Thermolec B-6U-FFB, B-10U-FFB, B-12U-FFB, B-15U-FFB, B-5U-M Installation Instructions Manual

THERMOLEC

Installation
Instructions
for
Electric
Boilers (USA)

JULY 2006

VERSION 9

1

1

Installation Guidelines for Thermolec Electric Boilers Model B

1 Important

1.1 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.

1.2 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.

2 Unpacking

2.1 Inspect the unit and check whether there are missing parts.

2.2 Report any damage or claims to the carrier immediately.

2.3 For all returns to be accepted they must be authorized by the manufacturer.

3 Location and dimensions

3.1 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" 9-1/2"

36" 0" 12" 6"

up to 18 kW 3ph

Long Models

18" 28" 9-1/2"

36" 0" 24" 6" 12"

up to 42 kW

3.2 The boiler room should be well ventilated as to maintain the temperature below 77°F.

3.3 The unit must be mounted level on a vertical wall with the outlet tting on the left side of the unit.

12"

2

4 Components

4 or 6 mounting holes

Electronic

temperature

sensor

Outlet 1-1/4’’ NPT

Incoloy elements High-limit

thermal cut-out

Solid state relays

9 1/2”

Mono or Dual energy
controller

Adjustable
electronic
aquastat
(output
temperature)

Temperature /
pressure
gauge

Inlet 1-1/4’’ NPT

Outdoor reset sensor

Fig. 3

Fig. 1

Diverting valve
terminals

18”

Diverting valve
control relay

Pump relay

Ground lug

Pump relay terminals
(dry contacts 10A)

18”

Thermostat terminals Fig. 2

Magnetic back-up contactor

Boiler control
transformer

Circuit breaker

3-way valve control
transformer

Fuse and
fuse holder

Note : The model shown here is a typical FFB boiler 20kW / 240 Volts / 1phase.

5 Standard specifications for all models

Table 2 on the following page give specifications and current for the standard models.

3

Table 2

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.

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

Mono-Energy Models B-5U-M B-6U-M B-8U-M B-9U-M B-10U-M B-12U-M B-15U-M

kW

BTU / H

Total Amps 20.83 25.00 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

Mono-Energy Models B-18U-M B-20U-M B-23U-M B-27U-M B-30U-M B-35U-M B-40U-M

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 6 8 9 10 11.5 15

17,060 20,472 27,296 30,708 34,120 39,238 51,180

18 20 23 27 30 35 40

61,416 68,240 78,476 92,124 102,360 119,420 136,480

A06 x 1A05 x 1)eziS rekaerB(

Standard Model Specifications @ 3ph

Dual-Energy Models B-18U-FFB B-24U-FFB B-30U-FFB B-35U-FFB B-40U-FFB

Mono-Energy Models B-18U-M B-24U-M B-30U-M B-35U-M B-40U-M

kW

BTU / H

Amps @ 208V / 3ph 48.00 66.69 83.37 96.00

No. Of Power Supplies 1 x 60

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

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.

Table 3

4

6 Water circulation and plumbing notes

Capacity (kW) US Gallons / min

5

1.8

6

2.0

9

3.1

10

3.5

12

4.2

15

5.3

18

6.2

20

7.0

23

8.0

25

8.8

30

10.4

35

12.2

40

13.9

Recommended Water Flow Rate vs Capacity

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

6.1 The system is designed to operate with a maximum output temperature of 180°F or

lower and a temperature rise across the unit of 20°F or lower.

Please refer to Table 4 for the recommended 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.

Table 5

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

6.3 The installation must have a drain valve, an expansion tank, maintenance valves and an automatic

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.

specified in Table 5 will not help to increase water flow.

5

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, 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 reasonably vented before starting the unit.

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 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

10987654321

°C

78 73 68 61 54 49 44 40 37 36

°F

172 163 154 142 129 120 111 104 99 97

Minimum

temperature

°C

°F

48 48 48 45 40 38 34 31 29 28

118 118 118 113 104 100 93 88 84 82

6