elco THISION L Specification sheet

Operation and Installation manual
for authorized technicians only
THISION L
02/2011 DOC3078 / 12103187

Contents
2
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
3
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
4
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.
2
4
1
3
5 6
8 7
9
10 11
12
13
14
15
16
17
18
19
20
21
2

Technical data
5
THISION L
65
THISION L
85
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
6
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
7
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
8
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.
1
2
3
4

Installation
Boiler installation
Connecting the boiler
9
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
10
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).
8
7
10
9
Outside sensor mounting
If an outside sensor (accessory) is
connected to the boiler, the sensor
should be positioned as shown on the
drawing.