thermital THE/TG Series Owner's manual

THE/TG
INSTALLATION, OPERATION, MAINTENANCE AND
SYSTEM MANAGEMENT MANUAL

The THERMITAL THE/TG 3S boilers conform to the Efficiency Directive 92/42/CEE.
When used in conjunction with a CE marked jet burner, they also satisfy the requirements of the
Gas Directive 2009/142/CE and applicable sections of the Electromagnetic Compatibility Directive
2014/30/UE and Low Voltage Directive 2014/35/UE.
When THE/TG 3S boilers up to 400 kW are used in conjunction with a fuel oil burner,
they conform to the Energy-Related Products Directive 2009/125/EC
and to the EU Delegated Regulation 813/2013
CHARACTERISTICS
- High efficiency
- Low emissions (when fitted with a low NOx burner)
MODEL CODE
THE/TG 90 3S 20042921
THE/TG 115 3S 20034707
THE/TG 166 3S 20034709
THE/TG 217 3S 20034712
THE/TG 255 3S 20034733
THE/TG 349 3S 20034736
THE/TG 448 3S 20034741
THE/TG 511 3S 20034743
THE/TG 639 3S 20042922
THE/TG 850 3S 20043427
THE/TG 1160 3S 20052321
THE/TG 1450 3S 20052322
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CONFORMITY
RANGE

Dear Customer,
Thank you for choosing a THERMITAL THE/TG 3S,boiler. You have purchased a modern, high
efficiency, quality product that is designed 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 THERMITAL Technical Assistance Centre. Their personnel are specially trained to keep
your boiler efficient and cheap to run. Technical Assistance Centres 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 trouble-free installation and efficient functioning of your THERMITAL THE/TG 3S boiler.
Please accept our renewed thanks for your purchase.
Thermital S.p.A.
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The following symbols are used in this manual:
b CAUTION! = Indicates actions that require
caution and adequate preparation
a STOP! = Identifies actions that you MUST
NOT do
This manual, Code 20035755 Rev. 20 (04/17) is made
up of 40 pages.
4
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CONTENTS
CONTENTS
GENERAL 5
General safety information 5
Precautions 5
Product description 6
Control panels 7
Recommended fuel oil burners 8
Recommended gas burners 8
Product identification 10
Technical data for boilers
with fuel oil burners <400 kw 11
Technical data for boilers
with gas burners <400 kw 12
Technical data for boilers > 400 kW 13
Start up 14
SYSTEM MANAGER 14
Temporary shutdown 15
Preparing for extended periods of disuse 16
Cleaning 16
Maintenance 17
Useful information 17
Unpacking the product 18
INSTALLER 18
Overall dimensions and weights 19
Handling 19
Place of installation 20
Installation in older systems
and systems requiring modernisation 21
Water connections 21
Anti-condensate pump 23
Combustion gas exhaust 23
Boiler door hinges 24
Changing the direction of door opening 24
Earth connection 28
Fitting the casing panels 29
Location of sensors 31
Preparing for initial start-up 32
TECHNICAL ASSISTANCE SERVICE 32
Initial start-up 33
Checks during and after initial start-up 34
Maintenance 35
- Opening the door 35
- Adjusting the door 35
Cleaning the boiler 36
Troubleshooting 37

aDo not allow children or infirm persons to operate
this THERMITAL THE/TG 3S boiler unsupervised.
a Do not operate any electrical devices or equipment,
including switches or domestic appliances, etc., if
you can smell fuel or fumes. If you detect any suspi-
cious smells:
- Ventilate the room by opening all doors and win-
dows.
- Close the fuel shut-off cock.
- Report the fault immediately to the THERMITAL
Technical Assistance Service or a professionally
qualified heating engineer.
aDo not touch the boiler while barefoot or wet.
aNever clean or service the boiler without first dis-
connecting it from the mains electricity supply
by turning the main power switch and the control
panel switch OFF.
aDo not tamper with or adjust the safety or control
devices without prior authorisation and instructions
from the boiler’s manufacturer.
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 The THERMITAL THE/TG 3S boiler must be
installed by a legally qualified heating engineer.
On completion of the installation, the installer 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 THERMITAL in this instruc-
tion manual, and that it conforms to all applicable
laws and standards.
b The boiler must only be used for the purpose speci-
fied by THERMITAL and for which it is designed.
The 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.
b If you notice any water leaking from the boiler, dis-
connect it immediately from the mains electricity
supply, shut off the water supply, and notify your
local THERMITAL Technical Assistance Centre or a
qualified heating engineer immediately.
The operation of any appliance that uses fuel, electrical power and water demands that a number of fundamental safety
precautions be respected.
b Periodically check that operating pressure in the
water circuit is over 1 bar but below the maximum
limit specified for the boiler. If this is not the case,
contact THERMITAL’s Technical Assistance Service
or a professionally qualified heating engineer.
b If the boiler is not going to be used for an extended
period of time, contact THERMITAL’s Technical
Assistance Service or a qualified heating engineer
to have it prepared for shut-down as follows:
- Switch the boiler OFF at the control panel and at the
mains power switch.
- Close the fuel cock and heating circuit water cock.
- Drain the central heating circuit if there is any risk of
freezing.
b Drain the central heating circuit if there is any risk of
freezing
b This instruction manual is an integral part of the boil-
er. It must be kept safe and must ALWAYS accom-
pany 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 replace-
ment immediately from your local THERMITAL
Technical Assistance Centre.
aNever pull, disconnect, or twist the electrical cables
coming from the boiler even if it is disconnected
from the mains electricity supply.
aDo not obstruct or restrict the vents in the room
where the boiler is installed. Adequate ventilation is
essential for correct combustion.
aDo not expose the boiler to the elements. 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.
aDo not switch the boiler off if outdoor temperature
drops below ZERO (risk of freezing).
aDo not store containers of flammable substances in
the room where the boiler is installed.
aDo not dispose of packaging material into the envi-
ronment, or leave it within the reach of children,
since it can become a potential hazard. Dispose of
packaging material in compliance with applicable
legislation.
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GENERAL
PRECAUTIONS
GENERAL SAFETY INFORMATION

THERMITAL THE/TG 3S steel boilers are high efficiency
triple flue pass boilers for central heating systems. When
combined with a storage cylinder, they can also be used
to produce domestic hot water.
THERMITAL THE/TG 3S boilers are monobloc boilers
with pressurised combustion. The flame from the burner
first enters the furnace (1st flue pass). Via an opening at
the other end of the furnace, the combustion gases then
enter a duct that takes them back towards the front of the
boiler (2nd flue pass).
This separation between the combustion gas return duct
and the furnace makes a major contribution to reducing
Nox emissions. Combustion gases remaining in the high
temperatures of the furnace is one of the main reasons
for the formation of NOx emissions.
At the front of the boiler, the combustion gases pass
through a recess in the door insulation and exit through
the tube bundle (3rd flue pass).
In the tube bundle, turbulators force the combus-
tion gases into a vortex-like path that improves the
efficiency of convection heat exchange. This system
achieves maximum heat absorption without risking dam-
age through thermal stress.
Once out of the tube bundle, the flue gases pas through
a chamber at the rear of the boiler, and into the vent flue.
Their special design (with tube bundle over the combus-
tion chamber) makes these boilers far narrower than
conventional pressurised boilers and therefore easier to
install in boiler rooms with narrow doors or where space
is limited.
The burner is installed in a hinged door to permit the
adjustment and servicing of both boiler and burner with-
out having to remove the burner.
The boiler body is thermally insulated by high efficiency
mineral wool insulation that reduces heat loss to an
extremely low level.
The boiler casing is made from pre-painted panels lined
with mineral wool insulation.
Max. permissible return temperature with a gas burner:
50°C
Max. permissible return temperature with a fuel oil
burner: 37°C
1
2 34 5
6
7
8
9
1013
11
12
1 - Door hinge
2 - Central heating return
3 - Central heating flow
4 - Safety device fitting
5 - Flue gas box
6 - Flue gas exhaust
7 - Access door for cleaning the flue gas box
8 - Condensate drain
9 - Boiler drain
10 - Door
11 - Flame inspection window
12 - Burner plate
13 - Control panel
MODELS UP TO 400 KW USED WITH FUEL OIL BURNERS CONFORM TO THE ENERGY-RELATED PRODUCTS
DIRECTIVE 2009/125/EC AND TO THE EU DELEGATED REGULATION 813/2013
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GENERAL
PRODUCT DESCRIPTION

The THERMITAL control panels that can be used with THERMITAL THE/TG 3S steel boilers are listed below. These con-
trol panels cater for all the needs of the heating system and of all the devices installed in it.
Respect the indications of the table rigorously to ensure trouble-free operation and maximum reliability of your boiler
over time.
b When a TBOX CLIMA TOP or CLIMA COMFORT control panel is installed, the boiler return (cold) line must be
equipped with a temperature sensor socket.
See the catalogue for the necessary accessory part numbers.
Single stage Two stage Modulating Cascaded Wood fuelled Solar DHW Direct CH circuit Mixed CH zone 1 Mixed CH zone 2
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
1 2
M
°C
CLIMA TOP
STANDARD    
Control by control panel with assistance of
accessories listed below
     
ACCESSORIES
Immersion temperature sensor 1 1 1 1
Solar collector temperature sensor 1
Pipe temperature sensor 1 1
CLIMA COMFORT
STANDARD  
Control by control panel with assistance of
accessories listed below
     
ACCESSORIES
Immersion temperature sensor 1 1 1
Solar collector temperature sensor 1
Pipe temperature sensor 1 1
Two-stage burner control kit 1
1 mixed zone kit 1
CLIMA MIX
STANDARD 
Control by control panel with assistance of
accessories listed below

ACCESSORIES
Pipe temperature sensor 1 1
1 mixed zone kit 1
BASIC R
STANDARD  
Control by control panel with assistance of
accessories listed below

ACCESSORIES
Two stage burner kit 1
BASIC ACS
STANDARD   
Control by control panel with assistance of
accessories listed below

ACCESSORIES
Two stage burner kit 1
Total shutdown kit 1 1
CONTROL PANELS
MODEL TYPE
TBOX CLIMA TOP Climate control
TBOX CLIMA COMFORT Climate control
TBOX CLIMA MIX Climate control
TBOX BASIC R Electro-mechanical
TBOX BASIC ACS Electro-mechanical
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GENERAL
CONTROL PANELS

The burners recommended to obtain the best possible performance from THERMITAL THE/TG 3S boilers are:
BURNER THE/TG 3S Burner plate
Model Code Type 90 115 166 217 255 349 448 511 639 850 1160 1450 Code
O
I
L
RG 3D 3739450 Two stage • •
RG 4D 3739750 Two stage • (R)
RL34 MZ TC 3470210 Two stage • (1) • 4031198 (1)
RL44 MZ TC 3470310 Two stage •
RL50 TC 3474632 Two stage
RL70 TC 3475032 Two stage
RL 100 TC 3475232 Two stage
RL 130 TC 3475432 Two stage
RL 190 TC 20011008 Two stage
BG 7.1D (Low NOx) 20015696 Two stage • (R)
RL 22 BLU (Low NOx) 20027479 Two stage • • (R) 4031198
RL 32 BLU (Low NOx) 20027481 Two stage • (R) • (R)
TG 2.50 3860510 Two stage • •
TG 2.70 3860511 Two stage •
RL 100 3475233 Two stage •
RL 130 3475433 Two stage •
RL 190 3475613 Two stage •
RL 42 BLU (Low NOx) 20027568 Two stage • • 4031196
RL 55/M BLU (Low
NOx) 3899200 Modulating • 4031197
RL 85/M BLU (Low
NOx) 3896010 Modulating • 4031197
(R) Reference burner used during performance qualification tests to derive the technical data declared.
BURNER THE/TG 3S Burner plate
Model Code Type 448 511 639 850 1160 1450 Code
G
A
S
TS 2.50 3865511 Two stage • •
TS 2.70 TL 3865512 Two stage •
RS 100 3785303 Two stage •
RS 130 3785503 Two stage •
RS 190 3785813 Two stage •
RS 50/M 3781613 Modulating • •
RS 70/M 3789611 Modulating •
RS 100/M 3789711 Modulating •
RS 130/M 3789811 Modulating •
RS 190/M 3787623 Modulating •
RS 45/M BLU TC
(Low NOx) 3897306 Modulating •
RS 55/M BLU TC
(Low NOx) 20038459 Modulating • 4031196
RS 68/M BLU TC
(Low NOx) 3897406 Modulating • 4031196
RS 120/M BLU TC
(Low NOx) 3897606 Modulating • •
RS 160/E BLU t.c.
(Low NOx) 3788030 Modulating •
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
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GENERAL
RECOMMENDED FUEL OIL BURNERS
RECOMMENDED GAS BURNERS

b See the instruction manual provided with the burner for further information on burner installation, electrical con-
nections, burner adjustments.
If a two stage burner is installed, 1st stage heat input must not be less than 70% of total heat input.
A
ø
L
IMPORTANT
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
adequate for the requirements of the boiler.
- Make sure that the length and diameter of the burner’s
blast tube 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) supplied with the boiler.
aDo not re-use old burners if their blast tube lengths are below those specified in the table.
THE/TG 3S 90 115 166 217 255 349 448 511 639 850 1160 1450
L min 128 128 128 128 155 155 195 195 200 200 205 205 mm
Diameter of door hole 140 140 162 162 180 180 205 205 205 230 230 270 Ø mm
Thickness of door 93 93 93 93 103 103 118 118 119 119 119 119 mm
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, compro-
mising 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
9
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GENERAL

b If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper installa-
tion and servicing may be rendered difficult.
-Serial number plate
This is located on the boiler body and speci-
fies the serial number, model, furnace power
and maximum operating pressure.
-Data plate
This lists the technical specifications and per-
formance 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 damage or lose this label, order a
replacement immediately from THERMITAL’s
Technical Assistance Service.
b One or more data labels may be supplied
in the document envelope. Identify the
correct label for the type of fuel.
The boilers are identified by two plates:
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
23270000581
WEEK OF
MANUFACTURE
FUEL
10
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GENERAL
PRODUCT IDENTIFICATION

b The stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pres-
sure at the connection to the flue gas exhaust.
b Values obtained in combination with the reference burners (R) indicated in the combination table.
b When used in conjunction with fuel oil burners, THE/TG 3S boilers <400kW conform to:
- Energy-Related Products Directive 2009/125/EC
- EU Delegated Regulation 813/2013
THE/TG 3S 90 115 166 217 255 349
Device type Central Heating
B23
Fuel Oil
Device category See burner
Maximum rated heat input HCV (LCV) 95,4
(90)
122
(115)
176
(166)
230,1
(217)
270,4
(255)
370,1
(349) kW
Minimum rated heat input (Q min) HCV (LCV) 74,2
(70)
95,4
(90)
122
(115)
176
(166)
230,1
(217)
270,4
(255) kW
Rated useful heat output max. (80/60°C) P4 85,1 108,3 157,4 207,5 244,0 334,7 kW
Rated useful heat output min. (80/60°C) (Pn min) 66,6 85.5 109,6 158,7 206,2 243,0 kW
30% heat output with return at 37°C (P1) 25,5 32,5 47,2 62,9 73,2 100,4 kW
Seasonal energy efficiency hs 89,0 89,0 89,0 90,0 90,0 90,0 %
Efficiency at rated heat input in high temperature
mode h4 (80-60°C) HCV (LCV)
89,1
(94,5)
88,8
(94,2)
89,4
(94,8)
90,2
(95,6)
90,3
(95,7)
90,4
(95,9) %
Useful efficiency at min Pn (80-60°C) HCV (LCV) 89.8
(95.2)
89,6
(95,0)
89,9
(95,3)
90,2
(95,6)
89,6
(95,0)
89,9
(95,3) %
Efficiency at rated heat input in Low temperature
mode h1 with return at 37°C HCV (LCV)
94,0
(99,7)
94,1
(99,8)
94,2
(99,9)
94,2
(99,9)
94,1
(99,8)
94,1
(99,8) %
Heat loss in standby mode 240 300 360 430 500 600 W
Flue gas temperature (∆T°) 106 103 103 106 100 106 °C
Flue gas mass flow rate (Pn Max) 0,040 0,050 0,072 0,094 0,110 0,151 Kg/s
Furnace pressure 1,0 1,4 1,8 2,7 2,9 3,6 mbar
Furnace volume 75 121 176 176 240 296 dm3
Total volume of flue gas side 112 176 253,5 261,5 357,5 443 dm3
Surface area for heat exchange 3,77 5,32 7,34 8,16 10,06 12,88 m2
Volumetric heat load (Pn Max) 1203 947 941 1229 1066 1180 kW/m3
Specific heat load (Pn Max) 22,6 20,4 21,4 25,4 24,3 26,0 kW/m2
Maximum operating pressure 6 bar
Maximum admissible temperature 110 °C
Maximum operating temperature 95 °C
Min. admissible water return temper. 37 °C
Pressure drop ∆T 10° C 22 25 27 45 43 75 mbar
Pressure drop ∆T 20° C 7 5 5 10 13 20 mbar
Water capacity 176 255 319 309 408 495 l
Consumption at full load (Elmax) 430 450 460 660 660 760 W
Consumption at part load (Elmin) 151 158 161 231 231 266 W
Electrical consumption in standby mode (Psb) 20 20 20 20 20 20 W
11
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GENERAL
TECHNICAL DATA FOR BOILERS WITH FUEL OIL BURNERS <400 KW

12
TECHNICAL DATA FOR BOILERS WITH GAS BURNERS <400 KW
(*) Heating appliance marketed before 1 January 2018, intended exclusively for replacement under the terms of EU
Regulation 813/2013, article 1,section 2, letter (g).
THE/TG 3S 90(*) 115(*) 166(*) 217(*) 255(*) 349(*)
Fuel Gas
Rated heat input minimum 70,0 90,0 115,0 166,0 217,0 255,0 kW
maximum 90,0 115,0 166,0 217,0 255,0 349,0 kW
Rated useful heat output Pn minimum 66,6 85,5 109,6 158,7 206,2 243,0 kW
maximum 85,1 108,3 157,4 207,5 244,0 334,7 kW
Useful efficiency at min. Pn 95,2 95,0 95,3 95,6 95,0 95,3 %
at max. Pn 94,5 94,2 94,8 95,6 95,7 95,9 %
Useful efficiency at 30% (Pn Max) 98,5 98,5 98,5 98,5 98,5 98,5 %
Constant pressure drop (Pn Max) < 1,4 < 1,2 %
Flue gas temperature (∆T°) 106 103 103 106 100 106 °C
Flue gas mass flow rate (Pn Max) 0,040 0,050 0,072 0,094 0,110 0,151 Kg/s
Furnace pressure 1,0 1,4 1,8 2,7 2,9 3,6 mbar
Furnace volume 75,0 121,0 176,0 176,0 240,0 296,0 dm3
Total volume of flue gas side 112 176 2.535 2.615 3.575 443 dm3
Surface area for heat exchange 3,8 5,3 7,3 8,2 10,1 12,9 m2
Volumetric heat load (Pn Max) 1.203 947 941 1.229 1.066 1.180 kW/m3
Specific heat load (Pn Max) 22,6 20,4 21,4 25,4 24,3 26,0 kW/m2
Maximum operating pressure 6 bar
Maximum admissible temperature 110 °C
Maximum operating temperature 95 °C
Min. admissible water return temper. 50 °C
Pressure drop ∆T 10° C 22 25 27 45 43 75 mbar
Pressure drop ∆T 20° C 7 5 5 10 13 20 mbar
Water capacity 176 255 319 309 408 495 l

13
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GENERAL
b The stack must guarantee the minimum draught specified by applicable technical standards, assuming zero pres-
sure at the connection to the flue gas exhaust.
THE/TG 3S 448 511 639 850 1160 1450
Fuel Gas / Oil
Rated heat input minimum 349 448 511 639 850 1160 kW
maximum 448 511 639 850 1160 1450 kW
Rated useful heat output Pn minimum 332,2 426,5 486,5 608,3 809,2 1104,3 kW
maximum 427,8 488,0 610,2 811,8 1107,8 1384,8 kW
Useful efficiency at min. Pn 95,2 95,2 95,2 95,2 95,2 95,2 %
at max. Pn 95,5 95,5 95,5 95,5 95,5 95,5 %
Useful efficiency at 30% (Pn Max) 98,5 98,5 98,5 98,5 98,5 98,5 %
Constant pressure drop (Pn Max) < 1,2 < 1,0 %
Flue gas temperature (∆T°) 104 105 102 108 112 107 °C
Flue gas mass flow rate (Pn Max) 0,195 0,221 0,278 0,367 0,507 0,626 Kg/s
Furnace pressure 2,9 5,4 5,2 6,7 3,9 4,6 mbar
Furnace volume 453 453 613 812 1065 1297 dm3
Total volume of flue gas side 682 682 899 1209 1656 2088 dm3
Surface area for heat exchange 18,58 18,58 23,45 30,60 40,40 51,82 m2
Volumetric heat load (Pn Max) 988 1127 1043 1046 1089 1118 kW/m3
Specific heat load (Pn Max) 23,0 26,3 26,0 26,5 27,4 26,7 kW/m2
Maximum operating pressure 6 bar
Maximum admissible temperature 110 °C
Maximum operating temperature 95 °C
Min. admissible water return temp. 50 °C
Pressure drop ∆T 10° C 70 90 52 42 75 75 mbar
Pressure drop ∆T 20° C 20 20 16 14 20 22 mbar
Water capacity 655 655 899 1193 1537 2211 l
TECHNICAL DATA FOR BOILERS > 400 KW

Have THERMITAL’s Technical Assistance Service start up your THERMITAL THE/TG 3S 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 disuse, the service engineer responsible for the boiler may
need to re-start it without involving the Technical Assistance Service.
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 water circuit is over 1 bar but below the
maximum limit specified for the boiler.
-
If the system is equipped with a temperature controller or
timer thermostat, make sure that it is switched on.
- Adjust the timer thermostat/s or temperature controller to
the desired temperature (~20° C).
- Turn the system’s main 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 man-
ual for your control panel.
ON
OFF
14
ENGLISH
SYSTEM MANAGER
START UP

The burner should now ignite and remain in operation
until the set temperature is reached.
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 panel.
b If a “LOCKOUT SHUTDOWN” occurs, wait about
30 seconds 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 prob-
lem persists after that, call THERMITAL ’s Technical
Assistance Service.
If you need to shut down the system for a short period,
proceed as follows.
- Turn the control panel power switch OFF and make
sure that the green power indicator goes out.
- Turn the mains power switch OFF.
b Do NOT perform this procedure if outdoor tem-
perature falls below ZERO (risk of freezing).
Then proceed as follows:
- Make the settings as instructed in the instruction man-
ual for your control panel.
- Make sure that the temperature controller or timer /
room thermostat is set to “frost protection” mode
.
ON
OFF
15
ENGLISH
SYSTEM MANAGER
TEMPORARY SHUTDOWN

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 mains power 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 THERMITAL Technical Assistance Service
if you encounter any problems in completing the
above procedure.
Use a cloth damped in soapy water to clean the boiler’s
external casing.
To remove stubborn marks, use a cloth damped in a 50%
mix of water and denatured alcohol or a suitable clean-
ing product.
Carefully dry the boiler after cleaning.
aDo not use abrasive cleaning pads or powder
detergents.
a Never clean the boiler without first disconnecting it
from the mains electricity supply by turning the main
power switch and the control panel switch off.
b The combustion chamber and flue pipes must be
cleaned periodically by THERMITAL’s Technical
Assistance Service or by a qualified heating engi-
neer (see “Cleaning the boiler” page 36).
ON
OFF
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SYSTEM MANAGER
CLEANING
PREPARING FOR EXTENDED PERIODS OF DISUSE

Seller: .............................................................................................................................................
Mr. .......................................................................................................................................................
Address .......................................................................................................................................
tel. .......................................................................................................................................................
Technical Assistance Service: ....................................................................
Mr. .......................................................................................................................................................
Address .......................................................................................................................................
tel. .......................................................................................................................................................
Fuel oil supplier: ............................................................................................................
Mr. .......................................................................................................................................................
Address .......................................................................................................................................
tel. .......................................................................................................................................................
Installer:.......................................................................................................................................
Mr. ......................................................................................................................................................
Address ......................................................................................................................................
tel. ......................................................................................................................................................
Please remember that THE PERSON RESPONSIBLE
FOR SYSTEM MANAGEMENT MUST ENSURE THAT
PROFESSIONALLY QUALIFIED HEATING ENGINEERS
UNDERTAKE PERIODIC MAINTENANCE AND
COMBUSTION EFFICIENCY MEASUREMENTS.
THERMITAL’s Technical Assistance Service 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.
Date Work done
Date Quantity supplied Date Quantity supplied Date Quantity supplied Date Quantity supplied
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SYSTEM MANAGER
USEFUL INFORMATION
MAINTENANCE

THERMITAL THE/TG 3S steel boilers come in:
1) BOILER BODY CRATE to which is attached the
documentation envelope (A) containing:
- Instruction manual
- Data label (to be applied to the casing on comple-
tion of the installation)
- Water test certificate
- Bar code labels
- Ceramic insulation.
b The instruction manual is an integral part of the
boiler. Once located, read it thoroughly and keep
it safe.
2) THE CASING PANELS complete with assembly
accessories.
3) THE FRONT COVER to fit on top of the front door.
IMPORTANT
For the boiler to function correctly, it must be connected
to a THERMITAL TBOX control panel and dedicated
control accessories.
A
A
THE/TG 90÷511 3S
THE/TG 1160÷1450 3S
THE/TG 639÷850 3S
(*) Casing panels supplied on the same pallet as the boiler.
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INSTALLER
UNPACKING THE PRODUCT

Only use lifting equipment of adequate capacity to move
and handle the boiler.
Remove the fixing screws and remove the wooden pallet
before positioning the boiler. b Wear suitable personal protective equipment and
use suitable safety devices
b When moving the boiler, take particular care not to damage the front panel.
B
C
D
B1
A
A1 E
THE/TG 3S 90 115 166 217 255 349 448 511 639 850 1160 1450
A - Width 660 710 760 760 820 820 890 890 1000 1047 1147 1237 mm
A1 - Base width 580 640 690 690 750 750 790 790 900 980 1070 1160 mm
B - Depth 1155 1330 1500 1500 1660 1960 2085 2085 2375 2657 2954 3173 mm
B1 - Base depth 860 1010 1180 1180 1296 1596 1692 1692 1965 2236 2533 2754 mm
C - Height 1205 1285 1390 1390 1524 1490 1685 1685 1830 1920 2080 2222 mm
D - Burner height 380 380 400 400 468 468 510 510 560 570 625 650 mm
E - Flue to base 180 190 200 200 225 225 250 250 270 270 270 270 mm
Weight (inclusive of casing) 335 420 515 535 715 840 1160 1160 1500 2040 2627 3440 kg
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INSTALLER
HANDLING
OVERALL DIMENSIONS AND WEIGHTS

THERMITAL THE/TG 3S steel boilers must be installed
in a dedicated boiler room, with adequately sized vents,
in compliance with applicable laws and standards.
If at all possible, the boiler should be installed on a
raised base to prevent the burner fan sucking up dust.
The gas supply pipe must be installed in such a way that
the boiler’s panelling can be removed and the front door
opened without having to remove the burner.
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 burn-
er is greater than the specific weight of air, install all
electrical parts at least 500 mm above floor level.
aDo not install the boiler outdoors. It is not designed
to work outdoors and is not fitted with the neces-
sary automatic anti-frost systems to do so.
≥1 m A
B
≥1 m
≥L
≥1 m
>10cm
H
THE/TG 3S 90 115 166 217 255 349 448 511 639 850 1160 1450
A- Length 660 710 760 760 820 820 890 890 1000 1047 1147 1237 mm
B- Depth 1155 1330 1500 1500 1660 1960 2085 2085 2375 2657 2954 3173 mm
H- Heigjt 1175 1285 1390 1390 1524 1490 1685 1685 1820 1900 2080 2222 mm
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INSTALLER
PLACE OF INSTALLATION