EN Installation Manual TWIN80C Wall hung, fan flue, room sealed, high efficiency gas boiler CHAPTER 1. GENERAL CHAPTER 2. INSTALLATION CHAPTER 3. COMMISSIONING CHAPTER 4. FAULT FINDING CHAPTER 5.
installation manual TWIN 80 EN CONTENTS CHAPTER 1. GENERAL 1.1. Technical data……………………………………………………………………………………………………………… 04 1.2. Dimensional sketch…………………………………………………………………………………….………………….. 05 1.3. Boiler layout…………………………………………………………………………………………….…………………… 06 1.4. Diagrams 1.4.1. Functional flow diagram………………………………………………………………….……………………. 08 1.4.2. Wiring diagram…………………………………………………………………………..…………………….. 09 1.5. Condensing boiler………………………………………………………………………………………………………….. 10 1.6. Operation 1.6.1. Display 1.6.
installation manual TWIN 80 EN 3.4. Chimney sweeper function 3.5. Gas/Air Ratio………………………………………………………………………………………………..……………….. 22 3.5.1. Pre-adjustment to be done in voltage-free condition: 3.5.2. Final Gas/Air adjustment (CO2 analysing) 3.6. Conversion to LPG…………………………………………………………………………………………………………. 23 3.7. MENU STRUCTURE……………………………………………………………………………………………………….. 24 3.7.1. Outdoor temperature sensor……………………………………………………………..…………………… 25 3.7.2.
installation manual TWIN 80 EN CHAPTER 1. GENERAL 1.1. Technical data Boiler type Gas type Electrical data 80C natural gas G20 Supply / Frequency LPG gas G30/G31 230 V / 50 Hz (195 ÷ 270V @ 47,5 ÷ 52,5Hz) Power consumption (max.) 280 W Thermostat voltage Dimensions and weight Emission value 24 Volt / OpenTherm / 0-10V Height 950 mm Width 710 mm Depth 360 mm Weight 65 kg CO2 8.2% - 8.8% 9.2% - 9.
installation manual TWIN 80 EN 1.2. Dimensional sketch Dimensions in mm Free space: There must be sufficient space at the top and bottom to be able to suspend the unit and to be able to connect all feed and drain pipes. Normally, roughly 300 mm is required. It is recommended to leave a free space of 150 mm on the left (for servicing reasons) and 50 mm on the right of the unit. The front of the unit must be easily accessible for servicing at all times.
installation manual TWIN 80 EN 1.3.
installation manual TWIN 80 EN pos 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 description Assembly frame Cover Flow collector Return collector Gas collector Unit type 40 Burner type 40 Pump Internal flow pipe Kst. pump type 40 Internal return pipe Kst.
installation manual TWIN 80 EN 1.4. Diagrams 1.4.1.
installation manual TWIN 80 EN 1.4.2.
installation manual TWIN 80 EN 1.5. Condensing boiler give their heat to the system water. The flue gases are fed outdoor, through the flue tube (F), into a combined flue tube exhaust canal. The formed condensation water (H2O) is discharged through the waste trap. The concentric air inlet and exhaust outlet need to be connected with one of the adapter sets. N00M990080 1.6.1. Display The display operates for both printed circuit boards.
installation manual TWIN 80 EN 1.9. Configurations 1.8. Permitted flue discharge and air supply resistance The total resistance of the flue tube and air supply together may not be greater than 125 Pa. Preferably use flue tube materials, roof ducts and exterior wall ducts with a quality mark. For the use of plastic exhaust pipes both units are protected with a flue gas temperature sensor. In normal operation the application may produce a visible white condensing “plume”.
installation manual TWIN 80 EN 1.10. Regulations In case of non-compliance with the regulations, no claims can be made against the guarantee conditions. General safety regulations The installation may only be performed by a recognised installer. Take note that internal parts of the unit can carry a dangerous electrical voltage (230 Volt). Take note that the unit, the various pipes and the flue gas exhausted by the unit can reach high temperatures (up to 90°C).
installation manual TWIN 80 EN • CHAPTER 2. INSTALLATION 2.1. Mounting Before unpacking the unit, check whether the type of gas to be used corresponds with the specification on the packing. If you have any questions, contact your supplier. • To prevent back injury, take account of the fact that the weight of the unit is roughly approx 65 kg. Care should be taken when unpacking and mounting the appliance.
installation manual TWIN 80 EN 2.3. WATER 2.2. GAS Both of the heat units are parallel jointed to central flow- and return water collectors. Make sure that the gas pipe work does not contain dirt, particularly with new pipes. Failure to install gas-appliances correctly could lead to accidents and prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with.
installation manual TWIN 80 EN 2.3.6. Condensation discharge 2.3.3. Expansion vessel In the central heating return pipe, as near as to the boiler, an expansion vessel must be fitted. The size of the expansion vessel must be determined on the basis of the central heating water temperature and the total water content the installation contains. Mounting: The siphon (packed with the boiler) fits onto the discharge pipe (Ø 32 mm) under the boiler.
installation manual TWIN 80 EN 2.4. PUMP 2.4.1. Unit system pump The TWIN 80C is equipped with 2x Wilo, type RS 15/7 internal circulation pumps. Depending of the cascade selection and heat demand one pump may run intermittent or both pumps may run simultaneously. Use with a low velocity header (open header) can also be selected. In this case a larger secondary sided water output has to be taken into account, in order to affect the height of the water temperature. Fig.
installation manual TWIN 80 EN 2.5. ELECTRICAL 2.5.1. Supply connection If a stationary appliance is not provided with a supply cord and a plug or with other means for disconnection from the supply having a contact separation of at least 3 mm in all poles, the instructions shall state that such means for disconnection must be incorporated in the fixed wiring.
installation manual TWIN 80 EN 2.6. Lay-out BIC992 2.6.1. Connectors & pinning X1 4-way Molex header 0.2” pitch X2 5-way Molex header 0.2” pitch X3 5-way Molex header 0.2” pitch X4 6-way Molex header 0.2” pitch X5 3-way Molex header 0.2” pitch X6 4-way Molex Minifit X7 4-way Molex header 0.2” pitch X8 6-way Molex header 0.
installation manual TWIN 80 EN 2.7. Green connector block The external regulations are to be connected to the green connector block. All connections are volt-free contacts. Therefore, do not connect any voltage to this block! 1. 2. 3. 4. Strip about 5 mm off the insulation of the wires of the connection concerned. Stick the stripped ends of the wires into connections of the connection block involved. Make sure that the wires do not make a short circuit. Firmly tighten the screws in the connection block.
installation manual TWIN 80 EN 2.8 Options with installer responsibility 2.8.2. 230 Volt room thermostat (installer responsibility) 2.8.1. All Coopra printed circuit boards have a terminal for connection of a line voltage 230 Volt room thermostat. • At present Coopra does not supply any connection cable for this option. Pinning TERMINAL X1 pin X1 1 2 3 4 PE = Earth N 230VAC room thermostat L 5 2.8.3.
installation manual TWIN 80 EN 3). Open the air bleed cocks of the radiators one at a time. Use an air bleed key for this. As soon as water comes out of the air bleed cock, shut the cock off again. CHAPTER 3. COMMISSIONING 3.1. Filling After venting of the system, the appliance and all pumps must be connected to the mains and be switched ON. If the unit is not yet filled with water, the display shows a flashing ‘P’ and the water pressure in bar. 3.4.
installation manual TWIN 80 EN 3.5.2. Final Gas/Air adjustment (CO2 analysing) The gas controls are set in the factory to the type of gas to be used. This type of gas is stated on the packaging and on the identification plate. To check the settings, you have to make a flue gas analysis. 3.5. Gas/Air Ratio Note that each unit has to be set according to the same procedure individually. Proceed as follows: (1).
installation manual TWIN 80 EN 3.6. Conversion to LPG First: Always screw the venturi adjusting screw fully clockwise until it blocks. High voltage! Fit a flue gas analyser (CO2 meter) in the measurement opening of the flue tube canal concerned. The wiring of the pump, the three-way valve, fan and wiring of the gas control can be under a voltage of 230 VAC.
installation manual TWIN 80 EN 3.7. MENU STRUCTURE • • • • Enter menu structure by pressing the Set/Reset button for 5 - 10 seconds. Change the parameter(left segment) by pressing the Set/Reset button once, shortly. Change the range value (two right segments) by pressing the “+” button or the “–“ button. To enter the view mode directly, press the “+” button for 5 – 10 seconds. The first upcoming reading is the system water pressure (8).
installation manual TWIN 80 EN 3.7.1.
installation manual TWIN 80 EN 3.8. CASCADE 3.8.1. Power mode (default) • • 3.8.2. Comfort mode (field adjustable) • • Menu parameter “o” = 01 (default) Both units run simultaneously. When the room thermostat or space unit indicates that heat is required for central or under floor heating, both units will heat simultaneously. The Master print calculates the system flow temperature and divides the necessary power over both units equally.
installation manual TWIN 80 EN CHAPTER 4. FAULT FINDING 4.1 Boiler states Burner is on - when the room thermostat is closed (heat demand) - and when the actual flow temperature is 5°C below the set point (desired central heating flow temperature) - and after 3 minutes anti-cycling time, if applicable, after a reciprocal stop.
installation manual TWIN 80 EN Pump monitoring: When the temperature difference between flow and return is greater than 30°C, the pump switches to a high speed. When the temperature difference drops below 10°C again, the pump switches back to a low speed. If the pump is on for a HWS demand (combi-boiler or external cylinder), the pump is continuously at high speed. System water pressure monitoring: If the system water pressure changes by more than ± 0.27 bar (and ± 0.
installation manual TWIN 80 EN 4.2. Status indications The left segment (A) indicates: • status code or • parameter value in menu mode The two right segments (B) indicate: • temperature or system water pressure or • parameter value (in menu mode) A dot on the status display indicates: The flame on burner is present. A = Status display B = Reading C = “+” button D = “-“ button E = Set/Reset F = Flame present 4.2.1.
installation manual TWIN 80 EN number d continuous b continuous C. continuous d. continuous b.
installation manual TWIN 80 EN 4.2.2. Status indication during “blocking action” What is a blocking action? The regulation blocks the burner till conditions are within certain requirements. During blocking operation, the display status shows a continuous indication. Each blocking action will stay during the 3 minutes anticycling time. Most blocking actions restore automatically. However, some need to be repaired or can be restored by interrupting the supply power.
installation manual TWIN 80 EN P/C continuous P/d continuous P/b continuous nc continuous Heating 1). low water-pressure (< 0.2 bar) 2). high water pressure (> 3.0 bar) DHW combi-boiler 1). low water-pressure (< 0.2 bar) 2). high water pressure (> 3.0 bar) HWS external cylinder 1). low water-pressure (< 0.2 bar) 2). high water pressure (> 3.0 bar) internal software blocking Ad 1). with water pressure below 0.2 bar, the regulation blocks with alternately a continuous P and the normal status.
installation manual TWIN 80 EN 4.2.3. Status indication during ”lock-out” - gas valve off - glow plug off - ionisation off - fan off (some lock-outs, post rinse for 1 minute) - pump on (max 24 hr) What is a lock-out? During lock-out operation, the display status shows a flashing indication. The regulation may lock-out for safety reason or after four consecutive failed start attempts. Most lock-out operations can be restored by pressing the ‘Set/Reset’ button.
installation manual TWIN 80 EN - If during standby a false flame signal is detected for more than 5 seconds, the boiler runs into lock-out 8 false flame signal flashing - If a false flame signal is detected with closed gas valve for more than 5 seconds, the boiler runs into lock-out check ionisation system - If a false flame signal is detected during pre-rinse / postrinse, the regulation blocks.
installation manual TWIN 80 EN 4.2.4.
installation manual TWIN 80 EN CHAPTER 5. PERIODICAL MAINTENANCE 5.4. Ionisation probe High voltage! When the unit burns on chimney sweeper function, the ionisation current can be read directly on the display. The wiring of the pump, the three-way valve, fan and wiring of the gas control can be under a voltage of 230 VAC. Correct ionisation current Full load: 6 µA DC to 13 µA DC Low load: 3 µA DC to 13 µA DC After the first year, have a certified installer or maintenance man inspect the appliance.
installation manual TWIN 80 EN (E000129016 - installation manual TWIN 80 EN - 030106v07 37
installation manual TWIN 80 EN (E000129016 - installation manual TWIN 80 EN - 030106v07 38
installation manual TWIN 80 EN (E000129016 - installation manual TWIN 80 EN - 030106v07 39
installation manual TWIN 80 EN 2007 Coopra Advanced Heating Technologies b.v. All rights reserved. Nothing from this document may be duplicated and/or made public by means of printing, photocopy, microfilm or in any other way without prior written permission from the manufacturer. This also applies to the appropriate drawings and/or diagrams.
