Elco RENDAMAX 30 Bedienungsanleitung

Operating Instructions

only for authorised experts

RENDAMAX 30

01/2007 Art. No. 12 076 446

doc2030

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

General information

Conditions

Warranty conditions

General information

Installation, set up, electrical connec-

tion 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.

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 fabbiso-

gno di calore degli edifici

EN 12 828

- Technical safety equipment for

heating units with lead tempera-

tures of up to 95 oC

-EnEV

-FeuVO

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 infor-

mation in the operating instructions

and the labels attached to the

burner.

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 Environ-

ment, 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.

Hot water quality

The composition and quality of the

system water directly affect the per-

formance 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 corres-

ponding to the computation of VDI

guideline 2035. If necessary, the water

must be softened. No chemical anti-

corrosion substances must be used.

In Austria,

ÖNORM H 5195-1 also applies.

In Switzerland,

SWKI No. 97-1 also applies.

Unknown water quality and replace-

ment systems

Frequently, substances and additives

are in hot water which impact on the

function and life of the burner.

Therefore, either

x heat the old system and then fully

empty before replacing,

x 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.

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

Product description

Components

Function description

Extent of delivery

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)

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 1st

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

x Burner with circuit diagram

x Documentation

Accessories

x VISTRON tank

x Flue systems

x Neutralisation unit / condensation

treatment

x Pump group

Product description

Circuit diagram

Compact gas fitting

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 POin the function of the

combustion air pressure PL.

If no air pressure is built up (PL= 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 2, class B/C

Mains power

Type 65-100 AC 24 V

Type 120 AC 230 V

Power consumption

Type 65-100 0,42 A

Type 120 0,09 A

Gas fitting incl. gas filter

1 Operating type

iStandby

qAutomatic operation

FSummer operation

jChimney sweep operation

2 Operating type selector

3 Fault display E

4 Lead temperature

5 Fault code (blinking)

6 Heating circuit status

CNight operation

BDay operation

(Blinking) Burner on

7 Service status

jI Service status minimum burner

output

jII Service status maximum burner

output

5 6 7 4 3 2

Product description

Technical data

RENDAMAX 30

65 85 100 120

Nominal heat output at 75o/ 60oMax/Min kW 58,8/8,3 77,5/15,5 87,2/17,4 108,9/21,8

Nominal heat output at 40o/ 30oC 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 75o/ 60oC % 106,3 106,3 106,3 106,3

Standard efficiency 40o/ 30oC % 110,1 110,1 110,1 110,1

Operability losses TK= 70oC % < 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 40oC / 30oC ca. l/h 9,7 12,8 14,4 18,0

Gas connection value Natural gas

E/H* (Hi=10.9 kWh/m3)m3/h 5,6 7,3 8,2 10,3

Natural gas LL (Hi=8.1 kWh/m3) m3/h 7,5 9,9 11,1 13,9

Liquid gas propane / butane

(Hi=12.8kWh/kg) kg/h 4,7 6,3 7,1 8,8

Min. gas flow pressure Natural gas

Liquidgas mbar

mbar 20

50 20

Exhaust gas mass flow for natural gas g/s 31 41 46 58

Exhaust gas temperature net, TV/TR75/60 °C 70 70 70 70

Exhaust gas temperature net, TV/TR40/30 °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. P$ 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 80o/60oC kW 59,2 77,8 88,2 109,0

Efficiency at nominal output at 100%, 80o/60oC % 97,5 97,3 98 97,7

Efficiency at partial load 30%, 40o/30oC % 108,1 108,1 108,1 108,1

Operability losses at 70oC 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) W 147 171 83* 137*

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"

L mm 405 510 560 670

L1 mm 90 90 90 90

W R 11/4" / Rp 1" R 11/4" / Rp 1" R 11/4" / Rp 1" R 11/4" / Rp 1"

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

oC, 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 require-

ments. 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.

45obends should be used for the

assembly. The vertical parts must be

fixed with straps.

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.

Installation example of separate

condensation pipe from the exhaust

gas pipe.

Assembly

Preparations for the assembly

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 appro-

priate 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.

Minimum distances

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