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CLAS PREMIUM

Comprehensive training manual covering operation, maintenance, and troubleshooting of condensing boilers. Learn about heating temperature ranges, control panel functions, heating requests, flame detection, modulation, and more.

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CLAS PREMIUM

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  1. Condensing boilers Training Manual GENUS PREMIUM CLAS PREMIUM

  2. 25 1 2 24 3 23 4 22 7 5 21 6 9 20 18 8 19 11 17 10 16 12 15 13 14 GENUS PREMIUM

  3. 25 1 2 24 3 23 4 22 7 5 21 6 9 20 18 8 19 11 17 10 16 12 15 13 14 CLAS PREMIUM

  4. 2 1 14 3 13 4 12 5 11 6 10 9 7 8 CONTROL PANEL GENUS PREMIUM

  5. A B W V U T S R Q P O N C D E M L K F H I J G DISPLAYGENUS PREMIUM

  6. 1 2 3 15 14 4 13 5 12 6 7 11 8 10 9 CONTROL PANELCLAS PREMIUM

  7. C.H. MODE

  8. C.H. MODE Parameter 4 20 : heating temperature range 1: 35÷82°C (high temp. - default) 0: 20÷45°C (low temp.) Parameter 4 25 : maximum heating temperatureParameter 4 26 : minimum heating temperature ZONE 1 Parameter 5 20 : heating temperature range 1: 35÷82°C (high temp. - default) 0: 20÷45°C (low temp.) Parameter 5 25 : maximum heating temperature Parameter 5 26 : minimum heating temperature ZONE 2 Parameter 6 20 : heating temperature range 1: 35÷82°C (high temp. - default) 0: 20÷45°C (low temp.) Parameter 6 25 : maximum heating temperature Parameter 6 26 : minimum heating temperature ZONE 3 (only with Clima Mananger)

  9. The heating request can be performed by: room thermostat 1, room thermostat 2, REMOCON and room sensor. Letter C will be displayed and then the delivery temperature (read by sensor NTC1) HEATING REQUEST When the boiler is at rest the valve is on the “sanitary” position. When heating is turned on the motor is supplied (inside shaft in), that closed the outlet of the secondary exchanger and puts pump intake in communication with the heating circuit ON the 3 Way-Valve The circulating device start is delayed 7 seconds after heating request in order to allow switching the 3 way valve; when it starts, the circulating device intakes the water coming from the heating system backflow and sends it to the primary exchanger PUMP ON

  10. To clean the combustion chamber, the ventilator is supplied at the maximum speed during pre-ventilation period 5 seconds. The same operation will be made after the burner OFF during 5 seconds Fan ON pre purge ventilation Fan ON pre purge ventilation Pre spark period Spark Generator ON + Ventilator at the soft ignition speed Pre spark period Spark Generator ON + Ventilator at the soft ignition speed To clean the ignition probes there is one pre spark period during and start as soon as finish the pre-ventilation period. In the same time the ventilator goes to the soft ignition speed. Gas valve ON The gas valve is supplied.

  11. Flame ionization is checked. (By the detection electrode). 1st attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be signalled 5 P1 and a second attempt will be made; 2nd attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be signalled 5 P2 3 rd attempt will be made ;3rd attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be shutdown 5 01 c with 40 seconds of post-ventilation at maximum speed and 2 minutes of post-circulation at minimum speed Flame detection CONTROL Ventilator at the ignition speed To stabilized the flame on the burner surface the ventilator stays at the ignition speed during a short period. The checking is made with heating return and delivery probes.ΔT del-ret and the delivery and return temperatures of the rising speed are checks. Only in the Genus P. the pressure is checked by a pressure sensor. Only in the Clas P. the pressure is checked by a pressure switch. WATER FLOW CHECK

  12. After flame detection the boiler is free to modulate the power according to the required thermal load. Modulation is carried out between the maximum heating power values (adjustable from the control panel with parameter 2 31)and the minimum power value (set made on the gas valve). The shut down temperature of the burner is operated as follows:1° min after flame detection: T off = T set-point + 8°C 2° min after flame detection: T off = T set-point + 6°Cstarting from the 3rd min after flame detection: T off = T set-point + 4°CWhen the burner switched off post ventilation for 5sec Max Switch off burner 88°C(fixed not adjustable) This logic is used to prevent the burner from shutting down too quickly with the system at temperature. Next ignition can be delayed from 0 to 7 minutes (default value = 3 min., adjustable from the control panel with parameter 2 36 ) FLAME MODULATION

  13. The pump has 2 speeds that are operated by the control of the heating delivery-return ΔT. It is operated as follows:ΔT del-ret < ΔT – 2°C → V2 pump speed Δt del- ret > ΔT → V3 pump speed where: ΔT= 20°C (default value can be set by parameter 2 39 between 10 and 30°C).Speed switching is carried out with a 5 minute delay (non-settable value) raising or diminishing. PUMP SPEED CONTROL • Performed from: • Produced till 27/08/2008:the thermostat with automatic reset (102±4°C) located on heating delivery (even while the burner if off). • Produced from 28/08/2008:delivery and return heating sensor to 102°C (even while the burner if off). • After a overheating a safety shot down occurs (not indicated) and after 5 sec if there is already a block shutdown of the boiler occurs (non volatile), indicated on the display with 1 01 OVERHEAT CONTROL

  14. D.H.W. FUNCTIONING

  15. 3-WAY VALVE Heating ON Heating OFF Switch shaft position Shaft position is OK A demand for Domestic hot water, is detected by the proportional flow meter. Now the boiler will be working on the SANITARY mode. The display will show letter d with the set temperature value DEMAND FOR D.H.W. When the boiler is on stand-by the valve is already on the SANITARY position. If there is a demand while the boiler is operating on HEATING mode, the three- way valve will be switched on SANITARY. During this passage the circulating device and the burner remain on. The outlet of the plate exchanger will be in communication with the pump intake directed towards the primary exchanger.

  16. In the same time: The pump (set automatically on maximum speed), intakes water coming from the outlet of the secondary and sends it to the primary exchanger. The ventilator is supplied at the soft ignition speed. The spark generator is supplied to clean the ignition probes. PUMP ON FAN ON SPARK ON Gas valve is supplied Gas valve ON Flame ionization is checked. (By the detection electrode). 1st attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be signalled 5 P1 and a second attempt will be made; 2nd attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be signalled 5 P2 3 rd attempt will be made ;3rd attempt with the power of slow ignition, if at the end of the safety time (8 sec) the flame has not been detected it will be shutdown 5 01with 40 seconds of post-ventilation at maximum speed and 2 minutes of post-circulation at minimum speed Flame detection CONTROL

  17. The check is made with heating return and delivery probes.ΔT del-ret and the delivery and backflow temperatures of the rising speed are checks. The pressure is checked by a pressure sensor. Only in the Genus P. the pressure is checked by a pressure sensor. Only in the Clas P. the pressure is checked by a pressure switch. WATER FLOW CHECK The burner output is modulated varying the VENTILATOR rpm between the minimum to the maximum speed. The burner runs until the scale prevention temperature is reached. The temperature is checked by the sanitary probe NTCs. FLAME MODULATION

  18. Performed from: • Produced till 27/08/2008:the thermostat with automatic reset (102±4°C) located on heating delivery (even while the burner if off). • Produced from 28/08/2008:delivery and return heating sensor to 102°C (even while the burner if off). • After a overheating a safety shot down occurs (not indicated) and after 5 sec if there is already a block shutdown of the boiler occurs (non volatile), indicated on the display with 1 01 OVERHEAT CONTROL To reduce the formation of scale in the secondary exchanger. During the D.H.W. modethe switch off andswitch on of the burnerdepends on the following values of temperature T set Temp. Antiscale. RE-Start NTC1 (NTC Delivery ) Non influente 85°C 81°C T set Temp. Antiscale. RE-Start NTCs (NTC DHW) > 52°C 65°C 64°C < 52°C 62°C 61°C SCALE PREVENTION temperature • N.B.: The sanitary switch-off logic could be changed by the parameter2 53: • 0 : Anti-scale (62 o 65°C)  default • 1 : Set-point + 4°C

  19. CLAS SYSTEM - TANK VERSION Parameter 2 28 1 (tank mode) The setting of the tank temperature (SET-POINT) is done through parameter 3 00

  20. CLAS SYSTEM - TANK VERSION A B

  21. CLAS SYSTEM - TANK VERSION Sanitary sensor (NTCs): Temperature range 40-60°C. The control of the temperature of the tank is managed in the following way: T tank ≥ T set : off burner, off pump T tank ≤ T set – Thyst : on burner, on pump where: Thyst=(T impostata/4)-5 T tank > (T set – Thyst)-1: burner on a the minimum power, independently from the flow temperature (NTC1) T tank≥80°C: safety shut down 209, that disappear when the temperature go down 75°C Flow heating sensor (NTC1): The PCB manages the flow temperature (NTC1) in the following way: T flow > 82°C : start modulation; T flow ≥ 86°C : burner off, pump on (on continuous) T flow ≤ 82°C : burner on

  22. CLAS SYSTEM - SYSTEM VERSION Parameter 2 28 2 (system mode) The tank temperature is manage thorough mechanical thermostat (ON/OFF). Flow heating sensor (NTC1): The PCB manages the flow temperature (NTC1) in the following way: T flow > 82°C : start modulation; T flow ≥ 86°C : burner off, pump on (on continuous) T flow ≤ 82°C : burner on

  23. SPECIAL FUNCTION • FLUE CLEANER” FUNCTION • COMFORT • ANTIFREEZE • WATER FLOW CHECK • AIR PURGE • SELF ADAPTIVE RESTART DELAY • AUTOFILLING (Genus Plus)

  24. FLUE CLEANER FUNCTION • This function is used to perform proper boiler combustion analysis and maximum and minimum gas calibration. Pressing the key reset for 5 sec will start two possible conditions: • Boiler on “Winter” mode, the 3-way valves is positioned on “heating” and the burner turns on even without heating requested. • Boiler on “Summer” mode, the burner turns on with the 3 way valve in Heating position and is possible to work also in DHW after opening the tap (cooling the system) • GENUS PREMIUM CLAS PREMIUM • To exit the “Flue cleaner” function press the RESET button. However after 10 minutes the function will be disabled automatically.

  25. This function reduces the hot sanitary water output time. The objective is reached by keeping the primary circuit in the boiler. By the sensor NTC1 check the outlet temperature from the main exchanger . The burner start only to min. power and the temperature is regulated according to the DHW set-point. See the table ACTIVATION Push the Comfort bottom on the control panel (green led switch on in Clas or the text coming on the display Genus) and is possible through the parameter 2 50 to choose different mode to work: 0 : disabled 1 : enabled for 30 minutes after sanitary request 2 : Enable constantly for one comfort selection. When is pushed the disable comfort the function come back to 1 position. During the Comfort function the display show the temperature read by NTC1 probe COMFORT FUNCTION

  26. ANTIFREEZE FUNCTION If, after 20 minutes, the CONDITIONS described in the 1st CASE are still present (3°C<NTC1<8°C) automatically check the EVENTS of the 2nd CASE

  27. ANTIFREEZE FUNCTION • The “Antifreeze” function works also if the NTC1 is broken and the display show the error code1 10. In this case the function works according to the return probe NTC2 but the burner doesn’t start only the pump is supplied. • The “Antifreeze” function works also if the NTC2 is broken (but to be good the NTC1) and the display show the error code1 12. In this case the function works according to the return probe NTC1 but the burner doesn’t start only the pump run. • In case of errors 1 10 and 1 12 the burner doesn’t start because there isn’t the possibility to have the flow check control • ---------------------------------------------------------------------------------------------------------------- • The “Antifreeze” function works only with the pump when: • Blocking for5 01 no detect flame. • Blocking 1 01 overheating temperature. • Both cases the display will show the respective error code and not the activation of Antifreeze function F

  28. ANTIFREEZE FUNCTION Fxy xy= °C

  29. WATER FLOW CHECK

  30. WATER FLOW CHECK

  31. AUTO PURGE FUNCTION The function start pressing for 5” the ESC button OR Through the parameter 7 01 3 way valve in sanitary Pump on 60sec at V3 3 way valve in heating 3 way valve in heating Pump on 60sec at V3 Pump on 60sec at V3 Pump off 30 sec Pump off 30sec. Pump on 60sec. at V3 Pump on 60sec. at V3

  32. SELF ADAPTIVE RESTART DELAY With the parameter 2 35it is possible chose the heating restart delay type: • 0: manual; • 1: automatic. MANUAL: with the parameter 2 36it is possible set the heating restart delay between 0 and 7 min. AUTOMATIC: the heating restart delay is calculated in base of the heating set-point temperature, see table below:

  33. WIRING POWER SUPPLY Power Supply 230Vac Resistance : 10 kohm SUPPLY SHAFT DHW 2-1 OUT CH 2-3 IN TREE WAY VALVE 4 5 1 • LEGEND • 3-way valve motor locking clip • Clips 3-way valve motor • to fix the body • Shaft • Seal O-ring D.H.W.Function C.H. Function 3 2 To check the position of 3way valve look the following parameter: 8 24 0 D.H.W. 8 24 1 C.H.

  34. SANITARYEXCANGER 16 plates for all models Hot water from the main exchanger, flows into A, transferring its heat and flows out through B The cold water from the domestic hot water mains, passes through the domestic proportional flow meter (thus starting up the boiler in domestic hot water mode) flows into C, heat up and flows out through D, ready for use in the distribution network.

  35. PUMP • Pump Wilo MTSL 15/5 HE-2. (GENUS PREMIUM 24 till 27/08/2008) • Pump Wilo INMTSL 15/5 HE-2. (GENUS PREMIUM 24 28/08/2008) • Pump Wilo MTSL 15/6,7-2CLF 12. (GENUS PREMIUM 30 and 36) • The PCB manage the modulating pump on two different speed: • speed V2 (55w) and V3 (80w). • In “DHW” the pump works always on V.3 to allow a good heating exchanging • In “CH” the pump could work with two speed through the control of the heating ΔT and is managed in the follow mode: ΔT man-rit < ΔT – 2°C → V2 • ΔT man-rit > ΔT → V3 • ΔT= 20°C of default parameter 2 39 (range from 10 to 30°C)Speed switching is performed with a 5 minute delay (value that cannot be set) up or down. • It is possible to exclude the modulation pump with the parameter 2 38 • -0: speed Low fix; • 1: speed Hi fix; • 2: modulating. The anti-sticking system enables the circulating device and the 3-way valve for 15 sec. every 21 hours from the last operation.

  36. PUMP 8 230=off 1=low speed 2=Hi speed Pump parameters CH mode: 2 37  Post-Circolation after CH request 2 38 Modulation types (fix or variable) 2 39 ΔT Regulation ( from 10°C to 30°C) 8 23 = 2 (only to check) 8 23 = 1 (only to check) Pump parameters after DHW request:: 2 54  0 ► 30” (fan 5”) NTC1<75°C 3min (fan 3min.) NTC1>75°C 2 54 1► 3min (fan 3min.) 8 23 = o pump off 145 145 Vac: max speed 0 Vac: min speed Pins 5 e 6

  37. AUTOFILLING (only Genus Premium - NOT UK) P POBJECTIVE To enable the function look the parameter 2 48 2 48 0 Disable 2 481 Enable Default = 1 B B1 C PB A PINDICATION PMINIMUM t Function enabld 1 P4 1st filling cycle 10 sec 1 P5 Waiting time 3 sec Stabilizing time 13 sec 1 P6 2ND filling cycle Up to POBIECTIVE or at the maximum for 40 sec • POBJECTIVE = 1.2 bar (default value, can be set with parameter 2 42 (between 0.9 and 1.5 bar) • PINDICATION = 0.6 bar (default value, can be set with parameter 2 41 (between Pminimum and 0.8 bar) • PMINIMUM = 0.4 bar (default value, can be set with parameter 2 40 (between 0.3 and 0.4 bar) • (B-B1) Waiting time were there isn’t check but only to stabilize the water pressure • (B1- C) Waiting time were the system check if there are leakege in the Heating System, if into this time the pressure deacrese of 0,13 bar the boiler goes in lockout

  38. AUTOFILLING (only Genus Premium - NOT UK) P POBJECTIVE B B1 C PB A PINDICATION PMINIMUM t Function enabld 1 P4 1st filling cycle 10 sec 1 P5 Waiting time 3 sec Stabilizing time 13 sec 1 P6 2ND filling cycle Up to POBIECTIVE or at the maximum for 40 sec • If the heating pressure goes below of 0,6 bar the Auto filling function is enabled and on the display appear the icon and text “Filling needed” and if the button is pressed start thefunction. • 3 W. V. in CH position • Pump and Burner stops if was working • Start the Autofillig procedure, and the consequent pressure check, in case of fault 1 P5 • check of pressure stability and in case of fault (pressure decrement of 0.15 bar) errore1 P6 • If necessary a second attempt will be done to arrive at objective

  39. AUTOFILLING (only Genus Premium - NOT UK) Anti back-flow valve (DHW to CH) Resistance coil = 3,7 KΩ Power supply = 220Vac

  40. AUTOFILLING (only Genus Premium - NOT UK) To fill the heating circuit completely empty proceed as it is shown below A B C

  41. MANUAL FILLING(only Clas Premium)

  42. HEATING PRESSURE SENSOR(only Genus Premium) A heating pressure sensor measure the water pressure values into the boiler/heating circuit that is showed on the LCD display. It’s possible to exclude the functioning o the pressure sensor putting the parameter 2 47 = 0 When the heating pressure goes below the advising the display shows the warning. There are two pressure warning 1 P4 and 1 08.With the error 1 08 need to fill the boiler till the normal value. Average Value: 0 bar = 0,3 Vdc 1.5 bar = 2,5 Vdc 3 bar = 4,8 Vdc Heating pressure configuration 2 47 0Clas model (ΔT probes) 2 471Egis model (pressure switch) 2 47 2 Genus (pressure sensor) Voltage measured = 0 Vdc (wires sensor not connected or short circuit) Voltage measured = 5 Vdc (wires inverted) Error code1 02

  43. Heating minimum pressure switch(only Clas Premium) The minimum pressure switch verifies the pressure in the heating circuit, with micro-switch ON/OFF. The settino are: OFF: 0,4 bar; ON: 0,6 bar. When it opens there is the safety shout down1 08

  44. CONDENSATION TRAP and DRAIN VALVE The condensation trap is integrated in the boiler, and located in front of flow part of hydraulic group. It can be accessed from the outside of the case, without opening the air chamber. N.B. Remember to fill the trap before commissioning the boiler. To empty the system turn the proper tap positioned on the lower part of the boiler anti-clockwise

  45. BY – PASS and HEATING FILTER HEATING FILTER By-pass VALVE

  46. PRIMARY EXCHANGER UNIT The generator is made with stainless steel smooth pipes (material: 304L. Diameter: 18 mm,Thickness: 0,8 mm). In order to have a maximum thermal exchange, the tubes are flattened and clamped to 6 mm. Bosses are used to maintain the distance between each coil (1,5 mm to 2 mm). The coils are series-mounted in parallel, two by two. One thermal fuse protects the primary exchanger. When the fume temperature is more than 167°C, the thermal fuse contact is opened and the defect 6 10 appears on the display.

  47. A B C D SANITARY PROPORTIONAL FLOW METER When turned on sanitary mode, the flow of water passes through the turbine that allows the PCB to measure the flow by means of a reed sensor. When there are variations of sanitary flow, through the measurement of the proportional flow meter, the PCB anticipates the gas opening or closing, to reduce the temperature oscillations. A cold water inlet filter is built-in the sanitary flow meter to stop impurities from getting in. There is also an anti-hammer device (trough the PCB) that can be set by parameter 2 52 between 0.5 sec and 20 sec (default 0.5 sec). You can see the sanitary flow by means of parameter 8 25and by INFO button. Reed sensor 0Vdc = no flow 5Vdc = no flow Tra 2Vdc e 3Vdc = flow DHW parameters2 52Anti water hammering delay 2 53 Sanitary switch off logic (MTS or C&M)2 55Heating start delay after sanitary request 8 25 DHW flow value lt/m 8 33 DHW temperature outlet °C

  48. PROBES PARAMETERS 2 53 Sanitary switch off logic (MTS or C&M) 2 55Heating start delay after sanitary request CHECK VALUES 8 25DHW flow value lt/m 8 31  NTC1 temperature 8 32  NTC2 temperature 8 33 DHW temperature outlet °C To check the delivery and return temperature use the two contact sensor. To read the sanitary water temperature the immersion sensor located on the sanitary outlet is used. If the NTCs sensor does not work properly the temperature will be checked by sensor NTC2 if the NTC1 sensor does not work properly the antifreeze function will be checked by sensor NTC2 (only pump circulation). Limit Temperature 88°C on NTC1

  49. BURNER UNIT

  50. 2 1 3 BURNER UNIT The cylindrical stainless steel premix burner pot Ø 70 mm is made up of a small-diameter perforated external casing on which the combustion occurs. a large-diameter perforated internal casing that balances the propagation of the gas. This burner can be used with natural gas and LPG.

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