Euroheat thermodual tda 30, Installation & Servicing Instructions Manual

Page 1: ...Installation Servicing Instructions Thermodual TDA 30 40 www euroheat co uk Part Number Serial Number ...

Page 2: ... boiler is installed We reserve the right to make changes which may then deviate from the technical details and illustrations in this operating manual 1 1 Structure of the Installation Manual NOTES ON THIS MANUAL This explains how to use this operating manual SAFETY NOTES This explains everything on the subject of safety that you should consider when using the heating system PLANNING AND INSTALLAT...

Page 3: ...ting manual SHT Austria does not assume any liability for this APPLICATION OF THE HEATING SYSTEM The heating system TDA Thermodual is designed for the use of wood pellets conforming to EN Plus standard and split logs w 30 materials not suitable for combustion are wood dust wood chips solid liquid or gaseous fossil fuels etc In addition no PVC containing waste products cardboard containers paper co...

Page 4: ...n necessary Opening doors and lids to hot combustion residues can pose the danger of fires Keep the openings closed during operation and when performing cleaning work allow the combustion residue to cool down before you place them in a fireproof container The boiler weighs over 750kg If the boiler is dropped during transport persons can be seriously injured and the boiler can be damaged Make sure ...

Page 5: ... 1 Y 1K2422 Casing complete including TC3 wiring loom 1 Y 8A4230 Thermocontrol panel TC3 1 Y 8A4240 Thermocontrol IO circuit board TC3 1 Y B21025 EW1 extension module 1 Y 4A2216 Immersion sensor 3 N 4A4210 External sensor AF200 1 N 4A4212 Flow sensor VF202 2 N 2X4305 Insulated glove 2 N 2X2516 Round brush 48 x 100 x 1200mm 1 N A21002 Cleaning set VN 22 55 1 N Please check your appliance carefully ...

Page 6: ...Installation Manual 6 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions TDA rear view with casing TDA right side view with casing TDA front view with casing TDA left side view with casing 4 Technical Data ...

Page 7: ... 1184 T1 1220 1220 B B1 865 852 865 852 H 1594 1594 A 1322 1322 C 830 830 D 563 563 E Filling door opening 400 400 F 337 337 Boiler weight kg approx 780 approx 780 Ø Flue pipe mm 150 150 Draught requirement Pa 15 15 Heating surface m2 2 1 2 1 G Supply and return Inch 5 4 5 4 G Safety supply and return 3 4 3 4 The type tested capacity range is to be inferred from the original test certificates and ...

Page 8: ...ther the filling door and ash door are closed Log loading door The filling door must be opened to insert firewood Log loading space Firewood is inserted into the filling space Secondary combustion chamber Unburnt gases are burnt in the secondary combustion chamber Ignition element The ignition element ensures automatic ignition of the pellets firewood Primary air flap The primary air required for ...

Page 9: ... 5 Description 1 Rear panel 2 Base plate and insulation pad 3 Left hand side panel 4 Right hand side panel 5 Control panel bracket 6 Control panel 7 Side cover 8 Filling plate 9 Control unit cover 10 Design element and protective cover 11 Front lid and insulation pad 12 Rear lid and insulation pad 13 Rear cover flame sensor cover 14 Ash tray ...

Page 10: ...allation Servicing Instructions A C C B B Legend TDA 30 40 A 2875 B 2260 C 2500 Legend TDA 30 40 A 3270 B 2750 C 2357 6 1 Minimum Boiler Room Sizing with Single 2500 Litre Accumulator 6 Boiler Room Sizing 6 2 Minimum Boiler Room Sizing with Twin 1250 Litre Accumulators ...

Page 11: ...e pellet hopper 1325 Minimum room width with manual fill pellet hopper 1820 Minimum room width with intermediate pellet hopper 1725 Minimum room depth 2357 Minimum room height 2100 Please note the above dimensions do not include the accumulator or expansion vessel If siting the accumulator in the boiler room then the necessary dimensions will need to be increased respectively including room height...

Page 12: ...00 E Width with Vario auger system 1127 Minimum room width with Vario auger system 2077 Minimum room depth 2357 Minimum room height 2100 Please note the above dimensions do not include the accumulator or expansion vessel If siting the accumulator in the boiler room then the necessary dimensions will need to be increased respectively including room height 6 4 Minimum Clearances Vario Flexible Auger...

Page 13: ... a Places of Special Fire Hazard it has to be treated as a separate compartment and the materials used for the lining of the walls and ceilings for fire protection must meet the National Class1 or European class C s3 d2 Any wall or floor between a garage and a house must have 30 minutes fire resistance with a self closing door and must be classed as smoke sealed along its jambs and head Any servic...

Page 14: ...he pallet At least two persons should always lift the boiler off the pallet Remove the top lid front and rear and top insulation slabs from the boiler Attach a suitable lifting hook to the two crane eyelets located on either side of the boiler The boiler can then be lifted using suitable lifting equipment forklift lifting frame Remove the base plate and insulation slab from underneath the boiler A...

Page 15: ...iler should be installed on a non combustible surface of a suitable construction Adjust the four legs on the base of the boiler so that it stands evenly or slightly raised to the rear 7 5 Siting the Boiler Adjustable Legs Place the ash tray in front of the assembled boiler 7 6 Fitting the Ash Tray ...

Page 16: ... of the boiler by using the adjustable screws on the feet of the hopper Insert the auger fully into the combustion chamber and secure firmly to the pellet insertion flange with the four bolts provided Connect the cable for the insertion motor 2 to the corresponding plug on the side panel of the boiler Connect the cable for the temperature sensor 13 to the corresponding plug on the side panel of th...

Page 17: ...r and ensure an airtight seal using a suitable high temperature sealant Drill through the flue starter stand and bolt to the two support brackets of the flue starter Mount the flue draught stabiliser onto the branch at the base flue starter Connect the drain plug on the base of the flue starter kit to a copper pipe and drain to waste 7 8 Connecting the Flue Starter Kit ...

Page 18: ...1233 Oct 2014 Edition 5 Installation Servicing Instructions Please see separate or instructions on connecting the Vario Flexible Auger or Visionconvey Screw Suction system 7 9 Connecting the Vario Flexible Auger or Visionconvey Suction system ...

Page 19: ...s with a clean boiler Always make sure that the flue gas can escape in a free and unhindered manner do not cover or block the chimney Flue gas must be able to escape through the chimney in such a way that the condensation of flue gas vapours in the chimney will not result in any damage It should be noted that flue gas temperatures below 160 C develop in the lower power range Therefore the heating ...

Page 20: ...tion 5 Installation Servicing Instructions 9 1 Basic Hydraulic Connections 9 Hydraulic Connections Heating circuit flow Heating circuit return Boiler safety set Auto air vent Thermal safety device Nickel cap valve Auto air vent Layering valve Pressure switch ...

Page 21: ...nual 9 2 Boiler Connections Key BF Boiler flow BR Boiler return TSF Thermal safety device flow TSS Thermal safety device sensor TSD Thermal safety device discharge DR Drain BF 1 1 4 BF 1 1 4 BR 1 1 4 BR 1 1 4 DR 1 2 TSS 1 2 TSD 3 4 TSF 3 4 830 563 1322 486 120 215 70 210 249 Ø 1 5 0 168 ...

Page 22: ...tions 9 3 Pipework Sizing The boiler to accumulator pipework should be a minimum of 32mm diameter 9 4 Boiler Flow and Return Opposite sides of the boiler must be used for the boiler flow and return to ensure sufficient heat transfer Ensure the unused connections are blanked off Option 1 Option 2 ...

Page 23: ...d into the sensor pockets to ensure an accurate connection Accumulator sensors are type KTY If the accumulator sensor cables require extending use only YSLY JZ signal and control cable 9 5 Accumulator Sensors Upper accumulator sensor position Lower accumulator sensor position Install the low pressure switch between the return temperature kit and boiler located on a branch above the pipe work as sh...

Page 24: ...diagram below Ensure the pump is mounted vertically to avoid pockets of air being trapped within 9 7 Return Temperature Kit Return from accumulator Flow to accumulator Return to boiler Flow from boiler Install the boiler safety set on a branch on the return temperature kit as shown below Ensure there are no shut off valves between the boiler safety set and boiler 9 8 Boiler Safety Set ...

Page 25: ...lve II III I Description I Return to boiler II Return from accumulator middle III Return from accumulator bottom Set Valve to normally open Description AB Return to boiler B Return from accumulator middle A Return from accumulator bottom Set valve to normally open AB B A Install auto air vents on all pipework where air may get trapped in the system Ensure the automatic air vents are installed vert...

Page 26: ...ty temperature sensor are inserted into the immersion sleeve on the same side as the boiler flow 9 11 Boiler Temperature Sensor and Safety Temperature Limiter Option 1 If utilising boiler flow on left hand side of boiler ensure the sensor pocket on the left hand of the boiler is utilised for the boiler temperature sensor and safety temperature sensor Option 2 If utilising boiler flow on right hand...

Page 27: ...agram A visible tundish must be installed in the boiler room on the drain of the thermal safety device The tundish can then be connected to waste 9 12 Thermal Safety Device Before installing on the system set the pressure on the expansion vessel to one bar The expansion vessel can then be installed as per the hydraulic diagram 9 13 Expansion Vessel Install the temperature gauges into the column of...

Page 28: ... 1 2 3 4 5 6 1 2 1 2 6 DOOR CLOSED SWITCHES 3 1 2 3 18 Not in use 17 INITIATOR PROXIMITY SWITCH 1 IGNITION 2 INSERTION AUGER 3 STORAGE AUGER 4 RS 485 DATA LINE TO BUSMODULE S 5 DISPLAY BOARD 6 DOOR CLOSED SWITCHES 7 TILTING GRATE 8 PRIMARY AIR FLAP 9 SECONDARY AIR FLAP 10 DRAFT FAN 11 SAFETY TEMPERATURE LIMITER 12 BOILER PUMP 13 TEMP PROBE INSERTION AUGER 14 TEMP PROBE BOILER 15 TEMP PROBE COMBUST...

Page 29: ...Mot valve boiler return Multi output MAINS Mandatory item to be connected by installer Optional item to be connected by installer if utilised by system The boiler requires a separate spur and supply line with a 13 amp fuse Fuse characteristics of the boiler are 10A type B Connect power to both the main control board into connection number 27 and the EW1 Extension Board connection number 58 10 3 Po...

Page 30: ...ation Manual 30 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions Accumulator sensors see 8 4 Return temperature kit see 8 6 Pressure switch see 8 5 Buffer layering valve see 8 8 Return temperature sensor see 8 7 ...

Page 31: ...ely The sensors should be located into the accumulator as illustrated below 10 4 Accumulator Sensors Upper accumulator sensor position Lower accumulator sensor position Connect the low pressure switch into the main control board input number 29 The low pressure switch should be located between the return temperature kit and boiler and located on a branch above the pipework 10 5 Low Pressure Switch...

Page 32: ...rature sensor should be located on the return to the boiler in an immersion sleeve in the main flow of water 10 7 Return Temperature Sensor The temperature sensor must always be in the water flow Connect the pump of the return temperature kit to the main control board output number 12 Connect the three way valve of the return temperature controller to the EW1 extension module output number 60 10 6...

Page 33: ... Valve II III I Description I Return to boiler II Return from accumulator middle III Return from accumulator bottom Set Valve to normally open Description AB Return to boiler B Return from accumulator middle A Return from accumulator bottom Set valve to normally open AB B A Valve set to normally closed Valve set to normally open Ensure the actuator is set to normally open see position of red tab a...

Page 34: ...4 Edition 5 Installation Servicing Instructions Install the outdoor temperature sensor in a shady location out of the wind and on the North side of the property Connect the sensor to the main control board input number 31 10 9 Outdoor Temperature Sensor ...

Page 35: ...SIHF 6 x 0 75mm L 3000 Mini Mate N Lok 6 poles 2 rows plug with bushing contact M Primary Air PA Label No 8 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 P3 P2 P1 CND Belimo LM24 5PO T C4 5k Silicon wire SIHF 6 x 0 75mm L 2300 Mini Mate N Lok 6 poles 2 rows plug with bushing contact M Electrical connection for primary air flap X8 Electrical connection for secondary air flap X9 11 1 Electrical connections of power...

Page 36: ...V AC M M3 PE L N N PE L Induced draught fan 10 Lambda probe with transfo 5 3 4 2 1 16 Mini Mate N Lock 6 pol connector Lambda cable 1 2 4 5 11 3 Electrical connection for flame sensor 11 4 Electrical connection for flame sensor Flame Probe X 15 Mini Mate N Lok 2 poles plug with bushing contact white green Silicon Wire green mantled 2500 Flamr Probe NiCrNi Flame sensor 15 Safety Temperature Limiter...

Page 37: ...2 1 16 Mini Mate N Lock 6 pol connector Lambda cable 1 2 4 5 Flame Probe X 15 Mini Mate N Lok 2 poles plug with bushing contact white green Silicon Wire green mantled 2500 Flamr Probe NiCrNi Flame sensor 15 Safety Temperature Limiter X11 1 2 3 4 1 2 C T1 STL 11 Boiler Sensor KTY81 210 X14 230V DC 1 2 F1 Boiler sensor 14 1 2 3 Draught Fan X10 230V AC M M3 PE L N N PE L Induced draught fan 10 Lambda...

Page 38: ...cing Instructions 11 7 Electrical connection for lambda sensor Safety Temperature Limiter X11 1 2 3 4 1 2 C T1 STL 11 Boiler Sensor KTY81 210 X14 230V DC 1 2 F1 Boiler sensor 14 PE L Lambda probe with transformer 16 6 5 3 4 2 1 16 Mini Mate N Lock 6 pol connector Lambda cable 1 2 4 5 ...

Page 39: ... 2 1 2 Mini Mate N Lok 2 poles plug with bushing contact Silicon wire SIHF 2 x 0 75mm L 3050 Mini Mate N Lok 2 poles adapter with pin contact Extension Ignition No 1 1 2 1 2 Mini Mate N Lok 2 poles plug with bushing contact Silicon wire SIHF 2 x 0 75mm L 2600 Mini Mate N Lok 2 poles adapter with pin contact Extension Insertion Sensor No 13 11 8 Electrical connections for insertion motor 11 9 Elect...

Page 40: ...r No 3 1 2 3 M Silicon wire SIHF 3 x 0 75mm L 2700 Tilting Magnet with Door Switch No 6 7 Connector Plug GDM Tilting Magnet 4 Com Com 5 3 3 TK 1 TK 2 Silicon wire SIHF 2 x 0 75mm L 750 Connector Mini Mate N Lok 5 poles plug with bushing contact TKS Wire End Cap TKS Type pizzato SHT Number Switch MV15 with 3D2410 Bushing VF C02 3D2412 11 11 Electrical connections for tipping grate and door contact ...

Page 41: ... output 24 Connect the pump of heating circuit 1 pump station to the main control board output 23 Connect a temperature sensor to the flow pipe on the heating side of the heating circuit 1 pump station Connect an analogue room device if used to the main control board input number 34 as follows SHT Analogue Room Device 1 M 2 F2 3 F1 12 1 Weather Compensated Heating Circuit 1 12 Optional Electrical ...

Page 42: ...he main control board output number 26 Connect the pump of heating circuit 2 pump station to the main control board output number 27 Connect a temperature sensor to the flow pipe on the heating side of the heating circuit 2 pump station to the main control board input number Connect an analogue room device if used to the main control board input number 33 as follows SHT Analogue Room Device 1 M 2 ...

Page 43: ...ated with a buffer accumulator tank Ensure there is always an adequate supply of fresh air in the central heating room When working on electrical electronic equipment such as the motor auger suction fan or on the control unit the on site main switch heating emergency switch must be switched off The pellet quality used must comply with the quality certificate EN plus based on the European Standard ...

Page 44: ...mperature is reached Before being operated the hydraulic system must be filled with water The system specific operating pressure lies between 1 0 bar and max 2 0 bar When working in sealed storage spaces and containers a second person must always be in attendance outside the storage space The doors must always be open when you enter the storage space and remain open The storage room must not be fi...

Page 45: ... in England In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries Separate legislation the Clean Air Northern Ireland Order 1981 applies in Northern Ireland Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been authorised in Regulations and that appliances used to burn solid fuel in those areas other ...

Page 46: ...TDA Thermodual Installation Manual 46 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions 14 Installation Notes ...

Page 47: ...IN1233 Edition 2 Installation Servicing Instructions 47 TDA Thermodual Installation Manual 14 Installation Notes ...

Page 48: ...ervicing Instruction Edition 2a January 2014 Part number IN1233 Copyright Euroheat Distributors HBS Ltd 2012 Inspiration and information 24 hours a day www euroheat co uk Wood burning stoves Wood biomass boilers Wood pellet stoves Space heaters Accessories Speak to one of our friendly team 01885 491100 British by design ...