DOMUSA EVOLUTION EV FDX Installation And Operating Instructions Manual

INSTALLATION AND OPERATING INSTRUCTIONS

¬ EVOLUTION EV FDX

ER-0170/1996

CGM-04/392

We thank you for having chosen a DOMUSA heating boiler. Within the product range of DOMUSA, you have chosen the Evolution EV FDX model. This boiler is capable of providing you with the temperature comfort suitable for your home, as well as balanced and economical Domestic Hot Water (DHW). This always together with a proper and gas-oil fed hydraulic installation.

This manual makes up an integral and essential part of the product and it will be delivered to the user. Read carefully the warnings and recommendations included in this manual, since they provide significant information as for safety of installation, usage and maintenance.

The installation of these boilers is to be carried out only by skilled personnel, in accordance with the standards in force and following the manufacturer’s instructions.

Either the start-up or any maintenance operations of these boilers are to be performed only by the Authorized Techincal Assistance Services of DOMUSA.

An improper installation of these boilers could result in damage to people, animals or property, and the manufacturer takes no responsibility on them.

1

INDEX Page

1 DESCRIPTION OF COMPONENTS ....................................................................................................................2

2 CONTROL ELEMENTS........................................................................................................................................3

3 INSTALLATION INSTRUCTIONS ........................................................................................................................4

3.1

LOCATION ............................................................................................................................................................4

3.2 HYDRAULIC INSTALLATION.....................................................................................................................................4

3.3 ELECTRICAL CONNECTION.....................................................................................................................................4

3.4 OIL INSTALLATION.................................................................................................................................................4

3.5 COMBUSTION PRODUCTS EXHAUSTION ..................................................................................................................4

4 COMBUSTION PRODUCTS EXHAUSTION .......................................................................................................7

4.1

COMBUSTION PRODUCTS EXHAUSTION AND AIR INTAKE DUAL-DUCT DEVICE Ø80 (TYPR C

53

) .....................................7

4.2 DOUBLE CONDUIT TO COAXIAL EXHAUSTION TRANSFORMATION ...............................................................................8

4.3 COMBUSTION PRODUCTS EXHAUSTION AND AIR INTAKE HORIZONTALLY-ARRANGED COAXIAL DEVICE Ø80-125 (TYPE

C13)...........................................................................................................................................................................9

4.4 COMBUSTION PRODUCTS EXHAUSTION AND AIR INTAKE VERTICALLY-ARRANGED COAXIAL DEVICE Ø80-125 (TYPE C

33

)10

5 INSTALLATION WATER-FILLING .....................................................................................................................11

6 DIGITAL DISPLAY..............................................................................................................................................11

7 TEMPERATURES SELECTION.........................................................................................................................12

7.1

BOILER SET POINT TEMPERATURE SELECTION ......................................................................................................12

7.2 DHW SET POINT TEMPERATURE SELECTION.........................................................................................................13

8 BOILER OPERATION ........................................................................................................................................13

8.1

WINTER MODE....................................................................................................................................................13

8.2 SUMMER MODE ..................................................................................................................................................14

9 ADITIONAL FUNCTIONS...................................................................................................................................15

9.1

PUMPS ANTI-BLOCK FUNCTION ............................................................................................................................15

9.2 BOILER ANTI-FREEZING FUNCTION .......................................................................................................................15

9.3 BOILER PRESSURE SENSORIZE FUNCTION ............................................................................................................15

9.4 PHONE RELAY CONNECTION ................................................................................................................................15

9.5 ROOM THERMOSTAT CONNECTION.......................................................................................................................15

10 REMOTE CONTROL E20 (OPTIONAL)...........................................................................................................16

11 BOILER SACURITY SYSTEMS .......................................................................................................................16

11.1

TEMPERATURE SAFETY LOCKING .......................................................................................................................16

11.2 BURNER LOCKING.............................................................................................................................................17

11.3 LOW PRESSURE LOCKING..................................................................................................................................17

12 BOILER WATER-EMPTYING ..........................................................................................................................17

13 BOILER STOP..................................................................................................................................................17

14 FIRST START-UP ............................................................................................................................................17

15 BOILER DELIVERY..........................................................................................................................................18

16 BOILER MAINTENANCE .................................................................................................................................18

16.1

BOILER CLEANING.............................................................................................................................................18

16.2 PREVENTS OF FREEZES ....................................................................................................................................19

16.3

BOILER WATER CHARACTERISTICS.....................................................................................................................19

17 CIRCULATING PUMPS FLOW CURVES........................................................................................................19

18 DIMENSIONS ...................................................................................................................................................20

19 TECHNICAL DATA...........................................................................................................................................22

20 ELECTRICAL CONNECTION DIAGRAM ........................................................................................................23

21 ELECTRICAL DIAGRAM..................................................................................................................................24

22 BURNER...........................................................................................................................................................22

22.1

MOUNTING.......................................................................................................................................................22

22.2 OIL INSTALLATION.............................................................................................................................................22

22.3 START UP OF THE BURNER ................................................................................................................................22

22.4 BURNER COMBUSTION ADJUSTMENT..................................................................................................................22

22.5 SELECTION OF OIL NOZZLE ................................................................................................................................22

22.6

DIMENSIONS ....................................................................................................................................................23

22.7

PRIMARY COMBUSTION AIR ADJUSTMENT ...........................................................................................................24

22.8 COMBUSTION LINE ADJUSTMENT........................................................................................................................24

22.9

CORRECT POSITIONING OF IGNITION ELECTRODES..............................................................................................24

22.10

OIL PRESSURE ADJUSTMENT ...........................................................................................................................25

22.11 OIL INSTALLATION DIAGRAMS ..........................................................................................................................26

22.12 TECHNICAL DATA............................................................................................................................................26

22.13 WORKING DIAGRAM ........................................................................................................................................27

22.14 OIL FLOW VERSUS NOZZLE AND PUMP PRESSURE .............................................................................................27

22.15 ELECTRIC DIAGRAMS ......................................................................................................................................27

Evolution FDX

2

22.16 OIL EASY CONNECTION ...................................................................................................................................28

23 ALARM CODES................................................................................................................................................30

24 FAILURES ........................................................................................................................................................31

Evolution FDX

2

1 DESCRIPTION OF COMPONENTS

7 8

454

11 12

13 1

4

16

18

9

3 2

1

17

1

5

106

1. Cast iron corp.

2. Condensator, INOX AISI 316.

3. Safety valve.

4. Automatic air vent.

5. DHW tank, INOX AISI 316.

6. DHW safety valve drainage siphon.

7. DHW safety valve.

8. DHW recirculation nipple.

9. Pressure sensor.

10. DHW temperature sensor.

11. Heating expansion vessel.

12. DHW expansion vessel.

13. Filling valve.

14. Heating pump.

15. Boiler temperature sensors.

16. DHW pump.

17. Blowoff valve.

18. Balance flue burner.

3

2 CONTROL ELEMENTS

2824 26 2725

2019 232221

19. ON/OFF neon light:

When it is light on, it indicates that the boiler is switch on.

20. Alarm warning neon light:

When it is light intermittent, it indicates that any alarm or blockout of boiler operation is produced.

21. Digital display:

It is the main display of operation of the boiler. It shows the different temperatures of the boiler, installation pressure and the different alarm codes.

22. Heating service neon light:

When it is light on, it indicates that it is selected the heating service, the boiler is in

winter mode.

23. DHW service neon light:

When it is light on, it indicates that it is selected the service of Domestic Hot Water. When the boiler only has this neon lighted on, it will be in summer mode.

24. Boiler temperature selector:

We will be able to select, in any moment, the set point of boiler temperature. It is a removable turning button. For its usage, push on it and it will be extracted, pushing again, it will hide.

25. Switch on button:

Pressing this button will switch on and shutdown the boiler.

26. SET button:

Pressing this button, you will accese to visualize the different temperatures of the boiler, in the digital display.

27. Services selection button:

We will be able to select the modes of operation of the boiler; service of heating + DHW (winter mode); or service only of DHW (summer mode).

28. DHW temperature selector:

We will be able to select, in any moment, the set point of DHW temperature. It is a removable turning button. For its usage, push on it and it will be extracted, pushing again, it will hide.

Evolution FDX

4

3 INSTALLATION INSTRUCTIONS

The boiler has to be installed by personnel authorized by the Department of Industry in accordance with the regulations and normative in force on this matter. Notwithstanding, it will be necessary to comply with the following recommendations when installing the boiler:

3.1 Location

The boiler is to be installed into a sufficiently ventilated site. It will be essential to provide access through one side of the boiler for maintenance tasks.

3.2 Hydraulic installation

The hydraulic installation should be made by qualified personnel staff. The installation standards are to be complied with, although the following recommendations should be taken into account:

- A thorough interior cleaning of the equipment piping is to be performed prior to the switching on of the boiler.

- It is recommended that cut-off valves be interspersed between the equipment piping and the boiler, in order to simplify the maintenance tasks.

- A minimum pressure of DHW of 0.5 bar is to be applied.

- It will be indispensable to drive the exit of condensed to a drainage, since the boiler Evolution is a condensation boiler and the quantity of generated water can be big. Also, before starting the boiler, it is recommended to fill the exit tube-siphon of condensed water, with the purpose of garnishing the exit of smoke per it.

3.3 Electrical connection

The boiler is ready to be connected at 220 V 50 Hz on plugs 1 and 2 of the terminal strip J1 (see Electrical Connection Diagram). Do not forget to do grounding.

In addition, the boiler is provided with two terminals J5 for the room thermostat connection (see Electrical Connection Diagram). For that, the bridge joining both terminals is to be removed and the room thermostat is to be connected there.

3.4 Oil installation

The model Evolution is supplied with an oil burner Domestic (4) (see the model in the Technical Data). For a correct oil line installation proceed in accordance with the burner instructions enclosed in this manual (see Burner). The oil line installation and the start up operation of the burner has to be carried out by qualified personnel staff.

3.5 Combustion products exhaustion

The installation of exhaustion of the products of combustion has to be carried out by qualified personnel staff and it will fulfill the requirements demanded in the legislation and effective regulatory schemes.

5

The Evolution boilers are balanced flueoil boilers, so that the combustion products exhaustion is carried out by means of an outlet duct and an air intake from outside. It is recommended that the position at the exhaustion duct exterior portion should be in accordance with the data of the following figures and table:

Position of the exhaustion duct

Minimum

distance

mm

A under a cornice

300

B between two horizontally-arranged ducts

1000

C from a next window

400

D between two vertically-arranged ducts

1500

E from a next venting grid

600

F under a balcony (*)

300

G under a window

600

H under a venting grid

600

I from a break back of a building

300

J from an angle of a building

300

K from the floor level

2500

L from a vertically/horizontally-arranged outlet or pipe (**)

300

M from a front surface at a distance of 3 metres from the exhaust gas outlet

2000

N like the previous one, but with opening

3000

(*) In so far the balcony width does not exceed 2000 mm. (**) If the pipe constructive materials were sensitive to the action from the flue gases, this distance should be

longer than 500 mm.

ATTENTION: All the fittings used in the combustion products exhaustion and air

intake are to be those supplied by Domusa firm.

Evolution FDX

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7

4 COMBUSTION PRODUCTS EXHAUSTION

4.1 Combustion products exhaustion and air intake dual-duct device ø80 (typr C53)

In this type, the combustion products exhaustion and air intake are carried out with separated pipes of Ø80 mm., by means of the dual-duct outlet Kit of Ø80 code CGAS000186. It is the default type of exhaustion for boilers Evolution.

The maximum length of pipe that can be installed is; 12 metres for the model EV 30 FDX; and 10 metres for the model EV 40 FDX, which is the result from adding the pipe metres for the air intake and those of the combustion products exhaustion. Each elbow of 90°, or two of 45°, reduces the available length by 0.6 metres.

It is recommended that the flue gases outlet pipe be fitted slightly upwardly-inclined 2º to 3º thus preventing water and condensate projections from being ejected outside.

Dual-duct outlet Kit ∅80

Cod . CGA S00018 6

1m. duct ∅80

Cod . CGA S00014 5

90º elbow ∅80

Cod . CGA S00014 7

45º elbow ∅80

Cod. CGAS000148

Installation examples:

L ≤ 12/10 mts .

Evolution FDX

8

4.2 Double conduit to coaxial exhaustion transformation

The boiler Evolution is given prepared for the exhaustion of the products of combustion and air intake by means of the system of double conduit of Ø80. When you want to carry out the exhaustion of combustion gases by means of coaxial tube of Ø80/125, you will use for it a Kit adaptor for coaxial tube Ø80/125 (given under order) Code CGAS000213

Kit adaptor for coaxial tube ∅80/125

Cod. CGAS000213

The transformation will be able to realize with two different mounting setups:

1. Back exit : it will be enough with disassembling the combustion air intake of the boiler, unscrewing the three screw, mount the adaptor in the exit of flue gases of the boiler backwards and using the flexible tube of entry of air, connect it to the adaptor.

2. Lateral or upwards exit: it will be realized in the same way, but to mount the adaptor kit laterally it is necessary to mount an elbow of 90º Ø80 (code CGAS000147), before the adaptor in the exit of flue gases.

In the following pictures they can observe both setups:

Combustion air intak

e

Back exit

Lat eral exit

90º elbow Ø80

9

4.3 Combustion products exhaustion and air intake horizontally-arranged coaxial device ø80-125 (type C13)

The combustion products exhaustion and air intake can be carried out through concentric pipes of Ø80 mm. for the combustion products exhaustion and Ø125 mm. for the air intake by means of the horizontally-arranged outlet Kit 1m Ø80-125 code CGAS000189.

The maximum horizontal length counted from the boiler, including the kit end, is; 6 metres for model EV 30 FDX; and 5 metres for model EV 40 FDX. Each elbow of 90°, or two of 45°, reduces the available length by 0.6 metres.

It is recommended that the flue gases outlet pipe be fitted slightly upwardly-inclined 2º to 3º thus preventing water and condensate projections from being ejected outside.

Horizontally-arranged outlet 1m ∅80/125

Cod . CGAS0 0 0 18 9

90º coaxial elbow ∅80/125

Cod . CGAS000 182

45º coaxial elbow ∅80/125

Cod . CGAS000 183

1m coaxial duct ∅80/125

Cod . CGAS000 184

Installation examples:

Evolution FDX

10

L ≤ 6/5 mts .

4.4 Combustion products exhaustion and air intake vertically-arranged coaxial device ø80-125 (type C33)

The combustion products exhaustion and air intake can be carried out through concentric pipes of Ø80 mm. for the combustion products exhaustion and Ø125 mm. for the air intake, by means of the vertically-arranged outlet Kit Ø80-125 code CGAS000231.

The maximum vertical length counted from the boiler, including the kit end, is; 7 metres for model EV 30 FDX; and 6 metres for model EV 40 FDX. Each elbow of 90°, or two of 45°, reduces the available length by 0.6 metres.

Vertically outlet ∅80/125

Cód . CGAS0 0 0 23 1

Bl ack t il e ∅80/125 Cód . CGAS0 0 0 07 4

45º elbow ∅80/125

Cód. CGAS000183

90º elbow ∅80/125

Cód . CGAS0 0 0 18

2

1m coaxial duct ∅80/125

Cód . CGAS0 0 0 18 4

Black tile ∅80/125 Cód. CGAS00007

5

Installation examples:

11

L ≤ 7/6 mts.

5 INSTALLATION WATER-FILLING

In order to fill the installation, open the filling valve (13) up to the digital display (left side) indicates a pressure between 1 and 1.5 bar. Filling is to be carried out slowly and with the automatic air vents (4) plug loose, so that the installation air will be released. In addition, the other parts of the installation are to be properly drained by means of the drip valves fitted for such a purpose. Once the installation has been filled up, close the filling valve.

The boilers Evolution incorporates a pressure sensor (9), which controls the pressure of the installation. If the installation doesn not have a minimum pressure of 0.5 bar, the boiler will blockout and an alarm of low pressure will be visualized ("AP").

NOTE: Switching-on the boiler without water could result in serious damage to it.

6 DIGITAL DISPLAY

The boiler Evolution is electronic and incorporates a digital display (21) for the visualization of those actual temperatures, the set point temperatures and the pressure of the installation. Under stand by conditions of the display, it visualizes the pressure, in its left side (bar), and the actual temperature of the boiler, in its right side (ºC). Pressing the button SET located under the display, it will be able to navigate per rest of the available visualization options, according to the following instructions:

SET button

Digital Dis pla

y

1. 5 6 3

Evolution FDX

12

Pressing the button of SET successively will select the different options to visualize. Once selected desired option, lapsed ten seconds, it will return to the stand by condition.

In the following table the different options of visualization of the display are described:

1. 5 6 3

bar ºC

Stand by condition. In the left side, the pressure is visualized and in the right side, the real temperature of the boiler.

T 1 63

Actual temperature of the boiler.

T2 45

Actual DHW temperature.

TC 70

Boiler set point temperature, selected with the boiler temperature selector button (24).

A( 45

DHW set point temperature, selected with the DHW temperature selector button (28).

SP 1.5

Actual boiler pressure, measured by the pressure sensor (11).

7 TEMPERATURES SELECTION

7.1 Boiler set point temperature selection

TC 70

/

The selection of the wanted temperature of boiler operation realizes by means of the removable turning button indicated in the picture. To extract the button, press slightly on it, to hide it again, push the button until it is locked. To select the wanted temperature, turn the

removable button, in that moment "tc" will appear in the screen and the selected set point

temperature will be visualized in it. Once selected the temperature, hide the button again, and lapsed ten seconds, the screen will return to the stand by status.

Also, it will be able to select the set point temperature of boiler, navigating with the SET button until the option

"tc" appears. Once located the screen in this option, turn the

removable button until selecting the desired temperature.

The range of set point temperature of boiler allowed is 30 - 85 ºC. The boilers model Evolution, are condensation boilers, per that reason, with the objective of obtaining the maximum performance of the boiler and energy savings in the operation, it is recommended to select a set point temperature among 55 - 70 ºC, whenever the heating system installed and the conditions of insulation of the housing allow it.

13

7.2 DHW set point temperature selection

A( 4 5

/

The selection of the wanted DHW temperature realizes by means of the removable turning button indicated in the picture. To extract the button, press slightly on it, to hide it again, push the button until it is locked. To select the wanted temperature, turn the removable button, in

that moment "AC" will appear in the screen and the selected set point temperature will be

visualized in it. Once selected the temperature, hide the button again, and lapsed ten seconds, the screen will return to the stand by status. The range of DHW set point temperature allowed is of 15 - 60 ºC.

Also, it will be able to select the DHW set point temperature, navigating with the SET button

until the option "AC" appears. Once located the screen in this option, turn the removable

button until selecting the desired temperature.

8 BOILER OPERATION

There are two different operating modes. The selection realizes by means of the services selection button, indicated in the picture. The selection will be able to visualize in the two neon lights of service, located in the right side of the screen.

1. 5 6 3

8.1 Winter mode

The boiler will be, at this mode, capable of heating the heating installation and producing domestic hot water, simultaneously. To select this mode, press the services selection button until the two neons (22) (23) light on. The burner will be put on. When the boiler reaches 53 ºC, it will be ready to heat the heating installation, starting up the heating pump for such a purpose. The burner will stop when the boiler has reached the boiler set point temperature selected. As soon as the room temperature is equal to or higher than that rated on the room thermostat of the installation (if any), the heating pump and the burner will stop. If a hot water tap is opened, it will enter to work the instantaneus DHW production system, providing a constant service of Domestic Hot Water to the DHW set point temperature selected.

Evolution FDX

14

8.2 Summer mode

The boiler will supply, at this position, only domestic hot water service. To select this mode, press the services selection button until the inferior neon lights on (23). The burner will be put on up to the boiler reaches 53 ºC. If a hot water tap is opened, it will enter to work the instantaneus DHW production system, providing a constant service of Domestic Hot Water to the DHW set point temperature selected.

15

9 ADITIONAL FUNCTIONS

The boiler Evolution EV FDX is equipped with an electronic control able to regulate the automatic operation of the boiler in an efficient way and it also includes the following aditional control features:

9.1 Pumps anti-block function

This feature prevents the blocking of the circulation pumps of the boiler, due to prolonged periods that the pumps don't work. This system will remain enable while the boiler is onnected to the electric network.

9.2 Boiler anti-freezing function

This feature protects the boiler of freezing during the freeze periods. When the temperature of the boiler decreases up to 6 ºC, it will start the heating circulation pump. If the temperature of boiler continues descending up to 4 ºC, it will put into operation the burner, heating the installation. Once enabled this feature, will be active until reaching 8 ºC in the boiler. This system will remain in alert while the boiler is connected to the electric network.

9.3 Boiler pressure sensorize function

This feature prevents of a bad operation of the boiler because a low level of water and an excess of pressure in the boiler. The pressure is sensed by a sensor of pressure (11), and its value is visualized in the digital display of the main board. When the pressure is lower than

0.5 bar, the electronic control stops the operation of the boiler and enables an alarm in the screen. When the pressure of the boiler is upper than 2.5 bar, it lights on an intermittent neon of alarms (20), warning of the excess of pressure. It is recommended, in this case, to call to Technical Assistance Service, and proceed to drain the boiler a little.

9.4 Phone relay connection

The boiler Evolution is prepared with the possibility of connecting a phone relay for switch on and switch off the boiler. This feature allows remote shutdown and light on the boiler, from any place, with a phone call. The connection of the relay to the boiler realizes connecting it in the terminal strip J6 (see Electrical Connection Diagram). When the phone relay is close, the boiler starts, and when the relay is open, the boiler will shutdown, remainding the anti-freeze protection and anti-block of pumps functions activated.

9.5 Room thermostat connection

The boiler has two terminals, in the terminal strip J5, prepared for the connection of a room thermostat or room timer (see Electrical Connection Diagram), which allow to control the heating service depending on the temperature of home. For its connection, it should take off the bridge of the terminals J5 and connect the room thermostat there.

The installation of a room thermostat will optimize the operation of the installation, adjusting the operation of the heating to the requirements of home, and obtaining some enhanced benefits of comfort. Also, if the thermostat allows the programming of the hours of operation (room timer), it will be able to adjust the heating system schedule to the usage of the installation.

Evolution FDX

16

10 REMOTE CONTROL E20 (OPTIONAL)

Together with the boiler Evolution, optionally, it can be supplied a remote control (E20), by means of which it will be possible to command the complete operation of the boiler from any site of the house, where it is mountted.

This remote control allows programming of the hours of comfort desired in the house, adapting the installation features to the requirements of comfort, by means of the measurement of the room temperature and adjusting the installation temperature to it. Also, from the remote control it will be able to adjust DHW and heating set point temperatures in any moment, as well as to visualize the diverse parameters of operation of the boiler, from the room where the remote control is mounted. Also, the remote control will warn of any abnormality of operation of the boiler.

The remote control is of easy installation, being only needed 2 communication wires betwen the boiler and the control E20. The connection to the boiler will realize connecting the two threads in the regleta of connections J4 (see Electrical Connection Diagram). For a correct installation and operation, read carefully the instructions attached with the remote control.

11 BOILER SACURITY SYSTEMS

The boiler electronic control system will be able to enable the following security locks of operation of the boiler. When anyone of these locks out take place the boiler stops working, it is visualized in an intermittent way an alarm code in the screen and the alarm warning red neon litgh will litgh on intermittently.

AL AT

If any of the following operation lock out was repetitive, shutdown the boiler and call to the nearest official TAS.

11.1 Temperature safety locking

When this locking happens, in the digital display (21) will visualize blinking the code "At" (Alarm of Temperature) and the alarm warning neon light. It will stop the burner.

It will take place whenever the boiler surpasses 110 ºC of temperature. To unlock, wait to the boiler temperature gets down below 100 ºC and press the button incorporated in the security thermostat, located inside the boiler in the bottom side of the electric box.

AL AT

bar ºC

17

11.2 Burner locking

When this locking happens, in the digital display (21) will visualize blinking the code "AQ" (Alarm of Burner) and the alarm warning neon light. It will stop the burner.

It takes place for any abnormality that could exist in the burner (4) or in the installation of fuel. To unlock, press the luminous button that lights in the burner.

11.3 Low pressure locking

When this locking happens, in the digital display (21) will visualize blinking the code "AP" (Pressure Alarm) and the alarm warning neon light. It will stop the burner and circulatuing pumps.

It takes place when the pressure of the boiler decreases below 0.5 bar, avoiding boiler operation when it is empty of water, because any leakage or maintenance operations. To unlock, fill the installation again, until the digital display (21) indicates between 1 and 1.5 bar.

12 BOILER WATER-EMPTYING

In order to empty the installation water, connect a pipe to the drainage valve of the boiler (1) and open it. Open the air vent valves, which is located higher than this on the installation, to accelerate the emptying process.

13 BOILER STOP

To shutdown the boiler, press the power on button (25). In the power off mode, and while the boiler is connected to the electric network and to the installation of fuel, the boiler stops working to give heating service and DHW service, but they continue activated the features of anti-freeze protection and pumps anti-block.

To shutdown the operation of the boiler completely, disconnect the boiler from electric network and cut the supply of fuel.

14 FIRST START-UP

The start-up of the boiler, for the validity of warranty to be in force, is to be carried out by an authorised Technical Assistance Service. Prior to proceeding to such a start-up, the following

steps will be performed:

- The boiler is to be electrically connected to the mains.

- The installation has to be filled up with water (the display must indicate between 1-1.5

bar).

- Oil is to come up to the burner at a pressure not higher than 0.5 bar.

A

L A

Q

bar ºC

AL AP

bar ºC

Evolution FDX

18

15 BOILER DELIVERY

The Technical Assistance Service, once the first start-up has been carried out, will explain the boiler operation to the users by informing them about the most necessary remarks.

The installer will be responsible for explaining to the users the operation of any control or regulation device that is a part of the installation and it is not supplied with the boiler.

16 BOILER MAINTENANCE

In order to maintain the boiler under correct operating conditions, a checking operation is to be made by DOMUSA’s authorised personnel on a yearly basis.

16.1 Boiler cleaning

To maintain the boiler under correct operating conditions, it is recommended to carry out one annual clean-up of the combustion chamber, flue gases pipes and condensator. For it, with the boiler, it is supplied an appropriate brush of clean-up. This brush is located in the front side of the boiler, near door.

The combustion chamber and flue gases pipes should not be cleaned with chemical products or steel hard brushes. It should put on special care after all the operations of

clean-up, making several power on cycles, checking the correct operation of all the components.

For a correct clean-up, follow the following recommendations carefully:

Boiler corp cleaning

- Open and extract the outside door of the boiler.

- Dismount the burner (4), unscrewing the female screw located in the upper side of

burner.

- Dismount the combustion chamber door and flue gases tap, unscrewing the six female

secrews located around them.

- Clean the flue gases pipes of cast iron corp with the cleaning brush supplied with the

boiler.

- Clean the combustion chamber of the boiler.

- Once concluded these operations of clean-up, mount the combustion chamber door, the

flue gasees tap, the burner and the external door of the boiler.

Condensator cleaning

- Open and retract the external top cover of the boiler, to access to the condensator,

located in the back side of the cast iron body.

- Open the upper cover of the condensator, to access to the flue gases pipes of it. To open

this cover, first turn on their shaft until the slots of the closing "clip" coincide in the external part of the cover (see picture), once turned the cover, extract it.

- Extract the smoke turbulators located inside the condensator.

- Clean the condensator with the cleaning brush supplied with the boiler.

19

- Once concluded these operations of clean-up mount again the smoke turbulators, the

cover of the condensator and the external top cover of the boiler.

Cleaning brush

1

2

Cl o si ng "clip" slots

3

16.2 Prevents of freezes

The boiler Evolution has a feature that garnishes of possible deteriorations of the installation because freezing, whenever it makes sure the correct electric energy supply. Anyway, and mainly in fields flogged by very low temperatures, it is recommended to take diligences with the purpose of avoiding damages in the boiler. It seeks advice to add anticer to the existing water in the heating circuit.

16.3 Boiler water characteristics

When the water hardness is higher than 25-30º F, the use of treated water for the heating installation is prescribed, in order to avoid the possible lime deposits on the boiler.

The treatment of the water used in the heating circuit is essential in the following cases:

- Very long circuits (with high water content).

- Frequent installation filling operations.

If it is necessary to drain the installation either partly or fully, the filling with treated water is prescribed.

17 CIRCULATING PUMPS FLOW CURVES

It will be possible to obtain, in the following diagrams, the hydrodriving pressure available in the installation at the boiler exit, having taken the boiler pressure drop into account. These charts include three curves corresponding to the three speeds of the circulating pumps provided with the boiler.

Evolution FDX

20

NYL 43-15

0

1

2

3

4

5

00,511,522,533,5

Q(m3/h)

H(m)

III

II

I

NYL 53-15

0

1

2

3

4

5

6

00,511,522,533,5

Q(m3/h)

H(m)

III

II

I

18 DIMENSIONS

550

L

ø80

130

1645

125

300

RC

IC

TR

ø80

A

1400

100

260

65

E

A

SH

SC

220

180

80

VS

705

SV

IAS

EAS

IC'

635

300

100

70

135

IC: Heating outlet. IC': Optional heating outlet.

RC: Heating return. EAS: DHW inlet.

IAS: DHW outlet.

MODEL

IC/IC'

RC

EAS

IAS

DIM.

A

DIM.

L

VS: Safety valve. EV 30 FDX

3/4"M 3/4"M

585

855

SC: Condensate drainage, 3/4" H. EV 40 FDX

1"M 3/4"M

560

955

SV: Security valve drainage siphon. EA: Combustion air inlet, Ø80. SH: Flue gases outlet, Ø80.

21

TR: DHW recirculating connection, 1/2" H.

Evolution FDX

22

19 TECHNICAL DATA

EVOLUTION EV 30 FDX EV 40 FDX

N. of cast iron elements - 3 4

condensation

Boiler type -

heating + DHW tank Heating input kW 29,3 40,5 Heating output kW 28,7 39,7 DHW tank capacity Lts. 130 DHW production in 10 min. ∆t=30ºC Lts. 321 DHW production in 1 hour ∆t = 30ºC Lts. 846 Recover time from 35 to 58 ºC min. 8 Heating temperature range ºC 30-85 DHW maximum temperature ºC 60 Heating security maximum temperature ºC 110 Heating security maximum pressure bar 3 DHW maximum temperature bar 7 Heating expansion vessel capacity Lts 8 12 Boiler water capacity Lts 19,2 23,2 Water pressure drop mca 0,3 0,4 Flue gases temperature ºC 67 83 Flue gases volume Lts 11,4 17,5 Flue gases flow Kg/s 0,0132 0,0186 Flue gases pressure drop mmH2O 2,0 2,1 CO emisions level mg/kWh 58 52 NOx emisions level mg/kWh 94,5 81,7 NOx class (EN 303-2) - 3 Combustion chamber lenght mm 300 400 Combustion chamber type - wet, three smoke steps Burner model Domestic - D-3 D-4 Burner type - ON/OFF Electric power - ~220-230 V - 50 Hz - 200 W Weight Kg 265 285 N. of stars (92/42/CEE Directive) -



23

20 ELECTRICAL CONNECTION DIAGRAM

To carry out the connection of the diverse options and components of this model, it incorporates a series of removable terminal strips of connection located on the back side of the main board. For their correct connection, follow the instructions of the following pictures carefully:

1

356

7

8910

11

4

J1J2

16

1

514

13

12

J3

J5

J4

N

F

bc7BC

QSc

Sa

T

A

E20

B

V

Bl ue

Bl ac

k

Bl ue

2

220 V

J6

BC: Heating pump. BV: DHW pump. Q: Burner. bc7: Burner's n. 7 plug. F: Phase. N: Neutral. Sc: Boiler temperature sensor. Sa: DHW temperature sensor.

TA: Room thermostat. E20: Remote control E20. J1: Power connector. J2: Components connector. J3: Sensors connector. J4: Remote control connector. J5: Room thermostat connector. J6: Phone relay connector.

Evolution FDX

24

21 ELECTRICAL DIAGRAM

7

6

12

5

4

3

J8

Fuse

R

J7

Power supply PCB

F

L

C

2

TS

C

21

Bridge

Ro s e

Bl ack

Whi t e

Ro s e

J7

SP

PC PS

Cont rol PCB

S1

ONS2ON

121234

TS: Security thermostat. FL: DHW flow switch. R: Phone relay.

SP: Pressure sensor. PC: Heating potenciometre.

PS: DHW pontenciometre.

J7: PCB's connector. J8: Climatic regulation connector. S1: Boiler model selection switches. S2: Floor heating selection switches.

Evolution FDX

22

22 BURNER

22.1 Mounting

Fix the burner support to the boiler. Fix the burner to the support. This allows a correct inclination of the flame tube towards the combustion chamber. Mount the oil aspiration and return tubes, including the oil-filter in the aspiration.

22.2 Oil installation "Domestic" burner is equipped with a self-aspiration pump, which allows the aspiration of

combustible from the tank which is installed in a lower level than the burner, as long as the pressure measured with a vacuometer in the pump does not exceed 30 cmHg.

22.3 Start up of the burner

Make sure that there is combustible in the tank, also that the oil valves are open and there is electric connection to the burner. Switch on the main switch. Unscrew the air-drains screw (manometer tap). Then, when the electrovalve opens, take the photocell sensor out of its place and approach it to a luminous source until oil comes out. Disconnect the burner and screw the drains-screw

22.4 Burner combustion adjustment

Observe the flame. If there is not enough combustion air, it will be dark and it will produce smoke which will close the uptake.

On the other hand, if there is too much combustion air, the flame will be white or white-blue coloured, reducing the efficiency and therefore not fulfilling the anti-pollution norms. Besides, the excess of air may difficult the ignition process.

The flame must be kind of orange coloured.

Due to the construction of the boiler, if it is difficult or impossible for you to see its flame, the combustion airflow can be set-up observing the smoke coming out from the chimney. If it is dark, the air in the burner will have to be increased and if it is white, the air in the burner will have to be decreased until there is no smoke at all.

If you are provided with a device, which verifies the composition of the combustion gases, it will be the best guide to adjust the flame, but if you do not have it, follow the preceding indications.

22.5 Selection of oil nozzle

Select the correct oil nozzle in accordance with the pressure, bearing in mind that 1 Kg/h of oil approximately produces 11.86 kW.

23

22.6 Dimensions

I

G

E F

H

F'

B

A

C

D

L

J

K

DIMENSION A B C D E F F' G H I J K L

LENGHT (mm)

292 265 140 152 215 75 98 290 ø80 205 100 100 ø90

F: Domestic D-3. F': Domestic D-4.

Evolution FDX

24

22.7 Primary combustion air adjustment

To adjust the primary combustion air, turn the screw as shown on the drawing by means of a 6 mm. Allen wrench. To increase the airflow, turn it to the right and to decrease it, turn it to the left.

22.8 Combustion line adjustment

To adjust the combustion line, unscrew the combustion line blocking screw "BL". Turn the line adjustment screw "RL" to the right to increase the airflow and to the left to decrease it. After the adjustment has been made, screw the combustion line blocking screw "BL".

BL

RL

+

-

3 mm

0

1

22.9 Correct positioning of ignition electrodes

To assure a good ignition of the burner Domestic, it is necessary to respect the measures shown in the drawing. Besides, before mounting the flame tube again, make sure that the blocking screws of the electrodes have been fixed.

10

0

25

2/3 mm

4 mm

22.10 Oil pressure adjustment

To adjust the pressure of the oil pump, turn the screw (1) to the right in order to increase it and to the left in order to decrease it.

1 - Pressure adjustment.

2 - Vacuometer nipple.

3 - Electrovalve.

4 - Manometer nipple.

5 - Oil outlet

6 - Oil return.

7 - Oil inlet.

MOD. AS47C

1

2

3

4

5

6

7

Evolution FDX

26

22.11 Oil installation diagrams

These diagrams and charts belong to oil line installations without reductions and with a perfect hydraulic sealed. It is highly recommended to use copper pipes. Depression of maximum 0,4 bar (30 cmHg) must not be exceeded.

In aspiration installation

H Pipes length

(m)

∅int 8 mm. ∅int 10 mm. 0,0 25 60 0,5 21 50 1,0 18 44 1,5 15 38 2,0 12 26 2,5 10 26 3,0 8 20 3,5 6 16

In charge installation

H Pipes length

(m)

∅int 8 mm. ∅int 10 mm. 0,5 10 20 1,0 20 40 1,5 40 80 2,0 60 100

22.12 Technical data

MODEL D-3 D-4 Minimum heat outlet Kg/h

1.5 2.3

Maximum heat outlet Kg/h

3 4.65

Minimum heat outlet kW

17.7 27.2

Maximum heat outlet kW

35.5 55.2

Motor power to 2800 r.p.m. W

90-110

Operating type

ON/OFF

Electric power

220 V - 50 Hz

Weight Kg

12.5

Preheater

Yes

In aspiration installation

H

In charge installation

H

27

22.13 Working diagram

5

10

15

1

2345

Kg/h

10200

20400 30600 40800 51000

Kcal/h

11.8 23.72 47.4435.58 59.3 Kw

mmH

2

O

OVERPRESSURE / FLOW

D-3

D-4

22.14 Oil flow versus nozzle and pump pressure

GPH 9 Atm.

Kg/h

10 Atm.

Kg/h

11 Atm.

Kg/h

12 Atm.

Kg/h

13 Atm.

Kg/h

14 Atm.

Kg/h

15 Atm.

Kg/h

0,40 1,45 1,55 1,60 1,67 1,75 1,80 1,87 0,50 1,80 1,90 2,00 2,10 2,20 2,27 2,33 0,55 2,00 2,10 2,20 2,30 2,40 2,50 2,60 0,60 2,20 2,30 2,40 2,50 2,60 2,70 2,80 0,65 2,35 2,50 2,60 2,70 2,80 2,90 3,05 0,75 2,70 2,85 3,00 3,15 3,25 3,40 3,50 0,85 3,10 3,25 3,40 3,55 3,70 3,80 4,00 1,00 3,60 3,80 4,00 4,20 4,35 4,50 4,70 1,10 4,00 4,20 4,40 4,60 4,80 5,00 5,10

22.15 Electric diagrams WITHOUT CONNECTOR

SATRONIC TF 830.3 LANDIS & GYR LOA 24

Evolution FDX

28

1 2 4 5 6 7 8 9

Precalentador

3

~

FR

TR

MB

MB'

EV

LB

Negro

Azul

TC TS

Ph

N

F

RP

1 2 5 6 8 10 11 123

FR

TR

∼

MB

EV1

LB

RP

Negro

Azul

TC

TS

Ph

N

4

EV2

Precalentador

F

7

WITH CONNECTOR

SATRONIC TF 830.3

LANDIS & GYR LOA 24

1 2 4 5 6 7 8 9 3

~

FR

TR

MB

~

MB'

EV

LB

Negro

RP

Azul

TC

TS

Ph

N

B4 S3

T2

T1 N L1

IG

F

CH

LB'

1 2 5 6 8 10 11 123

FR

TR

∼

MB

EV1

LB

RP

Negro

Azul

4

EV2

TC

TS

Ph

N

B4 S3T2T1 N L1

IG

F

CH

LB'

7

B4: Hour counter terminal. S3: Lockout lamp terminal. TC: Boiler thermostat. TS: Security thermostat. CH: Hour counter. IG: Main switch. F: Fuse. LB: Lockout lamp. LB': External lockout lamp.

FR: Photocell sensor. TR: Ignition transformer. MB: Oil pump. MB': Auxiliary oil pump. EV: Electrovalve. RP: Preheater's resistance. Ph: Phase. N: Neutral.

22.16 Oil easy connection

To connect and disconnect the red oil tube to the combustion line, proceed as follows:

29

- Press the connector o-ring in the direction of the arrow shown below, and simultaneously pull the red tube.

PRESS

O-RING

RED PIPE

OIL

OIL EASY CONNECT RACOR

Evolution FDX

30

23 ALARM CODES

The boiler Evolution EV FDX is equipped by an electronic circuit able to sense, by means of a continuing autotest, the operation lockouts and alarms of the boiler. When the electronic control senses an operation error, indicates it showing an alarm code in the screen of the display. In the following list the possible alarm codes are described:

CODE ALARM DESCRIPTION

AL AP

bar ºC

Pressure.

The pressure of the boiler is lower than 0,5 bar. The boiler stops working. To restart working it is necessary to fill the boiler betwen1 and 1.5 bar. This alarm happens when the installation is empting or when it is a leakage. If this alarm is repetitive, put in contact with the nearest technical service support.

AL AT

bar ºC

Temperature.

The boiler rise to the security temperature of 110 ºC. The boiler stops working. To restart working, push the scurity thermostat's button, once the temperature has decreased. If this alarm is repetitive, put in contact with the nearest technical service support.

AL A

Q

bar ºC

Burner.

Burner is lockout. To restart working, push the button located at the burner (4). This alarm happens when there is any operation error in the burner or in the oil installation. If this alarm is repetitive, put in contact with the nearest technical service support.

AL S1

bar ºC

Boiler sensor.

The boiler temperature sensor (8) is broken or disconnected. To change it, put in contact with the nearest technical service support.

AL S2

bar ºC

DHW sensor

DHW temperature sensor (3) is broken or disconnected. To change it, put in contact with the nearest technical service support.

AL S4

bar ºC

Pressure sensor

The pressure sensor (9) is broken or disconnected. To change it, put in contact with the nearest technical service support

NOTES: It will be helpfull communicating the alarm code to the technical service officer, when

their service is required.

31

24 FAILURES

This section provides an index of the most common failures in both the burner and boiler.

Burner failures:

It has already explained that the burner is equipped with a locking system indicated by a light, and it could unintentionally occur that it becomes locked making the push button be put on. In this case, unlock it by pressing the push button.

FAILURE CAUSE REMEDY

- Oil valve closed Open

- Power supply is not reaching the boiler Check

- Nozzle faulty or dirty Replace or clean

- Poorly-adjusted electrodes Adjust

- Timer at automatic position Set it to manual

IT DOES NOT

PUT ON

- Poorly-set room or boiler thermostat Set properly

- Nozzle faulty Replace

- Flame sensor dirty Clean

- Fume circuit clogged Clean

FREQUENT

LOCKING

- Oil filter or burner pump dirty Clean

Boiler failures:

FAILURE CAUSE REMEDY

- The pump does not rotate Unlock the pump

RADIATOR DOES NOT

HEAT

- Air in hydraulic circuit Drain the installation and boiler (The air vent plug is always to be loose)

- Poorly-adjusted burner Adjust properly

- There is no sealing on the uptake Eliminate the leakage

- Unstable flame Check the burner

EXCESSIVE

NOISE

- Uptake with no thermal insulation Insulate properly

Evolution FDX

32

NOTES:

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33

.......................................................................................................................................................

NOTES:

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Evolution FDX

34

.......................................................................................................................................................

NOTES:

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35

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POSTAL ADRESS FACTORY AND OFFICE

Apartado 95 Bº San Esteban s/n 20730 AZPEITIA 20737 RÉGIL (Guipúzcoa)

Telfs: (+34) 943 813 899 Fax: (+34) 943 815 666

www.domusa.es

CDOC000086 ING 05/05

DOMUSA EVOLUTION EV FDX Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual