Motan OPTIMUS MT, C15SPV 24MEFM, MAXOPTIMUS C17 SPV 31 MEF Technical Instructions

KÖBER LTD DUMBRAVA ROSIE - VADURI BRANCH OFFICE

Branch Office:Vaduri, No. 280, Alexandru cel Bun, Neamt District, Postal Code 617511, Romania

Phone : [phone], Fax : [phone]

E-mail : , www.motan.rooffi[email protected]

TECHNICAL INSTRUCTIONS

FOR INSTALLATION/ USAGE/ MAINTENANCE

Köber LTD

Vaduri Branch Office

1798

OPTIMUS MT

C15SPV 24MEFM

CONTENTS

General presentationof the wall hung gasboiler

Connection for evacuation of theflue gases ...............................................................

Operating mode

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

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

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

General description of the wallhung gas boiler ...........................................................

Description of the boilers types..................................................................................

Symbols ....................................................................................................................

General instructions concerning the safetyof the wall hung gas boiler ........................

Technical characteristics...........................................................................................

Functional and constructive characteristics ..............................................................

Constitutive elements of wall hung gas boiler.............................................................

The heat generator ...................................................................................................

The exhaust gases/water heat exchanger.................................................................

The heating and domestic hotwater circuits Hydrauliccircuits ..................................

The command and control system ............................................................................

The external shell ......................................................................................................

The hydraulic characteristic of circulationpump .........................................................

Mounting/installation instructions ..............................................................................

The location of the unit...............................................................................................

The central heating ...................................................................................................

The gas supply ..........................................................................................................

The electric power supply .........................................................................................

Instructions for the final user(beneficiary) ..................................................................

Operating instructions ..............................................................................................

The control panel .......................................................................................................

The LCD display board inthe user module .................................................................

The LCD display in theuser module ................................................

The pressure checking ..............................................................................................

Additional facilities that may beobtained by ...............................................................

Handing over to the beneficiary.................................................................................

Recommendations for the yearly checking ...............................................................

Marking, documents, packing, storage, transport, quality and warranty conditions .....

Marking ......................................................................................................................

Documents ................................................................................................................

Packing ......................................................................................................................

Storage .....................................................................................................................

Shipment ...................................................................................................................

Quality and warranty conditions .................................................................................

Responsibilities during the warranty period ...............................................................

Malfunctions which refer to themanufacturer's responsibility ....................................

Malfunctions which refer to theresponsibility of the utilities provider ...........................

Malfunctions for which the manufactureris not responsible .......................................

List and plans necessary formounting and putting into service ...................................

Plan 1 ........................................................................................................................

Plan 2 .........................................................................................................................

Plan 3 .........................................................................................................................

Plan 4 .........................................................................................................................

Plan 5 .........................................................................................................................

The domestic hot water module, The heating module, Antifrost function, Auto-checking

and safety functions, The boiler shutting down in safety conditions .....................................

The functioning of the heating unit
Other functions concerning the safety ofthe boiler

Pg
Pg
Pg.
Pg
Pg 4
Pg 5
Pg 5
Pg 6
Pg 6
Pg 7
Pg 7
Pg 8
Pg 8
Pg 9
Pg 10
Pg 10
Pg 10
Pg 11
Pg 11
Pg 12
Pg 13
Pg 13
Pg 13
Pg 13
Pg 13

Pg 15
Pg 16
Pg 17
Pg 17
Pg 18
Pg 19
Pg 19
Pg 20
Pg 20
Pg 20
Pg 20
Pg 20
Pg 20
Pg 20
Pg 21
Pg 21
Pg 22
Pg 22
Pg 23
Pg 23
Pg 24
Pg 25
Pg 26
Pg 27

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INTRODUCTION TO THE BOILER

General description of the boiler

The wall hung gas boiler is a fuel gas-consuming appliance which has the role of
turning the fuel gas power into thermal energy through burning.

This appliance runs unsupervised due to its protection and control systems.

The boiler is made of many parts that we are going to describe in the following

chapters.

The gas enters inside the boiler through the gas feeding circuit made ofa coupling
and a reducing valve which will be set at 20 mbar for G20 A(L) and A(H) subgroups.
The reducing valve will be set at 37 mbar for LPG (propane subgroups and propane­butane mixtures). Thus it gets into the gas valve which has the role of controlling the
gas discharge at the outlet to the burner.

The ignition achieves by flame activating by an ignition electrode, by means of

an ignition transformer.

During the combustion, the flame sensing is made by an ionization sensor.

The boiler type with forced draft is provided with a fan which evacuates the
exhaust gases. In the initiation phase, this evacuates an air volume to provide an
unexplosive ignition. The explosive ignition may occur due to a gas storage from the
non-operating period.

The combustion chamber, as a plate parallelotope, interior ceramics fibre-lined,

is designed to allow the transfer to the exchanger with less heat leakages.

In case of the CH circuit of the two heat exchangers type, the heat resulted from
fuel gas ignition is taken over by the monothermal heat exchanger and sent to the
thermal agent (water) which is delivered by the circulating pump through the heating
installation. In case of on the DHW circuit, a water discharge is detected by the
flowmeter, the 3- way gas valve is energized. The 3- way gas valve achieves the
transition from the central heating circuit on the short circuit through the plate heat
exchanger (the main plate heat exchanger) and the heat transfer is realized by means
of this to the DHW circuit (the secondary plate heat exchanger).

The scavenging is realized by means of the fan.

The running protection andcontrol are performed electronically. The boiler setting
is made from the control board (see the chapter concerning this subject).

DESCRIPTION OF THE BOILER

3

BOILER

TYPE

C15 SPV 24 MEFM

Useful power

Accessories

[kcal/h] The fan The pump

The

expansion

vessel

DHW

instant

production

20670

X X X X

SYMBOLS

S- with instant production of DHW (without cumulation)
P- with pump
V-with closed expansion vessel
24-the maximum power output in kW
M- the burner is supplied by a continuous modulating valve
E- the ignition and the control of the flame are electronically-made
F-the forced scavenging
M-monothermal

OPTIMUS MT

C 15 SPV 24 MEFM

GENERAL INSTRUCTIONS CONCERNING THE BOILER SAFETY

!
!

!

!

!

!

!

!
!

!

!

!

This manual is part of the product and it has tobe given to the user.

Read this manual carefully and keep it carefully for a further application by the user and by the

mounting and installing authorized personnel.

The installation, the putting into service, the service-repair operations and a periodical

technical checking are performed only by authorized personnel in accordance with the regulations
in force. All the indications of this manual must be respected; any exception may cause damages
and the producer isn`t responsible forthese.

In case of a defective running of the device, shut it down and call up immediately one of the

breakdown services units.

To guarantee the boiler efficiency and its correct running it is recommendable that the boiler be

checked yearly by the qualified personnel,complying with the manufacturer`s conditions.

If the device is sold or given, make sure it is delivered with its technical handbook in order to be

consulted by the new user/ installer.

In case of some components damaging there will be used only the original components. You

must have the manufacturer`s acceptance to use some components from another company, you
must obtain the writtenacceptanceof the producer sothat you may use those components.

This boiler will be used properly. Any other usewill be considered unsuitable.

There is excluded any contractual or extra-contractual responsibility of the producer for the

damages caused by the installing or usage errors and by thenon-observance of his instructions.

The maximum limit of the water hardness inlet is of maximum 5ºF (French degrees) on the

DHW circuit, equal to 50 mg CaCO2 or an equivalent quantity of other salts as Ca and Mg. It is
compulsory to install asoftener filter onthe domestic water circuit, a mechanical impurities filter (Y
filter) on the CH installation return and a pressure controller onthe gas supply circuit.

It is recommendable to use these boilers types presented in this manual to heat areas of 150

mp (at a mediumheight of 2,5 m of the heat volume).

Unsubmitting to these technical manual regulations as to the warranty certificate leads to

warranty loss.

4

RESETMOD

Name

Type OPTIMUS MT - C 15 SPV 24 MEFM

Forced

Sealed

92,7%

93,7%

10 - 23,7 kw

10,9 - 25,49 kw

20 mbar

35 mbar

30 - 37 mbar

230 VAC, 50 Hz

160 W

40 kg

1 L

1,1- 2,6 Nm /h

0,4 - 1,07 kg/h

Draft

Combustion chamber

Efficiency at maximum load

Efficiency at minimum load

Useful power (min/ max)

Burner nominal load (min/ max)

Gas pressure

NG on coupling ( behind the reducer)

NG on maximum admitted output

LPG

Power-supply

Power consumption

Weight

Heat exchanger output

-

0,5 ºi 3 bar

40 - 80°C

3/4"

1/2"

3/4"

275

415

700

850

7 L

Central heating

Minimum and maximum admitted pressure

Temperature on the heating circuit

Connections - inlet outlet central heating

- inlet outlet DHW

- gas supply

Dimensions - depth (mm)

- Width (mm)

- Height (mm)

- With mounted elbow (mm)

Expansion vessel with membrane

NG consumption (8500 kcal/ Nm3)
At useful power (max/ min)

LPG consumption (20425 kcal/ kg)
At maximum output

3

5

TECHNICAL CHARACTERISTICS

CONSTRUCTIVE AND FUNCTIONAL CHARACTERISTICS

30 - 60°C

13,5 l/min

9,7 l/min

7,5l/min

DHW temperature range

Flow values

Ät °C=25

Ät °C=35

Ät °C=45

PRINCIPAL COMPONENTS OF THE BOILER

The heat generator

It is designed to supply the necessary heat for the heating exchange withthe heating and DHW

circuits. It is made of the following elements:

The gas feeding circuit will be performed through a reducing valve which will set the inlet

pressure at 20-25 mbar NG,respectively 30-37 mbar for LPG.

It is compulsory to mount a pressure controller on the gas
feeding circuit.

1. The gas valve

2. The burner

is designed to allow a
continuous modulation of combustion,
supplying the minimum, medium and
maximum gas pressures required by the
boiler running at the minimum, medium and
maximum load. The connector between the
gas valve and the burner is the copper pipe
(14x1).

is stainless-made, forced or
atmospherics, with 11 cannularinclines and it
runs with fuel gas (NG or LPG). The burner
output is set in a modulated systemby means
of a gas modulating valve so that it supply a
maximum useful power of 23,7 kW.

3. The combustion chamber is design to
allow the heat transfer to the heat exchanger
with less heat leakages. We chose a simple
constructive solution as a rectangular piping
of 170 mm between the burner and the heat
exchanger. To reduce the heat leakages, the
piping walls are isolated indoor with heat
insulating material (ceramics fibres).

4

3

2

1

Domestic cold water pressure

Exhaust gases temperature at rated output

Burned gases connection ( input- output)

Burned gases connection length

Orientative values

Maximum water content in the installation

Maximum surface of the precinct

0,2 - 8 bar

142,4°C

O 100 / O 60

Max 3 m

150 l

150 m²

6

7

4

The boiler is provided with afan for scavenging.

The flue system and the air supply (for the boiler with forced draft) is made of two concentric

pipes connected to the outside of the room where the boileris mounted.

is monothermal, the domestic water is
heated through the plate heat exchanger.
From the power pointof viewthe rated output is of 24kW and the efficiency over 93%.

-

The fan

The exhaust gases/ water heat exchanger

The exhaust gases/ water heat exchanger

The heating and DHW circuits - Hydraulic circuits

- DHW circuit is with plateheat exchanger.

5

7

They are designed to allow thethermal
transfer to the external heating
and DHW installations.

- the loading circuit of the installation is
made of the valve and the copper pipe
connected to the domestic cold water
supply line;

- the relief valve of the circuit is designed
to reduce the pressure from the heating
circuit and to open at 3 bars full
pressure;

- the ventilation circuit of the installation
is made of an air-release valve which
allows the air discharge from the heating
circuit, mounted on the circulating pump
shell;

- The heating agent recirculating pump (7)
is designed to supply the output
necessary for the heating agent recycling
through the heating circuit;

- Expansion vessel is designed to allow
the expansion processes from the heat
installation, preventing from hydraulics
overstraining or damaging. This has a
capacity of 7 litres.

- The automatic by-pass circuit is made of
a copper pipe of 14x1 mm fixed between
the heating circuit turn and return and a
safety valve set to open at 0,3 bar to
allow the heat carrier recycling through
the heat exchanger and pump, in case of
some pressure differences,

between the external heat installation

turn and return at over 0,3 bar.

The heating circuit

8

The command and control system of the boiler running performs:

The command and controlsystem is madeof thefollowing components:

- the ignition and the protection when the flame is extinguished, provided by the electronic
ignition;

- the protection when the gas is switched off, provided by electro-valve;

- the water pressure signalling in the boiler, provided by minimum pressure sensor;

- the temperature signalling on the heating and DHW circuits, provided by the electronic board
functions;

- the setting of the heating cycle following the instructions of the temperature control switch;

- the safety of the boiler against excessive temperature, provided by the safety thermostat at
overpressure, through the safety valve and at water leakages through the minimum pressure
switch from the circuit;

- protection against draft deficiency, by the fan derangement or the exhaust piping blockage of

the exhaust gases, provided by the combustion pressure switch .

- the electronic board

-

- heating circuit temperature

sensor

- DHW temperature sensor

- Flowmeter

- Ignition/ ionization electrode

as a
controller of the boiler running
(see the attached drawing).

the measuring and pilot cells
of the functional parameters for the
boiler

which sends the
temperature signal to the electronic
control block of the heating circuit.

which sends the temperature signal
to the electronic control block of the
DHW circuit.

as a detector of
the DHW consumption which sends
the DHW circuit running command
to the electronic control block.

(8) with double role, of combustion
flame activation and sensing.

- Air pressure switch (9)

- Temperature sensors

- Temperature switch (10)

- Programmer ambient sensor

- Water pressure sensor

The external shell

as a detector and controller of the exhaust gases, which

determines the heating and DHW circuits running.

as reading the temperature on the heating circuit (the electronic

board display).

as a detector and controller of the maximum temperature on the
heating circuit which sends the non-running command of the heating circuit in case a maximum
admitted temperature is exceeded.

as setting the ambient temperature from a room (optional).

as a detector of the minimum pressure on the heating circuit.

It has a parallelepipedal shape. It is detachable and electrostatically painted.
The shell covers the pressurized combustion chamber and the enclosed installations.

9

10

8

11

For designing the central heating installation we must be aware of the hydraulic features of the
pump.

9

The hydraulic characteristic of the pump

Pressure pump P[mca]

Pump output Q[mc/h]

the third stage of
the speed

the second stage
of the speed

the first stage of
the speed

10

MOUNTING-INSTALLATION INSTRUCTIONS

The chapter addresses both to the qualified persons which contribute to the boiler installation
and to the beneficiary which is concerned that the effected works to be done following the
safety rules in operation of all the installations which contribute to the good running of the
boiler.

!

!

!

The boiler installation is not the same with the boiler

starting.

The boiler starting must be done by the authorized

personnel in accordance with the current legislation.

There is no guarantee without the authorized personnel

signing the putting into service statement, and the
company withdraws any boiler guarantee or running
responsibilities.

The boiler location

The central heating

In accordance with the current regulations: The norms for the designing and execution of the
NG supply systems, The norms for the NG supply systems utilization and The norms for the
designing and execution of the liquefied petroleum gas supply systems (LPG).
There are several conditions for installing the boilers:

-The appliances have the protection IP 40 level.

-The boiler may be installed in any room with an air humidity of maximum 60% between
20-30º C.

The heating system will be designed by the qualified and authorized personnel, in the
mounting/installing activities.

It is important to pay attention to the pipes dimensions, head losses and heating elements

while designing the heating system.

The installation filling up must bedone with softened water.

Couplings may be executed by gluing or compression fittings for the copper pipes, coupling
etc. The pipes must be provided with the necessary inclination for the ventilation and a light
evacuation to the adequate points fromthe installation.

Couplings and sockets

The evacuation. The evacuation points must be situated in the practicable places which allow
the water drainage from the heating circuit. It is recommendable that the minimum diameter should
be ½.

The ventilation. It is recommendable that the manual ventilators should be introduced on each
heating element (central heating). The water contains a certain quantity of resolved gases at the
first filling as well as thefurther water fillings of the heating system.

Once the system has been heated, the gases will be collected in the highest points of the
system whence they must discharged. The installation of some (manual or automatic) ventilators
will allow the evacuation both atthe first filling and during the running, in thesesystem points.

The filling. After the pipes connecting, the two circuits will be filled up with water gradually (the
boiler and the installation, respectively the coil from the DHW circuit) till the complete filling and it
should be checked so that thereare no leakages.

11

!

!

!

You must not use the boiler empty or only partly filled with
water.
THE USE OF EMPTY OR PARTLY FILLED BOILER MAY
LEADS TO EXPLOSION.
The domestic cold water supply pipe of the DHW
processing circuit remains permanently open (the
closing of the net is made only by the valves from the
discharge points) to allow the dilatation taking over from
this circuit.

MOUNTING-INSTALLATION INSTRUCTIONS

The gas supply

The gas supply (NG or LPG) must be done in accordance with the standards.

* The minimum/maximum inlet pressure in the gas valve, in case of using the natural gas
must be between 25-30mbarstatic and between 20-25 mbar dynamic.
* The minimum/maximum inlet pressure in the gas valve, in case of using LPG, must be
between 30-50 mbar static and 25-45 mbar dynamic.
In case of notsubsuming tothese standards the combustion performanceswill lower.
On installing you mustknow the gas type that the boilerhas beenset for,to resetit correctly for
another gas type if it needs.
For exchanging the NG running forthe LPG running you mustfollow two operations:
* The setting from the electronic board which is performed by positioning the J6 jumper
(see the Electrical Diagram) on the two pines LPG module. (The J6 jumper is situated on a
single pine methane gas module).
* The mounting of the nozzles set of 0,77 mm diameter used for LPG running. (The
diameter of these nozzles is 1,3mm for methane gas).

The exchanging for NG is realized by performing the setting operations, from above, in the

reverse sense.

The setting will be performed by the producer following the beneficiary request or the service

authorized according to the current standards, operation which is performed on putting intoservice.

! You must install a pressure controller on the gas supply

circuit.

! The gas supply pipes must not have diameters smaller than

the boiler coupling.

Electric power supply

The boiler must be connected to a monophase net of 230 V-50 Hz with zero protection,
through the 5A fusible plugs. The colours semantics will be as follow: brown= phase, blue=null,
green-yellow= earthing.

The external connections must be according to the current standards. The connection to the
electrical network of the building must allow a complete electrical isolation of the boiler in case an
intervention must be done.

12

!

!

You must not shut down the exhaust checking device, because

your life and healthwill bein danger.

Only the qualified personnel will do the replacement, according to

the current legislation andto theoriginal pieces used by the producer.

!It is obligatory to place the boilers in areas with ventilation

according to the current standards. The technical instructions
should be studied beforemounting/ installing, starting or servicing.

It`s forbbiden to install the boiler without earthing.

THE COUPLING FOR SCAVENGING

Without coupling to the chimney

The scavenging is made through a pipe of 60 mm diameter, coaxial with the air inlet

pipe of 100 mm diameter. The exhaust pipe is within the inlet one.

The input-output coaxial flue system is delivered with the boiler. It is made of an elbow,

input-output pipe and the necessary fittings.

13

INSTRUCTIONS FOR THE FINAL USER (BENEFECIARY)

The control, protection and automation elements provide:

* The flame ignition
* The flame sensing
* The temperature and water signalling in the boiler
* The temperature regulation on the heating circuit
* The temperature regulation on the DHW circuit
* The pump starting at the heating water demand
* The safety of the boiler at overheating and overpressure
* Draft deficiency (air pressure switch)
* The boiler safety at minimum water level (water pressure switch)
* The DHW demand sensing (flowmeter) and giving priority to this discharge

The indicators and the operating buttons are placed on the control board.
The chronothermostat or the room thermostat may be installed on demand.

UTILIZATION INSTRUCTIONS

The control board

Display board LCD in the user module

SW8

SW 7

SW2

Button - Operation function

This button shuts down/ opens out the boiler (the boiler is still connected to the
tension). In the module Off the board is deactivated completely excepting the symbol 1.
When activating, the activated symbols appear on the LCD display while the symbol 1
disappears

Summer/ winter: Pressing this button, you select summer or winter module. The activated

symbols are two for the summer (in this module, any value of the temperature is
displayed in stand-by, while, if there is any DHW demand, the DHW setting temperature
will appear) and 3 for thewinter module.

Reset from blocking: reset if theboiler isin Err E2, otherwise there will beno result.

On/Off:

Fig 1. The control board for OPTIMUS MT

SW3

DISPLAY

SW 5

SW1

SW6

SW4

SW7

SW2

SW8

14

SW 4

SW3

SW6

SW1

SW5

(-)

(+)

(-)

(+)

Comfort: pressing this button, you select the comfort module(symbol 6 on) and the

set range of the domestic circuit may decrease. Press again to cancel it (symbol 6
off).

Heating: Pressing the button once, the temperature preset by the heating is
displayed; the setting will decrease if you keep pressing. While visualizing the set
point by the heating, the symbol 8 is flickering. If the external probe is activated, the
temperature of the core circuit will not be changed directly, but two different
parameters will decrease: the wanted temperature into the room and after 5
seconds the symbol "- -" will appear on the display and it holds for one second,
then the dispersion coefficient into the building is displayed and may be changed.

Heating: Pressing the button once, the temperature preset by the heating is
displayed; the setting increases if you keep pressing. While visualizing the set point
by the heating, the symbol 8 is flickering. The heating, the temperature from the
room and the dispersion coefficient may be increased in the same way as SW3.

DHW: Pressing the button once, the preset temperature of the DHW is
displayed; if you keep pressing the setting will decrease. While visualizing the set
point by the heating, the symbol 7 is flickering.

DHW: Pressing the button once, the presettemperature ofthe DHWis displayed; if
you keep pressing the setting will decrease. While visualizing the set point by the
heating, the symbol 7 is flickering.

Chimney sweep" function: If you press SW7 and SW8 simultaneously, With the boiler

in Off position, youwill activate"Chimney sweep"function, thereleased temperature is
displayed and the symbol 5 starts flickering. After the normal starting cycle of the
heating it starts at maximum capacity. This situation persists till the temperature of the
core circuit reaches a safety threshold, after which the heat is deactivated andit will be
activated again in the moment that the temperature reduces below the limit. Any DHW
demand activates this function, but it may be done manually by pressing the button
SW7 and the symbol 5 willvanish.

-the heating system 30-80ºC

-the heating from bottom system 15-40ºC

-domestic hot water 30-60ºC

-DHW comfort 35-45ºC

-External sensor:
the temperature in the room 10-30ºC
dispersion coefficient 5-35ºC

-ignition power (soft-start) 0-99% of modulation current

-max. heating power 0-99% of modulation current

-max. fan speed 0-99% of fan speed

-min. fan speed 0-99% of fan speed

SW7+SW8

Values range controlled by the display panel LCD

Electronic board operating

15

DHW module in case of monothermal boilers (symbol 7 on)

The heating module (symbol 8 on)

Comfort plus function (symbol 13)

Anti-frost function (symbol 4)

"Chimney-sweep" function (symbol 5)

The self-checking system and the protection function

Ignition demand in the DHW module takes priority of the heating module. The burner
ignition takes place when a DHW demand appears; the boiler tries to supply hot water to the
user at a preset temperature. The demand is detected through the flowmeter. In this case, the
pump runs. If the hot water temperature is higher than the preset value, the boiler will shut
down. As soon as the heat wasted, the boiler is activated again.

If the boiler is on the winter programme and by deactivating the room thermostat, the domestic
water temperature is lower than the one set before, the boiler will carry out the ignition at soft­start power, the flame modulation starts and keeps running till the boiler reaches the running
position. If the water temperature is higher than the previous set limit, the boiler will shut down
but the pump will still be active; re-ignition occurs when the water temperature decreases below
the set value, on condition that a lapse of time "of preventing from appearing the frequent
cycles" have passed. The maximum power of the boiler in the heating module is set by means
of the buttons from the control panel during
the heating.

Symbol 13 inermitent - the conthrol system of boiler is achieving the mentain of temperature in
the primary circuit as so, at the request of DHW the time necessary for reaching the setted
temperature to be smaller then 5 seconds. This function is activated automatically at first
request of DHW and remains activated during 60 minutes.

When the sensor of the system detects a temperature lower than (6ºC), the burner is
activated in the heating module and the pump starts running. This state persists until the
cancellation temperature of the anti-frost function is reached (20ºC).

This function is created specially to cancel the normal adjustment of the boiler control,
allowing it function at the maximum heating power. The function is useful during installation and
the moment when the combustion products are verified according to the current standards. The
function may be deactivated manually from the control board or at any other DHW demand.

The system is provided with several diagnostic functions, signalling the operating position of the
boiler and the disturbances type which may occur on the control board display:

-the domestic water temperature:
the heating temperature in ºC (from 0ºC to 99ºC) or the DHW system is displayed ( if available)

-blocking the adequate temperature (irregularity):
in case of a failure in detecting the flame at the end of the three ignition cycles, the mother is
to block and the symbol flickering ErrE2 occurs on the control panel display.

-parasite flame (irregularity)
in case of a presence of a parasite flame, the symbol Err E1 flickering occurs.

16

- insufficient pressure of the water in the hydraulic core circuit (irregularity)

- Absence of draft on start (irregularity):

The boiler shutting-down in safety conditions.

The pressure visualizing

:
in case the pressure sensor measures an insufficient pressure of the water in the system, (<0,5
bar) the burner and the pump are deactivated and the flickering intermittent symbol Err E1
occurs on the display.
Disturbance of a temperature sensor (irregularity):

1.Sensor for the central heating water: any disturbance of the sensor caused by a wrong
contact or a short-circuit leads to the immediate deactivation of the burner, pump and the
flickering intermittent symbol Err E1 occurs.

2.Sensor for DHW: any disturbance of the sensor caused by the wrong contact doesn`t lead to
the immediate deactivation of the burner but to displaying the flickering intermittent symbol Err
E4 for monothermal boilers.

In case the pressure switch doesn`t commute the
TW pre-cleaning in due time, the boiler won`t start running and the intermittent symbol Err E5
will occur after 10 seconds. This irregularity vanishes when the flame is detected at the end of
the operating cycle.

-Removing the combustion products causes the activation of the safety devices (irregularity):
OPEN CHAMBER

The safety devices of the combustion products are activated and cause the boiler automatic
shutting down, the intermittent symbol E5 occurs on display. This irregularity disappears only
pressing the button SW3. In case the limit thermostat (LT) is activated, the system will shut
down automatically and the intermittent symbol Err E8 occurs on the control panel display. This
irregularity persists even if LT is deactivated. To reset the normal operating system it is sufficient
to press the reset button SW2.

In case the final user establishes that the appliance has an abnormal running, if the error codes
keep displaying or if the appliance manifestations can not be understood, he has the obligation
of shutting-down the boiler as soon as possible and in maximum safety conditions. The user
must perform the following operations:
* press STAND BY and the boiler shuts down
* disconnect the boiler from the electric power supply circuit by unplugging
* Disconnect the gas supply circuit by switching on the gas valves
* Interrupt the DHW and the DCW circulation by switching on the gas valves corresponding to
these circuits.
After boiler shutting down in maximum safety conditions, the user will call the service unit he
belongs to (see chapter 1, subchapter 1.4).

The pressure from installation is displayed and it is useful to installation filling up. The
beneficiary will check recurrently whether the pressure in installation has lowered below the
value set on filling.
The pressure will maintain between 1-2 bars. If the minimum pressure lowers below the value of
0,5 bars the boiler will display the E1 signal and it will shut down. If the pressure exceeds the
value of 3 bars, the safety relief valve will open and it will release the system from the
accumulated pressure.

17

THE BOILER RUNNING

ANOTHER FUNCTIONS CONCERNING THE BOILER SAFETY

1) The pump post-circulation

2) The pump anti-blocking function

3) The 3- way valve anti-blocking function

The antifreeze function

The boiler running will be < without permanent control> provided automatically by the controllers
installed on the boiler, and eventually by the environment devices (room thermostat). These
devices must be set at thetemperature corresponding to the controlled environment.

a. the temperature settingon the heating circuit will be between 40-80º
b. the room thermostat will be set atthe wanted temperature in the room.

In case the central heating installationis drawn off the tensionduring the cold period or in case,
due to some disturbances, the water temperature from the boiler will be below zero degree for
more than 2-3 hours, the boiler, the heating installation and the domestic water installation will be
exhausted.

Also the boiler supply will bedisconnected fromthe current and gases net.

Each time the boiler is shutting down (in the heating module), the pump keeps running for a
short period of time so that it could prevent from water overheating in the main heat
exchanger.

If the boiler doesn`t effect any cycle during a 24 h period, the pump will start running for a few

seconds to avoid blocking caused bythe non-running.

On each pump shutting down, the deflection valve is activated for one second and then it

reverts to the initial position.

4)

When the temperature sensor detect a temperature lower than 6oC,the burner is activated in
the heating module and the circulationpump start to operate.

Additional facilities you may obtain:

- Mounting an exterior temperature sensor, the boiler adjusts the heat carrier temperature
depending on the temperature value from outside the building, the room wanted temperature
and the heat leakage coefficient through the building walls.

90

80

70

60

50

40

30

20

10

0

- 40 - 20 0 20 40

Outdoor temperature [°C]

Recommended temperature [°C]

90

80

70

60

50

40

30

20

10

0

- 40

- 20 0 20

40

Outdoor temperature [°C]

Recommended temperature [°C]

T. amb = 30°C

Ke = 35

Ke = 5

T. amb = 10°C

The heating circuit temperature

diagram depending on the

outdoor temperature at

different set room

temperatures and Ke=1

The heating circuit temperature

diagram at different set

dispersion coefficients

Heating temperature=Room temperature +Ke*(room temperature-outdoor temperature)

Room temperature-the temperature of the room

Outdoor temperature-the external temperature

Ke- dispersion coefficient

18

19

Delivering to the user

RECOMMENDATIONS FOR YEARLYCHECKING

It is compulsory that the qualified personnel to instruct the user in great detail about the following
aspects on boiler starting:

The boiler starting and the shutting-down procedures, in safety conditions by checking the

following elements:

* the electric powersupply respectingthe polarity
* gas supply
* the central heatingcircuit supplyand loading
* the filling valvemust beclosed
* the pressure ininstallation by the manometerdisplaying fromthe controlpanel (1-2 bars)
* the valves from the DHW circuit should be opened
The running mode of the boiler and the possible problems which may occur. Also, the

importance of each buttonor switch from the control panel will be explained.

The user is warned that a water pressure falling in the system is caused by the heat carrier loss

which must be rectified before usingthe boiler again.

It is recommended that the user should ask for a checking of the boiler running by an

authorized person at least once ayear.

The user is warned upon theprecautions against freezing.
The instructions manual is delivered tothe user.

At the end of the instruction they must sign a document of putting into service, as he
assimilated the proper mode of the boiler utilization. This document is signed by the authorized
person too who performs the puttinginto service, who trained.

The person who performs the starting has the right of refusing the putting into service of the
boiler if he establishes that there are some irregularities, and he won`t contract the document till
these irregularities are remedied.

The one who performs the puttinginto servicehas notthe obligation of rectifying themounting
errors but he assumes the responsibility that the installations correspond to the chosen boiler from
the functional and constructive point ofview.

It is compulsory tocheck theboiler at a least two years period.

For a good running of the boiler and prolonging the boiler life it is necessary to be checked by
an authorized person at least once time a year. It is recommendable that this checking to be done
before the cold period, when the boiler won`t be used at the maximum capacity. The following
operations will be performed as: the main burner running is controlled and the burner is cleaned in
case this thing is compulsory; the boiler exhaust flue is checked and cleaned; the gas valve
controls are verified; the pump is verified; the scavenging system running is verified; the air
pressure switch running and the flue system tightness are verified; the combustion correctness is
checked, by analysing the exhaust gases; the gas supply systemtightness isverified, thedistrict
heating and the DHW circuits tightness are checked, the electrical installation is verified..

20

STAMPING, DOCUMENTS, PACKING, STORAGE, QUALITY AND
GUARANTEE CONDITIONS

STAMPING

PACKING

STORAGE

SHIPMENT

QUALITY AND GUARANTEE CONDITIONS:

A designated card is fixed on each product by sticking with following:

* The manufacturer company
* The name of the product
* The serial number and the lot
* Number of CE type examination certificate
* Quality Department authority sign
* The boiler type and size
* The gas type which the inputrated pressure has been set for

The boilers will be packed into the cardboard boxes, protected byboxboard angles.

The boiler will be delivered withall the installed components, less those from the Appliance book.

The boilers storage is achieved in dry places and protected by the bad weather and the chemical
agents.

During the shipment all the necessary measures must be taken to avoid the strokes or the

boiler damaging.

The guarantee is given if thefollowing conditions are provided:
* The correct installation andsetting by the authorized personnel.

* The yearly examinations are achieved on beneficiary demand and at the expense of the
beneficiary, the first year examination is compulsory to maintain theguarantee for the first two years
of usage.

* The exchanged components will be warranted for one year. This doesn`t mean that the
set guarantee period will prolong forthe entire device.

* The guarantee period prolongs from the moment the user has claimed the device
breakdown and till the time thedevice will be putted into service again.

* The heating installation designing and execution should be performed by qualified
person and a qualified unity (ifneed be).

* It is necessary to check andclean the installation before mounting the boiler in case of an
existing installations.

* The interventions during the warranty period will be performed only by the authorized
personnel of the manufacturer company.

Any repair by another person except the authorized personnel of the manufacturer company
leads to warranty loss.

DOCUMENTS

Each boiler is delivered with:

Technicalmanual, quality and guaranteecertificates,CE conformitydeclaration.

RESPONSIBILITIES DURING THE WARRANTY PERIOD

MAXOPTIMUS Boiler C 15 SPV 24 MEFM

MALFUNCTIONS WHICH REFER TO THE MANUFACTURER’S RESPONSABILITY

No.

Crt..

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Irregularities

Interrupted course or

defective sensors

Central heating

DHW

It doesn`t run or

it runs defectively

Defective

Pressure losses

Burner distortions

A defective running

You can`t operate the wanted
setting any more by pressing.

There is no information

displayed.

Any anormal function

determined by

electronical board

Defective ignition transformer

There is no spark between

the electrode and the burner

or it loses the spark due to

the defective isolation

or there is no flame.

Defective

Defective

Defective

The component

Temperature

sensors

The gas valve

The heat

exchanger

Ignition/

ionization electrode

Parasite spark

Replace the ignition/

ionisation electrode

The expansion vessel

The burner

The minimum

pressure sensor

The control board

(switch)

The electronical

board

Ignition

transformer

Ignition/ ionization

electrode

Overheating

thermostat

The fan

The air pressure

switch

Possible

error signal

E1

E1

E3

E4

E2

E7

E2

E5

E5

Repair mode

Renew the course

or replace the sensors

Replace the

gas valve

Replace the

exchanger

Replace the

expansion vessel

Replace the burner

Replace the

pressure sensor

Renew the course.
Replace the panel.

Replace the board

Replace the ignition

transformer.

Setting the distance.

Replace the electrode.

Replace the

overheating thermostat

Replace the fan.

Replace the

air pressure switch

21

MALFUNCTIONS WHICH REFER TO THE RESPONSABILITY OF THE UTILITIES PROVIDER

No.

Crt..

Causes

The component

The disturbed

system

Possible

error signal

Repair

mode

1

2

3

1

2

3

4

The boiler doesn`t

run, there is no

signal on display

The boiler starts

but there

is no flame.

The flame fires up
and then it puts out

The central heating

does not heat.

Electrical power supply

deficiency, inadequate

power circuit,

blown safety fuse

The gas valve is closed, the

ignition pressure is too low,
pressure controller isn`t set

adequately, there is air in the

gas pipe, the pressure is

lower than 0,5 bar

on the central heating

The reversal of phase with zero

The winter/summer switch is on

summer, the boiler was set

to run at a too low temperature,

the room thermostat is set at a
too low temperature, the pipes

lay-out is through a below 0º C

area and it froze, there

is air in installation.

E2

E2

The user calls the

authorized service

unit he belongs to.

The user calls the
authorized service

unit he belongs to.

The user calls the
authorized service
unit he belongs to.

The user calls the

authorized service
unit he belongs to.

The boiler doesn`t

run, there is no

signal on display

The boiler runs

intermittently .

Damage, noises

or vibrations

The running

with unsteady

temperature on

domestic water

- electrical power supply
deficiency (inadequate

electrical circuit,

blown safety fuse)

gas deficiency or unadjusted

inlet pressure into the

boiler or unadjusted

outlet pressure (burner)

Too low pressure

on domestic

water (>1bar)

Electrical

circuit

Gas supply

circuit

The domestic

water circuit

E2

Call the

electric

power

supplier

Call the

gas

supplier.

Call the

domestic

water

supplier.

MALFUNCTIONS FOR WHICH THE MANUFACTURER IS NOT RESPONSIBLE

No.
Crt.

Causes

The

component

Possible

error signal

Repair mode

22

LISTS AND PLANS NECESSARY FOR MOUNTING AND

PUTTING INTO SERVICE

Plan 1

The couplings arrangement of Wall hung gas boiler with forced draft

MAXOPTIMUS C15SPV24MEFM

THE Coupling

1. DHW inlet

CH turn DHW gas supply cold water CH return

2. DHW outlet

3. Central heating turn

4. Central heating return

5.Gas supply

1/2 ­1/2

” outside thread
”
”
”

3/4”

­3/4 ­3/4 -

-

outside thread
outside thread
outside thread
outside thread

DIMENSION

23

3

2

5

1 4

24

A

1

2

4

15

B

C

D E

6

7

16

12

14

13

9

19

10

8

11

5

3

17

18

Plan 2

Hydraulic diagram of The Wall hung gas boiler

with forced draft OPTIMUS - C15SPV24 MEFM

1.Electrical fan with Hall sensor

2.main heat exchanger

3.secondary heat exchanger

4.ignition/ionization electrode

5.electrical pump with exhauster

6.burner

7.gas modulator

8.3 bar safety valve

9.filling valve

10.flowmeter for the sanitary circuit

11.automatic by-pass

12. 3- way valve

13. temperature sensing probe for DHW

14. minimum water pressure switch

15. safety thermostat

16. temperature sensing probe for heating

17. expansion vessel

18. air pressure switch

19. drain valve

A. Heating turn
B. DHW outlet
C. gas inlet
D. cold water inlet
E. heating return

The Couplings diagram for the wall

hung gas boiler with forced draft

OPTIMUS MT- C15 SPV 24 MEFM

Plan 3

25

1

2

700

65 51 64 65

A B

C

D E

3/4” 3/4” 3/4”

1/2”1/2”

415

226

189

Panta 3% (aprox. 2 )

134

75

280

Gaz

Apa

125

155

189

94

Plan 4

Typical flue system applications for the

wall hung gas boiler with forced draft

C15SPV24MEFM

26

C12

C12x

C

12

C12x

C82

C32

C32x

C42

C22

C22

COAXIAL FLUE

TWIN FLUE

Lmin=1m; Lmax=3m

Lmin=1m; Lmax=5m

Lmin=1m; Lmax=5m

95

Plan 5

Electrical diagram for the wall hung gas boiler

C15SPV24MEFM

27

LIVE

NEUTRAL

PUMP

3 - WAY VALVE

N.C.

N.O.

1

J5

J1

56

EARTH

EARTH

ROOM
THERMOSTAT

LOCAL USER MANUAL
INTERFACE

55

54

J7

J13

J14

J2

J17

J16

J4

J9

J3

J18

TR 2

EARTH

FLAME
ELECTRODE

FAN

JP 1

CH PROBE

DHW PROBE

EXT. PROBE

FLOWMETER

RRESSURE

TRANSDUCER

MODULATOR COIL

CRONO TERMOSTAT
OPEN-THERM

961 INTERFACE

APS

GND

VCC

GAS VALVE

HALL SENSOR

SAFETY THERMOSTAT

INPUT

INPUT

0 Vdc

0 Vdc

+5 Vdc

+5 Vdc

52

51

50

49

48 47 46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

22

21

20

19

15

14

TO J3
(TO J9 IF MONOELECTRODE)

13

12

2

1

J20

F1

J11

U3

2

3

4

5

6

7

8 9

10

11