Bulex Thema Condens AS 48-A User manual

DEMİRDÖKÜM
MAKSİCONDENSE 48-65

MAKSİCONDENSE 48-65
01/2018 I Training 0020260859_00
Table of contents
1System overview and customer benefits ......................................................................1
1.1 System overview...............................................................................................................1
1.1.1 System components (examples) .......................................................................................3
1.1.2 Cascade of boilers.............................................................................................................5
1.2 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 .........................................................................................10
2System description.......................................................................................................11
2.1 System components........................................................................................................11
2.1.1 ErP efficiencies ...............................................................................................................12
2.2 Basic principles...............................................................................................................13
2.2.1 Nomenclature..................................................................................................................13
2.2.2 Unit types and scope of delivery......................................................................................15
2.2.3 G20 nominal heat input output in kW...............................................................................15
2.2.4 Scope of delivery.............................................................................................................16
2.2.5 Data plate..................................................................... Hata! Yer işareti tanımlanmamış.
2.3 Product design................................................................................................................17
2.3.1 Boiler (circulation water heater).......................................................................................17
2.4 Design.............................................................................................................................18
2.4.1 Functional diagram..........................................................................................................18
2.4.2 Hydraulic connection.......................................................................................................20
2.5 Electronics box................................................................................................................24
2.5.1 Control panel...................................................................................................................24
2.5.2 Unit display (AI)...............................................................................................................25
3Components and overall function................................................................................27
3.1 Overview of the components...........................................................................................27
3.1.1 Hydraulic module ............................................................................................................27
3.1.2 Unit NTC sensor..............................................................................................................31
3.1.3 Primary heat exchanger ..................................................................................................32
3.1.4 Gas/air technology design...............................................................................................35
3.1.5 Electronic components....................................................................................................49
3.1.6 Hydraulic connection network..........................................................................................51
3.2 Unit menu overview.........................................................................................................53
3.2.1 DIA display operating concept.........................................................................................53
3.3 Functional description .....................................................................................................59
3.3.1 Functional description of the pneumatic gas-air mixture..................................................59
3.3.2 Gas valve assembly with fan (pneumatic) functional diagram..........................................61
3.3.3 Software description; safety, special and standard functions...........................................62
3.3.4 Standard functions ..........................................................................................................62
3.3.5 Special functions.............................................................................................................74
3.3.6 Safety functions...............................................................................................................87
4Accessories...................................................................................................................93

Table of contents
03-2020 TEKNİK EĞİTİM VE DESTEK BÖLÜMÜ
.1 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
4.2 Description of the accessories.......................................................................................103
4.2.1 Use of the accessories..................................................................................................103
5Planning requirements and practical information ....................................................110
5.1 Installation sites and restrictions....................................................................................110
5.2 Product requirements....................................................................................................111
5.2.1 Minimum clearances .....................................................................................................111
5.2.2 Dimension drawing and connection dimensions............................................................112
5.2.3 Combustion quality requirements..................................................................................113
5.3 System requirements ....................................................................................................113
5.3.1 Pump diagrams.............................................................................................................113
5.3.2 Flue gas systems (certifications) ...................................................................................115
5.3.3 Water quality.................................................................................................................119
5.3.4 Line strainer or magnetite filter......................................................................................121
5.4 Basic system diagrams and wiring diagrams.................................................................123
5.4.1 Basic system diagrams .................................................................................................123
6Installation/start-up.....................................................................................................131
6.1 Installation checklist ......................................................................................................131
6.2 Detailed installation notes..............................................................................................132
6.2.1 Hydraulic connection.....................................................................................................133
6.2.2 Electrical connection .....................................................................................................135
6.2.3 Air and flue gas accessories..........................................................................................137
6.3 Start-up checklist...........................................................................................................138
6.3.1 Water composition.........................................................................................................139
6.3.5 Checking the gas setting...............................................................................................143
6.4 Regional legislation.......................................................................................................150
7Maintenance, troubleshooting and repair..................................................................151
7.1 Maintenance checklist...................................................................................................151
7.2 Detailed maintenance notes..........................................................................................153
7.2.1 Installing and removing components/modules...............................................................154
7.2.2 Recommended tools .....................................................................................................158
7.3 Troubleshooting ............................................................................................................159
7.3.1 Status codes, diagnostics codes, fault codes and check programmes...........................159
7.3.2 Troubleshooting and flowcharts.....................................................................................171
7.3.3 Measurement points and measured values...................................................................175
8Appendix......................................................................................................................184
8.1 Technical data...............................................................................................................184
8.2 DSN overview ...............................................................................................................185
8.3 ErP data........................................................................................................................186
8.4 Formulas.......................................................................................................................188
8.4.1 Hydraulics .....................................................................................................................188

8.4.2 Gas consumption relating to nominal load.....................................................................191
8.5 System checklist ...........................................................................................................192

MAKSİCONDENSE 48-65
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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. The domestic hot water generation is used in combination with domestic hot water cylin-
ders (FT series; solar cylinder).
─For radiator and underfloor heating, as well as peak-load boilers (Space heater unit types).
─Space-saving installation in the central utility room for the modernisation and new construction
of non-residential buildings, such as offices, businesses, restaurants, ...
─Flexible installation for systems and applications, e.g. cascade applications, hybrid applica-
tions, etc.
─Open-flued or room-sealed operation with a system-certified flue gas system.
─ErP compliant with an efficiency of 94%, A+ (combined with class VI control; ERP)
Equipment
─High-efficiency pump, water pressure sensor
─Stainless steel integral condensation heat exchanger
─Integrated cylinder/domestic hot water control system with prioritising diverter valve
─Diagnostics system with illuminated plain text display
─eBUS, integration for "Connectivity" available as an option.

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The new SDBG 48-65 kW condensing WHB is a compact, robust and technically
proven system boiler.

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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-
nation with a selection of straight forward accessories.

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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.
The direct supply is made possible by a new software function and a new 3 way valve (Orkli 11/4").

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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:
─Hanging rig,
─Fumes /
─Hydraulic /
─Insulation /
─System management
High efficiency with boiler cascade:
Each boiler comes into operation only if the heating demand is high enough.
When the demand is low, only one boiler operates
(The stand-alone boiler system consumes more energy, even when the need
for heating is low)

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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.
High operating reliability:
If one boiler goes down, the others continue providing heating or DHW.
The system does not stop.
Flexibility of installation:
It is easy to set and install on wall or on rigs (hydraulic advantage, auto-setting
fan, degassing process)
Boilers are compact and have a lightweight design
The whole system is cost-saving

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1.2 Customer benefits
1.2.1 Arguments for the installer
Feature
Function
Benefits for the installer
Flexibility of the installation
and application
1) Installation without low loss header
2) Approval for liquefied petroleum gas (LPG)
3) Compact design,
modular ground installation
(mounting frame, rack)
4) Flue gas cascade set
5) Automatic pipe length adjustment
(supply air/flue pipework)
1) Easy, economical and
time-saving positioning
2) Broad range of applications
3) Easy to combine into systems
4) Approved flue pipes
from one source
5) Automatic and
fail-safe settings
Reliability and
robustness
1) Proven stainless steel
heat exchanger (PWT)
2) Reliable combustion mixture
3) Reliable pneumatic gas-air
mixture
4) Comfort protection mode
1) Long, worry-free operating
cycle
2) SDBG DNA
3) Use of tried-and-tested technology
4) Satisfaction, trust
Competition requirements
1) Includes a high-efficiency pump
2) LL, H gas adaptation
3) Wide modulation range
4) 94% A efficiency as per ErP; A+ possible
with class VI control
1) Cost savings
2) Satisfaction
3) Save energy and reduce
boiler wear
4) Energy-saving and
environmentally friendly
Easy installation and start-up
1) Light and compact design
2) Automatic pipe length adjustment
(supply air/flue pipework)
3) Automatic partial load adjustment
4) Simplified range of accessories
1) Easy, economical and time-saving posi-
tioning
2) No risk of faults during
installation/start-up
3) Low-complexity application
4) Simplified selection of materials and
easy preparation of offers
5) Efficient and safe step-by-step
settings
Sales/customer service support
1) Training support
2) Service Centre support
3) Planning tools
4) Customer service support
5) Simplified range of accessories
6) Availability of spare parts
1) Complete support
(exclusivity)
"start-to-end" support
from our professional partners,
for end user satisfaction
Networking
1) MiPro control in combination
with:
MiLink communication module for re-
mote monitoring via "MiConnect" and
"MiPortal"
1) One control for all applications
2) Quick remote access for
diagnosis and fault analysis
3) Low complexity for
new installations.
4) Quick setup and
start-up of the system
5) Cost-saving service
6) Extended flexibility (service)

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1.2.2 Arguments for planners and architects
Feature
Function
Benefits for the architect/planner
Flexibility of the installation
and application
1) Installation without low loss header
2) Approval for liquefied petroleum gas (LPG)
3) Modular ground installation
(mounting frame, rack)
4) Flue gas cascade set
5) Automatic pipe length adjustment
(supply air/flue pipework)
1) Economical installation space
requirements
2) Integration as per applicable
requirements
4) Approved flue pipes
from one source
5) Automatic and
fail-safe settings
Reliability and
robustness
1) Stainless steel heat exchanger
2) Reliable combustion mixture
3) Reliable pneumatic gas-air
mixture
4) Comfort protection mode
1) Compliance with technical
regulations
2) Group DNA
3) Use of tried-and-tested technology
4) Satisfaction, trust, long
expected service life with minimised
maintenance costs
Competition requirements
1) Includes a high-efficiency pump
2) LL, H gas adaptation
3) Wide modulation range
4) 94% A efficiency as per ErP; A+ possible
with class VI control
1) Adapted to the market requirements
2) Compliance with technical
conformity
3) Save energy and reduce
boiler wear
4) Energy-saving and
environmentally friendly
Easy installation and start-up
1) Light and compact design
2) Automatic pipe length adjustment
(supply air/flue pipework)
3) Automatic partial load adjustment
4) Simplified range of accessories
1) Easy, economical and
time-saving positioning
2) No risk of faults
during installation/start-up
3) Low-complexity application
4) Simplified selection of materials and
easy preparation of offers
5) Efficient and safe step-by-step
settings
Planning assistance
1) Available in BIM database and
the SDBG CAD plug-in
2) Planning documents
3) Planning tools
1) Quick and secure integration
into construction drawings
2) Clear specification of unit
and system planning for efficient
operation
3) Online and offline system
configuration tools for efficient
and reliable planning
Sales/customer service support
1) Training support
2) Service Centre support
3) Customer service support
4) Simplified range of accessories
5) Availability of spare parts
1) Qualified and reliable
SDBG expert network for
efficient field support
Networking
1) VRC control in combination
with:
MiLink communication module for re-
mote monitoring via "MiConnect" and
"MiPortal"
1) Modular flexibility
2) One control for all applications
3) Modular design with
expansion modules
4) Quick setup and
start-up of the system

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1.2.3 Arguments for end customers
Feature
Function
Benefits for end customers
Flexibility of the installation
and application
1) Installation without a low loss header (48 kW)
2) Approval for liquefied petroleum gas (LPG)
3) Modular ground installation
(mounting frame, rack)
4) Flue gas cascade set
5) Automatic pipe length adjustment
(supply air/flue pipework)
1) Several possible installation
layouts and large, certified
range of accessories for flexible
installation and safe operation
Reliability and
robustness
1) Stainless steel heat exchanger
2) Reliable combustion mixture
3) Reliable pneumatic gas-air
mixture
4) Comfort protection mode
1) Long system service life
with minimised maintenance costs
Competition requirements
1) Includes a high-efficiency pump
2) LL, H, LPG gas adaptation
3) Wide modulation range
4) 94% efficiency as per ErP; A+
5) Comfort protection mode
1) Optimised operating mode for
minimising energy costs
and extending the unit's
service life
Easy installation and start-up
1) Light and compact design
2) Automatic pipe length adjustment
(supply air/flue pipework)
3) Automatic partial load adjustment
4) Simplified range of accessories
5) Start-up assistance function
6) Start-up instructions
1) Guided installation and
adjustment process for safe
and reliable system
setting and operation.
Reliability, long expected service
life, guaranteed minimised
energy costs
Sales/customer service support
1) Training support
2) Service Centre support
3) Customer service support
4) Simplified range of accessories
5) Availability of spare parts
1) Safety and trust
2) Qualified SDBG experts,
for targeted and
professional support
3) Good representation on the
market makes spare parts
quickly available
Networking
1) MiPro control in combination
with:
MiLink communication module for re-
mote monitoring via "MiConnect" and
"MiPortal"
1) Convenient monitoring of the
heating system with the
"MiPortal"
2) Comfort and efficiency thanks to
different user profiles and
active notifications during use.
3) Intuitive access and use
of the installation information
4) MiPortal access improves
reliability of supply and
dependability.

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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. The units are introduced with outputs of 48 kW and 65 kW
Special features
─108% standard efficiency (Hi) (50/30 dT)
─Modulation up to 1:5
─It can be installed without a low loss header thanks to new software function
─Unit hydraulics without bypass valve 48 kW unit
─New! Integrated air separator
─Pneumatic gas-air mixture
─Electronically controlled high-efficiency pump with additional pump programmes
─Operating with natural gas E or LL and LPG liquid gas (conversion kit)
─Gas conversion kits available

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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)
─eBUS
Product features of the 48–65 kW product
─Vertical pipe connections on the underside of the unit provide unhindered access when the unit
is being installed.
─New! 7-coil primary heat exchanger from the A+ project with additional manual purging device
for the new 9-coil version (9-coil PWT new development with Sermeta).
─Easy-to-clean unit siphon. The unit siphon does not necessarily have to be filled during start-up
(new design).
─Lower modulation limit at approx. 20% (Space heater, depending on unit type and gas type).
The 48–65 kW product range is the latest generation of condensing technology
from SDBG.
2.1.1 ErP efficiencies

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2.2 Basic principles
The new product generation is being introduced in the relevant SDBG markets. The following mar-
kets are introducing the product at the start of 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
Thema Condens 48 SB-A
Thema Condens 65 SB-A = Circulation water heater
Panther Condens 48 KKO-A = Circulation water heater
2.2.1.1 Description/explanation of the nomenclature
A
s
xx
A
Meaning
x
Boiler
x
Stainless steel combustion chamber with unit pump
x
Heating output
x
Gross calorific value, condensing
Nomenclature
xx
SB
A
Meaning
x
Heating output
x
Stainless steel combustion chamber with unit pump
x
Gross calorific value, condensing
Nomenclature
xx
KKO
A
Meaning
x
Heating output
x
Boiler
x
Gross calorific value, condensing
Nomenclature

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2.2.1.2 Description of the unit category
I
II
2
3
H
L
P
E
(S)
K
Meaning
x
One usable gas category
x
Two usable gas categories
x
Second gas family (natural gases)
x
Third gas family (liquid gases)
x
Group H gas (high gas)
x
Group L gas
x
Group P gas (propane)
x
Group E gas (G20/G25)
x
Less power with G25
x
NL market gas approval
Unit category