Operating Instructions only for authorised experts RENDAMAX 30 doc2030 01/2007 Art. No. 12 076 446
Table of contents Table of contents...2 General information...3 Conditions...3 Warranty conditions...3 Hot water quality...4 Product description Components...5 Function description...5 Extent of delivery...5 Circuit diagram...6 Compact gas fitting...6 Technical data...7 Dimensions...8 Information about system integration Chimney Exhaust...9 Condensation pipes...9 Assembly Preparations for the assembly...10 Air / exhaust system...11 Design variations...12 Exhaust systems, ambient air dependent...13 Example: exhaust system...13 Installing the burner...14 Dismantling / assembling the cover...14 Burner connection, filling the system...15 Electrical installation...16 Set up Control measures...17 Circulating pump...17 Control measures...18 Gas fitting settings...19 Switch field with operating field KM 628...20 Display in operating field KM628...21 Maintenance and service Removing device covers...22 Dismantling of the burner and gas fitting...23 Cleaning...23 Maintenance instructions...24 List of error messages...25 Notes...26 2
General information Conditions Warranty conditions General information Installation, set up, electrical connection and first operation are tasks for an expert. He is responsible for the correct implementation. Information for the operator The safety and function of the burner are reliable if the unit is regularly serviced by a heating expert. In order to guarantee regular implementation, it is recommended that a service contract be concluded. Before installation of the burner, the consent of the gas supply company and the district master chimney sweep must be obtained. Notes on our warranty conditions We exclude our guarantee for damage resulting from the following: - Unsuitable or incorrect use or operation - Incorrect assembly ot set up by the purchaser or third parties - Connection of parts of other origin - Operation of the unit with excess pressure or outside the work s performance details - Use of incorrect fuel - Non-compliance with the information in the operating instructions and the labels attached to the burner. Conditions Observe the following standards for a safe, environmentally friendly and energy-saving operation: DIN 1988 - Drinking water systems in properties, technical conditions for construction and operation DIN 18160 + EN 13 384 - Chimney TRGI (DVGW G600) - Technical regulations, gas installation ATV A 251 - Feeding condensation from furnaces into public wastewater systems State building regulations TRF - Technical regulations, liquid gas DVGW G688 - Burner technology EN 12 831 - Regole per il calcolo del fabbisogno di calore degli edifici EN 12 828 - Technical safety equipment for heating units with lead temperatures of up to 95 o C - EnEV - FeuVO In Austria, the following also applies: - ÖVGW TR Gas (G1) - ÖVGW TR Liquid gas (G2) - ÖNORM H 5152 Furnaces, planning aids - ÖNORM M 7443 Gas devices with atmospheric burners Part 1, 3, 5, 7 - ÖNORM M 7457 Gas devices with mechanically supported pre-mix burners - ÖNORM H 5195 Hot water norm - ÖVGW Guidelines G1 - Technical guideline for the erection of low pressure gas systems G2 - Technical guideline for the erection of liquid gas systems G41 - Gas furnaces, erection and connection G4 - Heating room guideline - The device is licensed according to Article 15a B-CG and according to the Furnace Directive VO (FAV 97) - The local building regulations must be observed In Switzerland, the following also applies: - PROCAL Heating materials supplier association - SVGW gas guidelines G1: Gas installations Swiss gas and water association - EKAS Form, 1942: Liquid gas guideline, part 2 - BUWAL Federal Ministry for the Environment, Forest and Landscape - VKF Union of cantonal fire insurance companies - Water treatments Observe the guidelines of SWKI No. 97-1 Water treatments for heating systems In addition, the country-specific directives and standards must be observed. 3
Hot water quality Hot water quality The composition and quality of the system water directly affect the performance of the overall system and the life of the boiler. Normally, mains water with a ph value of 7-8 can be used for the first filling and subsequent top-ups, provided that the water is not strongly corrosive (chlorine content > 150 mg/l) or is very hard (>14odH; hardness range IV). A drinking water analysis can be requested from the appropriate water supply company. If the specific system volume is greater than 20 litres / kw of heat output (e.g. through the installation of a hot water buffer tank), the maximum permitted chalk deposit must be determined by the filling and top-up water corresponding to the computation of VDI guideline 2035. If necessary, the water must be softened. No chemical anticorrosion substances must be used. Unknown water quality and replacement systems Frequently, substances and additives are in hot water which impact on the function and life of the burner. Therefore, either or heat the old system and then fully empty before replacing, carefully rinse the heating system after replacing. Ideally, the system should be rinsed directly after the first heating. Underfloor heating For old systems, underfloor heating systems and if there is problematic filling water, ELCO recommends fitting a heat exchanger from the accessories. In Austria, ÖNORM H 5195-1 also applies. In Switzerland, SWKI No. 97-1 also applies. Criterion Permissible value Effect of deviation ph value 7-8 Danger of corrosion of boiler components and heating system Hardness < 14 dh - Increased chalk deposits - Limited life of boiler Chlorine content < 150 mg/l Corrosion of alloyed materials 4
Product description Components Function description Extent of delivery 1 2 3 4 5 9 1 Smoke gas exhaust connection 2 Air infeed 3 Smoke gas temperature sensor 4 Heat exchanger 5 Ignition transformer 6 Blower 7 Regulator 8 On / off switch 9 Automatic ventilator 10 Noise insulation (types 65 and 85) 11 Gas valve 12 Venturi tube 13 Boiler pump (outside the boiler on types 100 and 120) 6 7 8 10 11 12 13 Product description The burner RENDAMAX 30 is certified with CE-0063BO3192 and therefore corresponds to the following standards and guidelines: - DIN EN 677 - EN 60 335 - EN 55 014-1/2-90/396/EWG - 89/336/EWG - 73/23/EWG - 92/42/EWG - DIN EN 483 - DIN EN 297 - DIN EN 656 - The NOx limits required by 1 st BlmSchV Section 7 (2) are met. The burner RENDAMAX 30 is a system with a closed combustion chamber which is independent of ambient air. The combustion air enters the device through an air infeed system. The burner is used for closed hot water heating systems. The boiler output is modulated to the current heating requirements by the integrated regulator. Heat exchanger The stainless steel heat exchanger is made from flat spirals and ensures a transfer of the exhaust gas s heat to the boiler water. The condensation takes place in the upper section of the heat exchanger. The condensation is fed down in the rear section of the heat exchanger. The control and regulator unit assumes the function of the automatic firing device and regulator of the modulating operation of the boiler and the hot water preparation. A display shows the operating status of the boiler. The automatic firing device controls and monitors the safety function process. Extent of the delivery Burner with circuit diagram Documentation Accessories VISTRON tank Flue systems Neutralisation unit / condensation treatment Pump group 5
Product description Circuit diagram Compact gas fitting 1 5 6 7 4 3 2 1 Operating type i Standby q Automatic operation F Summer operation j Chimney sweep operation 2 Operating type selector 3 Fault display E 4 Lead temperature 5 Fault code (blinking) 6 Heating circuit status C Night operation B Day operation (Blinking) Burner on 7 Service status ji Service status minimum burner output jii Service status maximum burner output Circuit diagram The circuit diagram is integrated in the burner with all the above operating elements. The system electronics KM628 offers: - Management for modulating boiler regulator - Hot water preparation Compact gas fitting The compact gas fitting works as a gas safety close valve and as regulator. The regulator functions as a pneumatic gas / air difference pressure regulator. On the gas side, it controls the gas pressure P O in the function of the combustion air pressure P L. If no air pressure is built up (P L = 0), the gas valve remains closed. The gas/ air pressure ratio and thus also the gas air volume ratio can be set and then/ remain almost constant over the set load range. Technical data Safety close valve Mains power Type 65-100 Type 120 Power consumption Type 65-100 Type 120 Gas fitting incl. gas filter 2, class B/C AC 24 V AC 230 V 0,42 A 0,09 A 6
Product description Technical data RENDAMAX 30 65 85 100 120 Nominal heat output at 75 o / 60 o Max/Min kw 58,8/8,3 77,5/15,5 87,2/17,4 108,9/21,8 Nominal heat output at 40 o / 30 o C kw 65,1/9,2 85,8/17,2 96,5/19,3 120,5/24,1 Nominal heat load kw 60,7/8,6 80,0/16,0 90,0/18,0 112,4/22,5 Standard efficiency 75 o / 60 o C % 106,3 106,3 106,3 106,3 Standard efficiency 40 o / 30 o C % 110,1 110,1 110,1 110,1 Operability losses T K = 70 o C % < 0,3 < 0,3 < 0,3 < 0,3 Max. blower pressure Pa 140 140 140 200 Water content l 6,6 8,4 10,3 12,0 Max. permissible water pressure bar 6 6 6 6 Max. permissible lead temperature C 90 90 90 90 Condensation volume at 40 o C / 30 o C ca. l/h 9,7 12,8 14,4 18,0 Gas connection value Min. gas flow pressure Natural gas E/H* (Hi=10.9 kwh/m 3 ) m 3 /h 5,6 7,3 8,2 10,3 Natural gas LL (Hi=8.1 kwh/m 3 ) m 3 /h 7,5 9,9 11,1 13,9 Liquid gas propane / butane (Hi=12.8 kwh/kg) Natural gas Liquid gas kg/h 4,7 6,3 7,1 8,8 mbar mbar Exhaust gas mass flow for natural gas g/s 31 41 46 58 Exhaust gas temperature net, T V /T R 75/60 C 70 70 70 70 Exhaust gas temperature net, T V /T R 40/30 C < 55 < 55 < 55 < 55 Gas category II2ELL3P / II2H3P Exhaust gas value group G61 G61 G61 G61 Construction type - Exhaust gas systems (B23; C13; C33; C43; C53; C63; C83) All All All All Ionisation flow min. 15,0 15,0 15,0 15,0 Connections: Air/exhaust gas pipe (concentric) DN 80/125 110/150 110/150 110/150 Air/exhaust gas pipe (parallel) DN 80/80 100/100 100/100 100/100 Heating lead / heating reflux (inner / outer) DN 25/32 25/32 25/32 25/32 Gas connection DN 20 20 20 20 Condensation pipe connection mm 25 25 25 25 ph value condensation ph 3,0 3,0 3,0 3,0 Electric connection / power consumption 230 V / VAC (*types 100 and 120 without boiler circuit pump) W 230 255 130* 215* CE ID number 0063BO3192 Weight, approx. kg 55 65 80 90 Nominal heat output at 80 o /60 o C kw 59,2 77,8 88,2 109,0 Efficiency at nominal output at 100%, 80 o /60 o C % 97,5 97,3 98 97,7 Efficiency at partial load 30%, 40 o /30 o C % 108,1 108,1 108,1 108,1 Operability losses at 70 o C average K temp. % < 0,3 < 0,3 < 0,3 < 0,3 Auxiliary energy + integrated boiler circuit pump (*types 100 and 120 without boiler circuit pump) 20 50 20 50 20 50 20 50 W 147 171 83* 137* 7
Product description Dimensions Type R30/65 R30/85 R30/100 R30/120 B1 mm 120 140 140 140 D mm 80 100 100 100 D1 mm 80 100 100 100 G R 3 / 4 " R 3 / 4 " R 3 / 4 " R 3 / 4 " L mm 405 510 560 670 L1 mm 90 90 90 90 W R 1 1 / 4 " / Rp 1" R 1 1 / 4 " / Rp 1" R 1 1 / 4 " / Rp 1" R 1 1 / 4 " / Rp 1" 8
Information about system integration Chimney Exhaust Condensation pipes Burner technology In the burner technology, the residual heat is removed from the exhaust gas trough cooling and condensation and is fed to the heating system. In this way, a higher degree of efficiency is achieved with low energy consumption. Information for the chimney Exhaust systems must be installed in a shaft corresponding to DIN 18 160 / Part 1. Check the exhaust gas pipes before assembling the burner Dimensions only apply to the use of the exhaust gas system made from polypropylene (PP) DN 110/150. The low exhaust gas temperatures required usual exhaust gas pipes specifically for burners. Examples: - Chimneys resistant to moisture - Condensation-sealed inner dish - Diameter of the connections (sleeves) must be considered for the minimum shaft cross-sections. Roof heating central Dependent on ambient air, max. pipe length 4 m Exhaust gas is extracted - via a DIBT (D) or VKF (CH) ÖTZ (A) authorised and tested exhaust pipe - into the chimney Pipes and pipe sections - outside shafts, must be freely accessible and checkable and must be protected against frost - inside shafts, must be rear ventilated. Exhaust pipes must be - moisture resistant - suitable for exhaust temperatures below 40 o C, and - secure against over-pressure. Recommendation: Accessories, exhaust pipe set Condensation pipes must not be securely installed. The condensation is trapped in a funnel and fed into the sewage system. Recommendation: Accessories, neutralisation device Note worksheet ATV A 251. Exhaust pipes Infeed / exhaust system The applicable local provisions for the design of the exhaust system must be observed. The burner can only be operated with approved exhaust systems. On site exhaust systems must be resistant to moisture, corrosion and sealed against condensation, and satisfy static and operating requirements. Unhindered escape of the exhaust gases must be guaranteed at the chimney opening (chimneypot is not recommended). The connection between chimney and burner must be fitted with a drop (3%) so that the condensation escaping through the exhaust system can flow back from the exhaust pipe. This connection should have as few bends as possible. Inspection openings must be planned in the exhaust pipe in accordance with official requirements. It is possible to use an exhaust system not dependent on ambient air. Exhaust pipes Horizontal pipes must be avoided in order to prevent the development of condensation. It must be ensured that the various components are connected to each other with proper seals. 45 o bends should be used for the assembly. The vertical parts must be fixed with straps. Installation example of separate condensation pipe from the exhaust gas pipe. Condensation The connection of the condensation pipe (under boiler) must lead to the exhaust pipe with drop. It must also be guaranteed that there is no risk of frost. 9
Assembly Preparations for the assembly Minimum distances Installation and distances Unrestricted access for operation and maintenance is only possible if the minimum distances are observed. Place of installation Do not install the unit in rooms with aggressive vapours (e.g. hairspray, perchloroethylene, tetrachlorocarbon), large occurrences of dust or high humidity (e.g. laundry rooms). The place of assembly must be secure against frost. If these requirements are not fulfilled, the warranty for damage shall lapse. When assembling the device, please ensure that no foreign parts (e.g. drill dust) enter the gas burner. Use covers. As different requirements apply in different Bundesländer, consulting the appropriate authorities and the appropriate district master chimney sweep is recommended before installation. Gas connection The laying of gas pipes and the gas connection are exclusively the tasks of the licensed gasfitter. Clean deposits from the heating network and gas pipes before connecting the gas burner, especially order systems. Please ensure that the gas pipes are laid free from tension. Before setting up, check the pipes and gas connections. The gas fittings on the burner can be pressurised to a maximum of 150 mbar. 10
Assembly Air / exhaust system Design variations Ambient air dependent B23 Exhaust connection to exhaust system Multiple configuration (underpressure / overpressure) Cellar installation Air supply via installation room Exhaust system via roof Minimum shaft cross-section Shaft rear ventilation according to DIN 18160 for design B23 (ambient air dependent) Exhaust pipe ø 110 mm > 168 188 Ambient air dependent, PPS / Alu white C33x Air exhaust system via roof in the same pressure area Cellar installation Exhaust-ventilation system to the exhaust chimney Air-exhaust system via roof Installation in exhaust chimney not sensitive to moisture Air exhaust system via roof in the same pressure area Floor, roof installation Exhaust, ventilation system via sloping roof or flat roof C43x Connection to AZ / LAS (2-speed) multiple configuration on site C53x Air infeed and exhaust to outside in different pressure areas on site C63x Air, exhaust connection on separately tested and supplied air/exhaust pipes Cellar, floor installation Exhaust, air infeed system through the external wall. Exhaust trough heat-insulated exhaust pipe or AZ-AW Exhaust pipe (standing air layer) at the external wall C83x Exhaust connection exhaust systems, multiple configuration (underpressure), combustion air infeed via separate air pipe on site 11
Assembly Air / exhaust system Design variations The local applicable provisions must be observed for the design of the exhaust system. Connection to gas / exhaust system Only original accessories and parts, including the offered lubricants for PPS exhaust systems, must be used for the concentric air/exhaust gas system. Gas burners with an air/gas design via a roof can only be installed in the attic or in rooms where the ceiling also forms the roof or there is only the roof construction over the ceiling. The air/gas design must not pass through other rooms. If a fire-resistance period is demanded for the ceiling, the pipes for the combustion air and exhaust system in the area between the upper edge of the ceiling and the roof skin must have a cladding which also has this fire-resistance period and comprises non-flammable materials. If no fire-resistance period is demanded for the ceiling, the pipes for the combustion air and exhaust system from the upper edge of the ceiling to the roof skin must be in a shaft of non-flammable, robust materials or in a metal protective pipe (mechanical protection). It must be possible to check exhaust pipes for free cross-sections. At least one corresponding revision and / or test opening must be fitted in the installation room must have in accordance with the appropriate district master chimney sweep. Exhaust connections are produced between the sleeve and seal. Sleeves must always be positioned against the direction of condensation flow. The air/gas system must be installed with a 3 o slope to the burner. Upon installation, the length to be calculated of the air and gas system through the roof must not exceed 4m. The calculated length of the air and gas system comprises the straight pipes and the length of the curved pipes. A 90 o bend is treated as 1m and a 45 o bend as 0.8m. In order to prevent mutual impacts on the air and gas systems through the roof, we recommend a minimum distance between the air and gas systems of 2.5m. Connection to air and exhaust chimney not sensitive to moisture (AZ), exhaust chimney or exhaust system Chimneys and exhaust systems must be approved under building regulations for furnaces (DIBT approval for D, VKF for CH and ÖTZ for A ). The size is calculated using the calculation tables according to the exhaust gas values. There must not be more than three 90 o bends. For chimneys, 0 Pa must be assumed when calculating the feed pressure. Connection to air and exhaust chimney not sensitive to moisture C43x (AZ) The straight air and exhaust pipes must not be longer than 1.4m when installing the air and exhaust chimney. There must not be more than three 90 o bends. The air and exhaust chimney AZ must be tested by the DIBT (German Institute for Building Technology); the VKF (Association of Cantonal Fire Insurance Companies), the ÖTZ and be approved for burners. Connection to exhaust chimney not sensitive to moisture or exhaust system B23 for ambient air dependent operation The straight air and exhaust pipes must not be longer 2m when installing an exhaust chimney. There must not be more than three 90 o bends. The exhaust chimney must be tested by the DIBT; the VKF, the ÖTZ and be approved for burners. Connection to a combustion air and exhaust system C63x without a tested gas furnace The straight air and exhaust pipes must not be longer 2m when installing a combustion air and exhaust system. There must not be more than three 90 o bends. The exhaust system must be tested by the DIBT; the VKF, the ÖTZ and be approved for burners. If the combustion air is taken from the shaft, it must be free from impurities. Multiple configuration of exhaust systems (not included in the delivery) The proof of the calculation, design and function from the manufacturer of the boiler system must be taken into consideration in the event of multiple configurations of the exhaust system. Temperature [ o C] Volume flow [m 3 /h] Mass flow [g/s] Feed pressure [Pa] RENDAMAX 30 max. / min. max. / min. max. / min. max. / min. 65 70 / 55 113 / 16 31 / 4 140 / 10 85 70 / 55 149 / 30 41 / 8 140 / 15 100 70 / 55 168 / 34 46 / 9 140 / 15 120 70 / 55 209 / 42 58 / 12 200 / 15 12
Assembly Exhaust systems, ambient air dependent Example: exhaust system 1 Boiler connection 2 T connector with lid 87.5 o 3 Pipe with sleeve 4 Support track 5 Support bend 6 Pipe with sleeve 7 Spacer 8 Furnace shaft cover 10 Revision piece 11 Bend 30 o 13
Assembly Installing the burner Dismantling / assembling the cover 2 1 1 1. 3 3 4 4 4 2. 5 6 7 Removing the boiler covers Loosen 2 screws (1) on the front cover (2) Slide the front cover up and remove Loosen the tension fasteners (3) on the side cover (4) Fold the side cover to the right and left and lift from the clips (5) Open the snap fastener (6) on the front cover plate (7) Remove the cover plate 14
Assembly Burner connection, filling the system The connection is only performed by an authorised expert. 1 2 Siphon and condensation trap Dismantle the siphon (1), fill and reassemble Connect the condensation trap or neutralisation equipment (accessory) with the siphon Note The condensation pipe (2) must not be securely connected to the wastewater pipe. The condensation must be able to be drip freely into a funnel. 3 Filling the system Connect the water pipe to the KFE tap (in the building) Open all radiator valves Fill cold system to 1 bar Check water quality Vent pump (if necessary, loosen blade wheel with screwdriver) Fill condensation siphon with water (approx. 05. l) Run pump several times After complete venting, fill system to the final operating pressure Close venting screw and remove filler pipe Replacement system Carefully rinse system Check seal at connection points Carefully vent system 5 1 4 2 6 1 Siphon 2 Condensation connection 3 Cable insert, external cabling 4 Gas connection ¾ 5 Lead connection 6 Reflux connection Connect the gas pipe Check seal of pipes Connect required exhaust closing plate (concentric / parallel) Insert boiler connector (concentric or parallel) from above into the respective opening and press into the socket. To do this, use the lubricant suitable for PPS exhaust pipes Connect exhaust collector to the exhaust system Assemble supports 15
Assembly Electrical installation General information Electrical installation and connection work must only be performed by an electrician. The VDE/ÖVE/Sev and EVU provisions and conditions must be observed. Mains connection and connection from building wires The device is designed for permanent connection and connection wires NYM 3 x 1.5 mm 2 or H05W-F 3 x 1 mm 2. Burner and switch field are wired. The mains connection is with a clamp (3) on the device via a power circuit envisaged and secured for this. It must be possible to separate the burner from the network by suitable means. Allpolar switches with a contact opening width > 3 mm or power protector switch can be used for this. Mains voltage: Mains connection fuse: Power consumption: 230 V, 50 Hz 10 A max. 420 W Wastewater pump power consumption Max. switched current KM628 1A / relay Max. 2.5 A total The switch field (1) can be folded up after the securing screw (2) has been removed. 3 1 2 16
Set up Control measures Circulating pump Water throughflow speed and pump data R30 Type t 20K Pump data Nominal throughflow Boiler resistance Pump type WILO Pump setting Feed amount at Q Residual feed amount at Q Max. power consumption* m 3 /h kpa kpa kpa W R30/65 2,57 20 RS 25/7 PWM 3/C max. 49 29 132 R30/85 3,38 25 RS 25/7 PWM 3/C max. 40 15 132 R30/100 3,78 28 TOP-S 30/7 *** 3 52 24 195 R30/120 4,70 30 TOP-S 30/7 *** 3 42 12 195 The boiler is fitted with a pump switch as standard. The pump is activated when the boiler is switched on. The pump continues to operate for a few minutes after the burner switches off. This period can be adjusted. The standard period is 2 minutes. *) Maximum pump power consumption stated in pump position 3 ***) Pump optional 17
Set up Control measures The first set up must be performed by an authorised expert. Before set up, the following checks must generally be performed: Check power supply Check pressure in the heating system Check pressure at the gas connection Check gas pipe seal Check perfect assembly of the exhaust accessories Check condensation pipe seal Minimum circulation quantity / flow monitoring It must be guaranteed that the device has a hydraulic throughflow when feeding heat. The device is fitted with a flow safety which monitors the throughflow. In order to maintain the minimum throughflow, it is recommended that points or a plate heat exchanger be fitted (both available as accessories) or the RENDAMAX 30 is connected to an open distributor. Before installation, please note the following: The size of the expansion tank must be sufficient, see notes on the water quality, if necessary fill with softened water. The system should be set up directly after filling in order to rule our standing air cushions as a corrosion ovens. Chalk deposits in the heating boiler are avoided by setting up the device at low system temperatures and maximum throughflow. During revision work, a complete exchange of the system water should be avoided. This can be achieved through partial dams or reuse of the trapped and filtered system water. 18
Set up Gas fitting settings Setting the combustion quality Connect the device to the water, gas and electricity Because of the different ignition behaviours of natural gas LL and natural gas E, the gas-air compound must be adjusted. After successful ignition, the prescribed CO 2 value at full load can be set by turning the control screw (2) on the gas valve. Set the CO 2 value for low load by turning the control screw (1) on the gas fitting Natural gas settings Natural gas L / H RENDAMAX 30 Gas connection pressure mbar 20 CO 2 max. 65/85/120 % 8,8 0,2 CO 2 max. 100 % 9,4 0,2 CO 2 min. 65/85/120 % 8,2 0,2 CO 2 min. 100 % 8,8 0,2 Min. And max. CO 2 values must always have a difference of 0.3%. 2 Natural gas liquid gas conversion The following diaphragms must be used for conversion to operation with liquid gas (included with the delivery as a set): R30 65: 6,0 mm R30 85: 6,0 mm R30 100: 6,8 mm R30 120: 8,0 mm Liquid gas settings Liquid gas RENDAMAX 30 Gas connection pressure mbar 50 1 CO 2 max. 65/85/120 % 9,8 0,2 CO 2 max. 100 % 10,4 0,2 CO 2 min. 65/85/120 % 9,0 0,2 CO 2 min. 100 % 9,6 0,2 Min. And max. CO 2 values must always have a difference of 0.3%. 19
Set up Switch field with operating field KM628 1 Operating type i Standby q Automatic operation F Summer operation j Chimney sweep operation 2 Operating type selector 3 Fault display E 4 Lead temperature 5 Fault code (blinking) 6 Heating circuit status C Night operation B Day operation (Blinking) Burner on 7 Service status ji Service status minimum burner output jii Service status maximum burner output Operating functions (flap closed) When the flap is closed, the desired operating status can be selected by turning the knob (2) left or right. i Standby Boiler not in use, frost protection active q Automatic operation Boiler in use for heating and hot water user F Summer operation Boiler in summer operation (only hot water use) ji Chimney sweep operation, minimum load Boiler in use, minimum load jii Chimney sweep operation, maximum load Boiler in use, maximum load 20
Set up Display in operating field KM 628 1 Parameter display P1 Current/set lead temperature P2 Current/set hot water temperature *P3 Desired lead temperature P5 Current outside temperature P6 Current exhaust temperature P9 Current burner output P10 Password 2 Optical interface 3 Reset / program button 4 Alarm LED 5 Parameter selector 6 Operating status outputs 7 Corresponding current measurement 8 Fault / parameter display 9 Operating status inputs *) P3 desired load (for KKM cascade manager) Information functions (flap open) Information menu When the flap is open, turning the knob (5) displays information. There are ten menus. Using the knob, a selection can be made. An arrow in the lower section of the LCD display indicates which parameter has been selected. No. P1 P2 P3 P5 P6 P9 P10 Parameter display Current / set lead temperature Current / set hot water temperature Desired hot water temperature (desired load for KKM cascade manager) Current outside temperature Current exhaust temperature Current burner output Only for trained engineers Overview of the symbols Input symbols H RT Bus Flame ionisation in operation Boiler released by external regulator Data bus in operation Output symbols Main gas valve voltage on Z F Ignition transformer voltage on Release of boiler ventilator Boiler pump voltage on Hot water load voltage on Setting the desired lead temperature for heating operation Only applicable without weather effect of 0-5 V signal Open flap (the arrow on the lower side of the LCD display indicates Parameter 1) Press reset / program button (3), Alarm LED lights up, turn the knob (5) left or right until the desired lead temperature appears in the display Press reset / program button (3), Alarm LED turns off Close flap Setting the desired hot water temperature for hot water use Only applicable when using the boiler s hot water function Open flap) Turn the knob to the right until the arrow on the lower side of the LCD display indicates Parameter 2 Press reset / program button (3), Alarm LED lights up, turn the knob (5) left or right until the desired hot water temperature appears in the display Press reset / program button (3), Alarm LED turns off Close flap 21
Maintenance and service Removing device covers Maintenance and cleaning work is only performed by the authorised expert. He is responsible for correct maintenance. Before the maintenance work, remove the device from the mains electricity and close the feed and reflux. The maintenance work should be carried out annually. The heat exchanger does not have to be cleaned if there is a small amount of dirt, but must be cleaned at least every two years. 2 1 1 1. 3 3 4 4 4 2. 5 6 7 Removing the boiler covers Loosen 2 screws (1) on the front cover (2) Slide the front cover up and remove Loosen the tension fasteners (3) on the side cover (4) Fold the side cover to the right and left and lift from the clips (5) Open the snap fastener (6) on the front cover plate (7) Remove the cover plate 22
Maintenance Cleaning 3 3 1 Dismantling the burner and gas fitting Loosen the electric plug connection Loosen 4 screws (1) on the blower (2) Loosen securing screws (3) on the burner (4) Remove the entire burner unit from the heat exchanger 4 2 3-4 mm 5-10 mm 5 6 7 8 Cleaning burner and blower Visually check the burner (4) and the blower (2). Dust deposits are usually blown away and burnt by the draft from the burner during normal operation. If there is additional dirt such as building dust, a careful cleaning of the metal material (5) must be undertaken using a vacuum cleaner. Check seals (6) surrounding the burner plate and the ceramic fibre seal (7) for damage and replace if necessary. Check adjustment of electrodes (8) 9 Cleaning the heat exchanger Rinse the heat exchanger (9) with clean water (remove persistent dirt with a thin plastic brush and then rinse) 23
Maintenance instructions RENDAMAX 30 Burner Maintenance and cleaning work is only performed by the authorised expert. He is are responsible for correct maintenance. The maintenance work should be carried out annually. The heat exchanger does not have to be cleaned if there is a small amount of dirt, but must be cleaned at least every two years. Measure and record the set emission values Switch off the main heating switch and secure against reactivation, or separate the device from the allpolar mains Close the gas tap Remove the device covers Dismantle the blower, gas valve and burner unit Remove ignition cable. Check ignition plug for breaks, damp (damp / wet ignition plugs cause error messages replace ignition plug) Check the burner (if necessary clean with paintbrush / nylon brush or vacuum cleaner) Check blower (if necessary clean with paintbrush / nylon brush or vacuum cleaner) Remove furnace chamber insulation Rinse heat exchanger with clean water (remove persistent dirt with a thin plastic brush and then rinse) Clean siphon and refill with water before reassembly Check seal of all connections to condensation-carrying parts. Remove any escaped condensation or other moisture Check securing screws, replace if necessary Check system pressure, expansion tank and safety valve. Dismantled seals for gas and water-carrying parts must be replaced for new ones when reassembling. This is the case, in particular, for O-rings on the gas valve and all burner seals Reassemble device ready for use Open gas pipe and check seal Switch on main heating switch Carry out function control with emission measurements If necessary, readjust values according to factory requirements. 24
List of error messages Error messages displayed on KM 628 Error messages The E symbol and an error code are displayed in the event of an error. Before correcting the error, the cause of the error must be found and remedied. The operating signal fails if an error occurs twice within six minutes (error code is shown on the display, with 3 above) or if there is an error which is active for longer than six minutes. 1. Maximum thermostat (STB) has reacted The lead temperature has exceeded its set value. Wait until the lead temperature is below the set value for at least one minute, then unlock the safety function by pressing the reset button. 2/3. Blocking entrance has been interrupted An external safety, connected to the clamps (ST 9.3-9.4) has reacted. Check and test this safety. 4. Flame disruption When starting combustion, no flame was detected during the set safety period. If the corresponding programming has been undertaken, a new start is possible. 5. Flames reduce during operation While the burner is in use, the respective ionisation flow was below 1 µa. Check and unlock this safety function by pressing the reset button. 6. Maximum temperature monitor (STW) has reacted The lead temperature has exceeded the value set for it or the water flow is too weak. 7. Maximum smoke gas thermostat has activated The smoke gas temperature has exceeded 100 o C. Remedy the fault and activate Reset. 11. Wrong flame signal An ionisation flow exceeding 1 µa has been measured while the burner is in use. Remedy the fault and activate Reset. 12. Defective lead temperature sensor The measured resistance of the temperature sensor is outside the range between -10 and +126 o C. Remedy the fault and press Reset. 13. Defective smoke gas temperature sensor / locked entrance has been interrupted The measured resistance of the smoke gas sensor is outside the range between -10 and +126 o C. Remedy the fault and press Reset. An external retainer, connected to the clamps (1 3) has reacted. Check and repair this retainer. 14. Defective water sensor The measured resistance of the water sensor is outside the range between -39 and +110 o C. Remedy the fault and press Reset. 15. Defective external sensor The measured resistance of the external sensor is outside the range between -39 and +110 o C. Remedy the fault and press Reset. 20/21. Error in the gas valve control After the burner has been switched off, no ionisation flow bas been measured for 5 seconds, which was greater than 1 µa. Remedy the fault and press Reset. 24. Wrong minimum blower speed When rinsing, a specific minimum bower speed is not achieved. Remedy the fault and press Reset. 25. Defective maximum blower speed A specific maximum blower speed has not been undercut for the ignition. Remedy the fault and press Reset. 26. Defective blower speed at stop When the blower is switched off, the selected speed is too high (300 revolutions / minute). Remedy the fault and press Reset. 30. CRC error in the control parameters An Eeprom error has occurred in the stored control parameters. Check and change this parameter set. 31. CRC error in the safety-relevant parameters An Eeprom error has occurred in the stored safety-relevant parameters. Check and change this parameter set. 32. Faults in the low voltage power supply The low voltage power supply is too small or the fuse is defective. Remedy the fault and press Reset. x.y. internal error An internal error has been detected in the electronics. Check and remedy this error. 25
Notes 26
Notes 27
Service: ELCO GmbH D - 64546 Mörfelden-Walldorf ELCO Austria GmbH A - 2544 Leobersdorf ELCOTHERM AG CH - 7324 Vilters ELCO-Rendamax B.V. NL - 1410 AB Naarden ELCO Belgium n.v./s.a. B - 1731 Zellik