Thermolec B-5U-FFB Manual de usuario

DECEMBER 2010

VERSION 11

THERMOLEC

Installation

Instructions

for

Electric

Boilers (USA)

CostPerMillionBtu

0.038 0.040 0.042 0.044 0.046 0.048 0.050 0.052 0.054 0.056 0.058 0.060 0.062 0.064 0.066 0.068 0.070 0.072 0.074 0.076 0.078 0.080 0.090 0.100

100% 11.14 11.72 12.31 12.90 13.48 14.07 14.65 15.24 15.83 16.41 17.00 17.58 18.17 18.76 19.34 19.93 20.52 21.10 21.69 22.27 22.86 23.45 26.38 29.31

150% 7.42 7.82 8.21 8.60 8.99 9.38 9.77 10.16 10.55 10.94 11.33 11.72 12.11 12.50 12.90 13.29 13.68 14.07 14.46 14.85 15.24 15.63 17.58 19.54

200% 5.57 5.86 6.15 6.45 6.74 7.03 7.33 7.62 7.91 8.21 8.50 8.79 9.09 9.38 9.67 9.96 10.26 10.55 10.84 11.14 11.43 11.72 13.19 14.65

250% 4.45 4.69 4.92 5.16 5.39 5.63 5.86 6.10 6.33 6.57 6.80 7.03 7.27 7.50 7.74 7.97 8.21 8.44 8.68 8.91 9.14 9.38 10.55 11.72

275% 4.05 4.26 4.48 4.69 4.90 5.12 5.33 5.54 5.76 5.97 6.18 6.39 6.61 6.82 7.03 7.25 7.46 7.67 7.89 8.10 8.31 8.53 9.59 10.66

300% 3.71 3.91 4.10 4.30 4.49 4.69 4.88 5.08 5.28 5.47 5.67 5.86 6.06 6.25 6.45 6.64 6.84 7.03 7.23 7.42 7.62 7.82 8.79 9.77

325% 3.43 3.61 3.79 3.97 4.15 4.33 4.51 4.69 4.87 5.05 5.23 5.41 5.59 5.77 5.95 6.13 6.31 6.49 6.67 6.85 7.03 7.21 8.12 9.02

350% 3.18 3.35 3.52 3.68 3.85 4.02 4.19 4.35 4.52 4.69 4.86 5.02 5.19 5.36 5.53 5.69 5.86 6.03 6.20 6.36 6.53 6.70 7.54 8.37

400% 2.78 2.93 3.08 3.22 3.37 3.52 3.66 3.81 3.96 4.10 4.25 4.40 4.54 4.69 4.84 4.98 5.13 5.28 5.42 5.57 5.72 5.86 6.59 7.33

0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05

75% 12.00 12.67 13.33 14.00 14.67 15.33 16.00 16.67 17.33 18.00 18.67 19.33 20.00 20.67 21.33 22.00 22.67 23.33 24.00 24.67 25.33 26.00 26.67 27.33

80% 11.25 11.88 12.50 13.13 13.75 14.38 15.00 15.63 16.25 16.88 17.50 18.13 18.75 19.38 20.00 20.63 21.25 21.88 22.50 23.13 23.75 24.38 25.00 25.63

82% 10.98 11.59 12.20 12.80 13.41 14.02 14.63 15.24 15.85 16.46 17.07 17.68 18.29 18.90 19.51 20.12 20.73 21.34 21.95 22.56 23.17 23.78 24.39 25.00

85% 10.59 11.18 11.76 12.35 12.94 13.53 14.12 14.71 15.29 15.88 16.47 17.06 17.65 18.24 18.82 19.41 20.00 20.59 21.18 21.76 22.35 22.94 23.53 24.12

90% 10.00 10.56 11.11 11.67 12.22 12.78 13.33 13.89 14.44 15.00 15.56 16.11 16.67 17.22 17.78 18.33 18.89 19.44 20.00 20.56 21.11 21.67 22.22 22.78

92% 9.78 10.33 10.87 11.41 11.96 12.50 13.04 13.59 14.13 14.67 15.22 15.76 16.30 16.85 17.39 17.93 18.48 19.02 19.57 20.11 20.65 21.20 21.74 22.28

95% 9.47 10.00 10.53 11.05 11.58 12.11 12.63 13.16 13.68 14.21 14.74 15.26 15.79 16.32 16.84 17.37 17.89 18.42 18.95 19.47 20.00 20.53 21.05 21.58

1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.60 2.70 2.80 2.90 2.95 3.00 3.05 3.10

75% 13.96 15.36 16.75 18.15 19.55 20.94 22.34 23.73 25.13 26.53 27.92 29.32 30.72 32.11 33.51 34.90 36.30 37.70 39.09 40.49 41.19 41.88 42.58 43.28

80% 13.09 14.40 15.71 17.02 18.32 19.63 20.94 22.25 23.56 24.87 26.18 27.49 28.80 30.10 31.41 32.72 34.03 35.34 36.65 37.96 38.61 39.27 39.92 40.58

82% 12.77 14.05 15.32 16.60 17.88 19.15 20.43 21.71 22.99 24.26 25.54 26.82 28.09 29.37 30.65 31.92 33.20 34.48 35.76 37.03 37.67 38.31 38.95 39.59

85% 12.32 13.55 14.78 16.01 17.25 18.48 19.71 20.94 22.17 23.41 24.64 25.87 27.10 28.33 29.57 30.80 32.03 33.26 34.49 35.73 36.34 36.96 37.57 38.19

90% 11.63 12.80 13.96 15.13 16.29 17.45 18.62 19.78 20.94 22.11 23.27 24.43 25.60 26.76 27.92 29.09 30.25 31.41 32.58 33.74 34.32 34.90 35.49 36.07

92% 11.38 12.52 13.66 14.80 15.93 17.07 18.21 19.35 20.49 21.63 22.76 23.90 25.04 26.18 27.32 28.45 29.59 30.73 31.87 33.01 33.58 34.15 34.71 35.28

95% 11.02 12.12 13.23 14.33 15.43 16.53 17.64 18.74 19.84 20.94 22.04 23.15 24.25 25.35 26.45 27.56 28.66 29.76 30.86 31.96 32.52 33.07 33.62 34.17

3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.80 3.90 4.00 4.10 4.20 4.30 4.40 4.50 4.60 4.70 4.80 4.90 5.00

75% 30.72 31.20 31.68 32.16 32.64 33.12 33.60 34.08 34.56 35.04 35.52 36.48 37.44 38.40 39.36 40.32 41.28 42.24 43.20 44.16 45.12 46.08 47.04 48.00

80% 28.80 29.25 29.70 30.15 30.60 31.05 31.50 31.95 32.40 32.85 33.30 34.20 35.10 36.00 36.90 37.80 38.70 39.60 40.50 41.40 42.30 43.20 44.10 45.00

82% 28.10 28.53 28.97 29.41 29.85 30.29 30.73 31.17 31.61 32.05 32.49 33.36 34.24 35.12 36.00 36.88 37.75 38.63 39.51 40.39 41.26 42.14 43.02 43.90

85% 27.10 27.53 27.95 28.37 28.80 29.22 29.64 30.07 30.49 30.92 31.34 32.19 33.03 33.88 34.73 35.57 36.42 37.27 38.11 38.96 39.81 40.66 41.50 42.35

90% 25.60 26.00 26.40 26.80 27.20 27.60 28.00 28.40 28.80 29.20 29.60 30.40 31.20 32.00 32.80 33.60 34.40 35.20 36.00 36.80 37.60 38.40 39.20 40.00

92% 25.04 25.43 25.82 26.22 26.61 27.00 27.39 27.78 28.17 28.56 28.95 29.74 30.52 31.30 32.08 32.87 33.65 34.43 35.21 36.00 36.78 37.56 38.34 39.13

95% 24.25 24.63 25.01 25.39 25.77 26.15 26.52 26.90 27.28 27.66 28.04 28.80 29.56 30.31 31.07 31.83 32.59 33.34 34.10 34.86 35.62 36.38 37.13 37.89

AnnualFuelUtilitizationEfficiency(AFUE)Themeasureofannualefficiencyofaresidentialheatingfurnaceorboiler.Accountsforoperationenergylossesoftheheatingunit

CoefficientofPerformance(C.O.P.)Thesameastheefficiencystatedasaratioofworkorusefulenergyoutputofasystemvs.theamountofenergyinputtedintothesystem

EnergyFactor(EF)Theefficiencyormeasureofoverallefficiencyofavarietyofappliances.WaterheaterefficienciesareratedbyEF

SystemEfficiency

(C.O.P.orEF)

138,900BTU/galllon

NaturalGas 100,000BTU/therm

$/ccf

Electricity 3412BTU/kWh

$/gal

SystemEffciency

FuelOil

5/18/2008

EnergyEfficiencyTerm

SystemEffciency

$/kWh

$/gal

SystemEffciency

Propane 95,500BTU/gallon

Page 1

1 Components

Note : The model shown above is a typical FFB boiler 15kW / 240 Volts / 1 phase.

Model shown below is a TMB boiler 11kW / 240 / 1 phase.

9”

Outlet 1-1/4ÊÊ NPT

Inlet 1-1/4ÊÊ NPT

Mounting holes

Electronic

temperature

sensor

18”

Temperature /

pressure

gauge

Incoloy elements Manual reset

thermal cut-out Solid state relays

Pump relay

Ground lug

Fuse and

fuse holder

Pump relay terminals

(dry contacts 10A)

Boiler control

transformer

Circuit breaker

13”

Magnetic back-up contactor

Fig. 1

Fig. 3

Outdoor reset sensor

9”

18”

Page 2

Table 2

NOTE: Other models, voltages and capacities available upon request. Please contact the factory.

Dual-Energy Models B-5U-FFB B-6U-FFB B-8U-FFB B-9U-FFB B-10U-FFB B-12U-FFB B-15U-FFB

kW 5 89105.75 11.5 15

BTU / H 17,060 19,619 27,296 30,708 34,120 39,238 51,180

Total Amps 20.83 23.96 33.33 37.50 41.67 47.92 62.50

No. Of Power Supplies 1 x 30A 1 x 30A 1 x 50A 1 x 50A 1 x 60A 1 x 60A 1 x 60A

(Breaker Size) 1 x 30A

Dual-Energy Models B-18U-FFB B-20U-FFB B-23U-FFB B-27U-FFB B-30U-FFB B-35U-FFB B-40U-FFB

kW 18 20 23 27 30 35 40

BTU / H

Total Amps 75.00 83.37 95.83 112.50 125.00 145.83 166.67

No. Of Power Supplies 1 x 60A 2 x 60A 2 x 60A 2 x 50A 3 x 60A 4 x 50A 4 x 60A

A06x1A05x1)eziSrekaerB(

Dual-Energy Models B-18U-FFB B-24U-FFB B-30U-FFB B-35U-FFB B-40U-FFB

kW 18 24 30 35 40

BTU / H 61,416 81,888 102,360 119,420 136,480

Amps @ 208V / 3ph 48.00 66.69 83.37 96.00

No. Of Power Supplies 1 x 60

2 x 50

2 x 60

(

Breaker Size

)

Amps

480V / 3ph 21.68 28.90 36.13 42.15 48.00

Disconnect Switch 30

Standard Model Specifications @ 3ph

(U.S.A.)

Standard Models Specifications @ 240V / 1ph

(U.S.A.)

n/a

Please use Table 3 below to select the wire size for the power supply.

Table 3

Wire Size 12 10 8 6 4 3 2 1 0 00 000

Amps @ 75°C (167°F) 20 30 45 65 85 100 115 130 150 175 200

Amps @ 90°C (194°F) 20 30 45 65 85 105 120 140 155 185 210

Notes :

Cable Amps Capacity vs Wire Size

1- This table should be used as a guide only. Always select the wire size according to the local

Electrical Code.

2- Always use wire suitable for 75°C (167°F) minimum, 300V or 600V as required.

3- All models with suffix "U" over 12 kW at 240V / 1ph require two feeders. Divide the Total

Amps by 2 to select the proper wire size.

4- COPPER WIRE ONLY.

2 Standard specifications for all models

61,416 68,242 78,479 92,128 102,360 119,420 136,480

Mono Models B-3TMBU B-6TMBU B-9TMBU B-11TMBU

kW 36911

BTU/H 10,236 20,472 30,708 37,532

Total Amps 12.5 25.0 37.5 45.8

Breaker size 1 x 20A 1 x 40A 1 x 50A 1 x 60A

TMB MONO Model Specifications @ 240V / 1ph (U.S.A.)

Page 3

Installation Guidelines for Thermolec Electric Boilers Model B

3 Important

3.1 These instructions should be used as a general guide only. Electrical Code and local utility requirements must

be followed and take precedence over these instructions.

3.2 Thermolec electric boilers are manufactured with quality components for maximum life, durability and

minimum service. To ensure a satisfactory installation it is imperative that you read these instructions

carefully before installing and operating the heating system.

Failure to do so may result in breach of warranty.

4 Unpacking

4.1 Inspect the unit and check whether there are missing parts.

4.2 Report any damage or claims to the carrier immediately.

4.3 For all returns to be accepted they must be authorized by the manufacturer.

5 Location and dimensions

5.1 These boilers are designed for wall mounting. Please see Table 1 below for overall dimensions.

Table 1 also gives the minimum clearances to combustible material as well as recommended distances for

ease of service (e.g. replacement of tubular elements).

5.2 The boiler room should be well ventilated as to maintain the temperature below 77°F.

5.3 The unit must be mounted level on a vertical wall with the outlet tting on the left side of the unit.

Models Width Height Depth Front Back Top Right Others

Short Models

up to 23 kW 1ph

up to 18 kW 3ph

Long Models

up to 40 kW

TMB

12"

36" 0" 24" 6" 12"

36" 0" 12" 6"

Table 1

Overall dimensions Clearances

Dimensions and Clearances

18" 18" 9"

13" 18" 9"

18" 28" 9"

Page 4

6.2 In order to ensure an adequate flow rate :

6.21 Pressure loss (referred as "Head") caused by water friction in the system should not exceed the

capacity of the pump.

6.22 Please refer to Table 5 below to find the copper pipe diameter (type L) recommended to

accommodate the water flow found in Table 4 above.

6.23 Elbows and valves will greatly add to the head loss in the system. An appropriate water flow rate

must be maintained to avoid tripping of the temperature limiter. Pipes with diameters larger than

specified in Table 5 will not help to increase water flow.

6.24 Head loss through the boiler tank is negligable and should not affect calculations of flow rates.

6.3 The installation must have a drain valve, an expansion tank, maintenance valves and an automatic

pressure reducing fill valve set at 15 PSI (104 kPA). A "T" fitting (1-1/4" NPT) must be installed at the

supply outlet of the unit. This "T" must be equipped with a reducing bushing 1-1/4" to 3/4" NPT, facing

upwards, to accept a 3/4" NPT pressure relief valve. This safety valve must be installed vertically. Except

for the pressure relief valve, the above plumbing supplies are not supplied with the unit. Please refer to

illustrations A, B and C at the end of this manual.

Table 4

Table 5

6 Water circulation and plumbing notes

6.1 The system is designed to operate with a maximum output temperature of 190°F or lower and a

temperature rise across the unit of 20°F or lower.

Please refer to Table 4 for the minimum flow rate versus the capacity of the boiler.

Maximum Flow Rate Pipe Diameter

US Gallons / min (Type L Copper)

4.3 3/4"

10.1 1"

17.3 1-1/4"

Maximum Flow Rate @ 15 psi

Capacity (kW) US Gallons / min

31.1

51.8

62.0

82.8

93.1

10 3.5

11 3.9

12 4.2

15 5.3

18 6.2

20 7.0

23 8.0

27 8.8

30 10.4

35 12.2

40 13.9

Minimum Water Flow Rate vs Capacity

Page 5

6.4 The automatic pressure relief valve supplied with the boiler is required to prevent dangerous pressure

build-ups in the system in case of system malfunction and may under certain conditions vent hot water.

Do not install the system where water could damage rugs, furniture, etc. When piping the relief valve to a

drain, check with local authority for recommended method of installation. Do not open or tamper with the

relief valve. If operated frequently or used to drain or flush the system, the valve could fail to seat properly

and thus leak.

Important safety notice : This safety valve is mandatory and must be installed as shown in the

illustrations A, B and C at the end of this manual. The omission of the safety valve installation will

create a very serious safety hazard and will void all warranties.

6.5 Automatic air vents should be installed at the highest point of the installation and above the level of the

boiler tank, ideally on all radiator units for best results or at points where air could possibly be trapped in

the system.

Caution : Make sure the system has been properly vented before starting the unit.

6.6 Depending on water conditions, determine wether water additives are necessary.

7 Mechanical installation

7.1 Mounting brackets are located on the sides of the boiler. Depending on the size of the unit, four or six

holes are provided. The unit may be attached directly to a combustible surface.

7.2 Use a circulator pump of appropriate capacity for the intended application. The pump should be placed as

close as possible to the boiler. Ensure that the water direction is correct. An arrow indicating the

circulation direction is generally visible on the pump casing.

7.3 Install inlet and outlet piping.

7.4 Install air vents, valves, the pressure relief valve supplied with the unit, expansion tank, etc.

7.5 When everything is finished, install the temperature / pressure gauge.

8 Electrical installation

8.1 Disconnect all power sources before opening the main panel and working within.

8.2 Read the nameplate and other markings carefully and wire strictly in accordance with the wiring diagram.

8.3 Wires and protective equipment must be sized according to the applicable Electrical Code.

8.4 Use only wires suitable for minimum 167°F.

8.5 Install the outdoor sensor on an exterior North wall and connect it with 18/2 wire to terminals

"OT / OT" on the electronic board (TH-600 series controller).

8.6 On the electronic aquastat (marked "WATER TEMPERATURE"), select the maximum water temperature

required (1-10) by the type of installation. Please see Table 6 below for the temperature obtained

according to the knob position. The minimum water temperature is reset automatically by the outdoor

sensor. Please see the variation graph in Fig 5.

10987654321

°C 88 81 75 67 58 50 45 42 39 36

°F 190 178 167 153 137 122 113 107 102 97

°C 48 48 48 45 40 38 34 31 29 28

°F 118 118 118 113 104 100 93 88 84 82

Table 6

Water Temperature controlled by Electronic Aquastat

Maximum

temperature

Minimum

temperature

Set-point

Page 6

Electronic Aquastat

Fig. 4 Fig. 5

8.7 The outdoor sensor will :

a) Maintain the selected maximum water temperature when the outdoor temperature is at +14° F or

colder.

b) Automatically and proportionally compensate by varying the water temperature between the

maximum and minimum when the outdoor temperature is between +14°F and +50°F.

c) Maintain the minimum water temperature when the outdoor temperature is between +50°F and

+68°F.

d) Prevent boiler operation above +68°F.

NOTE : If you choose not to use the outdoor sensor, don't connect it to the "OT / OT" terminals nor jumper

these terminals. You will not use this feature and the water will simply be maintained at the maximum

selected temperature.

8.8 Connect the thermostat or the zone valve end switch wires to "C" and "W1" terminals on the electronic

board. Power stealing thermostats require an isolation relay (not included).

8.9 Circulating Pump Control. The "P / P" terminals are connected to dry contacts of a relay (capacity up

to 1 HP) and are used to start the pump. This relay is switched ON with the first heating step and OFF

after the last one. A separate 120V / 1Ø service must be provided from the electrical panel to the boiler

for the pump. For Electric Boiler only systems, refer to the wiring diagram. For Electric Boiler with fossil

fuel backup, see the diagram on page 23 labeled ‘PUMP WIRING WITH FOSSIL FUEL BACKUP

BOILER’ as the pump must also run when another source of heat is selected.

Follow the extra steps dedicated to a FFB installation in the start-up sequence.

8.10 Set the room thermostat heat anticipator (when available) to 0.2 Amperes.

8.11 If the system is used with Load Management control, connect the Utility signal to "S1 / S2" terminals.

A closed contact enables the boiler, an open contact disables the boiler.

8.12 The installation is now ready for start-up procedure and testing.

9 Start-up procedure and test sequence

Do not energize electrical elements prior to purging system and verifying proper water circulation

Double check the following carefully :

9.1 All wiring and plumbing is complete.

9.2 Pipes have been cleaned, the system has been flushed and filled again.

9.3 Without powering the entire unit, install a jumper between the "P / P" terminals (using proper gauge of

wire) and switch the pump breaker ON as to let the pump run alone. Verify that the pump is running freely

and check for leaks. During this test, a lot of bubbles will travel through the system and air will be

eliminated by the automatic vents. You can accelerate the process by purging the radiators manually.

Shut off the pump breaker at the panel, then remove the jumper between the "P / P" terminals.

9.4 The pressure in the system has been stabilized at approximately 15 PSI (104 kPA).

9.5 The entire system is now almost free of air.

9.6 The room thermostat anticipator (when available) has been set at 0.2 Amperes.

9.7 Switch the boiler breaker ON at the main panel.

MAXIMUM

WATER TEMPERATURE

MINIMUM

WATER TEMPERATURE

°F +14 +23 +32 +41 +50

Page 7

9.8 Set the thermostat above the room temperature. The system should start.

9.9 Make sure the pump starts running as soon as the system starts.

9.10 Heating stages will be switched ON in sequence at 30 second intervals, confirmed by green lights on the

left hand side of the PC board on the TH600 or by red lights on the right hand side on the D22-B.

9.11 Wait for two minutes and measure the current drawn by the boiler and compare it with the one shown on

the nameplate.

9.12 When the required maximum water temperature selected on the aquastat (0-10) or controlled by the

outdoor sensor is reached, the electronic controller will modulate the boiler capacity to maintain the water

temperature, as long as the demand for heating is not satisfied. The bottom green light flashes

continuously on the TH600 or one of the red lights on the D22-B to indicate that the boiler is maintaining

the setpoint. When the room thermostat is satisfied, the heating stages will come OFF in sequence at 5

second intervals.

9.13 Set the room thermostat to the desired set point.

9.14 The boiler is now ready and functional.

Extra test steps for Electric with Fossil Fuel Backup Boiler installation

9.15 Disconnect the room thermostat wires from the existing boiler and connect them to "C" and "W1" terminals

on the electronic board of the electric boiler.

9.16 Connect two (2) wires from "B / B" control terminals of the electronic board on the electric boiler to the

T T (thermostat) terminals of the existing boiler.

9.17 Terminals "S1 / S2" on the electronic board should receive the utility Load Management Control wires.

9.18 Connect the pump terminals "P / P" in parallel to the existing thermostatic pump control as per wiring

diagram on page 23 to allow the operation of the pump in any of the "Dual-Energy" modes selected.

9.19 When the system is opperating in Fossil Fuel mode, the supply water temperature of the fossil fuel boiler

should never exceed 190°F which may trip the manual high limit in the electric boiler.

10 Test sequence for FFB Boiler systems

10.1 An FFB boiler is supplied with a three-position mode selector switch. Because of differences in regional

regulations, the electronic board has been factory set so as to allow the activation of the electric mode

depending on the unit destination. In the "Gas / Oil" position the thermostat will call upon the gas or oil

boiler or furnace to maintain the house temperature at the desired level. The "Dual-Energy" mode gives

automatic control to the outdoor sensor or alternate switching signals from the local utility for Load

Management control. When the Load Management contacts are closed, the "Electric" mode is selected.

When these contacts are open, the "Gas / Oil" mode is selected. A green pilot light indicates the mode

that has been selected.

OIL / GAS

DUAL ENERGY

Heating by means of Fossil Fuel Boiler

Dual-Energy mode - Electric is primary source of heat.

May be controlled by utility company.

Do not use the middle position

Fig. 6

Page 8

10.3 Simulate a heating demand by setting the thermostat higher than the room temperature.

10.4 Switch the mode selector to position and check that the burner responds to the thermostat demand.

10.5 Switch the mode selector to the "Dual-Energy" position . Install a jumper between terminals "S1 / S2";

the electric mode is automatically selected. The pump will start and the heating stages will be switched

ON in sequence at 30 second intervals. Measure the current drawn by the boiler and compare it with the

one shown on the nameplate. If you remove the jumper from terminals "S1 / S2", the system should switch

back to the "Oil / Gas" mode.

10.6 Switch the mode selector to the desired position and set the room thermostat to the desired temperature.

10.7 Your boiler is now ready and functional.

11 Installation examples

11.1 Installation A shows a Thermolec electric boiler in a Full-Electric Configuration.

11.2 Installation B shows a Thermolec electric boiler in a FFB-Series Configuration.

Water is always passing through both boilers even if only one heat source is selected at a time.

11.3 Installation C shows a Thermolec electric boiler in a Primary/Secondary Piping Configuration.

Water is pumped through multiple zones (more than two equally sized zones).

12 Position and electric values of heating elements

Standard values of heating elements at 240 Volts are 3kW, 5kW, 5.75kW, 8.75kW & 10 kW. Please refer

to the following sketches and tables to find the position and test value in ohms of each element. Please

ensure you disconnect the element wires completely before you make the resistance reading.

13 Replacement of heating elements

Heating elements nuts and cover bolts have been factory torqued with a calibrated tool. Please make

sure you have a torque driver and the proper sockets handy before you open the boiler tank.

Elements nuts should be torqued at :

130 inch-pound (in-lbs) or equivalent

Please ensure you use the double wrench method (i.e. an open key inside of the tank to hold the

element hexagon flange firmly and the torque wrench outside). Don't let the element turn while tightening

or it may become damaged.

Cover hex bolts should be torqued at :

70 inch-pound (in-lbs) or equivalent

Please make sure to tighten all nuts by hand first, then tighten them as per fig. 8 and finally apply the

proper torque with the torque wrench. Resist the feeling that the bolts could get torqued more (even if

possible) because that action would simply squash the silicone gasket to the point where it would

eventually lose all its resiliency and sealing properties.

Keep in mind that an equal torque is far more important.

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