Tilia Maxi 80 - 200 Assembly instructions

16150507 02-01
Maxi 80 - 200
CAST-IRON BOILERS
TECHNICAL MANUAL
Installation, operating and maintenance instructions
EKSKLUZIVNI UVOZNIK IN ZASTOPNIK:
TILIA d.o.o., Ljubljanska cesta 89, 8000 Novo mesto;
tel: [phone]; fax: [phone]; e-mail: [e-mail]; www.tilia.si

ATTENTION!
Theboilersinthisseries must keep
within the limits they are designed
for.
Any other use is to be considered
as improper and consequently
dangerous.
This limits are indicated on the
manufacturer´sdatadecal.
- Boiler type.
- Serialnumber.
- Maxboilerpower.
- Maxboilerpressure.
- Maxworkingtemperature.
- Supplyvoltage.
• Thismanualisanintegraland
esentialpartofdeliveryof the
boilerand must be given to the
User.
• Iftheboileristransferredorsold
tootherUsers (change of destina-
tionorrelocation)makesurethat
theInstallation,Operatingand
MaintenanceManualisalso
transferred so that it can be
consulted by the installer, the
maintenancetechnicianandby
thenew owner.
• Readthe warnings and
procedureswith care before
installing,fillingorstarting-upthe
systemandand before any
maintenance.The manual gives
importantinformation regarding
system safety and protction of
DEFINITIONS
The terms ATTENTION, WARNING
and NOTE have been used when
draving up the manual to underling
instructions or information
that are considered to be critical
or unusual.
The conditions that dictate use of
these terms are defined as follows:
ATTENTION!
Information or procedures which
can cause danger situations if they
are not complied with.
WARNING
Information or procedures which can
cause damage to the machine or to its
components if they are not complied
with.
NOTE
Information or procedures which can
simplifyorfacilitatemaintenance
procedures or important parts of the
text that need to be emphasised.
WARNINGS orREQUIREMENTS
This installation, Operating and
Maintenancemanualisapplicable for
all series
CTCMaxicast-ironboilersdesig-
ned to produce hot water (at tempe-
ratures below the boiling point and
atmospheric pressure) in central
heating systems.
Their operating pressure are up to 5
bar(testpressure: 7.5 bar).
Thermalpower ranges gofrom80kW
to 200 kW.
1
persons.
• Installation must be done in
accordancewithCurrent Law,
followingtheinstructionsgiven in
this manual.
Installationmustbeperformedby
professionallyqualified and
certifiedpersons.
• Neverpermittheappliance to be
usedoroperatedbyinexpert
persons.
Erroneous installation or in-
adequate use and maintenance
of the boiler can cause harm to
persons or property for which the
manufacturer declines all
responsibility.

DEFINITIONS................................................1
1 TECHNICAL DATA
1.1 Generalcharacteristics..................................................4
1.2 Deliverycontents............................................................ 4
1.3 Dimensions......................................................................5
1.4 Technicaldata................................................................. 6
2 ASSEMBLY
2.1 Boilerassembly.............................................................. 7
2.2 Burnerinstallation........................................................... 7
2.3 Insulationandshellinstallation...................................... 8,9
3 INSTALLATION
3.1 Plumbingsystem............................................................ 10
3.2 Pipelinesystemstandards............................................ 11
3.3 Heatingwater deliveryandreturnpipelines................ 11
3.4 Safety,controlandadjustmentdevices........................11
3.5 Watercharacteristics..................................................... 11
3.6 Electricalconnections,system......................................12
3.7 Wiringdiagram............................................................... 13
3.8 Heatingplant................................................................... 14
3.9 Connectiontothesmokestack..................................... 14,15
4 OPERATION
4.1 Controlpanel...................................................................16
5 SYSTEM START-UP, OPERATION
AND MAINTENANCE
5.1 Fillingtheheatingsystem.............................................. 17
5.2 Firststart-upandpreliminarychecks........................... 17
5.3 Dataforcheckingcombustion...................................... 18
5.4 Generalboileroperating regulations............................18
5.5 Safetyregulationsandperiodicchecks.......................19
5.6 Generalmaintenancestandards.................................. 20
5.7 Inspectionandmaintenance......................................... 20
5.8 Checkinghatchwayseal................................................ 20
3
TABLE OF CONTENTS

1. TECHNICAL DATA
1.1GENERALTECHNICAL
CHARACTERISTICS
CTC Maxicast-ironboilersarehigh
efficiency(superiorto 90%)generators
of hot water up to 90°C for central
heating. Thehighefficiencyofthistype
of system also achieves extremely
LOWNOxemissiontotheatmosphere.
WhenLOW-NOxburnersareinstalled
this boiler meets the most restrictive
Europeanairpollution Standards.
Theboilerbody(madeofmodularcast-
iron wet-chamber components)
functions in depression for the entire
rangeofadmissiblepower ratings.
Theboilerbodyiscomposedof:
a. Frontcomponentwithinspection
hatchwaysandsupportforthe
blown-airburner.
b. Intermediateelementswith
shapesdesignedfor high thermal
exchangeeven when operatingat
LOWtemperatures.
Thenumberof elements can vary
dependingonthe thermal
capacity of the boiler.
c. End element that connects to the
deliveryand return pipelinesand
to the smoke exhaust system.
4
All elements are connected together
by twin-taper connection nipples.
Structural rigidity is achieved by tie-
rods,which alsofunctiontocarryload-
bearing parts of the shell. Boiler
insulation is obtained by a thick layer
of glass wool applied directly to the
boilerbody and therearelement. The
shell, made of stove enamelled steel
sheet, is quite simple, efficient and
modular and permits access to
inspection and maintenance
hatchways by simply removing
(withoutanytool) the front panel. The
shell also covers and protects the
controlboardwhichis furnishedtested
andalready wired.
Specific boiler data are given on the
data-decalapplied to thebacksection
of the right side.
1.2DELIVERY CONTENTS
Delivery consists of 6 packages:
1 - Palletwithboilercomponents
.
2 - Box with putty for seals between
modularcomponentsurfaces.
Puttyapplicatorandtwin-taper
connectionnipples.
3 - Tie-rods forassembly.
4 - Boxcontainingthefront
hatchways,thehinge for the
lowerdoor,front plugs,
connectionflangesandseals,
sheathforcontrolinstrument
probesand baffles.
5 - Box containing the shell,
insulation,spacersforpositioning
the shell, installation screws,
nuts and washers, technical and
guaranteedocuments.
6 - Box containing the control panel,
complete
7 - Assembly tools for boiler body
assembly(optionalequipment)

1. TECHNICAL DATA
5
1.3DIMENSIONS
1. Heatingflow
2. Heatingreturn
3. Fluegasconnection
4. Drain
5. Sensortube

6
1. TECHNICAL DATA
BOILER CTC Maxi80100120140160180200
Numberof elements 6 7 8 9 10 11 12
Maxoutputpower kW 80 100 120 140 160 180 200
Maxinputpower kW 88,9 111,1 133,3 155,6 177,8 200,0 222
Fuel Gas/Fuel-oil
Workingefficiency % 90,0 90,0 90,2 90,4 90,4 90,5 90,6
Efficiency at 30% capacity % 88 88 88 88 88 88 88
Loss at the smokestack % 8,4 8,2 8,4 8,4 8,2 8,2 8,2
Smoketemperature* °C 205 200 202 202 200 200 200
Gas smoke flow rate kg/h 137 171 206 240 274 309 342
Fuel oil smoke flow rate kg/h 131 165 198 231 264 297 330
Smoke load losses mbar 0,10 0,15 0,28 0,30 0,40 0,55 0,66
Dimensionsofthecombustionchamber:
Length mm 565 686 807 928 1049 1170 1291
Diameter mm 380 380 380 380 380 380 380
Volumeof the combustion chamber dm372 86 101 116 131 145 159
Smokestack connection mm 200 200 200 200 200 200 200
Water contents l 66,0 76,5 87,0 97,5 108,0 118,5 129,0
Water side load loss Dt = 15°C mbar 9 12 18 28 35 45 60
Deliveryconnection “G 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½”
Returnconnection “G 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½”
Boiler depth P mm 885 1005 1130 1250 1370 1495 1620
Weightof empty boiler kg 410 465 520 575 630 685 740
* with CO2% = 13 for Fuel Oil and 10 for Gas
Max.operatingpressure bar 5
Testpressure bar 7,5
Controlthermostats °C 21-85
Safetythermostat °C 110
Code PIN CE 0063/ ...
1.4 TECHNICALDATA

2. ASSEMBLY
7
2.1 BOILERASSEMBLY
(see the instruction manual
for boiler body assembly)
– Theboiler mustbeinstalled so that
distancesfromboilerroomwalls
comply with the minimum
distances requiredbybuilding
codes. Distances, in any case,
mustguaranteeeasyaccess tothe
boilerfor maintenance
– Thesupportsurface for the boiler
must be horizontal.
– Pipelines that go to boiler
connectionsmustbesupported
andplacedsothattheydonotbring
dangerousforcestobearonthe
connectionsthemselves.
– Connections for the two hoses to
theburnermustbe fastened in the
mostconvenientposition for freely
openingtheburner support plate.
– Ventilationmustcorrectlyfurnishair
totheburner. Incoming fresh air
frombelow andevacuationof stale
air from the top part of the boiler
room.
FIG. 2 - Burner installation diagram
2.2 BURNERINSTALLATION
1- An installation counter flange for
the burner is installed on the
lower front door , which has to be
adaptedtothe tube andtothebur-
nerflange (figure2).
2-Iftheburner flange does not fit this
flangethen an adaptationflange
and ceramic fibre gasket must be
installed.
3-Thetubediameter can be different
fromthe diameter oftheholein the
insulation. If necessary, the hole
inthe insulation can be enlarged.
4 -Use a cutter to remove excess
insulation. Insulation is made of
ceramic fibres and can be cut by
normal cutting tools.
5 -The maximum hole diameter that
is admissible is 130/150 mm.
ATTENTION!
1 -The seat of the tube must be as
precise as possible to prevent
backfires or backflow of heat
which could scorch the burner
connection plate.
2 - If hole enlargement is
impreciseor if the hole (for easy
installation) is oversized then
the space between tube and
insulation or rough-cut edges
must be carefully and totally fil-
led with ceramic fibre after the
burner is installed.
3 -If an adaptation flange is also
installed, make sure that smoke
seals are installed on both
couplingsurfaces.
4 - Lubricate burneranchor screws
with graphite to make
subsequent removal easier.

2. ASSEMBLY
8
Legend
51- 57 Right side with from 6 to 12 elements 87 M10 threaded17x95 hexspacer
61-67 Left side with from 6 to 12 elements 88 D10washer
71-77 Cover with from 6 to 12 elements 89 M10 x 20 hex head screw
81 Centralpanel 90 M10 stud bolts
82 Top frontbracket 91-97 6 to 12 elements of mineral wool
83 Sheet metal strip 101 Rear sectionmineral wool
84 Toprear panel 102 M12 hex nut
85 Bottomrearpanel 103 D12washer
86 Spacer L=80 mm 3/8 tube 110 Control panelcomplete
2.3 INSULATION AND SHELL INSTALLATION (fig. 3)
NOTE
1 -This section describes,
insequence,theoperations
requiredforinstalling the
insulating mattress and the shell.
2 -Just a few easy to find tools are
required to install the shell.
Makesure tools areofgood quality
and are not damaged or worn.
3-The component numbersgivenin
thefigureareindicatedin order of
assembly and are used for the
entiredescription.
4-Performinstallationprocedures in
theorderthatisgiven.
Check,beforemovingontoanother
phase,that thepreviousphase has
been totally and correctly
performed.
FIG. 3 – Shell components

6. Carefullyunrollthecapillarytubes
forthetemperaturesensors and
threadthemintothesensorsheath
ontherearelement.
7. Remove the instrument control
panelcoverandmake electrical
connections as illustrated in fig. 4.
ATTENTION!
1. Run the control panel, circula-
tion pump and (if present) room
thermostat connection supply
cables through the cable glands
on the rear part of the side panel
and on the wall of the bracket
that also acts as the rear of the
instrument casing.
2. Connect the ground wire to the
connection terminal board( ).
3. Carefully check the ground
connection.This connection is
obligatory and must meet CEI
standards and requirements.
The manufacturer will not be
responsible for damage to per-
sons or property caused by fail-
ure to comply with this basic
requirement.
SHELLINSTALLATION
1. Install the bracket (82), placing it
on the upper tie-rods in the front
section,fasteningitwithnutsand
washers(102.103).
Subsequently install the six
spacers (86) (4 on the rear side
and 2 on the top front side).
2. Centretheinsulatingmattress
(91÷97)inplaceontheboilerbody,
fastening it with the strap.
3. Installtheright(51÷57)and left
(61÷67)sidepanels, making sure
theirconnection slotsmeshonthe
extensions from the tie rods.
Also, make sure that the spacers
(86)areinside the panels. Fasten
thesides to thebracket(82) using
self-tappingscrews.
4. Install the 2 M10 stud bolts (90),
positioning them in the two holes
nearthelower hub. Screw the
twothreadedhex spacers (87) on
these.Nowinstall the lower sheet
metalstrip (83) andfastenit to the
sides using self-tapping screws
andin thecentreby lettingthehex
headscrews(89)rubupagainst
thethreadedspacers.
5. Insertthe control panel(110)inits
seats and fasten it to the side
panelsusingself-tapping screws.
2. ASSEMBLY
9
8. Reinstall the top panel on the
controlpanel cover.
9. Installthetop cover (71÷77),
centring the holes on the
retainingpins.
10.Fasten the sides to the tie-rods
by tightening the nuts and
washers (installed at phase 3.
above).Donot use excessive
force.
11.Installthe front panel (81), cent-
ring the retaining pins with the
clamps.
12.Fully tighten the central screws
on the lower sheet metal strip.
(installedatphase4.above).
IMPORTANT
The data-decal must be applied
once the shell has been installed.
The data-decal, furnished with the
boilercasing, is installedon the top
rear corner of the right side panel.

3. INSTALLATION
3.1 PLUMBING SYSTEM
Important
Installation must be performedby technically qualified personnel.
10
Applicableinstallationstandardsare
for boilers in heating systems that
usepressurisedhotwaterwith
temperaturesbelowtheboiling point
atatmosphericpressure.
WARNING
CTC Maxi boilers have a
maximum 5 bar operating
pressure.
Consequently, make sure that the
hydraulicpressure measured
downstreamfrom the pressure-
regulatingvalve on thesupply
pipeline is not greater than this
0
10
20
30
40
50
60
70
80
4000 5000 6000 7000 8000 9000 10000 11000 12000
WATERFLOW RATE(Kg/h)
LOAD LOSSES (mbar)
CTC Maxi boiler water load losses
pressure.
Also, check that this maximum
pressureisnot exceeded when the
heating system is at operating
temperature.
Checkthatboiler relief valvedrains
are correctly connected to drain pits.
Boiler load losses are indicated in
thefollowingchart, in function of the
flowrateofwaterincirculation.

3. INSTALLATION
11
3.2 PIPELINE SYSTEM
STANDARDS
1- Theweightofconnection pipelines
andtheforcesgeneratedby
thermalexpansionmustnotbear
ontheboilerandsubjectflanges
and screws to stresses, which
could, with the passage of time,
cause problems with seal or
breakage.
2- If pipelines are long, they must be
equippedwithexpansionjoints,
zigzag elbows, etc.
3- Hot pipelines must be insulated to
preventheatlosses. Leave
pipelinesexposed only wherethey
requireperiodic inspection
(flanges,expansionjoint
connections, branches, etc.).
Insulationmustbeperformed in
accordancewith existing codes
andregulations).
4- It is good practice to furnish the
systemwithadrain cock. You can
usethepluggedholeonthe rear
elementforthispurpose.
3.3HEATINGWATER DELIVERY
AND RETURNPIPELINES
a- Installtwoon/offvalves when
connectingtheboilerto theheating
system pipeline network. This
makes it possible to isolate the
boilerfromthe rest of the heating
system.
3.5WATERCHARACTERISTICS
The chemical and physical characte-
ristics of pipeline system and refill
water are key factors for system
security and proper boiler operation.
Itiswell known that poorqualitywater
creates problems for the entire sys-
tem. The most common but also the
most important phenomena is the
depositof scale ontheheat exchange
surfaces. This scale, even if it is very
thin,hasLOWthermalconductivityand
insulates boiler walls. These are no
longer cooled by recirculating water
and are consequently subjected to
overheating that causes irregular
thermal expansion and localised
thermalshock. Inquireofspecialised
water treatment companies to set up
suitable automatic water test and
treatment systems. Water treatment
isnecessarywhen: pipelinesystems
are very large; the available water
supplyhas veryhardwater; whenever
the system must be partially or totally
emptied,forwhateverreason,andthen
refilled.
b- On/offvalves,wheninstalled,must
be placed so that they do not
excludesafetycomponentswhen
theyareactivated (pressure
switches, block thermostat, relief
valve/reliefpipeline, etc.). The
entire installation, in any case,
mustcorrespondtocurrent
regulations.
c- Avoidcreatingpoints where air
bubblescanformandstagnate
whendesigningandinstallingthe
pipeline system. If this cannot be
avoidedtheninstallautomaticair
bleedvalvesorbleedpipelinesthat
draintothegroundand that have
easily accessed manual control
valves.
3.4SAFETY,CONTROL
ANDADJUSTMENT DEVICES
Thesemustconformtocurrent
regulations. Maximumhydrostatic
pressuremustnotexceedthemaxi-
mumoperatingpressure indicated
onthename-plate.
ATTENTION!
Aninsufficient-water detectionsys-
tem must be installed in roof-
mounted heating plants; meaning-
heating plants where partial
emptying of the pipeline system
could cause irreparable harm
before it is detected.
Requiredwatercharacteristicsare:
Fill and refill water
Appearance clear
Max. total hardness 20° F
Max.free oxygen 0,0005 mg/l
Max. organic matter 0,5 mg/l
min. pH 8,5

3. INSTALLATION
12
3.6ELECTRICAL CONNECTIONS/
SYSTEM
1. Theboiler’selectricboardmust
bepowered with single-phase
230V/50Hzcurrentplusaground
cable.
2. When connecting supply cables
to the terminal board make sure
the groundcableis longer than
the line and neutral cables so
that it is the last to be
disconnected in case the wires
aretornoff.
3. Refertothewiringdiagramin
figure 3.7 to make connections.
4. Haveprofessionallyqualified
personnel check the system and
make sure it is properly sized for
themaximumpowerabsorbedby
theapplianceandthattheground
connectionisefficientand
complieswithCEI standards.
ATTENTION!
1. Ground resistance, in Ohms,
must comply with CEI
standards. The Manufacturer
declines all responsibility for
accidents or harm to persons
and property caused by failure
to comply withthisfundamen-
tal requirement.
2. Make sure the burner can only
function when at least one
water circulation pump is
functioning.
3. The control panel supply
cable must be placed inside
the shell above the insulating
mattress and must exit
through one of the cable glands
provided
(see SHELL INSTALLATION).
5. The main power supply to the
appliance cannot be through
extension cords, adaptation
sockets or multiple jacks.
6. Connections to power mains
must be through a two-pole
switch with at least 3 mm con-
tact gap. This functions as an
isolating switch to isolate the
boiler from the rest of the
electric system.
ATTENTION!
Use of any electrical component
requirescompliance witha few fun-
damentalrules and regulationsuch
as:
a) Never pull on, twist or cut
electric cables;
b) Never permit inexpert persons
to use the appliance;
c) Protect outdoors-electrical
equipment from weather (rain,
sun, fog, etc.).
The electrical system must conform
tocurrentregulations.
Inparticular a properconnectiontoan
efficientground systemmustbe made
accordingtoCEIstandards.
ATTENTION!
The manufacturer is not
responsible for damage to per-
sons or property caused by an
inadequate ground system
Have the electric system checked by
professionallyqualified personnel
who certify that it conforms to the
boiler’smaximumabsorbedpower.

13
3. INSTALLATION
3.7 WIRING DIAGRAM CTC MAXI 80-200

14
3. INSTALLATION
3.8HEATING PLANT
The heating plant must comply with
currentstandardsand regulations.
3.9CONNECTION TO THE
SMOKESTACK
The boiler must be connected to an
efficientand independentsmokestack
witha size calculatedaccordingtothe
thermal capacity of the boiler, the
heightof the smokestackandthe type
offuelbeing burned. The smokestack
must be perfectly hermetic and have
insulated smooth walls.
The connection between boiler and
smokestack must be the same size
asthe connectiontothe boiler. Itmust
slopeupward5%. If it is longer than1
meter then it must be insulated in
accordancewiththesafetyregulations
called for by safety standards.
Figure 5 illustrates the best structure
for a smokestack.
Insulation is necessary to prevent
excessive cooling of smoke. If the
temperatureofproductsofcombustion
drops below 160°C this creates
condensationof carbonresiduethat is
expelledintheatmosphere.
Condensation can also take place
even on perfectly insulated smoke-
stacks with high thermal inertia. This
is caused by repeated burner ignition
andstoppage at shortintervals,which
does not give the smokestack time to
reachandmaintainidealtemperatures.
We recommend installing lightweight
smokestackswithLOWthermalinertia
and with compact cross sections that
arenot oversized.

15
FIG. 6 – Structural characteristics of smokestacks
1 Boiler 6 Masonry
2 Smokestack connection 7 Mineralwool cladding
3 Refractorybrick 8 Smokestackmade of prefabricated
4 Ash collection bin parts with LOW thermal inertia
5 Top end of the smokestack 9 Raincap
3. INSTALLATION
9
5
Singlesmokestack
Multiplesmokestacks
"A"
"B"
6
7
8
6
7
8
21
4
3

16
4. OPERATION
1. Mainswitch
Agreenlamplightswhenpower
is on.
2. Control thermostat,
burner stage 1
Foradjustingtheboilertempera-
tureupto85°C.Recommended
temperatureis marked at the
scale.
3. Control thermostat,
burner stage 2
Foradjustingtheboilertempera-
ture.Recommended temperature
is marked at the scale.
4. Indicating lamp
burner lock-out
5. Safety thermostat
Thesafetythermostatdisconnect
the electrical power if the boiler is
overheated.Resetby pushing the
buttonwhichisunderthecover,
whentheboilertemperatureis
below65°C
6. Indicating lamp
safetythermostat
7. STB-switch
Used by serviceman to check the
safetythermostat
8. Boiler thermometer
9. Heating control (Option)
4.1CONTROL PANEL

17
5. SYSTEM START-UP, OPERATION AND MAINTENANCE
5.1 FILLING THE
HEATING SYSTEM
Afterinstallingtheburner:
a- Check that the drain cock is
closed.
b- Open the pipeline system gates or
supplyvalves.
c- Check that the sealed expansion
tank is pressurised.
d- Manuallyopenthemixingvalvehalf
way (if it exists).
e- Fill the heating systemwith the air
bleedvalvesopen.Closethevalves
whenonlywatercomesoutfrom
them, with no sign of air.
f- Check that the heating system
circulationpumpsand the
recirculation pump rotate in the
properdirection.
g- Check for air in the system by
openingthehighestbleedvalvesin
the pipeline system.
h- Check the pressure in the system
onthepressuregauge.
i- Check that the smokestack
damperisopen.
5.2 FIRST START-UP AND
PRELIMINARYCHECKS
a- Set the boiler thermostat at
approximately80°C.
Note
The manually reset safety
thermostat is already set at110°C.
b- Start the system circulation and
boilerrecirculation pumps, making
surewateractuallymovesbothin
the pipeline system and in the
boiler.
c- Start the burner and adjust it as
describedinitsoperatingmanual.
d- Checkthatthermostatsandcontrol
gaugesandinstrumentsfunction
properly.
e- Checkthattheconnectionbetween
boilerandsmokestackisperfectly
sealed. Anyleaksmustbesealed
offwithglassfibrecordand high
temperatureputty.
f- Checkthatfronthatchwaysare
perfectly sealed. Check, in
particular, thatflangeandburner
tube seals are perfect and do not
permit any smoke to leak out.
NOTE
If there are small leaks around
the hatchways, these are
eliminated by regulating the
pressure on the gasket. Do this
byadjusting the nuts thatclamp
the hatchways in a criss-cross
tightening pattern until the
defect is eliminated.
g- Check that there is sufficient draft
at the connection to the smoke-
stack.There must beadepression
(at least -1÷ -2 mm H2O) at all
pointsinthesmokestackandinany
flueswhentheboilerisoperating
atnormallevels.
h- Check that the sealed expansion
tankfunctionscorrectly. Check,in
particular, the settings of its safety
valves.
i- Checkfor andeliminatethecause
iftherearecontinuouschangesin
pressureandconsequently
continuoustopping-upswith water
(leaks in the pipeline system, in-
sufficientexpansiontank volume,
etc.).
j- Checkthatthereisno residual fuel
orforeignmatterinsidethe
combustionchamberandthatthe
ceramic fibre insulation is not
damaged.
k- Check that the burner flame is
adjustedso that itdoesnot contact
the walls of the combustion
chamber. This ensures proper
combustionand prevents damage
to the boiler body.
l- Thewatertemperature intheboiler
mustbebetween50and85°C. The
differencein watertemperature
betweenheatingsystem delivery
andreturnmustneverexceed20°C,
not even at the start.
m- Check for system seal when the
heating system is hot.
Theburner technicianshall,therefore,
adjusttheburner and checkifstart-up
is running well (without pulsation)
either with hot or cold stack.
Referto the instruction book for the
burner.

5. SYSTEM START-UP, OPERATION AND MAINTENANCE
5.3DATAFOR CHECKING
COMBUSTION
Referto the instruction book for the
burner.
5.4GENERAL BOILEROPERATING
REGULATIONS
Boilerefficiency anddurabilitydepend
onproper operation andmaintenance
aswellasoncorrectinstallation. The
followingguidelines mustbecomplied
with:
1- Ask a specialist to mix specific
anti-freezesin the heatingsystem
waterifthe boiler is used inzones
wheretemperatures can drop
severaldegrees below zero.
2- Periodically check that smoke
evacuationtubeseals are whole
andefficient.
3- Stop the boiler whenever it is
necessarytoperformworkor
maintenanceonstructures
installed near smokestacks and
their accessories. When work is
terminated,beforerestarting the
boiler, have a Specialist check to
make sure the smokestack flues
andsmokeevacuationdevicesare
efficient.
4- Never clean, the boilerand
equipmentinstalledintheboiler
roomwitheasilyflammable
products (gasoline, alcohol,
petroleum,kerosene,solvents,
etc.).
5- Neverleaveorstorecontainers of
flammable substances such as
solvents, paints, etc. in the boiler
room.
6- Clean the boiler room with the
burneroff.
7- Repeat the checks described in
previousinstructions(seeinstal-
lationand first start-up)whenever
you restart the boiler after a
periodofinactivity.
8- Periodically check that
thermostats,safetydevicesand
theboilerthermometer are
efficient.
9- Periodically check the hydraulic
sealofthe entiresystemtoprevent
frequent topping up with water
from forming dangerous scale
and corrosion in the boiler.
10- Once a year checks the state of
cleanlinessofthefurnace.
Remove all scale and soot as
necessary.
11- Any gas leaks must be
immediatelyeliminatedby
replacingwornseals.
12- Check the quality of combustion
once a year.
13- Avoid emptying the system: this
willpreventrustandscale.
Theheating systemmustbe designed
sothatsubsequent refilling with water
isreduced to aminimumand issimply
fortoppingup.
Refillswithwatermustalwaysbemade
and monitored from a single point in
the heating system.
Open expansion tanks must be sized
so that they compensate for natural
thermal expansion of the water in the
heating system. When a sealed ex-
pansiontankisused,thesafety valves
must not open during normal boiler
operation. Risks caused by scale de-
posits are not covered by the
guarantee. Werecommendusinganti-
scale products or systems when the
water that is used is especially hard.
Refill water must be softened if
frequent refills and topping-up
proceduresarea necessity.
18