Thermaflow TH9-210U MRK 2, TH9-250U MRK 2, TH9-330U MRK 2, TH12-210U MRK 2, TH12-250U MRK 2 Instructions For Use Installation And Servicing
...
ELECTRIC COMBINATION BOILER
(European Patent No: 1757678. Design Right Protected.)
TH9- 210U, TH9-250U, TH9-330U MRK 2
TH12-210U, TH12-250U, TH12-330U MRK 2
INCLUDES THERMAL SOLAR & WOOD BURNING STOVE WITH WATER JACKET APPENDIX
This product is suitable for connection to ~230-240V, 50Hz
INSTRUCTIONS FOR USE, INSTALLATION AND
SERVICING
for all models with serial No beginning 4-
TO BE LEFT WITH THE USER
The instructions consist of three parts; User, Installation and Servicing instructions, which include the guarantee registration
card.
The instructions are an integral part of the appliance and must, to comply with the current issue of the building, electrical
regulations and water by-laws, be handed to the user on completion of the installation.
GUARANTEE REGISTRATION
Thank you for installing a new Thermaflow product in your home.
Thermal innovations appliances, are manufactured to the very highest standards so we are pleased to offer our customers, a
comprehensive first year guarantee and a second year parts guarantee.
In the instruction envelope is to be found your guarantee registration card, which must be completed and returned to Thermafl ow
Ltd or register your Thermaflow appliance for 1st year guarantee protection by calling the below number.
Our guarantee gives you peace of mind valuable protection against breakd own by covering the cost of-
All replacement parts
All labour charges
All call-out charges
THERMAFLOW LTD
31-39 Napier Court, Cumbernauld, Glasgow, G68 0LG
Customer services
Tel
+44 (0) 870 850 5207
Fax +44 (0) 870 850 5208
Web www.therm
Issue Number: 2b Issue date: February 2012
Copyright Notice
This document contains proprietary information protected by copyright, and this Manual and documentation are copyrighted. All rights are reserved. No part of this
document may be photocopied or reproduced by mechanical, electronic, or other means in any form without permission from Thermaflow Ltd.
Copyright Thermaflow Ltd 2006-12 -All rights reserved.
aflowheating.co.uk
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
Contents
Instructions General .................................................................................4
0.1
0.2 Draining & Filling ......................................................................................5
0.3 Manual Handling Guidance ......................................................................5
0.4 TESTING & CERTIFICATION ....................................................................5
0.5 THE UNIT LOCATION................................................................................5
0.6 Water Connections ...................................................................................6
PART1 – INSTRUCTIONS FOR USE ....................................................................7
1.1 INTRODUCTION.........................................................................................7
1.2 Domestic hot water temperature .............................................................7
1.3 To turn the boiler off .................................................................................7
1.4 Maintenance and servicing ......................................................................7
1.5 Clearances .................................................................................................7
1.6 Draining and filling....................................................................................8
1.7 Replacement parts ....................................................................................8
1.8 Thermaflow TH Model MK2 ......................................................................9
TABLE 1.8.1 [DATA]............................................................................................10
Part 2 – INSTALLATION..........................................................................................11
2.1.1 Sheet metal parts .......................................................................................11
2.1.2 Statutory requirements .............................................................................11
2.1.3 DATA 11
2.1.4 ELECTRICAL SUPPLY...............................................................................11
2.1.5 Electrical supply ........................................................................................12
2.1.6 Heating system controls ...........................................................................12
2.2.1 Boiler Position............................................................................................12
2.2.2 Boilers in a compartment..........................................................................13
2.2.3 Clearances allow for external primary heat transfer kit .........................14
2.3.1 General notes .............................................................................................14
2.3.2 Safety valve ................................................................................................14
2.3.3 Pressure & Temperature Gauge ...............................................................14
2.3.4 Pump 14
2.3.5 Expansion vessel.......................................................................................14
2.3.6 By- pass ......................................................................................................14
2.3.7 Filling sealed systems...............................................................................14
2.3.8 Corrosion inhibitor ....................................................................................14
2.3.9 Draining ......................................................................................................15
2.4. Domestic hot water system ........................................................................15
2.4.1 General 15
2.4.2 Water pressure...........................................................................................15
2.4.3 HOT WATER FLOW RATE.........................................................................15
2.4.4 Hard water areas ........................................................................................15
2.5. Installation, PREPARATION [water connections] .....................................15
2.5.1 Water connections..................................................................................15
2.5.2 SAFETY VALVE DISCHARGE ..............................................................16
2.6 ELECTRICAL INSTALLATION REQUIREMENTS ........................................16
IMPORTANT 16
2.6.1 ELECTRICAL SUPPLY...............................................................................17
2.6.2b OFF-PEAK & 24 HR WIRING CIRCUITS2.6.2c OFF-PEAK TIMER & WIRING CIRCUIT
18
2.6.2c OFF-PEAK TIMER & WIRING CIRCUIT ...................................................19
2.6.2d SOLID FUEL & SOLAR WIRING CIRCUITS ............................................20
2.6.2e SOLID FUEL & SOLAR COMBINED WIRING CIRCUIT ..........................21
2.6.2f SOLID FUEL KIT WIRING CIRCUIT..........................................................22
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2.6.3 External Controls....................................................................................23
ELECTRICAL CONNECTIONS.......................................................................23
2.6.4 Supply cable connection [24 HR Supply]...............................................23
2.6.5 Heating system controls.........................................................................23
2.6.6 Electrical Test.........................................................................................24
2.6.7 Supply cable connection [Interrupted off peak supply]...........................24
2.6.8 Electrical Test.........................................................................................24
2.6.9 IMPORTANT: Electricity tariffs...............................................................24
2.7 Commissioning .............................................................................................25
2.7.1 Filling domestic water circuit ..................................................................25
2.7.2 Filling the heating system.......................................................................25
2.7.3 Domestic hot water flow rate..................................................................25
2.7.4 Temperature settings .............................................................................25
2.7.5 Heating system commissioning..............................................................26
2.7.6 Completion.............................................................................................26
2.7.7 INSTRUCT THE USER................................................................................26
Part 3 - SERVICING.................................................................................................27
3.1. Fault Finding ................................................................................................27
3.1.1 Fault: No domestic hot water or central heating.....................................28
3.1.2 Fault: No central heating, but hot water at taps......................................29
3.1.3 Fault: CENTRAL HEATING BUT No hot water at taps ..........................30
3.2 MAINTENANCE ........................................................................................31
Checking the pressure in the expansion vessel..............................................31
3.2.3 Checking the inline strainer....................................................................31
3.2.4 Checking the hot water blending valve...................................................31
3.2.5 Checking the concentration of corrosion inhibitor ..................................32
3.2.6 Preventing pump seizure in summer......................................................32
3.2.7Checking correct operation of electrical components..............................32
3.2.8 Low pressure switch...............................................................................32
3.2.9 Control and high limit manual re-set thermostats...................................32
3.2.12 Checking the heating elements............................................................33
3.2.13 Checking circuit breakers.....................................................................33
3.2.14 Checking the contactor.........................................................................33
3.2.15 Check the operation of the AQUA STAT..............................................33
4.1.1 SOLAR THERMAL LINKED INTO THE THERMAFLOW...........................34
4.1.2 SOLID FUEL SYSTEM LINKED INTO THERMAFLOW .............................35
4.1.3 EXTERNAL PRIMARY HEAT TRANSFER EQUIPMENT......................36
IMPORTANT PRE-INSTALLATION NOTES
Power supply and wiring
The power supply to the premises must meet the minimum requirements of the unit being
installed, with special attention given to the supply current, cable size and MCB recommendation.
The supply voltage to the appliance must never drop below 207 Volts.
Important
The electrical supply requirements:-
The 9 KW and 12 KW boilers meet the requirements of EN 61000-3.3
The 9 KW and 12 KW boilers must be installed in premises having a service supply of ≥ 100A
per phase.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
The 12 KW boilers must be installed in premises having a system impedance of not more than
0.1939 + J 0.1939Ω
0.1 Instructions General
A pressure reducing valve must be fitted to the cold water inlet if the incoming water pressure exceeds
300 KPA (3.0 Bar).
The primary operating pressure initial charge is 150 KPA (1.5 bar) this will increase to around 200 KPA
(2.0Bar) when the system has reached maximum temperature and will depend on system volume.
The primary expansion vessel pre-charge pressure is 100 KPA (1.0 bar) and has volume of 50 litres.
The secondary expansion vessel pre-charge pressure is between 200-350 KPA (2-3.5 bar) and has a
volume of 0.5 litres.
The primary pressure relief valve is set to 300 KPA (3.0 Bar).
TH9-210U MRK 2
TH9-210U MRK 2
Thermaflow Model Number
TH9-250U MRK 2
TH9-250U MRK 2
TH9-330U MRK 2
TH9-330U MRK 2
Primary storage capacity 218 Litres 250 Litres 330 Litres
Weight when Empty 60KG 70KG 75KG
Weight when Full 278KG 320KG 405KG
WARNING: BEFORE OBTAINING ACCESS TO TERMINALS, ALL SUPPLY CIRCUITS MUST
BE DISCONNECTED.
The TH9 has 3 and the TH12 has 4 heating elements fitted. Size 16” in length and are manufactured
from Inc-alloy EN60335.2.73.
The rated power input of the TH9 appliance is ~230- 240V, 50Hz, 8,250-9,000w
The rated power input of the TH12 appliance is ~230-240V, 50Hz, 11,000-12,000w
The elements fitted to the Thermaflow should NOT be replaced with elements which are not
approved for the Thermaflow boiler.
It is recommended that the Thermaflow has a safety and maintenance check on an annual basis.
A pressure reducing valve must be fitted to the cold water inlet of the appliance if the incoming
pressure exceeds 300kPA (3 Bar).
The position of the outlet from the discharge pipe shall be visible to the occupants and shall be
positioned away from any electrical devices.
The position of discharge pipes, (Tundish), drain valves and motorised valves etc, must be
positioned away from electrical components.
The water may drip from the discharge pipe of the pressure-relief device and must be left open to
the atmosphere.
The pressure relief device must be operated regularly to remove lime deposits and to verify that it
is not blocked.
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The discharge pipe connected to the pressure-relief device must be installed in a continuously
downward direction and in a frost free environment.
(Additional Information given in G3 of the building regulations for discharge pipes)
0.2 Draining & Filling
CAUTION: THE THERMAFLOW BOILER WORKS IN A PRESSURISED SYSTEM WHICH MUST
ONLY BE DRAINED, REFILLED AND PRESSURISED BY A COMPETENT PERSON.
There is a drain tap fitted to the Thermaflow boiler to drain the primary circuit within the boiler it is located
at the bottom of the appliance.
Further drain taps should be fitted into the pipe-work at the lowest point of the potable water circuit and
the heating circuit and should terminate outside the dwelling in a suitable position.
0.3 Manual Handling Guidance
During the appliance installation it will be necessary to employ caution and assistance whilst
lifting as the appliance exceeds the recommended weight for a one man lift.
DO NOT LIFT THE APPLIANCE BY ATTACHED PIPE-WORK OR COMPONENTS
In certain situations it may be required to use a mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
IMPORTANT INFORMATION
0.4 TESTING & CERTIFICATION
The boiler is tested and certified for safety and performance. It is therefore important that no alteration is
made to the boiler, without permission, in writing, from Thermaflow Ltd.
Any alteration not approved by Thermaflow Ltd, could invalidate the certification, boiler warranty and may
also infringe the current issue of the statutory requirements, see section 2.1.2
The unit should be stored in a dry environment and should be handled with care to prevent attached
components being damaged or connections becoming loose.
All connections should be checked for
leaks after installation.
0.5 THE UNIT LOCATION
The unit should be preferably located in a cupboard with a minimum dimension of;
L 700mm x B. 700mm x H. 2.4M for the 218L & 250L MRK 2 and
L 750mm x B. 700mm x H. 2.4M for the 330L MRK 2
The floor to which the unit is placed upon should be capable of withstanding a load of:
285KG for the 218L, 320KG for the 250L and 405KG for the 330L
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
The unit should be positioned in a manner that allows access to all components for future
maintenance.
If located in a cupboard the unit should be positioned with all components facing the entrance to
allow elements to be replaced if required or any of the other components.
0.6 Water Connections
There are six water connections to be made when installing the Thermaflow.
They are as follows:
1) Flow and return connections to the heating system are 22mm compression or push fit.
2) Cold water inlet-22mm compression.
3) Hot water outlet -22mm compression.
4) Pressure relief valve- 15mm compression.
5) The pressure relief valve connection should be used for no other purpose.
6) The heating expansion vessel- 22mm compression or push fit.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
PART1 – INSTRUCTIONS FOR USE
1.1 INTRODUCTION
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their
safety.
Children should be supervised to ensure they do not play with the appliance.
Please read these Instructions and follow them carefully for the safe and economical use of your
combination boiler.
This boiler must have been installed by a competent person in accordance with the current rules
in force in the countries of destination at the time of installation.
The boiler is automatic in operation once the external controls are set e.g. time clock or
programmable room thermostat.
IMPORTANT NOTICE
1.2 Domestic hot water temperature
Hot water is NOT user adjustable and is pre-set to 50ºC at the thermostatic mixing valve fitted on the hot
water outlet at the top left of the boiler. It is TMV3 rated for Anti Scald purposes.
The combination boiler is able to provide room heating as part of an under-floor or central heating system
and domestic hot water direct from the cold water supply, without the need for secondary storage.
1.3 To turn the boiler off
To turn the boiler off, isolate the boiler from both the electrical supplies i.e. the 24hr supply and the
interrupted supply, both isolating switches should be positioned next to the boiler.
1.4 Maintenance and servicing
To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked
and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular
installation conditions and usage, but in general once a year should be enough.
Servicing & maintenance should be carried out by a competent person in accordance with the rules in
force in the countries of destination.
To obtain service please call your installer or Thermaflow Ltd, using the telephone number on the
appliance or at the front of this manual.
Please be advised that the Thermaflow log book should be completed by the installation engineer on
completion of commission and servicing.
1.5 Clearances
The boiler requires a clearance in front and at the sides for safety, servicing and maintenance access,
see diagram 2.2.3 for the requirements.
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1.6 Draining and filling
Caution this boiler works in a pressurised syste
m which must only be drained, refilled and pressurised by
a person competent to do so.
Note: if the pressure gauge indicates a loss of pressure that is less than 60 KPA (0.9 bar),
YOU MUST CONTACT YOUR INSTALLER unless you have been instructed by your installer on how to
re-pressurise the system correctly.
1.7 Replacement parts
If replacements parts are required, contact your Installer, Service Company or Thermaflow Ltd. Please
quote the name and model of your appliance. (Ref. Spare Parts List - section 1.8.1).
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1.8 Thermaflow TH Model MK2
1a 22mm single check valve External
primary return
1b 22mm single check valve external
primary flow
1c 22mm single check valve HW
primary
1d 22mm single check valve CH primary
1e 22mm single check valve cold water
inlet
2 ‘Y’ pattern strainer
3 0.5L Potable Expansion Vessel
4a 22mm isolating valve
Central heating return
4b 22mm isolating valve
(cold water inlet)
5a Plate Heat Exchanger
Domestic HW
5b Plate Heat Exchanger
Solar circuit
5c Plate Heat Exchanger
Wood burner circuit
6 Thermostatic Blending Valve
HW outlet
7 Drain point (primary)
8a 22mm bend Cold supply to blending
valve and heat exchanger
8b 22mm bend CH Flow
8c 22mm bend CH Flow
9 Primary Expansion vessel
10a Tee for external primary transfer kit.
10b Tee for cold water circuit.
10c Tee for cold water circuit.
11a 0-50 degree aqua stat
11b 0-70 degree aqua stat fitted when
linked to (SOLID FUEL ONLY)
12 Automatic Air Eliminator
13 15-1/2” female adaptor
14a 2nd stage Manual re-set high limit
thermostat
14b 3rd stage Manual re-set high limit
thermostat
15 Temperature & pressure gauge
16 Element, low water pressure switch
and wiring cover panel
17 Electrical controls box
18 Grundfos Circulating Pumps
Complete with Isolating Valves.
18a HW Circuit pump
18b CH Circuit pump
18c External primary heat transfer circuit
pump
19 ½” boss for solar sensor pocket
20 Safety relief valve (3bar)
21 Filling Loop Assembly
22 316 Stainless Steel Vessel
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Unit Design (Protected by Design Rights)
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
TABLE 1.8.1 [DATA]
Lift Weight empty 60KG 70KG 75KG
Total Weight boxed 70KG 80KG 85KG
Weight Full 280KG 320KG 405KG
Heating Flow & Return 22mm Compression or push fit
Domestic Cold Water Inlet 22mm Compression
Domestic Hot Water Outlet 22mm Compression
Safety Relief Valve PRESET 300 KPA (3.0 Bar)
Safety Relief Valve Discharge 15mm Compression
Water Content Primary 216 248 328
Water Content Domestic (Secondary) 2 Litres / 0.44 Gallons
Primary Expansion Vessel 25 Litres / 5.5 Gallons. 35 Litres 7.7 Gallons
Secondary Expansion Vessel 0.5 Litres/0.11 Gallons
TH9-210U MRK 2 TH-250U MRK 2 TH-330U MRK 2
CH Cold Fill Pressure Min/Max 90 KPA (0.9 Bar) minimum / 150 KPA (1.5 Bar) maximum
D.H.W Working Pressure 20 – 300 KPA (0.2-3.0 Bar)
Max. CH system Content (Excluding unit volume) 140Litres 140Litres 160Litres
Electrical Mains Supply ~230-240V, 50Hz
Electrical Rating (Interrupted) & Supply Current TH9/ 8, 250-9,000w – 38 amp
TH12/ 11, 000-12,000w – 52 amp
MCB Rating (amp) 9Kw (40amp) or 12Kw (52amp) 40A or 63 A TYPE C MCB
Electrical Rating (24Hr) Control Circuit 95w, Fused 3amp or 6A Type B MCB
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
PART 2 – INSTALLATION
2.1.1 Sheet metal parts
Warning: when installing or servicing this boiler care should be taken when handling the edges of metal
parts to avoid any possibility of personal injury.
2.1.2 Statutory requirements
The installation of this boiler must be carried out by a competent person in accordance with the current
rules in force in the countries of destination at the time of installation, and in accordance with the relevant
requirements of the current issue of:
The Building Regulations
The Local Water Company bye-laws
The Building Standards Regulations (Scotland)
The Health and Safety at Work Act
Manufacturers instructions, supplied
Manufacturer’s instructions must not be taken as overriding statutory requirements.
2.1.3 DATA
The data label is on the front case of the boiler.
2.1.4 ELECTRICAL SUPPLY
Power supply and wiring
The power supply to the premises must meet the minimum requirements of the unit being installed, with
special attention given to the supply current, cable size and MCB recommendation. The supply voltage to
the appliance must never drop below 207 Volts.
Important:
The electrical supply requirements:-
The 9 KW and 12 KW boilers meet the requirements of EN 61000-3.3
The 12 KW boilers must be installed in premises having a service supply of ≥ 100A
per phase.
The 12 KW boilers must be installed in premises having a system impedance of not more than 0.1939 + J
0.1939Ω
WARNING: This boiler must be earthed
WARNING: Means for disconnection must be incorporated in the fixed wiring in accordance
with the wiring rules
WARNING: Electrical work must be carried out by a person competent to do so
All system components shall be of an approved type.
The electrical installation shall be in accordance with the current rules in force in the countries of
destination at the time of installation.
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2.1.5 Electrical supply
Means of disconnection of the electrical supply to the boiler must be incorporated in the fixed
wiring in accordance with the wiring rules.
Two isolators are required at the boiler when using an interrupted off peak supply eg.
E2000, one
for the 24hr supply, and the other for the interrupted supply (off peak if available).
If using Scottish & Southern Energy, only one isolator is required at the boiler.
Means of disconnection of the 24hr supply should be by a double pole switched fused spur (fuse rating
3 amp), having a minimum contact separation of 3mm in each pole. The fused spur should be readily
accessible and adjacent to the appliance. It should be identified as to its use.
Means of disconnection should not be fitted in a room containing a fixed bath or shower. The 24hr
mains supply cable and other cables for external controls must be heat resistant and flexible PVC type of
at least 0.75mm2 (24/ 0.20mm)
Means of disconnection of the interrupted supply (off peak) should be by a double pole switched
(60amp isolator with a 40 amp MCB Type C for the TH9/ model) and a switched (100 amp isolator with a
63 amp MCB Type C for the TH12/ model), having a minimum contact separation of 3mm in each pole.
The switched isolator and MCB should be readily accessible and installed at the origin of the supply to
the boiler. It should be identified as to its use.
Means of disconnection should be readily accessible and adjacent to the appliance. It should be
identified as to its use.
The interrupted mains supply cable must have a cross sectional area of at least (10mm² for the
TH9/ model) (16mm² for the TH12/ model). The mains supply cable at the boiler location should
be preferably encased by flexible conduit.
2.1.6 Heating system controls
The heating system should have installed: A timer and room thermostat or a programmable room
thermostat controlling the central heating system or under-floor heating.
If an under-floor heating system is being installed it must have its own pump and blending valve.
Thermostatic radiator valves should be installed in addition to the room thermostat for better economy
and energy saving.
2.2.1 Boiler Position
The boiler must be installed in accordance with the rules in force in the countries of destination. This
boiler is not suitable for fitting outside.
Any electrical switch must be positioned so that it cannot be touched by a person using a bath or
shower.
The boiler must be positioned on a level base or floor which is sufficiently robust to take its weight, (Refer
to table 1, “Data”)
If the location of the boiler or any part of the system is subject to severe cold weather conditions, it is
recommended that a frost thermostat is fitted. Any part of the system that may be vulnerable to freezing
must be protected.
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2.2.2 Boilers in a compartment
Where the installation of the boiler will be in an unusual position, the current issue of BS 6798 gives
detailed guidance on these requirements.
An existing cupboard or compartment modified for the purpose may be used, providing minimum
clearances are maintained. Details of essential requirements for cupboards or compartment design are
given in the current issue of BS6798.
The doorway opening should be of sufficient size to allow for easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment, permanent ventilation is not necessarily required
and will depend on compartment size and airflow around the boiler.
Compartment ventilation is required to dissipate heat from any external heating circuit pipe-work,
to prevent overheating of the electrical components and wiring.
Any existing compartment air vents must not be removed or blocked off.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
Diagram 2.2.3 - Clearances
2.2.3 Clearances allow for external primary heat transfer kit
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram
2.2.3 additional clearances may be required around the boiler for
installation. A clearance of 600mm is required at the front of the
boiler for maintenance and installation.
Thermaflow
Unit
2.3.1 General notes
The boiler is intended for use in a sealed system only.
front
700mm
2.3.2 Safety valve
The safety relief valve is an integral part of the boiler. It cannot
600mm
be adjusted but has a manual test device.
2.3.3 Pressure & Temperature Gauge
A pressure and temperature gauge is incorporated into the boiler to indicate the system pressure and
temperature. The gauge has a cold fill set pointer.
750mm
2.3.4 Pump
The circulation pump is integral with the boiler.
Diagram 2.3.5
2.3.5 Expansion vessel
The 210L and 250L units are supplied with a 25 litre expansion vessel and
the 330L is supplied with a 35 litre Expansion vessel. If the water content of the
heating system exceeds the maximum quoted in
table 1, [Data] an additional
Expansion
Vessel
expansion vessel should be connected into the system as close as possible
to the central heating return connection of the boiler. Ref. Di
agram 2.3.5
The charge pressure shall not be less than the static head at the point of
connection, which is the height of the top point of the system above the
expansion vessel.
Thermaflow ®
2.3.6 By- pass
An automatic by- pass valve should be incorporated in the system for maximum system
efficiency. (A By-Pass MUST be fitted to the system by the installer).
2.3.7 Filling sealed systems
The boiler has a filling loop incorporated within it, and pressure gauge to register the fill pressure.
There must be no permanent connection to the mains water supply; even though a non return valve is
supplied. Disconnect filling loop and seal both valves with suitable caps.
2.3.8 Corrosion inhibitor
The maintenance of sufficient concentration of corrosion inhibitor in your Thermaflow system is vital to
prevent corrosion. We would recommend sentinel X100, or equivalent. Dose appropriately according to
the size of the Thermaflow boiler and central heating system volume combined.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
2.3.9 Draining
A draining tap must be provided at the lowest points of the system, which will allow the entire
system to be drained.
The boiler has a drain tap fitted for draining of the primary circuit.
2.4. Domestic hot water system
2.4.1 General
The domestic hot water service must be in accordance with the rules in force in the countries of
destination.
2.4.2 Water pressure
For the minimum and maximum, working pressures of the domestic hot water circuit of the boiler refer to
(“data” table 1).
If the cold water inlet pressure exceeds 300 KPA (3 bar) a pressure reducing valve must be fitted
to the inlet to the boiler.
2.4.3 HOT WATER FLOW RATE
The boiler is capable of flow rates of 20-30 litres per/min @ 35ºC ∆t (depending on model). Hot water
flow rate and pressure will be determined by the volume and pressure of the incoming cold water supply.
2.4.4 Hard water areas
In areas where the water is “Hard” more than 200 mg / litre, it is recommended that a proprietary
scale reducer or water softener is fitted in the cold water supply to the boiler depending on what
is necessary to prevent lime scale build up in the heat exchangers, pipe-work or valves.
Consult the local water authority for additional advice.
A double check valve assembly must be fitted upstream of the scale reducer or water softener.
For the relative position of the scale reducer or water softener and pressure reducing valve if
required, refer to the Manufacturer’s instructions.
2.5. Installation, PREPARATION [water connections]
2.5.1 Water connections
See General Data Diagram 1.8.1 & table 1.8.1 for pipe work connections
It is recommended to flush out the domestic water and heating system before connecting to the
boiler.
While making the connections, do not subject any of the connections to heat as you may damage
the seals.
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2.5.2 SAFETY VALVE DISCHARGE
It must not discharge above an entrance or window or any type of public access.
The position of the discharge outlet shall be visible to the occupants and shall be positioned
away from any electrical devices.
The position of discharge pipes (Tundish) drain valves and motorised valves etc must be
positioned away from electrical components.
The water may drip from the discharge pipe of the pressure-relief device and must be left open to
the atmosphere.
The pressure relief device must be operated regularly to remove lime deposits and to verify that it
is not blocked.
The discharge pipe connected to the pressure-relief device must be installed in a continuously
downward direction and in a frost free environment.
The connection for the discharge is made at the bottom side of the safety relief valve.
This must be extended from the safety relief valve with not less than 15mm O.D. metal pipe, to
discharge, in a visible position, outside the building, facing downwards, preferably over a drain.
The pipe must have a continuous fall and be routed to a position so that discharge water,
possibly boiling or steam, cannot create any danger to persons, damage to property or external
electrical components and wiring.
2.6 ELECTRICAL INSTALLATION REQUIREMENTS
Power supply and wiring
The power supply to the premises must meet the minimum requirements of the unit being installed, with
special attention given to the supply current, cable size and MCB recommendation. The supply voltage to
the appliance must never drop below 207 Volts.
IMPORTANT
THE ELECTRICAL SUPPLY REQUIREMENTS:-
The 9 KW and 12 KW boilers meet the requirements of EN 61000-3.3
The 9 KW and 12 KW boilers must be installed in premises having a service supply of ≥ 100A
per phase.
The 12 KW boiler must be installed in premises having a system impedance of not more than
0.1939 + J 0.1939Ω
16
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2.6.1 ELECTRICAL SUPPLY
IMPORTANT
If the boiler is wired to the Scottish Power Domestic & Economy 200 tariff, it requires two separate ~230240V power supplies. A (24HR) supply for controls and an interruptible supply for the boiler. (Off Peak
power supply if it is
available).
The off peak or interruptible mains supply is wired according to the following
amp double pole isolator by way of flexible 16mm² cable into the main terminals in enclosure marked
on the boiler schematic on page 9 of this instruction manual, see diagram 2.6.1b on page 18.
17
diagram 2.6.1, from the 63
No.
If the boiler is wired to a 24 hour tariff or Scottish & Southern Energy Economy 10 tariff for wet electric
central heating then a separate 3 amp supply is not required for the controls as the controls are supplied
via the 6 amp MCB in the control box marked No.17 on the boiler schematic on page 9 of this instruction
manual, see
diagram 2.6.1b on page 18.
A Local isolator may also be required at the boiler position.
diagram 2.6.1
Supply
100A Double Pole
Isolating switch
With 50A or 63A Type C
MCB located at meter or
consumer unit
L*
*
N
*
E
* 25mm
CONNECT TO METER / TELE-SWITCH
2
COLOUR CODED METER TAILS
100A Double Pole
local Isolating switch
located at the Thermaflow
boiler position
100A Double Pole
Isolating switch located in the
Thermaflow boiler control box
L
N
E
CABLE SIZING
Boiler rating minimum Cable Size ~
230-240V-50Hz, 8,250-9,000w – 10mm², 11,000-12,000w – 16mm².
MCB MUST BE TYPE C.
2.6.2
The mains supply into the boiler shown in the diagram on page 9, should be wired to the 24HR supply via
3 Amp fused isolating switch located at the boiler,
ref. diagram 2.6.2b.
17
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p
A
)
Y
2.6.2b OFF-PEAK & 24 HR WIRING CIRCUITS
E
A
A1 A1
A2
11
14
N
E
CONTROLS
ONL
HWP
C
N/O
Programmable
Thermostat
Ie. Danfoss
TP5000si or
equivalent
With battery
operated
contacts
SOLAR
PUMP
Terminal A2 and
11 on solar relay.
See Diagram
18
T14 on solar or
solid fuel relay.
B
A2
11
1
A2
14
1
L
2
3
4
C
5
6
7
8
9
10
11
12
13
14
15
16
17
18
EXTERNAL PRIMARY HEAT
SOURCE CONTROLS
Fit link between terminal 14’s if
both solar and solid fuel are
being linked to the Thermaflow
A1 A1
C
N/C
C
1
CHP
C
2
1
N
2
A2
N/C
2
3
4
C
16A
E4
E3
E2
E1
LINK REMOVED
C
N/C
N/O
C
C
2
1
T11 solid
fuel relay
E3 E4
16A 16A
HEATING ELEMENTS
E3 not used on 9KW
models
A2 solid fuel
relay.
See Diagram
ISOLATOR
MCB
16A
REMOVE LINKS AND FIT OFF PEAK CONTROL IF
E10 OR EXTERNAL PRIMARY HEAT SOURCES ARE
BEING LINKED TO THERMAFLOW BOILER
EXTERNAL PRIMARY HEAT TRANSFER PUMP
TEMPERATURE CONTROL THERMOSTAT
T BOILER 0-90°C (SET TO 85°C
TAMPER PROOF CONTROL THERMOSTAT
SET TO 50°C
6A 100A
E1
E2
~240VAC
SUPPLY
IF E10 – Supply to
controls comes from
N L
LOW PRESSURE SWITCH
2ND STAGE HIGH LIMIT CUT
OUT MANUAL RESET
3RD STAGE HIGH LIMIT CUT
OUT MANUAL RESET
TAMPER PROOF CONTROL
THERMOSTAT SET TO 25°C
A – Solar Relay (Optional)
B – Solid Fuel Relay (Optional)
6A MCB in to
IF Scottish Power
E2000 tariff –
External 3AMP 24hr
supply must be
taken to supply
controls as shown
NEUTRAL SHOWN AS
DOTTED & SOLID
LINE SHOWS TWO
SEPARATE CIRCUITS
NO NEUTRAL OR
EARTHS SHOWN FOR
CLARITY
Requires ~240v – 3AMP
Supply when using
Scottish Power Domestic &
Economy 2000 tariff
SOLAR CONTROLLER
PUMP AT LOG
control
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2.6.2c OFF-PEAK TIMER & WIRING CIRCUIT
The Off Peak Control allows you to time the boiler to charge during the
All Connections are
Use the piece of 5 core heat
resistant flex supplied with the
Connections onto
main wiring terminal
reduced rate periods on wet electric central heating tariffs
The winter channel controls the
timing of the bottom two elements
on all Thermaflow boiler models via
contactor 1 on the Thermaflow
boiler
~240V AC
IMPORTANT
programmer.
on boiler.
OFF PEAK TIMER
The summer channel controls the
timing of the top element on a 9kw
Thermaflow
elements on the 12kw boiler via
N
E
10
12
11
Off Peak Timer
required when using
E10 wet electric tariff
or similar or when
linking external
primary heat source to
the Thermaflow boiler
The control allows you
to reduce running
costs substantially.
boiler and the top two
contactor.
Off Peak Timer
N
L
1
3
2 4
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2.6.2d SOLID FUEL & SOLAR WIRING CIRCUITS
Wiring Circuit & Equipment when
linking thermal solar to the
Thermaflow boiler
All Connections are
Neutral & Earth connections
not shown for clarity
Wiring Circuit & Equipment
when linking a wood
burner or solid fuel to the
Thermaflow boiler
All Connections are
Neutral & Earth connections
not shown for clarity
~240 VAC
~240 VAC
T14
Common L
CHP
T14
Common L
T9
Solar Controller
0-90 °C Control
Thermostat on
Thermaflow Boiler
2
Solar Pump
1 C 1 C
Solid Fuel
Relay on
Thermaflow
Boiler
Primary Heat Transfer
pump on Thermaflow
Thermaflow Solar Relay
on Boiler
11
12
A2
14
Primary Heat Transfer Pump
on Thermaflow Boiler
0-50 °C Control
Thermostat at Solid
Fuel Boiler
2
11
12
A2
14
Boiler
Pump at
Solid Fuel
Boiler
20
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2.6.2e SOLID FUEL & SOLAR COMBINED WIRING CIRCUIT
Wiring Circuit & Equipment when linking
both thermal solar and a wood burning
stove to the Thermaflow boiler
T14
Common L
Neutral & Earth
connections not shown
for clarity
Solar Cont
Relay for solar
circuit fitted on
Thermaflow boiler
roller
Solar Pump
A2
Primary Heat
Transfer Pump on
Thermaflow Boiler
0-90 °C Co
Thermostat on
Thermaflow Boiler
2
C
11
12 12
14
All Connections are
ntrol
0-50 °C Co
Thermostat at
Solid Fuel Boiler
2
1 C 1
11
A2
14
Relay for wood
burner circ
uit fitted
on Thermaflow
boiler
~240 VAC
ntrol
Pump at Sol
Fuel Boiler
id
21
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2.6.2f SOLID FUEL KIT WIRING CIRCUIT
Wiring diagram and additional equipment required
when linking a solid fuel appliance to the
Thermaflow boiler
Neutral & Earth
connections not shown
for clarity
Switched Live to A2 on
solid fuel relay fitted to
Thermaflow boiler
T18
T17
Junction Box
SL from T1 on 0-90°C
Control Thermostat
fitted on boiler
E
N
0-50°C Control
Thermostat fitted to
flow pipe at solid fuel
or wood burning
appliance
Pump at Solid Fuel Boiler
All Connections are
~240 VAC
Pump fitted at
Solid Fuel Boiler
2
1
C
0-50°C ControlThermostat fitted to flow
T2
pipe at solid fuel or wood burning
appliance
T17 on Thermaflow boiler terminal
Common 0-50°C ControlThermostat
fitted to flow pipe at solid fuel or wood
burning appliance
T11 on solid fuel relay fitted to Thermaflow
boiler
22
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2.6.3 External Controls
External heating controls should be connected to the appropriate terminals numbered in
diagram 2.6.2b.
WARNING: ALL EXTERNAL CONTROLS MUST NOT BE TAKEN FROM ANY OTHER POWER
SUPPLY OTHER THAN VIA THE
3 AMP FUSED ISOLATING SWITCH MENTIONED ABOVE.
ELECTRICAL CONNECTIONS
2.6.4 Supply cable connection [24 HR Supply]
Caution: To prevent an induced current from switching the central heating on when not required it is
important that the heating system control cables are separated from the other mains cables.
There is provided 1 or 2 heat resistant cables extending from the main panel situated between
both circulating pumps depending on the tariff being used. One cable has 3 cores. Live, Neutral
and earth to be connected to a 3 amp double pole fused isolator.
The other cable has 2 cores coloured brown and (blue core covered with brown sleeve) these are
both common live and switched live wires to be connected to external heating controls.
If the boiler is being connected to SSE E10 tariff the 3 core flex if already fitted, must be removed
and a link fitted between terminal 1 & 2 as shown in diagram 2.6.2b on page 18.
It is also advisable to fit the off-peak control when using a wet electric tariff other than Domestic
& Economy 2000.
IMPORTANT
If the boiler is connected to Scottish Power Domestic & Economy 2000 tariff it requires a
permanent mains supply through an external isolator (rated to 3amp) which must isolate any
heating system controls see
diagram 2.6.2b
Any heating system controls must not interrupt the mains supply to the boiler.
Standard colours are Brown- Live, Blue- Neutral and Green and yellow- Earth. Make the earth cable
of a greater length so that if the cable becomes strained the earth would be the last to become
disconnected.
CAUTION: IT IS ESSENTIAL TO MAKE SURE THAT THE POLARITY IS CORRECT.
2.6.5 Heating system controls
All external controls and wiring are required to provide a minimum of reinforced insulation at 250 vrms
between the parts of those devices operating at mains hazardous voltage and the user accessible parts
of those devices.
Note: for further information, see the building regulations 1991- conservation of fuel and power, 1995
edition- appendix G, table 4B.
When any kind of external heating system controls are being used to regulate the heating system
connect a single pole type, to the appropriate terminals of the connector shown in
the 2 core cable provided).
If the installation requires protection by a “Frost Thermostat” connect a single pole type, between
terminals 6 and 9 shown in
diagram 2.6.2b.
23
diagram 2.6.2b, or (to
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
2.6.6 Electrical Test
Carry out preliminary electrical system checks as below.
1) Test insulation resistance to earth of mains cables.
2) Test earth continuity and short circuit of all cables.
3 Test the polarity of the mains.
4 Refit the enclosure cover.
2.6.7 Supply cable connection [Interrupted off peak supply]
Open the enclosure situated at the top of the boiler.
Using 16mm² twin and earth cable of a suitable length route the mains interrupted supply cable through a
piece of suitably sized flexible conduit into the 100amp isolator shown in diagram 5.
Standard colours are Brown- Live, Blue- Neutral and the earth should be sleeved with a suitably sized
green and yellow earth sleeve.
Make the earth cable of a greater length so that if the cable is strained the earth would be the last to
become disconnected.
CAUTION: IT IS ESSENTIAL TO MAKE SURE THE POLARITY IS CORRECT.
2.6.8 Electrical Test
Carry out preliminary electrical system check as below:
1) Test insulation resistance to earth, of mains cables.
2 Test earth continuity and short circuit of all cables
3 Test the polarity of the mains.
4 Refit the enclosure cover.
2.6.9 IMPORTANT: Electricity tariffs
The Thermaflow will operate on any ~230-240V, 50Hz supply. The most economical option is a peak
avoidance tariff as described previously.
Scottish Power, Guernsey Electric Ltd, all have an 18 hour tariff.
Scottish & Southern Energy has an E10 wet electric heating tariff
Other areas offer their own tariffs, which may be viable for economic operation.
It is advisable to use the Thermaflow off-peak control when using off-peak tariffs other than the
24
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Scottish Power Domestic and Economy 2000 tariff as it reduces running costs substantially.
2.7 Commissioning
2.7.1 Filling domestic water circuit
Check that the boiler is isolated from the electrical supply, at both external isolators.
Fully open the domestic water supply stop cock or valve in the supply to the boiler.
Open all hot water draw-off taps and close them when water flows.
Check for water soundness of the whole domestic hot water installation and boiler.
2.7.2 Filling the heating system
Flush, fill and vent the system refer to section 3.7 “Filling sealed systems”.
The boiler and central heating system should be completely filled and purged of air before switching on
the power to the appliance. The cold fill pressure should register no more than 150 KPA (1.5 Bar). See
Table 1.8.1 (DATA), for minimum and maximum pressures.
Make sure the automatic air vent at the top of the boiler is operating correctly.
IMPORTANT.
MAKE SURE THE BOILER AND SYSTEM IS COMPLETELY FULL OF WATER AND ALL AIR IS
ELIMINATED BEFORE TURNING ON ANY OF THE POWER SUPPLIES TO THE BOILER.
Take care not to splash any of the electrical components.
Pressurise the system until the pressure is 150 KPA (1.5 Bar).
Check the heating system and
boiler for water soundness.
Check the operation of the safety valve by turning the safety valve knob in the direction of the arrow.
Lower the pressure to the initial cold fill design pressure of 150 KPA (1.5 Bar),
the set pointer on the boiler pressure gauge at this pressure also.
NOTE: When the boiler reaches its maximum temperature, the pressure will increase to around 200 KPA
(2.0 Bar)
2.7.3 Domestic hot water flow rate
The domestic hot water flow rate can be set by adjusting the stop cock on the cold water inlet to the
boiler.
2.7.4 Temperature settings
The maximum temperature setting for the domestic hot water is pre-set at 50ºC to prevent scalding and is
not user adjustable.
The maximum flow temperature setting for central heating is 82ºC this is the preset and is not adjustable.
refer to table 1.8.1. Position
25
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2.7.5 Heating system commissioning
Make sure the boiler and heating system is completely full of water. (SEE ABOVE SECTION 7.2)
Turn on both 24Hr & Interrupted power supplies. Allow approximately 120 - 300 minutes to bring the
boiler up to temperature (depending on model). Check that all external controls, are calling for heat.
Fully open all thermostatic and lock shield valves on each radiator.
The aqua stat, positioned at the bottom of the boiler is pre-set to 25ºC (It must remain at this setting)
Allow this system to reach maximum temperature then switch off both electrical supplies at the isolators.
Drain the system rapidly while still hot.
Fill and vent the system as described in section 7.2 “Filling the central heating circuit” Add inhibitor as
required refer to section 3.8 “Corrosion Inhibitor”
Set to the initial cold fill design pressure, using the external draining tap. Refer to table 1, and section 3.9
NOTE: The system fill pressure may require to be recharged once or twice in the first two to
three weeks after the initial commissioning of the boiler due to oxygen and air content in the
system being expelled through the automatic air eliminator.
There should be no further need to re-pressurise the system after this period. If the system
requires continuous re-pressurisation, there may be a leak in the installation.
2.7.6 Completion
Set any external heating control to the desired settings.
2.7.7 INSTRUCT THE USER
Instruct and demonstrate the isolating switches then advise the user of the efficient and safe operation of
the boiler.
Instruct and demonstrate the operation of any heating system controls.
Advise the user on the use and maintenance of any scale reducer or water softener and pass on any
relevant instructional documents.
Advise the user that to ensure continued efficient and safe operation of the appliance, it is
recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend
on the particular installation and usage, but in general once a year should be enough.
Any servicing should be carried out by a person competent to do so.
Advise the user of the precautions necessary to prevent damage to the system and building in the event
of the heating system being out of use during frost and freezing conditions.
Reminder- leave these instructions with the user.
Advise the user that the logbook should be completed by the engineer on completion of commissioning.
Failure to do so will invalidate the warranty. The user must sign the log book and retain it for future
reference.
26
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PART 3 - SERVICING
3.1. Fault Finding
MUST BE CARRIED OUT BY A PERSON COMPETENT TO DO SO
Before trying to operate the boiler make sure that:
The heating system pressure is at 150 KPA (1.5 Bar) when the system is COLD and 200 KPA (2.0 Bar)
when the system is at maximum temperature.
There is a permanent mains power, (24hr supply) to the terminals marked in the control panel on the
boiler in the schematic diagram on page 9 of this instruction manual.
There is power at the off peak (Interrupted) supply main switch in the control box at the top of the boiler
(Marked No 17 on the boiler schematic diagram on page 9 of this instruction manual.
WARNING: BEFORE OBTAINING ACCESS TO TERMINALS, ALL SUPPLY CIRCUITS MUST
BE DISCONNECTED.
IMPORTANT: ON COMPLETION OF THE FAULT FINDING TASK WHICH HAS REQUIRED THE
BREAKING OR REMAKING OF THE ELECTRICAL CONNECTIONS, THE CONTINUITY,
POLARITY, SHORT CIRCUIT AND RESISTANCE TO EARTH CHECKS MUST BE REPEATED
USING A SUITABLE MULTI- METER.
Type of fault
Check
No domestic hot water or central
heating
~230-240V Supply (24HR)
~230-240V Supply (Off Peak)
System water pressure at 150 kpa (1.5 bar)
External Off-Peak control
Low pressure switch
Master high limit manual re-set thermostat 3rd stage
Manual re-set Over Heat Thermostat 2nd stage
Contactor
Heating elements
No central heating but hot water
at taps
~230-240V Supply (24HR)
~230-240V Supply (Off Peak)
External controls
External Off-Peak control
Low pressure switch
Heating elements
Manual re-set Over Heat Thermostats 2nd & 3rd stage
Temperature at bottom of store
of 25ºC
Is central heating pump operating correctly?
Central heating but no hot water
at taps or temperature diminishes
after a short period
Auto air eliminator in closed position?
Pump valves in the open position?
Figure 17, page 9
Domestic hot water pump is not operating?
Secondary expansion vessel pressure (must be 2.0 -3.5bar)
Hot water blending valve?
Blockage in the primary flow pipe into the plate heat
exchanger?
27
must be above aqua stat setting
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
3.1.1 Fault: No domestic hot water or central heating
Is there ~230-240V at the 24HR supply?
Yes
Is there ~230-240V at the off peak supply?
Yes
Is system pressure above 150 KPA (1.5 Bar)?
Is the off peak control in the on position?
Yes
Is there continuity through low pressure switch?
Yes
Yes
Is there continuity through 2nd stage and 3rd stage master
high limit manual re-set safety thermostats?
Yes
Is there continuity through both contactors?
No
No
No
No
No
No
No
Check Fuse, MCB or Meter for correct
operation
Check Fuse or MCB
Increase Pressure
Turn on both channels
Replace low pressure switch
Re-set or replace thermostat
Replace Contactor(s)
Yes
Is there ~230-240V at each heating element and
continuity through thermostats within?
28
No
Replace thermostat as necessary
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3.1.2 Fault: No central heating, but hot water at taps
Is the off peak control in the on position?
Yes
No
Turn on both channels
Is there continuity through low pressure switch?
Yes
Is there continuity through 2nd stage and 3rd stage master
high limit manual re-set safety thermostat?
Yes
Is there continuity through contactor?
Yes
Is there ~230-240V at each heating element and
continuity through thermostats within?
Yes
Are external controls calling for heat?
Yes
Is temperature above setting on aqua stat?
(Should be set to 25
o
C)
No
No
No
No
No
No
Replace low pressure switch
Re-set or replace Thermostat
Replace Contactor
Replace as necessary
Adjust the setting
Re-check when temperature increases
Yes
Is there ~230-240V and continuity at terminals of the
aqua stat?
Yes
Is there ~230-240V supply at central Heating pump?
Yes
Is pump impeller turning?
Yes
Check thermostat and lock shield Valves on radiators are
open & calling for heat
No
No
No
Check ~230V Supply
Check for faulty external controls
Spin impeller or replace central heating
pump
29
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
g
(
)
3.1.3 Fault: CENTRAL HEATING BUT No hot water at taps
Is the automatic air eliminator on top of the boiler in the
closed position causing air to trap in the top of the boiler?
Is there ~230-240V at domestic pump terminals?
Is domestic pump operating correctly? Are the pump
valves in the open position?
Is there circulation through the primary side of the plate
heat exchanger?
Is the hot water blending valve set correctly?
Yes
Yes
Yes
No
No
No
No
No
Open the small screw cap on top of the
auto air eliminator
Check aqua stat. Temperature must be
lower than temperature setting of 25ºC
Open the pump valves. If they are
open, replace the pump
Disconnect primary flow from plate
heat exchanger and check for
blocka
e.
Rare occurrence
Adjust and retry
Yes
Is the pressure in the domestic expansion vessel
between 2.0bar and 3.5bar?
Yes
Has the hot water resumed?
No
No
Recharge to correct pressure or
replace if burst.
Check for blockage in filters. If clear,
replace hot water blending valve.
30
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
WARNING: FOR YOUR OWN SAFETY
SERVICING AND MAINTENANCE SHOULD BE CARRIED OUT BY A PERSON WHO IS
COMPETENT TO DO SO.
3.2 MAINTENANCE
Before commencing, refer to section 1. Installation
Checking the pressure in the expansion vessel
3.2.1 The primary expansion vessel (volume 25 or 30 litres) is the red or blue vessel connected to the
central heating boiler. Its purpose is to take up expansion in the boiler and central heating system.
The pressure can be accurately checked with the pressure relieved on the other side of the diaphragm.
To do this drain some water from the central heating system until the pressure gauge registers zero.
Connect a pressure gauge to the car tyre type valve on the vessel. The pressure should register 100
KPA (1.0 Bar). Refill heating system as described in section 2.7.2
3.3.2 The secondary expansion vessel (volume 0.5 litres) is the white or silver vessel connected to the
cold inlet of the boiler.
Its function is to take up expansion in the hot water pipe work and so protect the blender from damage.
The pressure can be accurately checked with the pressure relieved on the other side of the diaphragm.
To do this, isolate the water supply to the Thermaflow boiler and open a hot tap. Water will run for a few
seconds then stop.
Connect a pressure gauge to the car tyre type valve on the vessel. The pressure should register 200-350
KPA (2.0-3.5 Bar). Close the hot taps and turn the water supply back on.
3.2.3 Checking the inline strainer
Whilst the water is off, remove and clean the gauze in the brass strainer assembly. To remove the gauze
for cleaning un-screw the brass plug.
3.2.4 Checking the hot water blending valve
With the store temperature fully recovered, run a hot tap and check the flow rate and temperature.
If the hot water has deteriorated suddenly (over less than a month) then this points to a problem with the
blender.
A broken blender is usually linked to a loss of pressure in the secondary expansion vessel.
The expansion vessel protects the blender from damage when the water in the secondary system
expands as the water re-heats after water is drawn off.
31
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Check the pressure in the secondary expansion vessel as detailed previously in section 2.
If it does not hold pressure it will need to be changed. If this doesn’t resolve the problem, it will be
necessary to change the blender
Strip off the blender and check hot and cold mesh filters for blockage. (Clean if necessary).
3.2.5 Checking the concentration of corrosion inhibitor
We would recommend Sentinel X100, or equivalent. Dose appropriately according to the size of the
Thermaflow and central heating system volume combined and in accordance with the inhibitor
manufacturer’s guidelines.
3.2.6 Preventing pump seizure in summer
To prevent seizure of the central heating pump we recommend you turn the central heating on for 30
seconds or so every few weeks throughout the summer.
Seized pumps can usually be freed. The air release on the pump can be completely removed. A small flat
blade screwdriver can be inserted into the slot in the centre and rotated to free the pump.
3.2.7Checking correct operation of electrical components
WARNING: BEFORE OBTAINING ACCESS TO TERMINALS, ALL SUPPLY CIRCUITS MUST
BE DISCONNECTED.
3.2.8 Low pressure switch
To check correct operation of the low pressure switch, drain some water from the central heating system
until the pressure falls below 0.5 bar, then check continuity between terminals 1 and 2 there should be no
continuity between these terminals.
Re pressurise the boiler and re check there is continuity between the same terminals.
3.2.9 Control and high limit manual re-set thermostats
Check operation of the control and over temperature thermostats by checking for continuity between both
terminals.
(YOU MAY HAVE TO REMOVE THESE THERMOSTATS IF THE BOILER IS STILL HOLDING HOT
WATER. YOU CAN PLACE THE THERMOSTATS IN A BEAKER OF COLD WATER AND THEN
CHECK FOR CONTINUITY ACROSS THE THERMOSTAT).
3.2.10 CONTROL THERMOSTATS;
There are three or four of these thermostats in total. One is fitted in each heating element. The control
thermostats are individually preset.
They should not be tampered with. If a failure on one of the thermostats has occurred, take note of which
element it was removed from and contact Thermaflow Ltd for spares and advice.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
3.2.11 OVER TEMPERATURE THERMOSTATS;
(Manual re-set); there are two of these which will break the circuit to the coil on the contactor causing
power to break to the heating elements.
One is fitted above the central heating pump and one further up on the boiler. This second stage over
temperature thermostat is pre-set to 95ºC. It should not be tampered with.
If a failure on one of the thermostats has occurred you can re-set the thermostat by pressing the small
reset button on the thermostat.
If the thermostat continues to fail in an overheat condition a fault may have occurred in one or more of
the control thermostats within the heating elements.
Take note of which one it is and contact Thermaflow Ltd for spares and advice.
The second is also a manual re-set over temperature thermostat and is fitted on the boiler.
This is the 3rd stage manual re-set master over temperature thermostat. It will break the circuit to the
contactor on over temperature.
It is preset to 95ºC and sealed and should not be tampered with.
This will indicate a fault has occurred on one or more of the control thermostats within the
heating elements and will have to be investigated.
If it continues to fail in an over-heat condition the fault must be rectified before the appliance is
turned back on for use.
If a failure has occurred, contact Thermaflow Ltd for spares and advice.
3.2.12 Checking the heating elements
Check the resistance between live and neutral terminals on the element.
Replace the element if the resistance is greater than 10 m ohms.
3.2.13 Checking circuit breakers
Switch each circuit breaker off in turn and check that continuity is broken to each element.
3.2.14 Checking the contactor
Turn the main isolator off (this should be situated adjacent to the boiler) you should hear a small click
from the control box marked number 17 on the boiler schematic on page 9 of this instruction manual.
This indicates that the contactor has disconnected the circuit to the heating elements.
Turn the main isolator on and off a few times and listen for this noise. This will indicate correct operation
of the contactor.
3.2.15 Check the operation of the AQUA STAT
The Aqua Stat is positioned on the cold water inlet entering the boiler. Make sure
the external controls
are calling for heat. Remove the cover and turn the dial on the thermostat up and down and listen for a
small click.
As you turn the thermostat dial up and down check if the central heating pump, (positioned on the right
side of the unit) is switching on and off and do the same with the DHW pump on the left hand side.
If
this is the case, this indicates correct operation of the thermostat.
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THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
A
4.1.1 SOLAR THERMAL LINKED INTO THE THERMAFLOW
1. Solar Panels
2. Solar Pump Station
3. Solar Expansion Vessel
4. Discharge Tank
5. External Primary Transfer Kit
6. Thermaflow Electric Combi
7. Hot and Cold Demand
8. Space Heating
9. Primary Expansion Vessel
A. Solar Panel Flow Pipe
B. Solar Panel Return Pipe
C. Cold Water Supply
D. Hot Water Supply
E. Central Heating Flow
F. Central Heating Return
B
D
6
7
34
8
F C
3
2
4
5
E
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
p
4.1.2 SOLID FUEL SYSTEM LINKED INTO THERMAFLOW
FE Tank
Gravity Radiator
Temperature
Set 70˚C
For illustration purposes only
Manual Reset H/L
Thermostats
ermostat Control Th
Supply
L N E
Temperature
ermostat Control Th
Set 50˚C
Solid Fuel
Stove
35
Automatic Air
Eliminators at high
points on pipe work
Pump
Thermaflow external
primary heat transfer
Pum
-set
THERMAFLOW LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207
4.1.3 EXTERNAL PRIMARY HEAT TRANSFER EQUIPMENT
External Primary Heat Transfer Equipment
Flow connection on
Thermaflow boiler
Thermal Solar Circuit
Flow from
Solar
Return
Solar
from
Return connecti
on Th
ermaflow
boiler
Flow from
Wood Burn
Return fro
Wood Burner
on
er
m
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