Cranborne THI 5-25c User guide

HAMWORTHY HEATING LTD CRANBORNE THI 5-25c 500001116/B

Cranborne THI 5-25c

Wall Hung Gas Fired Condensing Boiler

Room Sealed or Open Flue

INSTALLATION, COMMISSIONING AND SERVICING

INSTRUCTIONS

IMPORTANT NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD

BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING THIS

APPLIANCE.

THE CRANBORNE THI 5-25c BOILER IS INTENDED FOR USE AS A DOMESTIC /

LIGHT COMMERCIAL APPLIANCE FOR HEATING AND DOMESTIC HOT WATER

INSTALLATIONS.

THIS BOILER IS FOR USE ON GROUP H NATURAL GAS (2ND FAMILY) I2H. PLEASE

ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND

RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER.

THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES

EC IDENTIFICATION No. CE-0085AQ0543

PUBLICATION NO. 500001116

ISSUE 'B'

AUGUST 2003

- 2 -

CONTENTS

I-PRESENTATION ................................................................................................................................... 5

1-DESCRIPTION ...................................................................................................................................... 5

II - TECHNICAL SPECIFICATIONS ........................................................................................................... 6

1-CHARACTERISTICS............................................................................................................................. 6

2-PIPE CONNECTION DIAMETERS........................................................................................................ 7

3-DIMENSIONS ........................................................................................................................................ 8

3.1-THI 5-25 C .................................................................................................................................... 8

4-LIST OF COMPONENTS..................................................................................................................... 10

4.1-THI 5-25 C............................................................................................................................... 10

4.6 - Control panel ........................................................................................................................... 15

5-MODULATING PUMP CHARACTERISTICS....................................................................................... 16

6-PRESSURE DROP IN THE BOILER (HEATING CIRCUIT)................................................................ 17

7-EXPANSION VESSEL CHARACTERISTICS...................................................................................... 17

8-THERMAL EFFICIENCY ..................................................................................................................... 18

III - OPERATION ........................................................................................................................................ 19

1-GENERAL OPERATING PRINCIPLE.................................................................................................. 19

2-OPERATION OF THE LMU MANAGEMENT UNIT............................................................................. 20

2.1 - Normal operating conditions ....................................................................................................20

2.2 - Operating diagram ................................................................................................................... 20

2.3 - Principle of air/gas servo-control system ................................................................................. 22

2.4 - Air pressure variation procedure ............................................................................................. 22

2.5 - Emission of pollutants .............................................................................................................. 22

3-FUNCTIONS......................................................................... ............................................................... 23

3.1 - Anti-freeze function .................................................................................................................. 23

3.2 - Anti-legionnella function .......................................................................................................... 23

3.3 - Pump run-on after the end of heating ...................................................................................... 23

3.4 - Pump kick or selector valve kick .............................................................................................. 23

3.5 - Boiler overheat protection ........................................................................................................ 23

3.6 - Monitoring of flue gas temperature .......................................................................................... 24

3.7 - Boiler return temperature control ............................................................................................. 24

3.8 - Monitoring of hydraulic pressure ............................................................................................. 24

3.9 - Anti-short burner cycle protection function .............................................................................. 24

3.10 - Cleaning function ..................................................................................................................... 24

3.11 - Regulator shutdown function ................................................................................................... 24

3.12 - LMU programmable key .......................................................................................................... 25

3.13 - Automatic summer/winter switching (only activated with outside sensor) ............................... 25

4-DIFFERENT VERSIONS OF THE THI ................................................................................................ 26

4.1 - THI basic model (without outside sensor, without room sensor) ............................................. 26

4.2 - THI with outside sensor only ...................................................................................................26

4.3 - THI with outside and room sensors ......................................................................................... 29

- 3 -

CONTENT

IV - INSTALLATION ................................................................................................................................... 30

1-GENERAL............................................................................................................................................ 30

2-VENTILATION ..................................................................................................................................... 31

2.1 - THI models with conventional flue connection ........................................................................ 31

2.2 - THI models with balanced flue connection .............................................................................. 31

3-COMBUSTION PRODUCT FLUEING ................................................................................................. 32

3.1 - Conventional flue outlets (B23 model) ..................................................................................... 32

3.2 - Balanced flue outlet ................................................................................................................. 33

4-SUPPORT BRACKET.......................................................................................................................... 40

5-HYDRAULIC CONNECTION ............................................................................................................... 41

5.1-Recommendations................................................................................................................... 41

5.2 - Accessories to connect, install or adjust .................................................................................. 41

5.3 - Under-floor heating recommendations .................................................................................... 42

5.4 - Heat exchanger flow rate ......................................................................................................... 42

5.5-Hydraulic connectionformodel THI 5-25 C............................................................................. 43

5.6 - Hydraulic connection for models THI C+ DHW production system of type BS ........................ 43

6-GAS CONNECTION ............................................................................................................................ 46

7-ELECTRICAL CONNECTION.............................................................................................................. 46

7.1 - Mains connection ..................................................................................................................... 46

7.2 - Connection of the sensors to the LMU management unit ....................................................... 46

7.3 - Under-floor heating safety ....................................................................................................... 46

7.4 - Wiring diagram ........................................................................................................................ 47

V-SETTINGS OF THE INSTALLATION TYPES ..................................................................................... 48

1-SINGLE CIRCUIT ................................................................................................................................ 48

2-DOUBLE CIRCUIT............................................................................................................................... 49

2.1 - Without room sensor ............................................................................................................... 50

2.2 - With room sensor .................................................................................................................... 50

3-ACCESS THE SETTINGS VIA THE QAA 73 ROOM SENSOR ......................................................... 50

3.1 - Access the lines 51 to 98 ......................................................................................................... 50

3.2 - Access the lines 501 to 755 ..................................................................................................... 51

VI - COMMISSIONING ............................................................................................................................... 52

1-PROTECTION OF THE INSTALLATION............................................................................................. 52

1.1 - Bionibal .................................................................................................................................... 52

1.2 - Bionibagel ................................................................................................................................ 52

2-FILLING THE INSTALLATION WITH WATER .................................................................................... 53

3-PRESSURE SENSOR......................................................................................................................... 53

4-GAS SUPPLY ...................................................................................................................................... 53

6-SETTING THE MAXIMUM POWER IN HEATING MODE................................................................... 54

7-VERIFICATIONS PRIOR TO COMMISSIONING................................................................................ 54

8-USER INFORMATION......................................................................................................................... 54

- 4 -

CONTENT

9-COMMISSIONING............................................................................................................................... 55

10 - FLAME SETTING ................................................................................................................................ 56

11 - COMBUSTION PRODUCT CHECKING.............................................................................................. 56

VII - GAS CONVERSION ............................................................................................................................ 57

1-SERVICE PRESSURE CONTROL...................................................................................................... 57

3-GAS/CO2/CO/NOX FLOW CONTROL................................................................................................ 58

3.1 - Surveillance procedure ............................................................................................................ 58

3.2 - Setting table ............................................................................................................................. 59

VIII - MAINTENANCE .................................................................................................................................. 60

1-SERVICING THE FAN AND THE BURNER........................................................................................ 60

2-SERVICING THE HEAT EXCHANGER OF THE BOILER SHELL...................................................... 61

4-CHECKING ACCESSORIES............................................................................................................... 61

5-EXPANSION VESSEL PRE-INFLATION PRESSURE CHECK .......................................................... 61

6-COMBUSTION PRODUCT CONDUITS.............................................................................................. 62

7-DRAINING ........................................................................................................................................... 62

8-SENSOR RESISTANCES ................................................................................................................... 62

IX - OPERATING FAULTS ........................................................................................................................ 63

X-OPTIONS ............................................................................................................................................. 65

1-REAR WALL SPACER ........................................................................................................................ 65

3-SET-UP TAKING ROOM TEMPERATURE INTO ACCOUNT (REG 73) ............................................ 66

4-LPB COMMUNICATION CLIP-IN KIT (REG 130) ............................................................................... 66

5-2ND HEATING CIRCUIT CLIP-IN KIT................................................................................................. 66

6-DOUBLE CIRCUIT KIT (REG 125)...................................................................................................... 67

7-PROGRAMMABLE RELAY CLIP-IN KIT (REG 127)........................................................................... 67

8-ZHTI 46 CONTROL UNIT (REG 129).................................................................................................. 67

9-ZHTI 47 CONTROL UNIT (REG 128).................................................................................................. 68

11 - SELECTOR VALVE KIT FOR CONNECTING THI..C/BS ................................................................... 68

XII - NOMENCLATURE .............................................................................................................................. 71

- 5 -

I - PRESENTATION

1 - DESCRIPTION

Standard description: wall mounted condensation

boiler for hot water heating, sealed combustion cir-

cuit, pre-mixing burner with air-gas supply, and

linear power modulation connecting combustion

product types B23, C13, C33, following EN 483 (04/

00)

The THI boiler is pre-set in the factory for natural

gas H (G20).

This boiler comprises all the necessary accessories

for the correct working of a water based central hea-

ting circuit specifically:

- one boiler comprising:

• a high performance double walled condensa-

tion exchanger,

- a pre-mixing burner, with stainless steel refracto-

ry grate,

- a variable speed 230 Volt fan controlled by the re-

gulator,

- a 230 Volt two way gas valve controlled by the air

pressure,

- electronic regulation which ensures power modu-

lation depending on the demands for heating or

DHW (LMU control unit),

- an outside sensor,

- an expansion vessel,

- a modulating pump PWM signal,

- a 3 bar safety-valve,

- a rear wall spacer,

OPTIONAL:

- Horizontal flue kit (C13) allowing the boiler to be

connected to a straight horizontal flue.

- Accessories for horizontal connection of the boi-

ler (C13) - (extensions, elbows etc.).

- Flue adapter (C33) allowing the boiler to be con-

nected to a vertical flue.

- Accessories for vertical connection of the boiler

(C33) - (terminal, extensions, elbows etc.).

- Adjustment as a function of the room temperature

(REG 73).

- 2nd heating circuit kit allowing the connection of

a secondary heating circuit (REG 125).

- 2nd heating circuit clip-in allowing the connection

of a secondary heating circuit.

- Clip-in LPB communication kit used for cascade

or multi-circuit installations (REG 130).

- Clip-in programmable relay kit allowing a secon-

dary pump to work in parallel (REG 127).

- Control unit ZHTi 46 (REG 129) controlling an ad-

ditional heating circuit.

- Control unit ZHTi 47 (REG 128) allowing cascade

management for two boilers.

- Selector valve kit for connecting THI..C/BS.

- 6 -

II - TECHNICAL SPECIFICATIONS

1 - CHARACTERISTICS

Model

THI

5-25 C

Certification CE0085AQ0543

Category/Countryof destination: GB

I2H

heat output 30/50 °C

60/80 °C kW

kW 5.4/25.8

4.8/23.9

Heat input kW 5.0/24.5

Efficiency Nett 30/50 °C

60/80 °C %

%108.0/105.3

97.5/96.0

Efficiency Gross 30/50 °C

60/80 °C %

%97.2/94.5

87.8/86.5

Efficiency according to92/42 CEE directive (30%)load %108.5

Useable gases (NG:Natural gas)NG H

Combustion product temperature maxi °C 80

Over-heating safety of combustion products °C 85

Flow rate of combustion products mini/maxi kg/h 9.0/44.1

Permitted back pressure (C13)maxi Pa 100

Air flow required for combustion m3/h 30

NOx

mg/kWh

<60

mg/kWh

<50

Heating service pressure mini/maxi bar 1/3

Heating circuit water temperature maxi °C 80

Water overheating safety thermostat °C 100

Boiler water capacitylitre 2.5

Primary water flow 60/80 °C m3/h 1.03

DP water (at nominal flow) mbar 130

Total capacity of expansion vessel litre 8

Useful capacity (with 5m static height)

litre 5

Thermal losses (DT30 K) W79

Acoustic output at minimum heat output 5,1 kW dBA 31,2

- 7 -

TECHNICAL SPECIFICATIONS

2 - PIPE CONNECTION DIAMETERS

Absorbed electrical power in heating mode :

Control alone Wmin. load: 23

max load: 37

Modulating pump mini W30

maxi W67

Stand By Position W9.2

Power supply/frequency 230 V (+ 10%. - 15%)/50 Hz

Protection factor

models B23

model C13/C33

IP 24

IP 44

Weight packaged kg 63

Models

THI

5-25 C

Models

THI

5-25 C

ÆCombustion products B23 mm 125

ÆCombustion products C13

C33

mm 75/110

80/125

ÆGas inlet inch 1

ÆHeating flow/return inch 1

ÆCondensation outlet mm 25

ÆSafety valve outlet inch 3/4

ÆDHW production system connection (option § 11 -

page 68) (* 3/4 with coupling) inch 1*

- 8 -

TECHNICAL SPECIFICATIONS

3 - DIMENSIONS

3.1 - THI5-25 C

540

760

495

120 82,5

100

55,6 55,5

61,5 184,5 42

361

THI-04-0

102

20,6

cd f

Fig. 1

Bottom view

Rear view

Legend:

a: Combustion products outlet

b: Gas inlet

c: Heating flow

d: Heating return

Connection DHW production system (option)

(THI C)

g: Condensate drain

h: Safety valve drain

- 10 -

TECHNICAL SPECIFICATIONS

4 - LIST OF COMPONENTS

4.1 - THI 5-25 C

104

2022

THI-02-0

1) Gas inlet

2) Gas unit (solenoids and regulator) 230 V

3) Gas burner

4) Combustion products outlet

5) Flue gas sensor

6) Heating flow

7) Heating outlet and safety sensor

8) Heating return manifold

9) Boiler return sensor

10)Ignition transformer 230 V

11) Fan 230 V

12) Boiler shell

13) Sight-glass

14) Microprocessor control panel

15)3 speed pump 230 V

16) Air bleed

17) Pressure sensor

18) Filter and drain tap

19) Safety valve 3 bar

20) Safety valve outlet

21) Siphon trap

22) Condensate drain

23) Combustion check window

24) Connection for domestic hot water production sys-

tem (option)

25) Expansion vessel

Fig. 5

- 15 -

TECHNICAL SPECIFICATIONS

4.6 - Control panel

THI Without room sensor or outside sensor

The heating (2) and hot water (3) temperatures set-

ting are manually set on the boiler control panel.

- The FUNCTION key (1) gives access to 2 opera-

ting modes:

• Auto mode operation (4): no access

• Winter mode operation: LED (5) on

• Summer mode operation: LED (5) off

THI Without room sensor and with outside sensor

Possibility of correcting the heating temperature (2)

computed automatically using the outside tempera-

ture and manual setting of the hot water temperatu-

re (3) on the boiler control panel. (The room

temperature setting can be changed by + or - 3°C

maximum according to the setting).

- The FUNCTION key (1) gives access to 3 opera-

ting modes:

• Auto mode function:

auto winter = Leds (4) and (5) on

auto summer = Led (4) on + Led (5) off

• Winter mode operation: LED (5) on

• Summer mode operation: LEDs (4) and (5) off

THI With room sensor and outside sensor

Fitting the QAA73 room sensor cancels the func-

tions of the heating temperature setting (2) and hot

water setting (3) on the boiler control panel. All the

temperatures required, together with the heating

programmes, are set on the QAA 73 (refer to the

sensor instructions).

bar

auto

Function

Info

°C

Reset

THI-01-0

1112

Fig. 10

1) The "Function" key gives access to 3 operating

modes by simply pressing the key:

auto mode: LED (4) on

winter mode: LED (5) on

summer mode: LED (4) and (5) off

2) Regulation of the heating temperature (setting

read on the display (13)) *

3) Regulation of the DHW temperature (setting

read on the display (13)) *

6) Maintenance key: reserved for servicemen or

maitenance (see overleaf)

7) "Info" key gives access to 5 types of information

on the display (13) by simply pressing the key:

Boiler outlet temperature: LED (9) on

Sensor temperature: LED (9) flashing

Boiler water pressure: LED (8) on

Operating phase: LEDs (8/9) off

Diagnostics: LEDs (8/9) off/

Display (13) flashing

10) Boiler reset button (After each reset, wait for

about 30 seconds before the restart = reset)

11) Alarm: Red LED on

12) Flame indicator: Green LED on

13) Digital display: Alternatively displays the setting

selected by the "Info" key and the current default

code

14) ON/OFF switch (depending on the models) **

*The function of the heating temperature (2) and DHW temperature (3)

potentiometers differs according the 3 examples below.

**The On/Off switch (after initial lighting) should be maintained in the "ON"

position in order to preserve all the automatic functions of the boiler (an-

ti-freeze, anti-legionella functions, etc).

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