DeDietrich MODULENS O AFC 18 Manual

Export
MODULENS O®EN
Oil-fired condensing boilers
AFC 18 - AFC 24 - AFC 30
Installation and
Service Manual
300026439-07

Declaration of conformity [
The device complies with the standard type described in
the EG declaration of conformity. It was manufactured and
commissioned in accordance with European directives.
The original declaration of conformity is available from the
manufacturer.
C003918-A

Contents
1 Safety instructions .....................................................................................6
1.1 Safety instructions ...............................................6
1.2 Recommendations ................................................7
1.3 Liabilities ...............................................................8
1.3.1 Manufacturer’s liability .............................................8
1.3.2 Installer’s liability .....................................................8
2About this manual ......................................................................................9
2.1 Symbols used .......................................................9
2.1.1 Symbols used in the manual ...................................9
2.1.2 Symbols used on the equipment .............................9
2.2 Abbreviations ......................................................10
2.3 After Sales Service Internet Site .......................10
3 Technical specifications ..........................................................................11
3.1 Homologations ....................................................11
3.1.1 Certifications .........................................................11
3.1.2 Oil category ...........................................................11
3.1.3 Additional Directives ..............................................11
3.1.4 Factory test ...........................................................12
3.2 Technical specifications ....................................12
3.2.1 Boiler specifications ..............................................12
3.2.2 Burner specifications .............................................14
3.2.3 Sensor characteristics ...........................................14
4 Product description .................................................................................15
4.1 General description ............................................15
4.2 Operating principle .............................................15
4.2.1 Skeleton Diagrams ................................................15
4.2.2 Circulation pump ...................................................20
4.2.3 Water flow rate ......................................................20
4.2.4 Burner operating cycle ..........................................20
4.3 Main parts ............................................................25
4.3.1 Boiler .....................................................................25
4.3.2 Fuel oil burner .......................................................26
4.4 Package list .........................................................26
4.4.1 Standard delivery ..................................................26
4.4.2 Accessories ...........................................................27
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5 Installation ................................................................................................29
5.1 Regulations governing installation ...................29
5.2 Choice of the location ........................................30
5.2.1 Type plate .............................................................30
5.2.2 Positioning of the appliance ..................................30
5.2.3 Ventilation .............................................................32
5.2.4 Main dimensions ...................................................33
5.3 Positioning the appliance ..................................36
5.3.1 Positioning the boiler on its own ............................36
5.3.2 Fitting the boiler to a DHW tank ............................39
5.3.3 Positioning the boiler to the left or right of a DHW
tank .......................................................................39
5.3.4 Reversal of the direction the control panel access
door opens ............................................................40
5.4 Hydraulic connections .......................................43
5.4.1 Flushing the system ..............................................43
5.4.2 Connecting the expansion vessel
(Depending on country, standard delivery or
optional) ................................................................44
5.4.3 Installing the deaerator ..........................................45
5.4.4 Hydraulic connection of the heating circuit ............46
5.4.5 Connection of the water circuit for domestic
use ........................................................................46
5.4.6 Connecting the condensate discharge pipe ..........46
5.4.7 Filling the condensate trap ....................................48
5.5 Oil connection .....................................................48
5.5.1 General .................................................................48
5.5.2 Connecting ............................................................49
5.5.3 Diameter and length of the oil pipes ......................49
5.6 Flue gas system connections - Depending on
country .................................................................50
5.6.1 Connections for the air and exhaust pipes - Forced
flow (forced flue) - Type C .....................................50
5.6.2 Connections for the air and exhaust pipes - Single
flow (chimney) - Type B ........................................52
5.7 Installing the outside sensor .............................57
5.7.1 Choice of the location ............................................57
5.7.2 Connecting the outside sensor ..............................58
5.8 Electrical connections ........................................59
5.8.1 Control unit ............................................................59
5.8.2 Recommendations ................................................60
5.8.3 Accessing the connection terminal blocks ............60
5.8.4 Connecting a direct heating circuit ........................62
5.8.5 Connecting a direct circuit and a circuit with 3-way
valve ......................................................................63
5.8.6 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................65
5.8.7 Connecting a direct heating circuit and an
independent domestic hot water tank ...................68
Contents
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5.8.8 Connecting two circuits and a domestic hot water
tank .......................................................................70
5.8.9 Connecting two heating circuits with pressure
breaker ..................................................................72
5.8.10 Hot water storage tank connection ........................73
5.8.11 Pool connection .....................................................80
5.8.12 Connecting a mixed tank .......................................82
5.8.13 Connecting the options .........................................83
5.8.14 Connection in cascade ..........................................84
5.9 Electrical diagram ...............................................86
5.9.1 Boiler .....................................................................86
5.9.2 Burner ...................................................................88
5.10 Filling the system ...............................................89
5.10.1 Water treatment ....................................................89
5.10.2 Filling the heating circuit ........................................90
5.10.3 Filling the drinking water circuit .............................91
6 Commissioning ........................................................................................92
6.1 Control panel .......................................................92
6.1.1 Description of the keys ..........................................92
6.1.2 Description of the display ......................................93
6.1.3 Access to the various browsing levels ..................96
6.1.4 Browsing in the menus ..........................................97
6.2 Checks and settings before
commissioning ...................................................98
6.2.1 Preparing the boiler for commissioning .................98
6.3 Putting the appliance into operation ................98
6.4 Setting the burner ...............................................99
6.4.1 Operations to be carried out before any attempt to set
the burner ..............................................................99
6.4.2 Setting the burner’s 3 operating outputs .............100
6.4.3 Checking combustion ..........................................101
6.5 Checks and adjustments after
commissioning .................................................102
6.5.1 Displaying the parameters in extended
mode ...................................................................102
6.5.2 Setting the parameters specific to the
installation ...........................................................102
6.5.3 Naming the circuits and generators ....................107
6.5.4 Setting the heating curve ....................................108
6.5.5 Finalizing work ....................................................110
6.6 Reading out measured values .........................110
6.7 Changing the settings ......................................111
6.7.1 Language selection .............................................112
6.7.2 Calibrating the sensors .......................................112
6.7.3 Professional settings ...........................................114
6.7.4 Configuring the network ......................................122
6.7.5 Return to the factory settings ..............................125
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7 Switching off the appliance ...................................................................126
7.1 Installation shutdown .......................................126
7.2 Antifreeze protection ........................................126
8 Checking and maintenance ...................................................................128
8.1 General instructions .........................................128
8.2 Chimney sweep instructions ...........................128
8.3 Customising maintenance ...............................129
8.3.1 Maintenance message ........................................129
8.3.2 Contact details of the professional for After Sales
Support ................................................................131
8.4 Standard inspection and maintenance
operations .........................................................131
8.4.1 Checking the hydraulic pressure .........................132
8.4.2 Checking the tightness of the flue gas discharge, the
air inlet and the condensates discharge ..............132
8.4.3 Checking the automatic air vent ..........................132
8.4.4 Cleaning of the heating body ..............................133
8.4.5 Cleaning the siphon ............................................137
8.4.6 Checking and replacing the installation’s oil
filter .....................................................................138
8.4.7 Maintenance of the burner ..................................138
8.5 Specific maintenance operations ....................142
8.5.1 Replacing the ignition electrodes ........................143
8.5.2 Maintenance of the air/flue gas drain connection
flues .....................................................................144
9 Troubleshooting .....................................................................................145
9.1 Anti-hunting ......................................................145
9.2 Messages (Code type Bxx or Mxx) ..................145
9.3 Message history ................................................148
9.4 Faults (Code type Lxx or Dxx) .........................148
9.4.1 Deletion of sensors from the memory in the
PCB .....................................................................154
9.5 Failure history ...................................................155
9.6 Parameter and input/output check (mode
tests) ..................................................................156
9.6.1 Control system sequence ....................................159
Contents
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10 Spare parts ..............................................................................................161
10.1 General ..............................................................161
10.2 Spare parts ........................................................162
10.2.1 Boiler body - Tank - Base - Fuel oil burner .........162
10.2.2 Hydraulics ...........................................................165
10.2.3 Expansion vessel 18 litres (Depending on country,
standard delivery or optional) ..............................166
10.2.4 Casing .................................................................167
10.2.5 Control panel .......................................................168
10.2.6 Fuel oil burner (Details) .......................................169
10.2.7 Spare parts list ....................................................170
11 Appendix – Information on the Ecodesign and Energy Labelling
Directives ................................................................................................174
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1 Safety instructions
1.1 Safety instructions
DANGER
This appliance can be used by children aged
from 8 years and above and persons with
reduced physical, sensory or mental capabilities
or lack of experience and knowledge if they have
been given supervision or instruction concerning
use of the appliance in a safe way and
understand the hazards involved. Children shall
not play with the appliance. Cleaning and user
maintenance shall not be made by children
without supervision.
DANGER
If you smell flue gases:
1. Switch the appliance off.
2. Open the windows.
3. Trace possible leaks and seal them
immediately.
WARNING
Depending on the settings of the appliance:
4The temperature of the flue gas conduits
may exceed 60°C.
4The temperature of the radiators may reach
95°C.
4The temperature of the domestic hot water
may reach 80°C (depending on the set point
temperature and activation of the
antilegionella function).
CAUTION
4Before any work, switch off the mains supply
to the appliance.
4Avoid direct contact with the flame viewport.
1. Safety instructions AFC 18 - AFC 24 - AFC 30
609/07/2015 - 300026439-07

1.2 Recommendations
WARNING
4Installation and maintenance of the boiler
must be carried out by a qualified
professional in compliance with prevailing
local and national regulations.
4When carrying out work on the boiler,
always switch off the boiler at the mains and
close the main oil inlet.
4After maintenance or repair work, check all
installations to ensure that there are no
leaks.
CAUTION
The boiler must be installed in a frost-free
environment.
Keep this document close to the place where the
boiler is installed.
Casing components
Only remove the casing for maintenance and repair
operations. Put the casing back in place after
maintenance and repair operations.
Instructions stickers
The instructions and warnings affixed to the appliance
must never be removed or covered and must remain
legible during the entire lifespan of the appliance.
Immediately replace damaged or illegible instructions and
warning stickers.
Modifications
Modifications to the boiler may only be carried out with the
written approval of your supplier.
AFC 18 - AFC 24 - AFC 30 1. Safety instructions
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1.3 Liabilities
1.3.1. Manufacturer’s liability
Our products are manufactured in compliance with the
requirements of the various applicable European
Directives. They are therefore delivered with [ marking
and all relevant documentation.
In the interest of customers, we are continuously
endeavouring to make improvements in product quality.
All the specifications stated in this document are therefore
subject to change without notice.
Our liability as the manufacturer may not be invoked in the
following cases:
4Failure to abide by the instructions on using the
appliance.
4Faulty or insufficient maintenance of the appliance.
4Failure to abide by the instructions on installing the
appliance.
1.3.2. Installer’s liability
The installer is responsible for the installation and
commissioning of the appliance. The installer must
respect the following instructions:
4Read and follow the instructions given in the manuals
provided with the appliance.
4Carry out installation in compliance with the prevailing
legislation and standards.
4Perform the initial start up and carry out any checks
necessary.
4Explain the installation to the user.
4If a maintenance is necessary, warn the user of the
obligation to check the appliance and maintain it in
good working order.
4Give all the instruction manuals to the user.
1. Safety instructions AFC 18 - AFC 24 - AFC 30
809/07/2015 - 300026439-07

2 About this manual
2.1 Symbols used
2.1.1. Symbols used in the manual
In these instructions, various danger levels are employed to draw the
user’s attention to particular information. In so doing, we wish to
safeguard the user’s safety, highlight hazards and guarantee correct
operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of a dangerous situation causing slight physical
injury.
CAUTION
Risk of material damage.
Signals important information.
¼Signals a referral to other instructions or other pages in the
instructions.
2.1.2. Symbols used on the equipment
4Protective earthing
~Alternating current
Before installing and commissioning the device, read
carefully the instruction manuals provided.
Dispose of the used products in an appropriate recovery
and recycling structure.
This appliance must be connected to the protective earth.
D000241-C
AFC 18 - AFC 24 - AFC 30 2. About this manual
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Caution: danger, live parts.
Disconnect the mains power prior to any operations.
2.2 Abbreviations
43CE: Collective conduit for sealed boiler
43WV: 3-way valve
4PCU: Primary Control Unit - PCB for managing burner operation
4PSU: Parameter Storage Unit - Parameter storage for PCBs
PCU and SU
4SCU: Secondary Control Unit - DIEMATIC iSystem control panel
PCB
4SU: Safety Unit - Safety PCB
4DHW: Domestic hot water
4Hi: Lower heating value LHV (Nett)
4Hs: Higher heating value HHV (Gross)
4HL: High Load - DHW tank with plate exchanger
4SL: Standard Load - DHW tank with coil
4SHL: Solar High Load - Solar DHW tank with plate exchanger
4MC: Boiler module
4CFC: Chlorofluorocarbon
2.3 After Sales Service Internet Site
The QR code or flashcode is used to access the internet site
containing the documentation and technical information regarding the
product. The QR code also appears on the appliance’s nameplate.
1 2
M002628-A
2. About this manual AFC 18 - AFC 24 - AFC 30
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3 Technical specifications
3.1 Homologations
3.1.1. Certifications
CE identification no CE : 1312 CN 5691
Type of connection Chimney: B23, B23P
Flue gas outlet: C13(x), C33(x), C93(x)
3.1.2. Oil category
4Standard oil as well as low sulfur content oil (max. viscosity 6 mm²/
s at 20°C)
4Bio-oil max. B10 (max. viscosity 6 mm2/s at 20°C).
-The bio-fuel oil B10 (or Bio 10) is a mixture of fuel oil with low
sulfur content (< 50 mg/kg) supplemented with 5.9 to 10.9 %
FAME* (% in volume).
-The bio-fuel oil B5 (or Bio 5) is a mixture of fuel oil with low sulfur
content (< 50 mg/kg) supplemented with 3 to 5.9 % FAME* (%
in volume).
-FAME* is produced from vegetable oil or processed animal fat.
EMAG: Fatty Acid Methyl Ester (also called EMAG : Ester
Méthylique d’Acide Gras).
3.1.3. Additional Directives
Apart from the legal provisions and Directives, the additional
Directives described in these instructions must also be observed.
For all provisions and Directives referred to in these instructions, it is
agreed that all addenda or subsequent provisions will apply at the
time of installation.
WARNING
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
AFC 18 - AFC 24 - AFC 30 3. Technical specifications
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3.1.4. Factory test
Before leaving the factory, each boiler is set for optimum performance
and tested to check the following items:
4Electrical safety
4Adjustment (CO2)
4Water tightness
4Oil tightness
4Checked the tightness of the combusted gas outlet and air inlet
4Parameter settings.
On commissioning, the installer is responsible for checking
the items mentioned above and, where necessary,
correcting them.
3.2 Technical specifications
3.2.1. Boiler specifications
Test conditions:
4CO2 of 12% at min output and 13% at max output with oil.
4Maximum operating pressure - Primary circuit (heating water):
3 bar (0.3 MPa)
4Maximum operating temperature: 85 °C
4Boiler temperature: Adjustable from 30 to 90 °C
4Safety thermostat: 105 °C
4Min flow temperature: 20°C
4Min. return temperature : 20°C
4Ambient temperature: 20 °C
Boiler AFC 18 AFC 24 AFC 30
Minimum
power
Full
power
Minimum
power
Full
power
Minimum
power
Full
power
Power input (Hi) kW 10.4 17.6 13.9 23.5 17.4 29.4
Nominal output (Pn) at 40/30°C kW 10.7 18.2 14.3 24.3 17.8 30.3
Nominal output (Pn) at 50/30°C kW 10.6 18 14.1 24 17.6 30
Nominal output (Pn) at 80/60°C kW 10 17.1 13.4 22.8 16.7 28.6
(1) These values are pertinent for flexible flue gas evacuation systems with a diameter of 80 mm (rigid ducts). The length of rigid flue gas
evacuation systems is restricted to 18 metres for technical reasons relating to start-up.
(2) 1 mbar = 10 mmWG = 100 Pa
3. Technical specifications AFC 18 - AFC 24 - AFC 30
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Boiler AFC 18 AFC 24 AFC 30
Minimum
power
Full
power
Minimum
power
Full
power
Minimum
power
Full
power
LHV efficiency 100 % Nominal
output (Pn) at
80/60°C
% 96.3 97.2 96.4 97.1 95.9 97.4
Flue gas
temperature
°C <60 <70 <60 <70 <65 <75
100 % Nominal
output (Pn) at
50/30°C
% 101.5 102.1 101.4 102 101.1 101.6
Flue gas
temperature
°C <40 <45 <40 <45 <45 <50
100 % Nominal
output (Pn) at
40/30°C
% 102.9 103.5 102.6 103.2 102.5 103
Flue gas
temperature
°C <40 <45 <40 <45 <45 <50
Annual efficiency
Hi
at 75/60°C % 101.1 100.9 100.7
at 40/30°C % 105.3 105.1 104.6
Pressure available at the flue gas
nozzle (Pn) mbar(1) 0.14 0.22 0.33
Pa 14 22 33
CO2 content (Minimum output - Start-
up output - Maximum output
% 12 - 13 - 13 12 - 13 - 13 12 - 13 - 13
Nominal water
flow rate at Pn
(50/30 °C)
ΔT = 20K m3/h 0.773 1.032 1.291
Stand-by losses ΔT = 30K W 109 109 128
Percentage of
losses through
the walls
compared with
the stand-by
losses
ΔT = 30K % 61 61 63
Loss of load
hydraulic circuit
(Pn)
ΔT = 10K mbar(2) 66.0 117.0 183.0
ΔT = 15K mbar(2) 29.0 52.0 81.0
ΔT = 20K mbar(2) 16.0 29.0 46.0
Electrical power of the boiler only with
no accessories
W 128 272 128 272 128 272
Water content litres 47 47 58
Mass flue gas flow rate (Nominal
output Pn 50/30 °C)
kg per
sec
0.0075 0.01 0.0125
Kg/h 27 36 45
Net weight (without packaging) kg 117 117 135
(1) These values are pertinent for flexible flue gas evacuation systems with a diameter of 80 mm (rigid ducts). The length of rigid flue gas
evacuation systems is restricted to 18 metres for technical reasons relating to start-up.
(2) 1 mbar = 10 mmWG = 100 Pa
AFC 18 - AFC 24 - AFC 30 3. Technical specifications
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3.2.2. Burner specifications
Modulating burner F10E2-5.18 +
AFC 18
F10E2-5.24 +
AFC 24
F10E2-5.30 +
AFC 30
Operation Modulating Modulating Modulating
Nominal output(1) kW 10.4 - 17.6 13.9 - 23.5 17.4 - 29.4
Fuel flow(2) Kg/h 0.9 - 1.5 1.2 - 2.0 1.5 - 2.5
Modulation range % 59 - 100 59 - 100 59 - 100
air nozzle Ø 19 22 26
Nozzle Danfoss (80°S) USG 0.30 0.40 0.50
Modulating oil pump Manufacturer’s pressure margin bar (MPa) 7 - 20
(0.7 - 2.0)
7 - 22
(0.7 - 2.2)
7 - 22
(0.7 - 2.2)
Max depression bar (MPa) 0.35
(0.035)
0.35
(0.035)
0.35
(0.035)
Max permitted pressure on entry bar (MPa) 2
(0.2)
2
(0.2)
2
(0.2)
Max permitted pressure on blocking bar (MPa) 2
(0.2)
2
(0.2)
2
(0.2)
Max pump air flow at 10 bar (1 MPa) l/h 45 45 45
(1) Power at an altitude of 400 m and at a temperature of 20°C. Heating value of fuel oil: LHV = 11,86 kWh/kg
(2) Bio-oil max. B10 (max. viscosity 6 mm2/s at 20°C)
3.2.3. Sensor characteristics
Outside sensor
Temperature in °C -20 -16 -12 -8 -4 0 4 8 12 16 20 24
Resistance in Ω 2392 2088 1811 1562 1342 1149 984 842 720 616 528 454
Outlet sensor circuit B+C
Domestic hot water sensor
System sensor
Flow sensor - Return sensor NTC
Temperature in °C 0 10 20 25 30 40 50 60 70 80 90
Resistance in Ω 32014 19691 12474 10000 8080 5372 3661 2535 1794 1290 941
3. Technical specifications AFC 18 - AFC 24 - AFC 30
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4 Product description
4.1 General description
Floor-standing condensing oil boiler
4Heating only (Optional domestic hot water production in
combination with a DHW tank).
4High efficiency heating.
4Low pollutant emissions.
4Modulating oil burner preassembled and preset.
4Stainless steel heating body.
4Top of the range electronic DIEMATIC iSystem control panel.
4Flue gas discharge via a forced flue or chimney type connection.
4.2 Operating principle
4.2.1. Skeleton Diagrams
nBoiler self-standing - Circuit A
1On/Off switch
2Control panel
3Burner
4Automatic air vent
5Heating flow
6Heating return
7Heating body
8Circulation pump
90.3 MPa safety valve (3 bar)
10 Condensate trap
11 Flue gas discharge
C003130-G
2
1
4
5
6
8
9
7
10
3
11
AFC 18 - AFC 24 - AFC 30 4. Product description
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nBoiler with 3-way valve option - Circuit B (Option
integrable)
1On/Off switch
2Control panel
3Burner
4Automatic air vent
5Heating flow direct circuit
6Heating return direct circuit
7Heating body
8Direct circuit circulating pump
90.3 MPa safety valve (3 bar)
10 Condensate trap
11 Flue gas discharge
12 3-way valve
13 Heating return valve circuit
14 Heating flow valve circuit
15 Heating pump circuit mixing valve
16 Non-return valve
12
C003131-i
4
5
6
3
8
9
7
13
14
15 1110
2
1
16
16
4. Product description AFC 18 - AFC 24 - AFC 30
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nBoiler with 100HL type domestic hot water tank
1On/Off switch
2Control panel
3Burner
4Automatic air vent
5Heating flow
6Heating return
7Heating body
8Circulation pump
90.3 MPa safety valve (3 bar)
10 Condensate trap
11 Flue gas discharge
16 Non-return valve
17 Domestic hot water outlet
18 Plate heat exchanger
19 Domestic hot water pump
20 Domestic hot water tank
21 Primary domestic hot water load pump
22 Domestic cold water inlet
M002429-G
2
1
4
5
6
3
16
8
9
7
10
19
20
18
17
11
16
21
22
AFC 18 - AFC 24 - AFC 30 4. Product description
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nBoiler with 160SL type domestic hot water tank
1On/Off switch
2Control panel
3Burner
4Automatic air vent
5Heating flow
6Heating return
7Non-return valve
8Heating body
9Circulation pump
10 0.3 MPa safety valve (3 bar)
11 Condensate trap
12 Calorifier load pump
13 Flue gas discharge
14 Domestic hot water tank
15 Domestic water coil
16 Manual bleed valve
17 Domestic cold water inlet
18 Domestic hot water outlet
Configuration with a DHW tank also enables the
connection of a circuit with mixing valve.
M002430-F
5
6
2
1
4
3
9
10
8
11
18 17
14
15
16
13712
7
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