operating instructions for qualified persons · 2014. 6. 15. · en 50165 electrical equipment of...

Operating Instructions for qualified persons

Condensing Gas Boiler THISION S

with High Efficiency Pump

06/2014 Art. Nr. 3750529

Table of Contents

Table of contents ....................................................................................... 2 General information ........................................................ 3

Heating water quality ...................................................... 4 Product description Functional description 5

Delivery scope THISION S ............................................. 5 Technical Specifications ................................................. 6 Technical Specifications for CH only .............................. 8

Dimensions ..................................................................... 9 Dimension drawing THISION S ...................................... 9 Control display ................................................................ 10

Hydraulics Circulating pumps ........................................................... 11 Low loss header 12 Plate heat exchanger...................................................... 14

Assembly Installlation, Mounting, Connections ............................... 15 Flue gas and supply air connection 16

Air supply/flue gas routing .............................................. 16 Design variants 16 Sizing .............................................................................. 17 Routing design ............................................................... 18

Installation Elektrical connections ..................................................... 19 Operating Instructions Main functions ................................................................ 20 Commissioning Preparation for operation 21

Flue gas quantity and adjustment ................................. 22 Minimum Output ........................................................ 23 Maximum Output ....................................................... 24 Gas conversion settings

THISION S 9.1/13.1, natural gas ................................. 25 THISION S 17.1/25.1, natural/liquid gas ...................... 26 THISION S 35.1 + 50.1, natural/liquid gas .................. 27 Gas conversion instructions

THISION S 9.1/13.1, natural gas ................................. 28 THISION S 17.1/25.1, natural gas ............................... 29 THISION S 25.1, natural/liquid gas.............................. 30 THISION S 35.1 + 50.1, natural/liquid gas .................. 31

Maintenance Checks and Inspections ................................................. 32 Maintenance and Service ....................................................................................... 34 Faults, Causes, Remedies Error codes and remedies .............................................. 36 Sensor Resistances........................................................ 37 Electrical diagram ........................................................... 38 Declaration of coonformity .............................................. 39

2

General Information

General Information

Installation, erection, power

connection and first start-up are

duties of a qualified person who is

responsible for proper completion of

these tasks.

Notes for the operating company

Both the safety and function of the

Thermo unit remain ensured if the

plant is regularly serviced by a

heating specialist. To ensure regular

scheduling it is recommended to

conclude a servicing agreement.

To operate the unit in a user-friendly

and stable way, we recommend also

building in the unit base included in

the options.

Prior to the installation of the

THISION S Thermo unit, first

obtain the approval of the gas

supply company and of the district

chimney sweeper.

Explanations to our warranty

terms

We do not grant warranty for

damages caused for the following

reasons:

- improper or inappropriate use or

operation or misuse

- faulty assembly or start-up by Buyer

or Third parties

- incorporation of parts from external

origin

- operating the plant with excess

pressure or outside the tolerances

specified by the works

- use of inappropriate combustibles - non-observance of the notes in the

Operating Instructions and

indications printed on the attached

labels on the Thermo unit

Regulations

You should adhere to the following

standards to ensure safe and non-

polluting and energy-saving

operation:

DIN 1988

- Drinking water supply systems

plants on land sites, technical

regulations for construction and

operation

90/396/EWG

- EU Guidelines for gas appliances 92/42/EWG - EU Guidelines for energy efficiency 97/23/EWG - EU Guidelines for pressure equipment

EN 437 - EU Guideline test gases - test pressures – product groups

EN 483 - Boilers for gaseous fuels

EN 677 - Central heating boilers for gaseous fuels EN 60335-1

Household and similar electrical appliances - Safety - Part 1: General requirements EN 50165

Electrical equipment of non-electric appliances for household and similar purposes - Safety requirements

DIN V-18160-1

- Chimney, planning and execution

DIN EN 12831

- Rules for the calculation of heat

quantities required in buildings

DIN EN 12828

- Safety equipment of heating

systems with admission

temperatures up to 95°C

For Germany also applicable:

- EnEV

Energy Saving Ordinance

- TRGI (DVGW G600)

Technical regulations, gas

Installation - ATV DVWK-A251

Introduction of condensate from

burner units into public sewage

systems - Land building regulations TRF

Technical regulations, liquefied gas - DVGW G688

Thermo unit technology

“Arbeitsblatt

For Austria also applicable:

- ÖNORM H 5152

Thermo unit burner systems,

Planning aids - ÖNORM M 7443

Gas units with atmospheric burner

Part 1, 3, 5, 7 - ÖNORM M 7457

Gas units with mechanically

supported premix burner - ÖNORM H 5195-1

heating water norm

- ÖVGW Directives

G1 Technical Directive for the

installation of low-pressure gas

systems

G2 Technical Directive for the

installation of liquefied gas systems

G41 Gas Thermo burner units,

installation and connection

G4 Heating room directive

- The unit is approved under Article

15a B-VG and under the burner

system Act VO (FAV 97)

- Always adhere to communal

building regulations

For Switzerland also applicable:

- GebäudeKlima Schweiz

Swiss association for heating,

ventilation and air conditioning

technology - SVGW gas guidelines G1:

Gas installations Swiss.

Association of Gas and Water

Professions - EKAS - Form, 1942:

Liquid Gas Guidelines, Part 2 - BAFU

Federal Office for the Environment - VKF

Association of Cantonal Fire

Insurances - SWKI

Swiss Society of HVAC Engineers

For Belgium also applicable:

- NBN D51-003

Also adhere to all relevant national

regulations and standards.

3

Heating Water Quality

Heating Water Quality

Both the composition and the quality

of the system water directly affect the

performance of the complete system

and life cycle of the boiler.

For first filling and subsequent supply

to the system, you can generally use

tap water of a pH value of 7-8 unless

it is very corrosive (chloride content >

150 mg/L) or very hard (> 14°dH;

hardness range IV).

You can obtain drinking water

analyses from the competent water

supply works. If specific system

volume is higher than 20 litres/kW

heating power (if any heating water

buffer tank is incorporated, for

instance), the maximum admissible

lime feed by the filling and supply

water should be determined by the

calculation procedure indicated in

VDI Directive 2035.

If necessary, the filling water should

be softened. Do not use any chemical

corrosion protection agents.

For Austria, ÖNORM H 5195-1

is also applicable.

For Switzerland, the directive

SWKI BT102-01 applies.

Unknown water quality and

substitution systems

The heating water often contains

substances and additives which

affect function and life cycle of

the Thermo unit.

Therefore you should either: heat up the old system and

completely discharge it prior to

replacing the system or

carefully flush the heating system

prior to replacing the system.

System flush will be most efficient

directly prior to first heating up.

Floor heating

You can directly connect floor heating

when pipes are sealed against

oxygen.

You usually have to build in a

temperature controller for the floor

heating system to prevent the pipes/

floor coverings from overheating. If

you do not know the model of floor

heating (when systems are replaced,

for instance) you have to install a

separating device between the

systems of boiler and floor heating

using a heat exchanger (option).

Criterion Admissible value Effect of deviations

pH value 7 - 8 Risk of corrosion for boiler components and heating

system

Hardness degrees < 14 dH / < 25 fH - increased lime depositing

- low life cycle of boiler

Chloride content < 150 mg/l Corrosion of alloy materials

4

Product Description

Functional Description of THISION S Delivery Scope

Legend: 1 Gas connection 2 Gas valve 3 Gas burner 4 Flue gas connection 5 Flue gas STL 100° C 6 Heating flow 7 Boiler supply STL 100° C 8 Heating return 9 Return line sensor 10 Ignition transformer 230 V

11 Fan 230 V 12 Heat exchanger / condenser 13 Flame inspection hole 14 Operator panel with LMU microprocessor 15 Energy saving pump 16 Automatic vent 17 Water pressure monitor 18 Fill and drain valve 19 Safety valve 3 bar 20 Safety valve outlet 21 Siphon 22 Siphon outlet 23 Analogue Manometer 24 Hot water return flow connection

Product Description

The THISION S is a wall-hung condensing and modulating gas condensing boiler with a premix burner. It has the following unique features:

- a large modulation range ensures long burner on times, minimises standby losses, start-up emissions, and material stress.

- flue gas temperature below 80°C - flue gas temperature fuse - also suitable for balanced flue

operation - device control panel with all control

elements - microprocessor with multi-function

display - automatic ignition with repetition and

ionisation control - water shortage protection device - analogue manometer - energy saving pump - built-in safety valve - stainless steel - heat exchanger with

ribbed tube condenser - storage tank loading function - extremely easy to maintain

- weather-driven control with QAA 75 remote control (optional)

- modern, thermocoated metal housing

Functional description

Using default values, the controller adjusts by changing the fan speed heat output to the actual heat demand of the heating system. To do this, the boiler supply temperature is continuously measured via a sensor.

If there is a deviation in the actual temperature from the desired temperature, the control immediately responds and adjusts the speed of the fan, and thus - via the gas valve- the boiler output also.

A deviation may result from:

- changing the boiler temperature default value on the LOGON B heating controller

- change in outside temperature

- hot water requirement

- change in heating curve

- change in heating system volume flow (from thermostatic valves and mixers)

The individual components working as a system ensure that the boiler output always meets the actual heat demand - within the control range of the device.

Consignment

The boiler is factory assembled and ready for operation, and is delivered in a cardboard box.

Included with the THISION S are:

- mounting rail (included in packaging)

- operating manual

- QAA 75 room temperature controller (optional) (unit packed separately)

- outdoor sensor (unit packed separately)

5

Product Description

Technical Specifications

Type THISION S 9.1 13.1 17.1 25.1

CE Approval Category SVGW No.

CE0085AT0244 DE-I2LL/AT-I2H

09-027-4

CE0085AQ0543 DE-II2ELL3B/P/

AT-II2H3B/P ÖVGW No. G2.777 09-027-4

G2777

Output Full load 80/60°C kW 9,1 13,3 16,9 23,9

40/30°C kW 9,9 14,6 18,3 25,7 Minimum 80/60°C kW 1,0 2,3 2,3 4,8 Load 40/30°C kW 1,2 2,7 2,7 5,4

Rated thermal input Full load kW 9,3 13,9 17,4 24,5 Minimum load kW 1,1 2,5 2,5 5,0

Boiler efficiency Full load 80/60°C % 97,8 97,4 97,4 97,4

40/30°C % 106,5 105,0 105,0 105,0 Minimum 80/60°C % 95,0 96,3 96,3 97,3

Load 40/30°C % 108,5 108,5 108,5 108,5

Efficiency factor % 108,5

Gas type Natural gas Natural gas or

liquid gas

CO2 Natural gas min./max. Vol. % 8,5 / 9,5 8,5 / 9,5 Flüssiggas min./max. Vol. % 10,5 / 10,5

NOX min./max. Annual emissions value

(3%O2) mg/m3

(3%O2) mg/m3

25/40

30

50/50

50

10/30

14

10/40

16

CO min./max. Annual emissions value

(3%O2) mg/m3

(3%O2) mg/m3

0/10 3

0/15 5

0/20 6

0/30 10

Standby losses Tk 70°C W 150

Tk 40°C W 85

Max. flue gas temperature 80/60°C 58 - 67

Flue gas mass flow max. kg/h 15 20 26 39

Max. residual flue gas pressure Pa 100

Water capacity l 3,2 Weight kg 52

Norm. gas flow pressure mbar 20 Natural gas 20 Natural gas /

50 liquid gas Min./max. gas flow pressure mbar 17,4/25 Natural gas 17,4/25 Natural gas

/ 50 liquid gas

Heating operating pressure min./max. bar 1 - 3 Operating temperature max. °C 90

Voltage/Frequency Volt/Hz 230 VAC / 50 Hz

Boiler power consumption min./max. W 18 / 37 18 / 37 18 / 37 18 / 34 Pump power consumption min./max. W 8 / 36 8 / 36 11 / 50 10 / 49

Width / Depth / Height mm 540 / 361 / 760

Male threaded gas connection R 1” Male threaded flow/return R 1” PPS flue gas connection nominal width DN 80 Supply air connection inside Ø mm 125

PVC condensate connection outside Ø mm 32

Sound pressure level at a distance of 1m dB(A) 39 - 53 40 - 51

Product information for system energy efficiency in accordance with DIN V4701-10: Nominal heating capacity Efficiency at nominal heating capacity Part load combustion efficiency

Qn (kW) η100% (%) η30% (%)

9,1 98,3

108,5

13,5 97,4 108,5

16,6 97,4 108,5

23,9 97,4 108,5

Return line temp. with 30% part load efficiency Standby mode heat loss

T 30% (C) q B,70 (%)

30 1,61

30 1,08

30 0,88

30 0,61

Aux. Power supply: Boiler incl. Heating circuit pump min./max.PHE (W) 26 / 73 26 / 73 29 / 87 28 / 83

6

Product Description

Technical Specifications

Typ THISION S 35.1 50.1

CE Approval Category SVGW No. ÖVGW No.

CE0085AR0323 DE-II2Ell3B/P / AT-II2H3B/P

09-027-4 G2.777

Output Full load

Minimum load

80/60°C 40/30°C 80/60°C 40/30°C

kW kW kW kW

34,1 36,8 9,7 10,8

48,7 52,5 9,7 10,8

Rated thermal input Full load

Minimum load

kW kW

35,0 10,0

50,0 10,0

Boiler efficiency Full load

Minimum load

80/60°C 40/30°C 80/60°C 40/30°C

% % % %

97,3 105,0 97,3 107,7

97,3 105,0 97,3 107,7

Efficiency factor % 108,2

Gas type Natural gas or Liquid gas

CO2 Natural gas Liquid gas

min./max. min./max.

Vol. % Vol. %

8,5 / 9,5 10,5 / 10,5

NOX Annual emissions value

min./max. (3%O2) (3%O2)

mg/m3

mg/m3

30/35 31

30/55 36

CO Annual emissions value

min./max. (3%O2) (3%O2)

mg/m3

mg/m3

0/10 3

0/25 8

Standby losses Tk 70°C Tk 40°C

W W

150 85

Max. flue gas temperature 80/60°C 58 - 67

Flue gas mass flow max. kg/h 54 77


Water capacity Weight

l kg

4,0 62

Norm. gas flow pressure Min./max. gas flow pressure

mbar mbar

20 Natural gas / 50 Liquid gas 17,4/25 Natural gas / 50 Liquid gas

Heating operating pressure Operating temperature

min./max. max.

bar °C

1 - 3 90

Voltage/Frequency Boiler power consumption Pump power consumption

min. / max. min. / max.

Volt/Hz W W

230 VAC / 50 Hz 19 / 47 10 / 70

Width / Depth / Height mm 765 / 361 / 760

Male threaded gas connection Male threaded flow/return PPS flue gas connection Supply air connection PVC condensate connection

nom. width inside outside

R R

DN Ø mm Ø mm

1” 1” 80 125 32

Sound pressure level at a distance of 1m dB(A) 40 - 51

Product information for system energy efficiency in accordance with DIN V4701-10: Nominal heating capacity Efficiency at nominal heating capacity Part load combustion efficiency Return line temp. with 30% part load efficiency Standby mode heat loss Aux. Power supply: Boiler incl. Heating circuit pump

min. / max.

Qn (kW)

η100% (%)

η30% (%)

T30% (C)

q B,70 (%) PHE (W)

34,1 97,3 107,7

30 0,54

29 / 117

48,7 97,3 107,7

30 0,38

29 / 117

7

Product Description

Technical Specifications for CH only

nur für CH

Type THISION S 10.1 21.1 30.1 40.1 45.1

Approval SVGW - No. 09-027-4

Output Full load

Minimum load

80/60°C kW

40/30°C kW

80/60°C kW

40/30°C kW

9,6

10,6

2,3

2,7

20,5

22,1

4,8

5,4

29,2

31,5

9,7 10,8

38,9

42,0

9,7 10,8

43,8

47,3

9,7 10,8

Rated thermal input Full load

Minimum load

kW

kW

10,0

2,5

21,0

5,0

30,0

10,0

40,0

10,0

45,0

10,0

Boiler efficiency Full load

Minimum load

80/60°C % 40/30°C %

80/60°C % 40/30°C %

97,4 106,0

96,3 107,7

97,4 105,0

97,3 107,7

97,3 105,0

97,3 107,7

97,3 105,0

97,3 107,7

97,3 105,0

97,3 107,7

Efficiency factor % 108,5 108,2

Gas type Natural gas or liquid gas

CO2 Natural gas min./max. Liquid gas min./max.

Vol. % Vol. %

8,5 / 9,5 10,5 / 10,5

NOX min./max. (3%O2) mg/m3 10/35 10/35 30/30 30/35 30/40

CO min./max. (3%O2) mg/m3 0/25 0/25 0/10 0/15 0/20

Standby losses Tk 70°C W 150 190

Max. flue gas temperature 80/60° 58 - 67 60 - 68

Flue gas mass flow max. kg/h 16 33 46 62 69


Water capacity l 3,2 4,0

Norm. gas flow pressure mbar 20 Natural gas / 50 Liquid gas

Heating operating pressure min./max. bar 1 - 3

Voltage/Frequency Boiler power consumption min./max. Pump power consumption min./max.

Volt/Hz W W

230 VAC / 50 Hz 18 / 37 18 / 34 8 / 36 10 / 49

230 VAC / 50 Hz 19 / 47 10 / 70

Width / Depth / Height mm 540 / 361 / 760 765 / 361 / 760

Male threaded gas connection Male threaded flow/return PPS flue gas connection Nom. width Supply air connection inside

R R

DN Ø mm

1” 1” 80 125

1” 1” 80 125

Sound pressure level at a distance of 1m dB(A) 40 - 51

8

Product Description

Dimensions THISION S

Dimensional Sheet THISION S

THISION S 9.1-25.1 mm

THISION S 35.1+50.1 mm

A 96,5 141,5 B 313,5 414,5 C 540,0 765,0

D 148,1 197,0 E 42,0 27,0

F 217,1 358,5 G 80,4 67,5 H 100,0 82,5 J 85,0 150,0

1 External flue gas connection Ø 80 mm Ø 80 mm 2 Male threaded gas connection R 1” R 1” 3 Male threaded heating flow R 1“ R 1“ 4 Male threaded heating return R 1“ R 1“ 5 Condensation outlet Ø 32 mm Ø 32 mm 6 Safety valve 3/4" 3/4" 7 Male threaded storage tank return R 1” R 1” 8 Concentric supply air connection Ø 125 mm Ø 125 mm

9 Mounting rail

Legend:

9.1-25.1 35.1+50.1 THISION S

9

Product Description

Control Display

A

M

H

B C D E F

G

L

I

Operation mode DHW (M)

For switching on the DHW operation (indication in display below DHW symbol) Operation mode heating zone(s) (I)

For setting 4 different heating modes: Auto (clock): Automatic operation

by time programm Comfort (sun): 24/7 heating in

comfort mode Reduction (moon): 24/7 heating in

reduced mode Standby: heating off, frost

protection activated.

Display (L)

Info mode (G)

Display possibility of following info without influence on boiler control: temperatures, operation mode Heating / DHW, error code.

Room temperature control (C)

for changing room comfort temperature

for changing setting when programming.

On/off switch (A)

Position 0:

Boiler and connected electrical components are not powered. Frost protection is not secured.

Position I:

The boiler and connected electrical components are powered and standby for operation.

Confirmation (OK) (D)

Return (ESC) (B)

These buttons are used for program-ming in combination with the rotary knob.

By pressing the ESC button it‘s possible to go back one level, changed values are not taken over by the controller.

By pressing the OK button it‘s possible to arrive in the next level or confirm changed values.

Manual mode (E)

This button is used for switching the boiler into manual mode. In manual mode all pumps will run and the mixing valves are no longer controlled, the burner setpoint is 60°C (indicated by spanner symbol).

In the display, the „tool“ symbol is shown. This manual mode should be used as a temporary measure to assure proper functioning of the boiler in case of a disfunctional controller or wrong settings, and should in no case be applied for a longer period.

Deaeration mode (E) By pressing the manual mode button longer than 3 seconds, the automatic hydraulic deaeration is activated e.g. after first filling the system. During deaeration, the system is switched to the protection mode . The pumps are switched on and off for several times. After deaeration, the boiler automatically returns to normal operation.

Legend: A On/off switch B Return (ESC) C Room temperature control D Confirmation (OK) E Manual mode F Chimney sweeper mode G Info mode H Reset button I Operation mode heating zone(s) L Display M Operation mode DHW

Chimney sweeper mode (F) Used for combustion analysis. By pressing the button once again, or automatically after 15 minutes, the chimney sweeper mode will be deactivated (indicated by spanner symbol). In case a mixing circuit is part of the heating system, the control continues normally.

Reset Button (H) By shortly pressing the reset button a burner lockout can be cancelled.

Notes

a After pressing reset once, wait for ca. 20 seconds (LMU initialising, error code 132 shows briefly; Gas flow control input is checked).

b When pressing reset twice, the LMU controller is locked manually (error code 153).

Press reset again. c Pressing reset without error

code triggers error code 153

10

Hydraulics

Circulating pumps

THISION® S 9.1-25.1 The boiler surface pump is factory set to continuous operation, so that the speed is adjusted according to the heat demand.

Technical Specifications UPM2 15-70 CIAO 1 x 230V Output (W) 63 - 4

Energy Efficiency Index EEI < 0,23

1 Circulating pump range and available pump pressure 2 Boiler resistance 3 Pump curves (full load)

THISION® S 35.1-50.1 The boiler circuit pump is factory set to operate at a constant speed, and the installer can set it to the desired lifting height.

Technical Specifications UPM2 15-70 AOS 1 x 230V Output (W) 70 - 10

Energy Efficiency Index EEI < 0,23

1 Circulating pump range and available pump pressure 2 Boiler resistance 3 Pump curve (full load)

11

Pump diagram

Pre

ssure

Hea

d (m

) P

ress

ure

Head

(m)

Pump diagram

Flow rate (m3/h)

Flow rate (m3/h)

2. Boiler resistance

3. Pump curves

1. Pump range

Hydraulics

Low loss header Plate heat exchanger

Calculation example: Heating with 16° dH (28° fH) filling water, new system (10 years) with optically clear water, system with floor heating (25 l plant capacity / kW boiler output) and a max. heating temperature during DHW charging of 90° C.

Result: The low loss header can be used. Safety devices are to be installed according to the relevant guidelines. In particular, with a system separation, both the boiler and heating circuit require an expansion tank.

Low loss header or

Low loss header

System-separation, PLHE

System separation

Water härdness Specific plant capacity

max. boiler output temperature (incl. DHW-charging)

In systems of over 40 kW with large water capacity or increased water hardness, the

requirement for a system separation must be checked using the adjacent diagram.

Legend:

A Old system > 15 years, with heavily polluted heating water. Once the system has been carefully rinsed, and the water has become optically clear, curve B should be used.

B New system < 15 years, with optically clean water

Plant capacity per kW system example; note: with large distribution networks and low energy housing, water capacity is generally higher:

1 5 l/kW (ventilation, DHW-System) 2 10 l/kW (convectors, fan heaters) 3 15 l/kW (radiators)

4 20 l/kW (pipe-radiators) 5 25 l/kW (floor heating) 6 30 l/kW (high volume cast iron

radiators) 7 35 l/kW (olders gravity heating-

systems)

Floor heating Underfloor heating can be connected

directly with oxygen-impermeable pipes.

It is always necessary to check whether an additional pump is needed.

A temperature monitor is always installed for underfloor heating, to protect the

pipes/flooring from overheating.

If the construction of the underfloor heating is not known (e.g. for system

replacement), you must install a system separation between THISION S and the

underfloor heating.

12

Hydraulics

Low Loss Header

Dimension drawing Low loss header

V1

R1

2

1

h1

4

B

h2

h3

3

V 2

R2

Legend

1 Deaeration valve connection 2 1/2" temperature sensor sleeve 3 S leeve 4 Fill and drain valve connection

V1 Heat generator flow V2 Heat consumer flow R1 Heat generator return R2 Heat consumer return

Chamber size Female thread Dimensions in mm Recommended flow rate

mm V1 / V2 / R1 / R2 B h1 h2 h3 max bis bei (with insulation)

60x60 Rp 1" 146 280 340 450 3,0 m3/h 26 kW T 7,5 °C

(100x100) 35 kW T 10 °C

52 kW T 15 °C

69 kW T 20 °C

60x60 Rp 1 1/4" 156 280 340 450 4,0 m3/h 35 kW T 7,5 °C

(100x100) 46 kW T 10 °C

69 kW T 15 °C

93 kW T 20 °C

80x80 Rp 1 1/2" 176 470 540 700 7,0 m3/h 50 kW T 7,5 °C

(125x125) 81 kW T 10 °C

122 kW T 15 °C

162 kW T 20 °C

80x80 Rp 2" 192 470 540 700 9,0 m3/h 78 kW T 7,5 °C

(125x125) 100 kW T 10 °C

157 kW T 15 °C

209 kW T 20 °C

The pressure loss in the low loss header is insignificant and can be neglected.

13

Hydraulics

Plate Heat Exchanger

Type x number Plates

a b c d L Weight S1 ... S4 Recommended layout

mm mm mm mm mm kg Male thread max. m3/h dP (kPa) kW at dt 10K

BX8TH x 52 315 73 278 40 121 4,3 G 3/4“ 2,15 10,5 25

B10TH x 56 289 119 243 72 135 6,8 G 1“ 4,30 11,0 50

B16H x 124 376 119 320 63 288 16,6 G 11/4“ 8,60 10,8 100

Dimension drawing

Plate heat exchanger

S1 = Boiler circuit flow S2 = Boiler circuit return S3 = Heating circuit flow S4 = Heating circuit return

Pre

ssu

re lo

ss in

kP

a

2 5

2 0

15

10

0

5

0,5 1,5 2,5 3,5 4,5 5,5 6,5 7,5

Flow rate in m3/h

Pressure drop curves

BX8THx52

B10THx56

B16THx124

14

Assembly

Installation, Mounting Water, Electric, Condensate Connections

Water connection

The boiler can be used for all hot water heating systems with a system pressure of at least 1.0 bar.

You must observe the safety regulations. Prior to commissioning, you must check that the heating supply and return is connected correctly.

Use the fittings supplied for the water connection. When removing the plastic caps from the water-carrying connections, test water may leak out.

Positioning

Always position the device so that operation and maintenance are easily possible.

The distance from the wall on each side must be at least 10 mm. Minimum clearance to the front is 800 mm (cabinet installation excluded).

The installation location must comply with the applicable guidelines and regulations.

Surface temperatures < 85°C.

Electrical System Connection

Der The boiler is factory-wired and ready for operation, and equipped with a 230V 50Hz connecting cable. The electrical installation must comply with the relevant STANDARD or the specific overall wiring diagram for the system.

The boiler must be protected with a

10 A fuse.

Phase and neutral must not be interchanged, or the boiler will cut out. The unit is not water resistant and therefore installation is only permitted in a non-splash-prone location.

Mounting

The boiler is attached horizontally to the wall, using the supplied mounting rail.

If the three pre-drilled holes are not suitable, drill additional suitable holes.

Installation und Distances

THISION S

Condensate connection

0.7 to 1.0 litres of condensate water are generated per m3 of burned natural gas, as a result of the extremely high energy efficiency.

Condensate arising in the boiler, in the flue gas pipe and in the chimney is to be conducted away into the public drainage system. Here, the regulations of the particular country must be observed.

The neutralisation of the condensate

may be necessary. The condensate must run out clearly visible through a funnel siphon (2). A fixed connection with the drainage system is not permissible.

Only non-corrosive and approved materials are to be used for the condensate drainpipe. The discharge is carried out in a frost-free room.

Lay the drain with a gradient in order to

avoid backflow.

Filling the siphon

Before taking the boiler into service, the

boiler-siphon (1) is to be filled with water

in order to prevent flue gases escaping

from the condensate connection.

The easiest way to fill ist to pour about 0.5 liter of water in the flue gas pipe (3). Otherwise unscrew the siphon to fill it.

During servicing and maintenance inspections, at least once a year, the condensate drain is to be cleaned , the

siphon and flue connections checked for

tightness and the boiler-siphon filled

with water.

DANGER:

Danger of poisoning!

If the siphon (1) is not full of water, or with open connections, flue gases arising can put people in mortal danger.

2

3

1

15

Assembly

Flue gas and supply air connection Air supply / flue gas routing design variants

Flue gas and supply air connection The boiler is suitable for open flue and balanced flue operation. The flue gas pipe must be disassembled for connection. For all flue gas systems you must ensure that no bypass is present between the supply air and flue gas. Pipe extenders may only be installed vertically to avoid condensate formation. For flue gas safety the boiler is equipped with a flue gas safety temperature limiter (STL) (set at 100°C) which does not therefore need to be provided on-site. The fresh air supply must be ensured. This is to be installed in accordance with applicable gas guidelines. Local regulations must be observed. We generally recommend balanced flue operation. Often there is a risk of corrosive vapours, especially in laundry or work areas, hairdressing salons, and in rooms where electroplating, printing or metalworking is taking place. In such cases, the supply air must be supplied from a suitable point outdoors.

Air/flue gas routing connection

Only original ELCO accessory parts may be used for the concentric air/flue gas routing.

Clearance between the air/flue gas routing and combustible materials is not required, because at nominal heating capacity no temperatures higher than 80°C can occur.

The air/flue gas routing must not be fed through other installation sites.

If gas condensing appliances are installed as externally wall mounted units (air/flue gas routing on outer wall), the nominal heating capacity in heating mode must be reduced to below 11 kW.

If the combustion forced air supply and air/flue gas control lines are enclosed within the floors of the building, the lines outside the installation room must be fed through a shaft with a minimum 90 minute fire resistance, and less in residential buildings, of minimum 30 minute fire resistance.

If the gas appliances are installed in rooms, in which only the roof structure is above the ceiling, the following requirements apply:

- If fire resistance is required for the ceiling, the combustion air and gas flue lines in the area between the upper of the ceiling edge and roof must have an enclosure panel, of the same fire resistance value, and made of non-combustible materials.

- If no fire resistance is required for the ceiling, the combustion air and gas flue lines in the area between the upper of the ceiling edge and roof must be laid in a shaft of non-combustible, dimensionally stable materials, or in a metal protective tube (mechanical protection).

Exhaust pipes must be able to be checked on their free cross section.

At least one a corresponding audit/inspection hole is to be provided in the installation site, in consultation with the competent local master chimney sweep. Flue gas connections must be made gases using sleeves and seals.

Sleeves are always installed against the direction of condensate flow. The air/flue gas routing must be fitted to the condensing boiler at a 1-3 % incline.

To avoid mutual interference in air/flue gas routing on the roof, we recommend a minimum air/flue gas routing separation of 2.5 m.

Connection to moisture-resistant air/exhaust flues (exhaust/supply air system), exhaust flues, or flue gas systems

Chimneys and exhaust systems must be officially approved for condensing furnaces (DIBt approval).

Sizing is done using the calculation tables, according to the exhaust gas value group. A maximum of three 90° bends may be installed. For chimneys, a working pressure of 0 Pa is to be used in the calculation.

Connection to a moisture-resistant exhaust flue or B23 exhaust system for open flue operation The air/flue gas routing must not be longer than 2 m when installed on an exhaust flue. A maximum of three 90° bends may be installed.

The exhaust flue must be checked by the DIBT and approved for condensing operation.

16

Assembly

Air supply / flue gas routing

Sizing (reference values)

D 80 / 100 flue gas pipe systems (room dependent)

Flue gas

system

Boiler type Flow direction changes

2 3 4 5 6

Total pipe length in metres (flue gas)

D 80 THISION S 9.1 32 29 26 23 20

THISION S 13.1 29 26 23 20 17

THISION S 17.1 25 22 19 16 13

THISION S 25.1 15 12 9 6 3

D 100 THISION S 35.1 26 24 22 20 18

THISION S 50.1 20 18 16 14 12

Flue gas/supply air system, D 80/125 and D 110/150 balanced flue (room air independent)

Flue gas

system Boiler type Riser pipe total pipe length in metres (flue gas/supply air)

D 80 / 125 THISION S 9.1 9

THISION S 13.1 12

THISION S 17.1 15

THISION S 21.1* 13

THISION S 25.1 12

THISION S 35.1 8

D 110 / 150** THISION S 25.1 15

THISION S 30.1* 15

THISION S 35.1 15

THISION S 40.1* 12

THISION S 45.1* 12

THISION S 50.1 12

*) applies only to Switzerland **) for Switzerland and Belgium Ø 100/150

Room air independent operation

For each 90°change in flow direction, 1.5 metres must be subtracted from the total pipe length. The boiler connection is carried out for all D80/125 devices. The additional resistance is taken into account in the above dimensions.

17

Dimensioning of flue gas and supply air piping for single boiler systems. The maximum possible flue gas and supply air pipe lengths (max. total length) with respect to x flow direction changes.

Important: Please note the comments regarding the flue gas and supply air and condensate connections in the Connections chapter.

Assembly

Air supply / flue Gas Routing Design Variants Ambient air dependent, ø80 PP

B23 Exhaust gas connection to exhaust gas system

Multiple assignment (negative pressure /overpressure)

Ambient air independent, ø 80/125 PP/Steel plate

18

C13 C13x

Air/exhaust gas routing through outside wall in the same pressure range

C33 C33x

Air/exhaust gas routing via the roof in the same pressure range. Flue gas outlet vertical endpiece.

C43 C43x

Air intake and flue gas outlet via a chimney system, integrated within the building.

C53 C53x

Fresh air supply and exhaust gas routing to the exterior in various pressure ranges. Flue gas outlet vertical endpiece.

C63* C63x

Specially designed for connection to approved separate supply air/flue gas systems devices.

C83 C83x

Air intake outside the building, flue gas outlet in chimney.

C93 C93x

Air/flue gas routing to exhaust flue above roof installation in damp resistant exhaust flue. min. ring clearances for exhaust pipes: Ø80 = 45mm Ø100 = 50mm Ø110 = 40mm

*) Not permitted for Belgium

Installation

Electrical Connections

NOTE: Before performing any procedures, you must ensure that the device is switched off.

To ensure greater security, the electrical system should be carefully checked by a qualified technician. The manufacturer is not liable for any injury caused by a lack of earthing conductor or due to faulty or defective power supply.

Make sure that the system is suitable for the maximum power consumption of the heater, as specified on the type plate. Check that there is adequate cable cross-section, or that it is no less than 1.5 mm

2.

In order to ensure the safety of the device, correct connection to an efficient earthing system is essential. The heater is supplied with power cable but no plug. The power cable must be connected to a 230 V - 50 Hz network, where LN polarity and grounding must be taken into account.

Important! The connection to the mains supply must be via a fixed connection (not with removable plug), which must be equipped with a two-pole switch with a contact opening of at least 3 mm.

QAC34 external sensor (X10-06) - The outdoor sensor is connected

using a cable of at least 2x 0.5 mm2.

In this way, a maximum length of 50 m is ensured. - The sensor should ideally be

positioned at a height of 2 - 2.5m above ground, and aligned northwards. In all cases, it must not be directly exposed to sunlight.

- Connect the outdoor sensor to the following connector: X10-06.

QAA75 remote control (X16) - Remove the 4 screws "C" from the

PCB cover "D". - The remote control is connected

using a cable of at least 2x0.5 mm2:

In this way, a maximum length of 50 m is ensured. - The remote control BUS cable (20-

30 V) must be installed separately from the 230 V/50 Hz cables.

- Connect to the remote control to connector X16.

Room thermostat (X10-01 or X10-02)

The thermostat must be attached to the electronic circuit board using the following connectors: X10-01 for room thermostat 2 or X10-02 for room thermostat 1.

Remove jumper only to connect the thermostat.

Floor heating safety thermostat (X3-01)

The safety thermostat for the floor heating is connected to connector X3-01.

When triggered, the device is completely switched off and lock (reset). Remove the jumper.

Note

The connection cable between the board and the peripherals (QAA75, QAC34 as well as the room thermostat) must be shielded.

The shielding must be grounded.

X3-01

X16

X10-01

X10-02

X10-06

19

Operating instructions

Overview of main functions

Button Action Procedure Display / Function

Set room temperature

Zone 1 and zone 2 Actuate rotary knob left/right Turn rotary knob Confirm with OK button or wait 5 sec. or press

Comfort setpoint with blinking temperature Blinking temperature in 0,5 °C steps from 10 to 30 °C

Comfort setpoint saved Comfort setpoint cancelled - after 3 sec. Main menu appears

Set room temperature for zone 1 or zone 2

Zone 2 independent from zone 1 Actuate rotary knob left/right Confirm with OK button Actuate rotary knob left/right Confirm with OK button or wait 5 sec. or press

Choose heating zone Heating zone is chosen Blinking temperature in 0,5 °C steps from 10 to 30 °C

Comfort setpoint saved Comfort setpoint cancelled - after 3 sec. Main menu appears

Switch on /off DHW operation

Press button DHW mode on / off (see indication below DHW symbol) - On: DHW mode by time programm - Off: no DHW operation - Safety functions activated

Change heating operation mode

Factory setting

Press button 1x Press

button 1x again

Press button 1x again

Automatic mode on, with: - Heating by time programm - Temperature setpoint by heating programm - Safety functions activated - Summer/Winter automatic switching activated - ECO-functions activated (see indication below operation symbol) Continuous COMFORT heating on, with: - Heating without time programm by comfort setpoint - Safety functions activated Continuous REDUCED heating on, with: - Heating without time programm by reduced setpoint - Safety functions activated - Summer/Winter automatic switching activated - ECO-functions activated Safety mode on, with: - Heating off - Temperature by frost protection - Safety functions activated

Controller Stop mode Press button > 3 sec. Press button > 3 sec. again

304: Controller Stopp mode insert setpoint after 3 sec. Main menu appears

Info display

Press button 1x Press button 1x again Press button 1x again .....

Press button 1x

INFO Segment displayed - Status Boiler - room temperature - room temperature minimum - Status DHW - room temperature maximum - Status zone 1 - outside temperature - Status zone 2 - outside temperature minimum - outside temperature maximum - Time / Date - DHW temperature 1 - Error indication - Boiler temperature - Maintenance indication - Flow temperature (Info display depends on configuration) Back to main menu; INFO Segment disappears

Operation by manual setpoint

Change factory setting boiler temperature

Press button 1x

Press button Press button Turn rotary knob -/+ Press button Press button Press button

Manual mode on (spanner symbol appears) - Haeting by fixed setpoint

(factory setting = 60 °C)

301: Manual mode insert setpoint? blinking temperature set value

Status boiler Manual mode off (spanner symbol disappears)

Deaeration Press button > 3 sec. Press button > 3 sec. again

312: Deaeration on Deaeration off

Activate chimney sweeper mode

Press button (< 3 sec.) Press button again (< 3 sec.)

Chimney sweeper mode on Chimney sweeper mode off

Temporary reduction of reduced temperature on QAA75

Press button Press button again

Heating by reduced setpoint Heating by comfort setpoint

RESET Reset button Press button (< 3 sec.) Press button again > 3 sec.

Boiler manually blocked, no release Boiler released, Alarm symbol disappears

= confirmation = cancel, return to main menu

20

Commissioning

Preparation for operation

A

M

H

B C D E F

G

L

I

Preparation for operation

To ensure correct operation, the system must be filled and fully deaerated.

Both the heating water side, as well as the domestic hot water side, must be filled and bled. The heating water side pressure can be read from the analogue manometer which is built in to THISION S.

Before starting the device, the siphon must be filled with water.

Gas connection

Before commissioning the device, the gas line and connections to the device must be checked for tightness. During pressure testing the device shut-off valve should be closed - the gas combination valve may be loaded with a maximum of 100 mbar.

The gas connection must be made in accordance with applicable guidelines and the gas supply provisions.

Between the shut off valve and the device, a screw connection must be installed; use the 3/4" connection fitting provided.

Remove any debris from the gas line. The gas flow rate must be adjusted only by a specialist. The minimum connection flow pressure is 17.4 mbar for natural gas and 50.0 mbar for LPG.

Legend: A On/off switch B Return (ESC) C Room temperature control D Confirmation (OK) E Manual mode F Chimney sweeper mode G Info mode H Reset button I Operation mode heating zone(s) L Display M Operation mode DHW

Filling and deaerating the THISION S and the heating system

Filling the heating system is carried out based on the conventional method.

The system must be deaerated on the heating and hot water sides.

The water pressure can be read, in bars, from the analogue pressure indicator or via the info button. Once the heating system filling and deaeration is completed, the boiler is operational.

After a reasonable period of time, the water pressure should be checked again refilled with water where necessary. (Note: Before filling with water, fill the hose itself with water; in this way, ingress of air into the heating system is avoided).

Deaeration mode By pressing the manual mode button longer than 3 seconds, the automatic hydraulic deaeration is activated e.g. after first filling the system. During deaeration, the system is switched to the protection mode . The pump(s) are switched on and off for several times. Then the 3-way valve (if present) is switched into DHW-mode, and again the pump(s) are switched on and off for several times. After deaeration, the boiler automatically returns to normal operation.

Commissioning

Make sure that the appliance gas, water and flue gas side is correctly connected. Set the master power switch to "On". Move switch "A" on the front panel to position "I = On".

The burner will now check all the components connected to the device. If there are any faults, they are shown on the display via an error message.

See "Error/warning messages" chapter.

The faults that can occur are explained there. Try to unlock the device, using the "H" reset button on the device a maximum of two times (possibly more during initial commissioning or after maintenance, as air may still be located in the various circuits).

21

Commissioning

Flue gas quantity and adjustment

2 1

The units are factory preset for natural gas H (G20)

Legend

1 Flue gas instrumentation opening

2 Combustion air instrumentation opening (annular gap)

A

M

H

B C D E F G

G

L

I Set up Remove the protective nipple "1". Insert the flue gas analyser probe into the opening of "1". Activate the chimney sweep function (max. load) or the controller stop function (min. load (max. load). Chimney sweep function The chimney sweep function is activated by a short press of the corresponding button (max. 3 seconds). Using the chimney sweep function, the required operation status is generated via the flue gas analysis which is carried out. The "Maintenance/special operation mode" symbol appears on the display. This function ensures that the device is operated at maximum output. Flue gas values The flue gas characteristics must correspond to the tables on pages 25-27. If this is not the case, please set the prescribed values, using the gas valve.

Controller stop function Activation

- Selection button (I) > 3 second press - The code 304 "controller stop" appears in the display, along with the "xxx%" modulation value

Change modulation value

- Press OK button (D), the modulation value flashes. Use setting knob (C) to change value - Confirm value using the OK button (D)

Exit function

- Selection button (I) > 3 second press

22

Commissioning

Flue gas quantity and adjustment (excluding Belgium) Minimum Output

A

P_OUT

P L

P_IN

B

Legend

P_IN Gas inlet pressure

P_OUT Gas output pressure

PL Control air pressure

A Full load adjusting screw

B Part load adjusting screw

Setting controller stop minimum output

Set the minimum output of the device as follows:

- Press the "I" button (Automatic/summer/winter/standby selection button) until "controller stop" appears on the bottom left of the display.

- Press the “D” (OK) button once, until the “0” digit blinks.

- Turn knob "C" (temperature knob/menu selection switch) anticlockwise, until the number "0" appears.

- Press the “D” (OK) button once, so that the “0” digit stops blinking. The device operates at 0% (minimum) of its output.

- Wait a minute, and carry out the combustion analysis. Set the adjacent CO2 values via the gas valve. The values given refer to the closed device. When the device is open (hood disassembled) the adjacent values are to be reduced by 0.15 Vol.-%. verringern.

Settings on the gas valve - Open the device as described

on page 38. - Remove the sealing plug from screw

"B" and, using an Allen wrench (4 mm), set the minimum output CO2 value.

- Note the rotation direction: - clockwise more CO2. - anticlockwise less CO2.

After adjustment, check the maximum output CO2 value. If changes have occurred here, these must be corrected. To end the analysis mode, press the button "I" until "controller stop off" appears in the display. Note

In the event of a fault, the PL (requires T-piece) or P must be measured (see reference values in the tables below).

23

Commissioning

Flue gas quantity and adjustment (excluding Belgium) Maximum Output

A

P_OUT

P L

P_IN

B

Legend

P_IN Gas inlet pressure

P_OUT Gas output pressure

PL Control air pressure

A Full load adjusting screw

B Part load adjusting screw

Setting controller stop maximum output

Set the maximum output of the device as follows:

- Press the "I" button (Automatic/summer/winter/standby selection button) until "controller stop" appears on the bottom left of the display.

- Press the “D” (OK) button once, until the “0” digit blinks.

- Turn knob "C" (temperature knob/menu selection switch) clockwise. This will update the number "0" in the display until "100" appears.

- Press the “D” (OK) button once, so that the “100” digit stops blinking.

The device operates at 100% (maximum) of its output.

- Wait a minute, and carry out the combustion analysis. Set the adjacent CO2 values via the gas valve. The values given refer to the closed device. When the device is open (hood disassembled) the adjacent values are to be reduced by 0.15 Vol.-%. verringern.

Settings on the gas valve - Open the device as described

on page 38. - The CO2 values are set using an

Allen key (3.5 mm) on screw “A”. - Note the rotation direction:

- clockwise less CO2. - anticlockwise more CO2.

After adjustment, check the maximum output CO2 value. If changes have occurred here, these must be corrected. To end the analysis mode, press the button "I" until "controller stop off" appears in the display. Note

In the event of a fault, the PL (requires T-piece) or P must be measured (see reference values in the tables below).

24

Commissioning

THISION S 9.1/13.1

Conversion of G20 to G25 Natural Gas (excluding Belgium)

Boiler construction

Type THISION S 9.1 13.1

Rated thermal input Part load/Full load kW 1,1/9,3 2,5/13,9

Ø Baffle plate Natural Gas H mm 3,00 3,80 Natural Gas L mm 3,20 4,20

Gas flow rate Natural Gas H G20 m3/h 0,12/0,98 0,26/1,47

(15°C 1013 mbar) Natural Gas L G25 m3/h 0,14/1,14 0,31/1,71

Ø Air supply ring Natural Gas H mm 12 16,5 Natural Gas L mm 12 16,5

Gas pressure P_OUT mbar 0,25/8,0 0,3/6,5

Air pressure adjustment (PL) Pa 35/950 40/780

CO2 Setting Natural Gas H % 8,0-8,5/9,0-9,5 8,0-8,5/9,0-9,5 Natural Gas L % 8,0-8,5/9,0-9,5 8,0-8,5/9,0-9,5

CO Emission Natural Gas H ppm 0/20 0/20

Note: The pressures given apply to a counter-pressure value of 0 Pa and may vary depending on the flue gas system connected.

25

Commissioning

THISION S 17.1/25.1 Conversion of G20 to G25 Natural Gas, or to Liquid Gas for 25.1 (excluding Belgium)

Boiler construction



Ø Baffle plate Natural Gas H mm 4,2 5,75 Natural Gas L mm 4,65 6,90 Propane mm - 4,65


(15°C 1013 mbar) Natural Gas L G25 DE/AT/CH

m3/h 0,31/2,14 0,61/3,01

Natural Gas L G25 BE m3/h 0,25/1,75 -

Propane G31 kg/h - 0,39/1,90

Ø Air supply ring Natural Gas H mm 18,20 29 Natural Gas L mm 18,20 29

Propane mm - 27




Propane % - 10,0-10,5/10,5-11

CO Emission Natural Gas H ppm 0-20 0-20

- 0-40


26

Commissioning

THISION S 35.1 + 50.1 Conversion of G20 to G25 Natural Gas or to Liquid Gas (excluding Belgium)

Boiler construction



Ø Baffle plate Natural Gas H mm - - Natural Gas L mm - -

Propan mm 6,40 6,40


(15°C 1013 mbar) Natural Gas L G25 m3/h 1,23/4,30 1,23/6,15

Propane G31 kg/h 0,78/2,72 0,78/3,88

Ø Air supply ring Natural Gas H mm - - Natural Gas L mm - -

Propane mm 31 31




Propane % 10,0-10,5/10,5-11,0 10,0-10,5/10,5-11,0

CO Emission Natural Gas H ppm 0-20 0-20 Propane ppm 0-40 0-40


27

Commissioning

THISION S 9.1/13.1 Conversion of G20 to G25 Natural Gas (excluding Belgium)

Gas conversion

Gas conversion may be carried out only by a specialist. Before carrying out any work, always shut off the electricity and gas supplies.

Conversion from G20 natural gas to

G25 natural gas

Gas unit outlet: - Unscrew the nut between the gas

pipe (2) and gas valve (1).

- Remove the gasket (8). - Replace G20 Ø 3.00/3.80 natural

gas baffle plate with G25 Ø 3.20/4.20 natural gas baffle plate (9) with O-ring (10) (see view A).

- Reassemble gas pipe and gas valve. When doing so, make sure that the gasket (8) supplied in the changeover kit is inserted correctly.

- Check the tightness of the gas flange with the burner operating.

- Check the CO2 values in the tables.

- If necessary, adjust the gas valve (see boiler technical description).

Conversion from G25 natural gas to G20 natural gas









Changeover kit G20 natural gas to G25 natural gas or G25 natural gas to G20 natural gas - 1 Changeover kit instructions - 1 Gasket for nut 3/4 - 1 Natural gas baffle plate (G20)

Ø 3.00/3.80 - 1 O-Ring for baffle plate - 1 Natural gas baffle plate (G25)

Ø 3.20/4.20 - 1 O-Ring for baffle plate - 1 settings sticker - 1 polythene bag - 1 G20/G25 THISION S 9.1 - 13.1

sticker

View A

1 Gas valve

2 Gas pipe

3 Fan air pipe

4 Burner

5 Air/gas adjustment

6 Brass air supply ring

7 Fan

8 Gasket

9 Baffle plate

10 Baffle plate O-ring

11 Fixing clamp for pipe blower/air burner sleeve

Legend

P_IN Gas mains pressure P_OUT Gas pressure (gas valve/burner)

28

Commissioning

THISION S 17.1/25.1 Conversion of G20 to G25 Natural Gas (excluding Belgium)

Gas conversion


Conversion from G20 natural gas to

G25 natural gas









Conversion from G25 natural gas to G20 natural gas









Changeover kit G20 natural gas to G25 natural gas or G25 natural gas to G20 natural gas - 1 Changeover kit instructions - 1 Gasket for nut 3/4 - 1 Natural gas baffle plate (G20)

Ø 4.20/5.75 - 1 O-Ring for baffle plate - 1 Natural gas baffle plate (G25)

Ø 4.65/6.90 - 1 O-Ring for baffle plate - 1 settings sticker - 1 polythene bag - 1 G20/G25 THISION S 9.1 - 13.1

sticker

View A

1 Gas valve

2 Gas pipe

3 Fan air pipe

4 Burner



7 Fan

8 Gasket

9 Baffle plate



Legend

P_IN Gas mains pressure P_OUT Gas pressure (gas valve/burner)

29

Commissioning

THISION S 25.1 Conversion of G20 or G25 Natural Gas to Liquid Gas (excluding Belgium)

Gas conversion


Conversion from natural gas to propane (G31) Burner air intake: - Remove the fan burner side

collar (11) and air supply ring (3).

- Replace air supply ring (6) in the burner air supply sleeve with the air supply ring Ø 27 contained in the changeover kit, with O-ring.

- Reconnect pipe (3) to the burner air supply sleeve.


pipe (2) and gas valve (1). - Remove the gasket (8). - Replace natural gas baffle plate by

propane baffle plate Ø 4.65 (9) with O-ring (10) (see view A).




Conversion from propane (G31) to natural gas H (G20) or L (G25) Burner air intake: - Remove the fan burner side

collar (11) and air supply ring (3).

- Replace air supply ring (6) in the burner air supply sleeve with the air supply ring Ø 29 contained in the changeover kit, with O-ring.

- Reconnect pipe (3) to the burner air supply sleeve.


pipe (2) and gas valve (1). - Remove the gasket (8).

- Replace propane baffle plate by baffle plate Ø 5.75 (9) for natural gas H (G20) or by baffle plate Ø 6.90 (9) for natural gas L (G25), with O-ring (10) (see view A).




Changover kit THISION S 25.1 Changeover kit Natural gas - liquid gas - 1 Changeover kit instructions - 1 Gasket for nut 3/4 - 1 Propane baffle plate (G31)

Ø 4.65 - 1 O-Ring for baffle plate - 1 Air supply ring Ø 27 - 1 O-Ring for air supply ring - 1 Settings sticker - 1 Polythene bag - 1 Sticker G31 THISION S 25.1 Changeover kit Liquid gas - natural gas - 1 Changeover kit instructions - 1 Gasket for nut 3/4 - 1 Natural gas baffle plate (G20)

Ø 5.75 - 1 O-Ring for baffle plate - 1 Natural gas baffle plate (G20)

Ø 6.90 - 1 O-Ring for baffle plate - 1 Air supply ring Ø 29 - 1 O-Ring for air supply ring - 1 Settings sticker - 1 Polythene bag - 1 Sticker natural gas THISION S 25.1

- 1 Aufkleber Erdgas THISION S 25.1

View A

1 Gas valve

2 Gas pipe

3 Fan air pipe

4 Burner



7 Fan

8 Gasket

9 Baffle plate



Legend

P_IN Gas mains

P_OUT Gas pressure (gas valve/burner)

30

Commissioning

THISION S 35.1 + 50.1 Conversion of G20 or G25 Natural Gas to Liquid Gas (excluding Belgium)

Gas conversion


Conversion to G25: Adjusting the gas valve

Conversion from natural gas to propane (G31) Burner air intake: - Carefully remove the fan (7) on the

flange (3) from the burner (4). - Insert the air supply ring Ø 31.0 (6)

into the burner air supply sleeve. - Carefully reconnect the fan (7) and

gasket to the burner flange (3).


pipe (2) and gas valve (1). - Remove the gasket (8). - Place propane closure Ø 6.40 (9)

with O-ring (10) (see view A) at the gas unit outlet.




Changeover kit Natural gas - liquid gas - 1 Changeover kit instructions - 1 Propane baffle plate (G31)

Ø 6.40 - 1 O-Ring for baffle plate - 1 Air supply ring Ø 31 - 1 O-Ring for air supply ring - 1 Settings sticker - 1 Polythene bag - 1 Sticker G31

THISION S 35.1 + 50.1

Changeover kit THISION S 35.1+50.1

View A

1 Gas valve

2 Gas pipe

3 Fan air pipe

4 Burner



7 Fan

8 Gasket

9 Baffle plate



Legend

P_IN Gas mains P_OUT Gas pressure (gas valve/burner)

31

Maintenance

Checks and inspections

Regular maintenance is essential for the safety, proper operation and long life of the heater. It should be performed in accordance with applicable regulations. It is advisable to carry out, at regular intervals, a combustion analysis, so as to control the performance and pollutant emissions of the heater in accordance with the applicable regulations.

Draining the system The procedure for draining the heating system is as follows: - Switch the heater off, turn the master

power switch to OFF and close the gas tap.

- Loosen the automatic deaeration valve.

- Open the system drain cock and catch the outflowing water in a container.

- Drain the system at the lowest points.

If the heater to be shut down is in an area, in which the ambient temperatures in the winter can drop below 0°C, it is recommended that you add an antifreeze agent into the water in the heating system, so as to avoid frequent bleeding.

When using such an agent, check carefully that the agent is compatible with the stainless steel from which the heater body is made. It is advisable to use antifreeze containing the corrosion-inhibiting PROPYLENE type GLYCOL (such as CILLICHEMIE CILLIT CC 45, which is non-toxic, is used both as antifreeze and corrosion protection and at the same time prevents scale formation). This is to be used in accordance with the manufacturer-prescribed doses corresponding to the expected lowest temperature.

The pH of the mixture of water and antifreeze in the heater circuit must be checked regularly. The mixture should be replaced if the measured value falls below the limit specified by the antifreeze manufacturer.

Do not mix different antifreeze types together

The manufacturer is not liable for damage to the unit or to the system caused by inappropriate use of antifreeze or additives.

Draining the hot water system To prevent freezing, the domestic hot water system must be drained as follows: - Close water supply tap. - Open all hot and cold taps. - Drain the system at the lowest

points.

Before starting maintenance - Turn off the power by turning the

master power switch on the heater to "OFF". - Close the heating and hot water systems gas and water taps. - Finally, the original settings are restored.

Notes

Before handling any parts of the appliance that may contain hot water (caution - scald risk!) they must be emptied and any bleed valves opened. Calcium deposits must be removed in accordance with the instructions indicated on the safety card for the product used. Ventilate the area, wear protective clothing, do not mix any different products, protect the device and surrounding objects. Reseal all openings necessary for reading or setting the gas pressure. Make sure that the nozzle is compatible with the type of gas used. If you smell burning or a strong gas smell, or see smoke escaping, immediately turn the power off, turn the gas tap off, and open the window. Then contact customer service.

Electrodes positioning Check the positioning of the electrodes as shown in the figure.

9.1/13.1/2-17.1

5-17.1/25.1/35.1/50.1

Ionisation electrode

Ionisation electrode

Spark igniter 9.1 - 50.1

32

Maintenance

Checks and inspections

General information Mindestens einmal im Jahr sollte das Gerät folgenden Kontrollen unterzogen werden: 1. Visual inspection of the overall

device status. 2. Visual inspection of the

combustion and disassembly and cleaning of the burner where necessary.

3. Following check "4" it may be necessary to disassemble and clean the burner and the nozzle.

4. Cleaning the main heat exchanger.

5. Check safety systems for correct operation: - Temperature limit protection.

6. Check gas supply safety systems for correct operation:

- Lack of gas and flame failure safety devices (ionisation).

7. Check the domestic hot water production efficiency (check flow and temperature)

8. Review the general functioning of the heater.

9. Remove oxide deposits on the ionisation electrode using an emery cloth.

Cleaning the primary heat exchanger flue gas side

To gain access to the primary heat exchanger, remove the burner. To clean, use water, a detergent and a non-metallic brush. Rinse afterwards with water.

Cleaning the siphon

Remove siphon and clean with water and detergent. Fill the siphon with water and assemble. NB: If the device is not used for a long time, the siphon must be filled before restart. It is dangerous to not refill the siphon with water, as this can allow flue gas to escape into the environment.

Functional test After maintenance is complete: - Put the device into operation. - If necessary, deaerate the heating

system. - Check the settings and proper

operation of all operating, adjustment and control elements.

- Check that the flue gas outlet/removal system for combustion air is fully sealed and working properly.

33

Maintenance and Service

B B

B B

A

C

A

1. During correct heating operation, no changes should be made to the control system.

2. Disconnect the device from the mains and close the gas tap.

3. Remove the panel.

To do this: Remove the securing screw from the snap lock (A) (Allen screws). Open the snap lock (A) at the top and bottom (THISION S 9.1-25.1).

4. Remove burner. To do this:

Loosen the four M8 Allen screws (B) on the burner. Loosen the union nut on the gas valve, remove ignition and ionisation cable, and ground wire and air control line.

34

Maintenance and Service

5. Vacuum the heat exchanger fins and clean the side panels with nylon brush.

Flush heat exchanger with water thoroughly and then remove the siphon and clean.

6. Clean burner and fan with a brush or a brass brush.

Check and clean ignition ionisation electrodes. If the electrodes have been replaced, they must be resealed (silicone).

Clean any dirt accumulation inside the casing with a vacuum cleaner or a damp cloth.

7. Put the whole assembly back together in reverse order.

8. Check all connections for gas tightness.

9. Check the system water pressure and top up if necessary. Purified siphon must be filled with water.

10. Perform functional test.

11. Calculate, measure and compare flow rate.

You may adjust the device, but do not overload.

12. Flue gas analysis

Check the rated thermal input with a full load and a partial load.

13. Restore control system to its original state.

35

Faults - Causes- Remedies

Error codes and remedies

The error message flashes on the LMU display. To cancel the lockout, the fault must be rectified, and then the Reset release button pressed down for at least 2 seconds.

Error codes LMU

36

Code No. Error description Troubleshooting Info

0 No error Normal

10 Outside temperature sensor error Check if sensor is correctly installed and connected Display

20 Boiler temperature 1 sensor error Check if sensor is correctly installed and connected Display

32 Flow temperature 2 sensor error Check if sensor is correctly installed and connected Display

40 Return temperature 1 sensor error Check if sensor is correctly installed and connected Display

50 DHW temperature 1 sensor error Check if sensor is correctly installed and connected Display

52 DHW temperature 2 sensor error Check if sensor is correctly installed and connected Display

61 Room unit 1 Check connections on the device Display

62 Room unit 1 type Check indoor space compatibility Display

78 Water pressure sensor

Increase pressure in the circuit (if P <0.2 bar), check pressure sensor connections

Error

81 LPB short-circuit/comm Check the wiring Display

82 LPB address collision Check address Display

91 Data loss in EPROM Change LMU Error

92 Device electronics error Change LMU Error

100 Two clock time masters (one is normal), programming problems

Check parameter 6606 in the configuration menu of the LMU 7 in the slave controller

Display

105 Maintenance message Read warning messages Display

110 STB lockout Check if shunt X3-01 is present and system water pressure is sufficient (pump, shut off valve, etc.)

Error

111 Temperature control activated

Check whether the water pressure in the system is sufficient (pump, shut off valve, etc.)

Display

117 Water pressure too high Check or adjust pressure if necessary to P < 3.5 bar Display

118 Water pressure too low Check or adjust pressure if necessary to P > 0.4 bar Display

128 Loss of flame during operation Check or adjust gas valve; check ionisation electrode and connections; exchange between phase and neutral is possible for transformer supply/ring gap measurement.

Display

129 Fan speed undershoot or overshoot Call Service Error

132 GP or LP error (safety shut-down) Check that flue gas guard or gas pressure switch have been activated, and that cable X10-03 is connected correctly.

Error

133 No flame after safety time Check that gas is supplied correctly to the boiler (Pi); Check gas valve state; check that the gas valve setting is correct; check condition of the following parts: Transformer, cables, ignition electrode, ionisation current value, line polarity!

Error

Faults - Causes- Remedies

Error codes and remedies

Code No. Error description Troubleshooting Info

140 Inadmissible LPB segment number or LMU address not allowed

Check address accuracy of parameters 6600, 6601 Display

151 Internal error / new LMU configuration Call service Display

152 LMU Parameterization error Check parameterization Display

153 Unit manually locked Press Reset for 3 seconds, then wait 20 seconds for the display to clear

Error

154 Plausibility criterion / Temperature gradient exceeded

Check values of criteria, which are connected to the boiler overheating protection, check the boiler circuit pump

Display

160 Fan error / Minimal fan speed not reached

Check the wiring from the fan and LMU; check if the fan rotates properly. If not, call service

Error

161 Max. fan speed exceeded Check power supply and connection of the fan cable Error

184 Modem function active Display only Display

185 Floor curing mode active Display only Display

303 Chimney sweeper mode active Disable mode manually Display

304 Controller stop mode active Disable mode manually Display

37

The temperature sensor resistances are measured after unplugging from the operator panel.

Temperature

Sensor resistance (Ohm)

Heating flow sensor Heating return sensor Water heating sensor

Flue gas sensor

0,00 °C 32624

10,00 °C 19897

15,00 °C 15711

20,00 °C 12493

25,00 °C 10000

30,00 °C 8056

40,00 °C 5324

50,00 °C 3599

60,00 °C 2483

70,00 °C 1748

80,00 °C 1252

90,00 °C 912

Sensor resistances

Temperatur

Sensor resistance (Ohm)

Outdoor temperature sensor

-20,00 °C 7578

-15,00 °C 5861

-10,00 °C 4574

-5,00 °C 3600

0,00 °C 2857

5,00 °C 2284

10,00 °C 1840

15,00 °C 1492

20,00 °C 1218

25,00 °C 1000

30,00 °C 826,8

35,00 °C 687,5

38

Electrical drawing

1. Mains power supply

2. Clip-in mains

3. Fan 230V

4. Circuit pump

5. Progr. digital output

6. PWM pump

7. Locking input (e.g.

STB)

8. DHW valve

(combi/comp)

9. Ionisation electrode

10. Fuel valve

11. Ignition 230V

12. Functional ground

13. Replaceable fuse

14. Transformer

15. Remote

16. HMI AVS37

17. Fan/PWM control

18. Water pressure sensor

19. Progr. digital input

20. Temp sensor return

21. Temp. sensor boiler

22. Flue gas STB -

Locking input

23. Cylinder temp sensor

24. Outdoor temp sensor

** Phase at rest *** According to parametrisation **** Take out bridge only when

connecting equipment

1. Mains power supply

2. Clip-in mains 3. Fan 230V 4. Circuit pump 5. Progr. digital

output (e.g. alarm)

6. PWM pump 7. Locking input (e.g. STB) 8. DHW valve

(combi/comp)

9. Ionisation Electrode

10. Fuel valve 11. Ignition 230V

12. Functional ground 13. Replaceable fuse 14. Transformer

15. Remote QAA75 16. HMI AVS37 17. Fan/PWM

control

18. Water pressure Sensor 19. Progr. digital

Input

20. Temp sensor return

21. Temp. sensor boiler

22. Flue gas STB locking input 23. Cylinder temp Sensor 24. Outdoor temp sensor

HMI

Mixing circuit Heating circuit

Progr. dig. Input (e.g. boiler enable)

X12 Slot: Not used X50 Slot: Clip-in X40 Slot

Boiler external - internal

39

Declaration of Conformity

Service: www.elco.net

operating instructions for qualified persons · 2014. 6. 15. · en 50165 electrical equipment of...

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