geminox THI 2-17 B 120 Owner's manual

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High technology heating
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THI 2-17 B 120
T30.36388.05
SERVICING
Gas conversion
Maintenance
Operating faults
Options
Parts lists

- 2 -
TABLE OF CONTENTS
I - FLOW AND SERVICE PRESSURE CONTROL ................................................................................... 3
1 - GAS/CO2/CO/NOX FLOW CONTROL AND SERVICE PRESSURE CONTROL ................................. 4
1.1 - Surveillance procedure .............................................................................................................. 5
1.2 - Setting table ............................................................................................................................... 6
II - MAINTENANCE .................................................................................................................................... 7
1 - SERVICING THE FAN AND THE BURNER.......................................................................................... 7
2 - SERVICING THE HEAT EXCHANGER OF THE BOILER SHELL........................................................ 8
3 - TANK MAINTENANCE .......................................................................................................................... 8
4 - CHECKING ACCESSORIES................................................................................................................. 9
5 - EXPANSION VESSEL PRE-INFLATION PRESSURE CHECK ............................................................ 9
6 - COMBUSTION PRODUCT CONDUITS (FLUE) ................................................................................... 9
7 - DRAINING ............................................................................................................................................. 9
7.1 - Draining the boiler ..................................................................................................................... 9
7.2 - Draining the hot water tank ........................................................................................................ 9
8 - SENSOR RESISTANCES ................................................................................................................... 10
9 - PRESSURE SENSOR......................................................................................................................... 10
III - OPERATING FAULTS ........................................................................................................................ 11
1 - OPERATING FAULTS LIST ................................................................................................................ 11
2 - MAINTENANCE................................................................................................................................... 13
2.1 - Maintenance alarm .................................................................................................................. 13
2.2 - Maintenance code ................................................................................................................... 13
2.3 - Coding of maintenance alarms ................................................................................................ 13
2.4 - General activation of maintenance alarms .............................................................................. 13
2.5 - Activation of the individual maintenance alarm ....................................................................... 14
2.6 - Acknowledgement of maintenance alarms .............................................................................. 14
2.7 - Resetting the maintenance alarms .......................................................................................... 14
IV - OPTIONS ............................................................................................................................................. 15
1 - SET-UP TAKING ROOM TEMPERATURE INTO ACCOUNT (REG 73) ............................................ 15
2 - LPB COMMUNICATION CLIP-IN KIT (REG 130) ............................................................................... 15
3 - 2ND HEATING CIRCUIT CLIP-IN KIT................................................................................................. 15
4 - DOUBLE CIRCUIT KIT (REG 125)...................................................................................................... 16
5 - PROGRAMMABLE RELAY CLIP-IN KIT (REG 127)........................................................................... 16
6 - PROGRAMMABLE RELAY CLIP-IN KIT (WITHOUT SENSOR) (REG 134) ...................................... 16
7 - ZHTI 46 CONTROL UNIT (REG 129).................................................................................................. 17
8 - ZHTI 47 CONTROL UNIT (REG 128).................................................................................................. 17
9 - 1ST CIRCUIT CONNECTION KIT....................................................................................................... 17
10 - TIMER KIT ........................................................................................................................................... 18
V - PARTS LISTS ...................................................................................................................................... 19

- 3 -
I - FLOW AND SERVICE PRESSURE CONTROL
Check that the boiler is properly adapted to the gas
used.
This operation must be carried out by a
qualified person equiped with a calibra-
ted combustion analyser.
Prior to any servicing cut the electrical and gas sup-
plies.
The boiler is preset in the factory for natural gas H
(G20) 20 mbar.
Check the gas circuit for leak tightness after each in-
tervention on the boiler.
!
THI-35-0
2
1
3
4
5
6
7
89
10
11
Po
V
Pi
K
PL
Fig. 1
1) Gas unit
2) Gas pipe
3) Air fan hose
4) Burner
5) Air/Gas servo-control
6) Brass air reducer
7) Fan
8) Flat seal
9) Gas reducer
10) Gas reducer o-ring
11) Fan/burner air sleeve hose faste-
ning clip

- 4 -
FLOW AND SERVICE PRESSURE CONTROL
1- GAS/CO
2/CO/NOXFLOW CONTROL AND SERVICE PRESSURE CONTROL
Po V
Pi
K
PL
ZEM-54-0
1
PL
2
P_OUT
P_IN
P_IN =Gas network pressure
Natural gas H (G20): 20 mbar,
P_OUT = Gas outlet pressure to the burner.
PL = Air pressure auto. control (fan- gas valve)
1 = Adjustment of the slope of the air/gas ratio characteristic when
the burner is at maximum rate. This setting is performed in
factory for type H natural gas (G20) or propane (G31). It can
be used to correct the pressure P_OUT to obtain the required
gas flow (section 1.2 - page 6 - chapter I - FLOW AND SERVI-
CE PRESSURE CONTROL -
SERVICING MANUAL).
Turn to decrease the gas flow
2 = Adjustment of the parallel offset only when the burner is at mi-
nimum rate. This screw is preset in the factory. Its setting
must not normally be changed. If necessary, perform this ope-
ration with a small scale manometer 0-10 mmCE, and a CO2,
CO analyser.
To modify the setting, if necessary, remove the protective
screw, then turn to increase the gas flow. When the settings
are made replace the protective screw.
!
Fig. 2 Pi= Gas network pressure
Natural gas H (G20): 20 mbar,
Po= Gas outlet pressure to the burner.
PL = Air pressure auto. control (fan- gas valve)
V = Adjustment of the slope of the air/gas ratio characteristic when
the burner is at maximum rate. This setting is performed in
factory for type H natural gas (G20) or propane (G31). It can
be used to correct the pressure Po to obtain the required gas
flow (section 1.2 - page 6 - chapter I - FLOW AND SERVICE
PRESSURE CONTROL -
SERVICING MANUAL).
Turn to increase the gas flow
K = Adjustment of the parallel offset only when the burner is at mi-
nimum rate. This screw is preset in the factory. Its setting
must not normally be changed. If necessary, perform this ope-
ration with a small scale manometer 0-10 mmCE, and a CO2,
CO analyser. Turn to increase the gas flow
SIEMENS/LANDIS
GAS VALVE
ref : VGU87A0236
SIT GAS VALVE
ref.: 848 SIGMA
!

- 5 -
FLOW AND SERVICE PRESSURE CONTROL
B23 chimney flue :
- Combustion control is carried out on the combus-
tion product outlet system external and directly at
the boiler outlet (with the boiler unit assembled).
This opening must be closed again after checking
C13 - C33 balanced flue :
- Combustion control is carried out on the boiler
through the opening (23) provided for this purpo-
se after the cap is removed. This opening must be
closed again after checking.
- To commission the burner:
• Activate the regulator shut-down function - ser-
vice key (6) (section 3.11 - page 18 -
chapter III - OPERATION - INSTALLATION
MANUAL) :
. the code flashes on the dis-
play screen (13),
- Gradually position the d.h.w. potentiometer (3) to
the maximum on the right:
• the burner switches to max. rate,
- Gradually move the V or 1 adjustment screw of
the gas unit (fig. 2 - page 4 - chapter I - FLOW
AND SERVICE PRESSURE CONTROL - SER-
VICING MANUAL) to obtain a stable flame.
-ChecktheCO
2/CO ratio (see setting table
section 1.2 - page 6 - chapter I - FLOW AND
SERVICE PRESSURE CONTROL - SERVICING
MANUAL),
- Set the d.h.w. potentiometer (3) to the maximum
on the left:
• the burner switches to the minimum rate,
-ChecktheCO
2/CO ratio (see setting table
section 1.2 - page 6 - chapter I - FLOW AND
SERVICE PRESSURE CONTROL - SERVICING
MANUAL),
- If necessary:
•adjustscrewK or 2 (fig. 2 - page 4 - chapter I
- FLOW AND SERVICE PRESSURE CON-
TROL - SERVICING MANUAL) (tightening and
untightening increases and decreases gas
flow).
Before starting the minimum rate set-
ting (V or 1 and K or 2 screws), wait for
a stable CO2/CO analyser read-out. Re-
peat switching from the minimum rate
to the maximum rate several times to
ensure that the setting has been done
properly.
- to return to normal operation, press on the sweep
key (6) for 3 seconds then release it.
Note:
- Remember to reposition the d.h.w. potentiometer
(3) to its initial value to return to the required
d.h.w. setting.
1.1 - Surveillance procedure
Fig. 3
23
THI-126-0
C33 - Vertical flue C13 - horizontal flue
!

- 6 -
FLOW AND SERVICE PRESSURE CONTROL
- Combustion product evacuation outlet back pres-
sure: 0 mmCE.
-Po/ P_OUT = Gas pressure at the gas valve re-
gulator outlet.
-PL = Servo-system air pressure (fan - gas unit).
- The Po / P_OUT and PL values may be more or
less high according to whether back pressure is
greater or smaller.
1.2 - Setting table
Models THI 2-17 B120
Natural gas burner type X07.36235
Heat output 30/50 °C
60/80 °C
kW
kW
2,6/18,3
2,3/16,9
Heat input kW 2,5/17,4
∅Gas reducer Gaz Nat H mm 4,20
∅Air reducer Gaz Nat H mm 18,2
Gas flow (15°C, 1013 mbar) Gaz Nat H m3/h 0,26/1,84
Gas pressure Po/ P_OUT (gas unit to burner) Gaz Nat H mbar 0,3/6,5
Servo-system air pressure (PL) Pa 40/810
CO2 Emission Gaz Nat H % 8,0-8,5/9,0-9,5
CO Emission Gaz Nat H ppm 0/20

- 7 -
II - MAINTENANCE
The annual inspection of the boiler and of the com-
bustion product outlet is compulsory and validates
the warranty. It must be carried out by a qualified
person.
Spare parts must be ordered by using the referen-
ces listed in chapter V - PARTS LISTS - page 19 -
SERVICING MANUAL, and specifying the type and
serial number of each part.
Before any servicing, cut the power
supply. Close the gas inlet of the boiler
and the isolation valves if required.
If the boiler is removed, provide a port at
the end of the gas piping.
Remove the front panel (item G) from
the boiler and disconnect the earth wire
(item O).
1 - SERVICING THE FAN AND THE BURNER
Check the state of the ventilator and the burner and
clean them if necessary (following their service ins-
tructions).
!
!
G
O
234
7
THI-85-00
10
1
6
5
589
A
7
4
B
Abb. 4

- 8 -
MAINTENANCE
Disassembling the burner/fan unit:
- Electrically disconnect the burner/fan unit:
• remove the 2 cable lugs connecting the ignition
electrode (3) to the ignition transformer (A),
• remove the cable lug connecting the ionising
electrode (2) to the X2-05 terminal of the boiler
control panel,
• remove the fan (7):
. from the connector of the fan power cord,
. from the connector of the fan's PWM signal,
- disconnect the air/gas servo-system (B) from the
gas valve,
Disassembling the fan:
- Unscrew the four screws (1) fixing the fan (7) to
the burner’s air sleeve (6),
- Clean it using a domestic vacuum cleaner by pla-
cing the suction device over the air inlet and outlet
successively.
Disassembling the burner:
- Unscrew the four screws fixing (5) the burner (4)
to the boiler shell (8),
- Disassemble the nut (9),
- Clean the burner (4) using a domestic vacuum
cleaner by placing the suction device over the air
inlet and the gas inlet successively,
- Check the ignition electrodes (3) and the ionisa-
tion electrodes (2).
When fitting back the burner/fan unit:
- Replace the seal at the level of the nut (9) and
check that there are no gas leaks,
- when fitting the fan back onto the boiler:
• check that the fan/burner seal (10) is correctly
positioned,
• check that there is no leakage at this seal and
replace it if necessary.
- check that the burner (4) and boiler shell (8) have
no leaks - replace the seal if necessary.
2 - SERVICING THE HEAT EXCHANGER OF THE BOILER SHELL
- The heat exchanger must be cleaned once the
burner has been disassembled (section 1 -
page 7 - chapter II - MAINTENANCE - SERVI-
CING MANUAL).
- Sprinkle the heat exchanger with water. The wa-
ter is evacuated through the condensate evacua-
tion siphon,
- when reassembling the burner onto the boiler
shell check the correct positioning of the gasket.
3 - TANK MAINTENANCE
- The stainless steel hot water tank is resistant to
lime scale. Nevertheless, the access flap gives
access to the tank and the exchanger.
Note :
- See section 5.2 - page 34 - chapter IV - INSTAL-
LATION - INSTALLATION MANUAL
39
2.25
3,5
40
ZEM-31-0-2-17
Fig. 5
3
2

- 9 -
MAINTENANCE
4 - CHECKING ACCESSORIES
- Check that the safety and control devices (3 bar
safety valve, air bleed, safety control box, etc.)
are operating properly.
- Clean the condensate drain siphon and then fill it
with water.
- Also check that neither the installation nor the
boiler present any water or fuel leaks (leaks may
produce a risk for safety and shorten the lifes-
pan).
- When it is frequently necessary to add water to
maintain pressure in the installation, even though
no leaks have been discovered, perform an ex-
pansion vessel check (section 5 - page 9 -
chapter II - MAINTENANCE - SERVICING MA-
NUAL).
5 - EXPANSION VESSEL PRE-INFLATION PRESSURE CHECK
- Drop the pressure in the heating installation by
opening the drain cock or the safety valve (pres-
sure gauge reading under 0.5 bar).
- Check the pressure in the expansion vessel and
if necessary bring it back up to pressure, or repla-
ce it if the membrane is punctured (water present
in the inflating valve).
- To optimise the efficiency of the vessel:
• adjust its pre-inflation pressure in line with the
installation. It must correspond to the static hei-
ght of the installation (H) expressed in bars
(height between the highest point of the instal-
lation and the expansion vessel, with 10 me-
tres = 1 bar),
• adjust the filling pressure of the installation to a
value of over 0.2 bar above the pre-inflation
pressure of the vessel (after totally bleeding
the air from the installation).
6 - COMBUSTION PRODUCT CONDUITS (FLUE)
- Check the combustion product evacuation con-
duit and the air inlet conduit at least once a year
(airtightness of the parts that may be disassem-
bled - conduits not obstructed).
7 - DRAINING
7.1 - Draining the boiler
- Cut the power supply,
- turn off the gas cock,
- turn off the heating flow/return valves (if they are
fitted),
- connect the drain valve (18) to the sewage sys-
tem,
- open the drain valve.
Ensure that the air bleed (item. 16) is
open, as soon as the pressure gauge in-
dicates a zero pressure to allow air to
enter the boiler shell.
7.2 - Draining the hot water tank
- Close the hot water supply valve of the network,
- open a hot water tap to make the pressure drop,
- remove the access flap (33) to allow air to enter
the tank (26),
- connect the drain valve (36) to the sewage sys-
tem,
- open the drain cock (36) at the bottom of the tank.
!
THI-98-0
16
18
Fig. 6
TIO-24-0
26
33
36
Fig. 7

- 10 -
MAINTENANCE
8 - SENSOR RESISTANCES
The resistance of the sensors must be measured
after they have been disconnected from the control
panel.
9 - PRESSURE SENSOR
The output voltage on the water pressure sensor is measured between the terminals GND (-) and OUT.
Resistance values of the sensors
Temperature
Heating outlet sensor
Boiler return sensor
Domestic hot water sensor
Flue gas sensor
0.00 °C 32624
10.00 °C 19897
15.00 °C 15711
20.00 °C 12493
25.00 °C 10000
30.00 °C 8056
40.00 °C 5324
50.00 °C 3599
60.00 °C 2483
70.00 °C 1748
80.00 °C 1252
90.00 °C 912
Resistance values of the sensors
Temperature Outside sensor
-20.00 °C 7578
-15.00 °C 5861
-10.00 °C 4574
-5.00 °C 3600
0.00 °C 2857
5.00 °C 2284
10.00 °C 1840
15.00 °C 1492
20.00 °C 1218
25.00 °C 1000
30.00 °C 826,8
35.00 °C 687,5
1
00
-7
5
-
0
GND (-)
OUT
IN (+)
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Input pressure (bar) 100-74-0
Output voltage (Volt)
Fig. 8