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Bulex Thema Condens AS 48-A Manual

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DEMİRDÖKÜM
MAKSİCONDENSE 48-65

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Summary of Contents for Bulex Thema Condens AS 48-A

  • Page 1 DEMİRDÖKÜM MAKSİCONDENSE 48-65...

  • Page 3: Table Of Contents

    MAKSİCONDENSE 48-65 Table of contents System overview and customer benefits ..............1 System overview ....................... 1 1.1.1 System components (examples) ..................3 1.1.2 Cascade of boilers......................5 Customer benefits ......................8 1.2.1 Arguments for the installer ....................8 1.2.2 Arguments for planners and architects ................9 1.2.3 Arguments for end customers ..................
  • Page 4 Table of contents Overview of accessories....................93 4.1.1 Electrical accessories ...................... 93 4.1.2 Hydraulic accessories ..................... 98 4.1.3 Overview of the different accessories New! ..............101 Description of the accessories ..................103 4.2.1 Use of the accessories ....................103 Planning requirements and practical information ............ 110 Installation sites and restrictions ..................
  • Page 5 8.4.2 Gas consumption relating to nominal load ..............191 System checklist ......................192...

  • Page 7: System Overview And Customer Benefits

    MAKSİCONDENSE 48-65 1 System overview and customer benefits 1.1 System overview Space heater 48-65kW View without casing Potential applications The Space heater units are intended for use as heat generators for closed domestic hot water central heating installations and for central domestic hot water generation in households. The Space heater units are delivered only as circulation water heaters with unit outputs of 48 and 65 kW.
  • Page 8 MAKSİCONDENSE 48-65 The new SDBG 48-65 kW condensing WHB is a compact, robust and technically proven system boiler. Notes 01/2018 Training 0020260859_00...

  • Page 9: System Components (Examples)

    MAKSİCONDENSE 48-65 1.1.1 System components (examples) Example: Heating system with low loss header; 2 x regulated heating circuit; 1 x non-regulated heat- ing circuit; DHW supply; 1 x MiPro; 2 x MiPro remote; 1 x RED 5 and MiLink Internet gateway. Area of application: Single-occupancy house, apartment/office building Remote access via "MiConnect"/MiPortal It is easy to handle and to place, as a stand-alone appliance or in cascade combi-...
  • Page 10 MAKSİCONDENSE 48-65 Example: Heating system without low loss header; 1 x non-regulated heating circuit; domestic hot water supply; 1 x MiPro; 1 x MiLink Area of application: Single-occupancy house Remote access via "MiConnect"/MiPortal New! For 7-coil and 9-coil heat exchangers (48 kW + 65 kW) Additional software function for the direct supply of the heating circuits, possible without low loss header.

  • Page 11: Cascade Of Boilers

    MAKSİCONDENSE 48-65 1.1.2 Cascade of boilers In line mounting (Rig) around the corner (Rig) Back to back mounting with rig Cascade installation: ─ Up-to 7 appliances in cascade ─ In-line (On the wall or on rigs) ─ Back-to-back / Around-corner layout Accessories range to manage single boiler installation as well as various cascade layouts: ─...
  • Page 12 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 13 MAKSİCONDENSE 48-65 Great modulation capability: Modulation is the boilers capability to match the heating demand. In a cascade system, the modulation ratio (ability to reduce the max output to the min. output) increases according to the number of boilers. This wider ratio implies a higher efficiency and comfort while reducing wear on components.

  • Page 14: Customer Benefits

    MAKSİCONDENSE 48-65 1.2 Customer benefits 1.2.1 Arguments for the installer Feature Function Benefits for the installer Flexibility of the installation 1) Installation without low loss header 1) Easy, economical and and application 2) Approval for liquefied petroleum gas (LPG) time-saving positioning 3) Compact design, 2) Broad range of applications modular ground installation...

  • Page 15: Arguments For Planners And Architects

    MAKSİCONDENSE 48-65 1.2.2 Arguments for planners and architects Feature Function Benefits for the architect/planner Flexibility of the installation 1) Installation without low loss header 1) Economical installation space and application 2) Approval for liquefied petroleum gas (LPG) requirements 3) Modular ground installation 2) Integration as per applicable (mounting frame, rack) requirements...

  • Page 16: Arguments For End Customers

    MAKSİCONDENSE 48-65 1.2.3 Arguments for end customers Feature Function Benefits for end customers Flexibility of the installation 1) Installation without a low loss header (48 kW) 1) Several possible installation and application 2) Approval for liquefied petroleum gas (LPG) layouts and large, certified 3) Modular ground installation range of accessories for flexible (mounting frame, rack)

  • Page 17: System Description

    MAKSİCONDENSE 48-65 2 System description This section provides you with general information about the product 48–65 kW: - Overview of the individual markets - Unit overview - Unit design 2.1 System components The new boilers are a further development of the condensing technology family from the SDBD brands.

  • Page 18: Erp Efficiencies

    MAKSİCONDENSE 48-65 Equipment with the 48–65 kW product ─ High-efficiency pump, electric water pressure sensor ─ Integral stainless steel condensation heat exchanger (Sermeta) ─ Integrated domestic hot water control via domestic hot water charging pump actuation ─ Diagnostics system with illuminated display (segments) ─...

  • Page 19: Basic Principles

    2018: BE; CZ; HU; IT; ES; VGI 2.2.1 Nomenclature Individual examples of the nomenclature used for the units are presented here. Thema Condens AS 48-A Thema Condens AS 65-A = Circulation water heater...
  • Page 20 MAKSİCONDENSE 48-65 2.2.1.2 Description of the unit category Meaning One usable gas category Two usable gas categories Second gas family (natural gases) Third gas family (liquid gases) Group H gas (high gas) Group L gas Group P gas (propane) Group E gas (G20/G25) Less power with G25 NL market gas approval Unit category...

  • Page 21: Unit Types And Scope Of Delivery

    2.2.2 Unit types and scope of delivery Space heater 48–65 market launch Mar- cate- Unit Introduction Brand gory Thema Condens AS 48-A (E-BE) 06/ 2018 II2H3P Bulex Thema Condens AS 65-A (E-BE) Panther Condens 48 KKO-A (H-CZ) 03/ 2018 II2H3P...

  • Page 22: Scope Of Delivery

    MAKSİCONDENSE 48-65 2.2.4 Scope of delivery ● Heat generator (boiler) ● Unit mounting bracket with screws and rawl plugs ● Wall template ● Hydraulic connections for flow and return (distribution) ● Condensate hose ● Drain hose for precipitation discharge ● Documentation ●...

  • Page 23: Product Design

    MAKSİCONDENSE 48-65 2.3 Product design 2.3.1 Boiler (circulation water heater) 48–65 kW boiler Notes TEKNİK EĞİTİM VE DESTEK 03/2020...

  • Page 24: Design

    MAKSİCONDENSE 48-65 2.4 Design 2.4.1 Functional diagram Space heater 65 kW Motor Impeller sensor Pump Valve NTC sensor Service valve Expansion re- Pressure sensor lief valve Notes 01/2018 Training 0020260859_00...
  • Page 25 MAKSİCONDENSE 48-65 Space heater 48 kW Motor Impeller sensor Pump Valve NTC sensor Service valve Expansion re- Pressure sensor lief valve Notes TEKNİK EĞİTİM VE DESTEK 03/2020...

  • Page 26: Hydraulic Connection

    MAKSİCONDENSE 48-65 2.4.2 Hydraulic connection Grommets for electrical supply lines Condensate discharge connection Heating circuit flow connection Heating circuit return connection Precipitation discharge connection Gas connection with test nipple Drop water connection of the air separator Grommet for pre-assembled C1/C2 line Underside of the 48–65 kW unit New features: ─...
  • Page 27 MAKSİCONDENSE 48-65 2.4.2.1 New! Hydraulic installation sets VC, SPACE HEATER, VM: 41–48 kW (7-coil) SAP: – 0020258498 4 bar Installation set with expansion relief valve and filling and drain cock VC, SPACE HEATER, VM: 65 kW (9-coil) SAP: – 0020258502 4 bar Installation set with (later 6 bar) expansion relief valve and filling and drain cock...
  • Page 28 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 29 MAKSİCONDENSE 48-65 Hydraulic accessories for new build and replacement: Connection set for existing safety valve and expansion vessel of the predecessor boiler. Hydraulic connection with pipe group and extension for replacement Hydraulic connection with pipe group for replacement Notes TEKNİK EĞİTİM VE DESTEK 03/2020...

  • Page 30: Electronics Box

    MAKSİCONDENSE 48-65 2.5 Electronics box 48–65 kW control panel Digital information and analysis system: The control panel comprises the unit display (AI), the On/Off unit main switch and the reset button to acknowledge certain operating blocks in the event of a fault. 2.5.1 Control panel 2.5.1.1 Description of buttons and symbols.

  • Page 31: Unit Display (Ai)

    MAKSİCONDENSE 48-65 2.5.2 Unit display (AI) 2.5.2.1 Key for the symbols on the display SDBG unit display Symbol Explanation Display of the current burner modulation rate (bar graph) Displays the current filling pressure of the heating installation: Permanently on: The filling pressure is within the permitted range. Flashing: The filling pressure is outside the permitted range (≤...
  • Page 32 MAKSİCONDENSE 48-65 Symbol Explanation Domestic hot water mode Heating mode Symbol for room thermostat/outdoor sensor 2.5.2.2 Hidden display menus The display comes with hidden maintenance menus. These menus contain different access levels for the diagnostics code that is to be edited. To achieve this, different codes are stored. On the one hand, there is the level (installer) that is used to configure the unit during initial start-up.

  • Page 33: Components And Overall Function

    MAKSİCONDENSE 48-65 3 Components and overall function What to expect from this section: This section provides detailed information regarding the individual components used and the overall function of the unit. The overall function is divided into: ● Standard functions ● Special functions ●...
  • Page 34 MAKSİCONDENSE 48-65 3.1.1.1 Air separator Air separator housing with automatic float air vent/ separation plate 3.1.1.2 48–65 kW manometer Manometer with two operating pressure ranges - Outer pressure range for the 65 kW unit output, up to 4 bar (later 6 bar) - Inner pressure range for the 48 kW unit outputs, up to 4 bar Notes 01/2018...
  • Page 35 MAKSİCONDENSE 48-65 3.1.1.3 48–65 kW heating pump (HEP) Lock 230 V Grundfos high-efficiency pump Top view of pump/connection box Design of the high-efficiency pump: The installed Grundfos UPMM 25–85 is a glandless circulation pump with cast iron pump housing. It features an EC motor with automatic output adjustment. The connection to the PCB is effected via a three-pin 230 V line and a separate PWM signal line.
  • Page 36 MAKSİCONDENSE 48-65 3.1.1.4 Water pressure sensor Water pressure sensor The units are fitted with a water pressure sensor. This continuously informs the electronics of the current heating water pressure in the unit using an electric signal. 3.1.1.5 Switching limits for water pressure sensor Switching off the unit and flashing fault message System pressure <...

  • Page 37: Unit Ntc Sensor

    MAKSİCONDENSE 48-65 3.1.2 Unit NTC sensor NTC 48 kW flow and return NTC 65 kW flow and return The units are equipped with two NTC sensors (VR 11 characteristics), with one sensor each attached to the flow and return using a clip. 3.1.2.1 NTC sensor for optional DHW cylinder charging mode/C1–C2 contact Sensor NTC plug-in coupling C1–C2 cylinder charging...

  • Page 38: Primary Heat Exchanger

    MAKSİCONDENSE 48-65 3.1.3 Primary heat exchanger Exemplary image of the primary heat exchanger/front view with insulating plate The heat exchanger consists of several heat exchanger elements – the coils. Each individual heat exchanger element then consists of a stainless steel bare tube coil with four threads. The heat ex- changer elements that are located upstream of the insulating plate are referred to as the "non- condensing level"...
  • Page 39 MAKSİCONDENSE 48-65 Primary heat exchanger cross-sections PWT 7-coil cross-section PWT 9-coil cross-section Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 40 MAKSİCONDENSE 48-65 3.1.3.1 New! Manual purging of the primary heat exchanger PWT purging valve PWT 65 kW (9-coil) manual purging Purging valve position on the PWT PWT front view As a new feature, the primary heat exchanger (9-coil) of the 65 kW unit is equipped with a manual purging valve.

  • Page 41: Gas/Air Technology Design

    MAKSİCONDENSE 48-65 3.1.3.2 Flue gas collector Flue gas collector; encapsulating Encapsulation of the heat exchanger (PWT) – presentation model The flue gas collector surrounds the entire heat exchanger and is constructed from plastic up to the air/flue pipe connection. Here, the entirety of the condensate that occurs and the proportional rain- water from the flue pipework on the collector drain pipes is drained 3.1.4 Gas/air technology design 3.1.4.1 New! Compact thermal module with electronic pneumatic gas-air mixture...
  • Page 42 MAKSİCONDENSE 48-65 New! Compact thermal module (65 kW) The Space heater compact thermal module consists of the following components: ─ Burner ─ Ignition and monitoring electrodes ─ ─ Venturi pipe ─ Mixture pipe ─ Gas valve assembly The compact module is a further development of the pneumatic gas-air mixture. The essential changes are: ●...
  • Page 43 MAKSİCONDENSE 48-65 3.1.4.2 Burner with ignition and monitoring electrode Burner flange with Space Detailed view of ignition and monitoring heater ignition electrode electrode Detailed view of burner design with additional mixing cylinder (Polidoro) The combustion gas-air mixture is pumped by the fan through the gas-air channel in the cylindrical burner.
  • Page 44 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 45 MAKSİCONDENSE 48-65 3.1.4.3 New! Ignition transformer Ignition transformer Detailed view of the ignition transformer Secondary connection cables Primary connection cables Detailed view of the ignition transformer electrical connection The ignition transformer is no longer a component on the PCB; instead, it is now attached to the gas valve assembly with a support plate.
  • Page 46 MAKSİCONDENSE 48-65 3.1.4.4 New! Space heater fan 41–48 kW Pabst Fan 65 kW Pabst Fan The purpose of the fan is to route the oxygen required for combustion to the burner and to release the flue gases created by combustion into the atmosphere. The pressure generated when pumping the volume flow is required to overcome the pressure losses of the air/flue pipe and combustion chamber and to control the gas-air mixture.
  • Page 47 MAKSİCONDENSE 48-65 3.1.4.5 New! 65 kW gas valve assembly Annual gap to the atmosphere Test nipple for gas jet pressure Gas pressure regulator; pre-set by plant Test nipple for gas connection pressure and gas flow pressure Gas expansion relief valves Honeywell VK 8205V 65 kW gas valve assembly with zero pressure regulator adjusting screw Detailed view of CO...
  • Page 48 MAKSİCONDENSE 48-65 Honeywell VK 4205V 65 kW section model Honeywell VK 8205V gas valve, source: Honeywell Servo pressure control The gas valves of the VK 8205VE/VK 8205V series contain a positive gas-servo system. This means that the main gas valve is kept closed even during actuation (unit start) by means of spring force. The spring force is only overcome by sufficient gas connection pressure and the main gas valve opens.
  • Page 49 MAKSİCONDENSE 48-65 3.1.4.6 New! 48 kW gas valve assembly Breather hole to the atmosphere Test nipple for gas jet pressure adjusting screw Gas pressure regulator; pre-set by plant Test nipple for gas connection pressure and gas flow pressure Gas expansion relief valves 48 kW gas valve assembly with zero pressure regulator The gas volume is adjusted to the air flow via the CO setting at full load using the CO...
  • Page 50 MAKSİCONDENSE 48-65 Honeywell VK 8205V 48 kW section model Honeywell VK 8205VE gas valve, source: Honeywell Servo pressure control The gas valves of the VK 8205VE/VK 8205V series contain a positive gas-servo system. This means that the main gas valve is kept closed even during actuation (unit start) by means of spring force. The spring force is only overcome by sufficient gas connection pressure and the main gas valve opens.
  • Page 51 MAKSİCONDENSE 48-65 3.1.4.7 New! 48–65 kW pipe supply air Fixing point on the heat exchanger Position of the additional borehole Supply air pipe with test point for the air pressure switch with warning label The new supply air pipe is equipped with an additional test point for an air pressure switch. An additional borehole is located on the sleeve to the gas valve assembly Venturi pipe in both output versions.
  • Page 52 MAKSİCONDENSE 48-65 3.1.4.8 New! Air pressure switch (pressure switch) for the supply air network Air pressure switch Test points/air pressure switch Supply air network/pressure switch Test points/air pressure switch Detailed view of the air intake pipe/test point As a new feature, an air pressure switch is being added to the 48–65 kW product supply air network. The air pressure switch ensures the supply of sufficient combustion air.
  • Page 53 MAKSİCONDENSE 48-65 3.1.4.9 New! Water drain collector (precipitation) Water drain collector Water drain rail with drainage Non-return device Water drain spigot with non-return device The new units are equipped with a water drain collector in order to collect and drain precipitation from the flue system's annular gap.
  • Page 54 MAKSİCONDENSE 48-65 3.1.4.10 New! Condensate siphon with float valve Condensate siphon Exploded view The condensate siphon is an in-house development (patented). The siphon is equipped with an additional floating element (3) that seals the path to the tundish so that it is gas-tight, even without a water reserve.

  • Page 55: Electronic Components

    MAKSİCONDENSE 48-65 3.1.5 Electronic components 3.1.5.1 PCB (BMU) 48–65 kW PCB (BMU) Basic information regarding the electronics: The PCB electronics contain all of the functions for operating and monitoring the boiler. The current unit status is monitored permanently, any faults are analysed and shown in the display. All-important data is saved on the PCB.
  • Page 56 MAKSİCONDENSE 48-65 3.1.5.3 Configuration of the connection terminals Slot colour Designation Description of the connection terminals Underfloor heating limiter thermostat. If the jumper is removed, the Blue Burner off burner switches off immediately, F.86 24 V room temperature control (on/off NL). Heating mode ends in the White 24 V= RT event of an interruption, "D.016"...

  • Page 57: Hydraulic Connection Network

    MAKSİCONDENSE 48-65 3.1.6 Hydraulic connection network 3.1.6.1 New! Unit connection set (scope of delivery) Scope of delivery of the hydraulic installation set The hydraulic set consists of: - 4 bar (7-coil), 4 bar (later 6 bar) (9-coil) expansion relief valve - Drainage nipple - 2 x 1 ¼"...
  • Page 58 MAKSİCONDENSE 48-65 3.1.6.2 Condensate discharge hose (scope of delivery) Condensate hose The hose is used to discharge the condensate to a siphon that must be additionally created on-site. The siphon feeds the condensate into the local sewage system. The hose has a rubber connector, which is placed on the unit siphon's drain connection. Please comply with the national regulations regarding the draining of condensate.

  • Page 59: Unit Menu Overview

    MAKSİCONDENSE 48-65 3.2 Unit menu overview 3.2.1 DIA display operating concept Control panel with display 3.2.1.1 Hidden display menus The display comes with hidden maintenance menus. These menus contain different access levels for the diagnostics code that is to be edited. To achieve this, different codes are stored. On the one hand, there is the level (installer) that is used to configure the unit during initial start-up.
  • Page 60 MAKSİCONDENSE 48-65 Diagnostics level 3.2.1.3 Changing the parameter value A parameter value can be changed using the "+" or "-" side of the button (3). The changed value is automatically saved after three seconds. 3.2.1.4 Selecting diagnostics parameters To change the diagnostics parameter, press the "+" or "-" side of the button (2) 3.2.1.5 Exiting the menu levels To exit the menu level, press the button (1) for three seconds, or the unit will return to normal mode after 15 minutes.
  • Page 61 MAKSİCONDENSE 48-65 3.2.1.6 Advanced functions/Information Summer mode: Summer mode – i.e. domestic hot water generation only, heating mode off – is activated by pressing the button (1) repeatedly until the right-hand side of the display is blank. Switch cylinder charging on or off: If a domestic hot water cylinder is connected, you can switch off cylinder charging without switch- ing off the heating mode.
  • Page 62 MAKSİCONDENSE 48-65 3.2.1.7 Unit status Unit control panel This function can be selected at any time in order to receive information about the current unit status. It also provides diagnostics support in the event of a unit block. To select the status, press and hold each "-" side of buttons 2 and 3 at the same time for three seconds.
  • Page 63 MAKSİCONDENSE 48-65 3.2.1.8 Check programmes By activating the different check programmes, individual test functions can be carried out. To select the check programme, press and hold button 1 and "+" on button 3 at the same time for three sec- onds.
  • Page 64 MAKSİCONDENSE 48-65 3.2.1.9 Fault history of the unit Unit control panel You can call up the last 10 fault messages in the unit history. To select the unit history, press and hold the "+" side of button 2 and the "-" side of button 3 for >3 seconds.

  • Page 65: Functional Description

    MAKSİCONDENSE 48-65 3.3 Functional description 3.3.1 Functional description of the pneumatic gas-air mixture Volume Air Power Modulation-set (Electronic) Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 66 MAKSİCONDENSE 48-65 Characteristic line – Output/target speed Flue gas Fan motor Primary gas regulation valve Primary gas valve Setting screw: Characteristic – Air volume/ Characteristic – Air volume/ gas volume gas volume Depending on the unit output required at the time, a rotational speed target value is forwarded to the fan as a PWM signal.

  • Page 67: Gas Valve Assembly With Fan (Pneumatic) Functional Diagram

    MAKSİCONDENSE 48-65 3.3.2 Gas valve assembly with fan (pneumatic) functional diagram Adjusting screw max. load Primary gas regulation diaphragm Annular gap Primary gas regulation valve Servo pressure regulator Servo valve Gas safety valve Once the electronics have detected the ignition speed of the fan, both gas valves (control valve and main gas valve) are opened.

  • Page 68: Software Description; Safety, Special And Standard Functions

    MAKSİCONDENSE 48-65 3.3.3 Software description; safety, special and standard functions The operating modes or functions are handled according to the following priorities: 1. Functions for handling faults (highest priority) 2. Chimney sweep function (P1) 3. Hot water and cylinder charging mode 4.
  • Page 69 MAKSİCONDENSE 48-65 3.3.4.2 Pump modes in heating mode Pump operation as a function of flow temperature The heating pump can be set in various operating modes using diagnostics code "D.018". Comfort: The pump is in operation if: ─ the "Summer mode" function is not active (see "D.023") and ─...
  • Page 70 MAKSİCONDENSE 48-65 3.3.4.3 Flow temperature control Flow temperature control is preferred for use in installations with radiators or in two-circuit, multi- circuit and cascade installations. As these installations account for the majority of applications, the units are supplied with this as the factory setting. The hysteresis of flow control is ± 5 K. With flow temperature control, all of the units are always operated with the lowest possible partial load in the first minute of operation.
  • Page 71 MAKSİCONDENSE 48-65 3.3.4.4 Return temperature control The actual return temperature value is recorded by the return NTC. The hysteresis of return control is +3/-1 K. Return target value Calculating the target return value It is possible to switch from flow temperature control to return temperature control under diagnostics code "D.017".
  • Page 72 MAKSİCONDENSE 48-65 3.3.4.5 Integrated outdoor temperature control system The unit is equipped with an outdoor temperature control system via a connected outdoor sensor. To use the function, two parameters are used for setting: - D.043 for setting the heat curve - D.048 for setting the heat curve's base point To determine the heat curve, the regional surface contact temperature for the system temperature must be determined.
  • Page 73 MAKSİCONDENSE 48-65 Flow temperature [°C] Outdoor temperature [°C] Base point of the heat curve The measured temperature value for the outdoor temperature sensor is related to a modulating thermostat function; due to this switching, the base point automatically shifts and therefore optimises the heat curve. If a weather-compensated control, e.g.
  • Page 74 MAKSİCONDENSE 48-65 3.3.4.6 VRC 9642 surface-mounted thermostat The flow temperatures in hot water underfloor heating systems are between 35 °C and 48 °C. They are limited to a maximum temperature of 55 °C to prevent damage to the heating screed. It is rec- ommended that the flow temperature should be restricted to +10 K above the surface contact tem- perature.
  • Page 75 MAKSİCONDENSE 48-65 The following diagram should clarify the possible change to the active partial heat load in %: Burner < 2 mins >2 <6 mins >6 < 10 mins > 10 < 15 mins + 10 mins Max. - 10 + 1 (5, …30) % 10, or 5) % Adaptive partial load –...
  • Page 76 MAKSİCONDENSE 48-65 3.3.4.9 Burner anti-cycling time for heating mode The burner anti-cycling time limits the number of switching cycles in Heating mode. It is started when the heat demand signal (terminals 3–4 VR 36, eBUS or internal regular shutdown) no longer exists. Effective burner anti-cycling time: Calculated Set maximum burner anti-cycling time...
  • Page 77 MAKSİCONDENSE 48-65 3.3.4.11 Cylinder charging mode with uniSTOR The units are equipped with two alternative cylinder charging options. Either via a NTC sensor cyl- inder or a C1/C2 switching contact. Cylinder charging with cylinder and NTC sensor The current cylinder temperature is reported to the electronics via the NTC. If the actual value of the cylinder NTC is 5 K below the target value set on the electronics box, the pump and fan are switched on and the prioritising diverter valve is moved to the domestic hot water position.
  • Page 78 MAKSİCONDENSE 48-65 Frost protection on the external cylinder When blocking the cylinder charging mode using the control, a target cylinder temperature of 15 °C is specified. Aqua Condens System plus differs according to market (data plate data) The target flow value for cylinder charging with NTC sensor is calculated from the target cylinder temperature plus ─...
  • Page 79 MAKSİCONDENSE 48-65 Cylinder charging requirement with external switching contact (C1/C2) An external control (switching) or a cylinder switching field carry out the time control and temperature regulation of the cylinder. The electronics of the unit are only notified of the cylinder heat requirement via the terminals "C1/C2".

  • Page 80: Special Functions

    MAKSİCONDENSE 48-65 3.3.5 Special functions 3.3.5.1 New! Control function of the remaining pump head, delta T limitation This function is introduced to enable the boiler to operate without a low loss header. You must ensure that the minimum circulation water volume is flowing through the primary heat ex- changer (PWT) in order to prevent steam hammers caused by the boiling medium.
  • Page 81 MAKSİCONDENSE 48-65 1. Zone: No circulation water volume (OFR). Modulation not enabled as the minimum volume flow of 125 l/hr per heat exchanger coil is not fulfilled. The burner therefore remains locked and the unit start is blocked. 2. Zone: Low circulation water volume (LFR). Modulation is enabled for a delta T of 15 K/minimum output (Pmin).
  • Page 82 MAKSİCONDENSE 48-65 3.3.5.2 New! Control function of the remaining pump head, temperature target value limita- tion Volume flow per heat exchanger coil and temperature difference limitation Boiling range Temperature difference 35–65 kW No flow rate/no igni- High flow rate 35–65 kW Low flow rate 35–65 kW tion 35–65 kW (HFR)
  • Page 83 MAKSİCONDENSE 48-65 3.3.5.3 New! Pump volume flow analysis The units are supplied without a bypass valve for the heating circuit. The "volume flow analysis" function was added in order to measure the volume flow in the unit circuit. The measurement is carried out by analysing the pump's PWM response.
  • Page 84 MAKSİCONDENSE 48-65 3.3.5.4 New! Calculating the remaining pump head (constant value) The remaining feed head of the high-efficiency pump is calculated by the electronics for the set remaining feed head (D.122 remaining feed head heating mode; D.148 remaining feed head cylinder charging mode) as a constant value for the pump.
  • Page 85 MAKSİCONDENSE 48-65 Description of D.014 In addition to the diagnostics code, a further function was stored. If the "Auto" setting (factory set- ting) is stored, the pump modulates in parallel with the current burner modulation, provided that a minimum volume flow (LFR) is exceeded. New! If the minimum volume flow (LFR) is not reached, the electronics switch the pump mode to "constant control"...
  • Page 86 MAKSİCONDENSE 48-65 3.3.5.5 New! Operating without a low loss header Units with an output of 48–65 kW are released for installation without a low loss header. In order to implement this installation type, a low or high volume flow must be ensured. The function is enabled under parameter setting...
  • Page 87 MAKSİCONDENSE 48-65 The following diagram shows the function relative to the flow temperature and the output: Output and delta T relative to the volume flow according to Proklima: 48 kW unit Maximum T volume flow Delta T Permitted output in kW High flow rate (HFR) Low flow rate (LFR) No flow rate/no...
  • Page 88 MAKSİCONDENSE 48-65 Note on D.014: If the parameter D.014 is set inside 1–5, the responsible planner must calculated and ensure the volume flow on-site. Notes 01/2018 Training 0020260859_00...
  • Page 89 MAKSİCONDENSE 48-65 3.3.5.6 New! Fault indication for volume flow fault D.149 The parameter D.149 describes the cause of a F.75 fault message in order to facilitate the fault diagnosis for Customer Service or the competent person. D.149 table: Sta- tus/fault Cause Description Operation interlock...
  • Page 90 MAKSİCONDENSE 48-65 3.3.5.7 New! Pump identification When the unit is started, the electronics check the available unit pump with an identification routine. This routine is only available in the pump electronics for the Grundfos UPMM 25–105 (65 kW) pump. No routine is available for the Grundfos UPMM 25–85 (48 kW) pump The pump sends the following diagram via the PWM analysis response: Response 1 Response 2...
  • Page 91 MAKSİCONDENSE 48-65 Start purging Pres- sure 0.5 bar 0.3 bar Activate purging (threshold) Time 30 s min. Flow chart for automatic purging Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 92 MAKSİCONDENSE 48-65 3.3.5.9 48–65 kW automatic air separator Functional principle: The air separator used has the task of continually dividing the remaining air bubbles in the heating circuit and then separating them via a downstream automatic air vent. The air separator is divided into four different zones, which are the following: ─...

  • Page 93: Safety Functions

    MAKSİCONDENSE 48-65 3.3.6 Safety functions 3.3.6.1 Gas flame sequence control Normal operation: As soon as the conditions for a burner start are met by the target/actual value comparison and the fan has reached its ignition speed, the ignition transformer and the gas valve assembly are actuated. The safety period of 5 seconds starts.
  • Page 94 MAKSİCONDENSE 48-65 Fault shutdown in operation If the flame shuts down in heating mode, the following occurs: ─ switch-off sequence of the gas valve assembly and the fan and ─ Four further start attempts (see section "Fault shutdown during start-up"). ─...
  • Page 95 MAKSİCONDENSE 48-65 3.3.6.5 Pressure change detection Pressure change evaluation Water pressure sen- Increase water pressure sor > 0.5 bar? Set prioritising di- verter valve to heat- ing mode, pump ON for 10 seconds Five further attempts Pressure change with pump 10 s ON, >...
  • Page 96 MAKSİCONDENSE 48-65 3.3.6.6 Dry fire test by NTC 1. Test for temperature change without burner operation The dry fire test can already be successful during unit start-up without burner operation. Testing process: If the burner is not in operation and the measured temperature value at T flow is > 110 °C or at T return is >...
  • Page 97 MAKSİCONDENSE 48-65 3.3.6.10 Unit start-up strategy Unit self-test before every heat demand: Switch on the unit. Check unit pressure. Automatic purging Fault message: If it is sufficient, man- and volume flow test F.75 ually start purge pro- successful? gramme P0 Boiler standby reached? Fault message:...
  • Page 98 MAKSİCONDENSE 48-65 3.3.6.11 Flue gas fan ARA (automatic pipe length adjustment) In this function, the connected length of the flue gas system (resistance) is correlated to the fan output (ARA). Thanks to this correlation, blocks in the flue pipework or overly long flue pipework’s are detected.

  • Page 99: Accessories

    MAKSİCONDENSE 48-65 4 Accessories What to expect from this section: This section provides you with an illustration of the important accessories for use the with Space heater system. The full overview of all accessories can be found in the normal country-specific planning information and price lists. 4.1 Overview of accessories 4.1.1 Electrical accessories Accessory modules for installation in the unit electronics box...
  • Page 100 MAKSİCONDENSE 48-65 Room thermostats Accessories Description Benefits Exacontrol E7C Room temperature control (eBUS) - Optimise the boiler - Combined with outdoor sensor on the boiler - Time programmes - Auto-adaptive heat curve netATMO An intelligent room temperature control as a 1-cir- cuit control with weather function can be used: - With a boiler (3-4-5 contact and/or 24 V RT contact)
  • Page 101 MAKSİCONDENSE 48-65 eBUS control, weather-compensated Accessories Description Benefits MiPro (R) The inexpensive weather-compensated control unit for simple systems, e.g. for residential dwellings or detached houses RED-3 MiPro + RED-3 wiring centre: All individual configurations are possible, espe- cially for new-build house or semi-detached houses with solar systems, heat pumps or multi- ple-zone systems, etc.
  • Page 102 MAKSİCONDENSE 48-65 eBUS control, weather-compensated Accessories Description Benefits MiPro remote (R) - Can be used with MiPro (R) - Remote control with room temperature control - Setting the target room temperature - Room air humidity measurement with activated cooling function MiGo Intelligent eBUS control as a 1-circuit control with weather function can be used with:...
  • Page 103 MAKSİCONDENSE 48-65 Gateway/connectivity Accessories Description Benefits MiLink is the central SDBG gateway ─ One gateway for all SDBG systems and the ability to offer additional services both today and in the future (remote access, app, EEBUS, Qivicon, single-room temperature MiLink control) ─...

  • Page 104: Hydraulic Accessories

    MAKSİCONDENSE 48-65 4.1.2 Hydraulic accessories Domestic hot water cylinder Description Benefits ─ FE standard cylinder Three-components Min. cylinder content of 300 litres Foamed insulation allows the maximum amount of energy to be saved while also offering a compact external diameter (fits through a standard door) ─...
  • Page 105 MAKSİCONDENSE 48-65 Other accessories Description Benefits ─ 230 V 3-port valve The valve enables switch- New! 11/4", supplied by Orkli ing between domestic hot water and heating mode. Other valves are not compatible due External installation in the to the noise class heat generator's installa- tion hydraulics ─...
  • Page 106 MAKSİCONDENSE 48-65 Other accessories Description Benefits ─ Condensate lifting unit with neutrali- Up to 200 kW output sation ─ Neutralisation Up to 450 kW ─ Condensate lifting unit with neutrali- Up to 360 kW sation Condensate lifting unit Notes 01/2018 Training 0020260859_00...

  • Page 107: Overview Of The Different Accessories New

    MAKSİCONDENSE 48-65 4.1.3 Overview of the different accessories New! May vary in the different markets. Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 108 MAKSİCONDENSE 48-65 Other ecoTECplus/5-5 accessories Description Benefits ─ New! Rig installation Installation of boiler Improved frame for ground in- cascades if wall- stallation mounting is not pos- sible (available space, statics) ─ New! Low loss header Ground installation Improved low loss header for accessory ground installation ─...

  • Page 109: Description Of The Accessories

    MAKSİCONDENSE 48-65 4.2 Description of the accessories 4.2.1 Use of the accessories 4.2.1.1 External 3-port valve Installed as a manifold in the heating flow of the heat generator. Path AB <—> A: To the domestic hot water standby zone, valve spring loaded Path AB <—>...
  • Page 110 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 111 MAKSİCONDENSE 48-65 4.2.1.3 Multi-functional module (2 in 7) The 2 in 7 multi-functional module can be used if it is necessary to connect external components. The data cable is connected to slot X40 on the PCB and the 230 V power supply is routed via the power supply cable to slot X12 on the PCB.
  • Page 112 MAKSİCONDENSE 48-65 4.2.1.4 External solenoid valve Connecting the external solenoid valve The external solenoid valve is actuated simultaneously with the actuation of the internal gas valve. 4.2.1.5 External heating pump Connecting the external heating pump The external pump is only actuated, if: - The internal pump is actuated (mandatory condition), - The prioritising diverter valve is in the heating position, - A delay of 20 seconds has passed since the prioritising diverter valve was switched to the heating...
  • Page 113 MAKSİCONDENSE 48-65 4.2.1.6 Circulation pump Connecting the circulation pump The electrical connection for a circulation pump is located on the external connection accessory. The time is controlled by the VRT 370(f)/VRC 700 control. 4.2.1.7 Operating and fault display Connecting the operating and fault display Closing contact = Fault message = grey Opening contact = Operating display = black The operating display lights up if the main switch of the unit is switched on.
  • Page 114 MAKSİCONDENSE 48-65 4.2.1.8 Cylinder charging pump Connecting the cylinder charging pump The cylinder charging pump outlet is always actuated if an external cylinder is being charged using the unit's internal control system. 4.2.1.9 Extraction hood/flue non-return flap Connecting the flue non-return flap (black), fume extraction hood (grey) The extraction hood is switched on when the burner is not running or 90 seconds after the unit has switched off.
  • Page 115 MAKSİCONDENSE 48-65 4.2.1.11 eBUS coupler connection MiPro The modulating bus coupler must be used to expand the systems if more than one heat generator is present in the installation. We recommend equipping each heat generator with a coupler. The first unit in cascades can also work without an eBUS coupler, but here the polarity must be checked (+ to +), (- to -).

  • Page 116: Planning Requirements And Practical Information

    MAKSİCONDENSE 48-65 5 Planning requirements and practical information In this section: You will learn more about the planning of the heating installation. You will receive information regarding connection dimensions, basic requirements of the installation site and installation examples. 5.1 Installation sites and restrictions Space heater 48–65 kW ...

  • Page 117: Product Requirements

    MAKSİCONDENSE 48-65 5.2 Product requirements 5.2.1 Minimum clearances Minimum clearances Min. clearances 275 mm: 80/125 mm diameter LAF LAF = air/flue pipe 180 mm; optimal approx. 250 mm 5 mm; optimal approx. 50 mm 500 mm; clearance for unit maintenance that is required to open the front of the unit. No clearance is required between the unit and components made of combustible parts because the temperature at the unit's nominal heat output never exceeds the maximum permissible temperature of 85 °C.

  • Page 118: Dimension Drawing And Connection Dimensions

    MAKSİCONDENSE 48-65 5.2.2 Dimension drawing and connection dimensions 48–65 kW dimension drawing Condensate siphon Flue connection (template) Heating flow Unit wall mounting Gas connection Gas connection pressure measuring point Heating return Flue connection (unit) Precipitation drainage Drip connection of the air separator 48 kW = 405 mm;...

  • Page 119: Combustion Quality Requirements

    MAKSİCONDENSE 48-65 5.2.3 Combustion quality requirements The combustion air must be technically free of chemical substances such as fluorine, chlorine, sul- phur, sprays, solvents and cleaning agents, paints, adhesives, etc. These types of substances may lead to corrosion damage in the unit or in the flue system during open-flued operation. If the combustion air is guided over the shaft's annular gap and to the heat production source, the following applies: ...
  • Page 120 MAKSİCONDENSE 48-65 Pump diagram for Grundfos UPMM 25–105; 9 heat exchanger coils ΔP constant Volume flow range without unit operation Volume flow range in limited temperature Volume flow in l/hr and modulation mode Remaining pump head 100% pump curve in hPa (mbar) Notes 01/2018 Training 0020260859_00...

  • Page 121: Flue Gas Systems (Certifications)

    MAKSİCONDENSE 48-65 5.3.2 Flue gas systems (certifications) The entire Space heater range is suitable for use with SDBG DN 80/125 PP flue gas accessories and has been system-certified for use with these. Deviating permissions (installation types) in the individual markets. 5.3.2.1 Possible flue gas installation types from the TRGI Open-flued installation types B 23: Flue connection to the flue system, combustion air supply via the installation room...
  • Page 122 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 123 MAKSİCONDENSE 48-65 5.3.2.2 Flue gas certifications according to market The following table shows the assignment of flue gas certifications for the product according to the different markets. Market Flue gas certification C13, C33, C53, C83, C93, B23, B23(P), B33, B53, B53(P) ES, PT C13, C33, C53, C83, C93, B23, B23(P), B33, B53, B53(P) C13, C33, C53, C63, C83, C93, B23, B23(P), B33, B53, B53(P)
  • Page 124 MAKSİCONDENSE 48-65 C43P C83P Notes 01/2018 Training 0020260859_00...

  • Page 125: Water Quality

    MAKSİCONDENSE 48-65 5.3.3 Water quality The heating water must be prepared, if ─ the entire fill and make-up water volume exceeds three times the rated volume of the heating installation during the use of the unit, or ─ the guideline values listed in the following table are not met. Total heating Total hardness at 20 l/kW Total hardness at...
  • Page 126 MAKSİCONDENSE 48-65 ─ Additives (corrosion inhibitors) intended to remain in the installation ● Fernox F1 ● Fernox F2 ● Fernox Superconcentrate Central Heating Restorer ● Fernox Superconcentrate Central Heating Protector ● Fernox Superconcentrate Boiler Noise Silencer ● Fernox Superconcentrate Central Heating Leak Sealer ●...

  • Page 127: Line Strainer Or Magnetite Filter

    MAKSİCONDENSE 48-65 5.3.4 Line strainer or magnetite filter Installation position of the line strainer When replacing the unit in an existing installation, installing a line strainer (33) in the heating instal- lation return is recommended. It is advisable to combine the use of a line strainer with a magnetite separator.
  • Page 128 MAKSİCONDENSE 48-65 Example of a magnetite separator Housing with separator Magnet Sample magnetite separator: SDBG range Using high-efficiency pumps in all boilers that are launched in EU member states and other markets Housing with separator means that the use of a magnetite filter is essential. Within the heating circuit, galvanic corrosion processes cause sludge to form which, in turn, is offset by ferrous metals.

  • Page 129: Basic System Diagrams And Wiring Diagrams

    MAKSİCONDENSE 48-65 5.4 Basic system diagrams and wiring diagrams 5.4.1 Basic system diagrams Item Designation Item Designation Heat generator heat exchanger module Domestic hot water back-up boiler 2-zone module Heating back-up boiler Pump group Heating/domestic hot water back-up Expansion relief valve boiler Solid fuel boiler with manual feed Potable water expansion relief valve...
  • Page 130 MAKSİCONDENSE 48-65 Item Designation Item Designation Heat recovery module Low loss header BufBtDH Bottom temperature sensor for DHW section Flexible connections of buffer cylinder BufTopC Top temperature sensor for heating section of Fan coil buffer cylinder Bottom temperature sensor for heating sec- Swimming pool BufBtCH tion of buffer cylinder...
  • Page 131 MAKSİCONDENSE 48-65 The following hydraulic plans are a selection for the product start. Deviations may be possible in individual markets. Contact MX-MCP for any questions. 5.4.1.1 Hydraulic plan 0020253234 41-65 kW hydraulic plan; cylinder function unit; direct heating circuit without low loss header Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 132 MAKSİCONDENSE 48-65 Hydraulic plan 0020253234 wiring Connection diagram 0020253234 Notes 01/2018 Training 0020260859_00...
  • Page 133 MAKSİCONDENSE 48-65 5.4.1.2 Hydraulic plan 0020253237 41-65 kW hydraulic plan; cylinder function unit; low loss header Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 134 MAKSİCONDENSE 48-65 Hydraulic plan 0020253237 wiring Connection diagram 0020253237 Notes 01/2018 Training 0020260859_00...
  • Page 135 MAKSİCONDENSE 48-65 5.4.1.3 Hydraulic plan 0020259028 41-65 kW hydraulic plan; cylinder function unit; low loss header Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 136 MAKSİCONDENSE 48-65 Hydraulic plan 0020259028 wiring Connection diagram 0020259028 Notes 01/2018 Training 0020260859_00...

  • Page 137: Installation/Start-Up

    MAKSİCONDENSE 48-65 6 Installation/start-up In this section: Here you will receive important information regarding the installation and subse- quently information regarding the start-up of the unit. Please keep in mind that this information is dependent on the market. Always observe the installation instructions supplied with the unit.

  • Page 138: Detailed Installation Notes

    MAKSİCONDENSE 48-65 6.2 Detailed installation notes The boiler has vertically positioned connections for flow/return/gas connection/condensate connec- tion (see next figure). ─ Open the press connection (A). ─ Insert the gas connection (B) into the press connection. ─ Secure the connection on the gas connection (C).

  • Page 139: Hydraulic Connection

    MAKSİCONDENSE 48-65 6.2.1 Hydraulic connection Installing the union nut in accordance with steps A to D ─ Installing the heating circuit return (11) to (17) ─ Installing the heating flow (1) to (10) ─ Heating return stopcock seal (19) ─ Installing the expansion vessel on the heating return Installing the hydraulic connections Notes...
  • Page 140 MAKSİCONDENSE 48-65 Installing the expansion relief valve (1) on the heating flow Installing the condensate discharge (2) on connection (1) The condensate discharge must always be laid frost-free and with a downward gra- dient of at least 48 mm per metre. The precipitation discharge can be laid with the condensate hose together with the on-site siphon.

  • Page 141: Electrical Connection

    MAKSİCONDENSE 48-65 6.2.2 Electrical connection Space heater 41–65 kW PCB (BMU) all markets 6.2.2.1 Connecting the control ─ Red: Room or weather-compensating eBUS control ─ White: 24 V room thermostat ─ Blue: Temperature cut-out (e.g. underfloor heating) As delivered from the factory: The "Burner off"...
  • Page 142 MAKSİCONDENSE 48-65 6.2.2.2 230 V connection 230 V connection 6.2.2.3 Terminal location for VR10 (cylinder sensor) and C1/C2 on the unit cable harness SDBG NTC plug-in coupling C1–C2 cylinder charging contact 6.2.2.4 X41 plug in the boiler's scope of delivery Item Description Item...

  • Page 143: Air And Flue Gas Accessories

    MAKSİCONDENSE 48-65 6.2.3 Air and flue gas accessories 48–65 kW units are fitted with an 80/125 mm diameter air/flue gas spigot as standard. Observe the supplementary information in the flue gas accessory catalogue. Flue gas analysis point Supply air analysis point Top view of the product Notes TEKNİK EĞİTİM VE DESTEK...

  • Page 144: Start-Up Checklist

    MAKSİCONDENSE 48-65 6.3 Start-up checklist Activity Description DIN EN 14336 prescribes that heating installa- Rinse the heating installation tions be rinsed or cleaned. Before being put into operation, the unit siphon Fill the unit siphon must be filled with water. The static height of the building must be taken If required, adjust the MAG pre-charge pressure into consideration here.

  • Page 145: Water Composition

    MAKSİCONDENSE 48-65 Activity Description In the diagnostics menu of the installer level, various parameters need to be changed to Adapting the unit to the heating installation adapt the boiler in line with the heating installa- tion in the best way possible. The Diagnostics codes table is included in the following section.
  • Page 146 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 147 MAKSİCONDENSE 48-65 6.3.3 Filling the heating installation Rinse the heating installation Connect the filling/drain cock (2) to the on-site filling device Open the water supply Open the thermostatic valves Open the service valves Slowly open the filling/drain cock (1) Open the purging nipple (3) and wait until the water escapes without bubbles. This nipple is only used for the first filling Monitor the filling pressure with the manometer, required filling pressure 1.5–2.5 bar Close the locks and check the pipe connections for tightness.
  • Page 148 MAKSİCONDENSE 48-65 6.3.4 Starting the boiler Actuate the mains switch. The start menu appears in the display 6.3.4.1 Check programme for purging the heating circuit Start condition and boiler purging: If the unit/system pressure has fallen below 0.3 bar for at least 15 seconds, the point for a purging sequence is set.

  • Page 149: Checking The Gas Setting

    MAKSİCONDENSE 48-65 6.3.4.2 Target flow value for heating mode (limitation) This parameter allows the required flow temperature to be set (first display level) This setting also limits a higher temperature demand from the control. 6.3.4.3 Target domestic hot water temperature (limitation) – first display level This parameter allows the required domestic hot water temperature to be set in connection with a domestic hot water cylinder.
  • Page 150 MAKSİCONDENSE 48-65 6.3.5.3 Checking the gas connection pressure and gas flow pressure 48 kW boiler Check programmes "P.01" and "P.02" are available for this. Check the unit functions (heating mode, domestic hot water mode) It is best to do this using the Live Monitor, since this allows you to read all of the main operating modes.
  • Page 151 MAKSİCONDENSE 48-65 65 kW boiler Check programmes "P.01" and "P.02" are available for this. Check the unit functions (heating mode, domestic hot water mode) It is best to do this using the Live Monitor, since this allows you to read all of the main operating modes.
  • Page 152 MAKSİCONDENSE 48-65 6.3.5.4 Checking the CO content Check programmes "P.01" and "P.02" are available for this. Check the unit functions (heating mode, domestic hot water mode) It is best to do this using the Live Monitor, since this allows you to read all of the main operating modes.
  • Page 153 MAKSİCONDENSE 48-65 6.3.5.5 Flow chart: ecoTEC 48–64 kW gas setting Start Adjustment Unit corresponds to the existing gas group required Open front cover. Connect the manometer for the flow pressure measurement. Start up the unit at full load Check programme P1 Is the flow pressure Decommissioning the within the permissible...
  • Page 154 MAKSİCONDENSE 48-65 Overview table for the CO check Within the ranges shown in the table, the CO2 need not be set during start-up. 7-coil 48 kW Natural Natural Select natural natural Unit G25.3 Permissible CO content after 8.6 ± 8.6 ± 9.1 ±...
  • Page 155 MAKSİCONDENSE 48-65 Gas conversion G20 to G25 G25.3 to G20 G20 to G27 G20 to G31 -2.5 +1.5 rotations -1 rotation +2.25 rotations 7-coil rotations clockwise anti-clockwise clockwise Value anti-clockwise +4.25 -3.5 rotations +3 rotations -6 rotations 9-coil rotations anti-clockwise clockwise anti-clockwise clockwise...

  • Page 156: Regional Legislation

    MAKSİCONDENSE 48-65 6.4 Regional legislation Notes 01/2018 Training 0020260859_00...

  • Page 157: Maintenance, Troubleshooting And Repair

    MAKSİCONDENSE 48-65 7 Maintenance, troubleshooting and repair In this section: You will receive important information regarding unit maintenance and advice for troubleshooting. You will also receive an overview of the fault messages and their cause for troubleshooting. 7.1 Maintenance checklist A visual inspection of the following parts must be carried out during each inspection: ─...
  • Page 158 MAKSİCONDENSE 48-65 A sample overview of all of the work steps required for inspection/maintenance is given in the following table: Required for Work step Annu- Inspection ally (interval) Check the air/flue gas installation for tightness and to ensure that it is secure;...

  • Page 159: Detailed Maintenance Notes

    MAKSİCONDENSE 48-65 7.2 Detailed maintenance notes Guidelines for carrying out maintenance work on the unit The flexible gas pipe may become damaged if weight is placed on it. Do not suspend the com- pact thermal module on the gas pipe, for example during maintenance work.

  • Page 160: Installing And Removing Components/Modules

    MAKSİCONDENSE 48-65 Guidelines for carrying out maintenance work on the unit Cleaning the unit siphon: The unit siphon should be cleaned at regular inter- vals. To do this, unscrew the lower section and clean away any dirt and depositions. Then fill the lower section up to ¾...
  • Page 161 MAKSİCONDENSE 48-65 4. Unplug the ignition cable (6) and the PE connection (5). 5. Remove the power supply (4) from the ignition transformer. 6. Remove the plugs (1) and (2) from the fan motor. 7. Remove the plug (3) from the gas valve. 8.
  • Page 162 MAKSİCONDENSE 48-65 7.2.1.3 Dismantling/cleaning the air separator 1. Pull off the clip (1). 2. Remove the connection pipe (2). 3. Loosen the fixing screws (1) 4. Remove the housing (2) from the air separator. 5. Clean the filter (3) using hot water. 6.
  • Page 163 MAKSİCONDENSE 48-65 7.2.1.4 Dismantling/cleaning the condensate siphon A Loosen the lower section of the siphon (1) from the upper section (2). B Remove float (3). C Fill the lower section of the siphon with water up to 10 mm below the upper edge. ─...

  • Page 164: Recommended Tools

    MAKSİCONDENSE 48-65 7.2.2 Recommended tools Basic tool set Electronic manometer Quick response thermometer Flue gas analyser Electronic leak detector Notes 01/2018 Training 0020260859_00...

  • Page 165: Troubleshooting

    MAKSİCONDENSE 48-65 7.3 Troubleshooting 7.3.1 Status codes, diagnostics codes, fault codes and check programmes 7.3.1.1 Status codes Status messages are displayed in the Live Monitor. Code Meaning Code Meaning Domestic hot water mode Heating mode SPACE HEATER; VC; VM; VHR = cylinder charging S.00 Heating: No heat demand...
  • Page 166 MAKSİCONDENSE 48-65 Code Meaning Code Meaning Waiting period: Water deficiency No heat demand: Controller (the boiler is within the waiting period S.30 (room thermostat terminal 3-4 = S.53 due to water deficiency (the difference blocks heating mode) between the flow and the return is too great)) Waiting time: Water deficiency No heat demand, summer mode...
  • Page 167 MAKSİCONDENSE 48-65 7.3.1.2 Diagnostics codes The diagnostics menu is integrated in the Installer level and can only be called up after entering a password. The diagnostics codes highlighted in bold in the following table can only be changed via the buttons of the DIA system. The bold information in the "Adjustable values"...
  • Page 168 MAKSİCONDENSE 48-65 Display Meaning/text Display values/adjustable values XXXX Parameter with code 96 entered – 0 =Auto (modulating pump control with constant pressure regulation) From 1–5 = pump fixed value control – 1 = 53% D.014 Pump speed target value – 2 = 60% –...
  • Page 169 MAKSİCONDENSE 48-65 Display Meaning/text Display values/adjustable values XXXX Parameter with code 96 entered Circulation pump [1]/External pump [2]/Cyl- inder charging pump [3]/Extraction hood Accessory relay 2 [4]/Ext. solenoid valve [5]/ D.028 Ext. fault message [6] (2 in 7 multi-functional module/VR 40) Not active: Solar pump [7]/eBUS remote control [8]/Legionella protection pump [9] D.029...
  • Page 170 MAKSİCONDENSE 48-65 Display Meaning/text Display values/adjustable values XXXX Parameter with code 96 entered D.076 Device Specific Number XX DSN DHW partial load in kW / setting range between min. and max. D.077 (output during cylinder charging SPACE output HEATER) In °C, adjustment range: 50–80 °C (75 °C) DHW max.
  • Page 171 MAKSİCONDENSE 48-65 Display Meaning/text Display values/adjustable values XXXX Parameter with code 96 entered If the fault message F.75 appears, a defined indication for fault analysis can be evaluated here. 0 = No fault 1 = Pump blocked 2 = Electrical pump fault 3 = Dry fire D.149 Detailed description of fault F.75...
  • Page 172 MAKSİCONDENSE 48-65 7.3.1.3 Detailed explanation Diagnostics code D.014: In addition to the diagnostics code, a further function was stored. If the "Auto" setting (factory set- ting) is stored, the pump modulates in parallel with the current burner modulation. New! If the minimum volume flow (LFR) is not reached, the electronics switch the pump mode to "constant control"...
  • Page 173 MAKSİCONDENSE 48-65 7.3.1.4 Fault messages If a fault message is present, this flashes in the display. If several fault messages are present, all of the fault messages are displayed in turn. Display Text display (description) Possible cause NTC defective, F.00 Interruption: Flow sensor (NTC) NTC cable defective, F.01...
  • Page 174 MAKSİCONDENSE 48-65 Display Text display (description) Possible cause Start-up failure Fault in gas supply such as: Gas meter or gas F.28 (unit does not start: Ignition attempts pressure monitor defective, air in the gas, during start-up unsuccessful) Operating failure Gas supply interrupted intermittently, (flame goes out during operation and Incorrect earthing of unit, F.29...
  • Page 175 MAKSİCONDENSE 48-65 Display Text display (description) Possible cause Flow sensor not correctly positioned on the Fault: Flow sensor flow pipe. F.71 (flow sensor reports a constant value) Flow sensor defective. Flow and/or return sensor defective (toler- F.72 Fault: Flow/return sensor ances too great) Line break in water pressure sensor line or Fault: Water press.
  • Page 176 MAKSİCONDENSE 48-65 Display Text display (description) Possible cause When the burner starts, no temperature change or an excessively small temperature change is registered by the flow or return temperature sensor. F.83 Fault: NTC temp. gradient Insufficient water in unit Flow or return temperature sensor not posi- tioned correctly on the pipe.

  • Page 177: Troubleshooting And Flowcharts

    MAKSİCONDENSE 48-65 7.3.2 Troubleshooting and flowcharts No heating, no do- mestic hot water Power supply not con- Does the unit have a Does the display nected; show the flow tem- mains supply of check the building cir- perature? 230 V? cuit breaker 2 A micro fuse defec- tive;...
  • Page 178 MAKSİCONDENSE 48-65 No domestic hot water Heating works Domestic hot water tar- Is the target tempera- get temperature locked Is the "water tap" ture for domestic hot by control; set the tar- symbol visible? water set correctly? get value according to customer requirements.
  • Page 179 MAKSİCONDENSE 48-65 No heating; domestic hot water works Summer mode active or eBUS actuation is blocking Status display the heating mode S.31 = ? Increase the max. target temperature. eBUS requirement < 20 °C, e.g. the external control is blocking the heating mode. Status display S.36 = ? Settings?
  • Page 180 MAKSİCONDENSE 48-65 7.3.2.1 Check programmes Check pro- Description gramme P 00 Check programme: Purging: The heating circuit and the domestic hot water circuit are purged via the automatic air sepa- rator. The heating pump is cyclically actuated. See automatic purge programme for the oper- ating sequence.

  • Page 181: Measurement Points And Measured Values

    MAKSİCONDENSE 48-65 7.3.3 Measurement points and measured values 7.3.3.1 Internal circuit diagram Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 182 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 183 MAKSİCONDENSE 48-65 BMU PCB C1/C2 analogue DHW contact Unit display (AI) Water pressure sensor Gas valve supply PWM for the heating circuit pump Flow sensor D.026 optional relay 3 way valve/DHW charging pump power sup- Return sensor Air pressure switch 230 V fan power supply Fan control signal 230 V heating circuit pump power supply...
  • Page 184 MAKSİCONDENSE 48-65 7.3.3.2 New! Honeywell gas valve assembly Honeywell VK 8205 VE + V Resistance measurement at the gas coils Between contact 1 + 3 114.5 Ω blue socket Notes 01/2018 Training 0020260859_00...
  • Page 185 MAKSİCONDENSE 48-65 7.3.3.3 Ignition transformer ecoTEC xx6/5-5 ignition transformer Ignition transformer circuit diagram Step 230 V Status/measured value Resistance between 3 and 4 0 No actuation > 100 Mohm 1 Actuation No ignition spark Ignition sparks with 25 Hz ± 4 Hz 2 Ignition Notes TEKNİK EĞİTİM VE DESTEK...
  • Page 186 MAKSİCONDENSE 48-65 7.3.3.4 BMU PCB terminals Space heater 41–65 PCB outputs and inputs Item Information Item Information X 41: Control accessories slot CH pump: Internal unit pump; 230 V Contacts: Outdoor sensor AF; DCF receiver DCF; Reference sensor RF; Earth OT Burner off: Block contact, e.g.
  • Page 187 MAKSİCONDENSE 48-65 7.3.3.5 NTC VR 11 sensor measured values Temperature (°C) Resistance (kΩ) Image VR 11 NTC flow and return 12.7 10.1 (10 K) Notes TEKNİK EĞİTİM VE DESTEK 03/2020...
  • Page 188 MAKSİCONDENSE 48-65 7.3.3.6 Table of optional cylinder sensor resistance values Temperature (°C) Resistance (kΩ) 5.39 4.24 3.37 2.70 2.17 1.75 1.43 1.17 0.96 0.80 0.66 0.55 0.47 0.39 0.33 0.28 0.24 0.21 0.18 VR 10 characteristics of cylinder sensor Notes 01/2018 Training 0020260859_00...
  • Page 189 MAKSİCONDENSE 48-65 7.3.3.7 Replacing PCBs The unit variants and output ranges are stored using software on the electronic PCB (BMU) and on the display PCB (AI) at the factory. Replacing a component: When servicing the system, the parameters of the component not replaced are transferred to the newly installed PCB (after switching on the unit) if replacing either of the two components.

  • Page 190: Appendix

    MAKSİCONDENSE 48-65 8 Appendix In this section: - You can find all required information in tabular form - Technical data - Further information - A collection of formulas for planning 8.1 Technical data Brand SDBG SDBG Range of units Space heater Space heater...

  • Page 191: Dsn Overview

    MAKSİCONDENSE 48-65 8.2 DSN overview Product Product Thema Condens AS 48-A (H-HU) Thema Condens AS 48-A (E-BE) Thema Condens AS 65-A (H-HU) Thema Condens AS 65-A (E-BE) Thermo Master Condens AS 48-A (H-ES) Panther Condens 48 KKO-A (H-CZ) Thermo Master Condens AS 65-A (H-ES)

  • Page 192: Erp Data

    MAKSİCONDENSE 48-65 8.3 ErP data Data sheet that is enclosed with the product. Notes 01/2018 Training 0020260859_00...
  • Page 193 MAKSİCONDENSE 48-65 Notes TEKNİK EĞİTİM VE DESTEK 03/2020...

  • Page 194: Formulas

    MAKSİCONDENSE 48-65 8.4 Formulas 8.4.1 Hydraulics 8.4.1.1 Volume flow (flow rate) �� ̇ = �� �� �� �� ̇ Volume flow ���� Pipe cross-section �� �� �� Flow speed �� ̇ = �� �� Volume Time 8.4.1.1 Calculation: Expansion vessel for closed heating installations Pressure factor calculation ����...
  • Page 195 MAKSİCONDENSE 48-65 8.4.1.2 Calculation of expansion vessel's pre-charge pressure in a closed heating installa- tion Expansion vessel pre-charge pressure ���� ���� = ���������� + ��. �� ������ ���� Pre-charge pressure of expansion vessel ���������� Hydrostatic pressure (building) ��. �� ������ Default Example: Height difference in the building from the lowest point of the heat generator to the highest point in the heating circuit.
  • Page 196 MAKSİCONDENSE 48-65 Notes 01/2018 Training 0020260859_00...
  • Page 197 MAKSİCONDENSE 48-65 Example: A cylinder water heater has a capacity of 300 l. The outlet pressure on the pressure reducer is ���� = 4 bar; the expansion relief valve's discharge pressure is ������ = 10 bar. Expansion volume: ∆�� = ��. �������� �� ������ = ��. �������� �� ������ �� = �� �� Pre-charge pressure in MAG-W: ����...
  • Page 198 MAKSİCONDENSE 48-65 8.5 System checklist Check during start-up/maintenance: Hydraulic integration as per installation instructions 2. Electrical wiring as per installation instructions 3. Water composition as per installation instructions 4. Flue gas system as per planning information 5. Gas connection pressure 6.
  • Page 199 All rights reserved. Approval is required for reproduction, in whole or in part, in written or electronic form. For the installation, always observe the installation and maintenance instructions enclosed with the unit. Planning examples are no substitute for having every single installation planned by a professional.

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Thema condens as 65-a

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