thermital THC 150 GREY, THC 800 GREY, THC 210 GREY, THC 600 GREY, THC 1000 GREY Installation, Operation And Maintenance Manual

...

THC 150-1450 GREY

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

ENGLISH

RANGE

MODEL CODE

THC 150 GREY 03504183 THC 210 GREY 03504184 THC 270 GREY 03504185 THC 350 GREY 03504186 THC 450 GREY 03504187 THC 600 GREY 03504188 THC 800 GREY 03504189 THC 1000 GREY 03504190 THC 1250 GREY 03504191 THC 1450 GREY 03504192 THC/C 270 GREY 20012752 THC/C 350 GREY 20012753 THC/C 450 GREY 20012754 THC/C 600 GREY 20012756

ACCESSORIES

For a complete list of accessories and details of their compatibility, refer to the Catalogue.

ENGLISH

Dear Customer, Thank you for choosing a T boiler. You have purchased a modern, high efﬁciency, quality product that is designed to give dependable and safe service and to provide comfort in the home for many years to come. Arrange for your boiler to be serviced regularly by an authorised Technical Assistance 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 efﬁcient functioning of your

THC GREY

boiler.

Please accept our renewed thanks for your purchase Thermital

CONFORMITY

THC GREY

boilers conform to:

- Directive 92/42/EEC on efﬁciency requirements

- Electromagnetic Compatibility Directive 2014/30/EU

- Low Voltage Directive 2014/35/EU

- Directive 2009/142/EC - Gas Appliances Models up to 400 kW conform to the Energy-Related Products Directive 2009/125/EC and to the EU Delegated Regulation 813/2013.

This manual, Code 068672EN - Rev. 32 (04/17) comprises 40 pages.

ENGLISH

Contents

CONTENTS

The following symbols are used in this manual:

CAUTION! =

Identiﬁes actions that require caution and

adequate preparation.

STOP! =

Identiﬁes actions that you MUST NOT do.

This manual, Code

- Rev. comprises pages.

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . 4

General Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . 4

Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description of the appliance . . . . . . . . . . . . . . . . . . . . . . . . 5

Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Recommended burners and technical speciﬁcations . . . . . 7

THC GREY GTM BLU with power < 400 kW . . . . . . . . . . . . 7

THC GREY PREMIX with power < 400 kW . . . . . . . . . . . . . . 9

THC GREY with power > 400 kW . . . . . . . . . . . . . . . . . . . . 11

Identiﬁcation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SYSTEM MANAGER . . . . . . . . . . . . . . . . . . . . . . . . 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 protected

whenever possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation in B23P conﬁgurationin . . . . . . . . . . . . . . . . . . 27

Door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Changing the direction of door opening . . . . . . . . . . . . . . 28

Removing the hinge assembly "B" . . . . . . . . . . . . . . . . . . . 30

Earth connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fitting the casing panels . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TECHNICAL ASSISTANCE CENTRE . . . . . . . . . . . 32

Preparing for initial startup . . . . . . . . . . . . . . . . . . . . . . . . . 32

Initial startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Checks during and after initial start-up . . . . . . . . . . . . . . . 33

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ENGLISH

GENERAL INFORMATION

General Safety Information

The boiler is delivered in separate crates. Check that it is complete, undamaged and as ordered as soon as you receive it. Report any discrepancies or damage to the dealer who sold it.

This product must be installed by a legally qualiﬁed heating engineer. On completion of the installation, the installer must issue the owner with a declaration of conformity conﬁrming that the installation has been completed to the highest standards in compliance with the instructions provided by T in this instruction manual, and that it conforms to all applicable laws and standards.

This product must only be used for the purpose for which it is designed and made, as speciﬁed by T.

T declines all responsibility, contractual or

other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use.

If you notice any water leaking from the boiler, disconnect it immediately from the mains electricity supply, shut off the water supply, and notify your local T’s Technical Assistance Centre or a qualiﬁed heating engineer immediately.

Periodically check that operating pressure in the water circuit is over 1 bar but below the maximum limit speciﬁed for the boiler. If this is not the case, contact Technical Assistance Centre T or a professionally qualiﬁed heating engineer.

If the boiler is not going to be used for an extended period of time, contact T’s Technical Assistance Centre or a qualiﬁed heating engineer to have it prepared for shut-down as follows

- Switch the boiler OFF at the control panel

- Turn the main system switch "off"

- Close the fuel cock and heating circuit water cock

- Drain the central heating circuit if there is any risk of freezing.

The boiler must be serviced at least once a year.

This instruction manual is an integral part of the boiler. It must be kept safe 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 precautions be respected:

It is forbidden to use electrical devices or equipment, such as switches, appliances, etc. if there is a smell of gas or un-burnt products. If so:

- Ventilate the room, opening doors and windows

- Close the fuel shut-off cock

- Report the fault immediately to the T's Technical Assistance Centre or a professionally qualiﬁed heating engineer.

Do not touch the boiler while barefoot or wet.

Never clean or service the boiler without ﬁrst disconnecting it from the mains electricity supply by turning the main power switch and the control panel switch OFF.

Do not tamper with or adjust the safety or control devices without prior authorisation and instructions from the manufacturer.

Do not plug or block the condensate drain outlet.

Never pull, disconnect, or twist the electrical cables coming from the appliance even if it is disconnected from the mains electricity supply.

Do not obstruct or restrict the vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion.

Do not expose the boiler to the elements. It is designed to work indoors.

Do not switch the boiler off if outdoor temperature drops below ZERO (risk of freezing).

Do not store containers of ﬂammable substances in the room where the boiler is installed.

Do not allow children or persons with reduced physical, sensorial or mental abilities or with insufﬁcient experience and knowledge to operate this system without proper supervision from the person responsible for its safe use.

Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation.

General information

ENGLISH

GENERAL INFORMATION

Description of the appliance

THC GREY

T steel boilers are triple ﬂue pass, condensing boilers for installation in a boiler room. While they are designed primarily for central heating purposes, in conjunction with a suitable storage cylinder they can also be used to produce domestic hot water. All parts that come into contact with the combustion gases are made from titanium stabilised stainless steel to ensure maximum resistance to the corrosive action of acid condensation. The boiler has been designed with the combustion chamber at the top and the smooth pipe tube bundle at the bottom to optimise heat exchange and energy efﬁciency and to maximise the condensing effect. The boiler has a high total water content which is differentially distributed between its top and bottom sections. This allows outgoing water to reach the set temperature quickly while maintaining the condensing effect and the water heating time around the tube bundle for as long as possible.

THC GREY

boilers feature lightly pressurised combustion chambers 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 completely to facilitate the inspection, maintenance and cleaning of internal parts and to speed up servicing in general. The front door can open in either direction and can be opened without removing the burner. The door is factory ﬁtted with hinges on the left, but these can be reversed if necessary to suit individual installations.

4 5

6 (*)

8 (*)

13 14

Burner

Flame inspection window with

Door

Casing

Outlet

Safety device ﬁtting

Heating return (high temperature)

Heating return (low temperature)

Blind plug

Instrument bulb/sensor sockets

Combustion chamber

Flue gas exhaust

Flue gas box

Inspection window

Condensate outlet

Boiler drain

Turbulators

Flue gas pipes

Second ﬂue pass

(*) On the THC 1450 GREY the low temperature heating return (8) is located at the rear of the boiler, and the

safety ﬁtting (6) is ﬂanged.

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GENERAL INFORMATION

Control panels

The T control panels that can be used with

THC GREY

steel boilers are listed below. These control panels cater for all the needs of the heating system and of all the devices installed in it.

TECH CLIMA 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 heating 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 single stage burner. Also for controlling solar heating system and cascaded boiler systems.

TECH CLIMA MIX

for controlling 1 additional mixed zone.

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GENERAL INFORMATION

Recommended burners and technical specications

THC GREY GTM BLU with power < 400 kW

The burners suggested to obtain the best performance of T THC GREY GTM BLU <400 kW boilers are:

BURNERS BOILER THC GREY GTM BLU

MODEL CODE 150 210 270 350

GAS

BS 3/M 3762350 x

(R)

RS 25/M BLU TC FS1 3910510 x

(R)

RS 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.

See the instruction manual provided with the burner:

- Burner installation

- Electrical connections

- Burner adjustments.

To assemble/disassemble the burners equipped with recirculation tube, it might be necessary to remove the latter before carrying out such operations (strictly comply with the use and maintenance manual of the burner).

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GENERAL INFORMATION

Technical specications

DESCRIPTION

BOILER THC GREY GTM BLU

150 210 270 350

Device type

Condensing boiler for central heating

B23 Fuel All gas fuels Device category See Burner

Rated heat input (Qmax) HCV (LCV)

166,5

(150)

233,1 (210)

299,7

(270)

388,5

(350)

Rated heat input (Qmin) HCV (LCV)

123,2

(111)

167,6 (151)

234,2

(211)

300,8

(271)

Useful (rated) heat output 147 205 264 344 Rated maximum useful heat output (80/60°C) P4 146,6 205,2 264,3 343,7 kW Rated min. useful heat output (80/60°C) (Pn min) 108,2 147,5 207,2 266,4 kW 30% heat output with return at 30°C (P1) 44,0 61,6 79,3 103,1 kW Seasonal energy efﬁciency ηs

92,0 93,0 93,0 93,0 %

Efﬁciency at rated heat input in high temperature mode η4 (80-60°C) HCV (LCV)

88,0

(97,7)

88,0

(97,7)

88,2

(97,9)

88,5

(98,2)

Useful efﬁciency at Pn min (80/60°C) HCV (LCV)

87,8

(97,5)

88,0

(97,7)

88,5

(98,2)

88,6

(98,3)

Efﬁciency at 30% rated heat input in low temperature mode η1 with return at 30°C (HCV)

97,7

(108,5)

98,5

(109,3)

98,4

(109,2)

97,9

(108,7)

Losses from stack for sensible heat (Qmax) 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 dm

Tot. volume of ﬂue gas side 272 292 413,0 482,0 dm

Heat exchange surface area 8,2 10,4 13,0 16,3 m

Volumetric heat load (Qmax) 872 1221 1120 1254 kW/m

Speciﬁc heat load 18 19,9 20,4 20,9 kW/m

Maximum condensate production 18,4 27,4 31,9 40,9 l/h Maximum working pressure 6 bar Maximum permitted temperature 110 °C Maximum operating temperature 95 °C Pressure drop ∆T 10°C 43,2 36,0 54,0 46,4 mbar Pressure drop ∆T 20°C 11,3 10,2 16,3 13,4 mbar Water capacity 323 360 495 555 l Consumption at full load (Elmax) 650 650 800 800 W Consumption at part load (Elmin) 132 195 240 240 W Electrical consumption in standby mode (PSB) 20 20 20 20 W

(*) Depends on return temperature (30-60°C)

The stack must guarantee the minimum draught speciﬁed by applicable technical standards, assuming zero pressure at the connection to the ﬂue.

Values obtained in combination with the reference burners (R) indicated in the combination table.

ENGLISH

GENERAL INFORMATION

THC GREY PREMIX with power < 400 kW

The burners suggested to obtain the best performance of T THC GREY PREMIX <400 kW boilers are:

BURNERS BOILER THC GREY PREMIX

ACCESSORIES

KIT

MODEL CODE 150 210 270 350

BURNER

PLATE

GAS

MODULATING

RX 180 S/PV 3790330 x

(R)

4031894

RX 250 S/PV 3790320 x

(R)

4031894

RX 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.

See the instruction manual provided with the burner:

- Burner installation

- Electrical connections

- Burner adjustments.

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GENERAL INFORMATION

Technical specications

DESCRIPTION

BOILER THC GREY PREMIX

150 210 270 350

Device type

Condensing boiler for central heating

B23 - B23P(*) Fuel All gas fuels Device category See Burner

Rated heat input (Qmax) HCV (LCV)

166,5

(150)

233,1 (210)

299,7

(270)

388,5

(350)

Rated heat input (Qmin) HCV (LCV)

123,2

(111)

167,6 (151)

234,2

(211)

300,8

(271)

92,0 93,0 93,0 93,0 %

Efﬁciency at rated heat input in high temperature mode η4 (80-60°C) HCV (LCV)

88,0

(97,7)

88,0

(97,7)

88,2

(97,9)

88,5

(98,2)

Useful efﬁciency at Pn min (80/60°C) HCV (LCV)

87,8

(97,5)

88,0

(97,7)

88,5

(98,2)

88,6

(98,3)

Efﬁciency at 30% rated heat input in low temperature mode η1 with return at 30°C (HCV)

97,7

(108,5)

98,5

(109,3)

98,4

(109,2)

97,9

(108,7)

Losses from stack for sensible heat (Qmax) 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) 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 dm

Tot. volume of ﬂue gas side 272 292 413,0 482,0 dm

Heat exchange surface area 8,2 10,4 13,0 16,3 m

Volumetric heat load (Qmax) 872 1221 1120 1254 kW/m

Speciﬁc heat load 18 19,9 20,4 20,9 kW/m

Maximum condensate production 18,4 27,4 31,9 40,9 l/h Maximum working pressure 6 bar Maximum permitted temperature 110 °C Maximum operating temperature 95 °C Pressure drop ∆T 10°C 43,2 36,0 54,0 46,4 mbar Pressure drop ∆T 20°C 11,3 10,2 16,3 13,4 mbar Water capacity 323 360 495 555 l Consumption at full load (Elmax) 400 430 450 1050 W Consumption at part load (Elmin) 140 160 180 250 W Electrical consumption in standby mode (PSB) 20 20 20 20 W

(*) The B23P conﬁguration may only be adopted with premix gas burners. (**) Depends on return temperature (30-60°C)

The stack must guarantee the minimum draught speciﬁed by applicable technical standards, assuming zero pressure at the connection to the ﬂue.

Values obtained in combination with the reference burners (R) indicated in the combination table.

ENGLISH

GENERAL INFORMATION

THC GREY with power > 400 kW

The burners suggested to obtain the best performance of T THC GREY >400 kW boilers are:

BURNERS BOILER THC GREY ACCESSORIES KIT

MODEL CODE 450 600 800 1000 1250 1450

BURNER FLANGE

HEAD SLIDING

GAS

MODULATING

RS 55/M BLU TC FS1 20038484 x 4031188 RS 68/M BLU T.C. 3897406 x 4031196 RS 120/M BLU T.C.D 3897606 x 4031196 RS 120/M BLU T.C.D 3897606 x 4031196 RS 160/M BLU TC FS1 3788006 x 20047680 RS 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.

See the instruction manual provided with the burner:

- Burner installation

- Electrical connections

- Burner adjustments.

ENGLISH

GENERAL INFORMATION

Technical specications

DESCRIPTION

BOILER THC GREY

450 600 800 1000 1250 1450

Device type

Condensing boiler for central heating

B23 - B23P(*) Fuel All gas fuels Device category See Burner

Rated heat input (Qmax) HCV (LCV)

499,5

(450)

666,0

(600)

888,0

(800)

1110,0 (1000)

1387,5

(1250)

1609,5

(1450)

Rated heat input (Qmin) HCV (LCV)

389,6

(351)

500,6

(451)

667,1

(601)

889,1

(801)

1111,1

(1001)

1388,6

(1251)

Useful (rated) heat output 442 589 786 982 1228 1424 Rated maximum useful heat output (80/60°C) P4 441,9 589,2 785,6 982,0 1227,5 1423,9 kW Rated min. useful heat output (80/60°C) (Pn min) 345,0 443,3 590,8 787,4 984,0 1229,7 kW 30% heat output with return at 30°C (P1) 132,6 176,8 235,7 294,6 368,3 427,2 kW Efﬁciency at rated heat input in high temperature mode

η4 (80-60°C) HCV (LCV)

88,5

(98,2)

88,5

(98,2)

88,5

(98,2)

88,5

(98,2)

88,5

(98,2)

88,5

(98,2)

Useful efﬁciency at Pn min (80/60°C) HCV (LCV)

88,6

(98,3)

88,6

(98,3)

88,6

(98,3)

88,6

(98,3)

88,6

(98,3)

88,6

(98,3)

Efﬁciency at 30% rated heat input in low temperature mode η1 with return 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 dm

Tot. volume of ﬂue gas side 737 860 1290 1454 1763 2097 dm

Heat exchange surface area 21,8 28,8 39,6 46,5 56,2 62,3 m

Volumetric heat load (Qmax) 1018 1210 1062 1183 1205 1161 kW/m

Speciﬁc heat load 20,1 20,3 18,5 21,0 21,7 22,6 kW/m

Maximum condensate production 52,2 73,8 88,0 111,4 132,7 159,5 l/h Maximum working pressure 6 bar Maximum permitted temperature 110 °C Maximum operating temperature 95 °C Pressure drop ∆T 10°C 33,8 30,2 128,7 121,5 100,4 150,1 mbar Pressure drop ∆T 20°C 9,0 8,5 28,7 30,6 28,4 36,3 mbar Water capacity 743 770 1320 1395 1825 1900 l

(*) The B23P conﬁguration may only be adopted with premix gas burners. (**) Depends on return temperature (30-60°C) (***) At Pn max and Tm = 80°C, Tr = 60°C e CO2 = 10,3%

The stack must guarantee the minimum draught speciﬁed by applicable technical standards, assuming zero pressure at the connection to the ﬂue.

+ 28 hidden pages

thermital THC 150 GREY, THC 800 GREY, THC 210 GREY, THC 600 GREY, THC 1000 GREY Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual