thermital COROLLA PACK 1000 Series User manual

COROLLAPACKSERIE1000

CONTENTS
1General Informations.................................. 4
2Warnings.......................................................... 5
3Technical features ........................................ 7
3.1 General features ............................................... 7
3.2 Main Advantages.............................................. 7
3.3 Safety Devices.................................................... 8
3.4 System Structure.............................................. 8
4Installation ....................................................11
4.1 Packaging and product identification....11
4.1.1 Installation room ............................................................ 12
4.1.2 Connections....................................................................... 12
4.1.3 System cleaning and water treatment.................. 12
4.1.4 Positioning and installation preparation ............ 13
4.1.5 Condensate drain............................................................ 13
4.1.6 Hydraulic system ............................................................ 14
4.1.7 Exhaust Flue...................................................................... 14
5Installation schemes..................................16
6Electrical Connections..............................17
6.1 Power supply...................................................17
6.2 Electrical Connections .................................17
6.2.1 Power connection........................................................... 18
6.2.2 Master board connection............................................ 18
6.2.3 Connections to thermoregulation devices.......... 18
6.2.4 Pump Connections ......................................................... 18
6.2.5 Room thermostat connection (on/off)................. 19
6.2.6 Outside temperature probe connection .............. 19
6.2.7 Anti freeze protection................................................... 21
6.2.8 Connection of an external regulation 0-10v ......21
6.2.9 Connection of an alarm device .................................21
6.2.10 Remote control.................................................................21
6.3 Emergency mode........................................... 21
6.4 Cascade installation...................................... 22
6.4.1 Power supply ....................................................................22
6.4.2 Serial Connection ............................................................22
6.5 Position of the flow probe.......................... 23
7First operating............................................. 24
7.1 Slave board setting ....................................... 24
7.2 Gas valve calibration.................................... 26
8Use and adjustment................................... 27
8.1 Control Panel: description......................... 27
8.2 Display during normal operation ........... 28
8.3 Function values display .............................. 28
8.4 User’s parameter change............................ 29
8.5 Monitor mode ................................................. 30
9Parameters List........................................... 31
10 Error List ....................................................... 33
10.1 Master board errors..................................... 33
10.2 Slave board errors......................................... 33
11 Electrical wiring diagram ....................... 34
12 Technical Data............................................. 36
13 Efficiency characteristics........................ 37

4
General Informations
The Manufacturer reserves the right to modify the data included in this documentation at any time and without any previous
warning.
This manual simply provides information and cannot be compared to a contract towards third parties.
Meaning of the symbols
In this manual are present the following symbols:
WARNING –All informations preceded by this symbol must be followed to prevent accidents and damage.
WARNING –informations preceded by this symbol must be followed to avoid heat related injuries (burns)
WARNING –All informations preceded by this symbol must be followed to avoid accidents of electrical origin (electric
shock)
FORBIDDEN –Operations that NEVER have to be done
ATTENTION –for actions that require special care and adequate preparation
1General Informations
Dear Customer,
congratulations for Your choice and thank You
for the trust You place in our products.
By purchasing COROLLA Serie 1000, You have
chosen a technology which is the best synthesis
of energy saving and functionality, compliant
with the strictest European safety standards.
For the realization of this product THERMITAL
follows these European and Italian laws and
standards.
Directive 2009/142/EC - Gas Appliances
Directive 92/42/EEC on efficiency re-
quirements for new hot-water boilers fired
with liquid or gaseous fuels ()
Electromagnetic Compatibility Directive
2014/30/EU
Low Voltage Directive 2014/35/EU
EN 15417
EN 13836
Directive ErP 2009/125/CE
Regulation (EU) N.813/2013
COROLLA Serie 1000 complies to R Collection –
ISPESL (Italian safety standard for hot-water
boilers plants with temperature not exceeding
110° C).
COROLLA Serie 1000 is a device that also has
the following features:
homologation (according to Directive
92/42/EEC) by the approval by the
prestigeous german ;
Maximum energy efficiency class (accord-
ing to Directive 92/42/EEC) identified by
the symbol ;
Belonging to the more restrictive class
with regard to pollution from nitrogen ox-
ide (fifth grade according to UNI EN 297);
Complies with Gas Directive 2009/142/EC
Patented heat exchanger.

5
Warnings
2Warnings
Corolla PACK Serie 1000 is a thermal unit
intended only for the use for which was specifi-
cally designed and built.
Hereby is excluded any liability for damages
caused to persons, animals or things, by errors
of installation, adjustment, maintenance and
improper.
In order to ensure safety and correct op-
eration, the installation shall always take place
in full compliance with the applicable Law and
with the instructions provided by the Manufac-
turer, and will always be carried out by profes-
sionally qualified technical personnel only. that
will release a declaration of conformity of in-
stallation made in a workmanlike manner, in
compliance with current regulations and guide-
lines in this handbook.
The equipment must be installed in appropri-
ate place and in combination with appropriate
systems as specified by law.
The device shall be OPERATED FOR THE
FIRST TIME by authorized Technical Support
Service only, within 8 days after equipment in-
stallation.
During the start-up, the Technical Support Ser-
vice shall complete the Warranty Certificate
and leave you a slip –to be preserved -, thus
starting the warranty period, whose conditions
are specified on the slip itself.
After removing the packaging check the
integrity and completeness of delivery and in
case of non-compliance, contact your dealer.
If there is a water loss, disconnect the
boiler from the main supply, close the water
supply and immediately call the technical assis-
tance.
Periodically check that the condensate
drain is free from obstruction.
Periodically check the pressure of the wa-
ter circuit is less than the maximum limit speci-
fied for the device.
This check has to be done with cold unit and
water
Otherwise contact the Technical Assistance
Centre.
Maintenance is mandatory and shall be
carried out at least once a year.
Please call Your local authorized Technical
Support Service. In any case, maintenance
should always be performed by qualified tech-
nicians, pursuant to the applicable Law.
Warranty assistance will be ensured only
if the warranty slip validated during the start-
up is shown.
The Manufacturer disclaims any and all re-
sponsibility resulting from damage due to tam-
pering, improper use or mistakes made during
equipment installation, operation and mainte-
nance.
In the event of a failure or malfunctioning, dis-
connect the equipment and do not try to repair
it.
Call the Technical Assistance Centre.
This manual shall be read carefully, in or-
der to operate the boiler in appropriately and
safely, and has to be accurately preserved to
make it available when needed, to the techni-
cian or installer, to facilitate proper installa-
tion, operation and maintenance of the boiler.
THERMITAL declines any and all responsibility
deriving from any translations which may re-
sult in wrong interpretations.
This manual is part of the boiler and must be
preserved. Also should always follow the boiler
in the event of its sale to another owner or us-
er, or a transfer to other place.
In case of damage or loss of this manual is pos-
sible to request another copy to the Technical
Assistance Centre.

6
Warnings
It is forbidden the use the equipment for
children and persons with reduced or lack of
experience and specific knowledge unless they
are assisted by personal qualified and respon-
sible for their safety.
It is forbidden to operate electrical appli-
ances such as switches, domestic devices, etc. if
you smell fuel or unburned.
In this case:
- Ventilate the room by opening doors and
windows;
- Close the gas valve;
- Immediately call the Technical Assistance
Centre or qualified personal.
Do not touch the boiler if you are barefoot
or you have parts of the body wet.
Is forbidden any maintenance operation
or technical cleaning before disconnecting the
boiler from the main supply.
Do not remove or modify safety equip-
ment or setting without the permission and the
manufacturer of the boiler.
Do not occlude the condensate drain.
Do not pull, twist the electrical wires, out-
going from the boiler, even if the device is dis-
connected from the main supply.
Do not obstruct or reduce the ventilation
openings.
Do not put the unit outdoor (if it is not a
specified outdoor unit).
Do not leave containers of flammable
substances in the room where it is installed the
device.
Do not dump the packing material. Keep
out of reach of children the packing material
because it can be potentially dangerous. It must
be disposed of as required by law.
The opening of metal casing of the device
and removing of the cover are prohibited to the
final user.
Any technical operation on the boiler must be
carried out by authorized personal.
It's prohibited to dispose the product as
domestic waste. At the end of its life, it can be
taken to a special differentiated waste collec-
tion center set up by local authorities, or to a
dealer providing this service in accordance
with European Directive 2002/96/EC.
The separate disposal of a household appliance
avoids possible negative consequences for the
environment and human health deriving from
inappropriate disposal and allows to recover
the materials it is made of in order to achieve
significant savings in energy and resources.

7
Technical features
3Technical features
3.1 General features
Corolla Pack Serie 1000 Pack is a condensing,
modular, pre-mixed, blown, thermal group; it is
made up of a series of Corolla thermal elements
installed in battery.
A pack is made of N°2, N° 3 or 4 heat exchang-
ers, each with a modulating power from 26 ti
128 kW; equipped with climatic regulation and
RS485 connection. Each device can be serially
matched up with same tipe units up to a total
installed power of 4096 kW (eight Corolla Pack
serie 1000 equal to a total of di 32 heat ex-
changers1). It is possible to connect up two
thermal groups (with a total of 8 heat exchang-
ers) directly using the internal 5” hydraulic
manifolds and the internal 3” gas manifold.
The generator efficiency reaches 109% on Hi.
This allow use of integrated plastic flue mani-
fold (PP). The system has continuous modula-
tion of both gas and combustion air flow.
Corolla Serie 1000 thermal group represents a
point of arrival in terms of managing economy
(efficiency until 109% on Hi, see Figure 1) reli-
ability and flexibility. In fact, thanks to the new
heat exchanger with improved power, to the
new electronic management, to the modularity
and versatility, it is possible to make a rapid
connection to any kind of heating system and
storage hot water production.
The insertion of a single thermal element in
cascade, over the traditional rotation of the ig-
1In case of installation of more than 32 unit (up to 60 unit)
please contact Technical Assistance Centre
nition, can take place with variable factor of
heating power load, so that when a certain
power percentage of the first element is
reached (e.g. 30%), the successive element al-
ready starts with the same load factor. This lat-
ter feature allows to share the power supplied
inside more than one heat exchangers with a
power/exchange surface ratio which is particu-
larly favourable for condensation latent heat.
3.2 Main Advantages
Blown air burner with total pre-mixing;
Condensing heat exchanger with 109% ef-
ficiency (see Figure 1);
Power from 26 to 512 kW ;
Possibility to manage 32 thermal units
(burners) in series for a maximum power
of 4096 kW;
80°C maximum flue temperature;
Plastic flue manifold in PP self-
extinguishing (see par. 4.1.7)
Water manifold, condensate and smoke
manifold inside the boiler;
Quick connection of both water, conden-
sate and flue manifolds (with exit on the
right and left side);
Standard climatic regulation of the tem-
perature.;
Modulating and modular regulation of the
single thermal elements power;
Automatic changeover (at adjustable time
intervals) of the burners ignition order2;
Choice of the cascade insertion criteria of
the burner (power %);
Hot water and systems at a different tem-
perature management , with or without
priority;
Winter/Summer automatic mode;
Anti-legionella mode (only available with
remote control);
Hour and week programming schedule
(only available with remote control).
Water differential pressure switch to con-
trol flux minimum flux for each unit
2The changeover of ignition will work only at every start of the
boiler. It's necessary that a room thermostat is connected, if it is
replaced by a jumper the boiler is always on and it never changes
the ignition order.
Efficiency
T Ritorno °C
Figure 1

8
Technical features
3.3 Safety Devices
All the functions of the thermal module are
electrically controlled. Any anomaly causes the
lock out of the single thermal element and the
automatic shut down of the gas valve.
The following devices are installed on the wa-
ter circuit:
Auto reset safety thermostat for each
thermal element;
Safety water differential pressure switch
for each thermal element;
STemperature probe on each thermal ele-
ment flow and return. Probes are managed
by an electronics homologated for safety
performances and with a double processor
technology. Such device allows to continu-
ally control both flow temperature and the
t between flow and return of the battery
element;
Modulating flow temperature regulation
for both single elements and the whole
battery.
The following devices are installed on the com-
bustion circuit:
Gas electro valve in B+C class for each
thermal element, with gas flux pneumatic
compensation according to the inlet air
flow ( air/gas 1:1 ratio);
Ionization electrode for continuous flame
detection;
Flue pipes temperature control for each
thermal element;
Both protection interventions and gas valve
shut-off occur, on each thermal element, when
the following situations take place:
Flame Extinguishing
Exchange circuit overheat
Exhaust high temperature
Air flow reduction
The equipment should not be operated in
service - even temporarily with the safety de-
vices altered or excluded.
The replacement of safety devices should
only be performed by authorized Technical As-
sistance Centre, using only original parts.
Refer to Spare Parts Catalog.
3.4 System Structure
Corolla Serie 1000 is made up of a series of Co-
rolla Thermal Units installed in battery placed
inside a metal casing.
Each thermal unit is connected to the system in
parallel position as compared to the others,
through a flow, return, gas, flue manifold and
condensate discharge manifold. According to
the heat demand, the regulation system
switches on and regulates the single thermal
units in order to guarantee an optimal balance
between power required by the system and
power supplied by the boiler (see Figure 2).
Each Corolla Serie 1000 can be serially
matched up with other similar boilers, even
with different power, in order to make modular
heating thermal plants made up of several “cas-
ings” which shall be hydraulic connected and
controlled by a single modular boiler inte-
grated inside each single Pack.
This regulation system has many advantages:
maximum exploitation of the condensation
technology, excellent modularity of each single
boiler and of the whole the battery ones, ratio
of the system modulation equal to 1:157 in or-
der to cover any power range from 26 to 4000
kW. All these features contribute to maximize
the economy of the condensing boiler and to al-
low an excellent system-boiler matching.
The ignition order of each single burner is fully
managed by a microprocessor logic device
which ensures an equal number of working
hours to each thermal unit.

9
Technical features
CONTENTS
1
Heat exchanger
8
Gas intercepting ball-valve
15
Flue Manifold
2
Burner
9
Water return intercepting valve
16
Unit flue pipe
3
Pump
10
Return water manifold
17
Water Flow Manifold
4
Flue manifold with clapet
11
Gas manifoldas
18
One way valve
5
Fan
12
Gas pipe
19
Water differential pressure switch
6
Air-gas mixing pipe
13
Condensate manifold
7
Gas valve
14
Condensate flexible pipe
Figure 2

10
Technical features
Components
1
Frame
9
Return probe
17
Venturi tube
2
Tools panel
10
Flue probe
18
Flow probe
3
Heat exchanger
11
Water differential pressure switch
19
Unit flue discharge
4
Air inlet
12
Gas valve
20
Gas manifold
5
Fan
13
Ignition electrode
21
Water flow manifold
6
Return detection tap
14
Automatic vent valve
22
Condensing manifold
7
Pump
15
Safety thermostat
23
Water return manifold
8
One way valve
16
Gas tap
Figure 4
Figure 3