Somy C0814, C2028, C2836, C3650 Installation, Operating And Maintenance Instructions

Installation, operating and
maintenance instructions

C0814 / C2028 / C2836 /C3650

1

INDEX

INTRODUCTION 2

Who should read these instructions 2
Symbols 2
Applicable standards 2
Important notes 2

USER GUIDE 3

Use of the boiler 3
Setting the burner to safety mode 3

DESCRIPTION 4

General description 4
Operating principle 4
Design characteristics 4
Boiler views and key to parts 4

TECHNICAL CHARACTERISTICS 5

General 5
Operating condition limits 5
Dimensions 5
Hot water output data 5
General characteristics 5

INSTALLATION 6

Boiler room 6
Chimney connections 6

Heating connection 7
Hot water connection 7
Electrical connections 8

COMMISSIONING 14

Filling the hot water and heating circuits 14
Using the boiler for the first time 14

MAINTENANCE 14

Recommendation 14
Boiler maintenance 14
Safety equipment maintenance 14
Draining the boiler 14

SPARE PARTS 15

Casings 15
Accessories 15
Electrical accessories 15

SERVICE RECORD 16

Details of the installation 16
Service engineer’s report 16

2

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

The following symbols are used in these instructions:

APPLICABLE STANDARDS

The products described in this document have been certified at
European level (European Directive 92/42/EEC «Efficiency»). They
have also been awarded the Belgian “OPTIMAZ” LABEL (fuel oil

boiler).

IMPORTANT NOTES

These instructions are an integral part of the equipment to which
they relate and must be handed to the user.

The product must be installed and serviced by qualified engineers
in accordance with the regulations in force.

ES

declines all liability for any damage caused as a result of
incorrect installation or in the event of the use of appliances or
accessories that are not specified by ES.

Failure to follow the instructions describing the

test operations and procedures may cause injury to
persons or risks of environmental pollution.

N.B.:
ES reserves the right to change the technical characteristics and
specification of its products without notice.

INTRODUCTION

Important instructions for correct operation of the
installation.

D A N G E R

HOT

Danger of burning.

Danger of electrocution.

Essential instructions to ensure the safety of
persons and the environment.

ES : Energy Solutions

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53%2'5)$%

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To ensure that your system operates correctly, please

have it serviced annually by a qualified engineer;
servicing should be completed before the start of the
heating season.

Starting the burner:
in normal operation the burner starts automatically if

the temperature of the boiler is below the set point.

Before carrying out any work on the boiler, isolate it

from the electrical supply at the switch on the external
control box.

Also place the main switch on the control panel to

“OFF”.

9OUSHOULDFAMILIARISEYOURSELFWITHTHECONTROLPANEL

FIG

The user must not attempt to gain access to the

components inside the control panel.

1. Control thermostat

When the boiler is used for heating only, the boiler temperature may
be set at 60 to 90°C. If the boiler is used to generate domestic hot
water and heating, the boiler’s control thermostat should be set at
80°C to ensure optimum operating conditions.

2. Main switch

Use this switch to turn the boiler on and off.

3. Summer/Winter switch

Use this switch to star t and stop the heating pump.

4. Thermostat-pressure gauge

This gauge shows the temperature of the boiler and the pressure in
the primary heating circuit. The temperature must not exceed 90°C.
If it rises above this point, turn off the boiler and check the settings
on the thermostat. If the problem persists, call a technician.
The pressure must not fall below 1 bar. If it does fall below this point,
look up the section entitled “Gauge pressure of the heating installation”
in this section below.

5. Manual reset high-limit thermostat

If the boiler temperature exceeds 103°C, this safety device will be
enabled. The boiler temperature must drop below 60°C to re-start.
Unscrew the cover and press the re-start key with a pen or an object
with a similar sharp point. Replace the cover. If the fault persists,
turn off the boiler and call a technician.

0UMPOPERATION

The pump is controlled by a reset high limit thermostat, which is

located at the rear of the boiler. This is pre-set at 45°C. When the
boiler starts up, it delays the activation of the boiler pump, thereby
preventing any risk of corrosion in the combustion chamber.

'AUGEPRESSUREOFTHEHEATINGSYSTEM

Your system must be fitted with a heating safety valve calibrated to

3 bars.

Ensure that the system is always under water pressure. When the

system is cold and the air inside it has been vented, the gauge

must indicate a pressure between 0.5 and 1.5 bar depending on
the height of the building.

4OADDWATERREFERTO&IGON0AGE

• Open the filling valve (5).

• Close the valve properly after filling.

• Vent the system in order to obtain an accurate reading of the
pressure inside the heating circuit.

3AFETYVALVES HEATINGCIRCUIT

If water is found to be escaping from one of the safety valves, stop
the boiler and contact your installer for advice.

A monthly test is recommended:

Lift the lever on the drain cock for a few seconds to ensure that the

safety valve is working correctly.

If there is a problem after this short test, please

contact your installer for advice.

The water escaping from the safety valve can

be extremely hot and cause serious burns.

D A NG E R

HOT

FIG#ONTROLPANEL

FIG0814 #ONTROLPANEL





2 5133

"52.%23(54$/7.

If the burner is not working:

1. The burner indicator lamp lights up.

2. Press the burner reset button &IG  on the burner. Turn the
boiler off for several seconds at the main switch, then restart the
boiler.

3. If the burner still does not work, rearm the manual reset highlimit
thermostat on the control panel &IG.

4. If the anomaly persists, please contact your installer.

FIG

 FIG























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3 1

4

DESCRIPTION

GENERAL DESCRIPTION

• Model is a single boiler (heating).

• Equipment required: a water connection kit for the heating circuit
supply (optional).

• The 0814 control panel includes a control thermostat and a
thermostat pressure gauge.

• The control panel on 2028 boilers includes a main switch,
a Summer/Winter switch, a thermostat pressure gauge, a control
thermostat and a manual reset high-limit thermostat.

• 0814 Model: output of 16.6 kW.

• 2028 Model: Outputs in the range 20 to 25 kW.

• 2836 Model: Outputs in the range 28 to 36 kW.

• 3650 Model: Outputs in the range 36.5 to 51 kW.

OPERATING PRINCIPLE

Simple to control, safety assured

The temperature of the water in both the heating circuit and the hot
water circuit is regulated by a single control. This is achieved by
means of the control thermostat and the bulb is located beside the
boiler outlet. switch.

• A manual reset high-limit thermostat locks the burner if the
primary water temperature reaches 103°C.

• A minimum thermostat, fitted at the rear of the boiler, and preset
at 45°C, delays the activation of the boiler pump. This prevents
any risk of corrosion in the combustion chamber.

DESIGN CHARACTERISTICS

Outer body

The outer body which holds the primary water is made from STW 22
heavy gauge steel.

Flue ways

The boiler’s flue ways can be accessed from the front and include
a set of removable turbulators, in either stainless steel or chrome,
which have been specially designed to provide the optimum
combustion efficiency.

Combustion chamber

The boiler features a large, water-cooled combustion chamber to
guarantee a good flame.

Removable burner chamber plate

The chamber plate is fitted on a hinge (left or right) and made from
STW 22 steel. It is protected from the flame by a ceramic fibre
padding and a vermiculite brick.

Insulation

The burner body is insulated with rock wool padding (50mm thick).

Casing

The boiler is covered with a steel casing that has been stove enamelled
at 220°C after scouring and phosphating.

BOILER VIEWS AND KEY TO PARTS

1. Top cover

2. Heating outlet

3. Heating return

4. Chimney connection

5. Heating circuit

6. Combustion chamber

7. Boiler drain cock

8. Fuel oil burner

9. Left-right removable burner chamber plate

10. Exchanger (flue ways)

11. Front panel

12. Control panel

1 2

756

3

12

10

9

11

8

4

fig. 5

5

TECHNICAL CHARACTERISTICS

GENERAL

The appliances are supplied fully assembled, tested and packed
standing on a timber base with impact protection strips and wrapped
in

heat-shrunk plastic film. When the appliance arrives, remove the

pac

kaging and check that no parts have been damaged in transit.

Ref

er to the dimensions and weights listed below for handling

pur

poses:

DIMENSIONS

OPERATING CONDITION LIMITS

Maximum service pressure (tank filled with water)

- Heating circuit: 3 bar

- Domestic hot water circuit : 10 bar (*)

Test pressure

(tank filled with water)

- Heating circuit: 4,5 bar

- Domestic hot water circuit : 13 bar (*)

Operating temperature

- Maximum temperature: 90°C

(*) if the boiler is connected to a domestic hot water production tank.

GENERAL CHARACTERISTICS 0814 2028 2836 3650

Input

kW

18.4 22.0 / 28.0 30.4 / 40.0 40.0 / 57.0

Output

kW

16.6 20.0 / 25.0 27.0 / 35.7 36.5 / 51.0

Pressure loss of the flue gas circuit

mbar

0.11 0.15 0.17 0.15

Heating circuit capacity

L

17 31 37 53

Heating connection (female)

Ø

3/4” 1” 1” 1” 1/4

A mm B mm C mm D Ø mm E mm F mm G mm Kg (*)

0814

370 565 495 80 425 357 187 62

2028

470 700 566 130 550 445 260 108

2836

470 765 566 130 615 510 260 122

3650

530 805 656 150 645 550 260 157

(*)

The weights shown are the drained weights.

A

G

B

E

Ø

D

C

F

BOILER ROOM

Important

• Never obstruct the ventilation.

• Do not store inflammable products in the boiler room.

• Avoid storing corrosive products such as paint, solvents, chlorine,
salt, soap or other cleaning products near the boiler.

Accessibility

The boiler room should be big enough to allow easy access to the
boiler. Minimum clearances around the boiler (mm):

- to the front 500

- to the rear 150

- to the sides 100

- above 700

Ventilation

The boiler room must have both low- and high-level ventilation

(see fig. 6).

For your information, the table below gives the minimum
ventilation requirements according to Belgian regulations.

The user must ensure that his boiler room ventilation complies
with local regulations.

A. High-level ventilation
B. Low-level ventilation
C. Draught stabiliser
D. Clea n ou t do or
E.

Height of lined chimney

F. Chimney diameter

A

B

D

F

E

C

Base

The base on which the boiler will be mounted must be made from
noncombustible materials.

CHIMNEY CONNECTIONS

IMPORTANT

The boiler must be installed by a qualified engineer

in accordance with the local standards and codes of
practice.

The diameter of the chimney must not be less than the

diameter of the boiler’s chimney reducer.

A chimney connector is required.

fig. 6 : Boiler ventilation

Important note:

The above table is shown by way of indication only as

regulations vary from country to country.

The high output of our boilers means that the flue

gases are at a low temperature.

The attendant risk of condensation may cause damage

to

some chimneys. To avoid this risk we strongly advise

tha

t you line the chimney.

Pl

ease contact your installer for any further information.

Chimney 0814 2028 2836 3650

E = 5 m Ø min. F mm 97 130 143 170

E = 10 m Ø min. F mm 82 130 130 143

E = 15 m Ø min. F mm 80 130 130 130

6

INSTALLATION

Ventilation 0814 2028 2836 3650

Fresh air supply min.

m

3

/h

33 50 72 102

High-level ventilation (A)

dm

2

150 150 150 150

Low-level ventilation (B)

dm

2

150 150 150 170

7

INSTALLATION

ES water kit

ES can supply an optional
pre-assembled water kit.
This kit comprises:

• A pump;

• A 3-way manual valve. This
valve can be power-operated if
required;

• Connection pipes that can be
used to connect a second
heating circuit;

• Two isolating valves;

• Connectors for the right- or
efthand mounting of the
expansion vessel, the safety
valve with pressure gauge and
the fill valve.

The expansion vessel is not

included.

Typical single-circuit connection

Drain

The drain cock and safety valve must be connected to the building
drain.

fig. 10 : Heating system connection

9

5

6

2

1

3

8 8

4

CONNECTING THE HEATING SYSTEM

1. 3-way power-operated mixer valve

2. Safety valve calibrated to 3 bar, with pressure gauge

3. Pump

4. Non-return valve

5. System filling valve

6. Expansion vessel

8. Heating system isolating valve

9. Drain cock

fig. 9 : ES water kit

ES : Energy Solutions

8

INSTALLATION

Optional accessories

Safety group Ø 3/4”

Pressure reducing valve Ø 3/4“

Thermostatic mixer Ø 3/4”

Expansion vessel 5 litres

ELECTRICAL CONNECTIONS

Power supply principle

The boiler operates on a single-phase supply of 230 V/50 Hz.
You should install a control box with main switch and 6A fuses
externally to the boiler to allow the boiler to be isolated from the supply
for servicing and repairs.

Statutory compliance

The installation must comply with your local standards and codes of
practice.

Safety

The stainless steel if present water tank must be provided with a
separate earth.

The boiler must be isolated from the electrical supply

before any work is carried out on it.

Electrical wiring of boilers

1. Main switch

2. Summer/Winter switch Thermal reset high-limit thermostat (95°C)

3. Control thermostat (60/90°C)

4. Manual reset high-limit thermostat (103°C max.)

5. Minimum thermostat 45°C (T.O.D)

6. Pump (optional)

7. Room thermostat

Wiring diagram key

B. Blue
Bk. Black
Br. Brown
G. Grey
Or. Orange
R. Red
W. White
Y/Gr. Yellow/Green

230V-50 Hz

6A

1 2

C

1 2

C

Br

B

B

R

Y/Gr

Br

Y/Gr

Bk

Or

W

G

B

Br

Y/Gr

B

R

R

B

G

1

2

5

4

3

6

7

W

Or

Or

Bk

Y/Gr

2028
2836
3650

230V-50 Hz

T1

T2

T1

T2

1 2

C

1 2

C

t

t

M

0814

4

5

3

6

G

G

R Or Or

B

Bk Br

Br

Bk

B B

B

L1 N CH HW

Central

heating

pump

2028, 2837 and 3650

From S3 and B4 of terminal block

0814

Circulation pump supply

Tank

stat

Room

stat

Hot

water

pump

INSTALLATION

9

WIRING FOR MULTI PUMP CONFIGURATION

INSTALLATION

MAINTENANCECOMMISSIONING

2. Vent the system.

3. Once you have vented the system, return the pressure to the
static pressure plus 0.5 bar.

Height of the heating system:

• 10 m ➠ heating circuit pressure = 1.5 bar

• 15 m ➠ heating circuit pressure = 2 bar

USING THE BOILER FOR THE FIRST TIME

1. Check the fuel oil supply connection and ensure that it is free
from leaks.

2. Check the electrical connection to the boiler and the boiler room
ventilation, and ensure that the flue gas discharge pipes and the
burner chamber plate are properly gas tight.

3. Set the boiler thermostat to between 60° and 90°C.

4. Place the Summer/Winter switch to the required position.

5. Place the main switch to “ON”.

6. Carry out the necessary venting operations, measurements and
settings.

RECOMMENDATION

It is compulsory to have the boiler serviced once a year. Boiler
servicing and checking must be carried out by a qualified engineer.

MAINTAINING THE BOILER

1. Isolate the boiler from the electrical supply at the switch on the
external control box and close the fuel oil supply valve.

2. Place the main switch on the control panel to “OFF”

(except for the

0814).

3. Remove the boiler front panel (1) (except for the 0814).

4. Loosen the two nuts or locking clamps for the 0814 to open the
burner chamber plate (2).

5.

Remove the insulating brick

(for the 0814 only).

6. Remove the stainless-steel turbulators (3).

7. Brush the flue ways, clean the chamber and vacuum up any soot
dep

osits.

8. Check the insulation of the burner chamber plate (4).

9. Before reassembling, clean the burner combustion head (5).

10. Check that the thermostats and safety valves are working
correctly.

14

MAINTENANCE OF SAFETY EQUIPMENT

- Check that all thermostats and safety devicesoperate correctly: the

boiler thermostat and the manual reset high-limit thermostat (103°C).

-

Check the heating circuit safety valves.

DRAINING THE BOILER

The water draining from the drain cock is
very hot and can cause serious burns.
Keep all persons away from running
hot water.

Draining the heating circuit (fig. 20)

1. Place the main switch on the control panel to “OFF”, isolate the
boiler from the electrical power supply at the switch in the external
con

trol box.

2. Close the isolating valves (8) in the heating circuit.

3.

Connect a flexible tube to the drain cock (9).

4.

Open the drain cock (9) to drain the heating circuit.

D A NG E R

HOT

FILLING THE HEATING CIRCUIT

IMPORTANT
If your boiler is connected to an ES tank, it is

ES : Energy Solutions

essential to fill the domestic water circuit before the
heating circuit.

1. Open valves 5 and 8 to fill the heating circuit and make sure the
pressure does not exceed 2 bars.

9

5

6

2

1

3

8 8

4

fig. 20

fig. 21

1

2

3

5

4

15

SPARE PARTS

N° CASINGS

0814 2028 2836 3650

A01 Right side 21471387 21471380 21471381 21471382

A02 Left side 21472387 21472380 21472381 21472382

A03 Front panel - 21473380 21473381 21473382

A04 Rear panel 21474387 21474380 21474381 21474382

A05 Top cover 21475387 21475380 21475380 21475382

A06 Unequipped control panel 21477387 21477380 21477380 21477382

A07 Front bridge 21473387 - - -

N° ACCESSORIES

B01 Unequipped body 30465160 30465153 30465154 30465155

B02 Burner chamber plate 2147P371 2147P380 2147P381 2147P382

B03 brick backplate - 2147E380 2147E381 2147E382

B04 Burner chamber plate insulating brick 51701000 51404028 51404029 51404030

B05 Door ceramic fibre insulating cord - 51401113 51401113 51401113

B06 Burner chamber insulating cover - 51401127 51401128 51401129

B07 Pressure gauge thermometer 54763009 54441008 54441008 54441008

B08 Drain cock, Ø 1/2” 55426001 55426001 55426001

B09 M 10 19x33mm hinge pin - 47405252 47405252 47405252

B10 Probe attachment spring 47438008 47438008 47438008 47438008

B11 Turbulators 50423098 50423097 50423097 50423098

B12 H.D.P.E. handle - 49410280 49410280 49410280

B13 Flame inspection window 50423008 50423008 50423008 50423008

B14 Grommet 54428001 54428001 54428001 54428001

B15 Brass pocket, Ø 1/2” / L. 100 mm 63438001 63438001 63438001 63438001

B16

Control panel self-adhesive - 617G0050 617G0050 617G0050

B17 Burner chamber plate insulation 51700033 - - -

B18 Door locking clamp 47405137 - - -

B19 Male/female brass chimney reducer, Ø 1/2” x 1/4” 43416065 43416065 43416065 43416065

B20 Clip retainer 47405004 47405004 47405004 47405004

B21 Stud 47405005 47405005 47405005 47405005

N° ELECTRICAL ACCESSORIES

C01 Full control panel - 24614108 24614108 24614109

C02 ON/OFF switch - 54428116 54428116 54428116

C03 Summer/Winter switch - 54428107 54428107 54428107

C04 90°C control thermostat 54442045 54442045 54442045 54442045

C05 Manual reset high-limit thermostat (103°C) 54442015 54764009 54764009 54764009

C06 Thermal reset high-limit thermostat (45°C) 54442027 54442027 54442027 54442027

C07 Wiring 25435217 - - -

16

SERVICE RECORD

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Model:

Serial number:

Heating system pressure setting:

Name and signature:

DETAILS OF THE INSTALLATION

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Comments:

Name and signature:

SERVICE NOTES

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Comments:

Name and signature:

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Comments:

Name and signature:

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Comments:

Name and signature:

Installation date:

% CO2 (max. load) :

Flue gas T°:

Efficiency:

Fuel oil pressure:

Comments:

Name and signature: