elco THISION L EVO Operation and Maintenance Manual

Installaon and Operaon manual

for authorised technicians only

THISION L EVO

10-2018 420010585004

4

EN

Contents

GENERAL REGULATIONS ................ 5

Applicaon ..................................... 5

Norms and regulaons ................... 5

Informaon for installer and mainte-

nance service personnel ................. 6

Data Plate ....................................... 7

CONSTRUCTION ............................. 8

Layout of the boiler ........................ 8

Operang principle ......................... 8

TECHNICAL DATA ............................ 9

Product informaon E.r.P. ............... 10

Dimensions ..................................... 12

EXTENT OF DELIVERY ..................... 13

Standard boiler ............................... 13

Accessories ..................................... 13

INSTALLATION ................................ 14

Boiler transport .............................. 14

Removing the casing ...................... 14

Warnings before installaon .......... 15

Boiler installaon............................ 15

Connecng the boiler ..................... 16

Outside sensor mounng ............... 17

Air/Flue gas system ........................ 17

Air/Flue gas connecons ................ 17

Air/Flue gas data ............................ 18

Air/Flue gas system-dimensioning .. 20

Accessories ..................................... 21

Installaon instrucons .................. 22

-Coaxial pipe .................................. 22

-Twin pipe ...................................... 23

-Vercal ue terminal .................... 24

-Horizontal ue terminal ............... 25

Wiring diagram - Legend ................ 26

Wiring diagram - Boiler .................. 27

COMMISSIONING........................... 28

Hydraulic system ............................ 28

Neutralisaon systems ................... 29

Gas supply ...................................... 30

Condensate connecon .................. 30

Flue and air intake connecons ...... 30

Prepare boiler for rst startup ........ 31

Combuson analysis ....................... 32

Combuson sengs ....................... 32

Check water ow ............................ 33

Check safety devices ....................... 34

Gas ghtness check ........................ 34

Boiler shut down ............................ 34

Commissioning protocol ................. 35

OPERATING INSTRUCTIONS ........... 36

Controls .......................................... 36

Display / Programming ................... 37

Overview of main funcons ........... 38

MAINTENANCE .............................. 40

Checklist ......................................... 40

Replacing the electrodes ................ 40

Cleaning condensate receptacle ..... 41

Cleaning and relling the syphon ... 41

Inspecon of combuson chamber 41

Physical and chemical check ........... 42

Maintenance Checklist ................... 43

LOCKOUTS ...................................... 44

SENSOR VALUES ............................. 46

DECLARATION OF CONFORMITY ... 47

NOTE .............................................. 48

5

General Regulaons

EN

Applicaon

Norms and regulaons

This boiler is CE approved and applies

to the following European standards:

• 1992/42/EEC Boiler eciency di-

recve.

• 2016/426/EEC Gas appliances reg-

ulaon.

• 2009/125/EC Direcve of the

European Parliament and of the

Council of 21 October 2009 estab-

lishing a framework for the seng

of ecodesign requirements for en-

ergy-related products.

• 811-813-814/2013 EU regulaon.

• 2014 / 30 / EU The Electromag-

nec Compability (EMC) Direc-

ve.

• 2014 / 35 / EU Low Voltage Direc-

ve.

• EN 13203-2: 2015 (Gas-red do-

mesc appliances producing hot

water - Part 2: Assessment of en-

ergy consumpon).

• EN 15036-1: 2006 Heang boilers -

Test regulaons for airborne noise

emissions from heat generators

- Part 1: Airborne noise emissions

from heat generators.

• EN-ISO 3743-1: 2010 Acouscs

- Determinaon of sound power

levels and sound energy levels of

noise sources using sound pres-

sure - Engineering methods for

small movable sources in rever-

berant elds - Part 1: Comparison

method for a hard-walled test

room.

• EN 15502-1: 2012 +A1:2015 (Gas-

red heang boilers - Part 1: Gen-

eral requirements and tests).

• EN 15502-2-1: 2012 (Gas-red

central heang boilers - Part 2-1:

Specic standard for type C appli-

ances and type B2, B3 and B5 ap-

pliances of a nominal heat input

not exceeding 1000 kW).

• EN 60335-1 Household and similar

electrical appliances - Safety- Part

1: General requirements.

• EN 60335-2-102: 2016 Household

and similar appliances - Safety

- Part 2-102: Parcular require-

ments for gas, oil and solid-fuel

burning appliances having electri-

cal connecons.

• EN 55014-1: 2006 Electromag-

nec compability- Requirements

for household appliances, electric

tools and similar apparatus Part 1:

Emission A1:2009, A2:2011.

• EN 55014-2: 2015 Electromag-

nec compability- Requirements

for household appliances, electric

tools and similar apparatus Part 2:

Immunity - Product family stand-

ard.

• EN 61000-3-2: 2014 Electromag-

nec compability (EMC) Part 3-2:

Limits — Limits for harmonic cur-

rent emissions equipment input

current ≤ 16 A per phase.

• EN 61000-3-3: 2013 Electromag-

nec compability (EMC) Part

3-3: Limits — Limitaon of voltage

changes, voltage uctuaons and

icker in public low-voltage supply

systems, for equipment with rated

current ≤ 16 A per phase and not

subject to condional connecon.

Addional naonal standards

Germany:

• RAL - UZ 61 / DIN 4702-8

Switzerland:

• SVGW

Austria:

• 15a V-BG

This documentaon contains

important informaon, which

is a base for safe and reliable

installaon, commissioning and op-

eraon of the THISION L EVO boiler.

All acvies described in this docu-

ment may only be excecuted by au-

thorized companies.

Changes to this document may be

eected without prior noce. We

accept no obligaon to adapt previ-

ously delivered products to incorpo-

rate such changes.

Only original spare parts may be

used when replacing components

on the boiler, otherwise warranty

will be void.

Applicaon

The boiler may be used for heang

and hot water producon purposes

only. The boiler should be connect-

ed to closed systems with a maxi-

mum temperature of 100°C (high

limit temperature), maximum set-

point temperature is 90°C.

Norms and regulaons

When installing and operang the

boiler, all applicable norms (euro-

pean and local) should be fullled:

• Local building regulaons for in-

stalling combuson air and ue

gas systems;

• Regulaon for connecng the boil-

er to the electrical appliance;

• Regulaons for connecng the

boiler to the local gas network;

• Norms and regulaons according

to safety equipment for heang

systems;

• Any addional local laws/regula-

ons with regard to installing and

operang heang systems.

6

General Regulaons

Informaon for installer and maintenance service personnel

The use of the appliance for

purposes other than those

specied is strictly forbidden.

The manufacturer cannot be held

responsible for any damage caused

by improper, incorrect and unrea-

sonable use of the appliance or by

the failure to comply with the in-

strucons given in this manual.

Installaon, maintenance and

all other intervenons must be

carried out in full conformity

with the governing legal regulaons

and the instrucons provided by the

manufacturer. Incorrect installaon

can harm persons, animals and pos-

sessions; the manufacturing com-

pany shall not be held responsible

for any damage caused as a result.

The boiler is delivered with

protecon packaging.

Once you have removed all the

packaging, make sure the appliance

is intact and that no parts are miss-

ing. If this is not the case, please

contact your supplier.

Keep all packaging material

(clips, plasc bags, polysty-

rene foam, etc.) out of reach of

children as it may present a poten-

al hazard.

Before any maintenance or

repair work is performed on

the boiler, make sure you have

disconnected it from the electric-

ity supply by switching the external

double pole isolator to the OFF po-

sion.

All repairs, should only be per-

formed using original spare

parts.

Index:

Risk of damage for the boiler

Risk of injury

Informaon for the User

Inform the user about the mode of

operaon of the system. Specically

deliver to the user the instrucon

manuals, informing him that they

must be stored with the appliance.

Also, remind the user to:

• Periodically check the water pres-

sure system and instruct him on

how to reintegrate and bleed.

.

• How to set the temperature and

the adjusters for a correct and

more economical management of

the system.

• To perform, according to legis-

laon, periodic maintenance

system.

• Do not change, in any case, the

sengs for supply of air for com-

buson and gas combuson.

• Pay aenon to the warnings

contained in the user manual.

This appliance can be used by children aged from 8 years

and above and persons with reduced physical, sensory or

mental capabilies or lack of experience and knowledge

if they have been given supervision or instrucon con-

cerning use of the appliance in a safe way and under-

stand the hazards involved children shall not play with

the appliance. Cleaning and user maintenance shall not

be made by children without supervision.

This product conforms to

Direcve

WEEE 2012/19/EU.

The symbol of the crossed waste

paper basket on the appliance

indicates that at the end of its

working life the product should be

disposed of separately from normal

domesc household rubbish, it must

be disposed of at a waste disposal

centre with dedicated facilies for

electric and electronic appliances or

returned to the retailer when a new

replacement product is purchased.

The user is responsible for the

disposal of the product at the end

of its life at an appropriate waste

disposal centre.

The waste disposal centre (which

using special treatment and recycling

processes eecvely dismantles and

disposes of the appliance) helps to

protect the environment by recycling

the material from which the product

is made.

For further informaon about

waste disposal systems visit your

local waste disposal centre or the

retailer from which the product was

purchased.

Symbols used on the data plate

Legend :

1 Brand

2

Country of origin

3 Boiler model - Serial number

4 Commercial reference

5 Certication number

6 Destination country - Gas category

7 Gas setting

8 Installation type

9 Electrical data

10 Factory settings

11 Maximum water pressure

12 Boiler type

13 NOx class / Efciency

14 Input rating nominal heating

15 Power output heating

16 Gases which may be used

17 Ambient operating temperature

18 Max. central heating temperature

26-05-2015

S/N 0000000KE000000000000

00

100% min.

η η

= =

MAX MIN

Q(Hi)

P

60/80C

30/50C

gas

mbar

gas

mbar

gas

mbar

0000000KE000000000000

6

0000000KE000000000000

5

0000000KE000000000000

4

0000000KE000000000000

3

0000000KE000000000000

2

0000000KE000000000000

1

PCT

0000000 KE 000000000000

26-5-2015 13:07:34

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

General regulations

Data plate

7

General Regulaons

EN

Symbols used on the data plate

1 Brand

2

Country of origin

3 Boiler model - Serial number

4 Commercial reference

5 Cercaon number

6

Desnaon country

- Gas category

7 Gas seng

8 Installaon type

9 Electrical data

10 Factory sengs

11 Maximum water pressure

12 Boiler type

13 NOx class / Eciency

14 Input rang nominal heang

15 Power output heang

16 Gases which may be used

17 Ambient operang temp.

18 Max. central heang temp.

Data Plate

4

3

1

2

11

6

7

9

8

10

5

16

12

18

17

14

13

15

Construcon

8

Operang principle

Layout of the boiler

Layout of boiler

The THISION L EVO boiler consists of

the following main components:

1. Casing

2. Access door to control panel

3. Flue gas connecon

(+ test point)

4. Air intake connecon

(+ test point)

5. Flow water connecon

6. Return water connecon

7. Gas connecon

8. Syphon

9. Input for wiring

10. Connecon for safety valve

11. Connecon for ll/drain valve

12. Control Panel

13. Fan

14. Gas valve

15. Ignion and ionisaon electrodes

16. Heat exchanger

17. Ignion transformer

18. Electrical input connecons

Operang principle

The THISION L EVO is a fully modu-

lang boiler. The control unit of the

boiler adapts the modulaon rao

automacally to the heat demand

requested by the system. This is

done by controlling the speed of the

fan. As a result, the venturi mixing

system will adapt the gas rao to the

chosen fan speed, in order to main-

tain the best possible combuson

gures and therewith the best e-

ciency. The ue gases created by the

combuson are transported down-

wards through the heat exchanger

and leave the boiler at the top into

the chimney connecon.

The return water from the system

enters the boiler in the lower sec-

on, where is the lowest ue gas

temperature in the boiler.

In this secon condensaon takes

place. The water is being transport-

ed upwards through the heat ex-

changer, in order to leave the boiler

at the ow connecon.

The cross ow working principle

(water up, ue gas down) ensures

the most ecient combuson re-

sults.

The LMS14 control unit can control

the boiler operaon based on:

• Boiler control

(stand alone operaon);

• weather compensated operaon

(with oponal outdoor sensor);

• with 0-10V external inuence (tem-

perature or capacity) from a build-

ing management system.

Technical data

EN

9

THISION L EVO

60 70 80 100 120 140

Nominal heat output at 80/60°C max/min

kW 56,5/15,5 65,5/15,6 75,3/19,4 92,9/18,7 111,9/22,5 130,4/26,2

Nominal heat output at 50/30°C max/min kW 60,4/17,2 70,0/17,2 79,7/21,2 98,9/20,6 118,5/24,8 137,8/28,9

Nominal heat output at 40/30°C max/min

kW 60,5/17,3 70,0/ 17,4 79,7/21,5 98,9/20,9 118,5/25,2 137,8/29,3

Nominal heat input Hi max/min kW 57,9/16,0 66,8/16,0 76,8/19,8 95,2/19,0 114,3/22,9 133,3/26,7

Modulaon rao - 3,6 4,2 3,9 5,0 5,0 5,0

Eciency at 80/60°C max/min

% 97,6/97,0 98,0/97,5 98,0/97,9 97,6/98,3 97,9/ 98,3 97,8/ 98,3

Eciency at 50/30°C max/min

% 104,4/107,4 104,8/107,3 103,8/107,2 103,9/108,5 103,7/108,4 103,4/108,3

Eciency at 40/30°C max/min

% 104,5/108,3 104,8/108,5 103,8/108,6 103,9/110,0 103,7/109,9 103,4/109,8

Eciency at 36/30°C load 30%

% 107,2 107,2 107,1 107,8 107,9 107,6

RAL 40/30 average

% 108,7 109,1 109,4 109,4 109,1 108,7

Heat Loss (Pstby) W 81,0 81,0 81,0 92,7 92,7 92,7

Max. condensate ow l/h 3,6 4,4 4,3 5,4 6,4 7,1

Gas consumpon G20 max/min (10,9 kWh/m

3

)

m

3

/h 5,3/1,5 6,1/1,5 7,0/1,8 8,7/1,7 10,5/2,1 12,2/2,4

Gas consumpon G25 max/min (8,34 kWh/m

3

)

m

3

/h 6,9/1,9 8,0/1,9 9,2/2,4 11,4/2,3 13,7/2,7 16,0/3,2

Gas consumpon G31 max/min (12,8 kWh/kg)

kg/h 4,5/1,3 5,2/1,3 6,0/1,5 7,4/1,5 8,9/1,8 10,4/2,1

Gas pressure G20

mbar 20

Gas pressure G25

mbar 25

Gas pressure G31 mbar 30/50

Maximum gas pressure

mbar 50

Max. temperature ue gas (high limit)

°C 90

Flue gas temperature at 80/60°C max/min

°C 59/57 60/57 61/58 60/56 63/56 66/57

Flue gas temperature at 50/30°C max/min

°C 43/35 44/34 45/33 44/33 46/33 48/33

Flue gas temperature at 40/30°C max/min

°C 42/33 44/33 44/33 43/32 45/32 47/32

Flue gas temperature at 36/30°C load 30%

°C 34 35 35 33 34 35

Flue gas quanty max/min

m

3

/h 83/22 98/22 113/27 139/27 168/33 202/38

CO level at 80/60 °C max/min

ppm 75/11 92/11 87/7 67/5 82/4 62/7

CO level at 80/60 °C max/min

mg/kWh 80/11 99/11 94/7 72/5 88/5 67/7

CO year emission EN15502

ppm 35,79 43,76 51,73 41,53 40,76 39,99

CO year emission EN15502

mg/kWh 38,44 47,00 55,56 44,60 43,78 42,95

CO

2

level G20-G25

Max. load

%

8,5 (+0 -0,2) 8,4 (+0 -0,2) 8,4 (+0 -0,2) 8,4 (+0 -0,2) 8,4 (+0 -0,2) 8,2 (+0 -0,2)

Min. load

9,0 (+0 -0,2) 9,0 (+0 -0,2) 9,0 (+0 -0,2) 8,5 (+0 -0,2) 8,5 (+0 -0,2) 8,5 (+0 -0,2)

Restricon ΔCO2 max.load - min. load (G20-G25) % - - - - - <0,3

CO

2

level G31

Max. load

%

9,6 (0 +0,2)

Min. load

9,6 (0 +0,2)

Restricon ΔCO2 max.load - min. load (G31) % CO

2 Min. load ≤ CO2 Max. load

NO

x

level at 80/60 °C max/min

ppm 25/10 30/11 34/16 25/11 22/15 15/15

NO

x

level at 80/60 °C max/min

mg/kWh 44/17 53/19 60/28 44/19 38/27 26/26

NOx emission EN15502 (ppm)

ppm 13,94 18,78 23,61 28,38 22,61 16,84

NOx emission Hi/Hs EN15502 (mg/kWh)

mg/kWh 24,60/22,15 32,61/29,36 40,61/36,57 46,67/42,03 38,19/34,40 29,71/26,76

NOx class EN15502

6

Max. permissible ue resistance

Pa 167 200 200 173 134 200

Water volume l 6 6 6 9 9 9

Water pressure max/min

bar 8/1 8/1 8/1 8/1 8/1 8/1

Max. water temperature

(High limit thermostat)

°C 100 100 100 100 100 100

Maximum temperature setpoint

°C 90 90 90 90 90 90

Nominal water ow at dT=20 K m

3

/h 2,4 2,8 3,2 4,0 4,8 5,6

Hydraulic resistance at nominal ow rate kPa 15 18 22 7 9 11

Electrical connecon

V 230

Frequency

Hz 50

Mains connecon fuse

A 10

IP class with Appliance Type B23(P) - IP30

Technical data

10

Product informaon E.r.P.

THISION L EVO

60 70 80 100 120 140

IP class with App. Type

C13, C33, C43, C53, C63, C83,

-

IPX4D

Weight (empty) Kg 83 83 83 96 96 96

Weight (lled with water) Kg 89 89 89 105 105 105

Sound Power Level (LWA) dB 55 55 56 62 57 57

Ionisaon current μA 1,15 1,15 1,15 4,2 1,15 4,2

Rpm max / min load G20-G25 rpm 6070/1770 7260/1800 7820/2060 6710/1570 6000/1370 5730/1300

Rpm max / min load G31 rpm 5810/1770 6710/1800 7190/2060 6090/1570 6000/1370 5460/1300

Rpm pre / post purge rpm 2800/2800

pre / post purge me sec 10/30

safety me sec 5

pH value condensate - 3,2

CE cercaon code

- CE-0063CM3576

Water connecons

- R1.1/4” R1.1/2”

Gas connecon

- R3/4” R1”

Flue gas connecon (DN)

- 100 130

Air intake connect

(room sealed use)

(DN)

mm 100 130

Condensate connecon

mm 22

Product informaons about the direcve 2009/125/EG and regulaon (EU) 811-813/2013

THISON L EVO

ICON

60 70 80 100 120 140

Condensing boiler

-

Yes Yes Yes Yes Yes Yes

Low-temperature boiler

-

No No No No No No

B1 boiler

-

No No No No No No

Cogeneraon space heater

-

No No No No No No

Combinaon heater

-

No No No No No No

ErP Heang 1) by return temperature 30°C 2) by return temperature and feed temperature (60-80°C)

Rated heat boiler

P

rated

kW

57 66 75 93 112 130

At rated heat output and high-tem-

perature regime

P4 kW 56,5 65,5 75,3 92,9 111,9 130,4

At 30 % of rated heat output and

lowtemperature regime 1)

P1 kW 18,6 21,5 24,7 30,8 37,0 43,0

Seasonal space heang energy

eciency

hs % 91,7 91,8 91,7 92,3 92,5 92,3

At rated heat output and high-tem-

perature regime 2)

h4 % 87,9 88,2 88,2 87,9 88,2 88,1

At 30 % of rated heat output and low

temperature regime 1)

h1 % 96,5 96,5 96,4 97,1 97,2 96,9

Auxiliary electricity consumpon

At full load

elmax kW 0,10 0,12 0,13 0,13 0,12 0,15

At 30% load el30% kW 0,03 0,03 0,04 0,03 0,04 0,03

In stand-by mode PSB kW 0,004

Supplementary heater

Standby heat loss Pstby kW 0,081 0,093

Ignion burner power consumpon Pign kW NA NA NA NA NA NA

Emissions of nitrogen oxides NOX mg/kWh

22 29 37 42 35 27

Technical data

EN

11

Product data sheet E.r.P.

Product data about the direcve 2010/30/EU and regulaon (EU) 811-813/2013

THISON L EVO 60 70

Seasonal space heang energy eciency class

8

Important:

The installation, consi ting of the boiler and all ac es ories including temperature control, together define the seasonal

heating energy efficiency ηs for the various models, as listed in the below table.

Product data sheet ErP

www.elco.net

THISION L

THISION L 50 65 85 100 120 145

Class VI, with use of components:

- THISION L

- Ambient temperature sensor QAA 75

(option)

- External temperature sensor QAC 34

Temperature controller contribution to

ηs: 4%

η

%

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

Class V, with use of components:

- THISION L

- Ambient temperature sensor QAA 75

(option)

Temperature controller contribution to

ηs: 3%

η %

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

Class II, with use of components:

- THISION L

- External temperature sensor QAC 34

Temperature controller contribution to

ηs: 3%

η

%

92 + 3

=95

92 + 3

=95

92+ 3

=95

92+ 3

=95

92+ 3

=95

92+ 3

=95

Product data about the directive 2010/30/EU and regulation (EU) 813/2013

THISION L 50 65 85 100 120 145

Seasonal space heating energy efficiency class

Rated heat output P

rated

kW

46 61 81 93 112 132

Annual energy consumption QHE kWh 0 0 0 0 0 0

Seasonal spa e heating energ

efficien

η

%

92 92 92 92 92 92

Sound power level, indoors/ outdoor LWA dB

62 62 66 66 68 67

A

8

Important:

The installation, consi ting of the boiler and all ac es ories including temperature control, together define the seasonal

heating energy efficiency ηs for the various models, as listed in the below table.

Product data sheet ErP

www.elco.net

THISION L

THISION L 50 65 85 100 120 145

Class VI, with use of components:

- THISION L

- Ambient temperature sensor QAA 75

(option)

- External temperature sensor QAC 34

Temperature controller contribution to

ηs: 4%

η

%

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

92 + 4

=96

Class V, with use of components:

- THISION L

- Ambient temperature sensor QAA 75

(option)

Temperature controller contribution to

ηs: 3%

η %

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

92 + 3

=95

Class II, with use of components:

- THISION L

- External temperature sensor QAC 34

Temperature controller contribution to

ηs: 3%

η

%

92 + 3

=95

92 + 3

=95

92+ 3

=95

92+ 3

=95

92+ 3

=95

92+ 3

=95

Product data about the directive 2010/30/EU and regulation (EU) 813/2013

THISION L 50 65 85 100 120 145

Seasonal space heating energy efficiency class

Rated heat output P

rated

kW

46 61 81 93 112 132

Annual energy consumption QHE kWh 0 0 0 0 0 0

Seasonal spa e heating energ

efficien

η

%

92 92 92 92 92 92

Sound power level, indoors/ outdoor LWA dB

62 62 66 66 68 67

A

Rated heat output

Prated

kW

57 66

Seasonal space heang energy

eciency

hs

% 91,7 91,8

Sound power level, indoors/

outdoors

LWA

dB 55 55

Important:

The installaon, consisng of the boiler and all accessories including temperature control, together dene the seasonal hea-

ng energy eciency hs for the various models, as listed in the below table.

THISON L EVO 60 70

Class VI, with use of components:

-

THISON L EVO

- Ambient temperature sensor QAA 75

(opon)

- External temperature sensor QAC 34

Temperature controller contribuon to

hs: 4%

hs %

95,7 95,8

Class V, with use of components:

-

THISON L EVO

- Ambient temperature sensor QAA 75

(opon)

Temperature controller contribuon to

hs: 3%

hs %

94,7 94,8

Class II, with use of components:

-

THISON L EVO

- External temperature sensor QAC 34

Temperature controller contribuon to

hs: 2%

hs %

93,7 93,8

100L

B

85

H

87

162162

81

180

A

F

W1 W2

G

M

215

D

74

154

638

Technical data

12

Model 60/70/80 100/120 140

Dim/Type

A mm

100 100 130

B mm

630

D mm

605

H mm

810 950 950

W1 mm

R1.¼ R1.½ R1.½

W2 mm

R1.¼ R1.½ R1.½

G mm

R¾

R1 R1

F mm

100 100 130

L

mm

140 190

M

mm

115 130

Side view

Boom view

Front view Back view

Dimensions

EN

13

Extent of delivery

Standard boiler

A boiler delivery package contains

the following components:

Component Pcs. Package

Boiler fully assembled and tested 1 Cardboard box on pallet

Mounng bracket incl. mounng xings 1 Together with manuals, in carton inside

boiler packaging

Syphon for condensate connecon 1 Inside boiler packaging

Operaon and Installaon manual 1 Envelope packed in cardboard box in boiler packaging

Standard boiler

Accessories

Addional to the boiler, the following

accessories can be ordered:

• Speed controlled pump incl. connec-

on kit;

• Safety valve, ll/drain valve and con-

necon for expansion tank;

• Set with water (2x) and gas (1x)

cocks;

• Gas lter incl. connecon kit;

• Min. gas pressure switch;

• Plate heat exchanger (dT=10K/15K

or dT=20K) incl. connecon kit;

• Low velocity header, suitable for

dT=10K/15K and dT=20K incl. con-

necon kit;

• Plug & play cascade kit (see cascade

manual for more details);

• Extension module AGU2.551 for

0-10V control of a modulang pump

and/or boiler capacity feedback to

abuilding management system;

• Electrical connecon for external

gas valve and/or room fan;

• Extension module AGU2.550 for

heang zone control or external gas

valve and/or room fan control in

combinaon with an alarm signal;

For each boiler a maximum of 3

AGU2.550 modules (2x heang

zone, 1x ext. gas valve / room fan in

combinaon with alarm) can be in-

tegrated in the boiler;

• Addional RVS63 heang zone con-

troller, when controlling more than

2 zones (incl. wall hung box, all nec-

essary sensors and sockets and con-

necon material for bus communi-

caon).

The above accessories are specially

designed for the THISION L EVO boiler

and therewith easy to install (plug

and play).

By choosing a combinaon of the kits

menoned above, you can create

your own complete system soluon.

Ask your supplier for more detailed

informaon.

3

1

2

Installaon

14

Boiler transport

Removing the casing

Remove the casing before installing

the boiler, in order to avoid damage to

the casing parts. Removing the casing

is done as shown in the diagrams

below.

Boiler transport

The THISION L EVO boiler will be

supplied as a complete unit being

fully assembled and pre-tested.

The THISION L EVO can be transported

with a crane or a transpallet, but it

has to be ensured that the boiler is

packed and xed on a pallet.

The straps must be connected to the

pallet.

Installaon

EN

15

Warnings before installaon

Boiler installaon

Installaon, rst ignion, maintenance and boiler repair, must only be carried

out by qualied persons.

Before installing the appliance

Before connecng the boiler, it

is rst necessary to perform the

following operaons:

• Thoroughly cleanse and ush

the system pipework in order

to remove any installaon de-

bris;

• Make sure that the boiler is

suitable for operaon with the

type of gas available (read the

informaon on the packaging

label and on the boiler data

plate);

• Make sure that there are no

obstrucons inside ue system

and that it does not contain

any discharge from other ap-

pliances, unless the ue is de-

signed to as a cascade system

serving mulple boilers;

• If connecng the boiler to an ex-

isng ue, check to make sure

that it is sound and is construct-

ed using suitable materials/com-

ponents (suitable for use with

over-pressure design gas red

condensing boilers);

• The system water must be dosed

with a good quality water treat-

ment to prevent deposion of

scale within the boiler compo-

nents and to inhibit corrosion

within the system;

• In the event of installaon on a

wall constructed of combusble

material (e.g. wood) make sure

to protect the wall by suitable

insulaon.

WARNING!

No inammable items should be le

near the boiler.

If dust and/or aggressive vapours are

present in the room in which it is to

be installed, the appliance must be in-

stalled room sealed.

Boiler installaon

The boiler should be posioned in

a frost-free boiler room. When po-

sioning the boiler, please note the

recommended minimum clearance

in the diagram. When the boiler

is posioned with less free space,

maintenance acvies will be more

dicult.

3 1 5 6 2 4

8

7

9

Installaon

16

Connecng the boiler

This chapter will explain how to

make all connecons to the boiler

with regard to:

• Hydraulic connecons

• Condensate drain connecon

• Gas connecon

• Flue gas connecon

• Air intake connecon

• Electrical connecon

The boiler should always be con-

nected in such a way, that the system

applies to all relevant standards and

regulaons (European, naonal and

local).

It’s the responsibility of the installer

to ensure that all standards and reg-

ulaons are respected.

Hydraulic connecons (1,2,3,4)

The boiler should always be con-

nected in such a way, that water ow

through the boiler can be ensured at

all mes.

Connect the ow (1) and return (2)

connecon of the system without

applying undue strain to the boiler

connecons.

The boiler contains a connecon

possibility for an (oponal) kit with

safety valve, ll/drain valve and an

expansion vessel connecon. The

safety valve must be connected to

the ow connecon (3) of the boiler,

the ll/drain valve and expansion

vessel connecon must be connect-

ed to the return connecon (4).

The (oponal) pump kit should be

mounted directly to the return con-

necon (2) of the boiler, before con-

necng to the system.

Condensate connecon (5)

Aer lling with water, the syphon

(included in delivery) should be in-

stalled to the connecon (5) at the

boom of the boiler.

Connect the hose to the draining sys-

tem in the boiler room.

The connecon to the draining sys-

tem should always be done with an

open connecon, in order to avoid

a ooding of the boiler in case of a

blocked drain.

Gas connecon (6)

The gas connecon must be made by

an authorized installer in accordance

with the applicable naonal and local

standards and regulaons.

Connect the gas line from the system

without applying undue strain to the

gas connecon (6) of the boiler. A gas

tap should be mounted directly be-

low the boiler.

ATTENTION: The Boiler is set for

G20-G25 gas type. To operate with

G31 gas type follow the procedures

described on page 30.

Electrical connecon

The electrical connecon must be

made by an authorized installer in

accordance with the applicable na-

onal and local standards and regu-

laons.

For the power supply it’s necessary

to use a mains isolator switch with

a contact opening of at least 3 mm

within the boiler room (according to

clause 22.3 of the EN-IEC-60335-1).

This switch can be used to switch o

the power supply for maintenance

purposes.

The boiler must be connected with a

power cord type H05V2V2-F.

All cables should be lead through the

cable glands (7 - 9) at the boom of

the boiler into the electro panel (8).

Connect all wires to the terminals ac-

cording to the wiring diagram of the

boiler, see pages 25-26.

8

7

Installaon

EN

17

Outside sensor mounng

Air intake/Flue gas system

Air intake/Flue gas connecons

Flue gas connecon (7)

Connect the ue gas system to the

ue gas connecon (7) of the boiler,

use uegas systems with seamless

connecons only. It’s not necessary

to make a separate condensate drain

for the ue gas system, as the con-

densate will be drained via the sy-

phon of the boiler.

Please note the following points:

• The diameter of the ue gas system

must be chosen by calculaon ac-

cording to the naonal regulaons;

• Construct the ue gas system as

short as possible (for maximum

length see planner documentaon);

• Horizontal ue secons must slope

of not less than 3° back towards the

boiler.

Air intake connecon (8)

The air intake can be connected in

case of room sealed installaon. The

diameter should be calculated ac-

cording to the naonal regulaons,

together with the ue gas system.

The total resistance of both systems

should never overcome the maxi-

mum permissible resistance of the

fan inside the boiler (see also chap-

ter: Technical data).

Outside sensor mounng

If an outside sensor (accessory) is

connected to the boiler, the sensor

should be posioned as shown on

the drawing.

Requirements and regulaons

Regulaons for the construcon of

ue gas systems are very dierent

for each country. It should be en-

sured that all naonal regulaons

with regard to ue gas systems are

respected. Pay aenon to the fol-

lowing recommendaons when di-

mensioning a ue gas system.

Only approved ue gas material may

be used.

The ue gas system must be

properly calculated to ensure a

safe funconing of the system.

Flue gas system components should

be removable for maintenance pur-

poses. Horizontal ue secons must

slope of not less than 3° back to-

wards the boiler.

This Boiler is cered for the ue gas

systems B23(P), C13, C33, C43, C53,

C63 and C83.

Materials

Only materials, which are heat re-

sistant and resistant to ue gases

and aggressive condensate, and CE

approved may be used.

Exclusively ue material as laid down

in the Elco catalogue may be used.

Please contact the local ELCO oce

for more informaon, at least for

conguraons C13, C33, C53.

Installaon

18

Air intake / Flue gas data

Air / Flue pipe data

Concentric pipe nominal diam.

Ø80/125

Tolerance female Ø internal

80,5

125

Ø100/150

Tolerance female Ø internal

101 mm

150 mm

Single pipe nominal diam.

Ø80

Tolerance female Ø internal

80,5

Ø100

Tolerance female Ø internal

101

±0.7

mm

Ø130

Tolerance female Ø internal

131

±0.7

mm

Material

PP (Concentric ue pipe) - Galva 0,4/Alluminium 1,3mm (Con-

centric air intake pipe)

PP (single pipe)

Material seal

EPDM black for corrosion class 1 / Viton for corrosion class 2

Heat resistance

0 W/m

2

K

Wall thickness

2.2 mm

Temperature class:

T120

Pressure class:

P1 max. 200Pa / H1 max. 5000Pa

Corrosion class:

W1

Locaon class

Concentric pipe: Only outside buildings / Single pipe: Only insi-

de buildings

Fire rang class

E

Outer wall class

(Concentric pipe only) L0

Distance to combusble materials

Concentric pipe: 00 mm / Single pipe: 30 mm

+1.0

- 0.5

+1.0

- 0.5

+1.0

- 0.5

+1.0

- 0.5

+1.0

- 0.2

Flue Gas data

Boiler

type

Nominal

heat output

Nominal

heat input

Flue

gas

connecon

(DN)

CO

2

Level

Flue gas

temperature

Flue gas

quanty

Max

permissible

ue

resistance

THISION L

EVO

kW kW mm % °C g/s Pa

max min max min max min max min max min max min

60 56,5 15,5 57,9 16,0 100 8,5 9,0 59 57 25 7 167 15

70 65,5 15,6 66,8 16,0 100 8,4 9,0 60 57 29 7 200 15

80 75,3 19,4 76,8 19,8 100 8,4 9,0 61 58 33 8 200 15

100 92,9 18,7 95,2 19,0 100 8,4 8,5 60 56 41 8 173 15

120 111,9 22,5 114,3 22,9 100 8,4 8,5 63 56 49 10 134 15

140 130,4 26,2 133,3 26,7 130 8,2 8,5 66 57 58 11 200 15

Installaon

EN

19

Air

intake / Flue gas system

Combuson air

drawn from the

room

B23 External ue gas exhaust. Air drawn from the room.

Combuson

air intake from

outside

C13

Air/exhaust gas roung through outside wall in the same pressure

range.

Exhaust gas/fresh air supply system through outside wall.

The Terminal outlets from separate combuson and air supply circuits

shall t inside a square of 50 cm for boilers with a heat input to 70 kW

and 100 cm with a heat input from 70 up to 100 kW.

C33

Flue gas exhaust and air sucon duct from outside with roof terminal

in the same range of pressure.

The Terminal outlets from separate combuson and air supply circuits

shall t inside a square of 50 cm and distance between the planes of

the two oreces shall be less than 50cm for boilers with a heat input

below 70 kW.

A square of 100 cm and distance between the planes of the two or-

eces shall be less than 100 cm with a heat input above 70 kW.

C43 Individual or shared ue gas exhaust and air sucon through ue duct-

ing built into the building.

C53 Flue gas exhaust leading outside and air sucon duct through external

wall not in the same range of pressure.

C63

Air and exhaust connecon to separate tested and supplied

air / exhaust pipes.

Basement / oor installaon.

Air and exhaust venng via exterior wall.

Exhaust venng through heat insulated exhaust pipe or moisture

resistant pipe.

Exhaust line (standing air layer) at exterior wall.

The terminals for the supply of combuson air and for the evacuaon

of combuson products shall not be installed on opposite walls of the

building.

C83 Flue gas exhaust through individual or shared ue ducng built into

the building. Air sucon through external wall.

Installaon

20

Air intake / Flue gas system - dimensioning

Twin Pipe ue gas system

Maximum permissible length of ue

gas system in m:

Twin Pipe flue

gas system

Equivalent length in m

Ø80 Ø100 Ø110 Ø125 Ø130

Straight

pipe

1 1 1 1 1

Bend R=D

90°/87°

1.5 1.8 2 2.2 2.2

Bend R=D

45°/43°

0.8 0.9 1 1 1

Concentric ue gas system

Maximum permissible length of ue

gas system in m:

Concentric

flue gas

system

Equivalent length in m

Bend R=D

90°/87°

Bend R=D

45°/43°

Ø100/150

1.5 1

Dimensioning

When dimensioning a ue gas sys-

tem, it’s necessary to perform a cal-

culaon check of the ue gas system

in order to verify if the choosen sys-

tem is applicable.

The previous tables show an example

of possible ue gas system, including

the maximum possible length of the

system.

This example only give an indicaon

of the possible length, but it can not

be used for ocial ue gas layout cal-

culaon. Each ue gas system has to

be calculated by an authorized com-

pany.

The maximum negave ue gas pres-

sure, which doesn’t aect the burner

modulaon rao, is 30 Pa. Higher

negave pressure will lead to limita-

on of the burner modulaon rao.

The maximum horizontal ue gas

length is 20 m. With horizontal

lengths longer than 20 m, a faultless

burner start in cold condion can not

be guaranteed.

Concentric ue gas system

The Boiler boiler models 60, 70, 80,

100 and 120 can be connected to a

concentric ue gas system.

Via a parallel-to-concentric adapter

(oponal) the boiler can be connect-

ed to:

• 100/150 concentric system.

See table for max. permissible ue

lengths.

TH-L Evo

Ø 80 / 125 Ø 100 / 150

60

14 38

70

12 33

80

7 23

100

- 11

120

- 7

Thision L

Evo

Ø80 Ø100 Ø110 Ø125 Ø130

Lmax

[m]

Lmax

[m]

Lmax

[m]

Lmax

[m]

Lmax

[m]

60

17 62 - - -

70

13 52 65 - -

80

7 36 47 - -

100

- 13 23 56 88

120

- 8 13 43 65

140

- - 5 14 23

23

Accessories

Single

Speed controlled pump

TH-L 50 - 85

Speed controlled pump

TH-L 100 - 145

Residual head with standard pump

Flue adapter parallel

The boiler is equipped with a flue on-

ne tion of 100mm (TH-L 50-120) or

130mm (TH-L 145). In case of using

110mm or 125mm flue tem , the

original adapter can be repla ed a

follow :

•

PPUHSODFHGE\PP

•

130mm repla ed by 125mm.

Flue adapter concentric

Concentric flue tems an be used

on the THISION L 50-120, by using a

parallel to on entric adapter.

Air inlet cover

The inlet o er an be u ed to o er

the air inlet onne tion of the boiler in

non room sealed condition, available in

100mm and 130mm.

Accessori

Single

24

Scambiatore a piastre

Il set comprende uno scambiatore a

piastre, un profilo di montaggio, una

condotta di rac ordo per circuito

primario e il materiale di raccordo.

Lo s ambiatore di calore è di ponibile

per l'utilizzo con dT=20K, dT=15K o

dT=10K.

Per la scelta del sistema, vedi tabella

sottostante. L'i olamento dello

scambiatore è in dotazione.

Un disegno quotato è riportato a

pagina 26.

Adattatore parallelo gas combusti

La caldaia è dotata di fabbrica di un

raccordo gas combusti di 100 mm

(TH-L 65-120) o 130 mm (TH-L 145).

Per l'utilizzo di materiali con diametro

110 mm o 125 mm lato gas combusti,

l'adattatore originale può essere

sostituito con i seguenti adattatori

opzionali:

• 100 mm sostituito con 110 mm;

• 130 mm sostituito con 125 mm.

Adattatore concentrico gas

combusti

Le THISION L 65-120 possono essere

collegate a un sistema concentrico per

gas combusti utilizzando un adattatore

da parallelo a concentrico.

Griglia aspirazione aria

La griglia può essere utilizzata per

coprire l'apertura di aspirazione aria

della caldaia in regime di tiraggio

naturale; disponibile nelle dimensioni

100 mm e 130 mm.

TH-L 65 TH-L 85 TH-L 100 TH-L 120 TH-L 145

Circuito primario dT=20K m

3

/h 2.6 3.4 4.0 4.8 5.6

dT=20K Tipo PWT CB52-40L CB52-40L CB52-40L CB52-50L CB76-40H

m

3

/h 2.6 3.4 4.0 4.8 5.6

kPa 5.1 8.5 11.6 11.3 9.7

dT=15K Tipo PWT CB52-40L CB52-40L CB52-40L CB52-50L CB76-40H

m

3

/h 3.5 4.5 5.3 6.4 7.5

kPa 8.7 14.7 20.0 19.4 16.8

dT=10K Tipo PWT CB52-40L CB52-50L CB52-50L CB76-40H CB76-50H

m

3

/h 5.2 6.8 8.0 9.6 11.2

kPa 18.9 21.8 29.6 26.9 24.3

Circuito secondario

Vaso espansione L 2 2 2 2 2

100mm 60-120

130mm 140

Installaon

EN

21

Air

intake / Flue gas system

Accessories

Types of boiler

Flue exhaust connecon

• coaxial connecon of the boiler to

the supply/exhaust ducng;

• split connecon of the boiler to

the exhaust ducng with air sup-

ply from outside.

The supply/exhaust ducng connec-

on kits are supplied separately from

the appliance, according to dierent

installaon soluons.

Air inlet cover

The inlet cover must be used to

cover the air inlet connecon of the

boiler in non room sealed condion,

available in 100mm and 130mm.

Flue adapter concentric

Concentric ue systems can be used

on the TH-L EVO 60-120, by using a

parallel to concentric adapter.

DN 100/150 = Ø

int

101

±0.3

/ 151

±0.3

DN 110/150 = Ø

int

111 /151

±0.5

- 0.6

±0.3

- 0.6

+0.3

- 0.6

+0.3

Flue adapter parallel

The boiler is equipped with a ue

connecon of 100mm (TH-L EVO 60-

120) or 130mm (TH-L EVO 140). In

case of using 110mm or 125mm ue

systems, the original adapter can be

replaced as follows:

• 100mm replaced by 110mm;

DN 110 = Ø

int

111

• 130mm replaced by 125mm.

DN 125 = Ø

int

126

> 500 mm

L > 250 mm

L >

250

L

>

250 mm

L > 250 mm

or

Max 1 meter

Max 2 meters

Max 1 meter

M&G • www.mg-flues.comM&G • www.mg-flues.com

max.

1000 mm

max.

1000 mm

max.

2000 mm

Clamp

3°

A

8-15 mm

!

B

Installaon

22

Air

intake /Flue gas system

Installaon instrucons - concentric pipe

Installaon

Fing the ue system to the appli-

ance must be carried out by a quali-

ed person in accordance with these

installaon instrucons.

General

• Store material inside.

• Pipes must be installed free of ten-

sion.

• Pay aenon to the ue direcon.

The sockets must be poinng to

the terminal.

• Don’t install the chimney on in-

ammable or wooden wall.

Cung the pipe

• Take out the inner tube by turning

it unl it releases from its posion.

• When shortening a concentric

pipe, cut equal amounts from both

the outer and inner tubes.

• Remove the burrs from the cung

edge to prevent cung the seals

• Re assemble the pipes.

Assembly ue gas system

Starng to assemble the pipes from

the boiler.

Assemble the pipes by turning and

pushing them ll the boom of the

seat.

NOTE: Don’t use soap or oil lubricant!

Use only water as lubricant.

Pipes bends

When using bends, the maximum

permissible length of ue gas system

can be determined from the table on

page 19.

Pipe extensions must be xed to the

wall using support clips. Use one

clamp for each extension directly be-

side the sleeve. Fit another clamp to

the extension aer each 90° bend.

Important

Install only outside buildings on walls

constructed from re resistant mate-

rial.

Cleaning

Outside can be cleaned with a wet

cloth moistened with a mild deter-

gent if necessary.

Install tension free

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elco THISION L EVO Operation and Maintenance Manual

elco THISION L EVO Operation and Maintenance Manual

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