THERMOSTAHL MULTIPLEX MCL User manual

MULTIPLEX (MCL)
INSTRUCTION MANUAL
ver. 1.1

THERMOSTAHL SOLAR thanks you for the confidence you show in
its products and assures you that you have made the right choice. The
THERMOSTAHL boiler is a reliable product and is manufactured with
materials of excellent quality by a great factory.
The name THERMOSTAHL means GUARANTEE for the buyer.
THERMOSTAHL provides heating solutions for more than 20
years on the market. The production experience and the expertise gives
us the opportunity to assure you concerning the quality policy we
follow and a large range of products who comply with ISO 9001
standards.
The last generation production technology and the seriousness
made THERMOSTAHL a well known name in the European market.

CONTENT:
STANDARDS—DIRECTIVES—SPECIFICATIONS
3
PREFACE
4
1. DESCRIPTION
5
2. DELIVERY /TRANSPORT
5
3. FEATURES OF THE BOILER MULTIPLEX
9
4. BOILER LOCATION
12
5. CHIMNEY
14
6. BOILER ASSEMBLING
16
7. CONTROL PANEL
16
8. MAINTENANCE GENERAL INSTRUCTIONS
18

STANDARDS—DIRECTIVES—SPECIFICATIONS
THERMOSTAHL boilers are manufactured according to the European Specifications:
Directive „Low Voltage” 73/23/CEE
Directive „Electromagnetic Compatibility” 89/336/CEE
Directive „Gas Devices” 90/396/CEE
Directive „Level of performance” 92/42
Standard EN 303.1
Heating Boilers
Heating boilers with burners and forced draught
Part 1: Terminology –General requirements –Testing and tagging
Standard EN 303.2
Heating Boilers
Heating boilers with burners and forced draught
Part 2: Special requirements for oil burners boilers with mechanical atomisation of fuel.
Standard EN 303-05
Heating Boilers with solid fuels
Standard EN 304
Heating Boilers
Testing Code for heating boilers for individual atomic oil burners
Standard TRD 702
Technical rules for steam boilers
Standard TRD 305-
306
Technical rules for steam boilers
Standard DIN 4791
Electrical conections between burner and boiler
Standard ΕΛΟΤ 763
Central heating boilers
Minimum dimensions of the combustion chamber
Standard ΕΛΟΤ 234
Central heating boilers - Terminology nominal power –technical requirements for heating
- Tagging
Standard ΕΛΟΤ 235
Central heating boilers –Rules of testing
Standard ΕΛΟΤ 4702
Central heating boilers –Rules of construction
The Instalation and set in function must meet the following standards:
• DIN 4755 and 4787 concerning combustion of EL light oil
• DIN 4756 and 4788 concerning gas combustion
• DIN 4705 concerning the calculation of the chimney
• DIN 4751 concerning the safety equipment of the instalation
• DIN 51603 concerning liquid fuels for boilers
• DIN 37116 concerning the electric wiring for the burner
• VDE: Standards acording to EN 60730 concerning automatic systems
• DVGW-G600: regulations for gas instalations
• EN 267: Atomic oil burners of monoblock type
• EN 676: Gas burners with ventilator
• EN 226: Burner conections
• EN 60335-1: Home safety and the afferent electrical applications
• EN 60529: Electrical protection level (cod IP)

PREFACE
This booklet contains useful and important information about the correct operation and
maintenance of the central heating boiler THERMOSTAHL. In addition, important instructions are
given to avoid accidents and serious damage, in order that the installation and the operation of
the boiler will be safe and no problems.
Read these instructions carefully, before you put the boiler into operation.
Familiarize yourself with its operations and controls and follow strictly the instructions
given!
If you have any questions or you need more information about particular points concerning
the THERMOSTAHL boiler, please do not hesitate to contact us. The technical data contained in
this booklet are based on the most recent information and are submitted to eventual reviews,
since new design improvements require it.
Our company reserves the right to change the design or/and the disposition of our products
in any time, without being obliged to adjust in a corresponding manner the previous products, too.

1. DESCRIPTION
The THERMOSTAHL –MULTIPLEX boiler is made of steel with exhaust pipes, with two
ways for the burning gases
It is adequate for burning solid fuels (wood, coal, coke,lignite) and liquid fuel in case of
adapting a burner (light oil - DIN 51603 and gases). The boiler MCL is a new product, designed to
function economically providing a constant heating of houses or industrial areas. It can be
connected to heating systems with central heating, air ovens with hot water.
The boiler is made of steel, the ideal material for thermal oscillations, resistant to dilatation
and constriction. The construction in one piece, without elements and other welded structures,
constitutes and advantage of Multiplex boiler. Moreover this boiler is protected against thermic
shocks.
The MCL boiler is designed in such a way that all the surfaces that come in contact with the
flame to be cooled by water, including the grid where the ash and the remains of burning are. The
two ways of exhaust from the upper side, the great number of exhaust pipes, the great volume of
the fire-box and the great volume of water in the boiler, as much as the simetric construction
determines a high performance.
2. DELIVERY-TRANSPORT
The MULTIPLEX MCL boiler is delivered in a package and accompanied with the following
parts:
• The boiler steel body
• The insulation fitted (it is of mineral fiber of 50 mm thickness and covered in aluminium
film) and well fixed with some plastic strips on the water shell plate, assures a very good thermic
insulation of the boiler.
• The cleaning brush for the smoke (from inside of the smoke pipes) and a little shovel for
cleaning the walls of the burning remains.
• 1 ventilator
• 1 control panel
• 1 thermomanometer
• 1 temperature and presure relief valve
• 1 blow down valve

• 1 draught regulator
• 1 safety collector, which contains 2 safety valves of 3 bars and 1 automatic deaerator
• Inox -steel turbolators
• Metal covers
The loading of the boiler is made by a forklift, a palette-lift or a crane (the boiler is provided
with a suspension hook). Secure the boiler during transport on the transport means, so as not to
slip. Consider seriously that the gravity centre is above the geometric centre. That means there
is need of a special care during transport and unloading the boiler.
At delivery the boiler has a stamp plate made of aluminum on which it is marked the
identification data and the function characteristics:
• Type and serial nr.
• Boiler power(Kcal/h or kW)
• Maximum work pressure
• Year of manufacture
Technical data

Type
HL
Power
Oper.
Pressure
Water
content
Heating
surface
Dimension
of feeding
door
Max
wood
length
Silo
Volume
Motor
Ventilator
kW
Mcal/h
bar
lit
m2
[mm] x
[mm]
mm
lt
kW
m3/h
23
23
20
2
85
3
710 x 380
500
350
0.18
250
35
35
30
2
95
3.4
710 x 380
600
350
0.18
250
47
47
40
2
105
3.5
710 x 380
400
350
0.18
250
58
58
50
2
120
4
730 x 500
500
370
0.25
350
69
69
60
2
140
4.5
710 x 380
600
370
0.25
350
81
81
70
2
140
5
710 x 380
700
370
0.25
350
93
93
80
2
160
5.5
710 x 380
800
370
0.25
500
116
116
100
2
200
6
710 x 380
900
370
0.25
500
140
139
120
2
260
8
710 x 380
800
600
0.37
500
160
162
140
2
290
9
370 x 625
900
600
0.37
780
190
186
160
2
330
10
370 x 625
1000
600
0.37
780
210
209
180
2
360
11
370 x 625
1150
600
0.37
900
230
233
200
2
420
13.5
370 x 625
1400
600
0.37
900
260
256
220
2
450
14
370 x 625
1400
600
0.37
900
290
291
250
3
620
17
370 x 625
1100
950
0.37
1400
350
349
300
3
720
21
860 x 490
1400
950
0.37
1400
1400
400
407
350
3
820
25
860 x 490
1600
950
0.37
1400
460
465
400
3
920
29
860 x 490
1850
950
0.37
1400
580
581
500
3
1020
33
860 x 490
2160
950
0.37
2600
700
698
600
3
890
31
860 x 490
1300
950
0.37
2600
750
756
650
3
1100
42
1230x520
1600
950
0.37
2600
800
814
700
3
1300
51
1230x520
1800
950
0.37
3800
870
872
750
3
1450
59
1230x520
2050
950
0.37
3800
930
930
800
3
1600
64
1230x520
2200
950
0.37
3800
1050
1046
900
3
1800
68
1230x520
2450
950
0.37
3800
1160
1162
1000
3
2000
72
1230x520
2650
950
0.37
3800
1400
1400
1200
3
3500
73
1730x740
2200
1900
00
0.37
3800
1600
1620
1400
3
3700
89
1730x740
2700
1900
0.37
3800

Dimensions
Type
A
B
B1
C
D
D1
E
F
G
H
I
K
Ø1
Ø2
T1
T2-
T3
HL
[mm]
[inch]
23
545
1200
1290
920
490
1150
550
110
1300
930
600
570
175
106
1
¼
½
35
545
1200
1290
1020
490
1150
550
110
1300
930
700
670
175
106
1
¼
½
47
545
1200
1290
850
490
1150
550
110
1300
930
500
480
175
106
1
¼
½
58
670
1280
1550
950
620
1400
630
120
1350
950
600
580
195
106
1
½
½
69
670
1280
1550
1050
620
1400
630
120
1350
950
700
680
195
106
1
½
½
81
670
1280
1550
1150
620
1400
630
120
1350
950
800
780
245
106
1
½
½
93
670
1280
1550
1250
620
1400
630
120
1350
950
900
880
245
106
1
½
½
116
670
1280
1550
1350
620
1400
630
120
1350
950
1000
980
245
106
2
½
140
910
1600
1850
1300
810
1730
610
100
1350
950
900
880
295
106
2
½
160
910
1600
1850
1400
810
1730
610
100
1570
930
1000
980
295
130
2
½
190
910
1600
1850
1500
810
1730
610
100
1570
930
1100
1080
295
130
2
½
210
910
1600
1850
1650
810
1730
610
100
1570
930
1250
1230
295
130
2
½
½
230
910
1600
1850
1900
810
1730
610
100
1570
930
1500
1480
295
130
2
½
½
260
910
1600
1850
1900
810
1730
610
100
1570
930
1500
1480
295
130
2
½
½
290
1100
2000
2000
1840
1000
2250
830
150
1570
930
1250
1210
345
130
2
½
½
350
1100
2000
2000
2090
1000
2250
830
150
2160
1085
1500
1460
345
185
3
1 ¼
400
1100
2000
2000
2340
1000
2250
830
150
2160
1085
1750
1710
395
185
3
1 ¼
460
1100
2000
2000
2590
1000
2250
830
150
2160
1085
2000
1960
395
185
4
1 ¼
580
1100
2000
2050
2840
1000
2250
830
150
2160
1085
1500
2150
395
185
4
1 ¼
700
1540
2400
2050
2330
1440
2590
980
210
2530
1785
1750
1420
490
265
4
1 ¼
750
1540
2400
2050
2580
1440
2590
980
210
2530
1785
1750
1650
490
265
5
1 ¼
800
1540
2400
2050
2830
1440
2590
980
210
2530
1785
2000
1900
490
265
5
1 ¼
870
1540
2400
2050
3080
1440
2590
980
210
2530
1785
2000
2150
490
265
5
1 ¼
930
1540
2400
2050
3330
1440
2590
980
210
2530
1785
2500
2400
490
265
6
1 ¼
1050
1540
2400
2050
3580
1440
2590
980
210
2530
1785
2500
2650
490
265
6
1 ¼
1160
1540
2400
2400
3830
1440
2590
980
210
2530
1785
2500
2850
490
265
6
1 ¼
1400
2100
2870
2150
3420
2000
4030
1180
335
3090
1950
2500
2390
590
345
6
1 ¼
1600
2100
2870
2150
3920
2000
4030
1180
335
3090
1950
3000
2890
590
345
6
1 ¼

3. FEATURES OF THE MULTIPLEX BOILER
3.1 MANUFACTURE MATERIALS
Steel OLT-37.2, STAS 500/2-80~S235JR SR EN 10025/90+AI/93
For fire plates and fire box : K 4120.2b STAS 2883/2-88~P265GH SR EN 10028-2/96
Fire tubes OLT 35KII STAS 8184-87~P 245 GH EN 10216-2/2000
Metal covers of 1 mm thickness (iron plate DKP) electrostatic painted at 200oC.
Insulation with glass fiber of 50 mm thickness with aluminium lining
Insulation of the door with refractory cement of the best quality.
3.2 ADVANTAGES
- Steel offers numerous advantages, which are of a particular importance
for the modern heating technique. Among these we mention the special
mechanical quality, remarkable formation possibilities, smooth surfaces and low
weight.
- a great advantage of THERMOSTAHL boilers is the great water
capacity, which allows the precise adjustment of its temperature and no
exceptional requirements concerning the water outflow. The interior energy of the
boiler contributes considerably to the protection of the enviroment, because the
great volume of water increases the storage capacity of energy, and reducing the
number of ignition starts of the burner (in case of adapting of a burner)
- Reliability .
- Energy savings.
- Enviromental friendly.
- Modern Design.
- Solid Construcţion
- Easy maintenance
- Big fire box.
- Large heating surface.
- High performance ≥ 78 ÷ 82%.
- Uniformal thermal charge.
- Low outlet of burned gases (180 -220oC).
- Long life without problems.
- Exceptional draught.
- High water volume.
- Possibility of working also with gas or liquid fuels
3.3 RUNING ORDER
It is based on the radiation generated by the flame in the combustion chamber and the
heat transmision by transfer and conductibility through the fire tubes (exhaust pipes).
The runing of the MULTIPLEX boilers is based on the most simple method of burning,
with free evacuation of the exhausts through the chimney. The burning proces takes place in
the combustion chamber, built in such a way that there may fit woods of long dimensions and
in quantities capable to maintain the operation for several hours. During the burning process
the flame develops twards all the points and heats the boiler walls who are cooled by water.
Later on, the exhausts are led through the smoke pipes from which they go to the
smoke box. The remains of the burning fall in the lower section of the boiler where there is an
ash tray specially designed for that.

The grate with water circulation is made of a number of pipes who holdup the ash heat.
The space from the grate alows the ash to fall in the lower side of the boiler in the ash tray.
The burning control is made with the ventilator’s help which is comanded by a control
panel and a mechanism which works as a thermostat. When the water is still cold, it allows
the air enter through the draught door. As the water heats up in the boiler, the sensor
expands and closes the draught door. In this way the flame control is achieved by reducing
the burning air.
The adjustment of the secondary burning air is made by the manual draught cupboard .
The MULTIPLEX boiler series can operarte also with liquid fuel (black oil, oil, residue
oils) or gases as an alternative solution. For this purpose there is the posibility of mounting at
the boiler’s door of a special flange for adapting a burner.
In case that the boiler works mostly with liquid or gas fuels, a delay of the exhausts
must be made by using of special turbiolators or by mounting a drop shutter at the chimney at
the „closed” position.
For a better burning the boiler is provided with a rear ventilator, fastened under the
smoke box. The ventilator’s flange is conected with a slited pipe that crosses the rear plate
and the combustion chamber and which has an optimal length to ensure a better air intake.
The ventilator is controled by the control panel, and the conection of the ventilator is made by
simply conecting the conecting wires. The ventilator is fed with 220 V and has powers
between 60 and 200 W, ,blowing air between 450 and 1050 m3/h, depending on the boiler’s
power.
For a good function of the Multiplex boilers and a longer life period, it is strictly
recomended the usage of dry wood with a humidity of maximum 20-25%. The boiler
powers prezented in this document are calculated based on this kind of wood. It is known that
the wood caloric power decreases significantly with the increase of the humidity in conformity
with the graph below.
Green wood has a low caloric power, it doesn’t burn well, produecs a lot of smoke and
reduces substantially the life period of the boiler and of the chimney. Also the power
decreases with 50% and the wood consumption is doubled. The fire wood must be
chopped from the logs in even pieces ,stored in a covered hall and dried at least one
year long before using it. In the boiler there will be used wood with the specific
maximum length for every boiler type mentioned in the technical book.
You may burn timber offal of great dimensions combined with fire wood. It is
recommended that that these offal’s should not exceed 15% from the combustion chamber
volume.

It is forbidden to use scraps from rubber, plastic materials etc as they produce
pollution and deteriorate the boiler.
There won’t be used wood scraps that were chemically treated.
It can be used higher caloric power fuels than wood, eg. Coal (anthracite, brown
coal, pit coal) or coke but Thermostahl Company must be announced before about
this, because there must be made some adjustments to the combustion chamber.
Burning coal with low caloric power (brown coal, lignite, peat) results in decreasing of
the thermal power of the boiler.
In the MCL boilers it is not recommended to burn powder coal or coal under the
granulation of 20 mm.
3.4 CONSTRUCŢON
3.4.1 The boiler body
The MULTIPLEX boiler is horizontal, with smoke pipes.
The main body of the boiler is made of killed steel plates St 37.2 STAS 500/2-
80~S235 JR SR EN 10025/90 hot rolled, conform DIN 17100. The cutting is made with a
high technology LASER machine. The THERMOSTAHL boiler is designed in such a way
that all its parts in touch with flames to be cooled by water. The profile, number and
length of the smoke pipes are designed specially for a maximal exploitation of the
exhausts.
The welding are made conform the standards 288-1 şi 288-3 şi DIN 50120, 50121-
50145, SR EN 1011.1/2001, by using electric welding machines (MIG-MAG), for realizing
a penetration of the steel plate on all its thickness. The welding quality is checked in
conformity with DIN 8563. The welding process is conform 131-ISO 4063.
The smoke box is screwed and has a special door for cleaning, isolated with
asbestos plate, who also works as a safety door (preventing explosion). The smoke box
pipe is wide enough to ensure the smoke evacuation resulted after the burning process. If
the drought is very strong, the evacuation speed of the smoke can be slowed down by
adjusting a butterfly dumper who is fitted above the pipe of the chimney. The water circuit
is opposed the exhausts.
Every boiler is separately tested at a hydraulic pressure of 4-5 bar (according to the
type) for checking the resistance and waterproofing. A strong insulation covers all the
water tank.

The access door towards the smoke pipes and the loading door are thermal-insulating lined.
They are also fitted with glass fiber braid for a very good insulation aganist the noxious from the
combustion chamber. Both doors have eye slits for an optical control of the burning process.
The access door of the combustion chamber has a flange adapted for fitting a burner, in
case that is desired. Otherwise it is compulsory that the flange is well fitted to avoid the exit of
burning gases from the combustion chamber.
4. BOILER INSTALLATION
4.1 Boiler installation:
Boilers can be installed in their own rooms located in the basement, ground floor or uper floors of
the industrial buildings of category C, D and E of fire danger, buildings for storage of nonflamable
materials and civil buildings, conform the valid legislation.
ATENTION! It is not admitted to locate the boiler room having a common wall or just
under rooms filled with people who cannot evacuate by themselves (hospitals, shops,
schools, kindergartens or similar) or under the ways of evacuation of these .
The boiler room has to be separated by the adjacent rooms with walls or ceilings with
suitable mechanical resistance, fireproof doors and without woods for windows.
The boilers having the caloric flow of 0,1 Gcal/h can be located in rooms having other
destinations, in which it will be arranged an appropriate space for locating that boilers. The boiler
location has to be made only based on a project checked by an authorized inspector, or by an
economic agent authorized in this aspect by ISCIR INSPECT or a similar authority.
For the heating centrals equipped with one or more boilers whose power exceeds 300 kW,
the installation project will be aproved from the point of view of the thermomechanic sketch by an
economic agent authorized by ISCIR INSPECT or a similar authority.
4.2 Room dimensions:
It is recommended that the installation of the boiler in the room should be made in such a
way that there is enough space for caring on of maintenance and cleaning works.
The boiler should be placed on horizontal plan and easily accessible from all sides.
The distance between the boiler and the front wall:
For boilers up to 100 KW –at least 1,5 m.
For boilers bigger than 100 KW –at least 2 m.
The distance between the boiler and the rear wall:
The adeqvate distance is the one that allows an easy acces for checking and maintenance.
The distance between the boiler and the side walls:
For boilers up to 300 KW –at least 0,6 m.
For boilers bigger than 300KW –at least 1 m.
Boiler’s room height

For boilers up to 70 KW –at least 2 m
For boilers bigger than 70 KW –at least 2,4 m
For boilers bigger than 230 KW –at least 3 m
For boilers bigger than 400 KW –at least 3,5 m.
Conform PT C 9-2003 the access in the boiler room of persons other than the authorised
personal in boiler exploitation and of the auxilliar equipment is prohibited.
The inspectors from ISCIR-INSPECT IT or likewise authorities, as much as the authorised
personal for technical surveilance may enter anytime in the boiler room on the basis of acces
card or special control documents.
!It is prohibited to give another destination to the boiler room, except the one
established in the project.
The acces and service spaces of various places in the boiler room, as much as the exits
ways to the doors should be always free.
In the boilers room of a greater nominal power than 300 KW, it should be a telephone or
other means of comunication with the exterior, which will avoid the useless walking of the boiler
operators.
In a vizible place of the boilers room, there would be listed the work instructions that will
consider the speciffic of the boilers in the room. There will be also listed internal instructions
concerning the operators task and the way of operating the boiler.
Observations:
In the boiler’s room :
a. must be clean;
b. the flamable objects should be removed;
c. must have a sewerage system;
d. must be enough ventilation;
e. the fuel reservoirs will be placed in separate spaces outside the
boiler’s room and be well ventilated. If they are placed in the boiler’s room they
should be separated by this one by a separating wall, in conformity with the valid
safety rules;
f. there, must exist a powder fire estinguisher next to the burner and a
hand fire estinguisher next to the door;
g. the chimney must be safe and with an adeqvate section;
h. it is advisable that the fuel tank (if it’s the case) to be installed in a
place away from sun rays, rain or fire sources ;
i. in case there is an alarm system, a smoke detector must be installed
on the ceiling of the boiler room;
j. the door must be metalic, without louvers or glass and it must open
twards the outside;
! It is forbiden to install the boiler in spaces with a lot of dust, dangerous gases or in
places with great humidity like the bathrooms.

5. THE CHIMNEY
The following will be respected:
Conform DIN 4705 and DIN 18160, the evacuation of exhausts in the atmosphere as much as the
reducing of the temperature of those on the way must be made in such a way that the
condensation and its consequences be avoided.
The correct running of the chimney is very important for the boiler running.
• Chimney tightness: no cool air is allowed to enter by cracks or openings, because in this case
the burning gases are cooled and produce condensation. There is the danger that the condensed
gases may enter the boiler and produce corosion. Likewise it must be avoided the entering of rain
water in the chimney .
• The evacuation of the exhausts should be smooth, with no obstacles –foreign parts (bricks,
bird nests, woods, grass, etc).
• The cleaning of the chimney esspecially in the exit points from the boiler and the elbows,
where the exhaust gases change their course. A clean chimney means a correct draught.
• The insulation of the chimney is compulsory.
• An uptight chimney can make many problems to the boiler, for example filling, a lot of
smoke, noises, bad running of the burner, etc. Another big problem is the forming of an air current
and vortexes that do not allow the easy evacuation of exhaust gases .
• The chimney must have an increased height twards the building.
• The material from which the chimney is built doesn’t have to be influenced by the exhaust
gases.
For all the above reasons it is required a periodic inspection of the chimney especially at the
beginning of the winter time.
ATTENTION:
A very little chimney gets clogged quickly. A very big chimney cools to much the exhaust gases
and produces condensation. So the chimney doesn’t have to be too big or too small.

At the roofs with escarpment of up to 20%, the height of the chimney end twards the roof
top, has to be of minimum 1000 mm.
If there are elements with increased height towards the roof (attics, antifire walls), the
chimney must surpass their height with at least 1000 mm, exception is made fot the chimneys
situated at a smaller distance than 3000 mm of these elements, in which case the surpass can be
reduced to 500 mm.
At the roofs with escarpment >20%, the height of the chimney depends on the nature of the
casing and the position of the chimneys towards the foxhole top, as it follows:
-The chimneys placed up to 1500 mm of the top must surpass the top of the roof with 500
mm for inflammable casings and with 1000 mm for flammable casings.
-The chimneys placed at greater distances have to have the evacuating opening at the
height of at least 1000 mm towards the casing (measured on the slope normal line) and to
surpass the plan that passes the foxhole top and has an escarpment of 100 with the horizontal.
The reasons for malfunction of solid fuels boilers:
1) Small active height of the chimney.
2) Untight masonry of the chimney.
3) Too narow masonry of the chimney.
4) The existence of foreign parts or narowing of the chimney section.
5) Untight drop shutter.
6) Draught regulator wrongly adjusted.
7) The foxhole is in the chimney.
8) Untight joints to the foxhole .
9) Untight cleaning bay .
10) Most of the foxhole is without insulation, too little escarpment .
11) Untight joints(flanges), deteriorated insulations.
12) Reduced draught because of carbon clogged on the flame tubes.
13) Carbon settlement.
14) Untight cleaning lid .
15) Untight doors and body.
16) Draught regulator wrongly adjusted or broken.
17) The auxilliary air bay for burning.
18) The ash tray full.
19) The water cooled grid obturated with ash.
20) Reduced ventilation or closed in the heating space.
21) The cleaning door of the chimney is untight.
22) Very high temperature of the burning gases (very strong draught of the chimney or
boiler heated at the limits for covering the needs of heating).
23) Very low temperature of the burning gases (obvious function under the parameters of
the boiler, the boiler is too big for the heating needs).
24) Burning of wet fuel with low caloric power.

6. BOILER ASSEMBLING
Metal covers assembling:
Metal covers assembling on the boiler’s body is done fast and easy paying respect to the
following instructions.
The assembling order is:
a. The side covers are assembled first.
b. The upper covers are assembled second.
c. Screw in the upper side of the side covers the front and rear covers with 2 screws
each. d. The door covers are assembled by screwing first the double ended bolts for conecting
the covers with the doors in the threaded bushings that are welded inside the boiler’s doors.
Note: For the MCL 40 - MCL 70 boilers we have only one cover for the sides. For the other boiler
series we have two or three covers for the sides.
7. THE CONTROL PANEL
Digital Electronic Controller PWC-1000
Operating instructions
Button A1 –A2 : They are used to increase and decrease the desired maximum water
temperature.
Button A3 : It is used for entering and exiting from the menu. For entering into the menu short
pressing is required, and for exiting long pressing.
Button A4 : It is used to turn on and off the controller (long pressing). It is also used for starting
and stopping the ignition process (short pressing).
After entering the menu buttons A1 and A2 are used to change the value of the selected
parameter, and buttons A3 and A4 are used to change the parameter we want to alter.

Settings
01
TEMP.WATER
Maximum water temperature.
02
TEMP.EXHAUST
Maximum exhaust temperature.
03
TEMP.CIRCULATOR
Water temperature that the circulator pump starts to operate.
04
TEMP.Bypass
Water temperature that the bypass valve starts to operate.
05
FAN AIR MAX
Maximum power amount of the fan (%) in the full burning process.
06
DT WATER
Temperature difference below the maximum water temperature that the fan
power starts to decrease.
07
DT EXHAUST
Temperature difference below the maximum exhaust temperature that the
fan power starts to decrease.
08
IGNITION TIME
Maximum time of the process “ignition”. Fan power is determined only by the
“ignition air” setting at this process.
09
IGNITION AIR
Power amount of the fan (%) in the ignition process.
10
Off TIME
Time that exhaust temperature must be below the “11-Off exhaust” so that
the controller is set into “end of fuel” process.
11
Off EXHAUST
Exhaust temperature value that determines when the fuel has ended.
12
CONS.PERIOD
Repeating time of the process “flame conservation”. In this process the fan
power works at “09-ignition air” so that the flame is conserved.
13
CONS.DURATION
Duration of the process “flame conservation”.

8. GENERAL MAINTENANCE INSTRUCTIONS
In conformity with DIN 4575 and 4756 regulations the periodic cleaning (even daily if it’s
necessary) of the boiler, must be performed by a qualified personnel to ensure an economic and
ecologic running.
The boiler needs a maintenance operation to be done at the end of the winter season. Special
care should be given to cleaning of the smoke tubes, to avoid the laying of carbon which can
damage them.
If a correct maintenance is not performed, then problems will arise such as:
Performance dropping
Increased fuel consumption
Increasing temperature of exhausts
Carbon layers
Reduced draught
Maintenance instructions
Disassemble the burner (if necessary).
Open the doors.
Disassemble the turbulators from the fire tubes and clean them with a special brush.
Clean the walls of the combustion chamber with a special crowbar.
Empty the ash tray.
Check the insulation bands and the glass fiber braids and replace them in case of
deterioration.
Check the refractory material on the door.
The safety valves and the temperature/pressure relief valve must be checked and
replaced in case of malfunction.
Check the water connections.
Check the draught regulator .
Check the filter from the water supply.
Check the eye slit thermoresistant glass.