CTC Union CTC 380 IC Instruction Manual

Providing sustainable energy solutions worldwide
162 105 11-1 2013-05-21
Installation- and maintenance instruction
CTC 380 IC
Oil condensing boiler unit
Models 17/19/24/29

CTC 380 IC
Models 17/19/24/29
162 105 11-1 2013-05-21

CTC 380 IC
5
1. Introduction
1.1 General information.........................................7
2. Important points
2.1 Important points...............................................8
2.2 Safety instructions ..........................................8
2.3 General installation conditions ........................8
3. Technical data
3.1 Technical data .................................................9
3.2 Measurements...............................................10
3.3 Description ..............................................11, 12
4. Installation
4.1 General information.......................................13
4.2 Transport .......................................................13
4.3 Unpacking .....................................................13
4.4 Boiler room ....................................................14
4.5 Connection to chimney..................................14
4.6 Flue gas temperatures ..................................14
4.7 Hydraulic connection boiler ...........................14
4.8 Shut-off valves...............................................14
4.9 Boiler safety valve .........................................14
4.10 Heating circulation pump...............................15
4.11 Heating circuit mixing valve...........................15
4.12 Connection of domestic hot water (DHW)
or additional heating circuits..........................15
4.13 Drainage/draining valve.................................15
4.14 Connection of domestic water heaters ........15
4.15 Filling .............................................................15
4.16 Manometer ....................................................15
4.17 Siphon ...........................................................15
4.18 Neutralisation box..........................................15
5. Electric installation
5.1 General information.......................................16
5.2 Heating circuit pump......................................16
5.3 Heating circuit mixing valve...........................16
5.4 Safety limit thermostat (STB) ........................16
5.5 Wiring diagram E-582450..............................17
5.6 Plant diagrams ..............................................18
6. Electric installation - comfort control
6.1 General information.......................................19
6.2 Basic unit RVS43.143 ...................................19
6.2.1 Terminal markings .............................19, 20, 21
6.2.2 Checking the LED .........................................21
6.3 Power pack AVS16.290.................................22
6.4 Operator unit AVS37.294...............................23
6.5 Change Language.........................................24
6.6 Selecting heating mode.................................24
6.7 Selecting DHW heating mode .......................25
6.8 Adjusting the room temperature setpoint ......25
6.9 Displaying information ...................................26
6.10 Reset function ...............................................27
6.11 Manual control...............................................27
6.12 Chimney sweep function ...............................27
6.13 Programming...........................................28, 29
6.14 User levels...............................................30, 31
6.15 Commissioning..............................................32
6.16 Time programs ..............................................33
6.17 Heating curve ................................................34
6.18 Flow temperature limitation ...........................35
6.19 Domestic Hot Water DHW.............................36
6.20 Reset to default parameters ..........................36
6.21 List of displays.........................................37, 38
7. Oil burner
7.1 General information.......................................39
8. First start - Commissioning
 8.1 Beforerststart .............................................40
8.2 First start .......................................................40
 8.3 Afterrststart ................................................40
9. Operation
9.1 General information.......................................41
9.2 Regular checks..............................................41
9.3 Standstill........................................................41
9.4 Risk of frost ...................................................41
9.5 Boiler cleaning...............................................42
9.6 Spiro-Condense system cleaning............42, 43
9.7 Drainage........................................................44
9.8 Oil operation ..................................................44
9.9 Faults.............................................................44
Declaration of conformity.............................................45
Table of contents
Burner manual at the latter part of this folder

CTC 380 IC
6

CTC 380 IC
7
1. Introduction
1.1 General information
• CTC 380 IC is a 3-stroke oil condensing boiler unit which meets the progressive
demands on profitability, convenience and environmental sustainability.
• CTC 380 IC was designed to minimise polluting emissions.
• CTC 380 IC is available in six sizes from 18 to 45 kW.
• CTC 380 IC provides the heating and hot water supply
for the entire house.
• CTC 380 IC has heating connections directed upwards and backwards
to facilitate installation.
• CTC 380 IC is equipped with an aligned and enhanceable comfort control
which comprehensively meets the need for convenient and energy-saving
operation.
• CTC 380 IC is equipped with a highly efficient Spiro-Condens system for effective
calorific value usage.
• CTC 380 IC can be easily cleaned thanks to the generous door and
even-wall heating surface.
• The type name of the boiler can be found on the product data plaque on the top
of the boiler.

CTC 380 IC
8
2. Important points
Read and observe this installation and operating manual before
installing and starting the boiler.
2.1. Important points
The following important points must be checked during installation:
• Unpack CTC 380 IC on delivery and check whether the product was not
damaged in transit.
• Any transport damage must be reported to t he supplier (carrier).
• Check whether an overflow line was laid from a possible installed safety valve
to the floor drainage.
• Examine the condition of the chimney, take measures against condensation water
formation.
2.2 Safety instructions
The following safety instructions must be observed when handling, installing and
operating the boiler:
• An unlockable safety valve which corresponds to the applicable norms must be
installed in an enclosed system; please refer to Section
INSTALLATION.
• Ensure that the boiler is disconnected from the mains supply before making
changes.
• The boiler and the regulation equipment must not be rinsed with water.
• The smoke duct and the boiler room duct for ventilation must not be
blocked.
• Check whether the bruner and its oil duct are leakproof.
• The boiler's switch must be deactivated when the oil burner is swivelled out,
e.g. during cleaning or maintenance.
2.3 General installation conditions
Smooth operation of the boiler series CTC 380 IC and the manufacturer's warranty
are only ensured if installation and operation are performed in compliance with these
instructions and the boiler is regularly cleaned.
Faults and damages which are caused by improper and violent damage do not release
the manufacturer from this warranty obligation.
Please hand over these instructions to your customer after installation.
Regulations:
The boiler and the heating system must be installed in
compliance with the applicable standards and construction
regulations by respective specialist companies only.

CTC 380 IC
9
3. Technical data
3.1 Technical data
CTC 380 IC 17 19 24 29
Rated input kW 17,8 19,7 24,5 29,3
Rated output 50/30 °C kW 18,2 20,1 25,0 29,9
Rated output 80/60 °C kW 17,2 19,0 23,7 28,3
Oil supply g/h 1190 1330 1680 2030
Flue gas mass flow rate g/s 6,08 6,80 8,59 10,38
Boiler water resistance (∆Τ 20Κ) mbar 95 125 175 160
Boiler efficiency 50/30 °C % 102 102 102 102
Flue gas temperature 50/30 °C °C 44 44 44 43
Flue gas temperature 80/60 °C °C 60 61 61 62
Max boiler operating pressure bar 3 3 3 3
Max operating temperature °C 110 110 110 110
Water content l 98 98 92 93
Weight kg 239 239 248 251
Number of flue gas heat exchangers units 1 1 1 2
Number of turbulators. units 6 6 9 9
Turbulator type 27/45 XS 27/45 XS 27/45 XS 27/45 XS
Electric data 230V 1N~ 230V 1N~ 230V 1N~ 230V 1N~
Oil burner type BF1 M1V BF1 M1V BF1 M1V BF1 M1V

CTC 380 IC
10
3.2 Measurements
Legend
1.PrimaryowR1”
2.ReturnowR1”
3.PrimaryowR1”
4.ReturnowR1”
5.ExpansionconnectionR1”
6.DrainageconnectionR1”
7. Flue gas outlet ø 100 mm inside
8. Condensation water drainage ø50 outside
9a. Basic unit Siemens RVS43.143
9b. Operating unit Siemens AVS37.294
9c. Power pack Siemens AVS16.290
10. Levelling feet M10
13.Rearcoverplate–spiralnnedtube
14.Topcoverplate–spiralnnedtube
484
600
90
141
120
550
895
460
3
4
6
7
8
10
12
13
472182 360
1194
50
418
648
1
2
5
9a
9b
9c
14
Ändr. meddel. Datum Nr Ändring Ändr. av Kontr. av
E
art. nr
Utgåva
Ämnes nr
Ersätter
art. nr
Ersättes av
Grupp
Produkt
Reg. nr
Benämning
Tol.system
Kontr.
Normgr.
Skala
Ritad
Material
Datum
Sign.
Distr till/Antal
Ytjämnhet RA
Godk. prod
Om ej annat angives gäller ovanstående
Denna ritning är CTC AB's egendom. Den får ej användas till skada för företagets intressen.
Diese Zeichnung ist das Eigentum der CTC AB und darf nicht zum Scha- den dieser Gesellschaft verwendet werden.
This drawing is the property of CTC AB and is not to be used against the interest of this com- pany
SJ
2007-08-27
Måttskiss 380 IC
Inst & skötselanvisning
125

CTC 380 IC
11
9a. Basic unit Siemens RVS43.143
9b. Operating unit Siemens AVS37.294
9c. Power pack Siemens AVS16.290
10. Levelling feet M10
13.Rearcoverplate–spiralnnedtube
14.Topcoverplate–spiralnnedtube
3.3 Description
The principle parts of the construction are made from tailor-made steel panel.
The boiler was subject to a pressure and leakage test and coated with close heat insula-
tion and powder-covered cladding panels.
1. Flue gas outlet
Connection to the rear.
2. Heat insulation
The entire boiler is equipped with a special heat insulation in
order to minimise heat loss.
3. Combustion chamber
The generous layout of the combustion chamber provides the
coordinated unit oil burner with ideal combustion properties.
4. DUOPLUS temperature system
The combustion chamber or heat recovery adjuncts are sur-
rounded by two coatings which allow dewpoint corrosion-safe
low temperature and a long lifecycle.
5. Ripples
Boiler sizes 35 and 43 kW are equipped with ripples. This
increases the heat exchanger surface and allows optimum heat
transmission to the heating water.
6. Turbulators
The task of the turbulators is to provide turbulence in the
heating gases so that more heat energy is transmitted to the
boiler water. All boiler sizes are equipped with standard turbulators ex works which are ideally aligned to every size.
The turbulators can be accessed from the front.
7. Cleaning door
Thanks to the generous cleaning door, the turbulators can be easily accessed and the heat recovery adjunct can
at the same time be easily accessed for maintenance and cleaning.
8. Swivelling arm
The cleaning door is equipped with hinges which serve as swivelling arm. This makes removing the oil burner
for inspection and service.
9. Levelling feet
The boiler is equipped with four adjustable feet.
10. Power pack
The power pack of the boiler control panel – Siemens AVS16.290. For further information, please refer to
Section Electric installation – comfort control.
11. Basic unit
The basic unit of the comfort control – Siemens RVS43.143. For further information, please refer to Section Electric
installation – comfort control.
12. Operating unit
The operating unit of the comfort control – Siemens AVS37.294. For further information, please refer to Section
Electric installation – comfort control separate attached instructions.
13. Oil burner
For further information, please refer to Section Oil burner.
14. Hood
The hood is an integrated, nicely shaped component of the boiler.
11
10
12
8
14
7
4
3
2
1
5
6
15
16
17

CTC 380 IC
12
16. Cleaning – spiral finned tube
Spiro-Condens system is easily accessible, through the the cover plate,
for cleaning .
17. Removal – spiral finned tube
It is possible to remove and clean the spiral finned tube of the exhaust
heat exchanger.
18. Condensation water drainage
The boiler is equipped with a ø 50 mm (exterior diameter)
connection for condensation water drainage.
A suitable siphon with a diameter of at least 13 mm must be fitted.
The siphon must be filled with water during boiler operation.
Maintenance of the siphon must be performed annually.
After the maintenance of the siphon, it must be filled with water.
If fitting a neutralisation system is required, the country-specific
regulations must be observed.
18
15
16
17
Ändr. meddel. Datum Nr Ändring Ändr. av Kontr. av
E
art. nr
Utgåva
Ämnes nr
Ersätter
art. nr
Ersättes av
Grupp
Produkt
Reg. nr
Benämning
Tol.system
Kontr.
Normgr.
Skala
Ritad
Material
Datum
Sign.
Distr till/Antal
Ytjämnhet RA
Godk. prod
Om ej annat angives gäller ovanstående
Denna ritning är CTC AB's egendom. Den får ej användas till skada för företagets intressen.
Diese Zeichnung ist das Eigentum der CTC AB und darf nicht zum Scha- den dieser Gesellschaft verwendet werden.
This drawing is the property of CTC AB and is not to be used against the interest of this com- pany
2006-05-02
Boiler
min 26,5 mm
Condensation water drainage

CTC 380 IC
13
4. Installation
4.1 General information
The installation must be performed in compliance with the applicable standards and
construction law regulations by respective specialist companies only.
The boiler must be connected to an expansion vessel in an open (with high positioned
expansion vessel and safety and return duct) or closed system. For an open system,
the distance between the expansion vessel and the expansion connection on top of the
boiler should not be less than 2.5 m in order to prevent an oxygen enrichment in the
system.
4.2 Transport
To avoid transport damage, do not unpack the boiler until it has been transported to its
site in the boiler room. The boiler can be handled and lifted in the following way:
◗Forklift
◗Lift band round the pallet. Note! Only with the packing on.
◗Sack barrow
◗ 1” pipes can be mounted in the lifting sleeves at the front and rear (see picture below).
4.3 Unpacking
To prevent transport damage the packaging must not be removed from the boiler until
it is in the boiler room at the place of installation. After removing the packaging, check
whether the boiler was damaged during transit. Any transport damage must be report-
ed to the supplier (carrier).
Standard delivery:
◗ Oil condensing boiler unit CTC 380 IC
◗ Cleaning tools
◗ Flow temperature sensor
◗ DHW tank temperature sensor
◗ Outdoor sensor
Bracing bushes

CTC 380 IC
14
4.4 Boiler room
The boiler room must comply with the applicable construction law regulations,
in particular the fire regulation, of the respective country. The boiler room must be
equipped with an opening for ventilation. The ventilation diameter should be at
least 6.5 cm2 per 1 kW of boiler power.
4.5 Connection to chimney
The boiler is designed for open operation. Existing engineering standards and building
regulations for the design/installation of the chimney must be taken into consideration.
Important conditions:
◗Good thermal insulation in order to as much as possible avoid temperature losses
from the connection between the boiler and the chimney.
◗Accurate sealing of the flue gas connections.
◗Heat-shock resistance as well as water- and steam tight.
4.6 Flue gas temperatures
The respective country-specific regulations regarding the flue gas systems
must be observed.
In some cases it is necessary to install a flue gas temperature thermostat, follow the lokal
regulations for flue gas systems. (Installation instructions are attached to the flue gas
temperature thermostat).
4.7 Hydraulic connection boiler
The dimensioning and plumbing of the system shall be accomplished according to the
measurements and datas in the part Technical information.
4.8 Shut-off valves
Shut-off valves must be installed between the heating circuit and heating boiler in order
to facilitate an eventual dismantling of the flue gas heat exchanger coil.
4.9 Boiler safety valve
In a closed system a certified safety valve must be installed in accordance with the
applicable regulations. The maximum operating pressure of the boiler is
3 bar. The hydraulic connection between boiler and safety valve must be designed so
that no increase in pressure is possible. The overflow pipe must be free and visible.
Any escaping heating water must be drained without danger.
(Warning! Risk of scalding).

CTC 380 IC
15
4.10 Heating circulation pump
A heating circuit pump must be mounted on the flow of the boiler. The pump is
supplied with power from the boiler. For further information regarding systems principles
and connections, see Electric installation – comfort control.
4.11 Heating circuit mixing valve
A heating circuit mixing valve must be mounted on the flow of the boiler. The heating cir-
cuit mixing valve is supplied with power from the boiler. For further information regard-
ing system principles and connections, see Electric installation – convenience regulaion.
4.12 Connection of domestic hot water (DHW) or
additional heating circuits
The connections on the rear of the boiler allow connecting the boiler directly to
additional heating circuits. It is possible to connect the boiler to a DHW system.
4.13 Drainage/draining valve
Drainage/draining valve shall be mounted on the drainage connection at the rear of the
boiler.
4.14 Connection of domestic water heater (storage)
If the CTC 380 IC is combined with a domestic hot water heater, it must be
ensured that its size and capacity correspond to the installed boiler capacity. The
connection must comply with the applicable construction law regulations. Usually
to be connected to the rear flow and return connections of the boiler.
For further information regarding the system principles and connections, see Electric
installation – comfort control.
4.15 Filling
Filling is performed via a filling valve for the heating system.
Alternatively, filling can also be carried out via an emptying valve.
4.16 Manometer
The manometer shall be connected to the expansion line of the boiler.
4.17 Siphon
See 3.3 Description, Section 18.
4.18 Neutralisation box
See 3.3 Description, Section 18.

CTC 380 IC
16
STB restore button
5. Electric installation
5.1 General information
The electric installation of the boiler must be performed by a specialist. The lines must
be laid in compliance with applicable regulations. The boiler is ready ex works for con-
nection.
5.2 Heating circuit pump
The heating circuit pump for the heating system is connected to the connection fastener
in the basic unit. The switch for the pump is on the comfort control of the
boiler.
5.3 Heating circuit mixing valve
The heating circuit mixing valve for the heating system is connected to the connection
fastener in the basic unit.
5.4 Safety temperature limiter (STB)
For extremely cold storage of the boiler, the safety temperature limiter can be
initiated. It is restored with the button at the front of the power pack.

CTC 380 IC
17
5.5 Wiring diagram E-582450
M
3
2
U
4
3
2
T
3
2
R
3
2
S
23
7
6
5
4
3
2
P
1A
5
4
N
L
RED
BROWN
BLUE
GREY
WHITE
BLACK
BLUE
BROWN
BLACK
YELLOW/GREENYELLOW/GREENYELLOW/GREEN
YELLOW/GREENYELLOW/GREENYELLOW/GREEN
2
Q
QX1
N
Y2
N
Y1
Q2
N
Q3
N
SK2
SK1
4
S3
T2
T1
N
L1
S3
L1
N
L
n
2
n
2
p
2
k
2
h
2
n
2
QAZ 36.522/109
QAD 36/101
QAC 34/101
f
2
b
2
3
b
2
1A
3B
Extension module
AVS 75.390/109
HMI
AVS 37.294/109
QAZ 36.522/109
M
BX2
M
BX1
M
B1
M
H1
M
B9
M
B3
M
B2
-
G+
CL-
CL+
CL-
CL+
MB
DB
X50
X60
X30
BSB
LPB
RVS 43.143
1
3B
2
PE
1
Elschema Kpl
582450
CTC 380 S/IC
Si Sicherung 6,3 AT
S1 Netzschalter mit Glimmlampe
STB Shutztemperaturbegrenzer 110 C
H1 Signalleuchte, STB verriegelt
2A
S1
4B
C
L N
Si
1:1
SJ
070403
STB
AVS 16.290/109
H1
Kontr. avÄndr. av Ändrad frånNrDatum Ändr.meddel.
Denna ritning är CTC AB's egendom. Den får ej användas till skada för företagets intressen.
Utgåva
Ämnes nr
E
art. nr
art. nr
Ersätter
Ersättes av
Grupp
Produkt
Reg. nr
Benämning
Tol.system
Kontr. Normgr.
Skala
Material
Ritad
Sign.
Datum
Distr till/Antal
Ytjämnhet RA
Diese Zeichnung ist das Eigentum der CTC AB und darf nicht zum Scha- den dieser Gesellschaft verwendet werden.
Godk. prod
Om ej annat angives gäller ovanstående
This drawing is the property of CTC AB and is not to be used against the interest of this com- pany
Si fuse 6.3 AT
S1 power pack with glowing light
STB safety temperature limiter 110°C
H1 signal light, STB-locked

CTC 380 IC
18
5.6 Plant diagrams
The applications are displayed as basic diagrams with additional functions.
The basic diagrams are possible applications which can be implemented without
multiple function outputs.
RVS43.143 basic diagram
Standard diagram
Standard diagram
Drinking water
with diversion
valve
B2
T2
2358A02
B3
Q3
Y1
B1
Q2
RG1
B9
B2
T2
2358A12
B3
Q3 B9
RG1
Q2

CTC 380 IC
19
6. Comfort-control
6.1 General information
The boiler is factory equipped with the Comfort-control Siemens Albatros2.
The Comfort-control consists of a basic unit, power pack and operator unit. The power
pack and operator unit creates together the control panel of the boiler. Part 6. describes
the principal information concerning the Comfort-control. Fore more information
concerning functions, programming, system principles etc., please see the Albatros2
Boiler Controller User Manual.
6.2 Basic unit RVS43.143
6.2.1 Terminal markings
U T S R Q P NL
QX1
N Y2
N Y1 Q2
N Q3
N SK2 SK1 4 S3 T2 T1 N L1 S3 L1 N
L
2354Z08
050110A
000020RVS43.143/109
1PRVS13.143/109
S050110000020
M BX2 M BX1 M B1 M H1 M B9 M B3 - - M B2 - G+ CL- CL+ CL- CL+
MB DB X50 X60 X30 BSB
n n p n k h f b b a
161 505 95

CTC 380 IC
20
Mains voltage
Use Termininal Type of
connector
L
N
L1
S3
Phase AC 230 V basic unit
Protective earth
Neutral conductor
Phase AC 230 V burner
Output burner fault
N L AGP4S.05A/109
L1
N
T1
T2
S3
4
Phase burner
Protective earth
Neutral conductor
Phase 1 st burner stage
1 st burner stage on
Input burner fault
Input burner stage 1 hours run
P AGP8S.07A/109
SK1
SK2
Safety loop
Safety loop
Q AGP8S.02E/109
N
Q3
Neutral conductor
Protective earth
DHW charging pump / diverting valve
R AGP8S.03A/109
N
Q2
Neutral conductor
Protective earth
1st heating circuit pump
S AGP8S.03B/109
Y1
N
Y2
1st heating circuit mixing valve opening
Neutral conductor
Protective earth
1st heating circuit mixing valve closing
T AGP8S.04B/109
N
QX1
Neutral conductor
Protective earth
1st multifunctional output
U AGP8S.03C/109