Riello Thermital TBOX BASIC ACS Technical manual

TBOX BASIC ACS
USE, INSTALLATION AND
MAINTENANCE MANUAL

2
ENGLISH
Lecco, 18th January 2012
The company
Riello SpA Heating Products Direction
Via Risorgimento 13
23900 Lecco
ITALY
hereby declares that the control panels bearing the brand: THERMITAL
models:
TBOX CLIMA COMFORT, TBOX CLIMA TOP, TBOX CLIMA MIX,
TBOX BASIC and TBOX BASIC ACS
conform to European Directive 2004/108/EC (Electromagnetic Compatibility), to European Directive
2006/95/EC (Low Voltage) and to the following European standards:
EN 60730-1:2000 Automatic electrical controls for household and similar use.
EN 60730-2-9:2000 Part 2: Particular requirements for temperature sensing controls.
EN 60529:1992 Specication for degrees of protection provided by enclosures (IP code).
EN 61000-6-2:2001 Electromagnetic compatibility. Immunity per industrial environments.
EN 61000-6-3:2001 Electromagnetic compatibility. Emission standard for residential, commercial
and light-industrial environments.

3
ENGLISH
Dear heating engineer,
Congratulations on having chosen a TBOX control panel. You have selected a modern, quality
product that is designed to give dependable, efficient and safe service and to provide comfort in
the home for many years to come. This manual provides information that is essential to the instal-
lation of the appliance. Used in conjunction with your own knowledge and expertise it will enable
you to install the appliance quickly, easily, and correctly.
Once again, please accept our thanks and our congratulations on your choice of product.
THERMITAL
MODEL CODE
TBOX BASIC ACS 20017207
RANGE

4
ENGLISH
CONTENTS
General Safety Information 5
Precautions 5
Product description 6
Identification 6
Technical specifications 7
Accessories 7
Unpacking the product 8
Dimensions and weight 8
Installation 9
Accessing internal components 11
Electrical connections 12
Positioning the sensors 13
Wiring diagrams 14
Layout 15
Description of functions 16
Useful information 18
This manual, Code 20020619 - Rev. 5 (04/17) is made
up of 20 pages.
The following symbols are used in this manual:
b = Identifies actions that require caution and ade-
quate preparation.
a = Identifies actions that you MUST NOT do.

5
ENGLISH
The operation of any appliance that uses electrical power demands that a number of fundamental safety precautions
be respected. In particular:
bCheck that the product is complete and undam-
aged as soon as you remove it from its packaging.
Contact the THERMITAL reseller from whom you
purchased the product if you notice any problems.
bThis product must be installed by a legally qualified
heating engineer. (In Italy heating engineers are
regulated by law no. 37 of the 22/01/2008.) On com-
pletion of the installation, the installer must issue the
owner with a declaration of conformity confirming
that the installation has been completed to the high-
est standards in compliance with the instructions
provided by THERMITAL in this instruction manual,
and that it conforms to all applicable laws and stand-
ards.
bThis control panel is designed and made for use with
boilers generating hot water up to 110°C, and must
be used exclusively for this purpose and within its
specified performance limits.
bThe manufacturer declines all responsibility, con-
tractual or other, for damage to property or injury to
persons or animals caused by improper installation,
adjustment, maintenance or use.
bThis instruction manual is an integral part of the
product. It must be kept safe and must ALWAYS
accompany the product, even if it is sold to another
owner or transferred to another user or to another
installation. If you damage or lose this manual,
order a replacement immediately from your local
THERMITAL Technical Assistance Centre.
aAlways turn the electrical power supply OFF at the
main switch before commencing any cleaning or
maintenance.
aDo not tamper with or adjust the safety or control
devices without prior authorisation and instructions
from the boiler’s manufacturer.
aNever pull, disconnect, or twist the electrical cables
coming from the appliance even if it is disconnect-
ed from the mains electricity supply.
aDispose of packaging materials in compliance with
applicable standards and legislation governing the
disposal of urban, domestic and industrial waste.
aNever switch the control panel on even for a short
period if the safety devices are not functioning cor-
rectly or have been tampered with.
aAll maintenance and repairs must be carried out by
a legally qualified heating engineer.
aDo not use water to extinguish fire in the control
panel. Switch power OFF at the mains power switch
to isolate the control panel electrically first. Then
use a class E fire extinguisher (marked “SUITABLE
FOR LIVE ELECTRICAL ITEMS”) to extinguish the
flames.
GENERAL SAFETY INFORMATION
PRECAUTIONS

6
ENGLISH
TABLEAU DE CONTROLE
CONTROL PANEL
PANNELLO DI CONTROLLO SCHALTTAFEL CUADRO DE MANDO
20Kgmax
–
–
l'Etichetta Caratteristiche Tecniche
il N° di codice riportato sull'imballo
20
40
60
80
100
0120
20
40
60
80
100
0120
Cod. :
20017207
Made in Italy
Mod. :
TBOX BASIC ACS
20017699_E0
230 V AC - 50 Hz - 6.3 (A) T
IDENTIFICATION
PRODUCT DESCRIPTION
TBOX BASIC ACS control panels are thermostatic con-
trol panels for boilers with single stage jet burners for
central heating and domestic hot water production in
storage cylinders. All thermostatic control devices com-
ply with applicable technical and safety standards, and
are housed in an ABS box and protected by a cover.
All the electrical control and safety devices in TBOX
BASIC ACS control panels are factory tested in com-
pliance with applicable technical standards. Control
panels may be installed on top of the boiler or on
one of its side panels, using the optional side panel
mounting kit.
TBOX BASIC ACS control panels are identified by:
bTo make the electrical connections to the various system components and to the burner, refer to the instructions on
page 12 and to the specific instructions supplied with each item and with the burner.
APPLICATION CHART
Burner Cascaded
boilers
Cascaded
boilers
Solar water
heating
systems
DHW storage
cylinders
Direct
zone
1st mixed
zone
2nd mixed
zone
TBOX
BASIC ACS
1
2 1
2-stage
with kit
- the code number on the box
- the technical data label

7
ENGLISH
ACCESSORIES
TECHNICAL SPECIFICATIONS
Description TBOX BASIC ACS
Power supply 230 (+/-10%) ~ 50 V ~ Hz
Maximum current draw 6,3 A
Main power switch (two pole) 250 ~ 10(4) V ~ A
Summer/Winter selector (single pole) 250 ~ 10(4) V ~ A
Fuse 250 ~ 6,3 T V ~ A
Power consumption - W
Function indicators 230 V
Manual reset safety thermostat (TS) (*) 110 (+0/-6) °C
Boiler control thermostat (TR) - field of adjustment 30 ÷ 82 (+/-3) °C
Storage cylinder control thermostat (TB) - field of adjustment 0 ÷ 70 (+/-3) °C
Minimum temperature thermostat (Tm)
Control range 30 ÷ 90 (+/-3)
°C
Working setting 40 °C
Maximum temperature thermostat (TL82)
Control range 30 ÷ 90 (+/-3)
°C
Working setting 82 °C
Boiler overtemperature dispersal thermostat (TL90)
Control range 30 ÷ 90 (+/-3)
°C
Working setting 90 °C
Boiler temperature gauge (TeC) 0 ÷ 120 °C
Storage cylinder temperature gauge (TeB) 0 ÷ 120 °C
Index of protection X4D IP
Cable length 3 m
(*) Homologated
ACCESSORY CODE
Two-stage burner control kit 4031067
Wall mounting kit 20010056
The following accessories are available, to be ordered separately:

8
ENGLISH
UNPACKING THE PRODUCT
TBOX BASIC ACS control panels come in a cardboard
box that also contains the instruction manual.
TABLEAU DE CONTROLE
CONTROL PANEL
PANNELLO DI CONTROLLO SCHALTTAFEL CUADRO DE MANDO
20Kgmax
BA
D
C
G
E
F
H
20
40
60
80
100
0120
20
40
60
80
100
0120
Description
A348 mm
B353 mm
C160 mm
D170 mm
E
236 mm
F
75 mm
G
208 mm
H
218 mm
Weight
3,2 kg
DIMENSIONS AND WEIGHT

9
ENGLISH
ASSEMBLY
TBOX BASIC ACS control panels can be installed either on the top of the boiler or on one of its side panels. Before
commencing installation, check the arrangement of the holes on the top panel or side panel of the boiler.
311
170
41
218
208
75
Lato SUPERIORE della CALDAIA
Lato ANTERIORE della CALDAIA
Lato SUPERIORE della CALDAIA
Lato FRONTALE della CALDAIALato FRONTALE della CALDAIA
Pannellatura LATERALE
Pannellatura SUPERIORE
Lato ANTERIORE della CALDAIALATERALE della CALDAIA
LATERALE della CALDAIA
Once you have identified the right holes for the type of installation required, proceed as follows:
- Push out the pre-formed slots on the boiler casing corresponding to the oval cable grommets in the control panel
- Perforate the membranes of the control panel cable grommets. Pull out the thermostat cable and route it through the
slot in the top panel
- Secure the control panel to the boiler casing.
FRONT of boilerSIDE of boiler FRONT of boilerSIDE of boiler
SIDE panels
TOP panels
FRONT of boiler FRONT of boiler
TOP of boiler

10
ENGLISH
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
to sensor socket
in boiler
to sensor socket
in boiler
FRONT OF BOILER
FRONT OF BOILER
HORIZONTAL installation
B
A
A
C
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
VERTICAL installation
to sensor socket
in boiler
Before you can install the control panel on a boiler side panel, proceed as follows:
- Remove the 4 screws (A).
- Remove the front trim (B), turn it through 180°, and fit it back on the body of the control panel (C).
- Install the control panel as instructed above.
A dedicated wall mounting kit is available. Refer to the instructions provided with the kit for details on installation.

11
ENGLISH
ACCESSING INTERNAL COMPONENTS
Only personnel from Technical Assistance Service or
professionally qualified heating engineers are allowed to
access components inside the control panel.
Proceed as follows if you need to access components
inside the control panel:
- Turn the system OFF at the mains power switch
- Remove the top panel (1) by pulling it outwards.
1
b Carefully unwind the thermostat cables and route them
through the relevant grommets. Insert the thermostat
sensors in the corresponding sockets in the boiler. Fix the
sensors securely in place. Use the cable straps provided
to secure the sensor cables.
Spring clip
Cable
Sensor
r
Radius ≥20 mm
Sensor socket

12
ENGLISH
ELECTRICAL CONNECTIONS
b The following instructions are mandatory:
1 -Use a single pole magnetic thermal trip switch
and disconnector conforming to IEC-EN stand-
ards (with a contact gap of at least 3 mm);
2 -Respect the L (Phase) - N (Neutral) polarity.
Keep the ground wire about 2 cm longer than the
power wires.
3 -Use cables with a cross section of 1.5 mm2or
more, complete with end terminals;
4 -
Always refer to the electrical wiring diagrams in
this manual when performing any electrical work.
5 -Make sure the appliance is connected to an
effective ground.
- Proceed as instructed in the “ACCESSING INTERNAL
COMPONENTS” section above to access the terminals
inside the control panel.
- Route the connection cables through the cable grom-
mets in the casing of the boiler or secured by the side
mounting bracket. Alternatively, use the holes provided
for cable glands or spiral sleeving. To use these holes,
push out the pre-formed hole covers in the correspond-
ing positions on the control panel.
- See the “WIRING DIAGRAMS” section for information
on how to connect up the individual devices.
- Tighten the screws on the cable clamps and screw up
the cable glands to secure the cables against pulling.
Secure the cables to the casing of the boiler as neces-
sary.
b Use the terminals provided to connect all 230 V
power users to ground.
a It is strictly forbidden to use gas and/or water pipes
to ground the appliance.
a Do not route the power cable or room thermostat
cables near hot surfaces (like heating circuit flow
pipes). Use a suitable class of cable if there is any
possibility of contact with parts at temperatures
above 50°C.
The manufacturer declines all responsibility for dam-
age caused by failing to ground the appliance ade-
quately or by failure to respect the wiring diagrams
provided in this manual.
All electrical connections must be made by a legally qualified heating engineer according to the following instructions.
(In Italy heating engineers are regulated by law 37 of the 22/01/2008.)
Tm
TL90
TL82
TS
TR
TB
Boiler temperature
gauge sensor
Storage cylinder
temperature
gauge sensor
TeC
TeB
Minimum
temperature
thermostat
sensor
Boiler
overtemperature
dispersal
thermostat
sensor
Maximum
temperature
thermostat
sensor
Boiler control
thermostat sensor
Storage cylinder
control thermostat
sensor
Safety
thermostat
sensor
L1 NPE
BURNER CH
PUMP
DHW
PUMP
T1 T2 S3 L1 N PE1 L1 N PE1
Power supply
PENL
TA
Cable glands “A”Cable grommets “B”

13
ENGLISH
POSITIONING THE SENSORS
Tm
TeB
TB TeC
TL90
TL82
TR TS
TA
AE
RI MI
PI
TBOX BASIC ACS
CaldaiaBollitore
MB
RB
PB
20
40
60
80
100
0120
20
40
60
80
100
0120
Tm - Minimum temperature thermostat sensor
TS - Safety thermostat sensor
TL90 - Boiler overtemperature dispersal thermostat sensor
TL82 - Maximum temperature thermostat sensor
TR - Boiler control thermostat sensor
TB - Storage cylinder control thermostat sensor
TeC - Boiler temperature gauge sensor
TeB - Storage cylinder temperature gauge sensor
TA - Room thermostat
AE - 230V~50Hz electrical power supply
MI - CH flow
RI - CH return
PI - CH pump
MB - Storage cylinder delivery
RB - Storage cylinder return
PB - Storage cylinder pump
bRefer to the manual supplied with the boiler to identify the sensor sockets correctly.
bInsert the thermostat sensors in the corresponding sockets and fix them securely in place. Use the cable
straps provided to secure the sensor cables.
BoilerStorage cylinder

14
ENGLISH
WIRING DIAGRAMS
MO1-1
CO1_6
CO1_3
MO1-2
MO1-4
MO2-8
MO1-5
MO2-7MO2-10
CO1_2
CO1_1
MO1-3
TR 30-82°C
TL82 30-90/R82°C
TL90 30-90/R90°CTB 0-70°C
Tm
30-90/R40°C
TS 110°C
H2 PB
MO2-12
MO2-13
H1
L1
N
PE
PI
TA
MO2-9
E/I
KA1
BA1
L1 T2
N
PE
S3
T1
B4 RS RS
BR
MO2-1
MO2-4
MO2-5
MO2-6
MO2-2MO2-3
CO1_8
IP
IP
FU
L1-N-PE 230V~50Hz power supply
FU Fuse 6.3 A-T
IP Main switch
TS Manual reset safety thermostat (110°C)
TR Boiler control thermostat (30-82°C)
TB Storage cylinder control thermostat (0-70°C)
Tm Minimum temperature thermostat (30-90/R40°C)
TL90 Boiler overtemperature dispersal thermostat
TL82 Maximum temperature thermostat
E/I Summer/Winter selector
KA1 Relay contacts
BA1 Relay coil
BR Burner
H1 Burner lockout indicator
H2 Overtemperature indicator
Connections to be made by the installer
TA Room thermostat
PI CH pump
PB Storage cylinder pump

15
ENGLISH
LAYOUT
3 421 9 107 85 6
18 17 16 15 14 13 12 11
20
40
60
80
100
0120
20
40
60
80
100
0120
b The cables for the TeB, TB, TL82, TL90, TeC, TS, TR and Tm sensors must be routed out of the electric control
panel and through the cable grommets in the boiler during installation.
1 - Summer/Winter selector
2 - Overtemperature indicator
3 - Manual reset safety thermostat (110°C)
4 - Boiler control thermostat (30-82°C)
5 - Boiler temperature gauge
6 - Storage cylinder temperature gauge
7 - Storage cylinder control thermostat (0-70°C)
8 - Fuse
9 - Burner lockout indicator
10 - Two pole ON/OFF switch
11 - Boiler overtemperature dispersal thermostat sensor (TL90) (accessible from inside)
12 - Minimum temperature thermostat sensor (Tm) (accessible from inside)
13 - Boiler control thermostat sensor (TR)
14 - Safety thermostat sensor (TS)
15 - Boiler temperature gauge sensor (TeC)
16 - Boiler maximum temperature thermostat sensor (TL82) (accessible from inside)
17 - Storage cylinder control thermostat sensor (TB)
18 - Storage cylinder temperature gauge sensor (TeB)

16
ENGLISH
DESCRIPTION OF FUNCTIONS
Main control panel ON/OFF switch (b)
This switch connects power to all controlled devices and
appliances.
b A delayed action 6.3 A fuse is installed inside the control
panel upstream from this switch (see wiring diagram).
Summer/Winter selector ( o /y)
Selects functioning mode:
- Summer (
o domestic hot water only)
- Winter (ydomestic hot water and central heating)
Boiler control thermostat (
r )
The boiler control thermostat lets you adjust boiler tem-
perature between 60 and 82°C The recommended set-
ting is around 70°C.
Storage cylinder control thermostat (
v )
The storage cylinder control thermostat lets you adjust
domestic hot water temperature between 0°C and 70°C
with priority logic. The recommended setting is around
50°C.
TBOX BASIC ACS
control panels are equipped with 5 homologated electromechanical thermostats, two temperature
gauges, a main power ON/OFF switch, a Summer/Winter selector, function indicators, a test button and a protective fuse.
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120
20
40
60
80
100
0120

17
ENGLISH
Safety thermostat (TS)
The safety thermostat shuts down the burner if boiler tem-
perature exceeds 110°C. To restore normal functioning,
remove the protective cover and press the button .
Use a suitable tool if necessary.
b If the safety thermostat (TS) shuts down the burner,
the red warning light comes on and any burner
error signals on the burner controller are lost.
Minimum temperature thermostat (Tm)
This thermostat prevents cold water from circulating and
causing condensation inside the boiler. It is located inside
the control panel, and is preset to 40°C. Adjustment
requires a suitable tool and is reserved for personnel from
THERMITAL’s Technical Assistance Service.
Maximum temperature thermostat (TL82)
This thermostat cuts in at 82°C during the DHW produc-
tion cycle to disable the boiler control thermostat. It is
located inside the control panel, and is preset to 82°C.
Adjustment requires a suitable tool and is reserved
for personnel from THERMITAL’s Technical Assistance
Service.
Boiler overtemperature dispersal thermostat (TL90)
CThis thermostat cuts in at 90°C to disperse overtem-
perature caused by thermal inertia. It is located inside
the control panel, and is preset to 90°C. Adjustment
requires a suitable tool and is reserved for personnel from
THERMITAL’s Technical Assistance Service.
20
40
60
80
100
0120
20
40
60
80
100
0120

18
ENGLISH
USEFUL INFORMATION
SELLER:
Mr. ......................................................................................................................................................
Address...........................................................................................................................................
tel. ......................................................................................................................................................
TECHNICAL ASSISTANCE SERVICE:
Mr. ......................................................................................................................................................
Address...........................................................................................................................................
tel. ......................................................................................................................................................
BOILER DETAILS
(From Data label):
Make ..................................................................................................................................................
Type ...................................................................................................................................................
Serial number ........................................................................................................................
Date of initial start-up ...............................................................................................
INSTALLER:
Mr. ......................................................................................................................................................
Address...........................................................................................................................................
tel. ......................................................................................................................................................
CONTROL PANEL DETAILS
(From product label):
Serial number ........................................................................................................................
Lot ......................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................
.........................................................................................................................................................................................................................................................................................................................................................

RIELLO S.p.A.
Via Ing. Pilade Riello, 7
37045 - Legnago (VR)
www.thermital.it
The manufacturer strives to continuously improve all products. Appearance, dimensions, technical
specifications, standard equipment and accessories are therefore liable to modification without
notice.
20020617 5 (04/17)