Top secret Secret Internal use only Public 4
Top secret Secret Internal use only Public 4. Installation D 2 x. ND Service Course
4. Installation 1. 2. 3. 4. 5. Before Installing Scope of delivery Product Label Dimensions Installation 1. Preparation 2. Mounting the unit 3. Piping Connection 4. Electrical Connection 5. Connecting the condense piping 6. Combining the boiler with options 2 Installation - Internal use only
4. 1 Before installing 3 Installation - Internal use only
4. 1 Before installing • Always read the manual first! • This gas boiler is NOT designed for room air dependent operation. • It is NOT allowed to combine flue system parts purchased from different suppliers. • Provide sufficient space around the unit for servicing and air circulation. • Avoid damages caused by deposits and corrosion. To prevent corrosion products and deposits, observe the applicable regulations of technology. 4 Installation - Internal use only
4. 2 Scope of delivery 5 Installation - Internal use only
4. 2 Scope of delivery Following items are included in the package : A. Combi Boiler B. Operation manual C. Installation manual D. Warranty certificate E. Wall mounting bracket F. Dowels and screws G. Installation template H. Condensate hose I. Cable glands 2 x. PG 7, 1 x. PG 9 6 Installation - Internal use only
4. 3 Product label 7 Installation - Internal use only
4. 3 8 Product label Installation - Internal use only a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v. Product number Electrical supply Maximum electrical power consumption Degree of protection Nominal heat output range @ 80/60 Nominal heat output range @ 50/30 Nominal heat input range Hot water amount @ DT=30 NOx class Maximum central heating pressure (bar) Maximum central heating pressure (MPa) Maximum domestic hot water pressure (bar) Maximum domestic hot water pressure (MPa) Country of destination(s) Country of origin Serial number Appliance type Efficiency class Gas category Gas type and supply pressure Product type Production date
4. 4 Dimensions 9 Installation - Internal use only
4. 4 Dimensions D 2 CND 024 A 1 AA D 2 CND 024 A 4 AA D 2 TND 012 A 4 AA D 2 TND 018 A 4 AA D 2 TND 024 A 4 AA 10 Installation - Internal use only
4. 4 Dimensions D 2 CND 028 A 1 AA D 2 CND 035 A 1 AA D 2 CND 028 A 4 AA D 2 CND 035 A 4 AA D 2 TND 028 A 4 AA D 2 TND 035 A 4 AA 11 Installation - Internal use only
4. 4 Dimensions D 2 CND 024 A 0 AAIT 12 Installation - Internal use only
4. 5 Installation 13 Installation - Internal use only
4. 5 Installation 1. Preparation For adequate operation, servicing and maintenance please follow installation space requirements. 14 Installation - Internal use only *Depending on the fluegas system required space can change. See manual.
4. 5 Installation 2. Mounting the unit • Mount the unit on vertical, flat walls only • The unit is not suitable for outdoor installation, unless it is protected by a housing which is designed and constructed for this unit (e. g. cupboard) • The wall on which the unit is mounted should be strong enough to carry the units weight. Build a reinforcement if necessary 15 Installation - Internal use only
4. 5 Installation 2. Mounting the unit • Drill holes for the mounting bracket (Ø 10 mm). Fasten the mounting bracket to the wall according to the mounting template. • 16 Installation - Internal use only Hang the unit on the bracket.
4. 5 Installation 3. Piping connection Important Attention Points: • Connect the gas piping according to applicable legislation of the country and gas supply company. • In case the gas piping is close to the wall and has to be connected to gas pipe connection of the boiler with an elbow, enough space must be left to take out the condensate trap.
4. 5 Installation 3. 1 Piping connection: D 2 CND 024 A 1 AA and D 2 CND 024 A 4 AA A: Central Heating Inlet Connection ¾” B: Domestic Cold Water Inlet Connection 1/2” C: Condensate Trap Discharge D: Domestic Hot Water Outlet Connection 1/2” E: Central Heating Outlet Connection ¾” F: Gas Pipe Connection ¾” G: Filling Valve H: Safety Valve Discharge Valve Strainer Tee connection Double check valve + filling hose Disconnector a. Isolation valve on domestic hot water supply pipe is tentative. b. External filling group used with model D 2 CND 024 A 4 AA. Use a disconnector or a double check valve according to local regulations.
4. 5 Installation 3. 2 Piping connection: D 2 TND 012 A 4 AA/D 2 TND 018 A 4 AA/ A: Central heating return connection, 3/4" D 2 TND 024 A 4 AA B: Storage tank return connection, 3/4" C: Condensate Trap Discharge D: Storage tank supply connection, 3/4" E: Central heating supply connection, 3/4" F: Gas inlet connection, 3/4" G: Safety valve discharge Valve Strainer Tee connection Double check valve + filling hose Disconnector a. External filling group used with models D 2 TND 012 A 4 AA, D 2 TND 018 A 4 AA and D 2 TND 024 A 4 AA. Use adisconnector or a double check valve according to local regulations.
4. 5 Installation 3. 3 Piping connection: D 2 CND 024 A 0 AAIT Valve 20 Installation - Internal use only A: Central heating return connection, 3/4" B: Domestic Cold Water Inlet Connection 1/2” C: Condensate Trap Discharge D: Domestic Hot Water Outlet Connection 1/2” E: Central Heating Outlet Connection ¾” F: Gas Pipe Connection ¾” G: Filling Valve H: Safety Valve Discharge Strainer Tee connection
4. 5 Installation 3. 4 Piping connection: D 2 CND 028 A 1 AA_D 2 CND 28 A 4 AA_ A: Central heating return connection, 3/4" D 2 CND 035 A 4 AA Valve B: Domestic Cold Water Inlet Connection 1/2” C: Condensate Trap Discharge D: Domestic Hot Water Outlet Connection 1/2” E: Central Heating Supply Connection ¾” F: Gas Pipe Connection ¾” G: Filling Valve H: Safety Valve Discharge Strainer Tee connection Double check valve + filling hose Disconnector a. Isolation valve on domestic hot water supply pipe is tentative. 21 Installation - Internal use only b. External filling group used with model D 2 CND 028 A 4 AA and D 2 CND 035 A 4 AA. Use a disconnector or a double check valve according to local regulations.
4. 5 Installation 3. 5 Piping connection: D 2 TND 028 A 4 AA_D 2 TND 354 A 4 AA Valve A: Central heating return connection, 3/4" B: Storage tank return connection, ¾” C: Condensate Trap Discharge D: Storage tank supply connection, ¾” E: Central Heating Supply Connection ¾” F: Gas Pipe Connection ¾” G: Safety Valve Discharge Strainer Tee connection Double check valve + filling hose Disconnector 22 Installation - Internal use only a. External filling group used with model D 2 TND 028 A 4 AA and D 2 TND 035 A 4 AA. Use a disconnector or a double check valve according to local regulations.
4. 5 Installation 4. Electrical connection The unit runs on 230 VAC 50 HZ. A power cable is delivered with the unit and must be connected to the power supply by an electrician and in accordance with the applicable legislation. The boiler electric connection must be made with a fuse of 2 A rating and 0, 75 mm 2 TTR type wire cable. Use ELCB (Earth Leakage Circuit Breaker) type fuse where available. 23 Installation - Internal use only
4. 5 Installation 5. Connecting the condensate piping Important Attention Points: • Condensate trap must be connected to a drain via an open connection. 24 Installation - Internal use only
4. 5 Installation 5. Connecting the condensate piping Important Attention Points: • Horizontal piping must fall a minimum of 45 mm/meter. • External piping should be kept as short as possible or thermally insulated to prevent freezing (depending on the installation winter climate condition). • Make sure that the condensate disposal system, the piping, and the fittings are made of acid resistant material like plastics. 25 Installation - Internal use only
4. 5 Installation 6. Connecting the flue duct • The flue duct must incline 3° to allow the condens to drain back to the unit. • The approved flue systems can be found in the installation manual. 26 Installation - Internal use only
4. 6 Combining the boiler with options 27 Installation - Internal use only
4. 6 Combining the boiler with options The optional equipment connectors are located outside of the switch box. The box should not be opened to connect the optional equipment. 28 Temperature Control Units Connector Connection Opentherm room thermostat X 1 M 3 -4 Solar NTC sensor X 1 M 1 -2 Outdoor sensor X 1 M 5 -6 Domestic hot water storage tank sensor X 1 M 7 -8 ON/OFF room thermostat X 2 M 5 -6 Solar stop contact X 2 M 7 -8 Ext. Power output (230 VAC) X 2 M 3 -4 Installation - Internal use only
4. 6 Combining the boiler with options 1. Opentherm room thermostat 29 Installation - Internal use only
4. 6 Combining the boiler with options 2. Cascade controllers Cascade Controller E 8 5064 V 1 (DRCASCACONTAA): This is a system manager which can cascade up to 8 boilers and control two direct or mixed zones. Cascade Controller E 8 1124 (DRZONECCONTAA): Zones can be increased up to 15 by using this additional zone controllers. This controller can manage two direct or mixed zones i. e. if additional 4 zone exists 2 x E 8 1124 is needed. If a mixing circuit is used as a direct one, a flow sensor is needed anyway to enable the circuit. Lago FB CAN (DRCBROOMTHEAA): This is a CAN Bus Room controller. It is an option and can be connected to each zone, i. e. if 3 zone exists 3 x Lago FB is needed. Co OT-CAN Adapter (DRCOCOADPTRAA): This is an adapter which converts Open. Therm communication to CAN communication. In case of cascaded boilers it is needed for every boiler, i. e. if 5 boiler exists 5 x OT/CAN adapter is needed.
4. 6 Combining the boiler with options 2. 1 Cascade controller E 8 5064 V 1 Connector I: 1. 1+2+3+GND: Buffer storage tank 2. 2+3+GND: Thermostat Heating circuit 1 3. 2+GND: Room sensor HC 1 4. 4+5: Flow sensor HC 1 5. 6+7: Storage tank sensor 6. 7+8: Boiler/header sensor 7. 9+10: Outdoor sensor 8. 1+GND: Flow sensor HC 2 Connector II: 1. Power supply N 2. Power supply unit L 1 3. Power supply relay L 1 4. Pump HC 1 5. Pump HC 2 6. Cylinder charging pump 7. Mixer motor HC 2 IN 8. Mixer motor HC 2 OUT 9. + 10 Burner stage 1 31 Installation - Internal use only
4. 6 Combining the boiler with options 2. 1 Cascade controller E 8 5064 V 1 Connector III: 1. 1 -3: Thermostat HC 2 2. 1+2: Room sensor HC 2 3. 2+3: Pulse counter for output measurement Connector IV: 1. Mixer motor heating circuit 1 IN/ Mulfunction relay 1 2. Mixer motor heating circuit 1 OUT/ Mulfunction relay 2 3. Collector pump 2/ Switching valve to solar tank 2/ Malfunction relay 3 4. Collector pump 1/ Malfunction relay 4 32 Installation - Internal use only Connector V: 1. Flow sensor heating circuit 1/ Malfunction relay sensor 1 2. Hot water tank low/ Malfunction relay sensor 2
4. 6 Combining the boiler with options 2. 1 Cascade controller E 8 5064 V 1 Connector VI: 1. 1+2: Burner stage 2/ HS 2/ Solid fuel Connector VII: 1. e. Bus: 0 -10 V Output Connector VIII: 1. PT 1000 => HS 2/ collector 2/ Malfunction relay sensor 2 2. PT 1000 => Collector 1/ Malfunction relay sensor 4 Connector IX: 1. 1+2: Data line CAN bus 2. 3+4 Power supply CAN bus 33 Installation - Internal use only
4. 6 Combining the boiler with options 2. 2 Cascade controller E 8 1124 Connector I: 1. 1 -3: FBR 2 (FBR 1) for heating circuit 1 2. 4+5: Flow sensor, heating circuit 2 3. 9+10: Outdoor sensor 4. 1+GND: Flow sensor HC 2 Connector II: 1. Power supply N 2. Power supply unit L 1 3. Power supply relay L 1 4. Pump HC 1 5. Pump HC 2 7. Mixer, heating circuit 2 open 8. Mixer, heating circuit 2 closed Connector III: 1. FBR 2 (FBR 1) for heating circuit 2 Connector IV: 1. Mixer, heating circuit 1 open 2. Mixer, heating circuit 1 closed Connector V: 1. 1+2: Flow sensor heating circuit 1 34 Installation - Internal use only
4. 6 Combining the boiler with options 2. 2 Cascade controller E 8 1124 Connector VI: 1. Malfunction relay 1 Connector VII: 1. e. Bus Connector VIII: 1. 1+2: Malfunction relay 1 sensor Connector IX: 1. 1+2: Data line CAN bus 2. 3+4: Power supply CAN bus 35 Installation - Internal use only
4. 6 Combining the boiler with options 3. 1 Direct zone via low loss header OT-CAN Adapter Cascade controller Lago FB Can
4. 6 Combining the boiler with options 3. 2 Direct zone + mixed zone via low loss header OT-CAN Adapter Lago FB Can Cascade controller Lago FB Can
4. 6 Combining the boiler with options 3. 3 Boiler in cascade: Direct zone via low loss header OT-CAN Adapter Lago FB Can OT-CAN Adapter Cascade controller
4. 6 Combining the boiler with options 3. 4 Boiler in cascade: Direct zone + mixed zone via low loss header OT-CAN Adapter Lago FB Can Cascade controller
4. 6 Combining the boiler with options 3. 5 Boiler in cascade: mixed zone + mixed zone via low loss header OT-CAN Adapter Lago FB Can Cascade controller
4. 6 Combining the boiler with options 3. 6 Boiler in cascade: DHW Tank + Direct Zone via low loss header Cascade controller OT-CAN Adapter Lago FB Can
4. 6 Combining the boiler with options 3. 7 Additional zones Cascade Controller Lago FB CAN
4. 6 Combining the boiler with options 4. Connecting options The options that have to be connected to the X 2 M connector must pop out from the inside of the unit via cable glands. These cable glands are sent with the unit and must be assembled to the bottem sheet of the boiler. The holes on the bottem sheet that are reserved for the cable glands are covered with insulation material and should be removed when glands are used. 43 Installation - Internal use only
Thank you
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