SOLID FUEL BOILER
MULTIPLEX MCL
INSTALLATION AND SERVICE MANUAL
VERSION:
2.1
UPDATE:
11.05.2013
Contents
1. GENERAL INFORMATION ................................................................................... 3
1.1. Proper use of the appliance ................................................................................ 3
1.2. Safety warnings ................................................................................................ 3
1.3. Data label ........................................................................................................ 3
1.4. Document information ....................................................................................... 3
2. TECHNICAL FEATURES AND DIMENSIONS ......................................................... 4
2.1. Technical features ............................................................................................. 4
2.2. Function principle .............................................................................................. 4
2.3. Dimensions ...................................................................................................... 5
2.4. Fuel ................................................................................................................. 7
3. BOILER MOUNTING ........................................................................................... 9
3.1. Transportation and delivery ................................................................................ 9
3.2. Boiler room ...................................................................................................... 9
3.2.1. General requirements .................................................................................. 9
3.2.2. Boiler room dimensions .............................................................................. 10
3.3. Mounting instructions ...................................................................................... 11
3.3.1. Fan ......................................................................................................... 11
3.3.2. Control panel ............................................................................................ 11
3.4. Chimney ........................................................................................................ 13
4. INSTALLATION ................................................................................................ 14
4.1. Hydraulic connections ...................................................................................... 14
4.2. Safety features ............................................................................................... 14
4.3. Overheating serpentine .................................................................................... 15
4.4. Return temperature protection .......................................................................... 15
4.5. Filling the system ............................................................................................ 16
4.6. Connection diagrams ....................................................................................... 17
4.6.1. Open expansion vessel connection .............................................................. 17
4.6.2. Closed expansion vessel connection............................................................. 18
5. ELECTRICAL CONNECTIONS ............................................................................ 19
5.1. General instructions ......................................................................................... 19
5.2. Control panel functions .................................................................................... 19
5.3. Wiring diagram ............................................................................................... 20
6. BOILER START-UP ........................................................................................... 21
6.1. Initial lighting checks ....................................................................................... 21
6.2. Start-up ......................................................................................................... 21
6.3. Checks to carry after initial start-up .................................................................. 21
6.4. Fuel loading .................................................................................................... 22
6.5. Combustion regulation ..................................................................................... 22
6.6. Chimney damper adjustment ............................................................................ 22
7. SERVICE AND MAINTENANCE .......................................................................... 23
7.1. Cleaning the boiler .......................................................................................... 23
7.2. Cleaning the chimney box ................................................................................ 24
7.3. Maintenance intervals ...................................................................................... 24
7.3.1. Daily maintenance ..................................................................................... 24
7.3.2. Weekly maintenance ................................................................................. 24
7.3.3. Monthly maintenance................................................................................. 24
7.4. Basic service procedures .................................................................................. 25
7.4.1. Service after overheating ........................................................................... 25
7.5. Maintenance after long stop .............................................................................. 25
8. TROUBLESHOOTING ........................................................................................ 26
9. WARRANTY...................................................................................................... 27
GENERAL INFORMATION
3
1. GENERAL INFORMATION
1.1. Proper use of the appliance
Before you make use of this appliance make sure you have read and fully understood the
instructions included in this manual.
The installation and use of the appliance must be performed according to the instructions
indicated in this manual in combination with the current national safety regulations.
The appliance is designed for use in pumped hot water central heating systems. Any other use
is considered improper and is prohibited. THERMOSTAHL declines any responsibility for
damages or injuries caused by improper use; in this case the risk is completely at the user’s
responsibility.
To ensure an efficient and flawless function of the appliance, it is strongly recommended that
you have performed an annual service by a qualified technician.
1.2. Safety warnings
All installation and maintenance procedures must be carried out by professional and authorized
personnel, in compliance with the indications in the present manual and national regulations.
Any failure to correctly install this appliance could cause damage or injuries!
Do not make modifications to parts of the appliance, unless you have contacted the company
and an authorized service contractor.
Only original accessories and spare parts must be used to ensure correct and safe function.
Make sure you respect the cleaning and maintenance procedures on the corresponding
intervals. Failure to do so can cause malfunction to the appliance and possible damages.
The boiler is design to function on the fuels indicated in the corresponding paragraph. Any
other fuel is prohibited. Do not use explosive or flammable substances! Do not store such
substances inside the boiler room.
The working pressure varies according to the model. Make sure you use the appropriate water
pressure. Working in a pressure higher than the one indicated in this manual is
strictly prohibited and dangerous!
1.3. Data label
The data label of the appliance is placed on the boiler’s side cover, on the external part. Make
sure that it is properly placed and readable.
On the label it is indicated the serial number and the manufacturing year of the appliance.
1.4. Document information
This document is an integral and indispensable part of the product and must be retained in
good condition by the user. Keep it in a safe place for future reference.
If the appliance is sold or transferred to another person, this manual has to always follow the
appliance and handed to the new user or installer.
TECHNICAL FEATURES AND DIMENSIONS
4
2. TECHNICAL FEATURES AND DIMENSIONS
2.1. Technical features
MULTIPLEX boiler is a steel solid fuel boiler, with cylindrical heat exchanger consisted of fire
tubes.
The boiler body is made of cold rolled steel St 37.2 STAS 500/2-80~S235 JR SR EN 10025/90
according to DIN 17100. The boiler is designed so that all the parts in contact with exhaust
gases are water cooled. The boiler body parts are assembled by welding. Weldings are
performed according to standards 288-1 and 288-3 according to DIN 50120, 50121-50145, SR
EN 1011.1/2001, by means of electric arc welding (MIG-MAG).
DESCIPTION OF COMPONENTS
Steel boiler body with cylindrical heat exchanger
Removable rear smoke box with inspection cleaning door
Upper door for cleaning the heat exchanger
Middle door for ignition and fuel loading, equipped with an inspection flange, which can also
be used for a burner mounting
Lower door for ash removal
Ash box positioned on the lower part of the fire chamber
Combustion fan positioned on the rear of the boiler
Air distributor on the bottom of the grate for even air distribution to all the boiler length
Rockwool body insulation of 50 mm thickness
Electrostatically painted external covers
Control panel for electromechanical operation
Safety heat exchanger (optional)
2.2. Function principle
The function of the MULTIPLEX boiler is
based on natural gas evacuation through
the chimney. The fuel is positioned on the
grate. The combustion takes place in the
fire chamber. During the combustion the
flame comes in contact with the side
walls of the fire chamber, which are
surrounded by water. The fire chamber is
of big volume in order to receive big
dimension logs and to ensure a long
autonomy.
The combustion air is supplied by the fan
and distributed through an air distributor,
positioned below the fuel grate. The
combustion is regulated through the fan,
controlled by the control panel.
Fig 1. Boiler function
The exhaust gases are guided through the heat exchanger to the smoke box, and afterwards
evacuated to the chimney. The smoke box is equipped with an inspection and cleaning door,
which also actions as an explosion relief.
The doors have an insulation cord to ensure air-tight closing. Each door is equipped with a
screwed handle, which must always be well tightened during the combustion. The flange on
the middle door has a rotating clamp, for secondary air adjustment and flame inspection. If
necessary, this flange can be removed, and a burner can be placed in its position.
TECHNICAL FEATURES AND DIMENSIONS
5
2.3. Dimensions
DIMENSIONS
Type
Feeding
door
A
A1 B H
H1 E C
T3
T1-
T2
T5
T6
mm
mm
mm
inch
MCL 70
600x360
910
810
860
1600
1720
1240
1280
245
2”
1 ¼”
¾”
MCL 80
600x360
910
810
980
1600
1720
1240
1380
245
2”
1 ¼”
¾”
MCL 90
600x360
910
810
1100
1600
1720
1240
1480
245
2”
1 ¼”
¾”
MCL 100
600x360
910
810
1200
1600
1720
1240
1580
295
2 ½”
1 ¼”
¾”
MCL 120
600x360
910
810
1330
1600
1720
1240
1680
295
2 ½”
1 ½”
¾”
MCL 150
600x360
910
810
1830
1600
1720
1240
2000
295
2 ½”
1 ½”
¾”
MCL 180
600x360
910
810
1830
1600
1720
1240
2300
295
2 ½”
1 ½”
¾”
MCL 200
500x810
1100
1000
1350
2000
2160
1500
1950
345
3”
2”
2x¾”
MCL 250
500x810
1100
1000
1600
2000
2160
1500
2200
345
3”
2”
2x¾”
MCL 300
500x810
1100
1000
1850
2000
2160
1500
2450
395
4”
2”
2x¾”
MCL 350
500x810
1100
1000
1850
2000
2160
1500
2450
395
4”
2”
2x¾”
MCL 400
500x810
1100
1000
2100
2000
2160
1500
2650
395
4”
2”
2x¾”
MCL 450
500x810
1100
1000
2100
2000
2160
1500
2650
395
4”
2”
2x¾”
MCL 500
1230x520
1540
1440
1600
2400
2650
1750
2300
445
4”
2 ½”
2x¾”
MCL 600
1230x520
1540
1440
1800
2400
2650
1750
25700
445
5”
2 ½”
2x¾”
MCL 700
1230x520
1540
1440
2150
2400
2650
1750
2820
495
5”
2 ½”
2x¾”
MCL 800
1230x520
1540
1440
2400
2400
2650
1750
3070
495
6”
3”
2x¾”
MCL 900
1230x520
1640
1540
2600
2870
2650
1750
3350
495
6”
3”
2x¾”
MCL 1000
1230x520
1640
1540
2800
2870
2650
1750
3500
495
6”
3”
2x¾”
TECHNICAL FEATURES AND DIMENSIONS
6
*Nominal output is obtained with good quality wood, with 15% humidity.
TECHNICAL DATA
Boiler
type
Nominal
Output*
P
max
Fire
chamber
length
Wood
consumption
Max.
wood
length
Fie
chamber
volume
Weight
kcal/h
kW
bar
mm
kg/h
mm
m3
kg
MCL 70
70.000
81
2,5
700
25-28
650
0,300
630
MCL 80
80.000
93
2,5
820
28-32
750
0,325
675
MCL 90
90.000
104
2,5
920
32-36
850
0,342
740
MCL 100
100.000
116
2,5
1080
36-42
950
0,362
800
MCL 120
120.000
139
2,5
1200
43-48
1000
0,400
880
MCL 150
150.000
174
2,5
1450
54-60
1250
0,475
990
MCL 180
170.000
208
2,5
1650
64-70
1450
0,574
1220
MCL 200
200.000
232 3 1000
72-80
900
0,625
1420
MCL 250
250.000
291 3 1100
89-104
1000
0,787
1600
MCL 300
300.000
349 3 1200
107-115
1100
0,937
2130
MCL 350
350.000
406 3 1450
110-130
1350
1,132
2160
MCL 400
400.000
465 3 1700
125-140
1600
1,327
2200
MCL 450
450.000
522 3 1700
130-150
1600
1,530
2650
MCL 500
500.000
581 4 1400
143-165
1300
1,800
3000
MCL 600
600.000
698 4 1600
178-205
1500
2,080
3400
MCL 700
700.000
814 4 1800
215-230
1700
2,350
4000
MCL 800
800.000
928 4 2000
240-275
1900
2,889
4800
MCL 900
1000.000
1.044 4 2200
250-285
2100
3,178
5500
MCL 1000
1000.000
1.116 4 2400
295-345
2300
3,320
5850
TECHNICAL FEATURES AND DIMENSIONS
7
2.4. Fuel
The MULTIPLEX series is designed for use with solid fuel of biogenic or fossil nature. This
means different types of natural wood, solid residues of organic nature coming from trees or
agricultural plants, wood briquettes of various types. Carbon or other similar fossil fuels are
allowed, but only in combination with wood and maximum 20% volume ratio at every load. If
you want to use solely carbon as fuel, please contact the manufacturer.
Good quality wood is oak, ash, beech, maple, olive tree and fruit trees, except cherry. Medium
quality wood is chesnut and birch. Low quality wood is poplar and willow.
Table 1. Calorific power of different types of wood
Every type of wood contains a significant amount of humidity, which highly affects its
combustion behaviour and calorific value. Boiler output, efficiency and autonomy will
significantly diminish as the humidity increases. The nominal data presented in this manual are
calculated for humidity content 15%.
For proper and efficient function and a long lifespan, it is strictly recommended that only dry
wood is used, with a humidity content of 15%. Practically, this means at least one year dry
wood. Maximum humidity content allowed is 25%.
As understood, wood is an extremely heterogenous fuel, due to differnet essences, different
humidity contents, shapes and dimensions. This is why the combustion behaviour higly varies
through time and average data as fuel consumption, autonomy, and output are very difficult to
forecast.
0
10
20
30
40
50
60
2,2
2,8
3,4
3,7
4,0
4,3
4,6
4,8
5,1
Humidity [%]
Lower Calorific Power [kWh/kg]
Calorific power in relation to humidity
Fuel
Calorific power
kWh/kg
kcal/kg
Oak
4,2
3.600
Beech
4,0
3.450
Birch
4,3
3.700
Poplar
4,1
3.500
Pine
4,4
3.800
Spruce, Fir
4,5
3.900
Wood briquettes
4,0 – 4,9
3.600 – 4.200
Carbon
Anthracite
5,6 – 6,5
4.800 – 5.600
Coal
4,5 – 6,4
3.900 – 5.500
Brown carbon
2,7 – 4,2
2.300 – 3.600
Lignite
1,6 – 3,8
1.400 – 3.300
TECHNICAL FEATURES AND DIMENSIONS
8
It is prohibited the use of laminated wood, or other chemical treatment.
It is prohibited the use of explosive, inflammable materials, plastic, domestic
residues, etc.
The boiler is provided with a flange for mounting a burner for use with oil or gas as an
alternative fuel. However, this option is an emergency alternative, and it is not recommended
that boiler is on stable function on oil or gas. The efficiency will be very low on such fuels.
If a burner is mounted, remove it before you use solid fuel again.
It is prohibited to manually feed solid fuel in the boiler simultaneously with the
burner function!
BOILER MOUNTING
9
3. BOILER MOUNTING
3.1. Transportation and delivery
The boiler is delivered on wood pallet, well positioned with metal plates. Remove them
carefully by unscrewinf the screws holding them in place.
The loading and unloading of the boiler must be performed with a forklift or a crane. A special
hook is provided on the upper part of the boiler for lifting.
The boiler is very heavy. Do not try to lift by hands or other unsuitable
equipment. Danger of injury! Perform all moves with extreme attention and care.
Remove the boiler packaging with attention. Keep the packaging material away from
chidren since it can be dangerous. After having unpacked everything, make sure that the
appliacne is intact and undamaged. In case of doubt do not use the appliance and inform the
supplier.
The MULTIPLEX boiler is delivered with the following equipment already fitted and mounted:
Boiler steel body
Rockwool insulation mounted on the boiler body and tightened with plastic tapes
Metal covers mounted on the boiler body
Turbinators positioned inside the fire tubes
The following accessories are positioned inside the boiler body. Remove them carefully by
opening the middle door.
Cleaning tools
Fan
Control panel
Safety kit
Drainage valve
In the documentation folder you will find:
Technical manual
Warranty leaflet
Declaration of conformity
3.2. Boiler room
3.2.1. General requirements
The boiler must be installed in a special and separate room. This room must be chosen so that
it offers easy access for fuel transport, air supply and exhaust gas evacuation. The doors of the
boiler room must be metallic, open outwards, and have at least 0,9 m width.
The boiler installation is prohibited in rooms with extensive dust, dangerous
gases, and moist spaces.
For the correct boiler function it is necessary that the boiler room has openings for natural
ventilation and combustion air supply. It is recommended that two different openings are used
for this purpose, positioned on opposite walls and diagonally to ensure good air circulation. The
total surface of the openings must be at least 1/12 of the boiler room surface. Forced
ventilation is prohibited in the boiler room.
The boiler room must be provided with a drainage channel. All safety devices must be
connected to this channel.
BOILER MOUNTING
10
The boiler room must have an appropriate fire extinguishing system, according to the
regulations in force. In case that the building is designed with a fire alarm system, a smoke
detector must be positioned on top of every boiler.
The fuel storage is prohibited in the boiler room. If so, the storage must be separated from the
boiler with a non-flammable wall, and proper distanced from the boiler.
3.2.2. Boiler room dimensions
The boiler must be placed on a horizontal plane, with adequate mechanical resistance to
support the boiler’s weight. The boiler must be positioned in the room in such a way so that it
is easily accessible from all the sides. The following dimensions are recommended (see Fig 2):
Distance from the front wall (N):
For boilers up to 100 kW – minimum 1,5 m
For boilers bigger than 100 kW – minimum 2 m
Distance from the rear wall (L):
Appropriate distance for maintenance access. Minimum 0,6 m.
Distance from side walls (M):
For boiler up to 300 KW – minimum 0,6 m
For boilers bigger than 300 kW – minimum 1 m
Boiler room height (H):
For boilers up to 70 kW – minimum 2 m
For boilers 70 to 230 kW – minimum 2,4 m
For boiler 230 to 400 kW – minimum 3 m
For boiler bigger than 400 kW – minimum 3,5 m
Distance between two boilers (P) must be at least 1m.
Fig 2. Boiler room dimensions
BOILER MOUNTING
11
3.3. Mounting instructions
3.3.1. Fan
The fan is positioned at the back side of
the boiler, at the flange provided.
Screw the fan in position with the
provided screws and mount with the
washers and nuts, as shown in the Fig 3
Fig 3. Mounting the fan
3.3.2. Control panel
The control is mounted at the side cover
of the boiler, as seen on Fig 4Error!
Reference source not found.. Inside
the package of the panel you will find two
plastic screws for mounting.
Remove the top cover of the boiler, insert
the screws from the inner side of the side
cover and fix the panel. Tighten the
screws.
Fig 4. Mounting the control panel
BOILER MOUNTING
12
All the instruments have capillary bulbs,
which must be inserted in the provided
boiler case. There are four bulbs that must
be inserted: thermometer, fan thermostat,
pump thermostat, safety thermostat. Pass
the cables through the oval hole on the
cover and guide them to the bulb case, as
shown on Fig 5. Do not bend or fold the
capillary tubes of the bulbs. Do not add
any substances like oil or Vaseline for
thermal conductivity, they can destroy the
bulbs! Secure the excess length on top of
the insulation, and pay attention not to
touch on hot metal surfaces. After
inserting them, secure them with the
metallic safety strip provided.
Fig 5. Inserting the bulbs
If the bulbs are not well inserted and secured in the case, there is danger that
the controls will not function and the boiler will overheat!
The control panel is equipped with fast
plugs for the devices (pump and fan).
Within the control panel you will find the
plugs for the devices. Connect as shown in
the Fig 6.
Connection cables must be of section 1,5
mm2.
Fig 6. Control panel connection plugs
BOILER MOUNTING
13
3.4. Chimney
The chimney installation must supply sufficient draught, air tightness and protection against
condensation.
The appropriate chimney installation is very important for the boiler’s efficient
and safe function!
The chimney must be positioned if possible in the interior of the building. It must be vertical,
with no changes in the direction. The cross-section of the chimney can be round or
rectangular. If the chimney is installed in the exterior, it must be insulated.
The horizontal part connecting the boiler’s chimney pipe with the vertical chimney must have
maximum length 2 m. If this distance is bigger, it is recommended to have a 15-30o inclination
upwards. The connection with the boiler’s chimney pipe must be air-tight.
The chimney must be equipped with a cleaning door at its base. Also cleaning doors are
recommended where there are changes in direction and ash can be accumulated. Tactical
cleaning is recommended (every 3 months) for efficient boiler function.
A chimney terminal must be installed at the end of the chimney for protection against weather
effects and foreign objects entrance. In areas with strong winds a special anti-downdraught
terminal is recommended.
The chimney height must exceed the roofline by at least 1 m. If there are other obstacles
positioned on the roof, the chimney height must exceed them by at least 1 m. If there are
multiple chimneys, minimum distance between them is 0,3m.
Each boiler should be connected to an independent chimney. Connection of multiple boilers to
the same chimney is not recommended.
Fig 7. Chimney distances
Fig 8. Chimney connection
INSTALLATION
14
4. INSTALLATION
4.1. Hydraulic connections
The boiler is intended for connection with an open expansion vessel network. The boiler can be
connected also with closed expansion vessel, if it is equipped with an overheating serpentine
(optional).
The boiler is intended for maximum working temperature 90oC and maximum pressure 3 bar
for boilers up to 500 kW, and 4 bar for bigger boilers.
When connected with a closed expansion vessel, its volume must be chosen double to a similar
installation on liquid or gas fuel.
If a connection pipe is not used, it must be sealed before water fill!
Legend
T1
Outlet
T2
Return
T3
Chimney pipe
T4
Discharge valve connection
T5
Safety kit connection
T6
Additional safety connection
4.2. Safety features
The boiler equipment includes a safety kit, which shall be connected to the corresponding
connection pipe T5. The kit consists of a safety valve, an air relief valve and a
thermomanometer. Bigger boilers are equipped with two or more safety valves.
Fig 9. Boiler safety kit
INSTALLATION
15
Additional safety equipment can be mounted at the connection pipe T6. This can be a dual
safety valve (pressure and temperature) or a cooling valve. Alternatively this pipe can be used
for connection with the expansion vessel.
4.3. Overheating serpentine
As an optional, the boiler can be equipped with an overheating protection serpentine. This is
incorporated in the boiler body, surrounding the fire chamber.
For the function of the safety serpentine, a discharge valve must be installed. The
bulb of the valve must be mounted on the boiler’s hot water delivery, at maximum distance
1m from the boiler.
Fig 10. Overheating serpentine connection
The valve can be connected on either side of the serpentine. Attention should be given to the
flow direction of the valve. The valve can be fitted on the cold water inlet or hot water outlet.
However, we recommend that the valve is fitted on the cold water inlet.
For the protection of the valve, a filter is recommended to be installed on the water line before
the valve.
On the opposite side of the serpentine, drainage must be connected.
The correct function of the discharge valve is crucial for the boiler’s safety.
Verify its function often and replace if defect.
4.4. Return temperature protection
For the correct function of the boiler and for protection against corrosion it is very important to
ensure steady temperature at the return of the boiler of at least 55oC.
This can be ensured by installing a recirculation pump between the boiler outlet and return
(see connection diagrams).
An alternative variation is by installing at the return of the boiler a three-way thermostatic
valve.
INSTALLATION
16
4.5. Filling the system
After completing all the hydraulic connections, the circuit may be filled with water. After filling
the system, open the radiators air valves to get rid of the air in the installation.
Verify that the installation pressure is according to the technical feature of the boiler. The
pressure must be verified through the boiler’s manometer. An additional manometer should be
installed on the cold water inlet to verify the cold pressure, at the lowest point of the
installation, at a point close to the boiler.
The whole installation must remain under nominal pressure for at least 10 minutes. During this
period, check that all the connections are tight and there are no water leakages. Make sure
that during this period no pressure drop appears.
After firing the boiler, make sure the network functions properly at working temperature and
pressure.
The hardness of the mains water supply affects the boiler’s life span. It is
recommended to use a water softener if water hardness exceeds 15of.
Do not fill the system at the working pressure! When the boiler will be heated,
the water pressure will raise. Filling pressure must be at least 1 bar lower than
working pressure!
INSTALLATION
17
4.6. Connection diagrams
4.6.1. Open expansion vessel connection
Legend
1-9.
Separation valves
10,11.
Radiator valves
12.
Radiators
13-15.
Safety valves
16.
Filling valve
17.
Drainage valve
18.
Cold water valve
19-24.
One-way valves
B
Hot water boiler
VED
Open expansion vessel
PCI
Central heating pump
PRC
Recirculation pump
RP
Pressure reducer
F
Filter
A
Air relief valve
FD
Water softener
INSTALLATION
18
4.6.2. Closed expansion vessel connection
Legenda
1-9.
Separation valves
10,11.
Radiator valves
12.
Radiators
13-15.
Safety valves
16.
Filling valve
17.
Drainage valve
18.
Cold water valve
19-24.
One-way valves
B
Hot water boiler
VE
Closed expansion vessel
PCI
Central heating pump
PRC
Recirculation pump
RP
Pressure reducer
F
Filter
A
Air relief valve
FD
Water softener
ELECTRICAL CONNECTIONS
19
5. ELECTRICAL CONNECTIONS
5.1. General instructions
All electrical connection must be performed by an authorized professional, in conformity with
the local regulations and the indications of this manual. Connections must be done according
to norms EN 60529 and EN 60335-1, and protection norms IP 40 and IP 44.
All wiring must be waterproof insulated. Exposed cables should be protected within plastic
channel. The main electrical supply of the boiler must be connected to an independent safety
of max 16A. The boiler room lighting must be on a separate circuit.
THERMOSTAHL is not responsible for accidents or malfunctions caused by
wrong or bad electrical connections.
5.2. Control panel functions
Fig 11. Control panel
The general switch ON/OFF interrupts the electrical supply to all the devices.
The fan thermostat interrupts the fan function when the preset boiler temperature has been
reached. It is recommended that this temperature is set between 70-90oC. This temperature
should never be set below 55oC.
The fan speed regulator regulates the fan rotating speed by means of a dimmer rheostat.
The pump thermostat starts the circulation pump function at the preset temperature. It is
recommended that this temperature is set around 45-55oC.
The safety thermostat will interrupt the fan function if the boiler temperature reaches above
95oC. If so, it needs to be reset manually by unscrewing the plastic cover.
The fan and pump indication lamps follow the function of the corresponding devices.
If a burner is connected to the control panel, it can be connected in the place of the fan and
regulated by the fan thermostat.
The control panel offers the possibility to connect with a room thermostat. When the room
thermostat contact opens, the fan function stops.
Legend:
1.
Thermometer
2.
Fan thermostat
3.
Safety thermostat
4.
Pump thermostat
5.
Fan speed regulator
6.
General ON/OFF switch
7.
Fan indication lamp
8.
Pump indication lamp
ELECTRICAL CONNECTIONS
20
5.3. Wiring diagram
Fig 12. Control panel wiring diagram
Legend:
M
General ON/OFF switch
TS
Safety thermostat
TB
Fan/Burner thermostat
TP
Pump thermostat
L
General function lamp
LB
Fan indication lamp
LP
Pump indication lamp
TR
Room thermostat
F1
Fuse safety
VT
Fan speed regulator
PE
Grounding
Unscrew the control panel back plate to have access to the connection terminals in the interior.
Connect the main electrical supply to the terminals 1,2,3 as indicated. The fan is connected to
the terminals 9,10,11 and the pump to the terminals 4,5,6.
Between the terminals 7,8 there is a jumper. If you want to connect a room thermostat,
remove the jumper and connect it to these two terminals.
Attention: The room thermostat must be a simple contact interruptor. It is not
allowed to connect a digital thermostat with an electrical signal output!
BOILER START-UP
21
6. BOILER START-UP
6.1. Initial lighting checks
Before you start the boiler, make the following checks:
Check that all the hydraulic connections and make sure they are tight. Make sure there is
no leakage or moisture on the pipes or other equipment.
Make sure that the connection with the chimney is air-tight and the chimney installation is
properly made.
Check that the controller bulbs are well inserted and secured in the boiler’s case.
Make sure that the pressure in the network is correct.
Check that the boiler pump and the central heating pumps function properly.
Make sure that the connection with the expansion vessel is correct and the expansion
volume is sufficient for the boiler. No valves should be installed between the boiler and the
expansion vessel.
Make sure the boiler’s separation valves are open.
Make sure that there is sufficient air supply and natural ventilation in the boiler room.
Do not store inflammable materials or fuel close to the boiler! Before you light
the boiler make sure the boiler room is clear and safe.
6.2. Start-up
To correctly start up the MCL boiler follow the next steps:
Make sure the control panel switch is set to OFF and that fan does not function.
Make sure the chimney damper is positioned in horizontal position (completely open).
Open the middle door (feeding door) and introduce a sufficient amount of small and thin
pieces of wood.
Using sheets of thin paper light the wood placed inside the boiler.
Close the middle door of the boiler. Open the lower door for natural combustion.
Wait several minutes until the flame develops and produces some embeds.
After formation of embeds, load the fire chamber with wood. Position them on top of the
grate.
Close the middle and the lower door and secure with the handles.
Turn on the general switch of the control panel and set the fan thermostat to the required
temperature. Fan begins operation.
It is prohibited to light the boiler with inflammable or explosive liquids.
6.3. Checks to carry after initial start-up
During the first start-up you need to carefully check the air-tightness of all the connections,
especially the doors and the connection with the chimney.
Check that the thermostats function properly and devices operate accordingly. Wait for the
boiler to reach the preset temperature and make sure the fan stops properly and the flame
falls down.
Check the temperature and pressure rise in the network. Make sure it is according to the
indications. Check if there is any water leakage in the network.
After burning of the fuel is completed, check the situation inside the boiler. If the walls are too
black, it means that there is insufficient air supply. If there is condensation forming on the
boiler walls, it means that the pump operation starts at a low temperature or the fuel has too
big humidity content. Make sure you set the pump according to the indications and you install
a return temperature protection system as indicated.
BOILER START-UP
22
6.4. Fuel loading
In order to correct add fuel to the boiler follow the next steps:
Stop the fan function by turning the fan thermostat to zero. Wait 30 seconds for the fume to
exit the boiler.
Open the middle door slowly to avoid leakage of smoke. Load a sufficient amount of fuel.
Each loading should be regulated according to the boiler output and the heat demand.
Never load too much to fuel to fill all the fire chamber volume! Maximum fuel should be 7080% of the fire chamber volume.
Close the door and secure with the handle.
Start again the fan function by putting the thermostat to the preset temperature.
When loading fuel in the boiler do not throw them but position them carefully.
6.5. Combustion regulation
After completing the fuel loading procedure and closing the door, set the required temperature
to the fan thermostat (noted “Burner”). After the fan is activated, have a look at the flame
shape and color through the flange provided on the middle door.
The flame will have to occupy about two thirds of the fire chamber and quietly lick the
cylindrical heat exchanger. Its shape must be fully developed and with not too many
detachments at the flame end. Its color must be vivid orange-yellow, not too transparent.
The combustion is regulated through the air delivery. By positioning the fan damper you
regulate the air pressure and by the control panel speed regulator you regulate the fan speed.
The combination of these two will result to the optimum air delivery in order to accomplish
perfect combustion.
GENERAL SUGGESTIONS
The flame needs to have reasonable dimensions and fill up the fire chamber as told.
The flame must not be too red (too low air supply).
The flame must not have big detachments and sparkles (too high air supply).
The flame must not be too small. If it is slow, easily influenced by air currents and the
chimney draught, it means that the air supply is too low.
The smoke at the chimney must be clear-grey. Black smoke means lack of air supply.
If too much ash and big coal pieces fall down to the ash box reduce the air supply.
The flame is too fast, dry, and might make a noise.
6.6. Chimney damper adjustment
The boiler chimney pipe is equipped with a damper.
This can be set in various positions to throttle the
exhaust gases.
At nominal function of the boiler this damper should
be normally open. Also it should always be at open
position at boiler start-up.
If the chimney draught is too big and the gases are
evacuated too fast, set this damper at a side
position by inserting the positioner at a different
hole.
If a burner is installed, it is recommended that the
damper is in completely closed position.
Fig 13. Chimney damper
SERVICE AND MAINTENANCE
23
7. SERVICE AND MAINTENANCE
7.1. Cleaning the boiler
Solid fuel boiler require regular cleaning in order to function properly and efficient. Cleaning
must be effected at least once a week. The boiler is equipped with three cleaning tools
appropriate for the cleaning procedure of the boiler, as shown in Fig 14.
Fig 14. Boiler cleaning tools
The boiler function must be stopped before cleaning! Make sure all the devices
are stopped, and the boiler has cooled down. It is strictly prohibited to clean the
boiler while in function!
Open the upper door to have access to the heat exchanger. Remove the turbinators from the
tubes, and clean the tubes with the appropriate tool. Afterwards clean the exterior surface of
the cylindrical heat exchanger with the exchanger cleaning tool, as shown in Fig 15. With the
same tool, scrape the ash and any other remains from the side walls of the boiler.
Fig 15. Cleaning of the heat exchanger
Open the lower door of the boiler and remove
the ash box. Empty all the containing ash.
With the ash cleaning tool you can scrape the
lower surface of the boiler for any residues of
ash.
The ash must be disposed in an
appropriate container! Do not throw the
ash together with the domestic garbage.
Be careful since ash might contain hot
particles, even long time after stop.
Fig 16. Removing the ash
Legend:
1.
Tubes cleaning tool
2.
Heat exchanger cleaning tool
3.
Ash cleaning tool
SERVICE AND MAINTENANCE
24
7.2. Cleaning the chimney box
To ensure efficient and safe function of the boiler, you must
clean the chimney box from ash residues at least every 3
months.
The ash box is equipped with a cleaning door for this
purpose, as shown in Fig 17Fig 17. In order to open the
door, unscrew the wing nuts, remove the washers and
springs that keep it in place.
Clean the interior of the chimney box and remove all the ash
and residues.
Put back the door the same way as removed.
The springs must not be omitted! They act as
safety in order of explosion of exhaust gases in the
chimney box.
Fig 17. Cleaning the chimney box
7.3. Maintenance intervals
7.3.1. Daily maintenance
The pressure of the network must be daily verified to be within the allowed limits. Make sure
that all the safety devices and pumps function properly.
7.3.2. Weekly maintenance
The boiler must be cleaned every 3-4 days or at least once a week, depending on the ash
quantity accumulated on the boiler walls and in the heat exchanger. Cleaning procedure must
be performed according to the instruction given in the corresponding paragraph.
Check the quantity of ash accumulated in the ash box. The ash disposal can be performed
every 1-2 weeks, depending on the ash quantity formed.
7.3.3. Monthly maintenance
Check the doors and the sealing cord. Make sure the contact with the boiler is air-tight. If ash
has accumulated on the sealing cord, clean it.
Check the fan and make sure it functions properly. Clean from dust and check that the air
passage is clear of obstacles and dust.
Remove the turbinators from the heat exchanger and check their condition.
It is recommended that you clean the chimney box of the boiler and the chimney pipes at least
every 3-4 months, in order to assure efficient and safe function of the boiler.
SERVICE AND MAINTENANCE
25
7.4. Basic service procedures
7.4.1. Service after overheating
If overheating occurs, the safety valves of the boiler must open. If the boiler is equipped with
an overheating protection coil, cold water will enter the coil to protect the boiler.
Make sure the boiler pump is working. In case of blackout open all the valves of the system to
let hot water out of the boiler. In any case a blackout protection UPS is recommended to be
installed on the boiler pump.
If the chimney damper is not fully opened, put it in fully open position.
All safety devices must lead to drainage! After overheating, make sure that all the water from
the safety devices has drained, and the system has filled with cold water. Check the pressure
and the temperature of the boiler.
At overheating, the safety thermostat will activate, and cut electrical supply to the fan. In that
case, you need to manually reset the safety thermostat and put the system back in function.
Unscrew the plastic cover of the safety thermostat and press the switch. Put the plastic cover
back.
Verify the causes of the overheating! If it happens again, check the installation
and function of the pumps and safety devices!
7.5. Maintenance after long stop
It is necessary to perform a general maintenance and cleaning of the boiler after the heating
season. Clean thoroughly all the surfaces of the boiler as described in the corresponding
paragraph. Also clean the chimney box, and all the chimney parts where ash might be
deposited. After cleaning all the ash, empty the ash box and leave the boiler clean for the next
winter season.
After long stop of the boiler, before you put in function you need to perform the following
checks:
Check the condition of the electric cables and the sensors. Make sure they are not
damaged. Check that the thermometer indicates the correct temperature and all the
thermostats function properly. Make sure the bulbs are properly positioned in the case.
Make a general check of the chimney and make sure it is clean and free of obstacles.
Verify the pressure in the heating network and the boiler.
Do not empty the water of the boiler and the heating installation after the
heating season! It will corrupt all the installation and especially the boiler.
Check that all the valves are working properly. Replace them if necessary. Pay special
attention so that all the safety equipment of the boiler functions properly!
Make sure all the ball valves of the boiler and other relative equipment are open.
Check the function of the pumps. They might be blocked after long stop.
Check that there have been no modifications to the installation and the boiler room
(ventilation openings, chimney, doors).
Check the fan and clean from dust. Turn it manually to ensure it is not blocked.
TROUBLESHOOTING
26
8. TROUBLESHOOTING
Problem
Cause
Solution
The lamps of the
control panel do not
light
- no electrical supply to the lamp
- the control panel is not
connected to electricity
- lamp defect
- electric cable defect
- check/replace the lamp
- connect to electricity
- check/replace the cabels
The boiler does not
reach set
temperature
- fan blocked
- air passages are blocked
- boiler is not cleaned
- incorrect boiler start-up
- insufficient water in the system
- too big pump debit
- boiler under dimensioned
- bad quality fuel used
- insufficient chimney draught
- check/replace the fan, check
the function of the fan regulator
and thermostat
- clean the air passages
- clean the boiler
- start the boiler correctly
- fill the system
- regulate the pump speed
- change the fuel used
- check/clean the chimney
High temperature in
the boiler, but low
temperature at the
radiators
- too high hydraulic resistance in
the heating network
- thermostatic mixing valve is
connected wrong
- increase the pump speed
- check/replace the mixing valve
Condensation
formation in the fire
chamber
- too big boiler power
- too low return temperature in
the boiler
- fuel with excessive humidity
- load less fuel in the chamber
- install a return protection
system/thermostatic valve
- change the fuel used
Smoke coming out of
the doors
- boiler doors not regulated
- defect sealing cord of the door
- insufficient chimney draught
- too high air supply by the fan
- regulate the doors so that the
sealing cord stays tight
- check/replace the sealing cord
- check/clean the chimney
- reduce the air speed
The fan does not
function or it makes
a lot of noise
- set temperature reached
- disconnected by safety
thermostat
- capacitor/motor defect
- bad electrical connection of the
fan
- correct boiler function
- reset manually
- check/replace the fan
- check the electrical connection
of the fan
WARRANTY
27
9. WARRANTY
1. Warranty duration is 3 years for all boiler parts under pressure, 1 year for other
electro-mechanical equipment. The warranty period starts from the date of installation,
but no longer than 120 days from the day of purchase.
2. The warranty covers costs of replacing parts that have been proved to be defect, and any
work that is connected with replacing these parts. Costs related to removing defect parts or
products, transportation, etc. are not covered by the producer’s warranty.
3. The producer will not accept to cover warranty terms in case of the following:
Maltreating the product and bad conditions of transportation and loading-unloading.
Wrong installation, failing to apply the directions given in the manual.
Improper use of the product.
Damages that have been cause by using improper fuels, with dimensions or
characteristics different from those described in the manual.
Damages from freezing if not necessary measures are taken against anti-freezing.
Incident of explosion due to use of impropriate chemical substances.
Electrical shocks that may harm electrical parts of the appliance.
4. Warranty is only valid if the installation is performed by a professional installer, authorized
by the producer, according to the local legislation and the instructions of this manual.
5. Warranty does not cover function problems or damages that are caused by bad chimney
installation, failing to respect the instruction of this manual and local legislation.
6. Warranty is not valid if the boiler cleaning, maintenance and service intervals are not
respected and the directions given are not followed.
7. Warranty is not valid if the maintenance is not performed by an authorized professional
according the instructions given and at the time intervals given.
8. Warranty does not cover costs related to emergency incidents like: earthquake, fire,
electrical blackout, robbery.
9. Warranty is not valid if the hardness of the water is over the allowed limits and no water
softening protection is installed.
10. The warranty is not transferable in case of reselling or replacing the product. A new
warranty should be accorded to the new user.
THERMOSTAHL ROMANIA
SISTEME TERMICE S.R.L.
DRUMUL OSIEI 57-59, sector 6
Bucuresti 062395, Romania
www.thermostahl.ro
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