Thermolec B-6U-FFB, B-10U-FFB, B-12U-FFB, B-15U-FFB, B-18U-FFB Installation Instructions Manual
...
THERMOLEC
Installation
Instructions
for
Electric
Boilers (USA)
DECEMBER 2010
VERSION 11
.
.
5/18/2008
s
CostPerMillionBtu
0.038 0.040 0.042 0.044 0.046 0.048 0.050 0.052 0.054 0.056 0.058 0.060 0.062 0.064 0.066 0.068 0.070 0.072 0.074 0.076 0.078 0.080 0.090 0.100
100% 11.14 11.72 12.31 12.90 13.48 14.07 14.65 15.24 15.83 16.41 17.00 17.58 18.17 18.76 19.34 19.93 20.52 21.10 21.69 22.27 22.86 23.45 26.38 29.31
150% 7.42 7.82 8.21 8.60 8.99 9.38 9.77 10.16 10.55 10.94 11.33 11.72 12.11 12.50 12.90 13.29 13.68 14.07 14.46 14.85 15.24 15.63 17.58 19.54
200% 5.57 5.86 6.15 6.45 6.74 7.03 7.33 7.62 7.91 8.21 8.50 8.79 9.09 9.38 9.67 9.96 10.26 10.55 10.84 11.14 11.43 11.72 13.19 14.65
$/kWh
250% 4.45 4.69 4.92 5.16 5.39 5.63 5.86 6.10 6.33 6.57 6.80 7.03 7.27 7.50 7.74 7.97 8.21 8.44 8.68 8.91 9.14 9.38 10.55 11.72
Electricity 3412BTU/kWh
275% 4.05 4.26 4.48 4.69 4.90 5.12 5.33 5.54 5.76 5.97 6.18 6.39 6.61 6.82 7.03 7.25 7.46 7.67 7.89 8.10 8.31 8.53 9.59 10.66
300% 3.71 3.91 4.10 4.30 4.49 4.69 4.88 5.08 5.28 5.47 5.67 5.86 6.06 6.25 6.45 6.64 6.84 7.03 7.23 7.42 7.62 7.82 8.79 9.77
325% 3.43 3.61 3.79 3.97 4.15 4.33 4.51 4.69 4.87 5.05 5.23 5.41 5.59 5.77 5.95 6.13 6.31 6.49 6.67 6.85 7.03 7.21 8.12 9.02
(C.O.P.orEF)
SystemEfficiency
350% 3.18 3.35 3.52 3.68 3.85 4.02 4.19 4.35 4.52 4.69 4.86 5.02 5.19 5.36 5.53 5.69 5.86 6.03 6.20 6.36 6.53 6.70 7.54 8.37
400% 2.78 2.93 3.08 3.22 3.37 3.52 3.66 3.81 3.96 4.10 4.25 4.40 4.54 4.69 4.84 4.98 5.13 5.28 5.42 5.57 5.72 5.86 6.59 7.33
0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
75% 12.00 12.67 13.33 14.00 14.67 15.33 16.00 16.67 17.33 18.00 18.67 19.33 20.00 20.67 21.33 22.00 22.67 23.33 24.00 24.67 25.33 26.00 26.67 27.33
80% 11.25 11.88 12.50 13.13 13.75 14.38 15.00 15.63 16.25 16.88 17.50 18.13 18.75 19.38 20.00 20.63 21.25 21.88 22.50 23.13 23.75 24.38 25.00 25.63
82% 10.98 11.59 12.20 12.80 13.41 14.02 14.63 15.24 15.85 16.46 17.07 17.68 18.29 18.90 19.51 20.12 20.73 21.34 21.95 22.56 23.17 23.78 24.39 25.00
85% 10.59 11.18 11.76 12.35 12.94 13.53 14.12 14.71 15.29 15.88 16.47 17.06 17.65 18.24 18.82 19.41 20.00 20.59 21.18 21.76 22.35 22.94 23.53 24.12
$/ccf
90% 10.00 10.56 11.11 11.67 12.22 12.78 13.33 13.89 14.44 15.00 15.56 16.11 16.67 17.22 17.78 18.33 18.89 19.44 20.00 20.56 21.11 21.67 22.22 22.78
NaturalGas 100,000BTU/therm
92% 9.78 10.33 10.87 11.41 11.96 12.50 13.04 13.59 14.13 14.67 15.22 15.76 16.30 16.85 17.39 17.93 18.48 19.02 19.57 20.11 20.65 21.20 21.74 22.28
95% 9.47 10.00 10.53 11.05 11.58 12.11 12.63 13.16 13.68 14.21 14.74 15.26 15.79 16.32 16.84 17.37 17.89 18.42 18.95 19.47 20.00 20.53 21.05 21.58
SystemEffciency
1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.60 2.70 2.80 2.90 2.95 3.00 3.05 3.10
75% 13.96 15.36 16.75 18.15 19.55 20.94 22.34 23.73 25.13 26.53 27.92 29.32 30.72 32.11 33.51 34.90 36.30 37.70 39.09 40.49 41.19 41.88 42.58 43.28
80% 13.09 14.40 15.71 17.02 18.32 19.63 20.94 22.25 23.56 24.87 26.18 27.49 28.80 30.10 31.41 32.72 34.03 35.34 36.65 37.96 38.61 39.27 39.92 40.58
82% 12.77 14.05 15.32 16.60 17.88 19.15 20.43 21.71 22.99 24.26 25.54 26.82 28.09 29.37 30.65 31.92 33.20 34.48 35.76 37.03 37.67 38.31 38.95 39.59
85% 12.32 13.55 14.78 16.01 17.25 18.48 19.71 20.94 22.17 23.41 24.64 25.87 27.10 28.33 29.57 30.80 32.03 33.26 34.49 35.73 36.34 36.96 37.57 38.19
$/gal
90% 11.63 12.80 13.96 15.13 16.29 17.45 18.62 19.78 20.94 22.11 23.27 24.43 25.60 26.76 27.92 29.09 30.25 31.41 32.58 33.74 34.32 34.90 35.49 36.07
Propane 95,500BTU/gallon
92% 11.38 12.52 13.66 14.80 15.93 17.07 18.21 19.35 20.49 21.63 22.76 23.90 25.04 26.18 27.32 28.45 29.59 30.73 31.87 33.01 33.58 34.15 34.71 35.28
138,900BTU/galllon
3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.80 3.90 4.00 4.10 4.20 4.30 4.40 4.50 4.60 4.70 4.80 4.90 5.00
95% 11.02 12.12 13.23 14.33 15.43 16.53 17.64 18.74 19.84 20.94 22.04 23.15 24.25 25.35 26.45 27.56 28.66 29.76 30.86 31.96 32.52 33.07 33.62 34.17
SystemEffciency
$/gal
FuelOil
75% 30.72 31.20 31.68 32.16 32.64 33.12 33.60 34.08 34.56 35.04 35.52 36.48 37.44 38.40 39.36 40.32 41.28 42.24 43.20 44.16 45.12 46.08 47.04 48.00
80% 28.80 29.25 29.70 30.15 30.60 31.05 31.50 31.95 32.40 32.85 33.30 34.20 35.10 36.00 36.90 37.80 38.70 39.60 40.50 41.40 42.30 43.20 44.10 45.00
82% 28.10 28.53 28.97 29.41 29.85 30.29 30.73 31.17 31.61 32.05 32.49 33.36 34.24 35.12 36.00 36.88 37.75 38.63 39.51 40.39 41.26 42.14 43.02 43.90
85% 27.10 27.53 27.95 28.37 28.80 29.22 29.64 30.07 30.49 30.92 31.34 32.19 33.03 33.88 34.73 35.57 36.42 37.27 38.11 38.96 39.81 40.66 41.50 42.35
90% 25.60 26.00 26.40 26.80 27.20 27.60 28.00 28.40 28.80 29.20 29.60 30.40 31.20 32.00 32.80 33.60 34.40 35.20 36.00 36.80 37.60 38.40 39.20 40.00
92% 25.04 25.43 25.82 26.22 26.61 27.00 27.39 27.78 28.17 28.56 28.95 29.74 30.52 31.30 32.08 32.87 33.65 34.43 35.21 36.00 36.78 37.56 38.34 39.13
95% 24.25 24.63 25.01 25.39 25.77 26.15 26.52 26.90 27.28 27.66 28.04 28.80 29.56 30.31 31.07 31.83 32.59 33.34 34.10 34.86 35.62 36.38 37.13 37.89
SystemEffciency
CoefficientofPerformance(C.O.P.)Thesameastheefficiencystatedasaratioofworkorusefulenergyoutputofasystemvs.theamountofenergyinputtedintothesystem
EnergyFactor(EF)Theefficiencyormeasureofoverallefficiencyofavarietyofappliances.WaterheaterefficienciesareratedbyEF
AnnualFuelUtilitizationEfficiency(AFUE)Themeasureofannualefficiencyofaresidentialheatingfurnaceorboiler.Accountsforoperationenergylossesoftheheatingunit
EnergyEfficiencyTerm
1 Components
Incoloy elements Manual reset
Electronic
temperature
sensor
thermal cut-out
Solid state relays
Mounting holes
Outlet 1-1/4ÊÊ NPT
Temperature /
pressure
gauge
Pump relay
Inlet 1-1/4ÊÊ NPT
Fig. 1
18”
Pump relay terminals
(dry contacts 10A)
Fuse and
fuse holder
Note : The model shown above is a typical FFB boiler 15kW / 240 Volts / 1 phase.
Model shown below is a TMB boiler 11kW / 240 / 1 phase.
Magnetic back-up contactor
Boiler control
transformer
18”
Circuit breaker
9”
Ground lug
Outdoor reset sensor
Fig. 3
18”
9”
13”
Page 1
A
A
A
A
(
)
A30A60A60A60A
(U.S.A.)
(U.S.A.)
Wire Size 12 10 8 6 4 3 2 1 0 00 000
Amps @ 75°C (167°F)
20 30 45 65 85 100 115 130 150 175 200
Amps @ 90°C (194°F)
20 30 45 65 85 105 120 140 155 185 210
Notes :
Cable Amps Capacity vs Wire Size
1- This table should be used as a guide only. Always select the wire size according to the local
Electrical Code.
2- Always use wire suitable for 75°C (167°F) minimum, 300V or 600V as required.
3- All models with suffix "U" over 12 kW at 240V / 1ph require two feeders. Divide the Total
Amps by 2 to select the proper wire size.
4- COPPER WIRE ONLY.
2 Standard specifications for all models
Mono Models B-3T MBU B-6TMBU B-9TMBU B-11TMBU
kW 36911
BTU/H 10,236 20,472 30,708 37,532
Total Amps 12.5 25.0 37.5 45.8
Breaker size 1 x 20A 1 x 40A 1 x 50A 1 x 60A
TMB MONO Model Specifications @ 240V / 1ph (U.S.A.)
Table 2
Standard Models Specifications @ 240V / 1ph
Dual-Energy Models B-5U-FFB B-6U-FFB B-8U-FFB B-9U-FFB B-10U-FFB B-12U-FFB B-15U-FFB
kW
BTU / H
Total Amps 20.83 23.96 33.33 37.50 41.67 47.92 62.50
No. Of Power Supplies 1 x 30A 1 x 30A 1 x 50A 1 x 50A 1 x 60A 1 x 60A 1 x 60A
(Breaker Size) 1 x 30A
Dual-Energy Models B-18U-FFB B-20U-FFB B-23U-FFB B-27U-FFB B-30U-FFB B-35U-FFB B-40U-FFB
kW
BTU / H
Total Amps 75.00 83.37 95.83 112.50 125.00 145.83 166.67
No. Of Power Supplies 1 x 60A 2 x 60A 2 x 60A 2 x 50A 3 x 60A 4 x 50A 4 x 60A
5 89105.75 11.5 15
17,060 19,619 27,296 30,708 34,120 39,238 51,180
18 20 23 27 30 35 40
61,416 68,242 78,479 92,128 102,360 119,420 136,480
A06 x 1A05 x 1)eziS rekaerB(
No. Of Power Supplies 1 x 60
NOTE: Other models, voltages and capacities available upon request. Please contact the factory.
Please use Table 3 below to select the wire size for the power supply.
Standard Model Specifications @ 3ph
Dual-Energy Models B-18U-FFB B-24U-FFB B-30U-FFB B-35U-FFB B-40U-FFB
kW
BTU / H
Amps @ 208V / 3ph 48.00 66.69 83.37 96.00
Breaker Size
Amps@ 480V / 3ph 21.68 28.90 36.13 42.15 48.00
Disconnect Switch 30
18 24 30 35 40
61,416 81,888 102,360 119,420 136,480
2 x 50
2 x 60
2 x 60
n/a
Table 3
Page 2
Installation Guidelines for Thermolec Electric Boilers Model B
3 Important
3.1 These instructions should be used as a general guide only. Electrical Code and local utility requirements must
be followed and take precedence over these instructions.
3.2 Thermolec electric boilers are manufactured with quality components for maximum life, durability and
minimum service. To ensure a satisfactory installation it is imperative that you read these instructions
carefully before installing and operating the heating system.
Failure to do so may result in breach of warranty.
4 Unpacking
4.1 Inspect the unit and check whether there are missing parts.
4.2 Report any damage or claims to the carrier immediately.
4.3 For all returns to be accepted they must be authorized by the manufacturer.
5 Location and dimensions
5.1 These boilers are designed for wall mounting. Please see Table 1 below for overall dimensions.
Table 1 also gives the minimum clearances to combustible material as well as recommended distances for
ease of service (e.g. replacement of tubular elements).
Table 1
Dimensions and Clearances
Overall dimensions Clearances
Models Width Height Depth Front Back Top Right Others
Short Models
up to 23 kW 1ph
18" 18" 9"
36" 0" 12" 6"
up to 18 kW 3ph
Long Models
18" 28" 9"
36" 0" 24" 6" 12"
up to 40 kW
TMB
5.2 The boiler room should be well ventilated as to maintain the temperature below 77°F.
5.3 The unit must be mounted level on a vertical wall with the outlet tting on the left side of the unit.
13" 18" 9"
36" 0" 12" 6"
12"
12"
Page 3
6 Water circulation and plumbing notes
Maximum Flow Rate Pipe Diameter
US Gallons / min (Type L Copper)
4.3 3/4"
10.1 1"
17.3 1-1/4"
Maximum Flow Rate @ 15 psi
Capacity (kW) US Gallons / min
3 1.1
5 1.8
6 2.0
8 2.8
9 3.1
10 3. 5
11 3. 9
12 4. 2
15 5. 3
18 6. 2
20 7. 0
23 8. 0
27 8. 8
30 10.4
35 12.2
40 13.9
Minimum Water Flow Rate vs Capacity
6.1 The system is designed to operate with a maximum output temperature of 190°F or lower and a
temperature rise across the unit of 20°F or lower.
Please refer to Table 4 for the minimum flow rate versus the capacity of the boiler.
Table 4
6.2 In order to ensure an adequate flow rate :
6.21 Pressure loss (referred as "Head") caused by water friction in the system should not exceed the
capacity of the pump.
6.22 Please refer to Table 5 below to find the copper pipe diameter (type L) recommended to
accommodate the water flow found in Table 4 above.
6.3 The installation must have a drain valve, an expansion tank, maintenance valves and an automatic
6.23 Elbows and valves will greatly add to the head loss in the system. An appropriate water flow rate
must be maintained to avoid tripping of the temperature limiter. Pipes with diameters larger than
specified in Table 5 will not help to increase water flow.
6.24 Head loss through the boiler tank is negligable and should not affect calculations of flow rates.
pressure reducing fill valve set at 15 PSI (104 kPA). A "T" fitting (1-1/4" NPT) must be installed at the
supply outlet of the unit. This "T" must be equipped with a reducing bushing 1-1/4" to 3/4" NPT, facing
upwards, to accept a 3/4" NPT pressure relief valve. This safety valve must be installed vertically. Except
for the pressure relief valve, the above plumbing supplies are not supplied with the unit. Please refer to
illustrations A, B and C at the end of this manual.
Table 5
Page 4
6.4 The automatic pressure relief valve supplied with the boiler is required to prevent dangerous pressure
build-ups in the system in case of system malfunction and may under certain conditions vent hot water.
Do not install the system where water could damage rugs, furniture, etc. When piping the relief valve to a
drain, check with local authority for recommended method of installation. Do not open or tamper with the
relief valve. If operated frequently or used to drain or flush the system, the valve could fail to seat properly
and thus leak.
Important safety notice : This safety valve is mandatory and must be installed as shown in the
illustrations A, B and C at the end of this manual. The omission of the safety valve installation will
create a very serious safety hazard and will void all warranties.
6.5 Automatic air vents should be installed at the highest point of the installation and above the level of the
boiler tank, ideally on all radiator units for best results or at points where air could possibly be trapped in
the system.
Caution : Make sure the system has been properly vented before starting the unit.
6.6 Depending on water conditions, determine wether water additives are necessary.
7 Mechanical installation
7.1 Mounting brackets are located on the sides of the boiler. Depending on the size of the unit, four or six
holes are provided. The unit may be attached directly to a combustible surface.
7.2 Use a circulator pump of appropriate capacity for the intended application. The pump should be placed as
close as possible to the boiler. Ensure that the water direction is correct. An arrow indicating the
circulation direction is generally visible on the pump casing.
7.3 Install inlet and outlet piping.
7.4 Install air vents, valves, the pressure relief valve supplied with the unit, expansion tank, etc.
7.5 When everything is finished, install the temperature / pressure gauge.
8 Electrical installation
8.1 Disconnect all power sources before opening the main panel and working within.
8.2 Read the nameplate and other markings carefully and wire strictly in accordance with the wiring diagram.
8.3 Wires and protective equipment must be sized according to the applicable Electrical Code.
8.4 Use only wires suitable for minimum 167°F.
8.5 Install the outdoor sensor on an exterior North wall and connect it with 18/2 wire to terminals
"OT / OT" on the electronic board (TH-600 series controller).
8.6 On the electronic aquastat (marked "WATER TEMPERATURE"), select the maximum water temperature
required (1-10) by the type of installation. Please see Table 6 below for the temperature obtained
according to the knob position. The minimum water temperature is reset automatically by the outdoor
sensor. Please see the variation graph in Fig 5.
Table 6
Water Temperature controlled by Electronic Aquastat
Set-point
Maximum
temperature
Minimum
temperature
10987654321
°C
88 81 75 67 58 50 45 42 39 36
°F
190 178 167 153 137 122 113 107 102 97
°C
48 48 48 45 40 38 34 31 29 28
°F
118 118 118 113 104 100 93 88 84 82
Page 5
Electronic Aquastat
MAXIMUM
WATER TEMPERATURE
MINIMUM
WATER TEMPERATURE
°F +14 +23 +32 +41 +50
Fig. 4 Fig. 5
8.7 The outdoor sensor will :
a) Maintain the selected maximum water temperature when the outdoor temperature is at +14° F or
colder.
b) Automatically and proportionally compensate by varying the water temperature between the
maximum and minimum when the outdoor temperature is between +14°F and +50°F.
c) Maintain the minimum water temperature when the outdoor temperature is between +50°F and
+68°F.
d) Prevent boiler operation above +68°F.
NOTE : If you choose not to use the outdoor sensor, don't connect it to the "OT / OT" terminals nor jumper
these terminals. You will not use this feature and the water will simply be maintained at the maximum
selected temperature.
8.8 Connect the thermostat or the zone valve end switch wires to "C" and "W1" terminals on the electronic
board. Power stealing thermostats require an isolation relay (not included).
8.9 Circulating Pump Control. The "P / P" terminals are connected to dry contacts of a relay (capacity up
to 1 HP) and are used to start the pump. This relay is switched ON with the first heating step and OFF
after the last one. A separate 120V / 1Ø service must be provided from the electrical panel to the boiler
for the pump. For Electric Boiler only systems, refer to the wiring diagram. For Electric Boiler with fossil
fuel backup, see the diagram on page 23 labeled ‘PUMP WIRING WITH FOSSIL FUEL BACKUP
BOILER’ as the pump must also run when another source of heat is selected.
Follow the extra steps dedicated to a FFB installation in the start-up sequence.
8.10 Set the room thermostat heat anticipator (when available) to 0.2 Amperes.
8.11 If the system is used with Load Management control, connect the Utility signal to "S1 / S2" terminals.
A closed contact enables the boiler, an open contact disables the boiler.
8.12 The installation is now ready for start-up procedure and testing.
9 Start-up procedure and test sequence
Do not energize electrical elements prior to purging system and verifying proper water circulation
Double check the following carefully :
9.1 All wiring and plumbing is complete.
9.2 Pipes have been cleaned, the system has been flushed and filled again.
9.3 Without powering the entire unit, install a jumper between the "P / P" terminals (using proper gauge of
wire) and switch the pump breaker ON as to let the pump run alone. Verify that the pump is running freely
and check for leaks. During this test, a lot of bubbles will travel through the system and air will be
eliminated by the automatic vents. You can accelerate the process by purging the radiators manually.
Shut off the pump breaker at the panel, then remove the jumper between the "P / P" terminals.
9.4 The pressure in the system has been stabilized at approximately 15 PSI (104 kPA).
9.5 The entire system is now almost free of air.
9.6 The room thermostat anticipator (when available) has been set at 0.2 Amperes.
9.7 Switch the boiler breaker ON at the main panel.
Page 6
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