Tilia Maxi 80 - 200 Montageanleitung

16150507 02-01

Maxi 80 - 200

CAST-IRON BOILERS

TECHNICAL MANUAL

Installation, operating and maintenance instructions

EKSKLUZIVNI UVOZNIK IN ZASTOPNIK:

TILIA d.o.o., Ljubljanska cesta 89, 8000 Novo mesto;

tel: 07/ 3324 442; fax: 07/ 3323 209; e-mail: info@tilia.si; www.tilia.si

ATTENTION!

Theboilersinthisseries must keep

within the limits they are designed

for.

Any other use is to be considered

as improper and consequently

dangerous.

This limits are indicated on the

manufacturer´sdatadecal.

- Boiler type.

- Serialnumber.

- Maxboilerpower.

- Maxboilerpressure.

- Maxworkingtemperature.

- Supplyvoltage.

• Thismanualisanintegraland

esentialpartofdeliveryof the

boilerand must be given to the

User.

• Iftheboileristransferredorsold

tootherUsers (change of destina-

tionorrelocation)makesurethat

theInstallation,Operatingand

MaintenanceManualisalso

transferred so that it can be

consulted by the installer, the

maintenancetechnicianandby

thenew owner.

• Readthe warnings and

procedureswith care before

installing,fillingorstarting-upthe

systemandand before any

maintenance.The manual gives

importantinformation regarding

system safety and protction of

DEFINITIONS

The terms ATTENTION, WARNING

and NOTE have been used when

draving up the manual to underling

instructions or information

that are considered to be critical

or unusual.

The conditions that dictate use of

these terms are defined as follows:

ATTENTION!

Information or procedures which

can cause danger situations if they

are not complied with.

WARNING

Information or procedures which can

cause damage to the machine or to its

components if they are not complied

with.

NOTE

Information or procedures which can

simplifyorfacilitatemaintenance

procedures or important parts of the

text that need to be emphasised.

WARNINGS orREQUIREMENTS

This installation, Operating and

Maintenancemanualisapplicable for

all series

CTCMaxicast-ironboilersdesig-

ned to produce hot water (at tempe-

ratures below the boiling point and

atmospheric pressure) in central

heating systems.

Their operating pressure are up to 5

bar(testpressure: 7.5 bar).

Thermalpower ranges gofrom80kW

to 200 kW.

persons.

• Installation must be done in

accordancewithCurrent Law,

followingtheinstructionsgiven in

this manual.

Installationmustbeperformedby

professionallyqualified and

certifiedpersons.

• Neverpermittheappliance to be

usedoroperatedbyinexpert

persons.

Erroneous installation or in-

adequate use and maintenance

of the boiler can cause harm to

persons or property for which the

manufacturer declines all

responsibility.

DEFINITIONS................................................1

1 TECHNICAL DATA

1.1 Generalcharacteristics..................................................4

1.2 Deliverycontents............................................................ 4

1.3 Dimensions......................................................................5

1.4 Technicaldata................................................................. 6

2 ASSEMBLY

2.1 Boilerassembly.............................................................. 7

2.2 Burnerinstallation........................................................... 7

2.3 Insulationandshellinstallation...................................... 8,9

3 INSTALLATION

3.1 Plumbingsystem............................................................ 10

3.2 Pipelinesystemstandards............................................ 11

3.3 Heatingwater deliveryandreturnpipelines................ 11

3.4 Safety,controlandadjustmentdevices........................11

3.5 Watercharacteristics..................................................... 11

3.6 Electricalconnections,system......................................12

3.7 Wiringdiagram............................................................... 13

3.8 Heatingplant................................................................... 14

3.9 Connectiontothesmokestack..................................... 14,15

4 OPERATION

4.1 Controlpanel...................................................................16

5 SYSTEM START-UP, OPERATION

AND MAINTENANCE

5.1 Fillingtheheatingsystem.............................................. 17

5.2 Firststart-upandpreliminarychecks........................... 17

5.3 Dataforcheckingcombustion...................................... 18

5.4 Generalboileroperating regulations............................18

5.5 Safetyregulationsandperiodicchecks.......................19

5.6 Generalmaintenancestandards.................................. 20

5.7 Inspectionandmaintenance......................................... 20

5.8 Checkinghatchwayseal................................................ 20

TABLE OF CONTENTS

1. TECHNICAL DATA

1.1GENERALTECHNICAL

CHARACTERISTICS

CTC Maxicast-ironboilersarehigh

efficiency(superiorto 90%)generators

of hot water up to 90°C for central

heating. Thehighefficiencyofthistype

of system also achieves extremely

LOWNOxemissiontotheatmosphere.

WhenLOW-NOxburnersareinstalled

this boiler meets the most restrictive

Europeanairpollution Standards.

Theboilerbody(madeofmodularcast-

iron wet-chamber components)

functions in depression for the entire

rangeofadmissiblepower ratings.

Theboilerbodyiscomposedof:

a. Frontcomponentwithinspection

hatchwaysandsupportforthe

blown-airburner.

b. Intermediateelementswith

shapesdesignedfor high thermal

exchangeeven when operatingat

LOWtemperatures.

Thenumberof elements can vary

dependingonthe thermal

capacity of the boiler.

c. End element that connects to the

deliveryand return pipelinesand

to the smoke exhaust system.

All elements are connected together

by twin-taper connection nipples.

Structural rigidity is achieved by tie-

rods,which alsofunctiontocarryload-

bearing parts of the shell. Boiler

insulation is obtained by a thick layer

of glass wool applied directly to the

boilerbody and therearelement. The

shell, made of stove enamelled steel

sheet, is quite simple, efficient and

modular and permits access to

inspection and maintenance

hatchways by simply removing

(withoutanytool) the front panel. The

shell also covers and protects the

controlboardwhichis furnishedtested

andalready wired.

Specific boiler data are given on the

data-decalapplied to thebacksection

of the right side.

1.2DELIVERY CONTENTS

Delivery consists of 6 packages:

1 - Palletwithboilercomponents

2 - Box with putty for seals between

modularcomponentsurfaces.

Puttyapplicatorandtwin-taper

connectionnipples.

3 - Tie-rods forassembly.

4 - Boxcontainingthefront

hatchways,thehinge for the

lowerdoor,front plugs,

connectionflangesandseals,

sheathforcontrolinstrument

probesand baffles.

5 - Box containing the shell,

insulation,spacersforpositioning

the shell, installation screws,

nuts and washers, technical and

guaranteedocuments.

6 - Box containing the control panel,

complete

7 - Assembly tools for boiler body

assembly(optionalequipment)

1. TECHNICAL DATA

1.3DIMENSIONS

1. Heatingflow

2. Heatingreturn

3. Fluegasconnection

4. Drain

5. Sensortube

1. TECHNICAL DATA

BOILER CTC Maxi80100120140160180200

Numberof elements 6 7 8 9 10 11 12

Maxoutputpower kW 80 100 120 140 160 180 200

Maxinputpower kW 88,9 111,1 133,3 155,6 177,8 200,0 222

Fuel Gas/Fuel-oil

Workingefficiency % 90,0 90,0 90,2 90,4 90,4 90,5 90,6

Efficiency at 30% capacity % 88 88 88 88 88 88 88

Loss at the smokestack % 8,4 8,2 8,4 8,4 8,2 8,2 8,2

Smoketemperature* °C 205 200 202 202 200 200 200

Gas smoke flow rate kg/h 137 171 206 240 274 309 342

Fuel oil smoke flow rate kg/h 131 165 198 231 264 297 330

Smoke load losses mbar 0,10 0,15 0,28 0,30 0,40 0,55 0,66

Dimensionsofthecombustionchamber:

Length mm 565 686 807 928 1049 1170 1291

Diameter mm 380 380 380 380 380 380 380

Volumeof the combustion chamber dm372 86 101 116 131 145 159

Smokestack connection mm 200 200 200 200 200 200 200

Water contents l 66,0 76,5 87,0 97,5 108,0 118,5 129,0

Water side load loss Dt = 15°C mbar 9 12 18 28 35 45 60

Deliveryconnection “G 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½”

Returnconnection “G 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½” 2 ½”

Boiler depth P mm 885 1005 1130 1250 1370 1495 1620

Weightof empty boiler kg 410 465 520 575 630 685 740

* with CO2% = 13 for Fuel Oil and 10 for Gas

Max.operatingpressure bar 5

Testpressure bar 7,5

Controlthermostats °C 21-85

Safetythermostat °C 110

Code PIN CE 0063/ ...

1.4 TECHNICALDATA

2. ASSEMBLY

2.1 BOILERASSEMBLY

(see the instruction manual

for boiler body assembly)

– Theboiler mustbeinstalled so that

distancesfromboilerroomwalls

comply with the minimum

distances requiredbybuilding

codes. Distances, in any case,

mustguaranteeeasyaccess tothe

boilerfor maintenance

– Thesupportsurface for the boiler

must be horizontal.

– Pipelines that go to boiler

connectionsmustbesupported

andplacedsothattheydonotbring

dangerousforcestobearonthe

connectionsthemselves.

– Connections for the two hoses to

theburnermustbe fastened in the

mostconvenientposition for freely

openingtheburner support plate.

– Ventilationmustcorrectlyfurnishair

totheburner. Incoming fresh air

frombelow andevacuationof stale

air from the top part of the boiler

room.

FIG. 2 - Burner installation diagram

2.2 BURNERINSTALLATION

1- An installation counter flange for

the burner is installed on the

lower front door , which has to be

adaptedtothe tube andtothebur-

nerflange (figure2).

2-Iftheburner flange does not fit this

flangethen an adaptationflange

and ceramic fibre gasket must be

installed.

3-Thetubediameter can be different

fromthe diameter oftheholein the

insulation. If necessary, the hole

inthe insulation can be enlarged.

4 -Use a cutter to remove excess

insulation. Insulation is made of

ceramic fibres and can be cut by

normal cutting tools.

5 -The maximum hole diameter that

is admissible is 130/150 mm.

ATTENTION!

1 -The seat of the tube must be as

precise as possible to prevent

backfires or backflow of heat

which could scorch the burner

connection plate.

2 - If hole enlargement is

impreciseor if the hole (for easy

installation) is oversized then

the space between tube and

insulation or rough-cut edges

must be carefully and totally fil-

led with ceramic fibre after the

burner is installed.

3 -If an adaptation flange is also

installed, make sure that smoke

seals are installed on both

couplingsurfaces.

4 - Lubricate burneranchor screws

with graphite to make

subsequent removal easier.

2. ASSEMBLY

Legend

51- 57 Right side with from 6 to 12 elements 87 M10 threaded17x95 hexspacer

61-67 Left side with from 6 to 12 elements 88 D10washer

71-77 Cover with from 6 to 12 elements 89 M10 x 20 hex head screw

81 Centralpanel 90 M10 stud bolts

82 Top frontbracket 91-97 6 to 12 elements of mineral wool

83 Sheet metal strip 101 Rear sectionmineral wool

84 Toprear panel 102 M12 hex nut

85 Bottomrearpanel 103 D12washer

86 Spacer L=80 mm 3/8 tube 110 Control panelcomplete

2.3 INSULATION AND SHELL INSTALLATION (fig. 3)

NOTE

1 -This section describes,

insequence,theoperations

requiredforinstalling the

insulating mattress and the shell.

2 -Just a few easy to find tools are

required to install the shell.

Makesure tools areofgood quality

and are not damaged or worn.

3-The component numbersgivenin

thefigureareindicatedin order of

assembly and are used for the

entiredescription.

4-Performinstallationprocedures in

theorderthatisgiven.

Check,beforemovingontoanother

phase,that thepreviousphase has

been totally and correctly

performed.

FIG. 3 – Shell components

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