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Summary of Contents for Thermasis CORTINA
- Page 1 Installation and User Manual Cortina-S-X ver.05 / Feb. 2021...
- Page 2 THIS MANUAL REFERS TO FOLLOWING CORTINA MODELS CORTINA 12S / CORTINA 12S-PACK / CORTINA 12X / CORTINA 12X-PACK CORTINA 18S / CORTINA 18S-PACK / CORTINA 18X / CORTINA 18X-PACK CORTINA 24S / CORTINA 24S-PACK / CORTINA 24X / CORTINA 24X-PACK...
- Page 3 Manufacturer’s Declaration of Conformity (EC) We, “BOYSIS MAKINE TAAHHUT SANAYI VE TICARET A.S.”, located at Şerifali Mahallesi Hüsrev Sokak No.2 Erişkenler Plaza Kat 3 34775 Ümraniye/İstanbul/Turkey (TR) hereby declare under our sole responsibility that Products Hot water boilers for pellets Models CT 12S / 18S / 24S / 32S / 40S CT 12X / 18X / 24X / 32X / 40X...
- Page 4 INTRODUCTION AND DELIVERY Cortina is a welded steel boiler designed for automatic burning of wood pellets to be used in hot water heating installations. Therefore, it can not be used for direct sanitary water supply. Main features and advantages of Cortina wood pellet boiler: •...
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Page 5: Warranty Conditions
WARRANTY CONDITIONS THE MANUFACTURER guarantees the product, with the exception of elements subject to normal wear (listed below), for a period of 2 (two) years; ▪ Starting from date of start-up, which is proven by a commissioning document that contains the name of the seller and the date when the sale / first start-up took place ▪... -
Page 6: Spare Parts
Any part that may be faulty as a result of negligence or careless use, incorrect maintenance or installation that does not comply with the manufacturer's instructions (see the relative chapters in user manuals of each product). The warranty will be rendered null and void in the event of damage caused by tampering, atmospheric agents, natural disasters, vandalism, electrical... -
Page 7: Safety Warnings
SAFETY WARNINGS 3.1 Basic safety instructions • Never get yourself into danger; give own safety the utmost priority. • Keep children away from the boiler room and fuel storage room. • Observe all instructions related to operation, maintenance, servicing and cleaning. •... - Page 8 WARNING – Risk of burns Do not touch the flue spigot or the flue gas tube. • Do not reach into the ash chamber. • Do not remove service cover due to volteged components under the cover • Do not clean the boiler until it has been allowed to cool down. •...
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Page 9: Technical Data
TECHNICAL DATA Cortina 12 / 18 / 24 / 32 / 40 Cortina 12-PACK / 18-PACK / 24-PACK / 32-PACK / 40-PACK... - Page 10 Models CT 12 CT 18 CT 24 CT 32 CT 40 Fuel specifications Wood pellets size 6 mm Fuel parameters shall comply to EN 14961 Boiler class Class 5 acc to EN 303/5 Operation mode With fan at flue exhaust working under pressure Maximum power output Minimum power output 10,2...
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Page 11: Installation
INSTALLATION 5.1 Handling the product Cortina is a heavy product, and care should be taken when carrying the boiler to the room where it is going to be installed. Carrying equipment of the product must be of enough capacity to support the boiler weight. - Page 12 Filling/draining port for S/X-PACK model 5.5 Rules for hydraulic circuit Cortina boiler can be installed in a pressurized heating circuit with addition of a closed expension tank in respect with one of the following schemes. If heat demand of building differs from the nominal capacity of boiler, we recommend a buffer tank between primary circuit and heating installation.
- Page 13 Globe valves (open) Cortina boiler Globe valves (closed) Boiler probe Check valve Buffer probe Strainer Return probe / Flow probe Safety valve Load valve / 3-way valve Manometer You can refer following hydraulic circuits diagrams with basic parameters attached: Configuration example 1...
- Page 14 Configuration example 3 Configuration example 4 Configuration 1 Configuration 2 Configuration 3 Configuration 4 On S/X-PACK models, circulation pump is installed on the return line. Above circuits are valid for X-PACK models as well, excluding pump and expansion vessel. You can install...
- Page 15 a thermostatic THREE-WAY LOAD VALVE to protect the boiler from condensation as shown below (one advice for this item, Regulus TCV3B with 55 C activation temperature) We recommend a buffer storage tank capacity of 25 to 50 litres per kW boiler output. For correct sizing of expansion tank, refer to calculations supplied by the manufacturer.
- Page 16 For this reason, minimum water pressure in a pressurized heating circuit must be above atmospheric pressure. Besides, pressure levelshould always be checked periodically. 5.6 Chimney connection Cortina boiler must be connected to an individual chimney that will provide at least the minimum draught requested.
- Page 17 5.7 Electrical installation The boiler is fed with 230 V. A regulator must be used in installations where the power supply is below 205 V or above 230 V. WARNING All electrical installations must be carried out by authorized persons in accordance with mandatory regulations and codes of practice.
- Page 18 Connecting CH and DHW pumps Use the socket given attached with the boiler to make the pump connection. Incorrect core termination can cause severe injuries and damage to the equipment. Take care not to interchange wires "L1" and "N". Recommended connecting cable H05VV-F3G 0.50 mm2 3-way valve connection If the 3-way valve connection is wanted remove the DHW pump cable connections...
- Page 19 If the external thermostat is not used don’t forget to bridge the terminals Boiler Control Panel Electrical Scheme WARNING • Before doing any work on the boiler related with electricity, ensure that the power supply cable is disconnected from the network electricity or turn off the main switch located at the back of the boiler •...
- Page 20 5.8 Optional accessories 5.8.1. Wi-fi module Thermasis 4HEAT wi-fi module can control all Cortina pellet boilers via smart phones or tablets (IOS and Android). It can be added to a boiler system, which is already installed, and only needs stable wi-fi network or ethernet connection. You can: ▪...
- Page 21 FUELS Wood pellets are natural wood (dried sawdust or waste from machining) that has been formed into pellets under high pressure. They have a very low moisture content and very high calorific value. 6.1 Pellet quality Pellets must comply with Class A1 or A2 according to one of the following standards: •...
- Page 22 • Use of unproper pellets in Cortina boiler can block air entrance to burner, can cause damage on boiler and chimney. Use of these kind fuels will make warranty of the boiler invalid. OPERATION INSTRUCTIONS FOR USER AND INSTALLERS 7.1 Control Panel buttons and leds •...
- Page 23 • Leds Description Button Function Heating Resistance Led On: Heating Resistance On Auger Led On: Auger in the On interval “ Led On: Pump On Valve Led On: Valve On Output V2 Led On: Output V2 On Output Aux2 Led On: Output Aux2 On Output Aux3 Led On: Output Aux3 On Pellet Level...
- Page 24 Browsing Menu: Push P3 button to enter in the User Menu. Using P4 and P6 buttons it is possible to select desired Menu or Submenu. Push P3 button to enter in the desired Menu or Submenu. The Setting menu consists of the parameter names (first/second row), the minimum, the maximum and the value (“Set”) current.
- Page 25 Load Menu to load the Auger This menu allows you to reset the message of Function 2 Reset Service Maintenance system. Summer - Winter Menu for modifying the plumbing plant functioning according to the season. On display appears one of these symbols: Chrono Menu Menu to set the time to turn on/off the system.
- Page 26 Program across midnight: set the hour of extinguishing of a day at 23:59 and set the hour of ignition for the next day at 00:00 • Weekly: program the times to switch on and off the system (there are 3 time slots). Daily Mon-Sun____________ Weekly...
- Page 27 Set Contrast ______ Contrast______ Set Minimum Light Push the buttons P4 and P6 to increase or decrease the contrast; P3 to save and exit, P1 to exit without save. Set Minimum Light This Menu allows setting the display light when any button is pushed. Set Minimum Light Set Contrast Set Minimum...
- Page 28 Switch ON the boiler with a long pushing of the button P2. Display on the LCD when the boiler is ON: 1. The Ignition is signalled by the word “ignition” 2. The Work state is signalled by the word “run mode” 3.
- Page 29 At the end of season, before shutting down the boiler, we recommend completely removing pellets from the hopper with the use of a vacuum cleaner with an extension. During periods of disuse, the boiler must be unplugged and placed in a dry place protected from the elements.
- Page 30 Er23 Boiler probe or Back boiler probe or probe Buffer open Er25 Engine cleaning broken Er26 Engine cleaning 2 broken Er27 Depression below the minimum threshold Er34 Depression above the maximum threshold Er52 Error Module I/O I2C Other Messages Displaying the status of the Temperature Sensors. The message is displayed during the check-up and indicates that the temperature reading on one or more probes is equal to the minimum value or the maximum value (depending on the Sond...
- Page 31 Auger Calibration Menu to change the Auger’s work time or speed. The system has 10 calibration’s steps (0 value is set by the factory). The calibration’s effect is valid only in Run Mode and Modulation for the current recipe. For each step the value is increased or decreased of a per cent value set in the Default Settings Menu.
- Page 32 Pre-Load A pre-defined starting dose of pellets is given into the burner by the auger. Variable Ignition This stage starts the ignition process. -The heat from the ignition element is directed at the pellets by the fan which runs at a relatively slow speed.
- Page 33 Standby / Extinguishing / OFF The system goes into STANDBY when the water in the buffer reaches its set temperature or the water in the boiler reaches its set temperature (whichever is sooner) and the system goes into an extinguishing mode. -The auger stops feeding pellets to the burner.
- Page 34 9.2. Cleaning the burner pot X-model burner has an auto grate cleaning system. However, both we recommend you to check ash and fuel residue on burner surfaces regularly. If you notice stucked air holes on burner surfaces, it should be cleaned. Remove cleaning cover shield, and open burning pot cleaning cover.
- Page 35 Fit the burner pot back again it original place: Cortina 18 to 40: Move ashes on the burner plate downwards onto bottom of boiler (where ashtray is loacted) using the same brush. Fit the burner pot back again it original place:...
- Page 36 CAUTION Before cleaning, let the boiler cool down completely leaving two hours after combustion terminated. Always wear a glove to protect your skin NOTICE When replacing the burner pot back in its, make sure that holes around burner pot flange corresponds with the pins on burner plate, and the feeding part has the clearance for pellts.
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Page 37: Maintenance
WARNING Do not take ash tray or ashes out of boiler, when they are hot MAINTENANCE We recommend an annual maintenance contract with an authorized after sale stuff approved by your dealer in your region. Before each new heating season, at least the following inspections and maintenance should be carried out: •... -
Page 38: Troubleshooting
TROUBLESHOOTING Error Code Cause Remedy ER 01 Pellet Thermostat tripped The pellet thermostat Check that the exhaust fan is running has detected heat Check for blockages in the flue, clear if found. travelling back up the Turn off power to the boiler drop tube into the burner Ensure the pellet drop tube is cool to the touch. - Page 39 Error Code Cause Remedy ER 04 Water Over Temperature The water in the boiler Check that the boiler is full of water by: has reached a Checking that the system is at the correct temperature of 95°C operating pressure (sealed systems only) Check the pump is working.
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Page 40: Revision Notes
REVISION NOTES Revision nr Revision date Revision detail 27.07.2017 All hydraulic schemes on Chapter 5.5 are modified together with item descriptions. Major parameter settings for each scheme are added. 09.12.2019 S and X versions collected in one single manual 23.02.2021 Warranty conditions updated, commissioning document added... - Page 41 START-UP / COMMISSIONING FORM END-USER INFORMATION NAME / SURNAME : _________________________________________________ ADDRESS : _________________________________________________ CITY / PROVINCE : _________________________________________________ COUNTRY : _________________________________________________ E-MAIL / GSM : _________________________________________________ SIGNATURE : _________________________________________________ PRODUCT INFORMATION PRODUCT MODEL : _________________________________________________ EXTRAS 1 : _________________________________________________ EXTRAS 2 : _________________________________________________ INVOICE DATE and...
- Page 42 START-UP / COMMISSIONING FORM General Checks Check Comments Wall plug voltage measurement _______V (AC) There is no damage because of transportation Chimney is clean, functioning well and meets the requirements defined in manuals Outputs are tested before start-up and working correctly Plumbing plant installation is made according to manuals, and necessary sensors are installed...
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