elco THISION WH Operation And Installation Manual
Operation and Installation manual
THISION WH
02/2011 DOC3078 / 12103187
Contents
Contents .................................................................. 3
General regulations ................................... 5
Application ................................................. 5
Norms and regulations .............................. 5
Construction Layout of water heater ............................... 7
Operating principle .................................... 7
Technical data ................................................................. 10
Water heater Installation .......................... 12
Connecting the water heater .................... 12
Commissioning Water and hydraulic system ...................... 17
Gas supply ................................................ 18
........................... 18
Flue and air intakeconnections ................. 18
Prepare water heater for first startup ........ 19
Combustion analysis ................................. 20
........... 21
Gas tightness check .................................. 21
Water heater shut down ............................ 21
Maintenance Checklist .................................................... 25
Replacing the electrodes ........................... 25
Cleaning the condensate receptacle ......... 26
Cleaning and refilling the syphon .............. 26
Inspection of the combustion chamber ...... 26
Water pressure and quality ....................... 27
Combustion analysis ................................. 27
Gas pressure ............................................. 27
Gas tightness check .................................. 27
Safety devices ........................................... 27
Maintenance Protocol ................................. 28
Loc
kouts
.................................................................. 22
Safety Provisions ...................................... 6
Thision WH principle ................................. 7
Unvented Applications .............................. 14
Cylinder diagnosis & controls .................... 19
Commissionign protocol ............................. 29
3
Condensate connections
Check functionality of safety devices
Cylinder venting .........................................
17
Safety
General regulations
Application
Norms and regulations
5
General regulations
This documentation contains important
information, which is a base for safe
and reliable installation, commissioning
and operation of the THISION L boiler.
All activities described in this document
may only be excecuted by authorized
companies.
Changes to this document may be effected without prior notice. We accept
no obligation to adapt previously delivered products to incorporate such
changes.
Only original spare parts may be used
when replacing components on the
boiler, otherwise warranty will be void.
Applic
ation
The THISION water heater may be
used for hot water production purpo-
ses only.
Norms and regulations
When installing and operating the
boiler, all applicable norms (european
and local) should be fulfilled:
Local building regulations for installing combustion air and flue gas systems;
Regulation for connecting the water
heater to the electrical appliance;
Regulations for connecting the water
heater to the local gas network;
Norms and regulations according to
safety equipment for heating systems;
Any
additional local laws/regulations
with regard to installing and operating
heating systems.
Additional national standards
Germany:
RAL - UZ 61 / DIN 4702-8
Switzerland:
SVGW
EKAS-Form. 1942: Flüssiggas-
Richtlinie Teil 2
Vorschriften der kantonalen Instanzen
(z.B. Feuerpoilizeivorschriften)
Netherlands:
GASKEUR BASIS
GASKEUR SV
GASKEUR HR107
Belgium:
HR TOP
The THISION L boiler is CE approved
and applies to the following European standards:
92 / 42 / EEC
Boiler efficiency directive
2009 / 142 / EEC
Gas appliance directive
2006 / 95 / EEC
L
ow voltage directiv
e
2004 / 108 / EEC
EMC directive
EN 483
Gas-fired central heating boilers Type C boilers of nominal heat input
not exceeding 70 kW
EN 15420
Gas-fired central heating boilers Type C boilers of nominal heat input
exceeding 70 kW, but not exceeding
1000 kW
EN 15417
Gas-fired central heating boilers Specific requirements for condensing
boilers with a nominal heat input
greater than 70 kW but not exceeding
1000 kW
EN 50165
Electrical equipment of non-electri
c
appliances for household and similar
purposes - Safety requirements
EN 15502-1
Gas-fired central heating boilers Part 1: General requirements and
tests
EN 55014-1 (2000)
Electromagnetic compatibility - Requirements for household appliances,
electric tools and similar apparatus Part 1: Emission
EN 55014-2 (1997)
Electromagnetic compatibili
ty - Requirements for household appliances,
electric tools and similar apparatus Part 2: Immunity - Product family
standard
EN 61000-3-2 (2000)
Electromagnetic compatibility (EMC) Part 3-2: Limits - Limits for harmonic
current emiss
ions (equipment input
current 16 A per phase)
EN 61000-3-3 (2001)
Electromagnetic compatibility (EMC) Part 3-3: Limitation of voltage
changes, voltage fluctuations and
flicker in public low-voltage supply
systems, for equipment with rated
current 16 A per phase and not subject to conditional connection
EN 60335-1 (2002)
Household and similar electrical appliances - Safety - Part 1: General requirements
EN 60335-2-102 (2006)
Household an similar electrical
appliances: Particular requirements
for gas, oil and solid-fuel burning appliance
s having electrical connections
Safety Provisions
Conditions
It is a statutory requirement that all gas appliances are installed in accordance with the manufactures instructions and
all current regulations in force, all instructions should be fully read before installing or using the appliance.
All installations should be carried out by competent persons as described in the Gas Safety (Installation & Use)
Regulations. i.e. GasSafe registered and holding current certification.
The work must be carried out by a competent person as described in the I.S. 813 Domestic Gas Installations with
reference to the following codes of practices.
The Manufacturers instructions MUST NOT be taken in any way as overriding statutory obligations.
This boiler has been tested and certified to comply with all necessary European directives, latest building regulations
and efficiency requirements for the SEDBUK scheme and as been approved with an efficiency band rating of A and
is CE marked and
complies with
92
/42/EEC Efficiency of Hot Water Boilers Directive
90/396/EEC Gas Appliance Directive
93/68/EEC Low Voltage Directive (was 73/23)
92/31/EEC Electromagnetic compatibility Directive
I.S. 813 Domestic Gas Installations
The Thision WH should be installed in compliance with
The building regulations (Scotland-consolidated)
Building Regulations (Northern Ireland)
Building Regulations
Water fittings regulations or water bylaws in Scotland
Local water company bylaws
The boiler should not be modified in any way. Any modifications will invalidate the gas approval and invalidate the warranty.
ATTENTION: High Voltage
Before opening the boiler casing for maintenance or servicing the 230VAC main supply to the boiler must be
disconnected!!
5
6
Construction
Layout of water heater
Operating principle
Layout of water heater
The THISION water heater consists
following main components:
1 Casing
2 Control panel
3 Flue gas connection (+ test point)
4 Air intake connection (+ test point)
5 Flow water connection
6 Return water connection
7 Gas connection
8 Syphon
9 Input for wiring
10 Connection for safety valve
11 Connection for fill/drain valve
12 Manometer
13 Fan
14 Gas valve
15 Ignition and ionisation electrodes
16 Heat exchanger
17 Inspection window
18 Ignition transformer
19 Electrical input connections
20 Controller
21 Condensate receptacle
Operating p
rinciple
The THISION WH is a fully modulating
water heater. The control unit of the
water heater adapts the modulation
ratio automatically to the heat demand
required. This is done by controlling the
speed of the fan. As a result, the whirlwind mixing system will adapt the gas
ratio to the chosen fan speed, in order to
maintain the best possible combustion
figures and therewith the best efficiency.
The flue gases created by the combustion
are transported downwards through the
heat exchanger and leave the boiler at
the top into the
chimney connection.
The return water from the system enters the boiler in the lower section,
where is the lowest flue gas temperature in the boiler. In this section condensation takes place. The water is
being transported upwards through the
heat exchanger, in order to leave the
boiler at the flow connection. The cross
flow working principle (water up, flue
gas down) ensures the most efficient
combustion results.
2
4
1
3
6 5
8 7
9
10 11
12
13
14
15
16
17
18
19
20
21
2
7
of the
The Thision WH is a standalone DHW charging system that
consists of a buffer tank, plate heatexchanger and a boiler.
The System is suitable for use in any building with
medium to large water usage, such as swimming pools,
gyms , sports clubs, fitness centres etc.
Hydraulic System Diagram
The Thision WH is a standalone unit that functions exceptionally.
Where there is a high demand for hot water there is an option
to connect two units together in parallel. It is essential that the
units are connected such that flow is distributed evenly through
both units
Caution!
The capacity of the built in water recirculation pump is
600 l/hr at the 20 kPa setting. The maximum loss of the
flow and recirculation system occurs at 65°C flow and
60°C return (3.kw). A greater loss will cause a lower
return temperature and therefore a longer loading
period.
Legend:
P1: Loading Pump
P2: Boiler Pump
T1: Loading Temperature Sensor
T2: Start Temperature Sensor
T3: Shut Down Temperature Sensor
T4: Primary Flow Temperaure Sensor
T5: Secondary Return Temperature Sensor
(optional sensor required)
Ensure that pipework is equal from both units to the
secondary flow and secondary return connection.
Thision Thision
Plan View of two Thisions in parallel
The Thision WH has been designed for ease of installation. For
the unit to provide DHW a minimum of the following is
required to be installed from the system to the unit:
1. 230Vac electrical supply
2. Mains cold water supply
3. DHWS secondary flow pipework
4. DHWS secondary return pipework
5. Gas supply pipework
6. Condense drain pipework
7. Flue gas outlet & Air intake pipework
8
Thision WH
Installing 2 Thision WH in parallel
T2
T5
T3
T4
T1
P1
P2
Secondary Return
Connection
Technical data
9
65
THISION L
85
THISION L
120
Nominal heat output at 80-60ºC max/min
kW 60.8/10.1 81.1/13.4 111.6/18.7
Nominal heat output at 75-60ºC max/min
kW 60.9/10.1 81.3/13.4 111.8/18.7
Nominal heat output at 40/30ºC max/min
kW 63.9/11.1 85.3/14.8 120.0/20.6
Nominal heat input Hi max/min
kW 62.4/10.4 83.3/13.8 114.3/19.2
Efficiency at 80/60ºC
% 97.4 97.4 97.6
Efficiency at 40/30ºC % 102.4 102.4 105.0
Annual efficiency (NNG 75/60ºC)
% 106.2 106.2 106.2
Annual efficiency (NNG 40/30ºC)
% >110 >110 >110
Standstill losses (T
water
= 70ºC) % 0.20 0.20 0.20
Max. condensate flow
l/h 3.5 4.8 7.7
Gas consumption H-gas max/min (10,9 kWh/m
3
) m3/h 5.7/1.0 7.6/1.3 10.5/1.8
Gas consumption L-gas max/min (8,34 kWh/m
3
) m3/h 7.5/1.2 10.0/1.7 13.7/2.3
Gas consumption LPG. max/min (12,8 kWh/kg)
kg/h 4.9/0.8 6.5/1.1 8.9/1.5
Gas pressure H-gas
mbar 20 20 20
Gas pressure L-gas
mbar 25 25 25
Gas pressure LPG
mbar 30/50 30/50 30/50
Maximum gas pressure
mbar 50 50 50
Flue gas temperature at 80/60ºC max/min
ºC 76/63 76/63 76/63
Flue gas temperature at 40/30ºC max/min
ºC 55/39 55/39 55/39
Flue gas quantity max/min
m
3
/h 119/19 159/25 213/35
CO
2
level natural gas H/E/L max/min % 8.5/8.5 8.5/8.5 8.7/8.5
CO
2
level liguid gas P max/min % -/- -/- -/-
NOx level
mg/kWh 39 39 39
CO level max/min
mg/kWh 98/7 98/7 98/7
Max. permissible flue resistance max/min
Pa 150/15 150/15 200/15
Water volume
l 3.5 4.8 7.7
Water pressure max/min
bar 6/1 6/1 6/1
Max. water temperature (High limit thermostat)
ºC 100 100 100
Maximum temperature setpoint
ºC 90 90 90
Nominal water flow at dT=20K
m
3
/h 2.6 3.4 4.8
Hydraulic resistance at nominal water flow
kPa 16 29 22
Electrical connection
V 230 230 230
Frequency
Hz 50 50 50
Mains connection fuse
A 10 10 10
IP class
- IPX4D IPX4D IPX4D
Power consumption boiler max/min (excl. pump)
W 98/26 167/38 228/36
Power consumption 3-step pump (optional)
W 150 205 210
Power consumption speed controlled pump (opt)
W 124 124 130
Weight (dry) with 250L cylinder
Noise level at 1 meter distance dB(A) - - -
-
Water connections
- R1.1/4" R1.1/4" R1.1/2"
Gas connection
- R3/4" R3/4" R1"
Flue gas connection
mm 100 100 100
Air intake connection (for room sealed use)
mm 100 100 100
Condensate connection
mm 22 22 22
CE-0063CM3576
kg
CE certification code
PH value condensate
Ionisation current minimum
-
µA 3 3 3
3.2 3.2 3.2
Weight (dry) with 500L cylinder kg
160
168 190
170 178 200
THISION L
Weight (wet) with 250L cylinder kg
Weight (wet) with 500L cylinder kg
413.5
422.8 447.7
673.5 682.8 707.7
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