62403278 - R03 aug.
SAFETY INSTRUCTIONS WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone.
SAFETY INSTRUCTIONS homeowner to save the installation manual near the heater so that service technicians may refer to it in the future. - These instructions must be read prior to installation. If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. - Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
TABLE OF CONTENTS 1 - GENERAL INFORMATION ................................................................ 6 1.1 - Key to the symbols used ...................................................................................... 6 1.2 - Warranty ................................................................................................................. 6 2 - GENERAL LAYOUT of the main components ................................ 7 3 - INSTALLATION ..........................................................
TABLE OF CONTENTS 3.29 - Accessing the internal components ................................................................ 41 3.30 - Converting the burner to use a different type of gas ..................................... 42 3.31 - Checking and adjusting the pressure of the gas supply ............................... 42 3.32 - Checking and adjusting the gas pressure at the burner ............................... 43 3.33 - Check CO2 level .....................................................................
1 - GENERAL INFORMATION This instruction manual refers to two types of heaters: When referring to this instruction manual, be sure of which type of heater you are AXIA 20E - this appliance working with. This can be is a wall mounted, direct vent verified by referring to the modulating space/water data plate marked “Space heater with input power rating water heater model” . This from 51,180 Btu/hr (15 kW) to data plate is located on the 90,000 Btu/hr (26.4 kW) bottom side of the heater.
2 - GENERAL LAYOUT of the main components 1 Connection for air intake in split system 2 Connection for coaxial pipe or for flue discharge in split system 3 Automatic air vent 4 Expansion tank 5 Gas valve 6 Safety relief valve 7 Circulator pump 8 Heat exchanger 9 Ignition module 10 Speed control board 11 Domestic hot water priority thermostat 12 Domestic hot water pipe 13 Domestic cold water pipe 14 Frame 15 Temperature-pressure gauge 16 Multifunction selector 17 Blower 18 Heater temperature control 20 Hig
3 - INSTALLATION 3.1 - PreInstallation control of the water pressure necessary in the system and the necessary measures for filling and for purging; inform the user on how to Installation must conform to the correctly set the temperatures requirements of the authority having and room thermostats to jurisdiction. In the absence of such conserve energy. requirements, installation must conform to: National Fuel Gas Code ANSI Z223.1/NFPA 54 and or CSA B149.1, Natural Gas and Propane Installation Code. 3.
3 - INSTALLATION 3.6 - Preparing to install the water heater Take the support bracket (see figure 2) and choose a position with proper clearances, as per Figure 4. CAUTION!!! When choosing a mounting surface for the heater. The weight of the heater with water is approximately 150 lbs (68 kg). Make certain that the wall can support such weight. Secure the bracket to the wall.
3 - INSTALLATION 3.8 - Supply and Return Piping The central heating supply and return pipes are marked with different colored caps, (supply red and return blue). If the heater is to be connected to an existing system it is advisable to wash out and remove any deposits from inside the existing pipes, and install a filter at the lowest point to trap any additional impurities when it is running. This equipment is designed for use in a closed loop system.
3 - INSTALLATION regulated to provide domestic hot water between 100°F (38°C) and 176°F (80°C). 3.17 - Water Hardness In hard water areas (above 150 Water p.p.m), it is recommended that a temperature over 125°F (52°C) can suitable water treatment device cause severe burns instantly. (softener with filters) be installed.
3 - INSTALLATION 3.20 - Connecting the supply, return, gas, cold water and hot water In its standard configuration, the heater comes with the fittings illustrated in figure 26. More information about this matter are in the next pages 3.21 - Safety relief valve An ASME approved safety relief valve, set at 30 psi (2 bar), is installed inside the heater. If the safety relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system.
3 - INSTALLATION 3.22 - Electrical connections connect the two ends of the Maintain the correct polarity cable to terminals 7 and 8; between live and neutral when connect the cable, using a connecting the heater. screwdriver to press down on the Ensure that the water and heating terminal block levers as shown in system pipes are not used as figure 8. ground plates for the electrical or telephone system.
3 - INSTALLATION 3.22.4 - Connecting the power supply cable To connect the electrical power cable, proceed as follows (refer to figures 6, 7, and 8): use a three-core cable with double isolation and a minimum cross section of 18 AWG (1.5 mm2); open the heater cover panels following the instructions given in chapter 3.
CE = Ignition module CS = Thermostat for C.S.B.
3 - INSTALLATION 3.22.6 - Multiwire electric diagram 16 Legend: see chapter 3.22.
3 - INSTALLATION 3.23 - Venting systems This heater can be fitted with either a concentric or split type venting system. The approved types of flue gas discharge configurations for this heater are shown in figure 9 Particular attention must be taken when installing the vent pipes that go through the wall to the outside. It must always be possible to carry out routine maintenance operations of the flue. The vent pipe must be installed in such a way that it can be removed, if needed, in the future.
3 - INSTALLATION 3.23.1 - Rotation of the flue discharge/air intake fittings The connection of the flue pipes to the heater can be rotated through 360°, in increments of 90°. This makes it possible to choose between 4 different relative positions (see figure 10) of the discharge and intake pipes, allowing for great versatility of installation. To carry out this operation (refer to figure 10): remove the fixing screws “A” from the top cover “B”. rotate the top cover to the desired position.
3 - INSTALLATION 3.23.2 - Kit for air intake/flue discharge To assist the installer, COSMOGAS has created flue kits, complete with all the necessary components for flue discharge and air intake. The four kits available are as follows: P/N 62617191 P/N 62617191. Split vent kit. This kit is used if you are taking the intake air from a different point than the flue gas discharge point. If you need additional extentions or elbows or other accessories, refer to figures 14, 15 and 16. P/N 62617186 P/N 62617186.
3 - INSTALLATION 3.23.3 - 80/80 split system Figure 11 - Installation of the 80/80 split system Figure 12 - Overall dimensions The heater is not supplied with fittings for the flue gas discharge/air intake connections. To connect the heater to an 80/80 split system it is necessary to order the special kit and install it as shown in figure 11. On the flue gas discharge side, it is recommended to install stainless steel pipes which are more resistant to the formation of condensation.
3 - INSTALLATION any other building openings (doors, windows, etc.) Do not place vent terminal where flue products can cause corrosion. CAUTION!!! All venting MUST be secured with screws, and MUST be sealed from flue or air leakage, see figure 13. CAUTION!!! The P/N 61302004 discharge vent temperature is above 250°F (121°C) while functioning, therefore it is essential that a thermal insulation protection sheath be used in the wall opening. 3.23.
3 - INSTALLATION 3.23.
3 - INSTALLATION 3.23.6 - 60/100 coaxial system The heater does not come with fittings for the flue gas discharge / air intake connection.
3 - INSTALLATION FIRST, insert the vent inner pipe into the vent elbow and tighten using self-tapping screws “N” SECOND, fit the outer pipe and secure it with proper screws “P” N = Screws provided O = Inner pipe P = Screws provided Q = This position shall be respected R = Discharge grid S = Intake grid CAUTION!!! Be careful when installing coaxial venting Proper assembly and installation of venting elbows and tubing must include the use of self-tapping screws to permanently secure in place the internal a
3 - INSTALLATION 3.23.
3 - INSTALLATION 3.23.
3 - INSTALLATION 3.23.9 - Combustion air supplied from inside Figure 24 - Installation examples of the air supplyed from inside with a split system If the heater is installed in a large open area such as a full basement or alcove, the combustion air can be supplied without the intake pipe, (See fig.24 and 25). The heater will draw all air for combustion through the top of the unit from the space around the heater. Ventilation should be adequate to provide sufficient air to properly support combustion.
3 - INSTALLATION 3.23.10 - Removing the condensation produced by flue gas discharge Due to the high efficiency of this heater, condensation will form in the discharge piping as a result of the cooling of the flue gases. It is therefore necessary to take every precaution to prevent this condensation from going inside the heater, by collecting it and removing it from the room. The condensation must be emptied in such a way as to avoid the release of flue gases into drains or the environment.
3 - INSTALLATION 3.24 - Water Connections Each heater contains a kit of accessories to help the installer make the water connections.
3 - INSTALLATION 1 2 By-pass valve 3 Heating drain cock 4 Radiators 5 Gas cock 6 Automatic feed 7 Safety Pressure relief valve (150 psi) 8 9 10 11 12 13 14 Back-flow preventer Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas supply Figure 27 - Hydraulic diagram of installation with radiators 30
1 Cosmogas combi 2 Heating drain cock 3 Sanitary drain cock 4 Gas cock 5 6 By-pass valve 7 Pressure relief valve, 150 psi 8 Radiator 9 Automatic feed 10 Back-flow preventer 11 Gas inlet 12 Mixing valve 13 Cold water inlet 14 Recirculating pump 15 Recirculating thermostat or timer 16 Recirculating return line 17 Hot water outlet 18 Cold water outlet 3 - INSTALLATION Figure 28 - Two heaters installation with domestic hot water recirculating system 31
1 2 3 4 5 6 7 8 Cosmogas combi Heating drain cocks Ball valves Gas cocks Back-flow preventer Supplementary expansione tank Manometer 9 Gas supply 10 Cold water inlet 11 Supply and return for central heating 12 Supply and return for eventual indirect water heater P1 Pump for central heating P2 Pump for indirect water heater VIC General automatic gas valve 3 - INSTALLATION Figure 29 - Three or more heaters installation with connection for indirect water heater 32
3 - INSTALLATION 1 Cosmogas combi 2 3 Heating Drain cock 4 Plate heat exchanger 5 Three ways valve 6 Floor protection thermostat set to 104°F (40°C) 7 Supplementary pump 8 Air vent 9 Radiant heating 10 Gas cock 11 12 13 14 15 16 17 18 19 20 21 22 Automatic feed Back flow preventer Pressure gauge Additional expantion tank Relief valve, 30 psi Pressure relief valve, 150 psi Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet Figure 30 - Example of heater installati
3 - INSTALLATION 1 2 3 4 5 6 7 8 9 10 11 Cosmogas combi Heating drain cock Pressure disconnector Flow checks Optional ball valve to isolate heater Supply piping to zones Gas cock Automatic feed Optional ball valve Back-flow preventer 12 13 14 15 16 17 18 19 20 21 22 Added system pump Optional ball valve Tees with drains to bleed zones Return piping from zones Pressure relief valve 150 psi Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet Figure 31 - Zoning wit
3 - INSTALLATION 1 2 3 4 5 6 7 8 9 10 Cosmogas combi Heating drain cock By-pass valve Optional ball valve to isolate heater Supply piping to zones Gas cock Automatic feed Ball valve Back-flow preventer 11 12 13 14 15 16 17 18 19 20 21 Zone valves Optional ball valve Tees with drains to bleed zones Return piping from zones Pressure relief valve, 150 psi Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet Figure 32 - Zoning with zone valves - Multizone hydronic pi
3 - INSTALLATION Connections inside junction box 11 Back-flow preventer 12 Circulating pumps 13 Ball valve to isolate zones 14 Tees with drains to bleed zones 15 Return piping from zones 16 17 I.W.H Aquastat or plate heat exchanger aquastat 18 Electrical three ways valve 19 Plate heat exchanger 20 Hot water outlet 21 Cold water inlet 22 Gas inlet 23 Hot water outlet from I.W.H.
3 - INSTALLATION Figure 34 - Indirect Water Heater and more pumps installation 37
3 - INSTALLATION Figure 35 - More pumps installation Figure 36 - Plate heat exchanger installation 38
3 - INSTALLATION External transformer 24V 115V Thermostat zone 1 External transformer 115V Thermostat zone 2 24V N COSMOGAS combi Heating thermostat zone 1 L COSMOGAS Combi 1 N Thermostat Thermostat 1 2 3 2 3 L Taco zone valves Heating zone valve 2 Heating zone valve 1 Figure 38 - Wiring diagram for taco zone valves End switch Zone valve 1 Motor Room thermostat zone 1 T87F thermostat 115VAC T87F thermostat 1 2 3 1 2 3 Figure 37 - Taco zone valves T87F thermostat Heating thermosta
3 - INSTALLATION 3.25 - Filling the heating system Fill the heating system using only cold water from the main water supply; proceed as follows: Check that the system has been filled and purged. The indicator on the pressure gauge “6” (see fig.48), should read between 15 and 25 psi (1 and 1.7 bar). If the pressure gauge reads below 15 psi (1 bar), open the automatic feed using the fast fill feature and allow the system to fill, untill the pressure gauge reads 25 psi (1.
3 - INSTALLATION 3.28 - Disassembling the cover panels To disassemble the cover panels, proceed as follows (refer to figure 41): unscrew the two “A” screws from the bottom of the front panel; pull the bottom of the front panel “B” out about 2 in. (5 cm); lift the front panel “B” out to release; release side panels “E” by swinging out front portion approximately 2 in. (5 cm); unscrew the “C” screws from the bottom panel and pull down panel section “D”. 3.
3 - INSTALLATION 3.30 - Converting the burner to use a different type of gas The conversion of the burner to use a different type of gas must be carried out by a qualified technician. CAUTION!!! If the available gas supply does not match the type of gas with which the heater can function, it is necessary to convert the appliance. To convert the heater from one gas type to another (NAT to LP or LP to NAT). The conversion kit is supplied together with the water heater. 3.
3 - INSTALLATION 3.32 - Checking 3.33 - Check CO2 and adjusting the level During normal operation at altitudes gas pressure at below 2000 ft (659 m), the CO2 (carbon dioxide) content of the the burner heater flue gases is given in table The gas pressure of the burner must match the values given in the table in chapter 8. The heater operates between two power levels, and therefore there are 2 values of burner pressure that must be checked, one for the maximum input rate and one for the minimum input rate.
3 - INSTALLATION 3.34 - Adjusting the input rating to the required heat loss The input rating of the heater can be varied anywhere between the minimum and maximum setting of the heater to meet the required heat loss of the space being heated. To adjust the input rating see diagram in paragraph 8.3 showing the correlation between the input rating with the gas pressure to the burner. This diagram can be applied to both NATURAL gas and LP gas.
4 - MAINTENANCE 4.1 - General cautions CAUTION !!! Maintenance must be performed by a qualified installer, service agency or the gas supplier. Maintenance should be carried out at least once a year, before the start of the winter season 4.
4 - MAINTENANCE 4.3 - Burner flame Periodically check the appearance of the burner flame. It should be uniformly distributed over the entire surface of the burner, it should be light blue in color, and the surface where combustion takes place should be black with incandescent red spots. 4.4 - Safety relief valves If the safety relief valves discharge periodically, this may be due to thermal expansion in a closed water supply system.
5 - USE IMPORTANT INFORMATION FOR THE USER - What to do when the smell of gas is present Turn the gas cock off and ventilate the room. Call a licensed authorized technician and, if necessary your local gas company. Follow the gas supplier’s instructions. If you cannot reach your gas supplier; call the fire department. - If water is leaking from the domestic water side: turn off the main cold water supply valve call a licensed authorized technician.
5 - USE 1 - Gas valve service switch 2 - High limit thermostat reset button 3 - Heater temperature control knob 4 - multifunction selector: A - OFF position B - Summer position, only DHW (green light ON) C - Winter position. DHW and space heating only when “C” orange light is ON D - Winter position, for safe money. DHW and space heating only when “C” orange light is ON E - Reset ignition module 5 - temperature gauge 6 - pressure gauge Figure 48 - Instrument panel 5.
5 - USE at minimum imput rate, in order to conserve energy. To use the heater more efficiently, it is recommended to set selector “4” to position “D”. If the winter is particularly cold, and the desired temperature inside the home can no longer be maintained, set selector “4” to position “C”. During winter operation, both the heating and the sanitary hot water functions are active. 5.
5 - USE programmed to start the heater when the room temperature drops below 47°F (8°C) If the heater will not be used for a prolonged period (over one year) we recommend draining the heating and domestic circuit using the procedure described in chapter 4.7 and 4.8, and closing gas supply cock. 5.14 - Precautions against freezing The heater is not protected against freezing.
6 - TROUBLESHOOTING 6.1 - Troubleshooting Sequence of operation to light the burner 51 All references to controls in this schema, unless specified otherwise, are referred to figure 48.
6 - TROUBLESHOOTING 6.2 - Troubleshooting Sequence of Operation for a Call for Heat All references to controls in this schema, unless specified otherwise, are referred to figure 48. 6.3 - Troubleshooting Sequence of Operation for a Call for D.H.W. All references to controls in this schema, unless specified otherwise, are referred to figure 48.
7 - SPARE PARTS Spare parts are available from your local authorized wholesale distributor. For a location of the one nearest you call Embassy Industries, Inc. at 631-694-1800.
8 - TECHNICAL DATA 8.
8 - TECHNICAL DATA Pressure (kPa) Pressure (ft H20) 8.2 - Curves of residual head for central heating system Where: 1 = first speed 2 = second speed 3 = third speed Flow rate (gal/min.) 8.3 - Curves burner pressureinput rating Input rating (kBtu/hr) Input rating (kW) Flow rate (lit/min) Where: A = AXIA 20E B = AXIA 29E Burner pressure (“WC) Burner pressure (mbar) Efficiency (%) 8.
FOR TECHNICAL SUPPORT CALL: Embassy Industries, Inc. 300 Smith Street Farmingdale, NY 11735 PH - 631-694-1800 Fax - 631-694-1832 www.embassyind.com sales@embassyind.com MANUFACTURED BY: COSMOGAS s.r.l. Via L. da Vinci 16 - 47014 MELDOLA (FC) ITALY info@cosmogas.com www.cosmogas.
