thermital THC 1000 GREY, Installation, Operation And Maintenance Manual

Page 1: ...THC 150 1450 GREY INSTALLATION OPERATION AND MAINTENANCE MANUAL ...

Page 2: ... comfort in the home for many years to come Arrange for your boiler to be serviced regularly by an authorised Technical As sistance Centre T Their personnel are specially trained to keep your boiler efficient and cheap to run They also stock any original spare parts that might be required This instruction manual contains important instructions and precautions that must be observed to ensure the ef...

Page 3: ...R 14 Putting into service 14 Preparing for extended periods of disuse 15 Cleaning 15 Maintenance 15 Useful information 16 INSTALLER 17 Unpacking the product 17 Overall dimensions and weights 18 Handling 18 Installation premises 19 Water in central heating systems 20 Water connections 22 Condensate evacuation 25 Neutralising the condensate 25 Hoses should also be fixed to the floor and suitably pro...

Page 4: ...afe and must ALWAYS accompany the boiler even if it is sold to another owner or transferred to another user or to another installation If you damage or lose this manual order a replacement immediately from your local T s Technical Assistance Centre Precautions The operation of any appliance that uses fuel electrical power and water demands that a number of fundamental safety pre cautions be respec...

Page 5: ...mbers for a smoother burner action and high temperature resistant stainless steel turbulators inside the tube bundle for maximum burner efficiency The boiler body is thoroughly insulated with a layer of high density glass wool The paint finished external panelling is also internally insulated with a layer of high density glass wool The boiler s front door and the flue gas chamber can be opened com...

Page 6: ...TOP for central heating 1 direct zone and 2 mixed zones and domestic hot water production with a single stage two stage or modulating burner Also for controlling solar heat ing system and cascaded boiler systems TECH CLIMA COMFORT for central heating 1 direct zone and 1 mixed zone and domestic hot water production with a sin gle stage burner Also for controlling solar heating system and cascaded b...

Page 7: ...S 25 M BLU TC FS1 3910510 x R RS 35 M BLU TC FS1 3910610 x R R Reference burner used during performance qualification tests to derive the technical data declared NOTE burners must be fitted with a gas ramp device b See the instruction manual provided with the burner Burner installation Electrical connections Burner adjustments b To assemble disassemble the burners equipped with recirculation tube ...

Page 8: ...max 1 7 1 7 1 5 1 5 Losses from casing with burner on 0 3 0 3 0 5 1 0 Constant pressure drop 300 420 540 700 W Flue gas temperature T 45 75 C Emissions at max heat input Nox 0 O2 80 mg kWh Flue gas mass flow rate Qmax 0 07 0 09 0 12 0 15 kg sec Furnace pressure 2 0 2 7 3 2 4 6 mbar Furnace volume 172 0 172 0 241 0 279 0 dm3 Tot volume of flue gas side 272 292 413 0 482 0 dm3 Heat exchange surface ...

Page 9: ...360 S PV 20067700 x R 20029111 RX 500 S PV 20077444 x R 20029111 R Reference burner used during performance qualification tests to derive the technical data declared NOTE burners must be fitted with a gas ramp device b See the instruction manual provided with the burner Burner installation Electrical connections Burner adjustments b To assemble disassemble the burners equipped with recirculation t...

Page 10: ... 0 3 0 3 0 5 1 0 Constant pressure drop 300 420 540 700 W Flue gas temperature T 45 75 C Emissions at max heat input Nox 0 O2 70 60 mg kWh Emissions at max heat input CO 0 mg kWh Flue gas mass flow rate Qmax 0 07 0 09 0 12 0 15 kg sec Furnace pressure 2 4 2 7 3 2 4 6 mbar Furnace volume 172 0 172 0 241 0 279 0 dm3 Tot volume of flue gas side 272 292 413 0 482 0 dm3 Heat exchange surface area 8 2 1...

Page 11: ... 160 M BLU TC FS1 3788006 x 4031187 RS 50 M MZ TC 3781622 x RS 70 M TC 3789610 x RS 100 M TC 3789710 x x RS 130 M TC 3789810 x RS 190 M TC 3787623 x GAS PREMIX RX 500 S PV 20077444 x 20067543 RX 850 S PV 20074219 x 20092252 RX 1000 S PV 20050087 x 20092252 RX 1000 S PV 20050087 x 20092252 NOTE burners must be fitted with a gas ramp device b See the instruction manual provided with the burner Burne...

Page 12: ...eturn at 30 C HCV 97 9 108 7 97 9 108 7 97 9 108 7 97 9 108 7 97 9 108 7 97 9 108 7 Losses from stack for sensible heat Qmax 1 9 Losses from casing with burner on 0 6 Constant pressure drop 0 2 Flue gas temperature T 45 75 C Flue gas mass flow rate Qmax 0 20 0 26 0 33 0 43 0 54 0 63 kg sec Furnace pressure 5 0 5 5 5 7 6 3 6 8 7 4 mbar Furnace volume 442 496 753 845 1037 1249 dm3 Tot volume of flue...

Page 13: ... 265 a Do not re use old burners if their blast tube lengths are below those specified in the table Identification The products are identified by Serial number plate This is located on the boiler body and specifies the serial num ber model and furnace power Data plate This lists the technical specifications and performance of the product It comes inside the documentation envelope On completion of ...

Page 14: ...Adjust the timer thermostat if installed or the tempera ture control to the desired temperature 20 C Turn the boiler s mains power switch ON Turn the control panel power switch ON and make sure that the green power indicator lights Make the settings as instructed in the instruction manu al for your control panel The burner should now ignite and remain in operation until the set temperature is reac...

Page 15: ...er gents a Never clean the boiler without first disconnecting it from the mains electricity supply by turning the mains power switch and the control panel switch OFF b The combustion chamber and flue pipes must be cleaned periodically by the manufacturer s Technical Assistance Centre or by a qualified heating engineer Maintenance Please remember that THE PERSON RESPONSIBLE FOR SYSTEM MANAGEMENT MU...

Page 16: ...ful information Seller Mr Address Tel Technical Assistance Centre Mr Address Tel Installer Mr Address Tel Date Work done Fuel oil supplier Mr Address Tel Date Quantity supplied Date Quantity supplied Date Quantity supplied Date Quantity supplied ...

Page 17: ...n of the installation Hydraulic test certificate Bar code labels Spare parts catalogue Ceramic insulation B Cleaning brush C b The instruction manuals are an integral part of the boil er therefore we recommend to read and keep them with care A C B 2 PANELLING CRATE complete with assembly accessories protected by cardboard packaging and a wooden crate b For the boiler to function correctly it must ...

Page 18: ...315 1450 1450 1630 1630 1910 1910 2030 2180 mm H1 Boiler height 1300 1300 1437 1437 1615 1615 1900 1900 2015 2167 mm D Height of burner plate 925 925 1030 1030 1235 1235 1390 1390 1495 1590 mm Weight of boiler 510 530 677 753 1095 1250 1870 2085 2515 3050 mm Weight of casing 50 50 60 70 90 120 140 160 215 230 kg Handling THC GREY T steel boilers are fitted with lifting at tachments Take great care...

Page 19: ... be installed according to stand ards NBN D51 003 NBN D30 003 NBN B61 002 heat output 70 kW and NBN B61 001 heat output 70 kW b When installing the boiler allow sufficient space around it to access all safety and control devices and to permit easy maintenance b If the specific weight of the gas supply to the burner is greater than the specific weight of air install all electrical parts at least 50...

Page 20: ...st all be put into service either contemporarily or with a very low rotation time during the initial period of service so as to evenly distribute the limited quantity of initial lime scale b A flushing cycle must be programmed after the plant has been installed to flush out any installation debris b Water used to fill a system for the first time and water used to top it up must always be filtered ...

Page 21: ...ar topping up with fresh water To eliminate contact between air and water and to prevent the latter from becoming oxidized it is necessary For the expansion system to be a closed vessel type correctly scaled and with the correct pre loading pres sure to be regularly checked For the installation to always be at a higher pressure than that of the atmosphere at any point comprising the pump suction s...

Page 22: ... the following table THC GREY 150 1250 models M M 7 6 5 H A N B 8 F E D C 2 3 4 1 76 I G L O THC GREY 1450 model M M 7 2 6 5 H I F 1370 G L O A N B E D C 2 8 3 4 1 b The choice of system components and the method of their installation are left up to the installer Installers must use their expertise to ensure proper installation and functioning in compliance with all applicable legislation b Circui...

Page 23: ...t to return 1 885 885 1050 1235 1400 1600 1800 2050 2200 2585 mm C Distance between heating returns 1 2 200 200 300 250 250 300 350 350 350 735 mm D Distance between heating return 2 and safe ty device fitting 285 285 300 450 600 700 750 850 850 850 mm E Distance between heating flow outlet and safety device fitting 400 400 450 535 550 600 700 855 1000 1000 mm F Distance between heating return 1 a...

Page 24: ...10 15 3 3 2 3 4 5 3 3 2 3 17 18 19 19 21 3 20 3 3 2 1 1 Boiler T THC GREY 2 Central heating system manifolds 3 Disconnect valves 4 System pumps 5 Non return valves 6 Automatic vent valve 7 Boiler safety valve 8 Boiler drain cock 9 Storage cylinder safety valve 10 System filling cock 11 CH expansion vessel 12 Remote controlled water tank T BSS 13 Storage cylinder drain cock 14 DHW expansion vessel ...

Page 25: ...ed condensa tion litres hour 54 180 Dimension mm 420x300x240 640x400x240 Q ty of granulate 25 kg 50 kg Fitting Ø 1 1 1 2 A B C The inlet fitting A of the N2 neutralisation unit the lower fitting must be connected to the boiler condensate drain fitting using the flexible hose C supplied This condensate drain hose is specially made to prevent combustion fumes escaping into the atmosphere The outlet ...

Page 26: ...be connected to the boiler room s waste water drain pit using another section of flexible hose not supplied b The connection pipes used must be as short and straight as possible and corrosion resistant Any curves or sharp bends can lead to the hoses becoming clogged and can therefore prevent proper condensate discharge If it is necessary to neutralise condensation produced in the chimney we recomm...

Page 27: ...ncrease combustion noise and affect combustion parameters b Joints must be sealed using suitable materials e g filler mastic or silicon based sealant b Uninsulated flues are potentially dangerous and can cause burns Installation in B23P configurationin The B23P configuration may only be adopted with premix gas burners The table below specifies maximum permissible flue back pressure Make sure that ...

Page 28: ...ket and two hinge fixing nuts System B on the larger sizes comes with a hinge fixing plate a nut and an internal compression spring A B A Smaller sizes system A Larger sizes system B Axis of door rotation Changing the direction of door opening The boiler door hinges are fitted on the right of the door in the factory If you need to reverse the direction of opening remove the boiler s side panel and...

Page 29: ...self supported by compression against the packing Remove the plug 1 taking care not to lose the compressed spring inserted in the threaded tube 2 3 4 2 3 6 6 5 6 5 6 4 4 4 Remove the bolt 3 and the nuts 4 Remove the nuts 4 that secure the hinge plate 5 to the door and remove the plate Remount the hinge plate on the opposite side ensuring that the cylinder projecting above the nut 6 enters into its...

Page 30: ...ed as follows Unscrew the nut and washer 1 from the earth terminal Attach the earth cable s eye connector 2 to the termi nal Make sure that the cable is of adequate size and complies with legislation in the country of installation Fit the nut and washer 1 to the earth terminal and tighten the nut Connect the other end of the cable to the system s earth bar 1 2 1 M6x30 brass b Another hole in the l...

Page 31: ... the boiler casing using the screws provided The front side panels 2 and 3 and rear side panels 4 and 5 over the boiler frame 1 and to the top side beams On models THC GREY 450 600 800 1000 1250 e 1450 also fit side panels 6 and 7 Secure the side panels in place using the top cross beams 8 and the screws provided Fit the top rear panel 9 the bottom rear bracket 10 and then the bottom rear panels 1...

Page 32: ...The water circuits have been properly bled The mains power connections to the boiler and its ac cessories burner pump control panel thermostats etc have been properly made b The phase neutral polarity has been respected b A ground earth connection is obligatory Initial startup Once you have completed all the preparatory steps proceed as follows to start up the boiler for the first time Turn the bo...

Page 33: ...re taken Set the boiler thermostat to the required setting making sure that the temperature control is in manual mode The control panel is switched OFF Set the room thermostat or timer to the required tem perature Make sure that there are no leaks around the boiler door seal If you detect any leakage of fumes increase the tightening of the door fixing bolts Make sure that all the pumps in the syst...

Page 34: ... seals System A Fit the door and tighten the main fixing bolts 1 until the seals start to compress Loosen the safety bolts 1 then fully screw in the main door fixing bolts 2 Make sure that the door is properly adjusted after every maintenance operation 3 System B Put the door in its correct position and tighten the main locking screws 2 until the packing starts to be com pressed b Make sure that t...

Page 35: ...ox through the opening of the inspection door 4 If more thorough cleaning is required remove the outer panels unscrew the eight fixing bolts and pull firmly on the flue gas box 5 to remove it from the boiler Check at regular intervals that the condensate drain 7 is not blocked 3 6 4 7 If necessary replace the seal 8 8 On completion of cleaning follow the above steps in the re verse order to refit ...

Page 36: ...y Air in the circuit Check the circuit pressure Check the vent valve The generator is at temperature but the heating system is cold Air in the circuit Bleed the circuit Pump malfunctioning Check unseize the pump Problem with minimum temperature thermostat if present Check the temperature setting There is a smell of fumes Fumes escaping into the air Clean the boiler body Clean the flue gas pipes Ch...

Page 37: ...37 ENGLISH TECHNICAL ASSISTANCE CENTRE TECHNICAL ASSISTANCE CENTRE ...

Page 38: ...38 ENGLISH TECHNICAL ASSISTANCE CENTRE TECHNICAL ASSISTANCE CENTRE ...

Page 39: ...39 ENGLISH TECHNICAL ASSISTANCE CENTRE TECHNICAL ASSISTANCE CENTRE ...

Page 40: ...Legnago VR www thermital it The manufacturer strives to continuously improve all products Appearance dimensions technical specifications standard equipment and accessories are therefore liable to modification without notice 068672EN Rev 32 04 17 ...