thermital THC 270 GREY User manual

THC 150-1450 GREY
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL

2
ENGLISH
RANGE
MODEL CODE
THC 150 GREY 03504183
THC 210 GREY 03504184
THC 270 GREY 03504185
THC 350 GREY 03504186
THC 450 GREY 03504187
THC 600 GREY 03504188
THC 800 GREY 03504189
THC 1000 GREY 03504190
THC 1250 GREY 03504191
THC 1450 GREY 03504192
THC/C 270 GREY 20012752
THC/C 350 GREY 20012753
THC/C 450 GREY 20012754
THC/C 600 GREY 20012756
ACCESSORIES
For a complete list of accessories and details of their compati-
bility, refer to the Catalogue.
ENGLISH
Dear Customer,
Thank you for choosing a Tboiler. You have pur-
chased a modern, high efficiency, quality product that is de-
signed to give dependable and safe service and to provide
comfort in the home for many years to come. Arrange for your
boiler to be serviced regularly by an authorised Technical As-
sistance Centre T. Their personnel are specially
trained to keep your boiler efficient and cheap to run. They also
stock any original spare parts that might be required.
This instruction manual contains important instructions and
precautions that must be observed to ensure the efficient func-
tioning of your THC GREY boiler.
Please accept our renewed thanks for your purchase
Thermital
CONFORMITY
T THC GREY boilers conform to:
- Directive 92/42/EEC on efficiency requirements
- Electromagnetic Compatibility Directive 2014/30/EU
- Low Voltage Directive 2014/35/EU
- Directive 2009/142/EC - Gas Appliances
Models up to 400 kW conform to the Energy-Related Products
Directive 2009/125/EC and to the EU Delegated Regulation
813/2013.

This manual, Code 068672EN - Rev. 32 (04/17) comprises 40 pages.
3ENGLISH
Contents CONTENTS
The following symbols are used in this manual:
b
CAUTION! = Identifies actions that require caution and
adequate preparation.
a
STOP! = Identifies actions that you MUST NOT do.
This manual, Code
- Rev.
comprises
pages.
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . 4
General Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of the appliance . . . . . . . . . . . . . . . . . . . . . . . . 5
Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended burners and technical specifications . . . . . 7
THC GREY GTM BLU with power < 400 kW . . . . . . . . . . . . 7
THC GREY PREMIX with power < 400 kW . . . . . . . . . . . . . . 9
THC GREY with power > 400 kW . . . . . . . . . . . . . . . . . . . . 11
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM MANAGER . . . . . . . . . . . . . . . . . . . . . . . . 14
Putting into service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparing for extended periods of disuse . . . . . . . . . . . . . 15
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Useful information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unpacking the product . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overall dimensions and weights . . . . . . . . . . . . . . . . . . . . 18
Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation premises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Water in central heating systems . . . . . . . . . . . . . . . . . . . . 20
Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condensate evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Neutralising the condensate . . . . . . . . . . . . . . . . . . . . . . . 25
Hoses should also be fixed to the floor and suitably protected
whenever possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation in B23P configurationin . . . . . . . . . . . . . . . . . . 27
Door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Changing the direction of door opening . . . . . . . . . . . . . . 28
Removing the hinge assembly "B" . . . . . . . . . . . . . . . . . . . 30
Earth connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fitting the casing panels . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TECHNICAL ASSISTANCE CENTRE . . . . . . . . . . . 32
Preparing for initial startup . . . . . . . . . . . . . . . . . . . . . . . . . 32
Initial startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Checks during and after initial start-up . . . . . . . . . . . . . . . 33
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4
ENGLISH GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
General Safety Information
b
The boiler is delivered in separate crates. Check that it
is complete, undamaged and as ordered as soon as you
receive it. Report any discrepancies or damage to the
dealer who sold it.
b
This product must be installed by a legally qualified heat-
ing engineer. On completion of the installation, the install-
er must issue the owner with a declaration of conformity
confirming that the installation has been completed to
the highest standards in compliance with the instructions
provided by Tin this instruction manual, and
that it conforms to all applicable laws and standards.
b
This product must only be used for the purpose for which
it is designed and made, as specified by T.
Tdeclines all responsibility, contractual or
other, for damage to property or injury to persons or ani-
mals caused by improper installation, adjustment, main-
tenance or use.
b
If you notice any water leaking from the boiler, discon-
nect it immediately from the mains electricity supply, shut
off the water supply, and notify your local T’s
Technical Assistance Centre or a qualified heating engi-
neer immediately.
b
Periodically check that operating pressure in the water
circuit is over 1 bar but below the maximum limit speci-
fied for the boiler. If this is not the case, contact Techni-
cal Assistance Centre Tor a professionally
qualified heating engineer.
b
If the boiler is not going to be used for an extended peri-
od of time, contact T’s Technical Assistance
Centre or a qualified heating engineer to have it prepared
for shut-down as follows
- Switch the boiler OFF at the control panel
- Turn the main system switch "off"
- Close the fuel cock and heating circuit water cock
- Drain the central heating circuit if there is any risk of
freezing.
b
The boiler must be serviced at least once a year.
b
This instruction manual is an integral part of the boiler.
It must be kept safe and must ALWAYS accompany the
boiler, 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 T’s Technical Assistance Centre.
Precautions
The operation of any appliance that uses fuel, electrical power
and water demands that a number of fundamental safety pre-
cautions be respected:
a
It is forbidden to use electrical devices or equipment,
such as switches, appliances, etc. if there is a smell of
gas or un-burnt products. If so:
- Ventilate the room, opening doors and windows
- Close the fuel shut-off cock
- Report the fault immediately to the T's
Technical Assistance Centre or a professionally quali-
fied heating engineer.
a
Do not touch the boiler while barefoot or wet.
a
Never clean or service the boiler without first discon-
necting it from the mains electricity supply by turning the
main power switch and the control panel switch OFF.
a
Do not tamper with or adjust the safety or control devic-
es without prior authorisation and instructions from the
manufacturer.
a
Do not plug or block the condensate drain outlet.
a
Never pull, disconnect, or twist the electrical cables com-
ing from the appliance even if it is disconnected from the
mains electricity supply.
a
Do not obstruct or restrict the vents in the room where
the boiler is installed. Adequate ventilation is essential for
correct combustion.
a
Do not expose the boiler to the elements. It is designed
to work indoors.
a
Do not switch the boiler off if outdoor temperature drops
below ZERO (risk of freezing).
a
Do not store containers of flammable substances in the
room where the boiler is installed.
a
Do not allow children or persons with reduced physical,
sensorial or mental abilities or with insufficient experience
and knowledge to operate this system without proper su-
pervision from the person responsible for its safe use.
a
Do not dispose of packaging material into the environ-
ment, or leave it within the reach of children, since it can
become a potential hazard. Dispose of packaging mate-
rial in compliance with applicable legislation.
Generalinformation

5ENGLISH
GENERAL INFORMATION
GENERAL INFORMATION
Description of the appliance
THC GREY Tsteel boilers are triple flue pass, con-
densing boilers for installation in a boiler room. While they are
designed primarily for central heating purposes, in conjunction
with a suitable storage cylinder they can also be used to pro-
duce domestic hot water.
All parts that come into contact with the combustion gases are
made from titanium stabilised stainless steel to ensure maxi-
mum resistance to the corrosive action of acid condensation.
The boiler has been designed with the combustion chamber at
the top and the smooth pipe tube bundle at the bottom to op-
timise heat exchange and energy efficiency and to maximise
the condensing effect.
The boiler has a high total water content which is differentially
distributed between its top and bottom sections. This allows
outgoing water to reach the set temperature quickly while
maintaining the condensing effect and the water heating time
around the tube bundle for as long as possible.
THC GREY boilers feature lightly pressurised combustion
chambers for a smoother burner action, and high temperature
resistant, stainless steel turbulators inside the tube bundle for
maximum burner efficiency.
The boiler body is thoroughly insulated with a layer of high
density glass wool.
The paint finished external panelling is also internally insulated
with a layer of high density glass wool.
The boiler’s front door and the flue gas chamber can be opened
completely to facilitate the inspection, maintenance and clean-
ing of internal parts and to speed up servicing in general.
The front door can open in either direction and can be opened
without removing the burner. The door is factory fitted with
hinges on the left, but these can be reversed if necessary to
suit individual installations.
3
2
1
4 5
6 (*) 78 (*)
10
9
11
12
13
14
15
16
19
18
17
1 Burner
2 Flame inspection window with
3 Door
4 Casing
5 Outlet
6 Safety device fitting
7 Heating return (high temperature)
8 Heating return (low temperature)
9 Blind plug
10 Instrument bulb/sensor sockets
11 Combustion chamber
12 Flue gas exhaust
13 Flue gas box
14 Inspection window
15 Condensate outlet
16 Boiler drain
17 Turbulators
18 Flue gas pipes
19 Second flue pass
(*) On the THC 1450 GREY the low temperature heating return (8) is located at the rear of the boiler, and the
safety fitting (6) is flanged.

6
ENGLISH GENERAL INFORMATION
GENERAL INFORMATION
Control panels
The Tcontrol panels that can be used with
T THC GREY steel boilers are listed below. These
control panels cater for all the needs of the heating system and
of all the devices installed in it.
TECH CLIMA TOP for central heating (1 direct zone and 2 mixed
zones) and domestic hot water production with a single stage,
two stage, or modulating burner. Also for controlling solar heat-
ing system and cascaded boiler systems.
TECH CLIMA COMFORT for central heating (1 direct zone and
1 mixed zone) and domestic hot water production with a sin-
gle stage burner. Also for controlling solar heating system and
cascaded boiler systems.
TECH CLIMA MIX for controlling 1 additional mixed zone.

7ENGLISH
GENERAL INFORMATION
GENERAL INFORMATION
Recommended burners and technical specications
THC GREY GTM BLU with power < 400 kW
The burners suggested to obtain the best performance of TTHC GREY GTM BLU <400 kW boilers are:
BURNERS BOILER THC GREY GTM BLU
MODEL CODE 150 210 270 350
GAS
BS 3/M 3762350 x(R)
RS 25/M BLU TC FS1 3910510 x(R)
RS 25/M BLU TC FS1 3910510 x(R)
RS 35/M BLU TC FS1 3910610 x(R)
(R) Reference burner used during performance qualification tests to derive the technical data declared.
NOTE: burners must be fitted with a gas ramp device.
b
See the instruction manual provided with the burner:
- Burner installation
- Electrical connections
- Burner adjustments.
b
To assemble/disassemble the burners equipped with recirculation tube, it might be necessary to remove the latter before
carrying out such operations (strictly comply with the use and maintenance manual of the burner).

8
ENGLISH GENERAL INFORMATION
GENERAL INFORMATION
Technical specications
DESCRIPTION BOILER THC GREY GTM BLU
150 210 270 350
Device type Condensing boiler for central heating
B23
Fuel All gas fuels
Device category See Burner
Rated heat input (Qmax) HCV (LCV) 166,5
(150)
233,1
(210)
299,7
(270)
388,5
(350) kW
Rated heat input (Qmin) HCV (LCV) 123,2
(111)
167,6
(151)
234,2
(211)
300,8
(271) kW
Useful (rated) heat output 147 205 264 344
Rated maximum useful heat output (80/60°C) P4 146,6 205,2 264,3 343,7 kW
Rated min. useful heat output (80/60°C) (Pn min) 108,2 147,5 207,2 266,4 kW
30% heat output with return at 30°C (P1) 44,0 61,6 79,3 103,1 kW
Seasonal energy efficiency ηs92,0 93,0 93,0 93,0 %
Efficiency at rated heat input in high temperature mode
η4 (80-60°C) HCV (LCV)
88,0
(97,7)
88,0
(97,7)
88,2
(97,9)
88,5
(98,2) %
Useful efficiency at Pn min (80/60°C) HCV (LCV) 87,8
(97,5)
88,0
(97,7)
88,5
(98,2)
88,6
(98,3) %
Efficiency at 30% rated heat input in low temperature
mode η1 with return at 30°C (HCV)
97,7
(108,5)
98,5
(109,3)
98,4
(109,2)
97,9
(108,7) %
Losses from stack for sensible heat (Qmax) 1,7 1,7 1,5 1,5 %
Losses from casing with burner on 0,3 0,3 0,5 1,0 %
Constant pressure drop 300 420 540 700 W
Flue gas temperature (∆T) < 45÷75 (*) °C
Emissions at max. heat input Nox (0% O2) < 80 mg/kWh
Flue gas mass flow rate (Qmax) 0,07 0,09 0,12 0,15 kg/sec
Furnace pressure 2,0 2,7 3,2 4,6 mbar
Furnace volume 172,0 172,0 241,0 279,0 dm3
Tot. volume of flue gas side 272 292 413,0 482,0 dm3
Heat exchange surface area 8,2 10,4 13,0 16,3 m2
Volumetric heat load (Qmax) 872 1221 1120 1254 kW/m3
Specific heat load 18 19,9 20,4 20,9 kW/m2
Maximum condensate production 18,4 27,4 31,9 40,9 l/h
Maximum working pressure 6 bar
Maximum permitted temperature 110 °C
Maximum operating temperature 95 °C
Pressure drop ∆T 10°C 43,2 36,0 54,0 46,4 mbar
Pressure drop ∆T 20°C 11,3 10,2 16,3 13,4 mbar
Water capacity 323 360 495 555 l
Consumption at full load (Elmax) 650 650 800 800 W
Consumption at part load (Elmin) 132 195 240 240 W
Electrical consumption in standby mode (PSB) 20 20 20 20 W
(*) Depends on return temperature (30-60°C)
b
The stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pressure at
the connection to the flue.
b
Values obtained in combination with the reference burners (R) indicated in the combination table.

9ENGLISH
GENERAL INFORMATION
GENERAL INFORMATION
THC GREY PREMIX with power < 400 kW
The burners suggested to obtain the best performance of TTHC GREY PREMIX <400 kW boilers are:
BURNERS BOILER THC GREY PREMIX ACCESSORIES
KIT
MODEL CODE 150 210 270 350 BURNER
PLATE
GAS - MODULATING
RX 180 S/PV 3790330 x(R) 4031894
RX 250 S/PV 3790320 x(R) 4031894
RX 360 S/PV 20067700 x(R) 20029111
RX 500 S/PV 20077444 x(R) 20029111
(R) Reference burner used during performance qualification tests to derive the technical data declared.
NOTE: burners must be fitted with a gas ramp device.
b
See the instruction manual provided with the burner:
- Burner installation
- Electrical connections
- Burner adjustments.
b
To assemble/disassemble the burners equipped with recirculation tube, it might be necessary to remove the latter before
carrying out such operations (strictly comply with the use and maintenance manual of the burner).

10
ENGLISH GENERAL INFORMATION
GENERAL INFORMATION
Technical specications
DESCRIPTION BOILER THC GREY PREMIX
150 210 270 350
Device type Condensing boiler for central heating
B23 - B23P(*)
Fuel All gas fuels
Device category See Burner
Rated heat input (Qmax) HCV (LCV) 166,5
(150)
233,1
(210)
299,7
(270)
388,5
(350) kW
Rated heat input (Qmin) HCV (LCV) 123,2
(111)
167,6
(151)
234,2
(211)
300,8
(271) kW
Useful (rated) heat output 147 205 264 344
Rated maximum useful heat output (80/60°C) P4 146,6 205,2 264,3 343,7 kW
Rated min. useful heat output (80/60°C) (Pn min) 108,2 147,5 207,2 266,4 kW
30% heat output with return at 30°C (P1) 44,0 61,6 79,3 103,1 kW
Seasonal energy efficiency ηs92,0 93,0 93,0 93,0 %
Efficiency at rated heat input in high temperature mode
η4 (80-60°C) HCV (LCV)
88,0
(97,7)
88,0
(97,7)
88,2
(97,9)
88,5
(98,2) %
Useful efficiency at Pn min (80/60°C) HCV (LCV) 87,8
(97,5)
88,0
(97,7)
88,5
(98,2)
88,6
(98,3) %
Efficiency at 30% rated heat input in low temperature
mode η1 with return at 30°C (HCV)
97,7
(108,5)
98,5
(109,3)
98,4
(109,2)
97,9
(108,7) %
Losses from stack for sensible heat (Qmax) 1,7 1,7 1,5 1,5 %
Losses from casing with burner on 0,3 0,3 0,5 1,0 %
Constant pressure drop 300 420 540 700 W
Flue gas temperature (∆T) < 45÷75 (**) °C
Emissions at max. heat input Nox (0% O2) 70 <60 mg/kWh
Emissions at max. heat input CO 0 mg/kWh
Flue gas mass flow rate (Qmax) 0,07 0,09 0,12 0,15 kg/sec
Furnace pressure 2,4 2,7 3,2 4,6 mbar
Furnace volume 172,0 172,0 241,0 279,0 dm3
Tot. volume of flue gas side 272 292 413,0 482,0 dm3
Heat exchange surface area 8,2 10,4 13,0 16,3 m2
Volumetric heat load (Qmax) 872 1221 1120 1254 kW/m3
Specific heat load 18 19,9 20,4 20,9 kW/m2
Maximum condensate production 18,4 27,4 31,9 40,9 l/h
Maximum working pressure 6 bar
Maximum permitted temperature 110 °C
Maximum operating temperature 95 °C
Pressure drop ∆T 10°C 43,2 36,0 54,0 46,4 mbar
Pressure drop ∆T 20°C 11,3 10,2 16,3 13,4 mbar
Water capacity 323 360 495 555 l
Consumption at full load (Elmax) 400 430 450 1050 W
Consumption at part load (Elmin) 140 160 180 250 W
Electrical consumption in standby mode (PSB) 20 20 20 20 W
(*) The B23P configuration may only be adopted with premix gas burners.
(**) Depends on return temperature (30-60°C)
b
The stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pressure at
the connection to the flue.
b
Values obtained in combination with the reference burners (R) indicated in the combination table.

11 ENGLISH
GENERAL INFORMATION
GENERAL INFORMATION
THC GREY with power > 400 kW
The burners suggested to obtain the best performance of TTHC GREY >400 kW boilers are:
BURNERS BOILER THC GREY ACCESSORIES KIT
MODEL CODE 450 600 800 1000 1250 1450 BURNER
FLANGE HEAD SLIDING
GAS - MODULATING
RS 55/M BLU TC FS1 20038484 x 4031188
RS 68/M BLU T.C. 3897406 x 4031196
RS 120/M BLU T.C.D 3897606 x 4031196
RS 120/M BLU T.C.D 3897606 x 4031196
RS 160/M BLU TC FS1 3788006 x 20047680
RS 160/M BLU TC FS1 3788006 x 4031187
RS 50/M MZ TC 3781622 x
RS 70/M TC 3789610 x
RS 100/M TC 3789710 x x
RS 130/M TC 3789810 x
RS 190/M TC 3787623 x
GAS - PREMIX
RX 500 S/PV 20077444 x 20067543
RX 850 S/PV 20074219 x 20092252
RX 1000 S/PV 20050087 x 20092252
RX 1000 S/PV 20050087 x 20092252
NOTE: burners must be fitted with a gas ramp device.
b
See the instruction manual provided with the burner:
- Burner installation
- Electrical connections
- Burner adjustments.
b
To assemble/disassemble the burners equipped with recirculation tube, it might be necessary to remove the latter before
carrying out such operations (strictly comply with the use and maintenance manual of the burner).

12
ENGLISH GENERAL INFORMATION
GENERAL INFORMATION
Technical specications
DESCRIPTION BOILER THC GREY
450 600 800 1000 1250 1450
Device type Condensing boiler for central heating
B23 - B23P(*)
Fuel All gas fuels
Device category See Burner
Rated heat input (Qmax) HCV (LCV) 499,5
(450)
666,0
(600)
888,0
(800)
1110,0
(1000)
1387,5
(1250)
1609,5
(1450) kW
Rated heat input (Qmin) HCV (LCV) 389,6
(351)
500,6
(451)
667,1
(601)
889,1
(801)
1111,1
(1001)
1388,6
(1251) kW
Useful (rated) heat output 442 589 786 982 1228 1424
Rated maximum useful heat output (80/60°C) P4 441,9 589,2 785,6 982,0 1227,5 1423,9 kW
Rated min. useful heat output (80/60°C) (Pn min) 345,0 443,3 590,8 787,4 984,0 1229,7 kW
30% heat output with return at 30°C (P1) 132,6 176,8 235,7 294,6 368,3 427,2 kW
Efficiency at rated heat input in high temperature mode
η4 (80-60°C) HCV (LCV)
88,5
(98,2)
88,5
(98,2)
88,5
(98,2)
88,5
(98,2)
88,5
(98,2)
88,5
(98,2) %
Useful efficiency at Pn min (80/60°C) HCV (LCV) 88,6
(98,3)
88,6
(98,3)
88,6
(98,3)
88,6
(98,3)
88,6
(98,3)
88,6
(98,3) %
Efficiency at 30% rated heat input in low temperature
mode η1 with return at 30°C (HCV)
97,9
(108,7)
97,9
(108,7)
97,9
(108,7)
97,9
(108,7)
97,9
(108,7)
97,9
(108,7) %
Losses from stack for sensible heat (Qmax) 1,9 %
Losses from casing with burner on 0,6 %
Constant pressure drop <0,2 %
Flue gas temperature (∆T) < 45÷75 (**) °C
Flue gas mass flow rate (Qmax) (***) 0,20 0,26 0,33 0,43 0,54 0,63 kg/sec
Furnace pressure 5,0 5,5 5,7 6,3 6,8 7,4 mbar
Furnace volume 442 496 753 845 1037 1249 dm3
Tot. volume of flue gas side 737 860 1290 1454 1763 2097 dm3
Heat exchange surface area 21,8 28,8 39,6 46,5 56,2 62,3 m2
Volumetric heat load (Qmax) 1018 1210 1062 1183 1205 1161 kW/m3
Specific heat load 20,1 20,3 18,5 21,0 21,7 22,6 kW/m2
Maximum condensate production 52,2 73,8 88,0 111,4 132,7 159,5 l/h
Maximum working pressure 6 bar
Maximum permitted temperature 110 °C
Maximum operating temperature 95 °C
Pressure drop ∆T 10°C 33,8 30,2 128,7 121,5 100,4 150,1 mbar
Pressure drop ∆T 20°C 9,0 8,5 28,7 30,6 28,4 36,3 mbar
Water capacity 743 770 1320 1395 1825 1900 l
(*) The B23P configuration may only be adopted with premix gas burners.
(**) Depends on return temperature (30-60°C)
(***) At Pn max and Tm = 80°C, Tr = 60°C e CO2 = 10,3%
b
The stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pressure at
the connection to the flue.

13 ENGLISH
GENERAL INFORMATION
GENERAL INFORMATION
IMPORTANT NOTES FOR BURNER INSTALLATION
Before fixing the burner to the boiler, make sure that:
- The door opens the right way (see the relevant sections
for details on how to reverse the door)
- The length (L) of the burner fixing bolts is less than
(S), i.e. the total depth of the seal, plates and washer.
Longer bolts can cause the door to warp, compromising
its ability to seal the boiler hermetically and permitting the
release of combustion fumes.
To ensure correct burner installation, also refer to the burner’s
own manual.
L < S
S
L
If you are installing a new boiler but re-using an old burner,
always perform the following checks:
- Make sure that the performance of the old burner is ad-
equate for the requirements of the boiler
- Make sure that the length and diameter of the burner
nozzle are as specified in the following table.
b
When you finish installing the burner in the boiler, fill the
gap between the burner’s blast tube and the refractory
material in the door with the ceramic insulation (A) sup-
plied with the boiler.
A
Ø
L
THC GREY
150 210 270 350 450
Burner head
L min. (mm) 110 170 180 180 195
Hole in door
Ø (mm) 162 162 180 180 210
THC GREY
600 800 1000 1250 1450
Burner head
L min. (mm) 200 200 200 200 205
Hole in door
Ø (mm) 210 235 235 230 265
a
Do not re-use old burners if their blast tube lengths are
below those specified in the table.
Identication
The products are identified by:
Serial number plate
This is located on the boiler body and specifies the serial num-
ber, model, and furnace power.
Data plate
This lists the technical specifications and performance of the
product. It comes inside the documentation envelope. On
completion of the installation you MUST apply it in a clearly
visible position at the top of one of the side panels. If you dam-
age or lose this label, order a replacement immediately from
T's Technical Assistance Centre.
b
If these plates or any other means of clearly identifying
the product are defaced, removed or lost, proper instal-
lation and servicing may be rendered difficult.
23270000581
WEEK OF
MANUFACTURE
Matricola
Modello
bar
kW
Pressione massima
di esercizio PMS
Portata Termica
nominale Qn (Hi)
Combustibile Utilizzato
Codice PIN
Portata Termica
Pressione massima
COLLEGAMENTO DI TERRA OBBLIGATORIO
Combustibile Utilizzato
Matricola
Codice
kW
mbar
bar
CALDAIA A CONDENSAZIONE
°C
kW
Contenuto acqua
Categoria dell' Apparecchio
Pressione focolare
Tipo di Apparecchio
Anno
Paese di destinazione
Modello
PMS
Qmax(Hi)
di esercizio
Tipo
Potenza Utile
Pn max 40/30°
Tmax
Temp. massima
ammessa
I
Portata Termica
kW
Qmin(Hi)
Potenza utile
kW
Pn max(Hi)
Potenza utile
kW
Pn min(Hi)
067637IT
067637IT
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)

14
ENGLISH SYSTEM MANAGER
SYSTEM MANAGER
SYSTEM MANAGER
Putting into service
Have T’s Technical Assistance Centre start up
your T THC GREY boiler for the first time. Once this
has been done, the boiler can be left to function automatically.
Under certain circumstances, such as after long periods of dis-
use, the service engineer responsible for the boiler may need
to re-start it without involving the Technical Assistance Centre.
To do so, perform the following checks and operations:
- Check that the gas cock and heating water cock are
open
- While the system is still cold, check that working pres-
sure in the central heating circuit is over 1 bar but below
the maximum limit specified for the boiler
- Since the control panel incorporates a temperature
control function, make sure that the control panel is
switched on
- Adjust the timer thermostat (if installed) or the tempera-
ture control to the desired temperature (~20° C)
- Turn the boiler’s mains power switch ON
- Turn the control panel power switch ON and make sure
that the green power indicator lights
- Make the settings as instructed in the instruction manu-
al for your control panel.
The burner should now ignite and remain in operation until the
set temperature is reached.
The burner will then switch off and on automatically to maintain
the set temperature without further operator action.
If any ignition faults or malfunctions occur, the burner performs
a “LOCKOUT SHUTDOWN”. This is shown by the red button
light on the burner and by the warning light on the control pan-
el.
b
If a “LOCKOUT SHUTDOWN” occurs, wait about 30 sec-
onds before resetting the burner.
To reset the burner, press the red button light on the burner
and wait until the flame ignites.
Repeat this operation 2-3 times at the most. If the problem
persists after that, call T’s Technical Assistance
Centre.
Systemmanager

15 ENGLISH
SYSTEM MANAGER
SYSTEM MANAGER
Preparing for extended periods of disuse
If the boiler is not going to be used for an extended period of
time, perform the following operations:
- Turn the control panel power switch OFF and make sure
that the green power indicator goes out
- Turn the main system switch "off"
- Close the fuel cock and heating circuit water cock
- Drain the central heating circuit if there is any risk of
freezing.
b
Contact your local TTechnical Assistance
Centre if you encounter any problems in completing the
above procedure.
Cleaning
Use a cloth damped in soapy water to clean the boiler’s exter-
nal casing.
To remove stubborn marks, use a cloth damped in a 50% mix
of water and denatured alcohol or a suitable cleaning product.
Carefully dry after cleaning.
a
Do not use abrasive cleaning pads or powder deter-
gents.
a
Never clean the boiler without first disconnecting it from
the mains electricity supply by turning the mains power
switch and the control panel switch OFF.
b
The combustion chamber and flue pipes must be cleaned
periodically by the manufacturer’s Technical Assistance
Centre or by a qualified heating engineer.
Maintenance
Please remember that THE PERSON RESPONSIBLE FOR
SYSTEM MANAGEMENT MUST ENSURE THAT PROFES-
SIONALLY QUALIFIED HEATING ENGINEERS UNDERTAKE
PERIODIC MAINTENANCE AND COMBUSTION EFFICIENCY
MEASUREMENTS.
T’s Technical Assistance Centre is qualified to
satisfy these legal requirements and can also provide useful
information on MAINTENANCE PROGRAMMES designed to
guarantee:
- Greater safety
- Compliance with applicable legislation
- Freedom from the risk of fines in the event of spot
checks.
Regular maintenance is essential for the safety, efficiency and
durability of the boiler.
Servicing is a legal requirement and must be performed at
least once a year by a professionally qualified heating engi-
neer.

16
ENGLISH SYSTEM MANAGER
SYSTEM MANAGER
Useful information
Seller:.....................................................................................
Mr.: .........................................................................................
Address: ................................................................................
Tel.:.........................................................................................
Technical Assistance Centre: ..............................................
Mr.: .........................................................................................
Address: ................................................................................
Tel.:.........................................................................................
Installer:.................................................................................
Mr.: .........................................................................................
Address: ................................................................................
Tel.:.........................................................................................
Date Work done
Fuel oil supplier:...................................................................
Mr.: .........................................................................................
Address: ................................................................................
Tel.:.........................................................................................
Date Quantity
supplied Date Quantity supplied Date Quantity supplied Date Quantity supplied

17 ENGLISH
INSTALLER
INSTALLER
INSTALLER
Unpacking the product
The THC GREY boiler is supplied in two separate packages.
1 BOILER BODY CRATE to which is attached the documenta-
tion envelope (A) containing:
- Instruction manual
- Data label (to be applied to the panelling on completion
of the installation)
- Hydraulic test certificate
- Bar code labels
- Spare parts catalogue
- Ceramic insulation (B)
- Cleaning brush (C).
b
The instruction manuals are an integral part of the boil-
er, therefore we recommend to read and keep them with
care.
A
C
B
2 PANELLING CRATE , complete with assembly accessories,
protected by cardboard packaging and a wooden crate.
b
For the boiler to function correctly, it must be connected
to a Tcontrol panel and dedicated control
accessories.
Installer

18
ENGLISH INSTALLER
INSTALLER
Overall dimensions and weights
A40 120 L1
L
150
D
H1
H
B 161
DESCRIPTION
THC GREY
150 210 270 350 450 600 800 1000 1250 1450
A - Base width 690 690 750 750 790 790 980 980 1070 1130 mm
B - Width 760 760 820 820 890 890
1080 1080 1170 1225 mm
L - Length
1455 1455 1630 1830 2035 2235 2560 2810 3010 3080 mm
L1 - Base depth
1295 1295 1470 1670 1875 2075 2400 2650 2850 2850 mm
H - Height of water fittings
1315 1315 1450 1450 1630 1630 1910 1910 2030 2180 mm
H1 - Boiler height
1300 1300 1437 1437 1615 1615 1900 1900 2015 2167 mm
D - Height of burner plate 925 925
1030 1030 1235 1235 1390 1390 1495 1590 mm
Weight of boiler 510 530 677 753
1095 1250 1870 2085 2515 3050 mm
Weight of casing 50 50 60 70 90 120 140 160 215 230 kg
Handling
THC GREY Tsteel boilers are fitted with lifting at-
tachments. Take great care when moving them and only use
lifting equipment of adequate capacity.
Remove the transport straps and remove the wooden pallet
before positioning the boiler.
b
Wear suitable personal protective equipment and use
suitable safety devices.

19 ENGLISH
INSTALLER
INSTALLER
Installation premises
T THC GREY steel boilers must be installed in a
dedicated boiler room, with adequately sized vents, in compli-
ance with applicable laws and standards.
If at all possible, the boiler should be installed on a raised base
to stop the burner fan sucking up dust and to facilitate installa-
tion of a condensate drain system.
The boiler condensate drain must be located above the height
of the lid of the system’s condensate neutraliser.
The gas supply pipe must be installed in such away that the
boiler’s panelling can be removed and the front door opened
without having to remove the burner.
b
In Belgium, boilers must be installed according to stand-
ards NBN D51.003, NBN D30.003, NBN B61.002 (heat
output < 70 kW), and NBN B61.001 (heat output >70
kW).
b
When installing the boiler, allow sufficient space around
it to access all safety and control devices and to permit
easy maintenance.
b
If the specific weight of the gas supply to the burner is
greater than the specific weight of air, install all electrical
parts at least 500 mm above floor level.
a
Do not install the boiler outdoors. It is not designed to
work outdoors and is not fitted with the necessary auto-
matic anti-frost systems to do so.
≥1 m
≥L
H1
≥1 m B
≥1 m L
~ 0,1 m
DESCRIPTION
THC GREY
150 210 270 350 450 600 800 1000 1250 1450
B - Width 750 750 850 850 900 900 1000 1000 1200 1250 mm
L - Length
1350 1350 1620 1820 1930 2140 2400 2700 2920 3100 mm
H1 - Overall height (boiler + base)
1420 1420 1540 1540 1700 1700 2010 2010 2130 2280 mm

20
ENGLISH INSTALLER
INSTALLER
Water in central heating systems
INTRODUCTION
Water used in central heating systems MUST be suitably treat-
ed to ensure the correct functioning of those systems and to
guarantee an extended working life for boilers and all other
system components. This applies not only to existing systems
but to newly installed systems too.
Sludge, lime-scale and pollutants present in the water can
cause permanent damage to the heating unit, also within a
short time and regardless of the quality standards of the ma-
terials used.
Contact the Technical Assistance Centre for any further infor-
mation on type and use of additives.
b
Always conform to the standards and legislation applica-
ble in the country of installation.
WATER IN CENTRAL HEATING SYSTEMS.
INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND
MANAGEMENT OF CENTRAL HEATING SYSTEMS.
1. Chemical and physical characteristics of water
The chemical and physical characteristics of water used in
central heating systems must conform to the requirements of
EN 14868 standard and to the following tables:
STEEL BOILERS
with furnace power < 150 kW
Initial filling
water
Regular ser-
vice water (*)
ph 6-8 7,5-9,5
Hardness °fH < 10° < 10°
Electrical
conductivity μs/cm < 150
Chlorides mg/l < 20
Sulphides mg/l < 20
Nitrides mg/l < 20
Iron mg/l < 0,5
STEEL BOILERS
with furnace power > 150 kW
Initial filling
water
Regular ser-
vice water (*)
ph 6-8 7,5-9,5
Hardness °fH < 5° < 5°
Electrical
conductivity μs/cm < 100
Chlorides mg/l < 10
Sulphides mg/l < 10
Nitrides mg/l < 10
Iron mg/l < 0,5
(*) values for water in system after 8 weeks of functioning
General note on water used to top up systems:
- If softened water is used to top up a system, 8 weeks
of functioning after topping up, verify that the water in
the system respects the above limits, in particular for
electrical conductivity
- This check is not necessary if demineralised water is
used to top up the system.
2. Central heating systems
b
Do not use automatic filling devices to add water to cen-
tral heating systems. Use a manual device instead and
record top-ups in the system service book.
b
If there are more than one boiler, they must all be put into
service either contemporarily or with a very low rotation
time during the initial period of service, so as to evenly
distribute the limited quantity of initial lime-scale.
b
A flushing cycle must be programmed after the plant has
been installed to flush out any installation debris.
b
Water used to fill a system for the first time and water
used to top it up must always be filtered (using synthetic
or metal mesh filters with a filtration rating of no less than
50 microns) to prevent sludge from forming and trigger-
ing deposit corrosion.
b
The heating system must be flushed out and cleaned
with good workmanship before filling up the existing sys-
tems. The boiler may not be filled until after the heating
system has been flushed out.
2.1 New central heating systems
The system must be filled up slowly the first time; once it is
filled and the air expelled it should never need to be topped
up again.
Systems should also be operated at maximum working tem-
perature the first time they are started up, in order to facilitate
de-aeration. (Gas is not released from the water at low tem-
peratures).
2.2 Reconditioning old central heating systems
If a boiler has to be replaced, do not refill the entire central
heating circuit if the quality of water in it conforms to require-
ments. If the quality of water fails to conform to requirements,
either recondition the old water or separate the water circuits
(water in the boiler circuit must conform to requirements).
3. Corrosion
3.1 Deposit corrosion
Under-deposit corrosion is an electrochemical process, due
to the presence of sand, rust, etc., inside the mass of water.
These solid substances generally deposit on the bottom of the
boiler (sludge), on tube and pipe heads or in the gaps be-
tween pipes and tubes.
Micro-corrosion phenomena may be triggered off owing to the
difference in electrochemical potential coming to be created
between the material in contact with the impurity and the sur-
rounding one.
3.2 Stray current corrosion
Corrosion from stray currents can occur due to the differing
electrical potentials between water in the boiler and the metal-
lic mass of the boiler or piping. This process leaves unmistake-
able traces i.e. small regular conical holes.
b
All metallic parts should be grounded by an efficient
earth cable for this reason.