Elco THISION L Fiche technique

Operation and Installation manual

for authorized technicians only

THISION L

02/2011 DOC3078 / 12103187

Contents

Contents .................................................................. 2

Safety General regulations................................... 3

Application................................................. 3

Norms and regulations .............................. 3

Construction Layout of boiler.......................................... 4

Operating principle .................................... 4

Technical data .................................................................. 5

Extent of delivery Standard boiler.......................................... 7

Accessories............................................... 7

Installation Boiler transport.......................................... 8

Removing the casing................................. 8

Boiler installation ....................................... 9

Connecting the boiler ................................ 9

Commissioning Water and hydraulic system ...................... 11

Gas supply ................................................ 12

Condensate connection............................. 12

Flue and air intake connections................. 12

Prepare boiler for first startup.................... 12

Combustion analysis ................................. 14

Check water flow ...................................... 15

Check functionality of safety devices ........ 16

Gas tightness check.................................. 16

Boiler shut down........................................ 16

Commissioning protocol ............................ 17

Operating instructions Controls .................................................... 18

Display / Programming.............................. 19

Overview of main functions ....................... 20

Maintenance Checklist.................................................... 21

Replacing the electrodes........................... 21

Cleaning the condensate receptacle ......... 22

Cleaning and refilling the syphon .............. 22

Inspection of combustion chamber............ 22

Water pressure and quality ....................... 23

Water flow rate .......................................... 23

Combustion analysis ................................. 23

Gas pressure............................................. 23

Gas tightness check.................................. 23

Safety devices........................................... 23

Maintenance protocol ................................ 24

Lockouts .................................................................. 25

Sensor values .................................................................. 28

Declaration of Conformity .................................................................. 29

Safety

General regulations

Application

Norms and regulations

General regulations

This documentation contains important

information, which is a base for safe

and reliable installation, commissioning

and operation of the THISION L boiler.

All activities described in this document

may only be excecuted by authorized

companies.

Changes to this document may be ef-

fected without prior notice. We accept

no obligation to adapt previously deliv-

ered products to incorporate such

changes.

Only original spare parts may be used

when replacing components on the

boiler, otherwise warranty will be void.

Application

The THISION L boiler may be used for

heating and hot water production pur-

poses only. The boiler should be con-

nected to closed systems with a maxi-

mum temperature of 100ºC (high limit

temperature), maximum setpoint tem-

perature is 90ºC.

Norms and regulations

When installing and operating the

boiler, all applicable norms (european

and local) should be fulfilled:

Local building regulations for install-

ing combustion air and flue gas sys-

tems;

Regulation for connecting the boiler to

the electrical appliance;

Regulations for connecting the boiler

to the local gas network;

Norms and regulations according to

safety equipment for heating systems;

Any additional local laws/regulations

with regard to installing and operating

heating systems.

Additional national standards

Germany:

RAL - UZ 61 / DIN 4702-8

Switzerland:

SVGW

EKAS-Form. 1942: Flüssiggas-

Richtlinie Teil 2

Vorschriften der kantonalen Instanzen

(z.B. Feuerpoilizeivorschriften)

Netherlands:

GASKEUR BASIS

GASKEUR SV

GASKEUR HR107

Belgium:

HR TOP

The THISION L boiler is CE approved

and applies to the following Euro-

pean standards:

 92 / 42 / EEC

Boiler efficiency directive

 2009 / 142 / EEC

Gas appliance directive

 2006 / 95 / EEC

Low voltage directive

 2004 / 108 / EEC

EMC directive

EN 483

Gas-fired central heating boilers -

Type C boilers of nominal heat input

not exceeding 70 kW

EN 15420

Gas-fired central heating boilers -

Type C boilers of nominal heat input

exceeding 70 kW, but not exceeding

1000 kW

EN 15417

Gas-fired central heating boilers -

Specific requirements for condensing

boilers with a nominal heat input

greater than 70 kW but not exceeding

1000 kW

EN 50165

Electrical equipment of non-electric

appliances for household and similar

purposes - Safety requirements

EN 15502-1

Gas-fired central heating boilers -

Part 1: General requirements and

tests

EN 55014-1 (2000)

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 1: Emission

EN 55014-2 (1997)

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 2: Immunity - Product family

standard

EN 61000-3-2 (2000)

Electromagnetic compatibility (EMC) -

Part 3-2: Limits - Limits for harmonic

current emissions (equipment input

current 16 A per phase)

EN 61000-3-3 (2001)

Electromagnetic compatibility (EMC) -

Part 3-3: Limitation of voltage

changes, voltage fluctuations and

flicker in public low-voltage supply

systems, for equipment with rated

current 16 A per phase and not sub-

ject to conditional connection

EN 60335-1 (2002)

Household and similar electrical appli-

ances - Safety - Part 1: General re-

quirements

EN 60335-2-102 (2006)

Household an similar electrical

appliances: Particular requirements

for gas, oil and solid-fuel burning ap-

pliances having electrical connections

Construction

Layout of boiler

Operating principle

Layout of boiler

The THISION L boiler consists of the

following main components:

1 Casing

2 Control panel

3 Flue gas connection (+ test point)

4 Air intake connection (+ test point)

5 Flow water connection

6 Return water connection

7 Gas connection

8 Syphon

9 Input for wiring

10 Connection for safety valve

11 Connection for fill/drain valve

12 Manometer

13 Fan

14 Gas valve

15 Ignition and ionisation electrodes

16 Heat exchanger

17 Inspection window

18 Ignition transformer

19 Electrical input connections

20 Controller

21 Condensate receptacle

Operating principle

The THISION L is a fully modulating

boiler. The control unit of the boiler

adapts the modulation ratio automati-

cally to the heat demand requested by

the system. This is done by controlling

the speed of the fan. As a result, the

Whirlwind mixing system will adapt the

gas ratio to the chosen fan speed, in

order to maintain the best possible

combustion figures and therewith the

best efficiency. The flue gases created

by the combustion are transported

downwards through the heat exchanger

The LMS14 control unit can control the

boiler operation based on:

Boiler control (stand alone operation);

weather compensated operation

(with optional outdoor sensor);

with 0-10V external influence

(temperature or capacity) from a buil-

ding management system.

and leave the boiler at the top into the

chimney connection.

The return water from the system en-

ters the boiler in the lower section,

where is the lowest flue gas tempera-

ture in the boiler. In this section con-

densation takes place. The water is

being transported upwards through the

heat exchanger, in order to leave the

boiler at the flow connection. The cross

flow working principle (water up, flue

gas down) ensures the most efficient

combustion results.

5 6

8 7

10 11

Technical data

THISION L

100

THISION L

120

THISION L

145

Nominal heat output at 80-60ºC max/min kW 60.8/10.1 81.1/13.4 92.9/15.6 111.6/18.7 132.2/23.3

Nominal heat output at 75-60ºC max/min kW 60.9/10.1 81.3/13.4 93.1/15.6 111.8/18.7 132.5/23.3

Nominal heat output at 40/30ºC max/min kW 63.9/11.1 85.3/14.8 100.0/17.2 120.0/20.6 142.3/25.6

Nominal heat input Hi max/min kW 62.4/10.4 83.3/13.8 95.2/16.0 114.3/19.2 135.5/23.9

Efficiency at 80/60ºC % 97.4 97.4 97.6 97.6 97.6

Efficiency at 40/30ºC % 102.4 102.4 105.0 105.0 105.0

Annual efficiency (NNG 75/60ºC) % 106.2 106.2 106.2 106.2 106.2

Annual efficiency (NNG 40/30ºC) % >110 >110 >110 >110 >110

Standstill losses (Twater = 70ºC) % 0.20 0.20 0.20 0.20 0.20

Max. condensate flow l/h 3.5 4.8 6.4 7.7 9.1

Gas consumption H-gas max/min (10,9 kWh/m3)m3/h 5.7/1.0 7.6/1.3 8.7/1.5 10.5/1.8 12.4/2.2

Gas consumption L-gas max/min (8,34 kWh/m3)m3/h 7.5/1.2 10.0/1.7 11.4/1.9 13.7/2.3 16.3/2.9

Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 4.9/0.8 6.5/1.1 7.4/1.3 8.9/1.5 10.6/1.9

Gas pressure H-gas mbar 20 20 20 20 20

Gas pressure L-gas mbar 25 25 25 25 25

Gas pressure LPG mbar 30/50 30/50 30/50 30/50 30/50

Maximum gas pressure mbar 50 50 50 50 50

Flue gas temperature at 80/60ºC max/min ºC 76/63 76/63 76/63 76/63 76/63

Flue gas temperature at 40/30ºC max/min ºC 55/39 55/39 55/39 55/39 55/39

Flue gas quantity max/min m3/h 119/19 159/25 178/29 213/35 253/44

CO2level natural gas H/E/L max/min % 8.5/8.5 8.5/8.5 8.7/8.5 8.7/8.5 8.7/8.5

CO2level liguid gas P max/min % -/- -/- -/- -/- -/-

NOx level mg/kWh 39 39 39 39 39

CO level max/min mg/kWh 98/7 98/7 98/7 98/7 98/7

Max. permissible flue resistance max/min Pa 150/15 150/15 150/15 200/15 200/15

Water volume l 3.5 4.8 6.4 7.7 9.1

Water pressure max/min bar 6/1 6/1 6/1 6/1 6/1

Max. water temperature (High limit thermostat) ºC 100 100 100 100 100

Maximum temperature setpoint ºC 90 90 90 90 90

Nominal water flow at dT=20K m3/h 2.6 3.4 4.0 4.8 5.6

Hydraulic resistance at nominal water flow kPa 16 29 15 22 34

Electrical connection V 230 230 230 230 230

Frequency Hz 50 50 50 50 50

Mains connection fuse A 10 10 10 10 10

IP class - IPX4D IPX4D IPX4D IPX4D IPX4D

Power consumption boiler max/min (excl. pump) W 98/26 167/38 195/30 228/36 248/44

Power consumption 3-step pump (optional) W 150 205 150 210 385

Power consumption speed controlled pump (opt) W 124 124 130 130 130

Weight (empty) kg 60 68 80 90 97

Noise level at 1 meter distance dB(A) - - - - -

Ionisation current minimum µA 3 3 3 3 3

PH value condensate - 3.2 3.2 3.2 3.2 3.2

CE certification code -

Water connections - R1.1/4" R1.1/4" R1.1/2" R1.1/2" R1.1/2"

Gas connection - R3/4" R3/4" R1" R1" R1"

Flue gas connection mm 100 100 100 100 130

Air intake connection (for room sealed use) mm 100 100 100 100 130

Condensate connection mm 22 22 22 22 22

CE-0063CM3576

Technical data

Dimensions TH-L 65 TH-L 85 TH-L 100 TH-L 120 TH-L 145

B mm 490 490 590 590 590

B1 mm 140 140 140 140 190

B2 mm 245 245 295 295 295

D mm 500 500 600 600 600

H mm 810 810 950 950 950

W1 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"

W2 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"

G mm R 3/4" R 3/4" R 1" R 1" R 1"

F mm 100 100 100 100 130

A mm 100 100 100 100 130

Extent of delivery

Standard boiler

Accessories

Standard boiler

A boiler delivery package contains the

following components:

Extension module AGU2.550 for

heating zone control or external gas

valve and/or room fan control in com-

bination with an alarm signal.

For each boiler a maximum of 3

AGU2.550 modules (2x heating zone,

1x ext. gas valve / room fan in combi-

nation with alarm) can be integrated

in the boiler;

Additional RVS63 heating zone con-

troller, when controlling more than 2

zones (incl. wall hung box, all neces-

sary sensors and sockets and con-

nection material for bus communica-

tion).

The above accessories are specially

designed for the THISION L boiler and

therewith easy to install (plug and play).

By choosing a combination of the kits

mentioned above, you can create your

own complete system solution. Ask

your supplier for more detailed informa-

tion.

Component Pcs. Package

Boiler fully assembled and tested 1 Cardboard box on pallet

Mounting bracket incl. mounting material 1 Cardboard box in boiler packaging

Syphon for condensate connection 1 Cardboard box in boiler packaging

Conversion kit for propane incl. instruction 1 Cardboard box in boiler packaging

Operation and Installation manual 1 Map packed in cardboard box in boiler packaging

Spare parts list 1 Map packed in cardboard box in boiler packaging

Wiring diagram 1 Map packed in cardboard box in boiler packaging

Accessories

Additional to the boiler, the following

accessories can be ordered:

Standard 3-step pump incl. connec-

tion kit;

Speed controlled pump incl. connec-

tion kit;

Safety valve, fill/drain valve and con-

nection for expansion tank;

Set with water (2x) and gas (1x)

cocks;

Gas filter incl. connection kit;

Min. gas pressure switch;

Plate heat exchanger (dT=10K/15K or

dT=20K) incl. connection kit;

Low velocity header, suitable for

dT=10K/15K and dT=20K incl. con-

nection kit;

Plug & play cascade kit (see cascade

manual for more details);

Extension module AGU2.551 for

0-10V control of a modulating pump

and/or boiler capacity feedback to a

building management system;

Electrical connection for external gas

valve and/or room fan.

Installation

Boiler transport

Removing the casing

Boiler transport

The THISION L boiler will be supplied

as a complete unit being fully assem-

bled and pre-tested. The packaging

dimension is 1050x572x575mm for

boiler types 65-85 and

1185x674x665mm for boiler types 100-

145, which makes it possible to trans-

port all models through a normal door

in one piece.

The THISION L can be transported with

a crane, but it has to be ensured that

the boiler is packed and fixed on a pal-

let. The straps must be connected to

the pallet.

Removing the casing

Remove the casing before installing the

boiler, in order to avoid damage to the

casing parts. Removing the casing is

done as shown on the pictures.

Installation

Boiler installation

Connecting the boiler

Boiler installation

The boiler should be positioned in a

frost-proof boiler room. If the boiler

room is on the roof, the boiler itself may

never be the highest point of the instal-

lation.

When positioning the boiler, please

note the recommended minimum clea-

rance in the picture. When the boiler is

positioned with less free space, mainte-

nance activities will be more difficult.

Connecting the boiler

This chapter will explain how to make

all connections to the boiler with regard

to:

Hydraulic connections

Condensate drain connection

Gas connection

Flue gas connection

Air intake connection

Electrical connection

The boiler should always be connected

in such a way, that the system applies

to all relevant standards and regulati-

ons (European, national and local). It’s

the responsibility of the installer to en-

sure that all standards and regulations

are respected.

Hydraulic connections (1,2,3,4)

The boiler should always be connected

in such a way, that water flow through

the boiler can be ensured at all times.

Connect the flow (1) and return (2) con-

nection of the system tension free to

the boiler connections.

The boiler contains a connection possi-

bility for an (optional) kit with safety

valve, fill/drain valve and an expansion

tank connection. The safety valve must

be connected to the flow connection (3)

of the boiler, the fill/drain valve and

expansion tank connection must be

connected to the return connection (4).

The (optional) pump kit should be

mounted directly to the return connecti-

on (2) of the boiler, before connecting

to the system.

Condensate connection (5)

After filling with water, the syphon

(included in delivery) should be in-

stalled to the connection (5) at the bot-

tom of the boiler. Connect the hose to

the draining system in the boiler room.

The connection to the draining system

should always be done with an open

connection, in order to avoid a flooding

of the boiler in case of a blocked drain.

Gas connection (6)

The gas connection must be made by

an authorized installer in accordance

with the applicable national and local

standards and regulations.

Connect the gas line from the system

tension free to the gas connection (6) of

the boiler. A gas cock should be moun-

ted directly behind the boiler.

A gas filter can be mounted directly on

the gas connection of the boiler.

1 2

5 6

3 4

Installation

Connecting the boiler

Flue gas connection (7)

Regulations for the construction of flue

gas systems are very different for each

country. It should be ensured that all

national regulations with regard to flue

gas systems are respected.

Connect the flue gas system to the flue

gas connection (7) of the boiler, use

fluegas systems with seamless connec-

tions only. It’s not necessary to make a

separate condensate drain for the flue

gas system, as the condensate will be

drained via the syphon of the boiler.

Please note the following issues:

It’s recommended to use stainless

steel or PPS fluegas systems

The diameter of the flue gas system

must be chosen by calculation ac-

cording to the national regulations

Construct the flue gas system as

short as possible (for maximum

length see planner documentation)

Construct horizonal ways with a mini-

mum angle of 3º

Air intake connection (8)

The air intake can be connected in ca-

se of room sealed installation. The dia-

meter should be calculated according

to the national regulations, together

with the flue gas system. The total re-

sistance of both systems should never

overcome the maximum permissible

resistance of the fan inside the boiler

(see also chapter: Technical data).

Electrical connection

The electrical connection must be

made by an authorized installer in

accordance with the applicable

national and local standards and re-

gulations.

For the power supply it’s necessary

to use a mains isolator switch with a

contact opening of at least 3 mm

within the boiler room. This switch

can be used to switch off the power

supply for maintenance purposes.

All cables should be lead through the

cable glants (9) at the bottom of the

boiler of the boiler boiler into the elec-

tro panel (10).

Connect all wires to the terminals

according to the wiring diagram of the

boiler (enclosed in map in boiler

packaging).

Outside sensor mounting

If an outside sensor (accessory) is

connected to the boiler, the sensor

should be positioned as shown on the

drawing.

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