Doc1078 R40 int1.pub - Stokvis Industrial Boilers International Ltd

ECONOFLAME R40
GAS FIRED
WALL MOUNTED
CONDENSING BOILERS
INSTALLATION, OPERATION & MAINTENANCE
DOCUMENTATION
STOKVIS ENERGY SYSTEMS
96R WALTON ROAD
EAST MOLESEY
SURREY
KT8 0DL
TEL: 020 8783 3050 / 08707 707 747
FAX: 020 8783 3051 / 08707 707 767
E-MAIL: info@stokvisboilers.com
WEBSITE: www.stokvisboilers.com
02/2011.2012.09.01.AC
DOC1078/XXXXXXXX
Contents
2
Contents
..................................................................
2
Safety
General regulations ...................................
Application .................................................
Norms and regulations ..............................
3
3
3
Construction
Layout of boiler ..........................................
Operating principle ....................................
4
4
Technical data
..................................................................
5
Extent of delivery
Standard boiler ..........................................
Accessories ...............................................
7
7
Installation
Boiler transport ..........................................
Removing the casing .................................
Boiler installation .......................................
Connecting the boiler ................................
8
8
9
9
Commissioning
Water and hydraulic system ......................
Gas supply ................................................
Condensate connection .............................
Flue and air intake connections .................
Prepare boiler for first startup ....................
Combustion analysis .................................
Check water flow ......................................
Check functionality of safety devices ........
Gas tightness check ..................................
Boiler shut down ........................................
Commissioning protocol ............................
11
12
12
12
12
14
15
16
16
16
17
Operating instructions
Controls ....................................................
Display / Programming ..............................
Overview of main functions .......................
18
19
20
Maintenance
Checklist ....................................................
Replacing the electrodes ...........................
Cleaning the condensate receptacle .........
Cleaning and refilling the syphon ..............
Inspection of combustion chamber ............
Water pressure and quality .......................
Water flow rate ..........................................
Combustion analysis .................................
Gas pressure .............................................
Gas tightness check ..................................
Safety devices ...........................................
Maintenance protocol ................................
21
21
22
22
22
23
23
23
23
23
23
24
Lockouts
..................................................................
25
Sensor values
..................................................................
28
Declaration of Conformity
..................................................................
29
Safety
General regulations
Application
Norms and regulations
General regulations
This documentation contains important
information, which is a base for safe
and reliable installation, commissioning
and operation of the R40 boiler. All
activities described in this document
may only be excecuted by authorized
companies.
Changes to this document may be
effected without prior notice. We accept
no obligation to adapt previously
delivered products to incorporate such
changes.
Only original spare parts may be used
when replacing components on the
boiler, otherwise warranty will be void.
Application
The R40 boiler may be used for heating
and hot water production purposes
only. The boiler should be connected to
closed systems with a maximum
temperature of 100ºC (high limit
temperature), maximum setpoint
temperature is 90ºC.
Norms and regulations
When installing and operating the
boiler, all applicable norms (European
and local) should be fulfilled:
Local building regulations for
installing combustion air and flue gas
systems;
Regulation for connecting the boiler to
the electrical appliance;
Regulations for connecting the boiler
to the local gas network;
Norms and regulations according to
safety equipment for heating systems;
Any additional local laws/regulations
with regard to installing and operating
heating systems.
The R40 boiler is CE approved and
applies to the following European
standards:
 92 / 42 / EEC
Boiler efficiency directive
 2009 / 142 / EEC
Gas appliance directive
 2006 / 95 / EEC
Low voltage directive
 2004 / 108 / EEC
EMC directive
EN 483
Gas-fired central heating boilers Type C boilers of nominal heat input
not exceeding 70 kW
EN 15420
Gas-fired central heating boilers Type C boilers of nominal heat input
exceeding 70 kW, but not exceeding
1000 kW
EN 15417
Gas-fired central heating boilers Specific requirements for condensing
boilers with a nominal heat input
greater than 70 kW but not exceeding
1000 kW
EN 50165
Electrical equipment of non-electric
appliances for household and similar
purposes - Safety requirements
EN 15502-1
Gas-fired central heating boilers Part 1: General requirements and
tests
EN 55014-1 (2000)
Electromagnetic compatibility requirements for household appliances,
electric tools and similar apparatus Part 1: Emission
EN 55014-2 (1997)
Electromagnetic compatibility requirements for household appliances,
electric tools and similar apparatus Part 2: Immunity - Product family
standard
EN 61000-3-2 (2000)
Electromagnetic compatibility (EMC) Part 3-2: Limits - Limits for harmonic
current emissions (equipment input
current 16 A per phase)
EN 61000-3-3 (2001)
Electromagnetic compatibility (EMC) Part 3-3: Limitation of voltage
changes, voltage fluctuations and
flicker in public low-voltage supply
systems, for equipment with rated
current 16 A per phase and not
subject to conditional connection
EN 60335-1 (2002)
Household and similar electrical
appliances - Safety - Part 1: General
requirements
EN 60335-2-102 (2006)
Household and similar electrical
appliances: Particular requirements
for gas, oil and solid-fuel burning
appliances having electrical
connections
Additional national standards
Germany:
RAL - UZ 61 / DIN 4702-8
Switzerland:
SVGW
EKAS-Form. 1942: FlüssiggasRichtlinie Teil 2
Vorschriften der kantonalen Instanzen
(z.B. Feuerpoilizeivorschriften)
Netherlands:
GASKEUR BASIS
GASKEUR SV
GASKEUR HR107
Belgium:
HR TOP
3
Construction
Layout of boiler
Operating principle
4
Layout of boiler
The R40 boiler consists of the following
main components:
3
1
2
12
10
11
5
6
8
7 9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Casing
Control panel
Flue gas connection (+ test point)
Air intake connection (+ test point)
Flow water connection
Return water connection
Gas connection
Syphon
Input for wiring
Connection for safety valve
Connection for fill/drain valve
Manometer
Fan
Gas valve
Ignition and ionisation electrodes
Heat exchanger
Inspection window
Ignition transformer
Electrical input connections
Controller
Condensate receptacle
20
2
16
19
13
14
15
18
21
17
Operating principle
The R40 is a fully modulating boiler.
The control unit of the boiler adapts the
modulation ratio automatically to the
heat demand requested by the system.
This is done by controlling the speed of
the fan. As a result, the Whirlwind
mixing system will adapt the gas ratio to
the chosen fan speed, in order to
maintain the best possible combustion
figures and therewith the best efficiency.
The flue gases created by the
combustion are transported downwards
through the heat exchanger
4
and leave the boiler at the top into the
chimney connection.
The return water from the system
enters the boiler in the lower section,
where is the lowest flue gas
temperature in the boiler. In this section
condensation takes place. The water is
being transported upwards through the
heat exchanger, in order to leave the
boiler at the flow connection. The cross
flow working principle (water up, flue
gas down) ensures the most efficient
combustion results.
The LMS14 control unit can control the
boiler operation based on:
Boiler control (stand alone operation);
weather compensated operation
(with optional outdoor sensor);
with 0-10V external influence
(temperature or capacity) from a
building management system.
Technical data
Nominal heat output at 80-60ºC max/min
kW
R40
65
60.8/10.1
R40
85
81.1/13.4
R40
100
92.9/15.6
R40
120
111.6/18.7
R40
150
132.2/23.3
Nominal heat output at 75-60ºC max/min
kW
60.9/10.1
81.3/13.4
93.1/15.6
111.8/18.7
Nominal heat output at 40/30ºC max/min
kW
63.9/11.1
85.3/14.8
100.0/17.2
120.0/20.6
132.5/23.3
142.3/25.6
Nominal heat input Hi max/min
kW
62.4/10.4
83.3/13.8
95.2/16.0
114.3/19.2
135.5/23.9
Efficiency at 80/60ºC
%
97.4
97.4
97.6
97.6
97.6
Efficiency at 40/30ºC
%
102.4
102.4
105.0
105.0
105.0
Annual efficiency (NNG 75/60ºC)
%
106.2
106.2
106.2
106.2
106.2
Annual efficiency (NNG 40/30ºC)
%
>110
>110
>110
>110
>110
Standstill losses (Twater = 70ºC)
%
0.20
0.20
0.20
0.20
0.20
l/h
3.5
4.8
6.4
7.7
9.1
Gas consumption G20 max/min (10,9 kWh/m3)
m3/h
5.7/1.0
7.6/1.3
8.7/1.5
10.5/1.8
12.4/2.2
Gas consumption G25 max/min (8,34 kWh/m3)
m3/h
7.5/1.2
10.0/1.7
11.4/1.9
13.7/2.3
16.3/2.9
Gas consumption G31 max/min (12,8 kWh/kg)
kg/h
4.9/0.8
6.5/1.1
7.4/1.3
8.9/1.5
10.6/1.9
Gas pressure G20 H-Gas
mbar
mbar
20
20
20
20
20
Gas pressure G25 L-Gas
25
25
25
25
25
Gas pressure G31 LPG
mbar
30/50
30/50
30/50
Maximum gas pressure
mbar
50
50
50
50
50
ºC
76/63
76/63
76/63
76/63
76/63
Max. condensate flow
Flue gas temperature at 80/60ºC max/min
30/50
30/50
ºC
55/39
55/39
55/39
55/39
55/39
m3/h
119/19
159/25
178/29
213/35
253/44
CO2 level G20/G25 max/min
%
8.5/8.5
8.5/8.5
8.7/8.5
8.7/8.5
8.7/8.5
CO2 level G31 max/min
%
-/-
-/-
-/-
-/-
-/-
NOx level
mg/kWh
39
39
39
39
39
CO level max/min
mg/kWh
98/7
98/7
98/7
98/7
98/7
Pa
150/15
150/15
150/15
200/15
200/15
l
4.0
4.7
6.5
8.0
9.4
bar
8.0/1.5
8.0/1.5
8.0/1.5
8.0/1.5
8.0/1.5
100
Flue gas temperature at 40/30ºC max/min
Flue gas quantity max/min
Max. permissible flue resistance max/min
Water volume
Water pressure max/min
Max. water temperature (High limit thermostat)
ºC
100
100
100
100
Maximum temperature setpoint
ºC
90
90
90
90
90
Nominal water flow at dT=20K
m3/h
2.6
3.4
4.0
4.8
5.6
Hydraulic resistance at nominal water flow
kPa
16
29
15
22
34
Electrical connection
V
230
230
230
230
230
50
Frequency
Hz
50
50
50
50
Mains connection fuse
A
10
10
10
10
IP class
-
IPX4D
IPX4D
IPX4D
IPX4D
IPX4D
10
Power consumption boiler max/min (excl. pump)
W
98/26
167/38
195/30
228/36
248/44
Power consumption 3-step pump (optional)
W
150
205
150
210
385
Power consumption speed controlled pump (opt)
W
124
124
130
130
130
Weight (empty)
kg
60
68
80
90
97
dB(A)
56/50
56/50
56/50
56/50
56/50
Noise level at 1 meter distance*
µA
3
3
3
3
3
PH value condensate
-
3.2
3.2
3.2
3.2
3.2
CE certification code
-
Water connections
-
R1.1/4"
R1.1/4"
R1.1/2"
R1.1/2"
R1.1/2"
Gas connection
-
R3/4"
R3/4"
R1"
R1"
R1"
Ionisation current minimum
CE-0063CM3576
Flue gas connection
mm
100
100
100
100
130
Air intake connection (for room sealed use)
mm
100
100
100
100
130
Condensate connection
mm
22
22
22
22
22
* non room sealed / room sealed
5
Technical data
Dimensions
6
R40/65
R40/85
R40/100
R40/120
R40/150
B
mm
490
490
590
590
590
B1
mm
140
140
140
140
190
B2
mm
245
245
295
295
295
D
mm
500
500
600
600
600
H
mm
810
810
950
950
950
W1
mm
R 1 1/4"
R 1 1/4"
R 1 1/2"
R 1 1/2"
R 1 1/2"
W2
mm
R 1 1/4"
R 1 1/4"
R 1 1/2"
R 1 1/2"
R 1 1/2"
G
mm
R 3/4"
R 3/4"
R 1"
R 1"
R 1"
F
mm
100
100
100
100
130
A
mm
100
100
100
100
130
Extent of delivery
Standard boiler
Accessories
Standard boiler
A boiler delivery package contains the
following components:
Component
Pcs.
Package
Boiler fully assembled and tested
1
Cardboard box on pallet
Mounting bracket incl. mounting material
1
Cardboard box in boiler packaging
Syphon for condensate connection
1
Cardboard box in boiler packaging
Conversion kit for propane incl. instruction
1
Cardboard box in boiler packaging
Operation and Installation manual
1
Map packed in cardboard box in boiler packaging
Spare parts list
1
Map packed in cardboard box in boiler packaging
Wiring diagram
1
Map packed in cardboard box in boiler packaging
Accessories
Additional to the boiler, the following
accessories can be ordered:
Standard 3-step pump incl.
connection kit;
Speed controlled pump incl.
connection kit;
Safety valve, fill/drain valve and
connection for expansion tank;
Set with water (2x) and gas (1x)
cocks;
Gas filter incl. connection kit;
Min. gas pressure switch;
Plate heat exchanger (dT=10K/15K
or dT=20K) incl. connection kit;
Low velocity header, suitable for
dT=10K/15K and dT=20K incl.
connection kit;
Plug & play cascade kit (see Modupak
cascade manual for more details);
Extension module AGU2.551 for
0-10V control of a modulating pump
and/or boiler capacity feedback to a
building management system;
Electrical connection for external gas
valve and/or room fan.
Extension module AGU2.550 for
heating zone control or external gas
valve and/or room fan control in
combination with an alarm signal.
For each boiler a maximum of 3
AGU2.550 modules (2x heating zone,
1x ext. gas valve / room fan in
combination with alarm) can be
integrated in the boiler;
Additional RVS63 heating zone
controller, when controlling more than
2 zones (incl. wall hung box, all
necessary sensors and sockets and
connection material for bus
communication).
The above accessories are specially
designed for the R40 boiler and
therewith easy to install (plug and play).
By choosing a combination of the kits
mentioned above, you can create your
own complete system solution. Ask your
supplier for more detailed information.
7
Installation
Boiler transport
Removing the casing
Boiler transport
The R40 boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The packaging
dimension is 1050x572x575mm for boiler
types 65-85 and 1185x674x665mm for
boiler types 100-150, which makes it
possible to transport all models through
a nomal door in one piece.
The R40 can be transported with a
crane, but it has to be ensured that the
boiler is packed and fixed on a pallet.
The straps must be connected to the
pallet.
Removing the casing
Remove the casing before installing the
boiler, in order to avoid damage to the
casing parts. Removing the casing is
done as shown on the pictures.
2
4
8
1
3
Installation
Boiler installation
Connecting the boiler
Boiler installation
The boiler should be positioned in a
frost-proof boiler room. If the boiler
room is on the roof, the boiler itself may
never be the highest point of the
installation.
When positioning the boiler, please
note the recommended minimum clearance in the picture. When the boiler is
positioned with less free space, maintenance activities will be more difficult.
Connecting the boiler
This chapter will explain how to make
all connections to the boiler with regard
to:
Hydraulic connections
Condensate drain connection
Gas connection
Flue gas connection
Air intake connection
Electrical connection
3
4
1
2
5
6
The boiler should always be connected
in such a way, that the system applies
to all relevant standards and regulations (European, national and local).
It's the responsibility of the installer to
ensure that all standards and
regulations are respected.
Hydraulic connections (1,2,3,4)
The boiler should always be connected
in such a way, that water flow through
the boiler can be ensured at all times.
Connect the flow (1) and return (2)
connection of the system tension free
to the boiler connections.
Condensate connection (5)
After filling with water, the syphon
(included in delivery) should be
installed to the connection (5) at the
bottom of the boiler. Connect the hose
to the draining system in the boiler room.
The connection to the draining system
should always be done with an open
connection, in order to avoid a flooding
of the boiler in case of a blocked drain.
Gas connection (6)
The gas connection must be made by
an authorized installer in accordance
with the applicable national and local
standards and regulations.
Connect the gas line from the system
tension free to the gas connection (6) of
the boiler. A gas cock should be
mounted directly behind the boiler.
A gas filter can be mounted directly on
the gas connection of the boiler.
The boiler contains a connection
possibility for an (optional) kit with safety
valve, fill/drain valve and an expansion
tank connection. The safety valve must
be connected to the flow connection (3)
of the boiler, the fill/drain valve and
expansion tank connection must be
connected to the return connection (4).
The (optional) pump kit should be
mounted directly to the return
connection (2) of the boiler, before
connecting to the system.
9
Installation
Connecting the boiler
8
7
10
Flue gas connection (7)
Regulations for the construction of flue
gas systems are very different for each
country. It should be ensured that all
national regulations with regard to flue
gas systems are respected.
Electrical connection
The electrical connection must be
made by an authorized installer in
accordance with the applicable
national and local standards and
regulations.
Connect the flue gas system to the flue
gas connection (7) of the boiler, use
flue gas systems with seamless connections only. It’s not necessary to make a
separate condensate drain for the flue
gas system, as the condensate will be
drained via the syphon of the boiler.
Please note the following issues:
It’s recommended to use stainless
steel or PPS flue gas systems
The diameter of the flue gas system
must be chosen by calculation
according to the national regulations
Construct the flue gas system as
short as possible (for maximum
length see Options manual)
Construct horizonal ways with a
minimum angle of 3º
For the power supply it’s necessary
to use a mains isolator switch with a
contact opening of at least 3 mm
within the boiler room. This switch
can be used to switch off the power
supply for maintenance purposes.
All cables should be lead through the
cable glands (9) at the bottom of the
boiler into the electro panel (10).
Connect all wires to the terminals
according to the wiring diagram of the
boiler (enclosed in map in boiler
packaging).
Air intake connection (8)
The air intake can be connected in
case of room sealed installation. The
diameter should be calculated according
to the national regulations, together
with the flue gas system. The total
resistance of both systems should never
overcome the maximum permissible
resistance of the fan inside the boiler
(see also chapter: Technical data).
9
Outside sensor mounting
If an outside sensor (accessory) is
connected to the boiler, the sensor
should be positioned as shown on the
drawing.
10
Commissioning
Water and hydraulic system
Commissioning of the boiler should be
carried out by authorized personnel
only. Failure to respect this condition
makes the guarantee void. A protocol
of the commissioning should be filled
out (see end of this chapter for example
of commissioning protocol).
This chapter explains the
commissioning of the boiler with the
standard boiler controller. When an
additional system controller is installed,
please refer to its manual for
commissioning the controller.
Boiler output
[kW]
Max. sum of alkaline earths
[mol/m3]
Max. total hardness
[ºdH]
50 - 200
2.0
11.2
200 - 600
1.5
8.4
Water quality
The system should be filled with water
with a pH value between 8,0 and 9,5.
The chloride value of the water should
not exceed 50 mg/l. Entry of oxygen
by diffusion should be prevented at all
times. Damage to the heat exchanger
because of oxygen diffusion will not
be taken under warranty.
In installations with higher water
volumes, it’s necessary to respect the
maximum filling and additional volumes
with corresponding hardness values as
stated in the german VDI2035 standard.
In the table you can find the nominal
values for filling and additional water for
the R40 according to the the VDI2035.
Concentrate
Ca(HCO3)2
Capacity of installation Q (kW)
150
200
250
300
400
500
600
mol/m3
ºdH
Maximum water (re)fill volume Vmax [m3]
≤0.5
≤2.8
-
-
-
-
-
-
-
1.0
5.6
-
-
-
-
-
-
-
1.5
8.4
3
4
5
6
8
10
12
2.0
11.2
3
4
5
6
6.3
7.8
9.4
2.5
14.0
1.9
2.5
3.1
3.8
5.0
6.3
7.5
≥3.0
≥16.8
1.6
2.1
2.6
3.1
4.2
5.2
6.3
Water pressure
Open the valves to the system. Check
the water pressure in the system. If the
water pressure is too low (see table
below), increase the pressure up to at
least the minimum required water
pressure in the table.
2
1
Minimum operating
pressure
[bar]
> 1.5
> 1.5
Flow temperature
[ºC]
90
80
The table at the left gives an indication
of the relation between the water
quality and the maximum water filling
volume during the lifetime of the boiler.
Consult the original text of the VDI2035
for more detailed information.
Filling can eventually be done via the
(optional) fill and drain valve (2) on the
return connection (1) of the boiler.
Hydraulic system
Check if the boiler is hydraulically
connected to the system in such way,
that water flow can be secured at all
times during burner operation. The water
flow is supervised by ∆T-protection in the
boiler and a lack of flow will lead to a
direct burner stop and lockout of the
boiler.
11
Commissioning
Gas supply
Condensate connection
Flue and air intake connections
Gas supply
Check the gas supply connection to the
boiler for tightness. If any leakage is
found, reseal the leakage before
starting the boiler!
1
Remove any air between the gas valve
and the gas line. This can be done at
the test point (1) at the gas pressure
switch. Don’t forget to close the test
point afterwards!
Check the gas type and values with the
local gas company, in order to know for
which gas type the boiler should be
commissioned.
Consult the conversion kit instruction if
the boiler is to be installed with natural
gas L or LPG.
2
Condensate connection
Remove the syphon (2) from the
condensate connection. Fill it with water
and place it back in the original
position. Make sure the syphon is filled
before starting the boiler, in
order to prevent flue gases discharging
through the condensate connection!
Flue and air intake connections
Check whether the flue and air intake
systems are made according to the
national and local regulations.
Installations which don’t comply with the
regulations, are not allowed to be
commissioned.
Make sure that all connections are free.
The size of flue gas and air intake
connections may not be reduced.
12
Commissioning
Prepare boiler for first startup
Legend:
A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I
Operation mode heating zone(s)
L Display
M Operation mode DHW
A
I
M
L
G
A
H
B
C
D
E
F
Preparation for first startup
Open the gas supply;
Enable the power supply to the boiler;
Switch on the boiler with the on/off
switch (A);
Make sure the boiler is in standby
mode (K);
Check the pump operation: make
sure the pump runs in the right
direction;
Release all air from the pump motor.
It‘s recommended to put the boiler on
50% load after the first startup, as this
is the best starting point to do a proper
combustion analysis. This can be done
with the following procedure:
Push button I >3 Sec, the boiler goes
into controller Stop mode.
Push the Info button (G), the actual
boiler load (%) appears in the display;
Choose "set up" (confirm with OK
button), now the boiler load can be
changed by rotating the wheel (C)
and confirming the 50% setting with
the OK button.
After checking the combustion values
(see next page), the controller Stop
mode can be stopped by pushing the
control mode button (I) >3 Sec.
13
Commissioning
Combustion analysis
Combustion check at full load
Start the boiler in controller stop mode
and go to 50% load. Now the boiler
operates at 50% load. Allow the boiler
to stabilise the combustion for 3
minutes. Then increase the boiler load
step by step up to 100%. Check the
gas pressure on the inlet of the gas
valve while increasing the boiler load:
the gas pressure should never go
below the minimum required value
see technical data. When an (optional)
minimum gas pressure switch is
connected, this must be set to 75% of
the required gas pressure.
1
Combustion settings max. load
for natural gas G20 / G25
CO2, max
COmax
%
ppm
CO2, max
%
R40/65-85
8.5±0.2
< 70
R40/100-150
8.7±0.2
COmax
ppm
< 70
Check the combustion settings via the
test point in the chimney connection
(1). If necessary, correct the settings
with the small adjustment screw at the
top of the gas valve (2).
2
3
ac-doc1078-03.2012
Combustion check at minimum load
Switch the boiler to minimum load (0%).
Check the combustion settings the
same way as described for full load. If
necessary, correct the settings with the
large adjustment screw at the top of the
gas valve (3).
Combustion check at 50% load
An additional reference check of
combustion values at 50% load is
recommended in order to check if the
gas valve is set in such way, that the
modulating behaviour is normal. The
CO2 value should be in between the
settings of full load and minumum load.
CO value should be equal to full load
and minimum load values.
Make sure that the boiler is set to
automatic operation and controller stop
mode is disabled after the combustion
test is finished.
14
Combustion settings min. load
for natural gas G20 / G25
CO2, min
COmin
%
ppm
R40/65-150
8.5 ± 0.2
< 30
Commissioning
Check water flow
Check water flow
The water flow through the boiler can
be checked with two different methods
shown below.
∆T measurement
Check the temperature difference over
the boiler (∆T flow-return) when the
boiler is running on 100% load. The
nominal ∆T is 20K and must be at least
between 10K and 20K for secure boiler
operation. An indication of the actual
flow rate can be found with the
following calculation (see table below
for nominal data):
qactual = (∆Tnominal / ∆Tmeasured) * qnominal [m3/h]
∆p measurement
Check the pressure difference over the
boiler (∆p flow-return) when the boiler
pump is running (burner on is not
required). The nominal ∆p for each boiler
type can be found in the table below,
actual ∆p must be within:
1.0*Δpnom ≤ ∆P ≤ 4.0*∆pnom . An
indication of the actual flow rate can be
found with the following calculation (see
table below for nominal data):
qactual = √(∆pmeasured / ∆pnominal) * qnominal [m3/h]
Water flow data
Nominal flow rate
[m3/h]
∆T at nominal flow rate
[ºC]
∆p at nominal flow rate
[kPa]
R40/65
R40/85
R40/100
R40/120
R40/150
2.6
3.4
4.0
4.8
5.6
16
29
22
34
20
15
15
Commissioning
Check functionality of safety devices
Gas tightness check
Boiler shut down
Check functionality of safety devices
All safety devices have to be checked
on good functioning. Safety devices on
a standard boiler are a water flow
temperature sensor, water return
temperature sensor, flue gas
temperature sensor and ionisation
electrode. These devices can be checked
as described below.
1
Flow temperature sensor (1)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 20.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
2
3
Return temperature sensor (2)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 40.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Flue gas temperature sensor (3)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 28.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Ionisation electrode (4)
Remove electrical connection from the
ionisation electrode while the boiler is
running, the boiler will go in lockout no.
128. The boiler will try to restart. With
the electrical connection removed, the
restart will result in lockout no. 133.
When the connection is already
mounted, the restart will be successful.
4
Measuring the ionisation current can
be done by mounting a multi-meter (set
to µA) in between the ionisation
electrode and its electrical connection.
The ionisation current should always
be above 1.2 µA, in normal conditions
it will be 6 µA and above.
5
16
Gas tightness check
Check the gas tightness of all sealed
connections with an approved soap or
electronic gas analyzer, for example:
Test points;
Bolt connections;
Gaskets of mixing system, etc.
Boiler shut down
When the boiler will not be used for
longer periods, shut down the boiler by
following procedure:
Switch the boiler in standby operation
(K);
Switch off the boiler with the on/off
switch (5);
Disable power supply to the boiler by
deactivating the mains isolator switch
in the boiler room;
Close the gas supply to the boiler.
Commissioning
Commissioning protocol
Project
Commissioning Protocol R40
Boiler type
Project
Serial number
Address
Year
City
Nominal load (Hi)
[kW]
Date
Nominal output (Hi)
[kW]
Engineer
[bar]
Installation:
System
Water pressure
Water pH
[-]
Water hardness
[ºdH]
Water chloride
[mg/l]
Water ∆T full load
[ºC]
[kPa]
Water ∆pboiler
[m3/h]
Water flow
Pump setting
[-]
Hydraulics:
Roof top

Ground floor

Basement

Other: .........................

Low velocity header

Plated heat exchanger

Bypass boiler

Other: .........................

Safety devices
High limit setting
Temp. limiter setting
Min. gas pressure switch setting
[ºC]
Water flow sensor checked

[ºC]
Fluegas sensor checked

Water flow switch checked

[mbar]
Ignition time burner
[sec]
Combustion analysis
100% load
50% load
Min. load
Gas consumption
[m3/h]
[m3/h]
[m3/h]
Gas pressure
[mbar]
[mbar]
[mbar]
[%]
[%]
[%]
CO2
O2
[%]
[%]
[%]
CO
[ppm]
[ppm]
[ppm]
NOx
[ppm]
[ppm]
[ppm]
Tatmospheric
[ºC]
[ºC]
[ºC]
Tfluegas
[ºC]
[ºC]
[ºC]
Twater, flow
[ºC]
[ºC]
[ºC]
Twater, return
[ºC]
[ºC]
[ºC]
Ionisation current
[µA]
[µA]
[µA]
pfan
[mbar]
[mbar]
[mbar]
ptop panel
[mbar]
[mbar]
[mbar]
pcombustion chamber
[mbar]
[mbar]
[mbar]
Remarks
17
Operating instructions
Controls
I
M
L
G
A
H
B
C
D
E
F
Operation mode DHW (M)
For switching on the DHW operation
(indication in display below DHW
symbol)
Confirmation (OK) (D)
Return (ESC) (B)
These buttons are used for programming in combination with the wheel.
Operation mode heating zone(s) (I)
For setting 4 different heating modes:
Auto (clock): Automatic operation by
time programm
Comfort (sun): 24/7 heating in comfort
mode
Reduction (moon): 24/7 heating in
reduced mode
Standby: heating off, frost protection
activated.
By pressing the ESC button it‘s possible
to go back one level, changed values
are not taken over by the controller.
Display (L)
Info mode (G)
Display possibility of following info
without influence on boiler control:
temperatures, operation mode
Heating / DHW, error code.
Room temperature control (C)
 for changing room comfort
temperature
 for changing settings when
programming.
18
Legend:
A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I
Operation mode heating zone(s)
L Display
M Operation mode DHW
By pressing the OK button it‘s possible
to arrive in the next level or confirm
changed values.
Manual mode (E)
This button is used for switching the
boiler into manual mode. In manual
mode all pumps will run and the mixing
valves are no longer controlled, the
burner setpoint is 60°C (indicated by
spanner symbol).
On/off switch (A)
Position 0:
Boiler and connected electrical
components are no powered. Frost
protection is not secured.
Position I
Position I:
The boiler and connected electrical
components are powered and standby
for operation.
Deaeration mode (E)
By pressing the manual mode button
longer than 3 seconds, the automatic
hydraulic deaeration is activated. During
deaeration the system is put in standby
mode
The pumps are switched on and off for
several times.
After deaeration, the boiler automatically
returns to normal operation.
Chimney sweeper mode (F)
Used for combustion analysis. By
pressing the button once again, or
automatically after 15 minutes, the
chimney sweeper mode will be deactivated (indicated by spanner symbol).
Reset button (H)
By shortly pressing the reset button a
burner lockout can be cancelled.
Operating instructions
Display / Programming
DHW mode selection
Heating operation mode selection
(Controller Stopp mode when
pressing > 3 sec.)
Display
Info button
Confirm
Manual mode
(Deaeration mode when pressing
> 3 sec.)
Quit menu
Reset
Chimney sweeper mode
Select
(turn left/right)
Heating to comfort setpoint Info level activated
Heating to reduced setpoint Programming
activated
Heating for frost protection setpoint Heating
temporarily switched off
Process running – please wait ECO function
active
Burner operating (only oil / gas boiler)
Error messages
Info level activated
Programming activated
Heating temporarily switched off
ECO function active
Holiday function active
Reference to heating circuit
Maintenance / special operation
Parameter number
Default mode
(buttons)
Programming
Press OK (1x)
Commissioning
Enduser
-
choose menu
confirm with OK- button
gewünschtes Menü
choose parameter auswählen
confirm with OK- button
mit Taste OK bestätigen
change value +- - with
mitwheel
Taste ESC zurück
confirm with OK button
zur Grundanzeige
return to main menu with ESC button
-
-
Press OK (1x)
Press INFO (4 sec.)
Expert
choose user level
confirm
with OK
button
gewünschte
Benutzer-Ebene
auswählen
choose
menu
mit Taste
OK bestätigen
confirm
with
OK
button
gewünschtes Menü auswählen
choose
parameter
mit Taste
OK bestätigen
confirm
withESC
OK button
mit Taste
zurück zur Grundanzeige
change value + - with wheel
confirm with OK button
return to main menu with ESC button
19
Operating instructions
= confirmation
= cancel, return to main
menu
Overview of main functions
Button
Action
Set room temperature
Procedure
Zone 1 and zone 2
Actuate wheel left/right
Turn wheel
Confirm with OK button
or wait 5 sec.
or press
Zone 2 independent from zone 1
Actuate wheel left/right
Set room temperature for Confirm with OK button
zone 1 or zone 2
Actuate wheel left/right
Confirm with OK button
or wait 5 sec.
or press
Switch on /off DHW operation
Deaeration
RESET
20
Comfort setpoint saved
Comfort setpoint cancelled
- after 3 sec. Main menu appears
Automatic mode on, with:
- Heating by time program
- Temperature setpoint by heating program
- Safety functions activated
- Summer/Winter automatic switching activated
- ECO-functions activated
(see indication below operation symbol)
Continuous COMFORT heating on, with:
- Heating without time program by comfort setpoint
- Safety functions activated
Continuous REDUCED heating on, with:
- Heating without time programmby reduced setpoint
- Safety functions activated
- Summer/Winter automatic switching activated
- ECO-functions activated
Safety mode on, with:
- Heating off
- Temperature by frost protection
- Safety functions activated
Press button > 3 sec.
Press button > 3 sec. again
304: Controller Stop mode
after 3 sec. Main menu appears
Press button 1x
Press button 1x again
Press button 1x again
…..
INFO Segment displayed
- Status Boiler
Press button 1x
Change factory setting
boiler temperature
Choose heating zone
Heating zone is chosen
Blinking temperature in 0,5 °C steps from 10 to 30 °C
Factory setting
Press button 1x again
Operation by manual
setpoint
Comfort setpoint saved
Comfort setpoint cancelled
- after 3 sec. Main menu appears
DHW mode on / off
(see indication below DHW symbol)
- On: DHW mode by time program
- Off: no DHW operation
- Safety functions activated
Change heating operation
mode
Press button 1x again
Info display
Comfort setpoint with blinking temperature
Blinking temperature in 0,5 °C steps from 10 to 30 °C
Press button
Press button 1x
Controller Stop mode
Display / Function
insert setpoint
- room temperature
- room temperature minimum
- Status DHW
- room temperature maximum
- Status zone 1
- outside temperature
- Status zone 2
- outside temperature minimum
- outside temperature maximum
- Time / Date
- DHW temperature 1
- Error indication
- Boiler temperature
- Maintenance indication
- Flow temperature
(Info display depends on configuration)
Back to main menu;
INFO Segment disappears
Press button 1x
Manual mode on (spanner symbol appears)
- Haeting by fixed setpoint
(factory setting = 60 °C)
Press button
Press button
Turn wheel -/+
Press button
Press button
Press button
301: Manual mode
blinking temperature
set value
Press button > 3 sec.
Press button > 3 sec. again
312: Deaeration on
Deaeration off
insert setpoint?
Status boiler
Manual mode off (spanner symbol disappears)
Activate chimney sweeper Press button (< 3 sec.)
mode
Press button again (< 3 sec.)
Chimney sweeper mode on
Chimney sweeper mode off
Temporary reduction of
reduced temperature on
QAA75
Press button
Press button again
Heating by reduced setpoint
Heating by comfort setpoint
Reset button
Press button (< 3 sec.)
Press button again > 3 sec.
Boiler manually blocked, no release
Boiler released, Alarm symbol disappears
Maintenance
Checklist
Replacing the electrodes
Maintenance of the boiler should be
carried out by authorized personnel
only.
In order to ensure continued good and
safe operation of the boiler, it should be
inspected at least once per year.
A maintenance protocol should be filled
out (see end of this chapter for example
of maintenance protocol).
Checklist
The following activities must be carried
out, see following paragraphs for an
extensive description of the main
activities:
Replace the ignition and ionisation
electrodes;
Clean the condensate receptacle;
Clean and refill the syphon;
Inspect the combustion chamber,
clean if necessary
(DON'T use water !);
Check the water pressure of the
system;
Check the water quality of the system
water as well as supply water;
Check the water flow rate through the
boiler;
Check/correct the combustion values
at full and mimimum load with a
combustion analyzer;
Check the gas pressure to the boiler;
Check the tightness of all sealed
connections and test points;
Check the functionality of all safety
devices;
Fill out a maintenance protocol.
Replacing the electrodes
The electrodes are positioned on the
top side of the boiler. Replace the
ignition electrode (1) and ionisation
electrode (2) as shown on the picture.
2
1
21
Maintenance
Cleaning the condensate receptacle
Cleaning and refilling the syphon
Inspection of combustion chamber
Cleaning the condensate receptacle
Disconnect the plug of the flue gas
temperature sensor (1);
Remove the condensate receptacle
(2);
Clean the receptacle;
Mount the condensate receptacle;
Connect the plug of the flue gas
temperature sensor.
1
2
Cleaning and refilling the syphon
Remove the syphon (3) from the
condensate connection;
Clean and fill it with fresh water;
Mount the syphon back in the original
position.
3
5
4
6
7
8
22
Inspection of combustion chamber
For inspection of the combustion
chamber the mixing system and burner
must be disassembled.
Switch off the boiler and close the gas
supply;
Remove the electrical connection
from the fan and gas valve (4);
Remove the electrical connection
from the electrodes (5);
Undo the gas connection at the inlet
of the gas valve (6);
Disassemble the top plate incl. mixing
system (7);
Remove the burner from the
combustion chamber (8);
Inspect the combustion chamber and
clean it with a vacuum cleaner if
necessary;
Assemble all components in opposite
order;
Open the gas supply and check all
connections for gas leakage;
Switch on the boiler.
Maintenance
Water pressure and quality
Check if the water pressure and quality
meet the requirements. Consult the
chapter “commissioning: water and
hydraulic system” for more detailed
information.
Water flow rate
Check if the water flow rate through the
boiler is within the limits. Consult the
chapter “commissioning: check water
flow” for more detailed information.
Combustion analysis
Check the combustion at full load and
minumum load, correct the settings if
necessary. An additional reference
check at 50% load is recommended.
Consult the chapter “commissioning:
combustion analysis” for more detailed
information.
Gas pressure
Check the dynamic pressure of the gas
supply to the boiler, when the boiler is
running at full load. In case of a boiler
cascade, all boilers should be running
at full load. See technical data for
required values.
Gas tightness check
Check the tightness of all sealed
connections with an approved soap or
electronic analyzer, for example:
Test points;
Bolt connections;
Gaskets of mixing system, etc.
Safety devices
Check the functionality and the settings
of all safety devices connected. Consult
the chapter “commissioning: Check
functionality of safety devices” for more
detailed information.
23
Maintenance
Maintenance Protocol
Maintenance Protocol R40
Project
Boiler type
Serial number
Year
Nominal load (Hi)
Nominal output (Hi)
[kW]
[kW]
System
Water pressure
Water pH
Water hardness
Water chloride
Water ∆T full load
Water ∆pboiler
Water flow
Pump setting
[bar]
[-]
[ºdH]
[mg/l]
[ºC]
[kPa]
[m3/h]
[-]
Safety devices
High limit setting
Temp. limiter setting
Min. gas pressure switch setting
Ignition time burner
[ºC]
[ºC]
[mbar]
[sec]
Project
Address
City
Date
Engineer
Water flow sensor checked
Fluegas sensor checked
Water flow switch checked



Combustion analysis
100% load
Gas consumption
Gas pressure
CO2
O2
CO
NOx
Tatmospheric
Tfluegas
Twater, flow
Twater, return
Ionisation current
pfan
ptop panel
pcombustion chamber
Remarks
24
3
[m /h]
[mbar]
[%]
[%]
[ppm]
[ppm]
[ºC]
[ºC]
[ºC]
[ºC]
[µA]
[mbar]
[mbar]
[mbar]
50% load
3
[m /h]
[mbar]
[%]
[%]
[ppm]
[ppm]
[ºC]
[ºC]
[ºC]
[ºC]
[µA]
[mbar]
[mbar]
[mbar]
Min. load
[m3/h]
[mbar]
[%]
[%]
[ppm]
[ppm]
[ºC]
[ºC]
[ºC]
[ºC]
[µA]
[mbar]
[mbar]
[mbar]
Lockouts
In case of a lockout, a warning symbol ( ) and a flashing error code appears on the display. The cause of a fault should first
be determined and eliminated before the boiler is being reset. The table below shows all possible lockouts with indication of
possible cause.
Error
code
Description of error
0
10
20
26
28
30
32
38
40
46
47
50
52
54
57
60
65
70
71
72
73
74
82
83
84
85
91
98
99
100
102
103
105
109
110
111
121
122
125
126
127
128
No error
Outside temperature sensor error
Boiler temperature 1 sensor error
Common flow temperature sensor error
Flue gas temperature sensor error
Flow temperature 1 sensor error
Flow temperature 2 sensor error
Flow temperature primary controller sensor error
Return temperature 1 sensor error
Return temperature cascade sensor error
Common return temperature sensor error
DHW temperature 1 sensor error
DHW temperature 2 sensor error
DHW primary controller sensor error
DHW circulation temperature sensor error
Room temperature 1 sensor error
Room temperature 2 sensor error
Buffer storage tank temperature 1 sensor error
Buffer storage tank temperature 2 sensor error
Buffer storage tank temperature 3 sensor error
Collector temperature 1 sensor error
Collector temperature 2 sensor error
LPB address collision
BSB wire short-circuit
BSB address collision
BSB RF communication error
EEPROM error lockout information
Extension module 1 error (collective error)
Extension module 2 error (collective error)
2 clocktime masters (LPB)
Clocktime master without reserve (LPB)
Communication error
Maintenance message
Boiler temperature supervision
STB lockout
TW cutout
Flow temperature 1 (HC1) supervision
Flow temperature 2 (HC2) supervision
129
130
131
132
133
146
Fan error or LP error
Flue gas temperature limit exceeded
Burner fault
Pump supervision error
DHW charging supervision
Legionella temperature not reached
Loss of flame during operation
GP or LP error
No flame during safety time
Configuration error collective message
25
Lockouts
Error
code
151
152
153
160
162
164
166
171
172
173
174
178
179
183
193
216
217
241
242
243
270
317
320
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
26
Description of error
Internal error
Parameterization error
Unit manually locked
Fan error
LP error, does not close
Error heating circuit flow switch
LP error, does not open
Alarm contact H1 or H4 active
Alarm contact H2 (EM1, EM2 or EM3) or H5 active
Alarm contact H6 active
Alarm contact H3 or H7 active
Limit thermostat heating circuit 1
Limit thermostat heating circuit 2
Unit in parameterization mode
Pump supervision error after flame on
Fault boiler
Fault sensor
Flow sensor / solar sensor error
Return sensor / solar sensor error
Swimming pool temperature sensor error
Limit function
Mains frequency outside permissible range
DHW charging temperature sensor error
BX same sensors
BX / extension module same sensors
BX / mixing group same sensors
Extension module same function
Mixing group same finction
Extension module / mixing group same function
Sensor BX1 no function
Sensor BX2 no function
Sensor BX3 no function
Sensor BX4 no function
Sensor BX5 no function
Sensor BX21 no function (EM1, EM2 or EM3)
Sensor BX22 no function (EM1, EM2 or EM3)
Sensor BX1 no function
Sensor BX12 no function
Collector pump Q5 not available
Collector pump Q16 not available
Solar Collector sensor B6 not available
DHW sensor B31 not available
Solar integration not available
Solar controlling element buffer K8 not available
Solar controlling element swimming pool K18 not available
Solid fuel boiler pump Q10 not available
Solid fuel boiler comparison sensor not available
Solid fuel boiler address error
Lockouts
Error
code
349
350
351
352
353
371
372
373
349
350
351
352
353
371
372
373
386
388
426
427
431
432
433
Description of error
Buffer return valve Y15 not available
Puffer address sensor
Primary controller / system pump address error
Pressureless header address error
Common flow sensor B10 not available
Flow temperature 3 (heating circuit 3) supervision
Limit thermostat heating circuit 3
Extension module 3 error (collective error)
Buffer return valve Y15 not available
Puffer address sensor
Primary controller / system pump address error
Pressureless header address error
Common flow sensor B10 not available
Flow temperature 3 (heating circuit 3) supervision
Limit thermostat heating circuit 3
Extension module 3 error (collective error)
Fan speed has lost valid range
DHW error no function
Feedback flue gas damper
Configuration flue gas damper
Sensor primary heat exchanger
Functional earth not connected
Temperature primary heat exchanger to high
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Sensor values
The diagrams show the sensor values
for all boiler sensors and optional
sensors available in accessory kits.
The diagrams contain average values,
as all sensors are liable to tolerances.
NTC 10kΩ temperature sensor
(flow, return, flue gas, DHW and header sensor)
60000
When measuring the resistance values,
the boiler should always be switched
off. Measure close to the sensor, in
order to avoid value deviations.
55000
50000
Resistance [Ohm]
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
-10
0
10
20
30
40
50
60
70
80
90 100 110
Tem perature [ºC]
NTC 1kΩ temperature sensor
(outdoor sensor)
7500
7000
6500
6000
Resistance [Ohm]
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
-20
-10
0
10
20
Tem perature [ºC]
28
30
40
Declaration of Conformity
Declaration of Conformity
Rendamax BV, Hamstraat 76, 6465 AG Kerkrade (NL),
Declares that the product
R40
Is in conformity with the following standards:
EN 298
EN 483
EN 15420
EN 55014-1 / -2
EN 61000-3-2 /-3
EN 60 335-1/ -2
And in accordance with the guidelines of directives:
92 / 42 / EEC (boiler efficiency directive)
2009 / 142 / EEC (gas appliance directive)
2006 / 95 / EEC (low voltage directive)
2004 / 108 / EEC (EMC directive)
This product is designated with CE number:
CE – 0063CM3576
Kerkrade, 16-11-2010
ing. G.A.A. Jacobs
Managing Director
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