Ecodense RT-65 One, RT-80 One, RT-150 One, RT-65 Twin, RT-80 Twin Installation, Operating And Maintenance Manual

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ROOF TOP SERIES CONDENSING BOILER INSTALLATION, OPERATING AND MAINTENANCE MANUAL

ECODENSE RT-65 One ECODENSE RT-80 One ECODENSE RT-100 One ECODENSE RT-125 One ECODENSE RT-150 One ECODENSE RT-65 Twin ECODENSE RT-80 Twin ECODENSE RT-100 Twin ECODENSE RT-125 Twin ECODENSE RT-150 Twin

www.ecodense.com

DEAR USER,

The Roof Top Series Condensing Boilers ECODENSE RT-65 One, ECODENSE RT-80 One, ECODENSE RT-100 One, ECODENSE RT-125 One, ECODENSE RT-150 One, ECODENSE RT-65 Twin, ECODENSE RT-80 Twin, ECODENSE RT-100 Twin, ECODENSE RT-125 Twin, ECODENSE RT-150 Twin are constructed and manufactured according to the most advance technological inventions and the safety rules. It is easy to use for our customers.

We recommend that you read this manual and safety warnings thoroughly before the

use of the device in order to ensure safe, cost effective and environmental-friendly use.

If you encounter any issue that is not explained clearly in this manual or you could

not understand, please contact with our service department.

We thank you for choosing ECODENSE brand.

This Operating Manual is an integral part of the device and must be maintained in a

plastic dossier and hung at a clearly visible place by the device.

TERMO ISI SİSTEMLERİ SAN.VE TİC.A.Ş.

Kartal Monumento Plaza

Kartal/İSTANBUL/TÜRKİYE

www.ecodense.com

06.06.2017 Rev. 00 1

Esentepe Mah.Milangaz Cad. No:75 K:3

Tel: +90 216 442 93 00 Fax: +90 216 370 45 03

e-mail:servis@ecodense.com

CONTENTS

WARNINGS ............................................................................................................................................... 3

Warning Symbols and Descriptions ........................................................................................................ 3

General Safety Rules .............................................................................................................................. 4

TERMS OF WARRANTY ......................................................................................................................... 5

Out of Warranty Conditions .................................................................................................................... 5

GENERAL CHARACTERISTICS OF CONDENSING BOILER ............................................................. 6

ECODENSE Roof Top Series Condensing Boilers for Outdoor Installation .......................................... 7

Technical Specifications ......................................................................................................................... 7

Boiler Safety ........................................................................................................................................... 7

Standart Equipments ............................................................................................................................... 7

ECODENSE Roof Top Series Boiler Components ................................................................................. 8

CIRCUIT SCHEMES ............................................................................................................................... 10

CLOSED CIRCUIT COMPONENTS ...................................................................................................... 13

Balance Tank ........................................................................................................................................ 13

Sizing Table For Expansion Tank ......................................................................................................... 14

Expansion Tank .................................................................................................................................... 15

Manometer ............................................................................................................................................ 15

Strainer ................................................................................................................................................. 15

Air Separator ......................................................................................................................................... 15

WATER QUALITY ................................................................................................................................. 16

TECHNICAL DATA ................................................................................................................................ 17

Capacity Table ...................................................................................................................................... 17

Condensing Boiler Dimensions ............................................................................................................ 19

Noise Level ........................................................................................................................................... 19

INSTALLATION ..................................................................................................................................... 20

General Controls ................................................................................................................................... 20

STACK CONNECTIONS ........................................................................................................................ 21

ASSEMBLY ............................................................................................................................................. 22

ECODENSE Assembly Instructions ..................................................................................................... 22

ECODENSE Single/CASCADE Assembly Instructions ....................................................................... 22

Assembly of Condensing Fluid Drain ................................................................................................... 22

ECODENSE CONTROL INSTRUCTIONS BEFORE START-UP ........................................................ 23

ELECTRICAL DIAGRAM ...................................................................................................................... 24

COMMISSIONING .................................................................................................................................. 25

Before Commissioning ......................................................................................................................... 25

Checks During Commissioning ............................................................................................................ 25

ADJUSTING COMBUSTIN PARAMATERS ......................................................................................... 26

Adjustment and Measurement Points .................................................................................................... 26

Adjusting Minimum Capacity ............................................................................................................... 27

Adjusting Medium Capacity ................................................................................................................. 27

Adjusting Maximum Capacity .............................................................................................................. 28

Adjsuting Time Schedule ...................................................................................................................... 28

MAINTENANCE ..................................................................................................................................... 29

Monthly Maintenance ........................................................................................................................... 29

Seasonal Maintenance ........................................................................................................................... 29

LIST OF ERROR CODE .......................................................................................................................... 30

SOLUTION RECOMMENDATIONS FOR SOME OF THE PROBLEMS ............................................ 34

AFTER SALES SERVICES ..................................................................................................................... 35

NOTES ..................................................................................................................................................... 36

06.06.2017 Rev. 00 2

I TEMİZLEYİNİZ.

WARNINGS

Warning Symbols and Descriptions

Symbols Symbol Descriptions

Important information and useful hints.

GAZ HATTIN

CLEAN GAS LINE. ЧИСТАЯ ЛИНИЯ ГАЗ.

Warning of danger to life or property.

Warning of electrical voltage.

Product handling information.

"Clean the gas line" warning on gas line.

Carry in an upright position. Fragile Item. Protect against water.

06.06.2017 Rev. 00 3

General Safety Rules

• All personnel engaged in installation, disassembly, commissioning, operation, control,

maintenance and repair should have received the necessary training and fully read and understood this manual.

• No changes that might damage the safety of the device must be made by persons and/or

organizations on the device.

• All operation, commissioning and installation works (except for burning adjustment) should be

carried out when the device is not operating and after disconnecting the power supply. Noncompliance with these rules may lead to serious bodily injuries and even death by electrical shocks or uncontrolled flame formation.

• Repairs concerned with safety elements should be carried out only by the manufacturing company.

• The device should never be used by children, mentally handicapped and inexperienced persons.

• Children must not be allowed to play with the device.

• Keep the device away from explosive and flammable materials.

• Device must intake air, and ventilation and air discharge holes must not be closed.

If you sense gas leakage;

• Shut down valves of all gas devices.

• Open all doors and windows.

• Do not turn on electric devices or do not turn them off if they are working.

• Do not use burner derived tools such as match and lighter.

• Inform the gas company.

Do not store any inflammable materials in boiler room.

Wear hearing protectors if there is noise in boiler room.

In case of fıre or other emergency;

● Switch off the main switch

● Close the main fuel shut-off valve outside the plant.

● Take appropriate actions

06.06.2017 Rev. 00 4

TERMS OF WARRANTY

Main and auxiliary equipment and all components used in ECODENSE RT-65 One, ECODENSE

RT-80 One , ECODENSE RT-100 One , ECODENSE RT-125 One, ECODENSE RT-150 One, ECODENSE RT-65 Twin, ECODENSE RT-80 Twin, ECODENSE RT-100 Twin, ECODENSE RT-125 Twin, ECODENSE RT-150 Twin Roof Top Series Condensing Boilers are guaranteed for 1 year by TERMO ISI SİSTEMLERİ A.Ş. starting from the date of commissioning under the maintenance, adjustment, operating conditions and relevant mechanic, chemical and thermal effects explained herein.

Please note that this warranty is only valid if the device(s) is commissioned and maintained by our authorized services.

Our company reserves the right to make any modifications on the product and all instructions thereof for improvement purposes.

Out of Warranty Conditions

• Any damage arising out of or in relation to customers’ non-compliance to their responsibilities

with regards to installation, commissioning, operation and maintenance,

• Any damage arising out of or in relation to commissioning, repairs and maintenance carried out by

unauthorized services,

• Any damage that may occur during transportation or storage of the product,

• Not preserving the product in its original packaging until the installation stage,

• Incorrect and poor electrical connections, Failures due to incorrect voltage applications, frequent

repetition of voltage fluctuations,

• Any damage that may occur as a result of incorrect fuel usage or, foreign substances in the fuel

used or using of the product without any fuel,

• Any damage that may occur due to foreign particles entered into the product during installation

and operation,

• Failures due to incorrect device selection,

• Any damage to unit due to natural disasters,

• Devices without any warranty certificates,

• Warranty Certificates without the stamp and signature of the authorized dealer or service,

• Devices with any falsification on the warranty certificate or without an original serial number.

• The risks during transportation of device under the responsibility of customer belong to the

customer.

• Presence of misuse faults are indicated in the reports issued by authorized service stations or our

authorized agent, dealer, representative or our factory in case of unavailability of authorized service stations.

• Customers may apply consumer protection arbitrator committee with regards to this report and

request for an expert report.

06.06.2017 Rev. 00 5

GENERAL CHARACTERISTICS OF CONDENSING BOILER

ECODENSE RT-65 One, ECODENSE RT-80 One , ECODENSE RT-100 One , ECODENSE RT125 One,ECODENSE RT-150 One, ECODENSE RT-65 Twin, ECODENSE RT-80 Twin, ECODENSE RT-100 Twin, ECODENSE RT-125 Twin, ECODENSE RT-150 Twin are heating devices operating with natural gas or LPG with a very low suction power, and equipped with high-duty, premix condensing control system with micro-processor. The boiler is composed of a heat exchanger with aluminum cooling fins and a steel premix burner equipped with ignition and ionization flame control, modulating fan and gas valve. ECODENSE RT-65 One, ECODENSE RT-80 One , ECODENSE RT-100 One , ECODENSE RT-125 One,ECODENSE RT-150 One, ECODENSE RT-65 Twin, ECODENSE RT-80 Twin, ECODENSE RT-100 Twin, ECODENSE RT-125 Twin, ECODENSE RT-150 Twin are designed for use as standalone as well as cascade.

06.06.2017 Rev. 00 6

ECODENSE Roof Top Series Condensing Boilers for Outdoor Installation

ECODENSE Roof Top series condensing boilers offer solution in hot water production for rooftop outdoor installation in many applications such as shopping centers, office buildings, hospitals and hotels.

ECODENSE condensing boilers, when used as CASCADE, meet high-capacity energy requirements with line-up operation and also expand the life-cycle by ensuring equal aging in boilers.

Technical Specifications

• High efficiency with premix condensing technology and micro-flame metal fiber coated steel burner,

• Provides energy saving through 5:1 modulating operation,

• 10 different capacity option between 65 kW-300 kW in ECODENSE RT One/Twin series,

• Operation option with natural gas and LPG,

• Easy hydraulic and gas circuit connections,

• When used as CASCADE, the panel on the boilers allows controlling 16 unit control for

ECODENSE RT One and 8 unit control for ECODENSE RT Twin series condensing boilers,

• Allows simple control with illuminated LCD panel which provides ease of use; and error codes and

boiler information can be displayed on this panel,

• Daily and weekly operation schedule can be programmed,

• Seasonal heat program can be prepared during summer and winter times,

• Operation in lower noise values,

• Environmentally-friendly with lower NOx and CO emission rates,

• Easy installation, operation and maintenance.

Boiler Safety

• When outdoor temperature goes below +4 °C, the boiler automatically protects itself and prevents

from freezing.

• The boiler protects itself, when the temperature of flue gas exceeds the set value during operation,

• The boiler protects itself during unexpected high temperatures with combustion space safety

thermostat.

Standart Equipments

• Primer hydraulic circuit circulating pump,

• Inlet and return collectors in size according to installed total power,

• Checkvalve in inlet line and safety valve in return line of the boiler,

• Ball valves in both inlet and return lines of the boilers,

• Balance container with residue, dirt and air separator return collectors in size according to total

installed power,

• Gas detector for the gas leakage control,

• Pressure gauge and ball valve in gas line,

• Thermometer in hydraulic circuits,

• Drain trap for each boiler,

• Ventilation grills for the air inlet and outlet,

• Eye bolt for easy transport.

06.06.2017 Rev. 00 7

ECODENSE Roof Top Series Boiler Components

ECODENSE WT 65 – ECODENSE WT 80

No. Material

1 2 3 4 Ignition transformer 16 Heater circuit return 5 6 7 8 9 10 11 12

Venturi Flue outlet Gas valve

Ignition electrode 17 Heater circuit supply Fan 18 Ionization electrode Automatic air relief cock 19 Condensing water release outlet Water pressure sensor 20 Condensing water trap Water flow sensor 21 Gas inlet Condensing water collection tray 22 Burner Control panel 23 Bulls eye Start/Stop

13 14 15

Reset Control card Boiler body

06.06.2017 Rev. 00 8

ECODENSE WT 100 – ECODENSE WT 125- ECODENSE WT 150

No. Material

1 2 3

Venturi Flue outlet

Gas valve 4 Ignition transformer 16 Heater circuit return 5 6 7 8 9 10 11 12

Ignition electrode 17 Heater circuit supply

Fan 18 Ionization electrode

Automatic air relief cock 19 Condensing water release outlet

Water pressure sensor 20 Condensing water trap

Water flow sensor 21 Gas inlet

Condensing water collection tray 22 Burner

Control panel 23 Bulls eye

Start/Stop

13 14 15

Reset Control card Boiler body

06.06.2017 Rev. 00 9

CIRCUIT SCHEMES

06.06.2017 Rev. 00 10

06.06.2017 Rev. 00 11

06.06.2017 Rev. 00 12

CLOSED CIRCUIT COMPONENTS

Balance Tank

Balance Tank (Separator) must be vertical.

Advantages:

Ø No hydraulic response occurs between the boiler circuit and the heating circuit. Ø Boilers and heating zones operate under suitable water flow.

Sizing of Balance Tank:

Ø In order to ensure healthy operation of the balance tank, accurate sizing must be made. Ø The boiler’s exit water temperature should be measured on the upper part of balance tank. Ø For this, a ½” muff should be welded onto tank, and also an air relief cock should be mounted. Ø Dimensions shown in the picture represent minimum dimensions required to be applied.

06.06.2017 Rev. 00 13

Sizing Table For Expansion Tank

SYSTEM

CAPACITY

EXPANSION

A B H

TANK

DIAMETER(D)

cm cm cm mm mm

INLET & OUTLET

DIAMETER(Ø)

65 33 38 48 100 50

90 38 44 55 125 50 115 42 47 59 125 50 130 47 54 68 150 65 170 54 62 77 150 65 230 59 67 84 200 80 345 72 82 103 200 80 460 83 95 119 250 100 575 93 106 133 250 100 690 102 116 145 300 125 805 110 126 157 300 125 920 118 134 168 350 150

1035 131 150 188 350 150 1150 138 157 197 400 200 1265 144 164 206 400 200 1380 150 171 214 450 200 1495 155 178 222 450 200 1610 162 185 230 450 200 1725 169 192 238 450 200

06.06.2017 Rev. 00 14

Expansion Tank

Expansion tank fore pressures must be adjusted according to system. Expansion tank should be placed parallel to circuit return line.

Manometer

A manometer with capacity of at least 0 to 6 bar must be connected to system. Manometer should be placed to easily visible spot from filling point, preferably same point as expansion tank.

Strainer

Any dirt or residue in circuit water causes damage got boiler and circuit components and decreases efficiency by reducing heat transfer. In order to prevent this problem a strainer must be connected to circuit.

Air Separator

The air in the water dissolves due to increasing temperature and flow in the circuit. Dissolved air causes cavitation, sound and efficiency loss. By using an air separator air is removed from the system.

06.06.2017 Rev. 00 15

WATER QUALITY

1. Before connection of condensing boilers any dirt and residue in circuit must be cleaned.

2. Refined water must be used while adding water to heating circuit due to any loss in closed circuit.

3. Permitted water hardness for water used in water circuit must comply with VDI 2035 standard.

The lime dissolved in water, settles on hot surfaces and forms an insulation layer when water temperature rises. This prevents heat transfer and high temperature might damage the heat exchanger. If boiler water cycles through water circuit, all circuit water must meet above requirements. If a plate heat exchanger separates boiler water and heating circuit water, only the water between boiler and heat exchanger must meet these requirements.

In order to prevent calcification, properties of water in circuit and water added must be as below:

Type Boiler Capacity

Total Water

Hardness (°F) Single 50-200 kW <20 Single 200-600 kW <15 Single >600 kW <0,2 Cascade All capacities <0,2

*Volume to capacity ratio of water in circuit must be higher than 20l/kW. Total volume of first filled water and additional water must be less than volume of system.

Note: pH value of unrefined water must be 7<pH<9. This pH value can be achieved after filling the circuit with main circuit water with pH value of 7 and air separation. pH value of refined water must be between 7-8,5 pH.

06.06.2017 Rev. 00 16

TECHNICAL DATA

Capacity Table

TYPE CAPACITY

kW -

ECODENSE RT-65 One 65 1 ECODENSE RT-80 One 80 1 ECODENSE RT-100 One 100 1 ECODENSE RT-125 One 125 1 ECODENSE RT-150 One 150 1 ECODENSE RT-65 Twin 130 2 ECODENSE RT-80 Twin 160 2 ECODENSE RT-100 Twin 200 2 ECODENSE RT-125 Twin 250 2 ECODENSE RT-150 Twin 300 2

BOILER

NUMBER

MAXIMUM

GAS INLET PRESSURE

mbar bar

21 6 21 6 21 6 21 6 21 6 21 6 21 6 21 6 21 6 21 6

OPERATING

PRESSURE

06.06.2017 Rev. 00 17

°C

WT 65

65 80,0 100,0 125,0 150,0

20 20,0 25,0 25,0 25,0 63,7 78,4 98,0 122,5 147,0 19,7 19,7 24,6 24,6 24,6

68 84,0 105,0 131,0 157,0 21,5 21,5 26,8 26,8 26,8

98,0% 98,0% 98,0% 98,0% 98,0% 98,5% 98,5% 98,4% 98,4% 98,4%

104,6% 105,0% 105,0% 104,8% 104,7% 107,5% 107,5% 107,2% 107,2% 107,2% 109,0% 109,0% 109,0% 109,0% 109,0%

10-65

90 90 90 90 90

5 5 7 7 9 6 6 6 6 6

0,8 0,8 0,8 0,8 0,8

G20-G31 G20-G31 G20-G31 G20-G31 G20-G31

21 21 21 21 21

37 37 37 37 37

65 65 65 65 65

60 60 60 60 60

42 42 43 45 45

32 32 33 35 35

230/50 230/50 230/50 230/50 230/50

X5D X5D X5D X5D X5D

100 100 100 200 200

3 3 6 6 6

3/4'' 3/4'' 3/4'' 3/4'' 1''

1'' 1'' 1'' 1'' 1''

50 50 55 55 64

80/125 80/125 80/125 80/125 80/125

5 5 5 5 5

WT 80 WT 100 WT 125 WT 150

10-65 10-65 10-65 10-65

TECHNICAL SPECIFICATIONS Unit

Capacity Maximum Heating Capacity kW

Minimum Heating Capacity kW Maximum Thermal Output (80°C / 60°C) kW Minimum Thermal Outlput (80°C / 60°C) kW Maximum Thermal Output (50°C / 30°C) kW Minimum Thermal Output (50°C / 30°C) kW Efficiency

Pmax. (80°C / 60°C) % Pmin. (80°C / 60°C) %

Pmax. (50°C / 30°C) % Pmin. (50°C / 30°C) % %30 (30°C) %

Usage Water Circuit Temperature Adjustment Range with

External Storage Tank Usage Central Heating Circuit

Maximum Operating Temperature °C Water Content Lt

Max. Operating Pressure bar Min. Operating Pressure bar

Gas Specifications Gas Type

Gas Inlet Pressure (G20) mbar Gas Inlet Pressure (G31) mbar

Combustion Data Max. Fume Temperature (80°C / 60°C) °C

Min. Fume Temperature (80°C / 60°C) °C Max. Fume Temperature (50°C / 30°C) °C Min. Fume Temperature (50°C / 30°C) °C

Electrical Specifications Voltage & Frequency V / Hz

Protection Class IP Energy Consumption W Electrical Fuse Amper Hydraulic Installation Specifications

Gas Connection inch Central Heating Circuit Inlet/Outlet inch

General Specifications Net Weight kg

Chimney Diameter (Ø) mm Nox Emission Class

G 20 Natural Gas, G 31 LPG

06.06.2017 Rev. 00 18

Condensing Boiler Dimensions

Device must be shipped in original packaging!

Clean the inside of fuel line thoroughly before installing the burner to the fuel line. Any damage that may occur due to solid objects and metal particles from the fuel line shall not be covered by our company.

Noise Level

When the condensing boiler is in operation, the maximum noise level released is <70 dBA. The noise level value corresponds to the value measured with semi-anekoik (semi-unreflecting acoustic) room testing according to the product standards at the time of expansion of the smoke release system, when the condensing boiler operates at the maximum heating power.

06.06.2017 Rev. 00 19

INSTALLATION

General Controls

Ø The heating capacity of the device should be determined based on the heat requirement calculated. Ø All parts necessary for the system must be available.

Ø Make sure that all protection and safety devices are available. Ø In order to prevent accumulation of dirt in the system, prevention of boiler operation and damage

given to the boiler by clogging, a filter must be mounted onto the system’s return pipe.

Ø The device is equipped with a freezing protection system to switch the device to the heating mode

when the temperature of distribution water drops below + 4 ˚C.

Ø Ensure that the gas connections are made with pipes confirming to the standards, and that there is

no leakage on these connections.

Ø Ensure that the electric connections are proper.

During cascade installation, do not forget to mount an external gas cut-off valve suitable to the devices.

Electrical Connection

Perform electrical connections according to the diagram provided. Follow general security rules during installation of electric wiring and making connections. Connect the earthing terminal in electric panel to the earthing installation.

Ø External Outdoor Sensor (Optional):

Connect the sensor to the relevant terminal. The length of electric cable for external sensor connection is max. 25 m. A 2x1.5 cable should be used. The sensor must not be exposed to the morning sun and if possible, to direct sunlight. Since the values to be read by the sensor will be affected, it must not be mounted close to any window, door, vent hole and heat sources.

Unsuitable places to mount external sensor

06.06.2017 Rev. 00 20

STACK CONNECTIONS

1. Horizontal stack extensions must be connected to boiler at 1.5°-3° angle in order to drain

condensing fluid.

2. Stack setup must be according to local ventilation conditions.

3. Stack connections must be leak proof.

Some examples of stack setup can be seen below:

06.06.2017 Rev. 00 21

ASSEMBLY

ECODENSE Assembly Instructions

ECODENSE condensing boilers are designed to work as CASCADE; they provide suitable space utilization for every stokehold design at required capacities.

ECODENSE Single/CASCADE Assembly Instructions

Ensure that required gas pressure supplied. Check the hydraulic circuit according the PID.

Assembly of Condensing Fluid Drain

1. Ensure that siphon is fully filled with water before activation of boiler.

2. Drain direction must allow flow of condensing fluid. Drain pipe must be planned to prevent any

clogging due to external effect like frost, etc. Drain parts must be plastic.

3. Boiler condensing outlet must be at least 19mm.

Condensing drain must not be changed or clogged after assembly. Clogging of condensing drain causes the boiler to automatically shut down or causes the siphon to overflow. It will be helpful to pour some hot water to the open parts of drain if there is a possibility of frost. Drain must be open at all times to ensure proper functioning of the boiler.

06.06.2017 Rev. 00 22

ECODENSE CONTROL INSTRUCTIONS BEFORE START-UP

1. Ensure that boilers are mounted on fixed, firm and robust.

2. Ensure that every boiler has connected to their own 6A fuse.

3. Closed circuit maximum operation pressure is 3 bars. Ensure that in CASCADE SYSTEMS,

hydraulic separator is used below 3 bars and plate heat exchanger is used above 3 bars. In situation where plate heat exchanger is used, hydraulic separators with suitable capacities must be used at both sides.

4. In single or CASCADE applications, safety valve fixed to 3 bars must be used. Adjustable safety

valve must not be used.

5. Ensure that stack connections in single or CASCADE, are at right radius and connected as leak

proof.

6. Control air purger, air separator and strainer are used in the system and connected according to

advised scheme.

7. A manometer to monitor system pressure must be present in system, control if it is mounted on the

system.

8. Control if the condensing fluid siphon is made of plastic, isolated against frost, at correct radius

and connected to condensing fluid drain with an angle. It should not be connected to rain drain.

9. Ensure that circuit and system are tested against leakage and system pressure is sufficient.

10. Ensure that gas pressure complies with boiler operation instructions. In situations where gas

pressure is higher than required pressure, a regulator must be used.

11. Ensure that sensors on boiler feed and circuit (outgoing-return temperature, ambient temperature,

boiler temperature sensors) are wired correctly. Wires of boiler feed and other equipment on circuit belong to user.

On first start-up if there is deficiency in the system detected by ECODENSE authorized service technicians, technicians are not allowed to activate the system.

Do not connect the circulation pump as the engine will be above and the engine will be below.

06.06.2017 Rev. 00 23

ELECTRICAL DIAGRAM

06.06.2017 Rev. 00 24

COMMISSIONING

Before Commissioning

Ø Open all open/closed valves between the device and systems. Ø Check gas connections by using foam and water solution for determining leakages on connections

carefully.

Ø Check the initial pressure of expansion tank. Ø Fill the water system. Ø Open all air relief cocks, and ensure that air circulation in the boiler and system is provided. Ø Ensure that there is no leakage in the water circuits, connections and boiler. Ø Make sure that the electrical connections are correct and the grounding is sufficient. Ø Check the accuracy of required gas pressure value. Ø Make sure that there is no flammable material adjacent to the boiler.

Checks During Commissioning

Ø Switch on the device. Ø Ensure the soundness of oil circuit and water system. Ø When the boiler is in operation, check sufficiency of flue and water pipes. Ø Check the soundness of condensation system and ensure its correct operation. Ø Make sure that water circulation takes place properly. Ø Make sure that gas valve is operating correctly. Ø Check the eligibility of values at minimum and maximum capacities by using a flue gas analyz Ø Check the compatibility of gas consumption with the values on the technical data table. Ø Make sure that parameters are programmed correctly.

06.06.2017 Rev. 00 25

ADJUSTING COMBUSTIN PARAMATERS

Instructions below are specially prepared for ECODENSE service technicians. Before shipment parameters of all the boilers are adjusted at suitable capacity and pressure at factory’s test stand. Settings mentioned below are for combustion optimization at field conditions. Appropriate allen keys and wrenchs must be used for screws and caps. Gas and air values must be adjusted by using a flue gas analyser.

Adjustment and Measurement Points

A: Throttle Adjustment Point B: Gas Feed Pressure Measurement Point C: Offset Adjustment Point D: Burner Gas Pressure Managament Point

During adjusting parameters follow below step;

1. Minimum capacity activation and combustion adjustment

2. Medium capacity emission control

3. Maximum capacity combustion adjustment and control

4. Minimum-maximum capacity combustion adjustment control

06.06.2017 Rev. 00 26

Adjusting Minimum Capacity

1. Connect probe of flue gas analyzer to measurement point.

2. Connect a manometer to the gas feed pressure measurement point and control if the pressure is at

suitable value.

3. In order to operate the boiler at minimum capacity activate cooling mode via A button.

4. Press selecting heating button for 3 seconds (“Controller stop function on “)will be seen on the

screen, by pressing Displaying information button, capacity value can be seen on the screen). Via

Adjusting of room Comfort setpoint button set boiler capacity to 18%. Later when you press OK button, boiler will start working at minimum capacity.

5. According to flue gas measurement values at minimum capacity, use A and C points for gas flow

rate. Use A point for coarse setting for gas flow rate and C point for precise gas flow rate. For both points, turning clockwise increases flow rate and turning counter clockwise decreases flow rate.

Adjusting Medium Capacity

1. Via Adjusting of room Comfort setpoint button set boiler capacity to 50%. Later when you

press OK button, boiler will start working at medium capacity. Control the flue gas values and start adjusting maximum capacity if flue gas values are ok.

06.06.2017 Rev. 00 27

Adjusting Maximum Capacity

1. Via Adjusting of room Comfort setpoint button set boiler capacity to 100%. Later when you

press OK button, boiler will start working at medium capacity.

2. According to flue gas measurement values at maximum capacity, use A and C points for gas

flow rate. Use A point for coarse setting for gas flow rate and C point for precise gas flow rate. For both points, turning clockwise increases flow rate and turning counter clockwise

decreases flow rate.

Check the emission values at minimum and maximum capacities again and adjust combustion parameters precisely by following above steps.

After adjustment of parameters are finished, close all measurement points as they will be leak proof.

Flue gas emission values and flue gas temperature limit values are given at below table:

CO2

Flue Gas

Temperature

<5,5

<50

8,4-9

<80

ppm

°C

Adjsuting Time Schedule

1. Press ESC button several times in order to get main screen.

2. Press “OK” button when you are at main screen. “Time and day adjusment” line will be seen on the screen.

Press “OK” again and select related line.

3. In order of clock, year and month informations will blink.

4. Set the blinking value and press “OK” after each setting.

06.06.2017 Rev. 00 28

MAINTENANCE

Monthly Maintenance

Monthly maintenance is a comprehensive process where general checks of condensing boiler and peripheral components are performed to prevent possible faults. After completion of maintenance and adjustment processes, make sure to perform an emission analysis.

Ø Clean gas and water line filters. Ø Perform insulation measurements of ignition and ionization electrodes, replace electrodes should

there be leakage to the body.

Ø Check ignition cables and sockets. Ø Check all wiring points. Tighten loose connections. Ø Check gas line pressure, it must be the same with the first adjusted pressure, otherwise the boiler

load and emission values will also have changed.

Ø Check all bolts of the boiler. Tighten loose bolts. Ø After starting the condensing boiler and making required adjustments, perform flue gas emission

measurement and check if there is an ideal combustion.

Seasonal Maintenance

It is a comprehensive maintenance work when the condensing boiler is re-started after long periods of shut-down or interruptions. After completion of maintenance and adjustment processes, make sure to perform a combustion analysis.

Ø Check ignition and ionization electrodes.

Ø Check the operating function.

Ø Check the inlet/outlet water sensors.

Follow installation directions during maintenance.

06.06.2017 Rev. 00 29

Code

Exterior temperature,

sensor error

Boiler temperature

sensor error

Solid fuel boiler temperature, senso

r error

General

flow water temperature,

sensor error

Flue gas temperature

, sensor error

Flow water temperature

1, sensor error

Flow water temperature

1, cooling

, sensor error

Flow water temperature

2, sensor error

Flow water t

emperature

, main control device

, sensor error

Return water temperature

1, sensor error

Cascade return water temperature

, sensor error

General return water temperature,

sensor error

DHW

temperature

1 sensor error

DHW

temperature

2 s

ensor error

Flow water temperature DHW, sensor error

DHW, recirculation sensor error

Room temperature1,

sensor error

Room temperature 2,

sensor error

Room temperature 3,

sensor error

Storage tank temperature

1 (

top),

sensor er

ror

Storage tank temperature

2 (bottom),

sensor error

Storage tank temperature

3 (middle),

sensor error

Collector temperature

1, sensor error

Water pressure

, sensor error

LPB address conflict

No BSB cable sectional/communicati

BSB cable address conflict

BSB RF

communication error

Data overwork at EEPROM

Additional module

1, error

Additional module

2, error

100

2 timer leader

102

Leader timer without redundancy

103

Communication error

105

Main

tenance message

109

Boiler temperature control

110

STB

(SLT)

locking

LIST OF ERROR CODE

Error Code

LPB

Error Description

06.06.2017 Rev. 00 30

Code

111

Temperature limit safety closing

117

Water pressure is very high

118

Water pressure is very low

119

Water pres

sure switch disengage

121

Heating circuit 1

flow water temperature not reached

122

Heating circuit 2

flow water temperature

not reached

125

Maximum boiler temperature exceeded

126

DHW supply temperature

not reached

127

DHW le

ionella tempe

rature not reached

128

Flame loss in operation

129

Incorrect air supply

130

Flue gas temperature limit exceeded

132

Gas pressure switch safety

shut down

133

Safet

y time for flame formation

exceeded

146

Sensor/control element configuration error

151

LMS14…

internal error

152

Parameter error

153

Device is manually locked

160

Fan speed threshold

not reached

162

Air pressure switch is not closing

164

Flow/pressure switch, heating circuit error

166

Air pressure switch error, it is not opening

169

Sitherm

Pro system error

170

Water pressure sensor error

, primary side

171

Alarm contact 1 is active

172

Alarm contact 2 is active

173

Alarm contact 3 is active

174

Alarm contact 4 is active

176

Water pressure 2 is very high

177

Water

pressure 2 is very low

178

Heating circuit 1 temperature limiter

179

Heating temperature 2 temperature limiter

183

Device is in parameter mode

Error Code

LPB

Error Description

06.06.2017 Rev. 00 31

Code

195

Maximum time per charging exceeded

196

Maximum time for charging per week exceeded

209

Heating circuit error

214

Motor monitoring

215

Diverter

valve fan air error

216

Boiler error

217

Sensor error

218

Pressure control

241

Flow sensor error for efficiency measurement

242

eturn sensor error for efficiency measurement

243

Pool sensor error

260 217 Flow water temperature

3rd

sensor error

270 215 Heat exchanger temperature difference is too high

317 214 Mains frequency out of acceptable range

320 217 DHW

supply temperatu

re, sensor error

321 217 DHW

outlet temperature

, sensor error

322 218 Water pressure

is too high

323 218 Water pressure

is too low

324 146 BX inlet,

same sensor

325 146 BX inlet

/additional module

, same sensor

326 146 BX inlet

/mixture group, same

sensor

327 146 Additional module,

same function

328 146 Mixture group,

same function

329 146 Additional module/mixture group

, same function

330 146 Sensor inlet BX1 no function

331 146 Sensor inlet

BX2 no function

332 146 Sensor inlet

BX3 no function

333 146 Sensor

inlet BX4 no function

335 146 Sensor inlet

BX21

no function

336 146 Sensor inlet

BX22

no function

339 146 Collector pump Q5

is lost

340 146 Collector pump

Q16 is lost

341 146 B6 sensor is lost

342 146 Solar energy supply

B31 sensor

is lost

343 146 Solar energy integration is lost

344 146 Solar energy control element

spare tank

is lost

346 146 Solid fuel boiler pump

Q10 is lost

347 146 Solid fuel boiler analogy sensor is lo

st 348 146 Solid fuel boiler address error

349 146 Accumulation tank return valve

Y15 is lost

Error Code

LPB

Error Description

345

06.06.2017 Rev. 00 32

146

Solar energy control element pool K18 is lost

Code

350 146 Accumulation tank address error

351 146 Main control device/system pump,

address error

352

146 Unpressurized cap,

address error

353 146 B10 sensor is lost

371 209 Heating circuit

3 flow water temperature

372 209 Heating circuit

3 temperature limiter

373 103 Additional module

374 169 Sitherm

Pro calculation

375 169 BV

step motor

376 169

Drift test limit value

377 169 Drift test is prevented

378 151 Internal recurrence

382 129 Recurrence speed

384 151 Auxiliary light

385 151 Mains low voltage

386 129 Fan speed tolerance

387 129 Air pressure tolerance

388 146 DHW sensor, no funct

ion

426 151 Flue gas damper feedback

427 152 Flue gas damper configuration

429 218 Dynamic water pressure is too high

430 218 Dynamic water pressure is too low

431 217 Primary heat exchanger sensor

432 151 Grounding function is not connected

433 216 Primary heat exchanger temperature is too high

Error Code

LPB

Error Description

06.06.2017 Rev. 00 33

SOLUTION RECOMMENDATIONS FOR SOME OF THE PROBLEMS

Problem Cause Explanation-Recommendation

Gas smell

Gas line/Gas connections

Unburned gas smell Flue tightness

Gas supply pressure Fan problem Check the working of fan.

Incomplete combustion

State of premix combustion head and heat exchanger

Combustion air connection

Gas pressure/Combustion

Shaky activation of burner No combustion after

ignition

parameters Electrode/Ionization

Electric connection

Boiler does not work.

Sensor connections

Control of leak proofing of connections is required. Be sure that measurement points are closed.

Be sure that flue connections are leak proof and measurement points are closed. Check the combustion parameters.

Check the gas pressure complies with stated values.

Check the state of combustion head and heat exchanger and ensure that both are clean.

Check that there is nothing that blocks air suction and if the impulse connection is correct.

Check the gas pressure and combustion parameters.

Check the position/state of the electrode/ionization rod.

Check the fuse and electrical connections. Ensure that connections of sensors are correct and

complete. Ensure that gas pressure complies with stated

Boiler can’t reach the desired temperature.

Gas pressure

Heat exchanger Control the state of combustion chamber.

Boiler control

values and there is constant gas flow at sufficient pressure.

Control that boiler is at correct operation mod and temperature settings.

Safety valve activates often.

Safety valve

Ensure that safety valve settings are correct and works properly.

Expansion tank Check if it works properly.

Pump does not work. Pump malfunction

Check the pump electric connections and parameters. Change the pump if there is proble in pump operation.

06.06.2017 Rev. 00 34

AFTER SALES SERVICES

Dear Customer,

We believe that providing a good service is as important as providing a good product. Therefore, we continue offering wide range of comprehensive services to our conscious customers.

Our contact details for your requests and complaints:

Esentepe Mah.Milangaz Cad. No:75 K:3

Kartal Monumento Plaza

KARTAL/İSTANBUL/TÜRKİYE

Tel: +90 216 442 93 00

Fax: +90 216 370 45 03

Factory Contact Details

Türkgücü OSB

Bülent Ecevit Bulvarı No:11

ÇORLU/TEKİRDAĞ/TÜRKİYE

Tel: +90 282 685 44 80-81

Fax: +90 282 685 42 09

You can also reach us through www.ecodense.com website and servis@ecodense.com e-mail address.

Please observe the following recommendations.

• Use the product in accordance with the principles of this manual.

• For any service demands regarding the product, please contact our Service Center from the

above-mentioned phone numbers.

• Upon your purchase, register your warranty certificate during installation.

06.06.2017 Rev. 00 35

NOTES

Please record and forward your measurements and observations to us.

www.ecodense.com

06.06.2017 Rev. 00 36

Ecodense RT-65 One, RT-80 One, RT-150 One, RT-65 Twin, RT-80 Twin Installation, Operating And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual