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Summary of Contents for Flexiheat Thermo Extra 28 kW
- Page 1 ELECTRIC BOILERS FOR CENTRAL HEATING Thermo Extra 28 - 96kW INSTRUCTIONS FOR INSTALLATION AND USE INSTRUCTIONS FOR INSTALLATION AND USE TMS-UT-0621-Z01-1 We reserve the right of alternations...
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Page 2: Table Of Contents
Contents General ..........................6 1. Introduction ........................7 1.1. Applicable documents ....................7 1.2. Retention of documents ....................7 1.3. Introduction ......................... 7 1.4. Heating curves ......................7 1.4.1. Availability of heating curves................. 7 1.4.2. About Heating curves ................... 7 1.4.3. - Page 3 ...................22 4.8. Filling the heating system 5. Commissioning .........................23 5.1. Central heating system check ..................23 5.2. Preliminary electrical check ..................23 Graphic control panel ( 'X' Control Panel) ...............24 5.3. 5.5. Service menu options .....................35 6. Periodic checking ......................36 7. Survey of possible malfunctions and irregularities in operation .........37 7.1.
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Page 4: General
General Read this document carefully before carrying out any installation, adjustment or service and follow the instructions • Keep these instructions close to the boiler! • The boiler must not be modified, changed, or rebuilt. • The correct settings are important for economical heating. •... -
Page 5: Introduction
1. Introduction Thank you for the confidence you have shown in us by purchasing our electric heating boiler. To use the boiler correctly and safely, and above all economically, read these instructions thoroughly before continuing with installation. The appliances must be installed by a competent person, who is responsible for adhering to the existing regulations, rules, and guidelines in force. -
Page 6: Why Does The Characteristic Heating Curve Have To Be Set
Factory defined curves If the heating curve is set optimally for heating your building, corrections will not be necessary. 1.4.3. Why does the characteristic heating curve have to be set? After the first settings of the heating curve authorized person can adjust, correct that curve if necessary. -
Page 7: Limiting The Minimum And Maximum Temperature Of Water In The Boiler
Inclination of the Offset curve Factory settings Room temperature is too low if the external temperature is Change with the first Add with offset above + 5 lower curve Room temperature is too low if the external temperature is Leave the curve 1,5 Add with offset between + 5 C and - 5... -
Page 8: Description
1.5.2. Description Domestic water conditioning has a preference order over central heating. Now via signaling the need for warming up the domestic hot water cylinder by the domestic water temperature sensor, the circulation pump of central heating is switched off and the circulation pump for domestic water is switched on. -
Page 9: Boiler Specifications
2. Boiler specifications 2.1 Dimensions Thermo Extra TECHNICAL DATA FOR THERMO EXTRA ELECTRIC BOILERS ¸¸¸¸Power Capacity Dimensions Weight Maximum Pipes Power supply operating Lit. BSP male pressure (bar) 1 ½” 400V 3N ~ 50/60 Hz 2” Page 11... - Page 10 2. 1.1 Recommended flows for T h ermo Extra up to 40k W output Recommended flows for boilers Thermo Extra up to 40kW The maximum flow rate is based on a delta T of 5°C ,minimum flow rate is based on 20°C 2.
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Page 11: Hydraulic Pressure Drop And Recommended Flows
2.2 Hydraulic pressure drop and recommended flows Pressure drop for Thermo Extra 2.4. Power supply characteristics POWER Nominal Fuse current Rated short- Rated short- Min. Fuse type RCCB switch current circuit circuit conductor's type breaking breaking cross-section capacity capacity (EN 60898) (IEC 947-2) 400V 3N ~ 50/60 Hz 28 kW... - Page 12 2.5. Function elements of Thermo boilers Thermo Extra 1. Primary flow 6. Electrical heaters 2. Return flow 7. Control panel 3. External boiler jacket 8. Inducers for el. Connections 4. Boiler 9. Contactors 5. Heat insulation 10. Charge and discharge valve Page 13...
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Page 13: General Requirements
3. General requirements 3.1 Contents included in delivery The Thermo Extra boilers are delivered pre-mounted in a package unit. Make sure that all parts have been delivered intact. For the exact list of parts see the figure and table below. If parts are damaged or missing, please consult our local sales office. -
Page 14: Installation Site
3.4. Installation site 3.4.1. Position of a boiler The location must provide adequate space for servicing and air circulation around the boiler. The boiler may be installed in any room, except a room containing a bath or a shower. The boiler must be mounted on a flat, vertical wall, which must be sufficiently robust to bear the weight of the boiler. -
Page 15: Power Supply
3.4.2. Power supply The boiler is rated as a high-power appliance and fixed wiring must be used. Please observe chapter 2.4. about fuse and conductor requirements. When connecting the appliance to the wiring the means for disconnection via a (MCB) must be incorporated into the supply wiring in accordance with the local wiring rules and regulations. -
Page 16: Filling And Preparing Heating System
3.5.3. Filling and preparing heating system. The system can be filled using the built-in filling valve or via a separate filling point fitted at a convenient position on the heating circuit. The connection must be removed when the filling is completed. -
Page 17: Boiler Installation Sequence
4. Boiler installation sequence 4.1. Transporting the appliance Important: The following lift operation exceeds the recommended weight for a one-man lift. General recommendations when handling Clear the route before attempting the lift. Safe lifting techniques are used – keep back straight – bend using legs. -
Page 18: Pipe Work Connection
4.4. Removing/fixing the front and bottom case Unwind two screws from the bottom side of boiler (1) and grasp the front panel by its sides, pull it towards the front (2) and remove it by lifting it off the unit (3). Fore service purposes as element replacing, or power cable installation, remove the bottom cover by unwinding two screws (4) and remove the cover from the case (5). -
Page 19: Power Supply Connection
4.6. Power supply connection Note: Before working on the boiler, turn off the power (e.g. MCB, switches) and protect against accidental switching on. The tightening torque for MCB is 2.0 Nm. A boiler is rated as a high-power appliance and fixed wiring must be used. Please observe chapter 2.4. -
Page 20: Connecting Temperature Sensors Or External Electrical Controls
4.7. Connecting temperature sensors or external electrical controls 4.7.1. Accessing sensor terminals To access sensor terminals, the main and control power supply must be disconnected. After the power supply is disconnected remove the front panel according to chapter 4.4. 4.7.2. Connecting external temperature sensor External temperature sensor (an optional extra) must be fitted in such manner that it is not affected by... -
Page 21: Connecting Room Thermostat And Time Switch
4.7.4. Connecting a room thermostat and / or time switch The terminals GND and DI1 on the control board are used for connecting a room thermostat or time switch .Please note any thermostat or time switch must be voltage free - i.e a voltage free contact Connection board Note: For more details see selected appendix from chapter 3.3. -
Page 22: Commissioning
5. Commissioning 5.1. Central heating system check Check for pressure in the system, it should be from 1.2 to 1.5 bar when the system is cold. Vent all heating elements and installation. 5.2. Preliminary electrical check ▪ Check if power cable is tightened on terminals. ▪... - Page 23 5.3 Control panel – option "X" Ž Mark Description Control panel power switch Cutout thermostat with manual deactivation (1) Cutout thermostat with manual deactivation (2) Touch screen...
- Page 24 5.1.1. Control panel display Control panel in stand-by mode Operating panel 1.2. Entering and navigating through the user menu Touch icon to enter the user menu. Touch icons for moving through the menu and changing values. Touch the desired option or symbol to select and confirm the value.
- Page 25 5.1.2. User menu options Menu language Language selection for menus and messages Power limit Limiting the maximum number of stages Info Display of information about the device itself and the operation of individual groups of heaters and the energy used Day/night mode Enabling/disabling operation in day and night mode Night temperature...
- Page 26 5.1.4. Example of changing the date and time Tap on the date and time screen to open the settings. REMARK: The time and date are automatically updated over the network!! Touch the field you want to change the value of, then after the marked field frame, by touching the symbol set the desired value.
- Page 27 It is also possible to adjust the desired value using the dial. To access the dial, touch the displayed temperature on the screen. Tap to enter the desired value, then tap the symbol on the screen to confirm and save the change or touch for recall.
- Page 28 It is also possible to adjust the desired value using the dial. To access the dial, touch the displayed temperature on the screen. Tap to enter the desired value, then tap the symbol on the screen to confirm and save the change or touch for recall.
- Page 29 Control panel connected to the network. To display the network settings, touch the marked icon on the screen. Network settings view. To adjust the network parameters, it is necessary to select the "Network settings" option in the user menu. If DHCP is active, it must be deactivated to adjust the parameters. DHCP activation/deactivation.
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Page 30: Service Menu Options
5.1.8. Entering and moving through the service menu To access the service menu, select the "Service menu" option in the user menu Enter the PIN to access the service menu. PIN code: 334112 Touch icons for moving through the menu and changing values. - Page 31 (displayed only if the outdoo r temperature Factory value: sensor is active Radiator heating: 1.5 Floor heating: 0.6 Stand-by temperature The minimum temperature that will be maintained in the boiler when in standby mode. Factory value: 15 °C Minimum boiler Limitation of the minimum boiler temperature that can be selected.
- Page 32 5.1.10. Signaling and display of errors in operation Error example "Overheating" If the boiler overheats, the overheating symbol will flash at the top of the screen. Tapping on the error symbol will open a message with a more detailed description of the error. A message with a description of the error.
- Page 33 5.1.11. Cascade mode Cascade mode must be enabled in the service menu, section: "Cascade mode" Cascade mode must be enabled on all slave boilers that are connected to the cascade!!! Do not turn on Cascade mode on the primary (master) boiler. In cascade mode, the input and output signal symbols of cascade operation are shown on the screen.
- Page 34 If boilers in cascade operation are controlled by means of an external temperature sensor or by means of analogue input signals 0-10 V, external control is performed only on the primary (master) boiler, all slaves must be set to "Local" control mode, and the external temperature sensor must be switched off.
- Page 35 5.1.12 Remote control via 0-10 Volt Select the desired control mode from the service menu, section: “Control mode“ Remote power control If remote power control is selected as the control mode, the remote control symbol and information about the active number of steps depending on the value of the input signal AI1 will be displayed at the bottom of the screen.
- Page 36 5.2 Connecting module 5.2.1. Connecting module layout Picture 3 Connecting module Picture 4 Connecting module – pin layout...
- Page 37 5.2.2 Outdoor temperature sensor connection The outdoor temperature sensor is connected to the screw terminals marked "TS2" on the connection module. The terminals of the outdoor sensor and the connection method are shown in the picture below: Picture 5 Connecting the external temperature sensor.
- Page 38 5.2. Connecting the sensor for DHW tank The sensor for DHW tank is connected to the screw terminals marked "TS3" on the connection plate. The sensor terminals for DHW tank and the connection method are shown in the picture below: Picture 6 Connecting the sensor for DHW...
- Page 39 5.2.4 Connection of signals for remote control via analogue inputs In the case of remote control via analogue signals 0-10 V, the following terminals are connected to the connection module: a) AI1 – analogue input (depending on the settings, it is possible to manage the desired temperature of the boiler or the desired active power) b) AO1 –...
- Page 40 5.2.5 Contacts connection remote MCB shutdown In case of overheating, when the temperature inside the boiler reaches a value of 110⁰C, the safety thermostats will activate the -K100 relay. In order to prevent the destruction of the boiler, it is necessary to interrupt the main power supply of the boiler in such a way as to turn off the main protective device MCB of the same.
- Page 41 Option 2: NC contacts for automatic shutdown in case of emergency Picture 9 Option 2 – NC...
- Page 42 5.2.6 Connecting pressure switches or other protective devices On the connection module there is a relay -K300 with 1 C/O contact outputs, to which the user is free to connect a pressure switch or any similar protection/signaling device. The relay is activated by connecting the signal conductor of the device (230 V; 50/60 Hz) to the faston output, which will activate the relay at the moment of action.
- Page 43 5.2.7. Maximum power signal If the boiler reaches the maximum level of power, a signal will be activated on the connection module and it is used to give an order to start operation to the next boiler with which it is connected in cascade.
- Page 44 5.2.8. Alarm In case of any boiler malfunction, the control panel will deactivate the alarm relay, which is constantly activated during normal operation. The voltage-free 1 C/0 contacts of the same are available to the user on the connection plate. The alarm relay contacts are shown in the picture below: Picture 12 Alarm relay contacts...
- Page 45 5.5. Service menu options Option Description Availability X control Underfloor heating Switch off or on underfloor heating. Switching underfloor panel heating on or off will reset Heating Curve, heating minimal and maximal temperature to factory defaults. Default: Off Outdoor Switch on or off use of external temperature sensor. X control Temperature When on Heating Curves will be used to calculate boiler...
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Page 46: Periodic Checking
X control Reset counters for heating groups. Counter information is Reset Counters displayed in User Menu -> Info panel Reset service Reset service interval to factory defaults. interval. X control (Service Menu -> Default: Reset Counters -> panel 12 months (home used boilers) Reset serv.interval) 6 months (industrial used boilers) X control... -
Page 47: Survey Of Possible Malfunctions And Irregularities In Operation
7. Survey of possible malfunctions and irregularities in operation 7.1. General list MALFUNCTION CAUSE ELIMINATION - there is no voltage there is no power supply from the replace fuse 100mA and on the control panel power net on one or more phases. check the cause of the blown at switching on fuse 100mA on the control panel is... -
Page 48: List Of Errors
- MCB cannot be safety thermostat is activated pre-reset safety thermostat reset and then the MCB switch contact authorized service personnel to resolve the exact source of the problem 7.2. List of errors MALFUNCTION CAUSE ELIMINATION Air is present inside the boiler’s reservoir vent installation. - Page 49 Domestic hot water cylinder temperature check sensor wiring sensor is not properly connected. contact authorized service Check sensor’s wiring. personnel to resolve the problem When sensor is operational, error will be automatically dismissed, and boiler will continue with normal operation. Domestic hot water cylinder temperature check sensor wiring sensor is not properly connected, or a...
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