Thermaflow TH12 Instructions For Use Installation And Servicing

Electric combination boiler ~230-240v, 50hz

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ELECTRIC COMBINATION BOILER

This product is suitable for connection to ~230-240V, 50Hz

INSTRUCTIONS FOR USE, INSTALLATION AND

The instructions consist of three parts; User, Installation and Servicing instructions, which include the guarantee registration

card.

The instructions are an integral part of the appliance and must, to comply with the current issue of the building, electrical

regulations and water by-laws, be handed to the user on completion of the installation.

GUARANTEE REGISTRATION

Thank you for installing a new Thermal Innovations product in your home.

Thermal innovations appliances, are manufactured to the very highest standards so we are pleased to offer our customers, a

comprehensive first year guarantee and a second year parts guarantee.

In the instruction envelope is to be found your guarantee registration card, which must be completed and returned to Thermal

Innovations (UK) Ltd or register your Thermal Innovations (UK) Ltd appliance for 1st year guarantee protection by calling the

below number.

Our guarantee gives you peace of mind valuable protection against breakdown by covering the cost of-

•

All replacement parts

•

All labour charges

•

All call-out charges

THERMAL INNOVATIONS (UK) LTD

31-39 Napier Court, Cumbernauld, Glasgow, G68 0LG

Customer services

Tel

+44 (0) 870 850 5207

Fax

+44 (0) 870 850 5208

Web

www.thermaflowheating.co.uk

Issue Number: 2.2 Issue date: April 2008

This document contains proprietary information protected by copyright, and this Manual and documentation are copyrighted. All rights are reserved. No part of this

document may be photocopied or reproduced by mechanical, electronic, or other means in any form without permission from Thermal Innovations (UK) Ltd.

(Patent Pending. Design Right Protected.)

TH12/210U, TH12/250U & TH12/330U

TH9/210U, TH9/250U & TH9/330U

(INCLUDES SOLAR APPENDIX)

SERVICING

TO BE LEFT WITH THE USER

Table of Contents

Summary of Contents for Thermaflow TH12

Page 1 ELECTRIC COMBINATION BOILER (Patent Pending. Design Right Protected.) TH12/210U, TH12/250U & TH12/330U TH9/210U, TH9/250U & TH9/330U (INCLUDES SOLAR APPENDIX) This product is suitable for connection to ~230-240V, 50Hz INSTRUCTIONS FOR USE, INSTALLATION AND SERVICING TO BE LEFT WITH THE USER The instructions consist of three parts;...
Page 2: Table Of Contents
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Contents Instructions general ..................4 Draining & Filling ..................5 Manual Handling Guidance ..............5 TESTING & CERTIFICATION ..............5 THE UNIT LOCATION ................5 Part1 - INSTRUCTIONS FOR USE................7 INTRODUCTION ..................7...
Page 3 THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 2.7 Commissioning .....................21 2.7.1 Filling domestic water circuit..............21 2.7.2 Filling the heating system ...............21 2.7.3 Domestic hot water flow rate ..............22 2.7.4 Temperature settings................22 2.7.5 Heating system commissioning ..............22 2.7.6 Completion .....................23...
Page 4: Instructions General
EN60335.2.73. The rated power input of the appliance is ~230- 240V, 50Hz, 8,250-9,000w The TH12/210U, TH12/250U and TH12/330U all have 4 heating elements fitted. Size 16” in length and are manufactured of Incaloy EN60335.2.73. The rated power input of the appliance is ~230-240V, 50Hz, 11,000-12,000w...
Page 5: Draining & Filling
MUST ONLY BE DRAINED, REFILLED AND PRESSURISED BY A COMPETENT PERSON. There are two drain taps fitted to the Thermaflow boiler, one to drain the potable circuit within the boiler and one to drain the primary circuit within the boiler both drain taps are located at the bottom of the appliance.
Page 6 THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 There are five water connections to be made when installing the Thermaflow, they are as follows: 1) Flow and return connections to the heating system are 22mm compression.
Page 7: Part1 - Instructions For Use
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 PART1 - INSTRUCTIONS FOR USE INTRODUCTION This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Page 8: Draining And Filling
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Draining and filling Caution this boiler works in a pressurised system which must only be drained, refilled and pressurised person competent to do so. by a YOU MUST Note: if the pressure gauge indicates a loss of pressure that is less than 60 KPA (0.6 Bar)
Page 9: General Data
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 GENERAL DATA Diagram 1.8.1 Enclosure for Low Pressure cut-out switch & Master non-reset-able over-temperature thermostat Safety Relief Valve 300kPA (3bar) Enclosure for Contactor and Circuit Breakers...
Page 10 THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 TABLE 1.8.1 [DATA] TH9/12/210 TH9/12/250 TH9/12/330 Lift Weight 60KG 65KG 75KG Total Weight 70KG 77KG 85KG Weight Full 270KG 315KG 405KG Heating Flow Return 22mm Compression...
Page 11: Part 2 - Installation
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 PART 2 - INSTALLATION 2.1.1 Sheet metal parts Warning: when installing or servicing this boiler care should be taken when handling the edges of metal parts to avoid any possibility of personal injury.
Page 12: Electrical Supply
(60amp isolator with a 40 amp MCB Type C for the TH9/ model) and a switched (60 amp isolator with a 50 amp MCB Type C for the TH12/ model), having a minimum contact separation of 3mm in each pole.
Page 13: Boilers In A Compartment
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 2.2.2 Boilers in a compartment Where the installation of the boiler will be in an unusual position, the current issue of BS 6798 gives detailed guidance on these requirements.
Page 14: Clearances
2.3.8 Corrosion inhibitor The maintenance of sufficient concentration of corrosion inhibitor in your Thermaflow system is vital to prevent corrosion. We would recommend sentinel X100, or equivalent. Dose appropriately according to the size of the Thermaflow and central heating system volume combined.
Page 15: Draining
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 2.3.9 Draining A draining tap must be provided at the lowest points of the system, which will allow the entire system to be drained. The boiler has two drain taps fitted to it one for primary and one for secondary.
Page 16: Electrical Installation Requirements
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 The position of discharge pipes (Tundish) drain valves and motorised valves etc, must be positioned away from electrical components. The water may drip from the discharge pipe of the pressure-relief device and must be left open to the atmosphere.
Page 17: Supply
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 2.6.1 SUPPLY The boiler requires two separate ~230-240V power supplies. A (24HR) supply for controls and an interruptible supply for the boiler. (Off Peak power supply if it is available).
Page 18 THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 2.6.2 No 21 The mains supply into the enclosure marked on the boiler diagram should be wired to the 24HR ref. diagram 2.6.2a supply via 3 Amp fused isolating switch located at the boiler,...
Page 19: External Controls
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Diagram 2.6.2b 2.6.3 External Controls diagram External heating controls should be connected to the terminals marked R1 & R2 shown in 2.6.2b . All external controls should be connected to terminals marked R1 & R2 in the enclosure marked No 22 diagram 1.8.1.
Page 20: Electrical Connections
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Electrical Connections 2.6.4 Supply cable connection [24 HR Supply] Caution: To prevent an induced current from switching the central heating on when not required it is important that the heating system control cables are separated from the other mains cables.
Page 21: Supply Cable Connection [Interrupted Off Peak Supply]
4 Refit the enclosure cover. Electricity tariffs The Thermaflow will operate on any ~230-240V, 50Hz supply. The most economical option is a peak avoidance tariff as described previously. Scottish Power, Eastern Energy, Guernsey Electric North Eastern Electricity all has an 18 hour tariff.
Page 22: Thermal Innovations (Uk) Ltd | Thermaflow® Electric Combination Boiler | Tel: 0870 850
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Make sure the automatic air vent at the top of the boiler is operating correctly. IMPORTANT MAKE SURE THE BOILER AND SYSTEM IS COMPLETELY FULL OF WATER AND ALL AIR IS ELIMINATED BEFORE TURNING ON ANY OF THE POWER SUPPLIES TO THE BOILER.
Page 23: Completion
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 NOTE: The system fill pressure may require to be recharged once or twice in the first two to three weeks after the initial commissioning of the boiler due to oxygen in the system being expelled through the automatic air eliminator.
Page 24: Part 3 - Servicing
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 PART 3 - SERVICING 3.1. Fault Finding MUST BE CARRIED OUT BY A PERSON COMPETENT TO DO SO Before trying to operate the boiler make sure that: The heating system pressure is at 120 KPA (1.2 Bar) when the system is cold and 200 KPA (2.0 Bar)
Page 25: Fault: No Domestic Hot Water Or Central Heating
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Fault: No domestic hot water or central heating Is there ~230-240V at the 24HR supply? Check Fuse, MCB or Meter for correct operation Is there ~230-240V at the off peak supply? Check Fuse or MCB Is system pressure above 60 KPA (0.6 Bar)?
Page 26: Fault:no Central Heating, But Hot Water At Taps
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Fault: No central heating, but hot water at taps Is there continuity through master high limit stat? Replace Thermostat Is there continuity through contactor? Replace Contactor...
Page 27: Fault:central Heating But No Hot Water At Taps
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Fault: CENTRAL HEATING BUT No hot water at taps Is the automatic air eliminator on top of the boiler in the Open the small screw cap on top of the...
Page 28: Isolation
The pressure can be accurately checked with the pressure relieved on the other side of the diaphragm. To do this, isolate the water supply to the Thermaflow and open a hot tap. Water will run for a few seconds then stop.
Page 29: Checking The Concentration Of Corrosion Inhibitor
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Checking the concentration of corrosion inhibitor We would recommend Sentinel X100, or equivalent. Dose appropriately according to the size of the Thermaflow and central heating system volume combined and in accordance with the inhibitor manufacturer’s guidelines.
Page 30: Checking The Elements
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 Checking the elements Check the continuity between live and neutral terminals on the element. Replace the element if there is no continuity. Checking circuit breakers Switch each circuit breaker off in turn and check that continuity is broken to each element.
Page 31: Appendix I - Solar Connection
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 APPENDIX I – SOLAR CONNECTION A1.1 Solar Pipe work Schematic...
Page 32: A1.2 Solar Wiring Schematic
THERMAL INNOVATIONS (UK) LTD | THERMAFLOW® ELECTRIC COMBINATION BOILER | Tel: 0870 850 5207 A1.2 Solar Wiring Schematic...

This manual is also suitable for:

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Thermaflow TH12 Instructions For Use Installation And Servicing

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