thermital THC V E OIL BLU Series Manual
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thermital THC V E OIL BLU Series Manual

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INSTALLATION, TECHNICAL
ASSISTANCE CENTRE AND SYSTEM
MANAGEMENT MANUAL
THC V E OIL BLU

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Summary of Contents for thermital THC V E OIL BLU Series

  • Page 1 INSTALLATION, TECHNICAL ASSISTANCE CENTRE AND SYSTEM MANAGEMENT MANUAL THC V E OIL BLU...
  • Page 2 CONFORMITY THC V E OIL BLU condensing boilers conform to the following directives: • Efficiency Directive 92/42/EEC (✫✫✫✫) • Electromagnetic Compatibility Directive 2014/30/UE • Ecodesign Directive 2009/125/CE for energy-related products • Energy Labelling Directive 2010/30/EU • Low Voltage Directive 2006/95/CE •...
  • Page 3 Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly. Once again, please accept our thanks and our congratulations on your choice of product. Thermital ENGLISH...

  • Page 4: Table Of Contents

    CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TECHNICAL ASSISTANCE SERVICE .

  • Page 5: General

    The boiler must only be used for the purpose spe- As soon as you open the packaging, check imme- cified by THERMITAL and for which it is designed. diately that the contents are all present and unda- maged. Contact the THERMITAL reseller from...

  • Page 6: Product Description

    - A flue gas thermostat in the bottom of the secondary Safety devices must only be replaced by THERMITAL’s Technical Assistance Service using heat exchanger that triggers a fault condition if flue gas original spare parts. Refer to the spare parts cata- temperature exceeds 90°C.

  • Page 7: Product Identification

    PRODUCT IDENTIFICATION THC V E OIL BLU boilers are identified by two plates: - Data plate This lists the appliance’s technical specifications and performance data. T067732GE RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR) Mod. Cod. N° PAESE DESTINAZIONE/PAYS DE DESTINATION/BESTIMMUNGSL LAND VON B ESTEMMING : COMBUSTIBILE/COMBUSTIBLE/BRENNSTOFF/BRANDSTOF :...

  • Page 8: Design

    DESIGN THC V 35 E OIL BLU SIDE VIEW FRONT VIEW TOP VIEW 1 - Top panel 2 - Front panel 3 - Side panel 4 - Secondary heat exchanger 5 - Condensate drain siphon 6 - Inspection panel 7 - Automatic vent valve 8 - Safety valve (3 bar) 9 - Boiler sensor sockets 10 - Boiler body...
  • Page 9 THC V 55 E OIL BLU SIDE VIEW FRONT VIEW TOP VIEW 1 - Top panel 2 - Front panel 3 - Side panel 4 - Automatic vent valve 5 - Safety valve (3 bar) 6 - Pressure gauge 7 - Secondary heat exchanger 8 - Condensate drain siphon 9 - Inspection panel 10 - Boiler sensor sockets...

  • Page 10: Technical Specifications

    TECHNICAL SPECIFICATIONS THC V Description 35 E OIL BLU 55 E OIL BLU condensing boiler for central heating Type of boiler B23-B23P-C13-C33-C63 Fuel Heating fuel oil (Light oil) Rated heat input at furnace referred to HVC (LCV) 36,6 (34,5) 58,4 (55) Useful (rated) heat output Rated heat output (60-80°C) P4 33,3...

  • Page 11: Accessories

    ACCESSORIES CODE ACCESSORY THC V 35 E OIL BLU THC V 55 E OIL BLU Mixed zone kit 20039723 Second mixed zone electrical kit 20011194 Flue kit 80/125 20012802 20012802 Sealing kit 80/80 20012807 20012807 Solar collector sensor kit 4031913 4031913 Storage cylinder temperature sensor kit 4031847...

  • Page 12: Location Of Sensors

    LOCATION OF SENSORS THC V 35 E OIL BLU 1 - Boiler temperature sensor 2 - Safety thermostat sensor 3 - Flue gas thermostat sensor THC V 55 E OIL BLU 1 - Boiler temperature sensor 2 - Safety thermostat sensor 3 - Flue gas thermostat sensor Characteristics of boiler, flow and storage cylinder sensors Measured temperature (°C) - Resistance ( Ω...

  • Page 13: Pumps

    PUMPS THERMITAL THC V E OIL BLU boilers come without a pump. A pump must therefore be provided on installation. In order to choose a pump of the right size, bear in mind the boiler’s water-side pressure drop, as shown in the figure below.

  • Page 14: Functional Wiring Diagrams

    FUNCTIONAL WIRING DIAGRAMS GENERAL ENGLISH...

  • Page 15: Control Panel

    CONTROL PANEL PRIMARY USER INTERFACE / CONTROLS bottom view 1 - Safety thermostat trip indicator. 2 - Electronic operator unit (controller). 3 - DHW production on/off button (only present if the optional remote storage cylinder is installed). A line appears under the "...
  • Page 16 SECONDARY USER INFORMATION / DISPLAY A - DHW mode: ON or OFF B - Central heating modes: AUTOMATIC CONTINUOUS COMFORT Continuous REDUCED COOLING Frost protection. The "t" symbol is displayed. C - Small numeric display: time D - Message area E - Daily heating program indicator F - Large numeric display: current value G - Display symbols:...
  • Page 17 MAIN SCREEN Boiler temperature A1 - DHW production mode: ON or OFF. Press the DHW button to (3) to switch DHW on or off (as shown by the line under the symbol). B1 - Central heating modes: Press the central heating mode button (5) to activate the various modes as shown by the line under the corresponding symbol.

  • Page 18: Mode Selection

    MODE SELECTION Press the central heating mode button (5) to select the various modes. The active mode is shown by a line under the corresponding symbol. Boiler temperature Automatic In automatic mode, room temperature is controlled by the time program. Characteristics: - Central heating operates according to the time program.
  • Page 19 Setting the room temperature setpoint Turn the knob (14) to set the desired room temperature comfort setpoint . Proceed in a similar way to set the room temperature redu- ced setpoint . Comfort setpoint - Press the "OK" button (13). - Select “Heating circuit 1”.
  • Page 20 Hold the button down for the duration of the test . The test terminates as soon as you release the button. This test must only be performed by the THERMITAL Technical Assistance Service, since it raises boiler temperature over the normal permitted limits. RESET function (parameter 6205)

  • Page 21: User Levels

    (User, Commissioning, etc.). Parameter values on the Commissioning, Heating engineer and OEM levels must only be changed by the THERMITAL Technical Assistance Service. Time of day and date Operator unit EXAMPLE: SETTING THE CURRENT TIME - From the main screen press "OK".
  • Page 22 Ora e data - The message area shows the current hour. Press "OK". Ore / minuti Time of day and date Hours/minutes - The display flashes the current hour. Turn the knob to go on or back to the correct value. Press "OK"...

  • Page 23: System Manager

    SECTION RESERVED FOR SYSTEM MANAGER (ONLY FOR THC V 55 E OIL BLU MODEL) START-UP Have THERMITAL’s Technical Assistance Service start-up your 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 user may need to re-start it without involving the Technical Assistance Service.
  • Page 24 Setting the room temperature setpoint Turn the knob (14) to set the desired room temperature comfort setpoint . Proceed in a similar way to set the room temperature redu- ced setpoint . - Press the "OK" button (13). Comfort setpoint - Select “Heating circuit 1”.
  • Page 25 °C Outside temperature Heating curve slope must only be set by the THERMITAL Technical Assistance Service. If no room units are installed, the room temperature setpoint set on the control panel simply performs a par- allel shift of the heating curves.

  • Page 26: Temporary Shutdown

    TEMPORARY SHUTDOWN If you are going to be away for a short period of time like a weekend or a short holiday, etc. proceed as follows. - Press the central heating mode button (5) to select "Protection" mode (b). Power to the boiler remains switched on, and the dis- Boiler temperature play remains active.

  • Page 27: Cleaning

    THAT PROFESSIONALLY QUALIFIED PERSONNEL UNDERTAKE PERIODIC MAINTENANCE 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.

  • Page 28: Useful Information

    USEFUL INFORMATION Seller: Installer: ........................................................Mr . Mr .............................................................. Address Address ......................................................Tel . Tel ............................................................Technical Assistance Service: ..............Mr ................................ Address ............................Tel ............................... Date Work done Fuel oil supplier: ......................

  • Page 29: Unpacking The Product

    INSTALLER UNPACKING THE PRODUCT THC V E OIL BLU boilers come in a robust palletised wooden cage, protected by a PVC sheet. The following items are delivered in a plastic bag inside the boiler: - Installation, operation and maintenance manual - Spare parts catalogue - Certificate of warranty - Hydraulic test certificate...

  • Page 30: Handling

    HANDLING Once you have removed the packaging, proceed as follows to handle the boiler. - Remove the top panel (6) by pulling it upwards - Remove the screws (2) securing the boiler to the wooden pallet - Make sure that the equipment you use to move the boiler is adequate for the weight involved - Lift the boiler carefully off the pallet using the eyebolts (4) inside the unit.

  • Page 31: Place Of Installation

    PLACE OF INSTALLATION THC V E OIL BLU boilers must be installed in rooms with suitably sized air vents conforming to applicable technical standards. When installing the boiler, allow sufficient space These boilers must be installed indoors. They are not around it to access all safety and control devices and designed for outside use.
  • Page 32 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 STEEL BOILERS...
  • Page 33 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 requi- rements. 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).

  • Page 34: Water Connections

    WATER CONNECTIONS THC V E OIL BLU boilers are designed and made for installation in combined central heating and domestic hot water production systems. The water fittings have the following specifications: THC V 35 E OIL BLU THC V 55 E OIL BLU THC V Description 35 E OIL BLU...
  • Page 35 FUNCTIONAL WATER SCHEMATIC MI Dir MI Mix RI Dir RI Mix °C Valve group 1 - Solar collector 16 - Non-return valve - Collector outlet 2 - Collector sensor socket 17 - Thermostatic mixer valve - Collector return 18 - BPS solar storage cylinder 3 - Manual bleed valve PI Mix - Mixed circuit pump 4 - Vent cock...

  • Page 36: Draining The Condensate

    Drain It is mandatory to use a condensate trap (see the THERMITAL catalogue). ELECTRICAL CONNECTIONS THC V E OIL BLU condensing boilers are fully wired in the factory. Only the following electrical connections re-...
  • Page 37 Proceed as follows to make these connections. - Pull up and remove the top panel (1) from the boiler - Unscrew the screws (2) and remove the cover (3) from over the control panel - Make the electrical connections to the boiler’s terminal Power supply block (MO1) as shown alongside.
  • Page 38 CH circuit pump and/or other optional components - The boiler is pre-cabled for the connection of a CH circuit pump, mixer valve and mixed CH circuit safety thermostat. Mixed circuit safety thermostat Circuit pump Mixer valve Automatic shut-off device (DAI) (not supplied;...

  • Page 39: Outside Sensor Connections

    OUTSIDE SENSOR CONNECTIONS Correct positioning of the outside sensor is essential to proper indoor temperature control. The sensor must be installed outside the building to be heated, about 2/3 of the way up a NORTH or NORTH-WEST facing wall, well clear of any flues, doors, windows and out of direct sunlight. Fixing the outside sensor to the wall - Unscrew the cover from the sensor casing to access the terminal block and the fixing holes.
  • Page 40 Correspondence table Measured temperature (°C) – Resistance of outside sensor ( Ω ). T (°C) R (Ω) T (°C) R (Ω) T (°C) R (Ω) T (°C) R (Ω) -30.0 13'034 -9.0 4'358 12.0 1'690 33.0 -29.0 12'324 -8.0 4'152 13.0 1'621 34.0...

  • Page 41: Fuel Connections

    FUEL CONNECTIONS THC V E OIL BLU boilers have their fuel connections at the rear. Fuel supply hoses must pass through the gap between the boiler base and the floor before being connected to the fuel pump. If the fuel oil feed system is in negative pressure, the return line must reach the same height as the suction line.

  • Page 42: Flue Gas Outlet And Comburent Air Inlet

    Use of heat resistant, condensate resistant and stress resistant rigid pipe and sealed joints is mandatory. THERMITAL THC V E OIL BLU boilers can be installed as "sealed" boilers with the addition of the relevant acces- sory kit.
  • Page 43 These length must be reduced by 3 metres for every 90° curve and by 1.5 metres for every 45° curve. All flue seals must be made from condensate (acid) resistant materials. THERMITAL THC V E OIL BLU boilers can also be installed in B23 open configurations using suitable piping in compliance with applicable laws and stan- dards.

  • Page 44: Filling And Emptying The System

    FILLING AND EMPTYING THE SYSTEM THC V E OIL BLU boilers require a filling pipe connect- ed to the central heating circuit return pipe. See Appendix II for further information on water tre- atment for the central heating system. FILLING THE CENTRAL HEATING SYSTEM - Make sure that the boiler’s drain cock (1) is closed before you start filling the system.

  • Page 45: Technical Assistance Service

    TECHNICAL ASSISTANCE SERVICE EMPTYING Switch the electricity supply OFF at the system’s main switch and at the control panel before starting to empty O F F the boiler or storage cylinder. EMPTYING THE CENTRAL HEATING SYSTEM - Open any non-return valves in the CH circuit to facilitate emptying.

  • Page 46: Initial Start-Up

    INITIAL START-UP Once you have completed all the checks listed above, proceed as follows to start up the boiler for the first time. - Switch the electricity supply ON at the system’s main switch and at the control panel. Check that the display comes on. O F F - When the boiler is first powered on, it performs a num- ber of self-tests.

  • Page 47: Checks During And After Initial Start-Up

    CHECKS DURING AND AFTER INITIAL START-UP Once the boiler has started up, make sure that it shuts down and re-starts properly too. Proceed as follows: - Switch the control panel OFF. - Press button (5) to switch from "Automatic" (s) mode to "Protection"...

  • Page 48: Temporary Shutdown

    TEMPORARY SHUTDOWN If you are going to be away for a short period of time like a weekend or a short holiday, etc. proceed as follows. - Press the central heating mode button (5) to select "Protection" mode (b). Power to the boiler remains switched on, and the dis- Boiler temperature play remains active.

  • Page 49: Maintenance

    MAINTENANCE Regular maintenance may be a legal requirement. In Italy it is required by Presidential Decree 412 of the 26th August 1993. It is also essential for the safety, efficiency and durability of the boiler. Proper maintenance keeps consumption and emissions down, and ensures that the boiler continues to operate reliably over time.

  • Page 50: Oil Burner

    OIL BURNER DESIGN 1 - Reset button with lockout indicator 7 - Oil pump 2 - UV sensor 8 - Flange with heat shield 3 - Air damper adjuster screw 9 - Flue gas recirculation slots 4 - Burner control box 10 - Blast tube 5 - Oil pump pressure adjuster screw 11 - Motor...
  • Page 51 REMOVING THE BURNER Proceed as follows to remove the burner. - Close the fuel shut-off cocks. - Disconnect the connector (1). - Disconnect the connector (2) from the burner controller. - Disconnect the air inlet pipe (3). - Unscrew the fixing screws (7) and remove the cover (8) from the burner body.
  • Page 52 Reverse the above steps to reassemble. If the burner needs to be completely removed from the boiler, disconnect the hoses (5) first. Use a suita- ble rag to soak up the fuel that inevitably comes out. REPLACING THE NOZZLE Proceed as follows to replace the nozzle. - Unscrew the fixing nut from the flange and remove the burner.
  • Page 53 - Fit the flame tube (4) as shown in the figure alongside. REPLACING THE COMBUSTION HEAD AND ELECTRODES Proceed as follows to access the combustion head and electrodes. - Unscrew the fixing nut from the flange and remove the burner. - Turn it around, hook it over the flange (1) and loosen the screws (2).
  • Page 54 OIL PUMP 1 - Suction port 2 - Return port 3 - By-pass screw 4 - Pressure gauge fitting 5 - Pressure regulator 6 - Vacuum gauge fitting 7 - Valve 8 - Auxiliary pressure measurement fitting ADJUSTING PUMP PRESSURE Turn the adjuster screw (5) to achieve the pressure setting specified in the table on page 49 ADJUSTING THE AIR DAMPER...
  • Page 55 REMOVING THE BURNER CONTROL BOX Proceed as follows to remove the burner control box: - Unscrew the screws (1) and remove the cover (6) from the coil (4). - Remove the coil (4) and disconnect its connectors. - Unscrew the screws (2), open the cover (3) and remove all the components inside.
  • Page 56 FUNCTIONING PROGRAM NORMAL FUNCTIONING - Power supply - Heat request PH - Heater - Startup thermostat FM - Fan motor - Ignition electrode - Fuel oil supply solenoid valve - Flame detector LED - Lockout button diagnostics Red flashing rapidly No signal required OPERATING TIMES ≤...
  • Page 57 LOCKOUT BECAUSE OF IGNITION FAILURE - Power supply - Heat request PH - Heater Lockout - Startup thermostat FM - Fan motor - Ignition electrode - Fuel oil supply solenoid valve Green flashing Green Orange - Flame detector flashing flashing LED - Lockout button diagnostics LOCKOUT BECAUSE OF EXTRANEOUS LIGHT OPERATING TIMES...
  • Page 58 Colour codes for burner reset button LED Seconds Speed of Functioning status LED colour code flashing Standby Led off Pre-heating time Green flashing Slow Pre-ventilation Orange flashing Slow Safety time Green flashing Slow Functioning Green Extraneous light (false flame signal) Green + Red flashing Slow Power supply frequency error...
  • Page 59 PRE-HEATING FUNCTION The burner controller has a fuel oil pre-heating function. In the pre-heating phase, the burner waits for the startup ther- mostat, located at the nozzle holder, to close. If the thermostat has not closed after 600 seconds, the burner controller locks out. If the flame goes out during normal functioning, the controller checks whether the pre-heating startup contacts are closed of not.
  • Page 60 INTERNAL VOLTAGE ERROR The burner controller automatically checks that internal voltage is correct. An error is indicated by the LED flashing. - If an error is detected during initialisation, make sure that it is transient and that the burner starts up. - If an error is detected after a lockout, the burner will not start up.
  • Page 61 TROUBLESHOOTING Fault Possible cause LED colour code Possible solution Check for voltage at L, N and in the plug No electrical power LED off Check the condition of the fuses Check that the safety thermostat has not tripped Burner does not The flame detector is ignite when heat Green + Red flashing...

  • Page 62: Disassembling And Cleaning The Boiler

    DISASSEMBLING AND CLEANING THE BOILER Perform the following operations before beginning any maintenance or cleaning. - Switch the electricity supply OFF at the system’s main switch and at the control panel. O F F EXTERNAL CLEANING Clean the boiler’s casing panels and control panel with a soft cloth damped in soapy water.
  • Page 63 Cleaning the boiler body - Release the clips (10) and remove the cover (11) from the flue gas box. - Remove the turbulators (12) and check them for wear. Replace as necessary. - Use a flue brush or other suitable tool to clean inside the flue gas pipes.
  • Page 64 Cleaning the secondary heat exchanger Remove the flue then proceed as follows. - Unscrew the screws (1) and remove the top cover (2). - Remove the turbulators (3) and check them for wear. Replace as necessary. - Use a flue brush or other suitable tool to clean inside the flue gas pipes.

  • Page 65: Troubleshooting

    TROUBLESHOOTING The first time the boiler is started up and the first time it restarts after a burner lockout or temperature lockout, the burner performs fuel preheating for about 2 and a half minutes. On subsequent startups the motor starts as soon as the boiler controller requests heat.
  • Page 66 CAUSE CORRECTIVE ACTION FAULT Central heating safety valves - Check the circuit pressure. Central heating circuit pressure. - Check pressure reducer trip frequently . functioning. - Check efficiency of safety valves. - Check the efficiency of the Fault with DHW expansion vessel expansion vessel.
  • Page 67 APPENDIX I ENGLISH...
  • Page 68 RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.thermital.it The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specifications, standard equipment and accessories are therefore liable to modification without notice.

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