TERMOSTROJ TermoMini Installation Manual & Users Manual

We reserve the right of alternations. Contents General ................................................................................................................................. 1 1. Introduction ....................................................................................................................... 1 1.1. Applicable documents ................................................................................................. 1 1.2. Retention of documents .............................................................................................. 1 1.3. Introduction ................................................................................................................. 2 1.4. Frost protection ........................................................................................................... 2 2. Boiler specifications ........................................................................................................... 2 2.1. Dimensions in mm ...................................................................................................... 2 2.2. Elements of TermoMini ............................................................................................... 4 3. General requirements ........................................................................................................ 5 3.1. Contents included in delivery ...................................................................................... 5 3.2. Preliminary remarks .................................................................................................... 5 3.3. Installation site ............................................................................................................ 5 3.3.1. Position of a boiler ................................................................................................ 5 3.3.2. Power supply ........................................................................................................ 6 3.4. System requirements .................................................................................................. 6 3.4.1. Pipe work.............................................................................................................. 6 3.4.2. Cleansing and flushing the system ....................................................................... 6 3.4.3. Filling and preparing heating system .................................................................... 7 3.4.4. Pressure relief valve ............................................................................................. 7 3.4.5. Pressure gauge .................................................................................................... 7 3.4.6. Expansion vessel .................................................................................................. 7 3.4.7. Circulating pump................................................................................................... 7 3.4.8. Air in boiler ........................................................................................................... 7 4. Boiler installation sequence ............................................................................................... 8 4.1. Transporting the appliance .......................................................................................... 8 4.2. Select position for boiler .............................................................................................. 8 4.3. Fitting the boiler hanging bracket ................................................................................ 8 4.4. Removing/fixing the front and top case ....................................................................... 9 4.5. Power supply connection ............................................................................................ 9 4.6. Connecting temperature sensors or external electrical controls .................................10 4.6.1. Accessing connection plate .................................................................................10 4.7. Filling the heating system ...........................................................................................10 5. Commissioning .................................................................................................................10 5.1. Heating system check ................................................................................................10 5.2. Preliminary electrical check ........................................................................................10 5.3. Pump .........................................................................................................................11 5.4. Working with standard control panel ..........................................................................12 5.4.1. Heating functions .................................................................................................14 5.4.2. Access to special service menu ...........................................................................15 5.4.3. Control panel “Z” – OPTION ................................................................................16 6. Maintenance .....................................................................................................................17 6.1. Periodic checking .......................................................................................................17 6.2. Cleaning.....................................................................................................................17 7. Survey of possible malfunctions and irregularities in operation .........................................18

We reserve the right of alternations. Figures Figure 1 TermoMini dimensions, flow and return positions .................................................... 2 Figure 2. Expansion vessel and power supply characteristics ............................................... 3 Figure 3. TermoMini elements ............................................................................................... 4 Figure 4. Contents included with delivery .............................................................................. 5 Figure 5. Minimal distances for installing the boiler ................................................................ 6 Figure 6. Wall mounting ......................................................................................................... 8 Figure 7. Removing front and top case .................................................................................. 9 Figure 8 Power supply connection ......................................................................................... 9 Figure 9 Connection relay plate ............................................................................................10 Figure 10 Pump NMT PLUS 25/40 .......................................................................................11 Figure 11 Pump characteristics ............................................................................................12 Figure 12 Standard electronic control panel .........................................................................12 Figure 13 Control panel “W” - OPTION .................................................................................16 Figure 14 Hydraulic sketch for TermoMini with OPTION control panel type “Z” ....................16 Tables Table 1. Expansion vessel characteristics ............................................................................. 3 Table 2. Power supply characteristics ................................................................................... 3 Table 3. List of TermoMini elements ...................................................................................... 4 Table 4. Table of contents included with delivery ................................................................... 5 Table 5. Pump electric and performance information ............................................................11 Table 6. Pump general information .......................................................................................11 Table 7 Possible malfunctions ..............................................................................................19

• The boiler must not be modified, changed or rebuilt. • The correct settings are important for economical heating. • The type and serial number of the boiler must be quoted whenever you contact manufacturer or service, see the identification plate. General safety instructions!! - Children shall not play with the appliance. - Cleaning and user maintenance shall not be made by children without supervision. - Children should be supervised to ensure that they do not play with the appliance. - Boiler is not intended for outdoor use. Technical safety instructions!! - Keep the water pressure between recommended limits – see chapter 3.4.3, page 7. - Do not install boiler close the heat source (for instance, fireplace, wood stove etc…). - Incompetent repairs can cause serious danger to users. - Defective parts may be replaced only by the original or approved by the manufacturer, - Switch off main power by MCB before opening the boiler. - Boiler has built-in frost protection. When the boiler is not in use, leave the main power active that protection stay active. 1. Introduction Thank you for the confidence you have shown to us by purchasing our central heating boiler. In order to use the boiler to the utmost correctly and safely, and above all economically, read thoroughly these instructions before continuing with installation. A competent person, who is responsible for adhering to the existing regulations, rules and guidelines, must install the appliances. 1.1. Applicable documents The following additional documents are provided with the appliance: For the owner of the system: Instructions for use Warranty card For the qualified technician: Instructions for installation Electrical drawing for the appliance 1.2. Retention of documents Please pass on this manual to the owner of the system. The owner should retain the manuals so that they are available when required. Read this document carefully before carrying out any installation, adjustment or service and follow the instructions

independent or additional source of heat. TermoMini boilers offer you a possibility to reduce the power of the heater if necessary. The power can be easily reduced through the control panel. This way it is possible to adapt the boiler to the utmost to circumstances on the spot. The boiler operates on a principle of rapid heating smaller water quantities, so that exploiting energy is already 100%. TermoMini boilers are used for radiator and floor heating. Temperature operation area is from 20°C to 90°C. TermoMini boilers are designed in such way that in apartment-contained central heating they can fit well with your furniture. 1.4. Frost protection The software in control panel provides boiler frost protection. When frost protection is controlled for entire central heating system by room thermostat, please consult room thermostat manuals for more details. 2. Boiler specifications 2.1. Dimensions in mm Figure 1 - TermoMini dimensions and flow and return positions

characteristics Volume of Expansion Vessel [L] 6 Maximum Expansion Vessel Pressure [MPa (bar)] 0,3 (3) Filling Pressure [MPa (bar)] 0,10 (1,0) Maximum Pressure In the Heating System [MPa (bar)] 0,3 (3) Height Of the Central Heating System [m] 4 Effective Capacity Of Expansion Vessel [L] 3,0 Adsorption Capacity [%] 50 Maximum Amount of Water in the System [L] 86 Table 2. Power supply characteristics Power [kW] 230 V~N 400V 3N ~ 50/60 Hz 3 4,5 6 9 9 12 Nominal current [A] 13 19,6 26,1 39,2 13,1 17,5 Fuse current [A] 16 25 32 50 16 25 Rated short- circuit breaking capacity Icn (EN 60898) [kA] 10 10 10 10 10 10 Rated short- circuit breaking capacity Icn (IEC 947-2) [kA] 15 15 15 15 15 15 Min. conductor's cross- section [mm2] 3x2,5 3X4 3X6 3X10 5X2,5 5x4 Fuse type B16 B25 B32 B50 B16 B25 RCCB switch type [A] 25/0,03 25/0,03 40/0,03 63/0,03 25/0,03 25/0,03 Figure 2. Expansion vessel and power supply characteristics

Power connection protection cover Figure 3 - TermoMini elements Table 3. List of TermoMini elements 1. Primary flow 10. Expansion vessel 2. Return flow 11. Circulation pump 3. External boiler shell 12. Pressure relief valve (0,3 MPa / 3 bar) 4. Boiler 13. Automatic air vent 5. Heat insulation 14. Charge and discharge valve 6. Electrical heaters 16. Air-indicator 7. Control panel 17. Manifold 8. Inducers for el. connections 9. RCCB switch and relays

3.1. Contents included in delivery TermoMini boilers are delivered pre-mounted in a package unit. Make sure that all parts have been delivered intact. For the exact list of parts, see the figure and table below. If parts are damaged or missing, please consult our local sales office. Figure 4 - Contents included with delivery Table 4. Table of contents included with delivery Item Quantity Description 1 1 TermoMini boiler 2 1 Instructions for installation and use Electrical drawing Warranty card 3 1 Hanging bracket 3.2. Preliminary remarks When connecting the appliance to the fixing wiring, the means for disconnection (MCB) must be incorporated in fixing wiring in accordance with the local wiring rules. If the boiler is out of function during wintertime, there is a danger of installation freeze. In this case, boiler should be filled with antifreeze liquid for central heating. If this is not possible water should be drained out of the system with the help of charge and discharge valve. Recommended pressure of central heating installation is between 0,12 MPa (1,2 bar) and 0,15 MPa (1,5 bar), maximum pressure is 0,25 MPa (2,5 bar). 3.3. Installation site 3.3.1. Position of a boiler The location must provide adequate space for servicing and air circulation around the boiler. The boiler can be installed in any room, although particular attention is drawn to the local regulations in respect to the installation of a boiler in a room containing a bath or a shower. The boiler must be mounted on a flat, vertical wall, which must be sufficiently robust to bear the weight of the boiler. The boiler can be installed on a combustible wall, subject to the requirements of the Local Authorities and Building Regulations.

Figure 5 - Minimal distances for installing the boiler It is possible to reduce recommended minimal distances, but the following requirements must be met: Power supply connection, located at bottom of boiler must be accessible Bottom part of boiler must be accessible to allow change of heater Control panel on bottom side of boiler must be accessible Basic air circulation must be maintained. 3.3.2. Power supply The boiler is rated as a high-power appliance and fixed wiring must be used. Please observe chapter 2.2. about fuse and conductor requirements. When connecting the appliance to the fixing wiring the means for disconnection (MCB) must be incorporated in fixed wiring in accordance with the local wiring rules. RCCB (RCD) switch 0,03A sensitivity is fitted inside a boiler. Note: In some cases, additional measures must be taken, subject to the requirements of the Local Authorities. 3.4. System requirements 3.4.1. Pipe work Pipe work that is not a forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated under floor spaces. Draining taps must be located in accessible positions, which permit the draining of the whole system including the boiler and the hot water system. 3.4.2. Cleansing and flushing the system Flushing of system is highly recommended this will prevent damage to the appliance made by dirt from the system.

The system can be filled using the built-in filling valve or via a separate filling point fitted at a convenient position on the heating circuit. The connection must be removed when filling is completed. Where local Water Authority regulation does not allow temporary connection, a sealed system filler pump with break tank must be used. The heating system will not be filled automatically from the domestic hot water side. Note: For the heating system to operate properly the indicator of manometer must be between 1,2 and 1,5 bar when system is cold. Maximum pressure is 2,5 bar and minimum 0,8 bar. It is very important to use soft water or fluids for central heating. Do not fill the system with water from private source. 3.4.4. Pressure relief valve A pressure relief valve is provided with the boiler. This safety device is required on all sealed heating systems and is preset at 0,3 MPa (3 bar). The pressure relief valve must not be used for draining purposes. 3.4.5. Pressure gauge This is factory fitted to the TERMO-Mini boilers and indicates the primary circuit pressure to facilitate filling and testing. 3.4.6. Expansion vessel TermoMini boiler incorporate an expansion vessel. Refer to chapter 2.2 for more information about incorporated expansion vessel. If the nominal capacity of the built-in expansion vessel is not sufficient for the heating system (for instance in the case of modernization of old open systems) an additional expansion vessel can be installed externally to the boiler. It should be fitted in the return pipe as close as possible to the boiler. 3.4.7. Circulating pump The circulation pump is included in TermoMini boilers. The following figure represents pump characteristics - see chapter 5.3. 3.4.8. Air in boiler Boiler is fitted with the air detector that will stop boiler in the case of air presence.

4.1. Transporting the appliance Important: The following lift operation exceeds the recommended weight for a one-man lift. General recommendations when handling Clear the route before attempting the lift. Safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition your feet. If two persons are performing the lift, ensure coordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. It is recommended to wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip. Always use assistance if required. Positioning of Appliance for Final Installation Fit bracket securely onto wall before lifting appliance into position. Ensure that stable balance is achieved and lift upwards to drop into place onto bracket. Ensure coordinated movements during a two-person lift to ensure equal spread of weight of load it is recommended to wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. 4.2. Select position for boiler Refer to chapter 3.3.1. for information regarding the appliance position. In general, the boiler must be positioned in such manner that: • There is enough space around the boiler for service and maintenance • There is no chance for boiler to be submerged into water • There is no chance for boiler to be poured with significant amount of water • Normal level of air circulation can be maintained • All necessary pipe work can be connected 4.3. Fitting the boiler hanging bracket Fix the hanging bracket (2) to the wall (1) using the plugs and M8 or M10 screws. Lift up boiler (3) above hanging bracket (2), gently lean it to the wall (1) and slide it down to the hanging bracket (2). Figure 6 - Wall mounting

substantial part of the timber frame capable of bearing the weight of the boiler. 4.4. Removing/fixing the front and top case Figure 7 - Removing front and top case Grasp the front case by its sides, pull it towards the front and remove it by lifting it of the unit, push top cover towards back and lift it of the unit. 4.5. Power supply connection Note: Before working with the appliance, turn off the power supply (MCB) and secure against restart. This device must be earthed. Tightening torque for RCCB is 2,5 Nm. Figure 8 - Power supply connection

4.6.1. Accessing connection plate In order to access connection plate, power connection protection cover (Figure 2) must be removed by unwinding two screws M4 and pulling protection cover out. Figure 9 - Connection relay plate 4.7. Filling the heating system For the heating system to operate properly the indicator of manometer must be between 1.2 and 1.5 bar when the system is cold. It is very important to use soft water or fluids for central heating. 5. Commissioning 5.1. Heating system check Check for pressure in the system, it should be from 0,12 MPa (1,2 bar) to 0,15 MPa (1,5 bar) when the system is cold. Vent all heating elements and installation. 5.2. Preliminary electrical check Check if power cable is tightened on RCCB (RCD) terminals Check the presence of phase on RCCB (RCD) input terminals inside boiler

voltage on the appliance, the appliance itself can be damaged. Test the RCCB (RCD) switch by pressing T button on it 5.3. Pump The pump impeller is made of noryl. Pump casing is made of grey cast iron. Embodiment of the casing is single made. Figure 10 - Pump NMT 25/40 Table 5. Pump electric and performance information Table 6. Pump general information Max. flow, Qmax [m3/h] 2,6 Medium temperature [°C] 5-95 Max. height, Hmax [m] 4 Ambient temperature [°C] 0-40 Default pressure [bar] 10 Recommended system pressure at 50/80/110 °C [bar] 0,05/0,4/1,1 Power [W] 5-25 Current [A] 0,05-0,2 Voltage [V]* 230 Insulation class F Protection level IP44 * single-phase

5.4. Working with standard control panel Figure 12 - Standard electronic control panel

2. Multipurpose – temperature indicator (temperature of boiler, adjustment of temperature) 3. Signalization of operation degree of heaters (1, 2, 3) 4. Pressure indicator 5. Switch for central heating switching on and off 6. Adjustment of temperature in boiler 7. Signalization of boiler operation (green light) Switching on of central heating By switching the switch (5) to the position 1, the central heating system is switched on. Upon switching on the desired water temperature in boiler is displayed for 5 seconds, signalization of boiler operation is twinkling (7). After 5 seconds the real temperature in the boiler is displayed (2); if the current temperature in the boiler meets the desired one, the signalization lamp of the boiler operation (7) is switched off. Adjustment of desired temperature of central heating By pressing the key for temperature adjustment (6) the desired temperature in the boiler appears, the signalization lamp of the boiler operation (7) is twinkling. By repeated pressing upwards or downwards it is possible to increase or decrease the desired water temperature. When the temperature is adjusted it is sufficient to wait for 5 seconds (signalization lamp of the boiler operation (7) does not twinkle) in order for the boiler to memorize new temperature. Air in the boiler ‘’LU’’ If air appears in the boiler, the signalization of air in the boiler ‘’LU’’ is shown on display (2) and the boiler stops the operation. In this way the boiler is protected against burning through because of appearance of air. To continue the operation, the boiler should be vented. If the boiler is correctly vented, the operation of boiler continues automatically. Voltage drop ‘’SP’’ If the voltage in the network line drops below 180V by phase, the signalization of under voltage protection ‘’SP’’ is shown on display (2), the boiler automatically switches off in order to protect electronics and contactors inside the boiler. The boiler will automatically continue the operation when the network voltage reaches values above 180V. Cutout thermostat - turning on Cutout thermostat (safety thermostat) (1) protects the boiler against rapid increase of temperature above 115°C. The fuse turns off the boiler and ejects the RCCB (RCD)-switch. To continue the operation, it is necessary to take off the protection cover from the cutout thermostat and press the red key, after which the RCCB (RCD)-switch should be switched on again. NOTE: If the room thermostat is on, check if it is set at the necessary room temperature and if supply batteries are in order, otherwise the boiler will not operate. . 46. 46 Red dot in lower right corner of display is showing - boiler is off on control panel but main power (RCCB switch) is in ON position Display is showing real temperature in boiler - red dot is illuminate Display show settings parameter during programming - without red dot Clarification of LED display layout

Display of desired temperature in the boiler If the key (6) is held pressed less than 5 s the LED display will show the desired temperature in the boiler. The value is displayed for 5 seconds, after which the display normally shows the real temperature of water in the boiler. Setting the desired temperature in the boiler By pressing the key (6) user can enter the boiler temperature menu. The desired boiler temperature is blinking. By pressing the key (6) UP or DOWN, the desired boiler temperature can be set in steps of 1°C. If the key is held pressed less than 5 s the value from the display becomes the desired boiler temperature. Possible adjustment is from 20°C up to 90°C for radiator heating. Possible adjustment is from 15°C up to 45°C for under floor heating. Reset to factory defaults By pressing the key (6) longer than 15 seconds, all parameters will return to the factory default values and controller will be reset and show software version.

>10 sec >15 sec >20 sec >15 sec 15 15 2 15 >5 sec >25 sec >30 sec Power ON >5 sec >5 sec >5 sec 45 3 1 . >5 sec >5 sec >5 sec >5 sec >5 sec Press simultaneously to access service menu Access to special service menu To access in special service menu, press simultaneously key (6) during switching ON main switch on boiler - RCCB (in that moment key (7) must be turned off) Limiting maximum boiler temperature By pressing the key (6) user can limit maximum boiler temperature. Factory defined maximum temperature starts to blink. By pressing up or down user can set new maximum temperature. If the key is depressed for more than 5s, value on the display will be memorized and becomes active. Radiator heating: Adjustment range 60°C-90°C, factory default 80°C Underfloor heating: Adjustment range 30°C-50°C, factory default 80°C Setting the minimal boiler temperature By pressing the key (6) user can set minimal boiler temperature. Minimal boiler temperature starts blinking. By pressing the key user can select the desired minimal boiler temperature. Temperature changes in steps of 1°C. If the key is depressed for more than 5s, value on the display will be memorized and becomes active. Radiator heating: Adjustment range 20°C-45°C, factory default 45°C Underfloor heating: Adjustment range 15°C-30°C, factory default 30°C Setting the heating pump delay By pressing key (6) user can change pump delay time between 0 - 15 min. Factory settings is 2. Selecting the time delay between steps for power regulation By pressing the key (6) user can change the time delay between step for power regulation in the range from 5 to 60 seconds. Default value depends on the number of stages for power regulation – each stage will add 5 seconds. 3 stages will have 3*5=15 seconds between successive stages turn-on. Turn of delay is fixed to 1 second. Selecting the number of steps for power regulation By pressing the key (6) servicer can change the number of steps for power regulation. By pressing the key it is possible to select 1 to 3 steps for power regulation. Default settings: 3 power levels. Change in the number of stages will cause time delay parameter to be changed (see above) ! Selecting the number of pumps for controlling By pressing the key (6) servicer can change the number of pumps, one or two – only for option control panel “Z“

Figure 13 - Control panel “Z” - OPTION Figure 14 - Hydraulic sketch for TermoMini with OPTION control panel type “Z” 1. Multipurpose – temperature indicator (temperature of boiler, sanitary water, adjustment of temperature) 2. Signalization of operation degree of heaters (1., 2., 3.) 3. Signalization of air appearance in the boiler (red light) 4. Signalization of under voltage protection (red light) 5. Signalization of boiler operation (green light) 6. Adjustment of temperature in boiler 7. Switch for central heating switching on and off 8. Sanitary water temperature adjustment 9. Switch for switching on and off the sanitary water preparation 10. Signalization of sanitary water preparation and consumption 11. Indicator of pressure in a boiler 12. Thermal fuse

6. Maintenance 6.1. Periodic checking We recommend the inspection of the device once a year by the authorized service provider (before heating season). This service is not included in the warranty. During the inspection all electric and water connections should be tightened, the system should be vented and – if necessary – filled up, valves and general functionality of the device should be checked. RCCD switch - pressing the TEST button must disconnect the RCCD switch. This testing procedure insures that switch is functioning properly. We recommend this test once or twice in heating season. Safety valve should be checked once a year (before the beginning of heating season) to ensure proper functioning and avoiding appearance of water calculus. If the boiler is not connected to the room thermostat or if the boiler is out of function during the winter time, there is a danger of installation freezing. In this case the system should be filled with antifreeze liquid for central heating, and if this is not possible water should be drained out. 6.2. Cleaning It is not permitted to use aggressive media (e.g. gasoline, kerosene or solvent) for cleaning the product. Media for cleaning plastics or dishwashing media can be used for the external shell and decorative cover. Control panel should be cleaned with dry or moist cloth (not wet).

MALFUNCTION CAUSE ELIMINATION - there is no voltage on the control panel at switching on - there is no power supply from the net on one or more phases - fuse 100mA on the control panel is burned through - RCCB switch is disconnected - replace fuse 100mA and check the cause of burning - contact authorized service personnel to resolve the problem - By switching on, the switches on the control panel display the voltage, but the boiler does not heat - check the adjustment of the room thermostat, - limiting thermostat is activated - indicator of air presence in the boiler blocked the operation, - defective switch, - heaters are burned through - check the set temperature on the room thermostat, replace batteries, or the room thermostat is faulty, - vent the boiler in order to turn off the lamp “air in boiler” - temperature in boiler is on desired value, but radiators do not heat - circulation pump does not operate, - air stopper on central heating installation prevents circulation - vent installation - boiler does not provide enough heat - one phase is missing on supply - a part of heater is burned through - in a three-phase system the three different phases are not brought to the boiler - check fuses on the main panel, - contact authorized service personnel to resolve the problem - the switcher can be heard while operating (it buzzes) radio and TV- interferences - poor voltage in the net - defective relay - contact authorized service personnel to resolve the problem - boiler in operation “roars” - the system is not well vented, - defective heater - vent the system - contact authorized service personnel to resolve problem - pressure in the system varies - defective expansion vessel, - the vessel pressure is too low or too high - contact authorized service personnel to resolve the problem - the actual temperature in the boiler is higher than the desired temperature and the safety thermostat is activated - defective relays - contact authorized service personnel to resolve the exact source of the problem - RCCB switch disconnects - defective heater, - humidity on conductors, - safety thermostat is activated - check leakage, - contact authorized service personnel to resolve the exact source of the problem

cannot be reset - safety thermostat is activated - pre-reset safety thermostat and then the RCCB switch - contact authorized service personnel to resolve the exact source of the problem Table 7. Possible malfunctions