EN_Englisch. Log Boiler kw. Installation

Transcription

1 EN_Englisch Log Boiler kw Installation

2 Conditions for warranty, guarantee, liability 4 Conditions for warranty, guarantee, liability...4 Data and dimensions...6 Regulations, standards and guidelines...7 Boiler room...8 Electrical connection...9 Energy-saving pumps...9 Chimney Basics Dimensioning, requirements Requirements, connecting pipe Water hardness and corrosion Air venting, compensation, system separation Return riser and safety devices Buffer Hydraulic integration Hydraulic integration of several buffers Parallel buffers with internal Tichelmann Parallel buffers with external Tichelmann Serial buffers Hydraulic schematic Installation Minimum clearances for maintenance Air valves for log boilers Air valves for log boilers with pellet flange Draught fan Rear wall insulation, door frame Side panels, boiler control system Cable duct, flue gas temperature sensor Temperature sensor - flow Lambda probe, temperature sensor - return Connecting draught fan Actuators Cleaning lever for turbulators...40 Insulation door, control panel Panel on top side of boiler Insulation at base of boiler...46 Electrical installation Terminal diagram...48 Checklist for proper installation Meanings of symbols Important NOTICES for operation. CAUTION: Failure to observe these notices can result in property damage. STOP: Failure to observe these notices can result in personal injury. 2

3 Electrical installation 48Preface Dear heating technician, The satisfactory function of a customer's new heating system depends to a large extent on its installation. So before starting the installation, please invest 15 minutes to get an overview with this manual. Warranty and guarantee You should also read the "Conditions for warranty, guarantee, liability" (see page 4 of this manual) carefully. All of the requirements we impose are intended to prevent damage that neither you nor we wish to occur. Housing and electrical equipment will be installed at the end The electrical equipment and the housing will only be installed after all piping and installation tasks have been completed. That helps avoid damage to these sensitive parts. Training the customer To avoid errors in operation, please explain to your customer (preferably using the user manual) exactly how the new heating system works and how it should be operated and maintained. Extended warranty for commissioning performed by an authorised partner company If your newly installed boiler is commissioned by an authorised partner company or one of our customer service employees, we offer an extended warranty. Refer to our warranty conditions in effect at the time of purchase. Service agreement You can ensure the best care by taking out a service agreement with one of our certified heating system contractors or our own customer service. SH Montage

4 Conditions for warranty, guarantee, liability We can only guarantee and accept liability for the function of our boiler if it is properly installed and operated. Requirement for warranty, guarantee and liability is that this boiler be used in accordance with its intended purpose, only for heating and hot water supply with no more than 2,000 fullload hours annually, and, in particular, that the following general conditions be observed during installation and operation: For set-up, a dry room is required. In particular, only condensation dryers may be used as clothes dryers in the same room. Local building and fire protection regulations must be observed. The log wood boiler is suitable for use with air-dried split logs with no more than 20% water content and wood briquettes. Use with unsuitable fuels, especially refuse, coal and coke, and also wet wood, is not permitted. The combustion air must be free of aggressive substances such as chlorine and fluorine from solvents, cleaning agents, adhesives and propellants, or ammonia from cleaning agents, to prevent corrosion of the boiler and chimney. Water is the intended heat-transfer medium. For special anti-frost requirements, up to 30% glycol may be added. Softened water is required for the initial fill-up of the heating system and for refilling after repairs. For the initial fill-up, the value of 20,000 lt dh for the system volume in litres multiplied by the hardness (in degrees of German hardness) may not be exceeded. The ph value should be set between 8 and 9. Addition of hard water should be minimised to limit limescale build-up in the boiler. Set enough shut-off valves to avoid bleeding large amounts of water during repairs. Any leaks in the system must be repaired at once. Ensure a minimum return temperature of 60 C to the boiler. A safety valve (3 bar) as protection against excess pressure and a thermal relief valve (95 C) to protect against overheating must be installed by the contractor. To protect against air suction if the system cools off, an expert must provide a sufficiently large expansion tank or a pressure maintenance system. Sufficient air venting must also be ensured. Open expansion tanks or underfloor heating with permeable piping also have a high air intake, resulting in above-average boiler corrosion. Corrosion damage to the boiler due to improper air venting or high air intake is excluded from warranty, guarantee and liability. Operation at lower power than the lowest power specified on the type plate is not permitted. Only components provided by us may be used for expansion of the control system, except for commonly used units such as thermostats. Cleaning and maintenance are required as specified in the user manual. Repairs are only permitted with spare parts provided by us. The only exceptions are common standardised parts such as electrical fuses or fastening materials, as long as they possess the required features and do not restrict the functionality of the system. 4

5 Conditions for warranty, guarantee, liability The installing contractor is liable for proper installation according to the boiler's installation instructions and the relevant rules and safety regulations. If you as customer have installed the heating system partly or entirely without relevant training and in particular without up-to-date practical experience, without having the installation checked by a trained and responsible expert, we exclude defects in our delivery and consequential damages resulting from this cause from our warranty, guarantee and liability. For repair of defects carried out by the customer or by third parties, ETA only bears the costs or remains obligated by warranty if this work was approved in advance by the customer service of ETA Heiztechnik GmbH. Subject to technical alterations We reserve the right to make technical modifications without notice. Printing and typesetting errors or changes of any kind made in the interim are not cause for claims. Individual configurations depicted or described here are only optionally available. In the event of contradictions between individual documents regarding delivery scope, the information in our current price list applies. SH Montage

6 Data and dimensions SH kw (40-60 kw) Cleaning lever and actuators can be mounted left or right sided a Flow R5/4 female b Return R5/4 female c Drain R1/2 female d Safety heat exchanger R1/2 male > (1180) > (1894) 1502 (1684) Ø (1652) >2030 (>2350) > (716) > (362) d c b a 1323 (1504) (510) Wood gasification boiler SH Rated capacity kw , Beech log efficiency, partial/full load* % 95,4 / 92,9 92,7 / 89,3 93,6 / 91,4 93,6 / 91,4 93,6 / 91,4 Fuel chamber mm 560 mm deep for 0,5 m logs, 340 x 365 mm door opening Fuel chamber volume Litres Beech log combustion period, partial/full load* h 19,2 / 8,6 12,1 / 6,3 14,1 / 7,1 14,1 / 5,6 14,1 / 4,7 Dimensions without housing, W x D x H mm 588 x 940 x x x Weight kg Water content Litres Waterside resistance (ΔT = 20 C) Pa / 190 / 370 / 220 / 340 / 480 / mws 0,019 0,037 0,022 0,034 0,048 Flue gas mass flow rate, partial/full load g / s 7,0 / 12,8 10,4 / 18,6 12,2 / 24,0 12,2 / 30,2 12,2 / 35,4 CO2-content in dry flue gas, partial/full load* % 12 / / / 14,5 14 / 14,5 14 / 15 Exhaust temperature, partial/full load* C 100 / / / / / 160 Flue draught 2 Pa for partial load / 5 Pa for full load required over 30 Pa draught limiter required Carbon monoxide (CO) emission Partial/full load* mg/mj mg/m³ 13%O2 153 / / / / / / 46 Dust emissions full load* mg/mj mg/m³ 13%O Unburned hydrocarbon emissions (CxHy) Partial/full load* mg/mj mg/m³ 13%O2 2 / 3 3 / 4 19 / 7 25 / 10 2 / < 1 3 / < 1 Electrical power consumption Partial/full load* W Recommended buffer storage tank volume Litres > 1.100, opt > 2.200, opt Maximum permissible operating pressure 3 bar Boiler rating 5 according EN 303-5:2012 Temperature adjustment range C Suitable fuels Spruce and beech up to W20 Maximum permissible operating temperature 95 C Electrical connection 1 x 230 V / 50 Hz / 13 A Minimum return temperature 60 C *Data from test reports of BLT Wieselburg, log numbers 041/10, 028/99 and 007/00. The test reports of BLT Wieselburg can be found on the Internet at: blt.josephinum.at Conforms to EU standards BLT Wieselburg Austria TÜV South Germany Quality seal of Holzenergie Schweiz Austrian ecolabel Listed on the Energy Technology List The Certification Mark for Onsite Sustainable Energy Technologies 6

7 Regulations, standards and guidelines Before setting up the boiler system, consult the responsible chimney sweep This device complies with EN Heating boilers for solid fuels EN /A1:96 Safety of electrical appliances DIN 4702 part 1 and 4 Heating boilers 97/23/EC Pressure equipment directive 2006/42EC Machinery directive 89/106/EEC Regulations for building products 73/23/EEC Low voltage directive 89/336/EEC EMC directive 93/68/EEC Amendment to 72/73 and 89/336 Conformity has been demonstrated. The relevant documents and the original declaration of conformity (CE) are in the manufacturer's files. Regulations State building regulations Industrial and fire safety regulations State fire regulations In Germany, the EnEG (Energy Saving Act) with its enacted EnEV ordinances for energysaving insulation and energy-saving building technologies In Germany, 1.BImSchV, initial ordinance for enforcement of the federal pollution control act for small-scale furnaces. In Austria, Article 15 a, agreement on protective measures regarding small-scale furnaces In Austria, Article 15 a, agreement on saving energy In Austria, ÖNORM H 5170, heating systems - construction and fire safety requirements In Switzerland, VKF/AEAI fire safety regulations Standards and guidelines VDI 2035, prevention of damage due to corrosion and scaling in hot-water heating systems with flow temperatures up to 120 C. Instead of the maximum hardness of 11.2 dh for 20 to 50 lt/kw specific system volume, the maximum lime content of the initial fill-up for the boiler described here is limited to 20,000 lt dh (system volume in litres multiplied by the hardness in degrees of German hardness). EN 12828, heating systems in buildings - planning for hot-water heating systems. The safety temperature limiter (100 C) is already installed in the boiler described here. The contractor must install a sufficiently large expansion tank (at least 10% of the system volume), a safety valve and a thermal emergency cooling valve. EN 12831, heating systems in buildings - method for calculating standard heating load EN 13384, flue systems - thermal and fluiddynamic calculation methods EN , flue systems for heating appliances dependent on ambient air - planning, installation and commissioning Only in Germany, DIN 18160, flue systems - planning and design Buffer storage tank is essential For a wood fire that cannot be indefinitely reduced in intensity, minimum heating load can be a problem. A buffer that can store surplus boiler output is essential. In Germany, 1. BImSchV (first Federal Emission Control Act) stipulates a minimum buffer volume of 55 litres per kw of boiler output. For a 30 kw boiler, that's 1,650 litres, which is a thoroughly adequate buffer volume. The lower the return temperature to the buffer, the greater its heat storage capacity. The buffer utilisation of radiators can be improved considerably with very finely adjustable thermostat valves (Kv less than 0.35). With a fresh water module, the hot water supply can be integrated in the buffer to save space, and solar can also be integrated in the buffer very simply and effectively. SH Montage

8 Boiler room Requirements for the surroundings The boiler may only be installed in dry surroundings. The permitted ambient temperatures are between 5 and 30 C. Ash The ash must be kept in non-flammable containers with covers. Fire extinguisher In Austria at least a powder extinguisher ABC 6 kg is required. Better is a foam extinguisher AB 9 litre, which causes less damage when extinguishing. The fire extinguisher should be kept outside the boiler room, easily visible and easily accessible. In Germany and Switzerland, no fire extinguishers are required for heating systems in private residences. In spite of this, we recommend having one in the house. No heating appliances in the vicinity of escape routes No boiler may be installed in stairwells, hallways or rooms through which escape routes lead to the outside. Installation or boiler room A boiler room is required in Germany for 50 kw or more, and in Switzerland for over 20 kw. Different laws apply in the individual Austrian states (boiler room in Upper Austria from 15 kw; Styria from 18 kw; Lower Austria from 26 kw; Salzburg from 35 kw; Burgenland, Tyrolia, Vorarlberg and Vienna from 50 kw; for Carinthia a boiler room is required for all central heating systems). Boiler room A boiler room must be built with fire-resistant walls and ceilings F90 (EI90), in Switzerland El30 up to 70 kw and EI60 above 70 kw. An escape door to a corridor or to the outside is required. The door F30 (El30) must open in the direction of escape and be self-closing with a tight seal. Boiler room doors that open into escape routes must be F90 (EI90). In Germany there may be no connection to other rooms. Minimum crosssections for air inlets and outlets are required. Required cross-sections for air inlets and outlets Boiler output Minimum areas including 20% extra for bars Austria Germany Switzerland Inlet Outlet Inlet/outlet Inlet >206 cm² 20 kw 25 kw >258 cm² >180 cm² 35 kw >361 cm² >240 cm² >216 cm² 50 kw >515 cm² 70 kw >228 cm² >721 cm² 90 kw >276 cm² >927 cm² 130 kw >347 cm² >252 cm² >372 cm² >1339 cm² 200 kw >533 cm² >336 cm² >540 cm² >2060 cm² 400 kw >1067 cm² >576 cm² >1020 cm² >4120 cm² Installation room for smaller boilers Smaller boilers can be installed in any room with a sufficient air supply. The area immediately surrounding the boiler must be non-flammable. In Germany, for up to 35 kw rated output, either at least one door to the outside or one window that can be opened (rooms with connection to outside), and a room volume of at least 4 m³ per kw of boiler output, is required. The room volume may also include other rooms connected via air inlets in the doors. Fuel storage In Germany, up to 10,000 litres (6.5 tons) of pellets can be stored in the room where the boiler is installed. For larger quantities, a separate fireresistant F90 (EI90) storeroom is required. In Austria, only a weekly's supply of wood may be stored next to the boiler. For pellets, a separate storeroom F90 (EI90) with a T30 (EI30) door is required. As a result of amendments to building laws, up to 10 tons of pellets may be stored in the boiler room in some states. In Switzerland, up to 10 m³ of pellets can be stored in separate boiler rooms (EI60); the clearance from the boiler must be 1 m. For larger quantities, a separate storeroom (EI60 separated from the building) is required; here wood may be stored together with straw or hay. 8

9 Electrical connection Energy-saving pumps Electrical connection Observe the national regulations and any special regulations of local energy utilities. Supply cable 3?? x x 1.5?? mm² with flexible wires wires 230 V??????????????????????????? AC / 50 Hz C13 A / L+N+PE A circuit breaker in the mains power input is required. Emergency stop switch In As a Austria, rule, no heating emergency systems stop installed switch is in required boiler for rooms log wood must boilers. be equipped with an emergency stop switch which may not affect the room's lighting. The switch must be situated immediately outside the access door and clearly marked. For boiler rooms that are only accessible from outdoors, these switches may also be within the boiler rooms, immediately next to the access doors. In Germany, a boiler room is only necessary above 50 kw boiler output, so only then is an emergency stop switch also required. A single-pole emergency stop switch is integrated into the boiler's safety chain. It only affects the combustion air supply. The pumps continue running to cool the boiler. Not just for the subsidy Many incentive programmes either demand energy-saving pumps and hydraulic calibration or grant extra bonuses for them. This is no coincidence, since a single heating circuit with an old pump uses up to 10% of the electricity in an average four-person household. Energy-saving pumps For an underfloor heating system that needs a large amount of water circulation throughout the heating season, an electronic pump with a fixed speed setting is sufficient. For individual room temperature control, the pump must react to the heating in individual rooms being switched on or off. It needs to adjust the amount of water and the delivery height to current demand. Differential pressure controlled energy saving pumps with "Energy Label A" can do that perfectly. The pump built into the boiler is already a highly efficient variable-speed pump. SH Montage

10 Basics Chimney For every boiler a chimney of its own The better the boiler and the chimney are matched, the greater the energy of the flue gases leaving the chimney and thus the certainty that they will rise into the air from the top. If the diameter is too large, the chimney will not be heated sufficiently and the exit velocity and temperature will be too low. The flue gas then lacks the energy to rise and in extreme cases, the smoke can sink down along the roof. Chimneys with a diameter more than 50% greater than needed must be renovated to reduce the diameter. If a chimney is designed for use with two simultaneously operating boilers, it may prove to be oversized for the partial load from only one boiler. If there is really only one chimney available, a buffer storage tank can help avoid a too-small partial load. Chimney renovation - before it's too late Compared to older boilers, modern ones are much more efficient and have lower amounts of flue gas with considerably lower temperatures. The water in the flue gas condenses and destroys old masonry chimney walls, very slowly but also inexorably. Timely renovation before the chimney wall has been destroyed can be performed quickly and easily by inserting a tube. But if the flue gas condensates have penetrated the mortar joints, then the entire flue must be dismantled and rebuilt. Sewage connection for the chimney For the condensation that forms in the chimney, a DN 25 sewer connection via trap is needed. The resulting amount of water is small. If no sewer connection is possible, then a bucket that is checked regularly can also be used. A fan-assisted boiler and a gas-fired boiler may not be connected to the same chimney Most gas-fired boilers do not have a sealed air flap and when the fan-assisted boiler is started while the chimney is cold, the flue gas is pushed through the gas boiler into the boiler room. Even a flue gas damper in the gas boiler's flue pipe will hardly help since these dampers are not certain to close with a good seal. With atmospheric gas boilers, old fireclay chimneys only stay dry with the gas boiler's overflow opening. The water from the flue gas condenses in the chimney. During pauses in firing, air flows through the overflow opening and dries the chimney. If this air stream is blocked by a flue gas damper, the moisture can destroy an old fireclay chimney. Fan-assisted boiler and wood-burning stove on the same chimney - a dangerous combination This combination is not expressly forbidden, but it is dangerous. Every wood-burning stove has an air intake through which any fan-assisted boiler, whether oil or wood, will blow flue gas into the living area through a cold chimney. If the wood-burning stove's firebox door is not closed and the boiler is defective at the same time, even acute carbon monoxide poisoning is possible. The wood-burning stove needs a significantly larger chimney cross section, which cannot be heated by the fan-assisted boiler. Cold flue gas does not rise from the opening; it sinks and can reach living quarters through open windows. It may also be possible to hear the boiler's fan in the living quarters through the wood-burning stove. Clarify with the chimney sweep In any case, the chimney's suitability should be clarified with the chimney sweep 10

11 Chimney Dimensioning, requirements Small chimney diameter required Please note that for partial-load operation with flue gas temperature of only 100 C, the large chimney cross sections that were previously typical for solid fuel are no longer optimal. If the cross section is too large, the flue gas is no longer certain to rise from the chimney opening and may flow along the roof and sink to the windows of the living quarters. Height Chimney diameter in cm above INSERT TABLE! (required minimum diameter) boiler 20 kw 30 kw 40 kw 50 kw room 60 kw floor 6 m 18 (16) cm 18 (16) cm 20 cm* 20 cm* 7 m 16 (14) cm 18 (15) cm 18 (16) cm 20 cm* 8 m 15 (13) cm 16 (14) cm 18 (15) cm 18 (16) cm 9 m 15 (13) cm 15 (13) cm 18 (15) cm 18 (15) cm 10 m 15 (13) cm 15 (13) cm 16 (14) cm 18 (15) cm 11 m 15 (13) cm 15 (13) cm 16 (14) cm 18 (15) cm 12 m 14 (12) cm 15 (13) cm 16 (14) cm 18 (15) cm *) For boiler outputs over 30 kw and chimney heights under 8 m, a chimney joint tilted 45 can help achieve the required draught of 5 Pa at full load with acceptable cross-sections (a size smaller than indicated in the table). Normally no deflagration damper The boiler is designed with safety routines in the control system to prevent deflagrations, so no deflagration damper (also often called a blowback flap) is required if the connecting pipe is short and ascends to the chimney. If a deflagration damper is needed at high points before descending sections or at the beginning of a long horizontal section (L > 20 x D), it must be situated so that people are not endangered by a deflagration. Obsolete regulations require the wrong chimney Laws and regulations demand a flue system that is moisture-resistant for oil and gas and one that is resistant to soot fires for solid fuels. Wood is a solid fuel. But in the lower output range, the temperature of the flue gas can be under 100 C and condensates can be deposited in the chimney. So the chimney must be moisture-resistant, "against regulations". Whoever builds a chimney resistant to soot fires can then look on helplessly as the condensate destroys the chimney wall. Soot fires are possible in natural-draught boilers or wood-burning stoves regulated by throttling the air supply. When the wood fire is at full intensity and the boiler temperature has been reached, a thermostat closes the air flap. That stops the combustion, but since the combustion chamber temperature doesn't fall, the wood continues to gasify. Uncombusted wood gas condenses to tar in the chimney; the tar can be ignited by sparks from the fire. With modern lambda-controlled wood boilers, such a soot fire is nearly impossible since the control system reduces the wood gasification and and not the not air. the In air, modern so there lambda-controlled is no lack of air and pellet no flammable boilers, the tar control in the system chimney. shuts The down low exhaust the fire temperatures by stopping the of pellet a modern supply boiler without also provide closing off no the ignition air supply. source So there for a is soot no fire. lack With of air a and modern no and flammable properly tar maintained the chimney. wood The boiler, low there exhaust is no danger temperatures to chimneys of a modern from soot boiler fires. also provide no ignition source for a soot fire. With a modern and properly maintained wood boiler, there is no danger to chimneys from soot fires. Moisture-resistant W3G flue systems Since 2005 there are W3G chimneys (classified according to the German DIN 18160), which are resistant to both moisture and soot fires. These chimneys are approved for all fuels. Most of these W3G chimneys have ceramic inner pipes, which have a significantly longer service life than metal chimneys due to their acid resistance. SH Montage

12 Requirements, connecting pipe Chimney Chimney renovation with stainless steel pipe? Maybe the chimney has already been renovated for oil or gas with a stainless steel pipe, and now a conversion to wood or pellets is planned. Or the chimney is too tight to install a ceramic pipe with a sure seal. If a moisture-resistant inner pipe is installed in a sufficiently fire-resistant casing, the German association of chimney sweeps has found the following solution to the standards and regulations dilemma: "in the certification of suitability and safe use for heating systems, it should be noted that after a soot fire the long-term durability cannot be ensured and penetration of the chimney by moisture cannot be ruled out so that it may be necessary to replace the inner pipe (Criteria for Determination of Suitability and Safe Use of Heating Systems - October 29 th 2008, page 12). Replace inner pipe after a soot fire After a soot fire, the inner pipe is in all likelihood no longer sufficiently leakproof, making the chimney subject to damage by moisture so that the inner pipe needs to be replaced without fail, regardless of whether its resistance to soot fires has been checked or not. Fit the chimney connection just under the ceiling! Even though the current boiler can be connected to the chimney at a low height, it is better if you fit the chimney connection just below the ceiling. The flue pipe is easier to install, and the vertical connection pipe is long enough for an emission measurement. Structure-borne noise To avoid structure-borne noise, there should not be a fixed connection between the flue pipe and the chimney! Good exhaust systems are acoustically isolated. When steel pipes are connected to a fireclay chimney, ceramic fibre bandages have proven effective at preventing structure-borne noise as well as damage to the refractory sleeve. Connecting pipe to chimney insulated The connection between the boiler and the chimney should be insulated with at least 30 mm, preferably 50 mm, of mineral wool to avoid thermal losses that can lead to a build-up of condensation. Cleaning aperture in the connecting pipe Easily accessible cleaning apertures must be available for cleaning the flue pipe. Install short, airtight and ascending connections "Attractive" right-angle flue offsets with two or more bends are bad in a flue gas conduit. The optimum to strive for is the shortest pipe from the boiler to the chimney with a minimum of direction changes. The flue gas conduit to the chimney must be leakproof (use heat-resistant silicone covered with pure aluminium adhesive tape to seal sleeved pipes without gaskets); otherwise smoke emission into the boiler room can be expected during ignition. Install the flue gas conduit so it ascends toward the chimney! Long, horizontal flue gas conduits to the chimney Use a tight cross section, apply above-average insulation (50 mm and more) and provide enough cleaning apertures. Calculations indicate that a connecting pipe with a large cross section would reduce the required chimney cross section. However, with low flow speeds ash deposits will form and then the theoretically calculated flue draught will be lost again. With a large chimney cross section, the unbent length of the connecting pipe can be at maximum half of the effective chimney height (calculation required). 12

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14 Water hardness and corrosion Softened water and shut-off valves If a buffer storage tank is installed in the heating system, the system should be filled with softened water. The lime is deposited on a very small area in the boiler and forms layers of insulating limescale. The boiler wall is no longer sufficiently cooled and stress cracks can result. To keep the lime content to a minimum during minor repairs, shut-off valves are essential at all buffer connections and all heat distribution branches. When is decalcifying necessary? For the initial fill-up of the heating system with the boiler, the lime content of all water in the heating system may not exceed the value of 20,000 lt dh (system volume in litres multiplied by the hardness in degrees of German hardness). 20,000 lt dh = permitted hardness in dh litres of water Example: 20,000 lt dh = 10 dh 2000 litres To maintain the limit of 20,000 lt dh, the system must be softened to 10 dh. Softening with a salt-regeneration ion exchanger We recommend softening water with saltregeneration ion exchangers, just as drinking water is softened. This method does not remove salt from the water. It exchanges the calcium in lime against sodium from the salt and has considerable advantages. It is cheap and chemically stable against contamination. In addition, it has a natural alkalinity that generally results in a sufficiently non-corroding ph value of around 8. No hybrid installations A disadvantage of salt-regeneration ion exchange is the salt content with its high electrical conductivity, which can lead to electrolytic corrosion, especially of aluminium or galvanized steel. If only steel, brass, gunmetal and copper are used in the heating system and the use of stainless steel is limited to small areas, then no corrosion problems should be expected even with salty water. Inside a heating system, galvanized and aluminium parts are always in danger of corrosion, especially in combination with copper tubing. In practice this means no hot-galvanized fittings and no mix of galvanized tubing with copper tubing. There is an illogical exception: galvanized steel tubing combined with boilers or buffer storage tanks made of steel. Presumably the uniform zinc layer dissolves uniformly and is dispersed evenly throughout the system without localised corrosion. Complete desalination not required If there is no aluminium (heat exchanger in the gas boiler or aluminium radiator) in the system, then no expensive desalination with ion exchange cartridges or osmosis is required. Lime stabilisation can be dangerous The addition of lime stabilising agents prevents limescale. However, we advise against doing so. These agents increase the salt content and result in an undefined ph value. If large amounts of water are added, exactly the same agent must be used again. Mixing with other water additives or with antifreeze can result in corrosion. ph value between 8 and 9 may require dosing with trisodium phosphate If the heating water's ph value is not greater than 8 after a week of operation, increase it by adding 10 g/m³ of trisodium phosphate (Na3PO4) or 25 g/m³ of trisodium phosphate dodecahydrate (Na3PO4.12H2O). Wait another 2-4 weeks before making further corrections. The ph value may not exceed

15 Air venting, compensation, system separation Initial protection with corrosion inhibitors These agents line the new and still uncoated internal surfaces with a protective film; this is only possible in a new system. If corrosion has already begun, these agents cannot help anymore. Use corrosion inhibitors sparingly. For systems with buffers whose water volume is large in relation to the internal surfaces, it is preferable to use half rather than double the quantity specified by the manufacturer. Protection against atmospheric corrosion To reliably protect the entire heating system against corrosion, air intrusion should be kept to a minimum and any air that does gain entry must be released as soon as possible. The most important measures are described below. Air vent at highest point in flow No system is completely airtight. Air that gets into the system is transported to the boiler with the return flow since water can take up more air as it gets colder and as the pressure increases. The air is released again at the point in the system with the highest temperature and the lowest pressure. The two typical points for releasing gases are the hot boiler and the highest point in the flow. Install an air valve at the upper end of the line from the boiler outlet (already installed in PU and PC boilers) and also at the highest point in the flow of the entire system. The boiler safety groups with horizontal connection to the ascending flue pipe, which have unfortunately become so common, are not suitable for air venting. For large, unseparated underfloor heating systems, an absorption filter for the entire water flow should be installed in the flow after the boiler (Spirovent, Flamco or Pneumatex are typical manufacturers). At least 10% compensating volume To minimise air suction through the system's pipe connections (which are watertight but not absolutely airtight) when the system cools, a sufficiently large expansion tank with at least 10% of the system volume is needed. Protect the expansion tank against shut-off All shut-off valves along the path from the expansion tank to the boiler and to the buffer storage tank must be capped valves, or the hand wheels or levers must be removed from the valves (hang on the valve with a wire) to ensure that they cannot be closed by accident. Adjust expansion tank pressure Most expansion tanks are delivered with primary pressure of 1.5 bar. The pressure should be adjusted by releasing nitrogen so that it is 0.3 bar higher than the static pressure at the place of installation, but the pressure should not fall below 0.9 bar. Example 1: height difference between expansion tank and highest point in the system p st = 11 m = 1.1 bar: 1.1 bar bar = 1.4 bar pressure setting. In this case, you can also contact our customer service to set the system's cut-off pressure to 1.5 bar. Example 2: height difference between expansion tank and highest point in the system p st = 5 m = 0.5 bar: 0.5 bar bar = 0.8 bar -> 0.9 bar pressure setting. Here the minimum pressure of 0.9 bar must be chosen. The factory setting of 1.0 bar for the cut-off pressure is compatible with this minimum pressure setting. No open expansion tanks Open expansion tanks allow air into the system - not allowed. Impermeable plastic tubing or system separation "Impermeable" plastic tubing simply undercuts a standard limiting value; there is no absolutely impermeable tubing. Even composite tubing with aluminium sheathing is not absolutely impermeable. A rule of thumb: up to 3,000 running metres of underfloor heating pipe, use impermeable composite tubing; for larger systems, system separation with a heat exchanger is imperative. If a system separation is installed, then common single-wall tubing can also be used. For older underfloor heating systems, always install a system separation because their tubing is not very airtight. SH Montage

16 Return riser and safety devices Return riser Wood contains water. If the temperature in the boiler is too low, steam condenses from the flue gas onto the heat exchanger surfaces. Corrosion and a leaky heat exchanger are the result. To prevent this, the water temperature at the boiler inlet must be at least 60 C. Since the return temperatures are usually lower, a return riser is needed - preferably with a mixer that provides controlled, heated flow to the boiler return. The return riser mixing valve also controls the buffer charging output. To reduce the output, the return temperature is raised over 60 C to reduce the spread compared to the boiler's setpoint temperature. With the spread the output that can be consumed from the boiler is limited. Thermal emergency cooling valve against overheating The safety heat exchanger built into the boiler must be connected by the heating technician to the house's cold water supply via a thermal outlet valve (opening temperature 95 C) to protect the boiler against overheating if the pump fails. The minimum pressure in the cold water line must be 2 bar. Connect the supply line to the lower connector of the safety heat exchanger; the upper connector is for outlet to the sewer. To prevent the supply line from being shut off accidently, remove the levers from shut-off valves or the hand wheels from valves and hang them there with a piece of wire. Safety valve against overpressure A safety valve with 3 bar opening pressure must be installed on the boiler. No shut-off valve may be installed between the boiler and the safety valve. If solar or other heat sources provide energy to the buffer storage tank via a heat exchanger, a safety valve (3 bar maximum) is also required on the buffer storage tank. Normally an expansion tank that is too small or defective, or blocked heating lines, are the cause for activation of the safety valve. The safety valve must be on top of the boiler or in the flow in order to also discharge heat in an emergency. Only this way can it discharge heat by blowing out hot water and steam. The discharge must be directed to the sewer via an easily visible, open flow path (siphon funnel) so malfunctions and, above all, a non-closing valve can be recognised. If no sewer is available, the discharge must be directed into the ground in a pipe so nobody is endangered by hot water or steam. visible drain to sewer Cold water connection Isolating valve Remove hand wheel Strainer Thermal emergency cooling valve The discharge must be have an easily visible, open flow path so malfunctions can be recognised. Direct the discharged water to the sewer via a siphon funnel or at least with a pipe into the ground so that nobody can be scalded if the valve is activated. Even for cold water coming from a domestic well with its own pump, a thermal emergency cooling valve must be installed on the boiler. With a generously dimensioned air vessel, enough water for cooling will come even if there is a power failure. If the electricity supply is very uncertain, a dedicated air vessel for the thermal emergency cooling valve is required. 16

17 Buffer A minimum power level is necessary to achieve clean and complete combustion The smaller the fire in the boiler, the lower the temperature will be in the combustion chamber. At about a third to a quarter of the full load, the combustion temperature drops below 700 C and the tar components in the wood gas no longer burn completely. This drastically reduces the efficiency (it can drop to below 50%), causes tar build-up in the boiler's heat exchanger and in the chimney and also results in unacceptable pollution due to unburned hydrocarbons. To maintain a clean-burning wood fire with maximum fuel efficiency, a minimum power level must be maintained and the best way to achieve this is to use a buffer storage tank. Why a buffer storage tank? Many old log boilers that do not have buffer storage tanks are still in use, so why do we need them with today's wood-burning systems? The answer to this frequently asked question is as follows: In the days before heating control systems, the boiler used the thermal mass of the entire house as a buffer. If the boiler is replaced, and the radiators are fitted with new thermostat valves and/or a weather-dependent mixing system, the log boiler is operated at too low an output level in autumn and spring when the heating requirements are minimal. At low output levels, the temperature in the combustion chamber drops, but production of wood gas doesn't. Hard-to-burn components of the wood gas, such as tar or acetic acid no longer combust; instead, they condense (create tar deposits) either in the boiler's heat exchanger or in the flue. The materials that are not deposited pollute the environment. A buffer storage tank is necessary to control this low-load operation, which inevitably occurs with a modern, energy-saving heating system. Heat produced by the boiler for which there is no immediate use within the building is offloaded into a buffer storage tank and retrieved by the heating system as needed, for example, when the boiler is not operating. As a log wood boiler cannot simply be switched off once it has been started up and while there is still wood burning in it, it should be possible to store in the buffer the energy content of the wood that is still in the combustion chamber. to the hot water tank Flow from boiler "Buffer top" temperature sensor just under the connection The boiler controls its output based on the reading from the "Buffer middle" temperature sensor. Enough to provide sufficient heat to start a consumer. Not too much to ensure that the buffer is still able to store heat after the heating circuits have been switched off. "Buffer bottom" temperature sensor just above connection Return to boiler No external timer thermostats The factory-standard controls include weekly timers for two heating circuits. If the heating pumps are controlled by the boiler control, heat can be drawn from the boiler during periods when the temperature setting has been lowered as long as there is wood in the boiler. This is especially important if you accidentally put too much wood on in the evening, or if you intentionally heat up the boiler to its full extent in anticipation of a cold night. Timer thermostats will switch off the heating pumps punctually at the preset time, even if wood is still burning in the boiler, and even if the (undersized) buffer is incapable of storing more heat. The only solution for the boiler is to stop its air intake. Although this puts the fire out without overheating the boiler, the wood will continue to emit gas and the unburned wood gas resulting from the lack of air will create tar deposits in the boiler and flue. SH Montage

18 Hydraulic integration Buffer For the largest possible buffer storage capacity and for maximum solar yield even in winter, low return temperatures are the goal. The best stratified buffer can t unmix what has been mixed by heat distributors. Especially in houses where radiators and underfloor circuits are present, no mixing heat distributors should be installed, the returns should be connected directly to the buffer. An underfloor heating system can still be operated with the return from radiators. If a solar heating system is connected, only the cold returns from an underfloor heating system or from a fresh water module may be fed into the solar-heated lower third of the buffer. This results in lower solar panel working temperatures with significantly higher efficiencies and also significantly higher solar yield. An oil or gas boiler should always be connected only above the upper quarter of the buffer. With a start relief the house will get warm faster when the heating is switched on. Siphon loops downward at all connections avoid heat losses in summer. With conventional hot water supply Log wood boiler flow Heating circuits flow Hot water tank flow Oil/gas boiler flow Upper buffer sensor Oil/gas boiler return With fresh water module Upper buffer sensor for hot water Upper buffer sensor Cold water Hot water Log wood boiler flow Heating circuits flow Oil/gas boiler flow Oil/gas boiler return Middle buffer sensor Hot water tank return Start relief Middle buffer sensor High-temperature circuits return Start relief Log wood boiler return Heating circuits return M Log wood boiler return Low-temperature circuits return M Lower buffer sensor ETA stratified buffer SP Lower buffer sensor ETA stratified buffer SP With solar exchanger and fresh water module Upper buffer sensor for hot water Upper buffer sensor Cold water Hot water Log wood boiler flow Heating circuits flow Oil/gas boiler flow Oil/gas boiler return Middle buffer sensor Solar flow High-temperature circuits return Lower solar buffer sensor Solar return Log wood boiler return Low-temperature circuits return Lower buffer sensor Start relief M With stratified charging module and fresh water module Upper buffer sensor for hot water Upper buffer sensor Cold water Hot water Log wood boiler flow Heating circuits flow Oil/gas boiler flow Upper solar buffer sensor Oil/gas boiler return Middle buffer sensor Solar flow Solar return High-temperature circuits return Start relief Log wood boiler return Low-temperature circuits return M Lower buffer sensor ETA stratified buffer Solar SPS + lower solar buffer ETA stratified buffer SP 18

19 Buffer Hydraulic integration of several buffers Parallel or serial connection between several buffers When there are several buffers, normally the parallel connection (top with top and bottom with bottom) is the better solution. With a parallel connection, the entire buffer volume is available to installed heat exchangers such as solar heat exchangers or internal water heat exchangers and suspended hot water tanks. Flow Solar flow (Return) Solar return If two buffer storage tanks of different dimensions are connected in parallel, then the flow must be connected to the higher one or the lower one must be raised so that the upper connection can be horizontal. A serial connection between two buffers has no advantages over a parallel connection; if anything it is a disadvantage. For example, a suspended hot water tank can get no heat from the second buffer or an internal heat exchanger cannot heat on both buffers. For this reason, with serial buffers one should connect a solar supply using either heat exchangers in both buffers or better with an external heat exchanger. Flow Return Return With rare exceptions, the use of the serial connection (buffer 2 top and buffer 1 bottom connected) is limited to overcoming spatial obstacles in the given installation situation. Only a serial connection is possible if the passage to a door needs to be kept free or for large distances between buffers. Tichelmann connection for higher outputs For parallel connection with one-sided connection, the volume of the second buffer is integrated via thermosiphon principle. The exchange between the two tanks is driven only by gravity and limited by the hydraulic resistance of the junctions, so for medium outputs a Tichelmann connection is required. With a 6/4" connection, a maximum of 5,500 l/h at 0.25 mh 2 O pressure loss is possible (for flow and return connections together). This corresponds to 130 kw at a spread of 20 C. Therefore, for higher outputs external piping, either symmetric or with Tichelmann connection, is needed. With more than two tanks, external piping with Tichelmann connection is also needed to fill and drain all tanks uniformly. Parallel buffer storage tanks one-sided connection Flow Maximum 2 buffers Return internal Tichelmann connection Flow Maximum 2 buffers Return Symmetric connection Flow Return external piping with Tichelmann connection Flow Maximum 2 buffers Return Buffer connections 5/4" DN32 up to 25 kw boiler output up to 80 kw boiler output for more than 80 kw boiler output for more than 80 kw boiler output Buffer connections 6/4" DN40 up to 40 kw boiler output up to 130 kw boiler output for more than 130 kw boiler output for more than 130 kw boiler output and/or for more than two buffer storage tanks Buffer storage tanks demand softened water If buffer storage tanks are installed in a heating system, the system must be filled with softened water. Around 0.25 kg of limescale will precipitate from a cubic metre of water with 15 of German hardness. SH Montage

20 Parallel buffers with internal Tichelmann Buffer The basic principle of the internal Tichelmann is diagonal flow; two buffers are connected together at the top and bottom (= parallel connection). For output up to 90 kw, a connection with DN32 (ETA buffer connection set) is sufficient, for 30 kw at least R1 or 28 mm copper. On one tank, the boiler outlet is connected at the top; on the other the boiler return is connected at the bottom. Two parallel buffers and conventional hot water supply Return lines with strongly differing temperatures should be fed into the buffer storage tank separately Log wood boiler flow Heating circuits flow Hot water tank flow Oil/gas boiler flow Oil/gas boiler return Hot water tank return High-temperature circuits return Log wood boiler return Low-temperature circuits return Start relief M ETA stratified buffer SP DN32 DN32 ETA stratified buffer SP Upper buffer sensor Middle buffer sensor Lower buffer sensor Two parallel buffers with fresh water module and solar stratified charging For a sufficiently large hot water reserve, the enabling temperature should be over 45 C!! Return lines with strongly differing temperatures should be fed into the buffer storage tank separately Upper buffer sensor for hot water Log wood boiler flow Heating circuits flow Oil/gas boiler flow Upper buffer sensor Buffer top solar Oil/gas boiler return Middle buffer sensor High-temperature circuits return Lower buffer sensor + lower solar buffer Log wood boiler return Low-temperature circuits return Start relief M ETA stratified buffer SP To minimise pipe circulation losses it is helpful to make the connections with downward siphon loops. DN32 DN32 ETA stratified buffer SP Cold water Hot water Solar flow Solar return 20

21 Buffer Parallel buffers with external Tichelmann The basic principle of the external Tichelmann is parallel flow through several buffer storage tanks, which is achieved with diagonally alternating connection of the collectors. The last buffer on the flow collector is the first on the return collector. To achieve uniform charging/discharging, the stub lines should be minimum one or two sizes smaller than the collector. There is no output limit for this circuit. Total output up to Shut-off valves on buffer Collector line at least 30 kw DN 20 DN25 R 1-28x1,5 60 kw DN 25 DN32 R 1¼ - 35x1,5 90 kw DN 32 DN40 R 1½ - 42x1,5 160 kw DN 32 DN50 R 2-54x1,5 300 kw DN 40 DN65 R 2½ - 76x2 450 kw DN 40 DN80 R 3-89x2 Three or more parallel buffers with hot water tank or internal water heat exchanger Log wood boiler flow Heating circuits flow Hot water Hot water tank flow Oil/gas boiler flow Upper buffer sensor Oil/gas boiler return Middle buffer sensor Solar flow Lower boiler sensor solar Solar return Lower buffer sensor Log wood boiler return Heating circuits return Hot water tank return Log wood boiler flow Heating circuits flow Oil/gas boiler flow Upper buffer sensor for hot water Upper buffer sensor Cold water Hot water Upper solar buffer sensor Oil/gas boiler return Middle buffer sensor High-temperature circuits return Solar flow Solar return Lower buffer sensor + buffer bottom solar Start relief Stratified buffer with/without internal water heat exchanger M Cold water For a small solar heating system, individual buffers can be shut down in the summer to reduce the total volume. Three or more parallel buffers with fresh water module and solar stratified charging Log wood boiler return Low-temperature circuits M return To minimise pipe circulation losses it is helpful to incorporate siphon loops downward in the connection lines. ETA stratified buffer SP ETA stratified buffer SP ETA stratified buffer SP ETA stratified buffer SP ETA stratified buffer SP SH Montage

22 Serial buffers Buffer If there are different buffer types, or if not all buffers can be set up in one group, serial connection of the buffers is necessary. Note that for serial buffer connection, integration of a solar heating system only works satisfactorily if a fresh water module is used for the hot water. Solar tanks with internal solar exchangers are only of limited effectiveness. Combination tanks with suspended hot water tanks or internal water heat exchangers are unsuitable for a serial buffer connection. Total output up to Number of buffer storage tanks 30 kw 4 Connection line at least DN25 R1-28x1,5 Solar flow Oil/gas boiler return Lower boiler sensor solar Solar return Start relief M 50 kw 4 DN32 R1¼ - 35x1,5 80 kw 4 DN40 R1½ - 42x1,5 100 kw 2 DN40 R1½ - 42x1,5 140 kw 4 DN50 R2-54x1,5 Serial connection and conventional hot water tank or fresh water module Upper buffer sensor for hot water Upper buffer sensor Log wood boiler flow Heating circuits flow Oil/gas boiler flow Cold water Hot water High-temperature circuits return Middle buffer sensor Lower buffer sensor Log wood boiler return Heating circuits return Hot water tank return 65 kw 2 DN32 R1¼ - 35x1,5 ETA stratified buffer Solar SPS ETA stratified buffer SP Serially connected buffers with fresh water module and solar stratified charging Upper buffer sensor for hot water Log wood boiler flow Heating circuits flow Oil/gas boiler flow Cold water Hot water Upper buffer sensor Middle buffer sensor Upper solar buffer sensor 170 kw 2 DN50 R2-54x1,5 ETA stratified buffer SP Solar flow Solar return Oil/gas boiler return Lower buffer sensor + lower solar buffer Log wood boiler return Low-temperature circuits return M ETA stratified buffer SP ETA stratified buffer SP High-temperature circuits return To minimise pipe circulation losses it is helpful to incorporate siphon loops downward in the connection lines. ETA stratified buffer SP 22

23 Buffer Serial buffers SH Montage

24 Hydraulic schematic Buffer pump MC1 Room 1 Room 2 Outside temperature T MK2 Heating temp. limiter T flow 1 T flow 2 (Pos. 7) Pump 1 Pump 2 Mixing valve 1 M 4x1² Mixing valve 2 M 4x1² T buffer top 2x0,5² 2x0,5² T buffer middle A AB M 2x0,5² B T buffer bottom M 3-way valve Return riser A Start relief Hot water tank pump Buffer AB B M 3-way mixing valve T boiler Hot water tank 2x0,5² Return temp. 3x1² 3x1² 3x1² 4x1² 4x1² 3x1² 2x0,5² Heating circuit control for 2 mixing circuits for installation in the boiler: SH1-0 T Cold water 4x0,5² 4x0,5² 2x0,5² Cold water 2x0,5² THW 2x0,5² THWC 24

25 Hydraulic schematic Buffer pump M MC1 Room 1 T flow 1 MC2 Heating temp. limiter Room 2 T flow 2 Pump 1 Mixing valve 1 M Pump 2 Mixing valve 2 M Return riser Return temp. T Cold water T outside 2x0,5² 4x0,5² 4x0,5² Twisted Pair 2x2x0,6² CAN bus (L = max. 400m) Set the enabling temperature for the heating circuits high enough so that enough heat remains in buffer for the fresh water module. T Collector 2x0,5² 4x1² Wall housing for ETA FWM + SLM for standard control system T buffer top HW 2x0,5² 2x0,5² DN32 T buffer top 2x0,5² Solar buffer top 2x0,5² Tres T buffer middle 2x0,5² Oil/gas boiler Auxiliary boiler pump B B ETA stratified buffer SP ETA stratified buffer SP AB AB A M A 3-way valve 3-way mixing valve Start relief CW HW ETA stratified charging module M 4x1² 3x1² 2x0,5² 3x1² T buffer bottom Solar buffer bottom² 2x0,5² DN32 ETA fresh water module 2x0,5² 3x1² 4x1² 3x1² 3x1² 2x0,5² 2x0,5² 4x1² 3x1² SH Montage

26 Minimum clearances for maintenance Installation Minimum clearances for maintenance for SH The adjacent sketch shows the space requirements and clearances for maintenance and installation of the boiler. > 300 mm The dimensions in parentheses apply for 40, 50 and 60 kw boilers. >200 mm 610 (710) mm SH kw 1100 (1174) mm On one side, left or right, the boiler needs 800 mm of clearance for maintenance, so it can also be set up in a mirror image of the sketch. > 800 mm > 800 mm Will an SH-P boiler be installed for a TWIN burner? If a TWIN auxiliary boiler for pellets might be installed later, the additional space it will need must be taken into account when setting up the SH boiler. Mirror image for TWIN to the left > 500 mm SH-P kw TWIN 20/26 > 400 mm 610 mm 686 mm > 100 mm The sketch shows a boiler with right-hand pellet burner; for a left-hand pellet burner a mirror image applies mm > 800 mm 26

27 Installation Air valves for log boilers Installing air valves on an SH boiler without TWIN burner Installation of the air valves for an SH boiler without an additional flange for a TWIN burner is described here. The air valves for an SH boiler with a pellet flange for the TWIN burner (SH 20P, SH 30P) are different; their installation is described on page 29. SH kw boiler Fuel chamber door Ignition door Combustion chamber door Take both air valves from fuel chamber Take both shafts, including air valves, from the fuel chamber. Prepare shafts for air valves Pull the cotter pin on the spring side. Then remove the washer, the spring and an air valve from the shafts for primary and secondary air. Push shafts into boiler Push both shafts into the air boxes from the side on which the actuators will not be mounted. SH Montage

28 Minimum clearances for maintenance Installation Position air valves Turn both air valves to the closed position. Replace air valves Push the air valves, springs and washers onto the air valve shafts. Both air valves must be installed in the closed position on both sides. Install cotter pins on air valve shafts Install cotter pins on the air valve shafts so that the air valves are pressed against the air boxes by the springs. The air valves must be completely flush with the air boxes on both sides of the boiler. Install actuator brackets Attach the brackets for the actuators to both air valves. Fasten each bracket with an M8 long nut and a self-tapping screw. Turn both air valve shafts and check their smoothness of movement. 28

29 Installation Air valves for log boilers with pellet flange Air valves for log boilers with pellet flange The air valves for a log boiler with pellet flange for the TWIN burner are different; for boilers without a burner flange, see page 27. Take both air valves from fuel chamber Take both shafts, including air valves, from the fuel chamber. Prepare air valve shafts for primary and secondary air Pull the cotter pin on the spring side. Remove the washer, the spring and an air valve from both shafts. SH Montage

30 Air valves for log boilers with pellet flange Installation Push air valve shafts into boiler Push both air valve shafts into the air boxes from the side on which the TWIN will be installed later. Position air valves Turn both air valves to the closed position. Replace air valves Push the air valves, springs and washers onto the air valve shafts. Both air valves must be installed in the closed position on both sides. Install cotter pins on air valve shafts Install cotter pins on the air valve shafts so that the air valves are pressed against the air boxes by the springs. The air valves must be completely flush with the air boxes on both sides of the boiler. 30

31 Installation Draught fan Install actuator brackets Attach the brackets for the actuators to both air valves. Fasten each bracket with an M8 long nut and a self-tapping screw. Turn both air valve shafts and check their smoothness of movement. Take draught fan from fuel chamber Take the draught fan out of the fuel chamber. Install draught fan Attach the draught fan to the rear side of the boiler with 3 M8 x 60 wing screws. The draught fan's electrical connector must be on the right when viewed looking towards the boiler. SH Montage

32 Rear wall insulation, door frame Installation Attach angle bracket to rear wall insulation Fasten the angle bracket to the rear wall insulation with 3 self-tapping 3.5 x 9.5 screws. Angle bracket Attach rear wall insulation to boiler Press the rear wall insulation onto the rear side of the boiler. Install door frame Attach the door frame to the front of the boiler with 4 M5 X 10 round-headed screws. Break out openings for air valve shafts from side panel Take the side panel for the side on which the actuators are to be mounted. Use a screwdriver to break out both openings for the air valve shafts from this side panel. 32

33 Installation Side panels, boiler control system Install left and right side panels Attach the side panels to the rear side of the boiler with 6 M5 X 10 round-headed screws. Attach the side panels to the front side of the boiler with 4 M5 X 10 round-headed screws. Place insulation on top of boiler Place the largest piece of insulation in the middle of the boiler's top side. Attach boiler control system to door frame Loosen both M8 long nuts on the inner side of the door frame. Place the boiler control system on the boiler and remove the cable ties. Fasten the boiler control system to the door frame with the long nuts. SH Montage

34 Cable duct, flue gas temperature sensor Installation Change length of cable ducts The cable ducts for the left and right sides of the boiler are different due to the openings. Put both cable ducts on the boiler and fit their lengths to the boiler room. The cable ducts should extend at least 5 cm over the rear wall of the boiler; ideally they should extend to the wall behind the boiler. > 5 cm Fasten cable ducts Fasten the left and right cable ducts with one 3.5 x 9.5 self-tapping screw each. Connect control system's earthing wire Run the earthing wire from the control system to the rear side of the boiler and screw it onto the side wall. Install flue gas temperature sensor Run the wire for the flue gas temperature sensor (striped silver-black) to the flue outlet. Insert the temperature sensor into the coupling on the flue outlet and secure it with the screw. Let it project in far enough so that the screw clamps the sensor's metal sleeve and not the wire. 34

35 Installation Temperature sensor - flow Install temperature sensor on flow Run the cable for the temperature sensor through the cable ducts to the flow connection on the rear side of the boiler. Screw the front part of the clamp into the immersion sleeve. Place the cap on the temperature sensor and insert the sensor into the immersion sleeve as far as it will go. Then push the cap forward and screw it onto the clamp. Connect cable for flow temperature sensor Connect the cable to the GM-C circuit board at the S500 / T1 terminal. S500 / T1 Install temperature sensor on boiler body Insert the temperature sensor for the safety temperature limiter (copper wire with black insulation) into the immersion sleeve next to the heat exchanger cover on the top of the boiler. Push the sensor into the immersion sleeve as far as it will go, then attach the retaining spring. Place insulation on top of boiler Place the remaining pieces of insulation on top of the boiler. SH Montage

36 Lambda probe, temperature sensor - return Installation Install lambda probe Unscrew the retaining tube on the rear side of the boiler and insert the lambda probe into the retaining tube. Together with the copper washer and the retaining tube, screw the lambda probe into the boiler. Use a pipe wrench to tighten the lambda probe's retaining tube securely. Install lambda probe cable Run the lambda probe's cable along the rear of the boiler in the right cable duct to the circuit board. Connect lambda probe cable Connect the cable to the SH-C circuit board at the S570 terminal. S570 Install temperature sensor on return Run the cable for the temperature sensor through the cable ducts to the return connection on the rear side of the boiler. Screw the front part of the clamp into the immersion sleeve. Place the cap on the temperature sensor and insert the sensor into the immersion sleeve as far as it will go. Then push the cap forward and screw it onto the clamp. 36

37 Installation Connecting draught fan Connect cable for return temperature sensor Connect the cable to the GM-C circuit board at the S500 / T2 terminal. S500 / T2 Install draught fan cable Run the draught fan's cable on the rear side of the boiler next to the cable duct. Connect draught fan cable Connect the cable to the SH-C circuit board at the S91 and S585 terminals. S585 S91 SH Montage

38 Actuators Installation Turn air valve shafts to 45 position Turn both air valve shafts to the 45 position. 45 Turn actuator to middle position Press the button on the actuator to turn the actuator by hand. Turn the actuator to the middle position so that the recess is centred. Attach brackets to actuators Fit the brackets to the rear sides of both actuators. Attach actuators Press the actuators with the brackets onto both air valve shafts. Tighten the screws on the brackets. 38

39 Installation Actuators Connect cable to upper actuator Connect the cable to the upper actuator and run it through the cable ducts to the circuit board. Connect the cable to the SH-C circuit board at the S583 terminal. S583 Connect cable to lower actuator Connect the cable to the lower actuator and run it through the cable ducts to the circuit board. Connect the cable to the SH-C circuit board at the S584 terminal. S584 Attach cable cover Run the actuator cables under the cover. Screw the cover onto the side panel with a 3.5 x 19 selftapping screw. Insert rubber caps Insert two rubber caps into the openings on the left and right side panels. SH Montage

40 Cleaning lever for turbulators Installation Remove heat exchanger cover Turn the fixing nut anti-clockwise to loosen it and detach the ball knob by twisting it half a turn anti-clockwise. 180 Ball knob Then remove the heat exchanger cover. Fixing nut Insert cleaning lever for turbulators Insert the cleaning lever into the boiler from the side on which the actuators are installed. Fasten cleaning lever for turbulators Insert the cleaning lever into the turbulator linkage and turn it towards the rear side of the boiler. Attach the cleaning lever to the turbulator linkage with the bolt. Close heat exchanger cover Replace the heat exchanger cover. Turn the fixing nut until it is as far up as possible. Turn the ball knob clockwise as far as it will go. Close the heat exchanger cover tightly with the fixing nut. 40

41 Installation Insulation door, control panel Disassemble hinges on insulation door Lay the insulation door on a pallet and disassemble the top and bottom hinges. Install hinges for insulation door on door frame The insulation door can be hinged on the right or the left. In this description, the door is hinged on the right side of the boiler. Fasten both hinges to the door frame with 2 M5 x 20 countersunk screws each. If the insulation door is hinged on the left, the three boiler doors must also be reinstalled. Insert cable chain into control panel Insert the cable chain with cables into the control panel as illustrated. The cable chain must extend from the control panel on the side on which the door hinges are installed. Insert cable chain bolts Insert both cable chain bolts into the openings in the control panel. SH Montage

42 Cleaning lever for turbulators Installation Connect control panel earthing to insulation door Lay the insulation door on the pallet with the inner side facing down. Connect the control panel's earthing cable to the top side of the insulation door. Install cover on control panel Screw the cover onto the control panel with 6 selftapping 3.5 x 9.5 screws. Attach control panel to insulation door Place the control panel on the insulation door. Fasten it with 4 M5 x 10 round-headed screws. Insert door handle The door handle must be installed on the side opposite the hinges. Insert the door handle at an angle into the opening at the base of the control panel. 42

43 Installation Cleaning lever for turbulators Attach door handle Fasten the door handle with 2 M5 x 10 roundheaded screws. Install insulation door on boiler Hang the insulation door on the hinges and secure it with the hinge pins. Install cable chain on boiler Insert the cable chain behind the cover and fasten the end of the chain to the circuit board with 2 self-tapping 3.5 x 9.5 screws. Screw cover onto door frame Attach the cover to the door frame on the side opposite the cable chain with a self-tapping 3.5 x 9.5 screw. SH Montage

44 Cleaning lever for turbulators Installation Connect control system's power plug Connect the cable to the SH-C circuit board at the S81 terminal. S81 Connect CAN bus to control system Connect the cable to the GM-C circuit board. CAN Bus Switch off boiler with main switch Switch the main switch on the boiler to the off position. Connect boiler's power supply Make the electrical connection to the boiler: Supply cable 3 x 1.5² with flexible wires 230 V AC / 50 Hz C13 A / L+N+PE Connect the cable to the SH-C circuit board at the S80 terminal. S