...
  • Page 2 CONFORMITY SUNDAY 200 SOL boilers conform to the following directives: • Gas Appliances Directive 2009/142/CE • Boiler Efficiency Directive 92/42/CEE (HHHH) • Electromagnetic Compatibility Directive 2014/30/EU • Ecodesign Directive 2009/125/CE for energy-related products • Low Voltage Directive 2014/35/EU • Energy Labelling Directive 2010/30/EU •...
  • Page 3 Dear heating engineer, Congratulations on having chosen a THERMITAL boiler. You have selected a modern, quality pro- duct that is designed to give dependable, efficient and safe service and to provide 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 " Pumps " Wiring diagram " Control panel " Installer Unpacking the product "...

  • Page 5: General Safety Information

    GENERAL SAFETY INFORMATION As soon as you open the packaging, check imme- Periodically, and when the system is cold, check diately that the contents are all present and undam- that operating pressure in the heating circuit is between 1 and 1.2 bar. If water pressure is consist- aged.

  • Page 6: Product Description

    More than one high or low temperature zone can be heated, with the addition of the relevant multi-zone accessories. See the THERMITAL catalogue for details. The main technical characteristics of SUNDAY 200 SOL boilers are:...

  • Page 7: Safety Devices

    SAFETY DEVICES The boiler is fitted with the following safety devices: The intervention of a safety device indicates a potentially dangerous malfunction in the sys- - autodiagnostics with display of error codes - microprocessor control and display of NTC sensor tem, and means that you must contact Technical continuity Assistance Service immediately.

  • Page 8: Identification

    Categoria: Combustibile: Combustible: Categorie: Brennstoff: Brandstof: Kategorie: RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.thermital.it T067752GE Caldaia a condensazione - Chaudière à condensation NOx: European Directive Brennwertkessel - Condenserende verwarmingsketel 92/42/EEC: η = Cod. N° P.nom.G20=...

  • Page 9: Layout

    LAYOUT 40 60 80 1 Cover panel 2 Top front panel 3 Automatic vent valve 4 Bleed manifold 5 Water pressure switch 6 Deviator group drain cock 7 Deviator valve 8 CH/storage cylinder pump 9 CH circuit fill cock 10 Bottom front panel 11 DHW thermostatic mixer valve 12 Solar circuit non-return valve 13 Solar circuit pump...

  • Page 10: Technical Specifications

    TECHNICAL SPECIFICATIONS SUNDAY Descrizione 20/200 SOL 30/200 SOL condensing boiler for mixed heating "B23P-B53P-C13-C13x-C23-C33-C33x- Device type C43- C43x-C53-C53x-C63-C63x-C83-C83x" Fuel G20-G31 Device category II 2H3P Furnace heat output ref. PCS (PCI) 22,7 (20,4) 33,2 (30) Furnace heat output ref. PCS (min.) 3,9 (3,5) 6,7 (6) Useful heat output (nominal)
  • Page 11 SUNDAY Descrizione 20/200 SOL 30/200 SOL At full load Elmax At partial load Elmin Standby PSB P sb Calculated with one 90° curve, 24 x 1 metre extensions and a 1 metre horizontal collector. SUNDAY Descrizione 20/200 SOL 30/200 SOL Type of storage cylinder Vitrified Cylinder layout...

  • Page 12: Water Circuit

    WATER CIRCUIT CH flow CH flow Solar circuit outlet Solar circuit outlet DHW outlet Cold water inlet Primary heat exchanger 14 CH/storage cylinder pump 28 Storage cylinder drain cock CH flow temperature sensor 15 CH circuit drain cock 29 200 litre storage cylinder Safety thermostat 16 Deviator group 30 DHW circuit expansion vessel (8...

  • Page 13: Location Of Sensors

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

  • Page 14: Pumps

    PUMPS TECHNICAL SPECIFICATIONS CENTRAL HEATING SYSTEM/ STORAGE CYLINDER 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) CENTRAL HEATING SYSTEM/ STORAGE CYLINDER PUMP CURVE [kPa]...
  • 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 TECHNICAL SPECIFICATIONS SOLAR HEAT SYSTEM PUMP DESCRIPTION ERP ready 2015 Electrical consumption EEI Part 3 (*) ≤ 0,20 P L,Avg (**) ≤ 27 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) SOLAR HEAT SYSTEM PUMP CURVE [kPa]...

  • Page 18: Wiring Diagram

    WIRING DIAGRAM GENERAL ENGLISH...

  • Page 19: Control Panel

    CONTROL PANEL THE MAIN CONTROL PANEL 40 60 80 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 (NOT USED) The temperature of the domestic hot water is preset to 44°C in the factory. The thermostatic mixer valve has to be adjusted to change this value (see page 41).
  • Page 20 SOLAR CONTROLLER Function selector Enter button Parameter selector Escape button Function selector No function selected / Stand-by. (The display Storage cylinder top temperature sensor shows that the system is switched on but in - The display reads out the temperature currently stand-by mode) measured by storage cylinder top temperature sensor F3.

  • Page 21: Unpacking The Product

    UNPACKING THE PRODUCT The boiler is delivered in a single package on a wooden pallet, covered by a PVC sheet and inside a wooden crate. The following items are delivered in a plastic bag (A) inside the boiler: - Installation and Maintenance Manual for the boiler - User Manual - Spare parts catalogue - Certificate of warranty...

  • 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.

  • Page 23: Place Of Installation

    PLACE OF INSTALLATION SUNDAY 200 SOL boilers can be installed in any indoor When installing the boiler, allow sufficient space location provided the flue gases are adequately removed and comburent air drawn in from outdoors. Provided the around it to access all safety and control devices boiler is properly installed, the boiler room itself does not 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 200 SOL boilers in old systems or systems requiring modernisation, always perform the following checks: - Make sure that the central heating circuit has been - Make sure that the flue is able to withstand the tem- flushed out to remove all sludge and lime scale, and perature of the combustion gases and that it has been that it has been bled and seal tested.
  • 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. Always maintain a slope “i” of over 3° and ensure that the diameter of any hose used is greater than that of the boiler’s own condensate drain pipe.

  • 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 installa- tion: - Connect the boiler to the mains power supply (single phase 230V-50Hz) using the cable (1) from the rear of the appliance.
  • Page 30 - Open the cover (D) to access the internal terminals and make the connections as shown in the diagram below. CR Remote control SE Outdoor temperature sen- nero Room thermostat TBT/ACP Fuse 3.15A F (fast) TBT Low temperature thermostat APC Condensate pump alarm M3÷M5 Connection terminals SOLAR COLLECTOR TEMPERATURE SENSOR (SColl)

  • 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

    FUEL CONNECTIONS The boiler must be connected to the methane gas supply in compliance with the relevant standards. Perform the following checks before making the con- nection: - Check that the boiler is compatible with the type of gas supplied. - Check that the gas supply pipes have been thoroughly cleaned.
  • Page 33 B53P Upstream fan. Comburent air intake directly from the room where the boiler is installed. Flue gas vent via horizontal or vertical flues designed to operate at positive pressure, with air ventilation to room. C13 Concentric wall vent. Twin flue pipes can also be 40 6080 3 2 1 40 6080...
  • Page 34 Coaxial flues (Ø 80/125) An adapter kit must be used in order to install this size of Pressure drop (m) Maximum straight length of flue. Coaxial flues can be oriented in whatever direction coaxial flue Ø 80/125 (m) 45° bend 90°...
  • Page 35 “FORCED/OPEN INSTALLATION” (TYPE B23P/ B53P) Boiler gas vent flue (Ø 80) Pressure drop (m) Maximum length of flue gas The vent flue can be oriented in whatever direction is vent pipe (Ø 80) 45° bend 90° bend most convenient for the room. In this configuration, a Ø 80 (20/200 SOL) 60-80 mm adapter must be fitted in order to connect the boiler to a Ø...

  • Page 36: Filling And Draining The System

    FILLING AND DRAINING THE SYSTEM SUNDAY 200 boilers incorporate a CH system fill cock. Make sure that the system filling cock (2) is closed before you start to fill or drain the system. FILLING THE STORAGE CYLINDER - Make sure that the central heating circuit and storage cylinder drain cocks (4) and (3) are closed.
  • Page 37 FILLING THE SOLAR HEATING CIRCUIT Glycol / water proportions for different Heat transfer liquid minimum temperatures Use only non-toxic propylene glycol as heat transfer fluid. Minimum outdoor % glycol by weight temperature °C Mix the propylene glycol with water (preferably deminer- - 3,5 alised), by pouring the glycol into a container of water and not vice-versa.
  • Page 38 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 (2) is closed. - Close the shut-off cocks for the central heating and domestic hot water circuits.

  • Page 39: 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 40 Repeat these steps until the pressure in the CH circuit stabilises between 1 and 1.2 bar. 40 60 80 To interrupt the automatic venting cycle unscrew the Combustion analysis four screws (A), remove the front trim (B) and press the combustion analysis button (CO). SUMMER ( ): With the function selector set to Summer, Ç...
  • Page 41 SETTING DOMESTIC WATER TEMPERATURE Domestic hot water temperature is preset to 44°C in the factory. Domestic hot water from the 40 60 80 Adjust the thermostatic mixer valve to change this value. SOLAR STORAGE CYLINDER The following table shows the hot water temperature val- user ues for the different mixer valve knob positions.
  • Page 42 SOLAR CONTROLLER The first time you switch on the boiler, you will need to set time and day. To do so, proceed as follows. - Turn the function selector (3) to " " - Turn the parameter selector (4) until the "Clock" menu appears.

  • Page 43: Shutdown

    RESET FUNCTION To reset the boiler, turn the function selector to “ ”, then É return it to its previous position and check that the red LED goes out. Provided correct functioning conditions have been restored, the boiler restarts automatically. As soon 40 60 80 as the burner ignites the green LED lights and the digital display will read out current operating temperature.

  • Page 44: Warning Leds And Errors

    If the boiler is not going to be used for an extended peri- od of time, proceed as follows to prepare it for shutdown. - Turn the function selector to OFF/RESET. - Turn the mains power switch OFF. - Close the fuel shut-off cock and the central heating and DHW circuit shut-off cocks.

  • Page 45: Automatic Temperature Control

    For 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 46 Example: if the calculated value is 1.3, it lies between the 1 and 1.5 curves. Choose the nearest curve, in this case 1.5. Adjust the trimmer under the DHW temperature setting knob to select KT. The following KT values can be set: standard system: 1,0 - 1,5 - 2,0 - 2,5 - 3,0 under-floor system 0,2 - 0,4 - 0,6 - 0,8.

  • Page 47: 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 48 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. 20/200 Heating curve (Qnheating) –...
  • Page 49 ADJUSTING THE GAS VALVE - Switch on mains power to the boiler. Max. gas - Open the gas cock. power screw - Turn the function selector to OFF/RESET (the display shows “- -”). - Pull off the DHW temperature selector knob (3) and the 40 60 80 function selector knob (7).

  • Page 50: Conversion From One Gas Type To Another

    CONVERSION FROM ONE GAS TYPE TO ANOTHER The boiler can be converted from one gas type to another quite simply, without even having to remove the burner. The burner comes configured for use with methane gas (G20) as stated on the boiler’s gas plate. The burner can be converted for use with propane gas (G31) using the kit supplied with the boiler.

  • 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.
  • Page 53 Setting the solar controller param- eters If you ever have to replace the solar controller, you must reset parameters 22 = 7, 47 = 50 and 54 = 4. These parameters are protected by a password (0000). Proceed as follows: - Turn the function selector (3) to "...

  • Page 54: Troubleshooting

    TROUBLESHOOTING CAUSE SOLUTION FAULT Check that all joints are tight and There is a smell of gas. Leaks from the supply circuit. that the pressure measurement points are closed. There is a smell of Check: There is a smell of combustion combustion fumes.
  • Page 55 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. Check correct functioning. Boiler settings. Check temperature setting. Boiler temperature settings. Check temperature setting. Burner locks out.
  • Page 56 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 57 CAUSE SOLUTION FAULT Solar controller reached Maximum temperature has been The solar circuit pump does maximum temperature exceeded in the collector or in not work, even if the collector stopped the pump. The pump will temperature sensor detects a the storage cylinder. temperature higher than that start working again as soon as the in the storage cylinder.
  • Page 58 TECHNICAL ASSISTANCE SERVICE ENGLISH...
  • Page 59 TECHNICAL ASSISTANCE SERVICE ENGLISH...
  • Page 60 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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