elco R 600 Operation And Installation Manual

R600

Operation and Installation manual
for authorized technicians only

Betriebsanleitung
für die autorisierte Fachkraft

Bedienings- en Installatiehandleiding

alleen voor bevoegde vakmensen

Notice d’installation et d’emploi

réservée à l’usage des techniciens agréés

Istruzioni per l'uso

solo per il tecnico autorizzato

07/2010 DOC3070 / 12099579

Operation and Installation manual
for authorized technicians only

R 600

07/2010 DOC3070 / 12099579

Contents

2

Contents .................................................................. 2

Safety General regulations ................................... 3

Application ................................................. 3

Norms and regulations .............................. 3

Construction Layout of boiler .......................................... 4

Operating principle .................................... 4

Technical data .................................................................. 5

Extent of delivery Standard boiler .......................................... 7

Accessories ............................................... 7

Installation Boiler transport .......................................... 8

Removing the casing ................................. 9

Boiler installation ....................................... 10

Connecting the boiler ................................ 11

Commissioning Water and hydraulic system ...................... 13

Gas supply ................................................ 14

Condensate connection ............................. 14

Flue and air intake connections ................. 14

Prepare boiler for first startup .................... 15

Combustion analysis ................................. 16

Check water flow ...................................... 17

Check functionality of safety devices ........ 18

Gas tightness check .................................. 18

Boiler shut down ........................................ 18

Commissioning protocol ............................ 19

Operating instructions Controls .................................................... 20

Display / Programming .............................. 21

Overview of main functions ....................... 22

Maintenance Checklist .................................................... 23

Replacing the electrodes ........................... 23

Cleaning the condensate receptacle ......... 24

Cleaning and refilling the syphon .............. 24

Inspection of combustion chamber ............ 24

Water pressure and quality ....................... 25

Water flow rate .......................................... 25

Combustion analysis ................................. 25

Gas pressure ............................................. 25

Gas tightness check .................................. 25

Safety devices ........................................... 25

Maintenance protocol ................................ 26

Lockouts .................................................................. 27

Sensor values .................................................................. 30

Declaration of Conformity .................................................................. 31

Safety

General regulations
Application
Norms and regulations

3

General regulations

This documentation contains important
information, which is a base for safe
and reliable installation, commissioning
and operation of the R600 boiler. All
activities described in this document
may only be excecuted by authorized
companies.

Changes to this document may be ef­fected without prior notice. We accept
no obligation to adapt previously deliv­ered products to incorporate such
changes.

Only original spare parts may be used
when replacing components on the
boiler, otherwise warranty will be void.

Application

The R600 boiler may be used for heat­ing and hot water production purposes
only. The boiler should be connected to
closed systems with a maximum tem­perature of 100ºC (high limit tempera­ture), maximum setpoint temperature is
90ºC.

Norms and regulations

When installing and operating the
boiler, all applicable norms (european
and local) should be fulfilled:

Local building regulations for install-

ing combustion air and flue gas sys­tems;

Regulation for connecting the boiler to

the electrical appliance;

Regulations for connecting the boiler

to the local gas network;

Norms and regulations according to

safety equipment for heating systems;

Any additional local laws/regulations

with regard to installing and operating
heating systems.

Additional national standards

Germany:

RAL - UZ 61 / DIN 4702-8

Switzerland:

SVGW
EKAS-Form. 1942: Flüssiggas-

Richtlinie Teil 2

Vorschriften der kantonalen Instanzen

(z.B. Feuerpoilizeivorschriften)

Netherlands:

GASKEUR BASIS
GASKEUR SV
GASKEUR HR107

Belgium:

HR TOP

The R600 boiler is CE approved and
applies to the following European
standards:

 92 / 42 / EEC

Boiler efficiency directive

 2009 / 142 / EEC

Gas appliance directive

 73 / 23 / EEC

Low voltage directive

 2004 / 108 / EEC

EMC directive

EN 656

Gas-fired central heating boilers –
Type B boilers of nominal heat input
exceeding 70 kW but not exceeding
300 kW

EN 15420

Gas-fired central heating boilers ­Type C boilers of nominal heat input
exceeding 70 kW, but not exceeding
1000 kW

EN 15417

Gas-fired central heating boilers ­Specific requirements for condensing
boilers with a nominal heat input
greater than 70 kW but not exceeding
1000 kW

EN 13836

Gas fired central heating boilers ­Type B boilers of nominal heat input
exceeding 300 kW, but not exceeding
1000 kW

EN 15502-1

Gas-fired central heating boilers ­Part 1: General requirements and
tests

EN 55014-1 (2000)

Electromagnetic compatibility - Re­quirements for household appliances,
electric tools and similar apparatus ­Part 1: Emission

EN 55014-2 (1997)

Electromagnetic compatibility - Re­quirements for household appliances,
electric tools and similar apparatus ­Part 2: Immunity - Product family
standard

EN 61000-3-2 (2000)

Electromagnetic compatibility (EMC) ­Part 3-2: Limits - Limits for harmonic
current emissions (equipment input
current 16 A per phase)

EN 61000-3-3 (2001)

Electromagnetic compatibility (EMC) ­Part 3-3: Limitation of voltage
changes, voltage fluctuations and
flicker in public low-voltage supply
systems, for equipment with rated
current 16 A per phase and not sub­ject to conditional connection

EN 60335-1 (2002)

Household and similar electrical appli­ances - Safety - Part 1: General re­quirements

EN 60335-2-102 (2006)

Household an similar electrical
appliances: Particular requirements
for gas, oil and solid-fuel burning ap­pliances having electrical connections

Construction

Layout of boiler

Operating principle

4

Layout of boiler

The R600 boiler consists of the follow­ing main components:

1 Casing
2 Front panel
3 Adjustable feet
4 Control panel (below cover)
5 Flue gas connection
6 Air intake connection
(under casing)
7 Gas connection
8 Flow water connection
9 Return water connection
10 2nd (hot) return water connection
(for split system use)
11 Filling/draining valve
12 Electrical input connections
13 Frame
14 Burner/1st heat exchanger
assembly
15 2nd/3rd heat exchanger assembly
16 Water headers
17 Condensate receptacle
18 Whirlwind gas/air mixing system
19 Fan
20 Gas valve
21 Gas pressure switch
22 Inspection opening
23 Ignition and ionisation electrodes
24 Syphon
25 Removable flue gas adapter

Operating principle

The R600 is a fully modulating boiler.
The control unit of the boiler adapts the
modulation ratio automatically to the
heat demand requested by the system.
This is done by controlling the speed of
the fan. As a result, the Whirlwind mix­ing system will adapt the gas ratio to
the chosen fan speed, in order to main­tain the best possible combustion fig­ures and therewith the best efficiency.
The flue gases created by the combus­tion are transported downwards
through the boiler and leave at the back
side into the chimney connection.

The LMS14 control unit can control the
boiler operation based on:

Boiler control (stand alone operation);
weather compensated operation

(with optional outdoor sensor);

with 0-10V external influence

(temperature or capacity) from a buil­ding management system.

The return water from the system en­ters the boiler in the lower section,
where is the lowest flue gas tempera­ture in the boiler. In this section con­densation takes place. The water is
being transported upwards through the
boiler, in order to leave the boiler at the
top (burner) section. The cross flow
working principle (water up, flue gas
down) ensures the most efficient com­bustion results.

1 5 4 2 7 6

3 8 12 9 10

14 22 23 18, 19, 20, 21 25

13 24 15 16 17 11

Technical data

5

R601 R602 R603 R604 R605 R606 R607
Nominal heat output at 80/60ºC max/min*

kW 142.1/23.3 190.1/39.5 237.2/39.5 285.2/39.5 380.2/76.6 475.3/76.6 539.0/76.6

Nominal heat output at 75/60ºC max/min*

kW 142.2/23.5 190.3/39.5 237.4/39.5 285.5/39.5 380.6/76.6 475.8/76.6 539.6/76.6

Nominal heat output at 40/30ºC max/min*

kW 150.7/26.7 201.6/45.2 251.4/45.1 302.3/45.2 403.1/87.7 503.9/87.7 571.5/87.7

Nominal heat input Hi max/min*

kW 145.0/24.5 194.0/41.5 242.0/41.5 291.0/41.5 388.0/80.5 485.0/80.5 550.0/80.5

Efficiency at 80/60ºC

% 98.0

Efficiency at 40/30ºC % 103.9
Annual efficiency (NNG 75/60ºC)

% 106.8

Annual efficiency (NNG 40/30ºC)

% 110.4

Standstill losses (T

water

= 70ºC) % 0.21 0.18 0.17 0.16 0.15 0.14 0.13

Max. condensate flow

l/h 11 15 19 22 30 37 42

Gas consumption H-gas max/min (10,9 kWh/m

3

) m3/h 13.3/2.3 17.8/3.8 22.2/3.8 26.7/3.8 35.6/7.4 44.5/7.4 50.5/7.4

Gas consumption L-gas max/min (8,34 kWh/m

3

) m3/h 17.4/2.9 23.2/5.0 29.0/5.0 34.9/5.0 46.5/9.7 58.2/9.7 66.0/9.7

Gas consumption LL-gas max/min (8,34 kWh/m

3

) m3/h 17.4/2.9 23.2/5.8 29.0/5.8 34.9/5.8 46.5/11.2 58.2/11.2 66.0/11.2

Gas consumption LPG. max/min (12,8 kWh/kg)

kg/h 11.3/1.9 15.2/3.2 18.9/3.2 22.7/3.2 30.3/6.3 37.9/6.3 43.0/6.3

Gas pressure H-gas

mbar 20

Gas pressure L/LL-gas

mbar 25

Gas pressure LPG

mbar 30/50

Maximum gas pressure

mbar 100

Flue gas temperature at 80/60ºC max/min

ºC 78/61

Flue gas temperature at 40/30ºC max/min

ºC 56/30

Flue gas quantity max/min*

m

3

/h 238/40 318/69 397/69 477/69 636/134 795/134 901/134

CO

2

level natural gas H/E/L/LL max/min % 10.2/9.4

CO

2

level liguid gas P max/min % 11.9/10.0

NOx level max/min

mg/kWh 35/15

CO level max/min

mg/kWh 14/8

Max. permissible flue resistance max/min

Pa 160/10 160/10 200/10 200/10 200/10 250/10 250/10

Water volume

l 27 31 35 61 68 75 82

Water pressure max/min

bar 8/1

Max. water temperature (High limit thermostat)

ºC 100

Maximum temperature setpoint

ºC 90

Nominal water flow at dT=20K

m

3

/h 6.1 8.1 10.2 12.2 16.3 20.4 23.1

Hydraulic resistance at nominal water flow

kPa 10 18 28 15 27 42 55

Electrical connection

V 230/400

Frequency

Hz 50

Mains connection fuse

A 16

IP class

- IP20

Power consumption boiler max/min (excl. pump)

W 158/43 200/35 230/35 260/35 470/61 650/61 770/61

Power consumption 3-step pump (optional)

W 170/90 190/120 380/210 380/210 530/300 720/380 1150/600

Power consumption speed controlled pump (opt)

W 180/10 180/10 435/25 435/25 450/25 800/35 800/35

Power consumption bypass pump (optional)

W 55/35 85/65 170/90 170/90 190/120 460/225 470/280

Weight (empty)

kg 295 345 400 465 535 590 650

Noise level at 1 meter distance dB(A) 59
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063BS3840
Water connections

- R2" DN65 PN16

Gas connection

- R3/4" R1" R1" R1" R1.1/2" R1.1/2" R1.1/2"

Flue gas connection

mm 150 150 200 200 250 250 250

Air intake connection (for room sealed use)

mm 130 150 150 150 200 200 200

Condensate connection

mm 40 40 40 40 40 40 40

* min load on gasses H/L/LPG. For type R602-R607 on gasses LL-Gas min value is 15% higher.

Technical data

6

Dimension R601 R602 R603 R604 R605 R606 R607

L mm 1105 1260 1470 1220 1435 1585 1735

L2 mm 127.5 127.5 137.5 137.5 187.5 187.5 187.5

H mm 1480 1480 1500 1500 1500 1500 1500

H2 mm 1120 1130 1130 1150 1245 1245 1245

B mm 670 670 670 770 770 770 770

B2 mm 225 235 235 235 215 215 215

B3 mm 260 260 260 310 310 310 310

B4 mm 260 260 260 490 490 490 490

B5 mm 130 130 130 245 245 245 245

D1 mm (Diam.) 130 150 150 150 200 200 200

D2 mm (Diam.) 150 150 200 200 250 250 250

W1 R" / DN R2" R2" R2" DN65 PN16

W2 R" / DN R2" R2" R2" DN65 PN16

G R R 3/4" R 1" R 1" R 1" R 1 1/2"

1 Electrical connections
2 Gas supply
3 Water supply
4 Water return (Cold)
5 Air Intake (under casing)
6 Water 2nd return (Hot)
7 Boiler water drain valve 1/2"
8 Flue gas Outlet
9 Condensate drain
flexible hose 25mm diam.

Extent of delivery

Standard boiler
Accessories

7

Standard boiler

A boiler delivery package contains the
following components:

The above accessories are specially
designed for the R600 boiler and there­with easy to install (plug and play). By
choosing a combination of the kits men­tioned above, you can create your own
complete system solution. Ask your
supplier for more detailed information.

Extension module AVS75 for heating

zone control or external gas valve
and/or room fan control.
For each boiler a maximum of 3
AVS75 modules (2x heating zone, 1x
ext. gas valve / room fan) can be inte­grated in the boiler;

Additional RVS63 heating zone con-

troller, when controlling more than 2
zones (incl. wall hung box, all neces­sary sensors and sockets and con­nection material for bus communica­tion).

Component Pcs. Package

Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border,

sealed in PE foil

Adjustable feet 4 Mounted on frame of the boiler

Syphon for condensate connection 1 Cardboard box on top of heatexchanger

(under casing)

Conversion kit for natural gas L and propane incl. instruction 1 Cardboard box on top of heatexchanger

(under casing)

Operation and Installation manual 1 Map attached to back panel of the boiler

Spare parts list 1 Map attached to back panel of the boiler

Wiring diagram 1 Map attached to back panel of the boiler

Accessories

Additional to the boiler, the following
accessories can be ordered:

Standard 3-step pump incl. connec-

tion kit;

Speed controlled pump incl. connec-

tion kit;

Safety valve, manometer and de-

aerator (3,4,5 or 6 bar) incl. connec­tion kit;

2x max. water pressure switch and 1

external high limit thermostat incl.
connection kit;

Gas filter incl. connection kit;
Max. gas pressure switch;
External high limit thermostat incl.

connection kit;

Gas valve leakage tester (not possi-

ble for R601);

Controlled bypass (incl. pump) incl.

connection kit;

Plate heat exchanger (dT=10K/15K or

dT=20K) incl. connection kit;

Low velocity header, suitable for

dT=10K/15K and dT=20K incl. con­nection kit;

Duo header for connecting 2 boilers

in cascade (excl. connection kit);

Installation

Boiler transport

8

Boiler transport

The R600 boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The maximum width is
670mm for models R601-R603 and
770mm for models R604-R607, which
makes it possible to transport all mo­dels through a normal door in one pie­ce. The boiler can be transported with a
pallet truck, entering either from the
front or from the side.
Whenever necessary, the boiler can be
dismantled into smaller parts for easier
transport inside the building. The table
below shows the main dismantled parts
with their weight and dimensions.

When the boiler has to be transported
with a crane, it is necessary to remove
the casing before connecting the boiler
to the crane. Always connect the crane
to the frame of the boiler by using
straps.

Component R601 R602 R603 R604 R605 R606 R607

Burner/1st heat exchanger assembly Weight [kg]

Length [mm]

Width [mm]

Height [mm]

86
735
400
321

100
885
400
321

112

1035

400
321

135
735
680
321

158
885
680
321

181

1035

680
321

198

1185

680
321

2nd/3rd heat exchanger assembly Weight [kg]

Length [mm]

Width [mm]

Height [mm]

90
735
400
244

103
885
400
244

116

1035

400
244

150
735
680
244

170
885
680
244

198

1035

680
244

219

1185

680
244

Condensate receptacle

Weight [kg]

Length [mm]

Width [mm]

Height [mm]

7
589
385
225

9
739
385
225

10
889
385
225

11
589
665
225

12
739
665
225

13
889
665
225

15

1039

665
225

Frame

Weight [kg]

Length [mm]

Width [mm]

Height [mm]

15
990
624
335

16

1140

624
335

17

1350

624
335

17

1100

724
335

18

1320

724
335

19

1470

724
335

21

1620

724
335

Front U-frame with electronic board Weight [kg]

Length [mm]

Width [mm]

Height [mm]

11
628

1304

202

11

628

1304

202

11

628

1304

202

12

728

1304

202

12

728

1304

202

12

728

1304

202

12

728

1304

202

1 Hoisting belt (4x)
2 Wooden retaining beam (2x)
3 Hoisting belt position (4x)

1
2

3

Installation

Removing the casing

9

Boiler transport
Remove the casing before transporting
the boiler, in order to avoid damage to
the casing parts during transportation.
Removing the casing is done as fol­lows:

1.

2.

3.

4.

5.

6.

Installation

Boiler installation

Boiler installation

The boiler should be positioned in a
frost-proof boiler room. If the boiler
room is on the roof, the boiler itself may
never be the highest point of the instal­lation.
When positioning the boiler, please
note the recommended minimum clea­rance in the picture. When the boiler is
positioned with less free space, mainte­nance activities will be more difficult.
Once the boiler is in the correct positi­on, the wooden blocks (1) should be
removed and the adjustable feet (2)
(with vibration absorption dampers)
should be adjusted to the right height.
Water and gas connections should be
done after mounting the feet, as they
affect the exact height of all connecti­ons.

10

1

2 2

Installation

Connecting the boiler

11

Connecting the boiler

This chapter will explain how to make
all connections to the boiler with regard
to:

Hydraulic connections
Condensate drain connection
Gas connection
Flue gas connection
Air intake connection

(under casing)

Electrical connection

The boiler should always be connected
in such a way, that the system applies
to all relevant standards and regulati­ons (European, national and local). It’s
the responsibility of the installer to en­sure that all standards and regulations
are respected.

Hydraulic connections

The boiler should always be connected
in such a way, that water flow through
the boiler can be ensured at all times.
Connect the flow (4) and return (5) con­nection of the system tension free to
the boiler connections. If the boiler is
used in a system with two return cir­cuits, the common return becomes the
low temperature return, the 2nd return
connection (6) is the high temperature
return (remove cap/flange before con­necting).

The (optional) accessory kit with safety
valve, manometer and deaerator
should be mounted on the flow connec­tion (4) of the boiler, before connecting
to the system.

The (optional) pump kit should be
mounted directly to the return connecti­on (5) of the boiler, before connecting
to the system.

Condensate connection (8)
After filling with water, the syphon
(included in delivery) should be in­stalled to the connection at the bottom
of the condensate receptacle. Lead the
hose under the frame at the back of the
boiler and connect it to the draining
system in the boiler room. The connec­tion to the draining system should al­ways be done with an open connection,
in order to avoid a flooding of the boiler
in case of a blocked drain.

8

1 3

4 5 6

Installation

Connecting the boiler

12

Gas connection (1)

The gas connection must be made by
an authorized installer in accordance
with the applicable national and local
standards and regulations.

Connect the gas line from the system
tension free to the gas connection (1) of
the boiler. A gas cock should be moun­ted directly behind the boiler.

A gas filter can be mounted directly on
the gas connection of the boiler.

Flue gas connection (7)

Regulations for the construction of flue
gas systems are very different for each
country. It should be ensured that all
national regulations with regard to flue
gas systems are respected.

Connect the flue gas system to the flue
gas connection (7) of the boiler, use
fluegas systems with seamless connec­tions only. It’s not necessary to make a
separate condensate drain for the flue
gas system, as the condensate will be
drained via the syphon of the boiler.
Please note the following issues:

It’s recommended to use stainless

steel or PPS fluegas systems

The diameter of the flue gas system

must be chosen by calculation ac­cording to the national regulations

Construct the flue gas system as

short as possible (for maximum
length see planner documentation)

Construct horizonal ways with a mini-

mum angle of 3º

Air intake connection (3)

The air intake can be connected in ca­se of room sealed installation. The co­ver (3) must be disassembled in order
to connect the air intake piping to the
connector inside the boiler. The diame­ter should be calculated according to
the national regulations, together with
the flue gas system. The total resistan­ce of both systems should never over­come the maximum permissible resis­tance of the fan inside the boiler (see
also chapter: Technical data).

Electrical connection

The electrical connection must be ma­de by an authorized installer in
accordance with the applicable national
and local standards and regulations.

For the power supply it’s necessary to
use a mains isolator switch with a con­tact opening of at least 3 mm
within the boiler room. This switch can
be used to switch off the power supply
for maintenance purposes.

All cables should be lead through the
cable glant (2) from the back of the
boiler boiler into the electro panel
(11).

Connect all wires to the terminals
according to the wiring diagram of the
boiler (enclosed in map attached to
back panel of the boiler).

1 7 3

2

11

Commissioning

Water and hydraulic system

13

Water quality

The system should be filled with water
with a PH value between 8,0 and 9,5.
The chloride value of the water should
not exceed 50 mg/l. Entry of oxygene
by diffusion should be prevented at all
times. Damage to the heat exchanger
because of oxygene diffusion will not
be taken under warranty.

Boiler output

[kW]

Max. sum of alkaline earths

[mol/m3]

Max. total hardness

[dºH]

50 - 200 2.0 11.2

200 - 600 1.5 8.4

Concentrate

Ca(HCO3)2

Capacity of installation Q (kW)

150 200 250 300 400 500 600

mol/m

3

dºH Maximum water (re)fill volume V

max

[m3]

≤0.5 ≤2.8 - - - - - - -

1.0 5.6 - - - - - - -

1.5 8.4 3 4 5 6 8 10 12

2.0 11.2 3 4 5 6 6.3 7.8 9.4

2.5 14.0 1.9 2.5 3.1 3.8 5.0 6.3 7.5

≥3.0 ≥16.8 1.6 2.1 2.6 3.1 4.2 5.2 6.3

Minimum operating

pressure

[bar]

Flow tempe-

rature

[ºC]
> 1.5 90
> 1.0 80

Water pressure

Open the valves to the system. Check
the water pressure in the system. If the
water pressure is too low (see table
below), increase the pressure up to at
least the minimum required water
pressure in the table.
Filling can be done via the fill and drain
valve (2) on the return connection (1) of
the boiler.

1

2

Hydraulic system

Check if the boiler is hydraulically con­nected to the system in such way, that
water flow can be secured at all times
during burner operation. The water flow
is supervised by the water flow switch
in the boiler and a lack of flow will lead
to a direct burner stop and lockout of
the boiler.

Commissioning of the boiler should be
carried out by authorized personnel
only. Failure to respect this condition
makes the guarantee void. A protocol
of the commissioning should be filled
out (see end of this chapter for example
of commissioning protocol).

This chapter explains the commissio­ning of the boiler with the standard boi­ler controller. When an additional sys­tem controller is installed, please refer
to its manual for commissioning the
controller.

In installations with higher water volu­mes, it’s necessary to respect the maxi­mum filling and additional volumes with
corresponding hardness values as sta­ted in the german VDI2035 standard. In
the table you can find the nominal va­lues for filling and additional water for
the R600 according to the the VDI2035.

The table at the left gives an indication
of the relation between the water quali­ty and the maximum water filling volu­me during the lifetime of the boiler.
Consult the original text of the VDI2035
for more detailed information.

Commissioning

Gas supply
Condensate connection
Flue and air intake connections

14

Gas supply

Check the gas supply connection to the
boiler for tightness. If any leakage is
found, reseal the leakage before star­ting the boiler!

Remove any air between the gas valve
and the gas line. This can be done at
the test point (1) at the gas pressure
switch. Don’t forget to close the test
point afterwards!

Check the gas type and values with the
local gas company, in order to know for
which gas type the boiler should be
commissioned.
Consult the conversion kit instruction if
the boiler is to be installed with natural
gas L or LPG.

Condensate connection

Remove the syphon (2) from the con­densate connection. Fill it with water
and place it back in the original positi­on. Make sure the syphon is filled
before starting the boiler, in
order to prevent flue gases dischar­ging through the condensate connec­tion!

Flue and air intake connections

Check whether the flue and air intake
systems are made according to the
national and local regulations. Installati­ons which don’t comply with the regula­tions, are not allowed to be commissio­ned.

Make sure that all connections are free.

The size of flue gas and air intake con­nections may not be reduced.

1

2

Commissioning

Prepare boiler for first startup

15

1

M

H

B C D E F

I

L

G

A

Legend:

A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I Operation mode heating zone(s)
L Display
M Operation mode DHW

Preparation for first startup

Open the gas supply;
Enable the power supply to the boiler;
Switch on the boiler with the on/off

switch (1);

Make sure the boiler is in standby

mode (K);

Check the pump operation: make

sure the pump runs in the right
direction;

Release all air from the pump motor.

It‘s recommended to put the boiler on
50% load after the first startup, as this
is the best starting point to do a proper
combustion analysis. This can be done
with the following procedure:

Push button I >3 Sek, the boiler goes

into controller Stopp mode.

Push the Info button (G), the actual

boiler load (%) appears in the display;

Choose „set up“ (confirm with OK

button), now the boiler load can be
changed by rotating the wheel (C)
and confirming the 50% setting with
the OK button.

After checking the combustion values
(see next page), the controller Stopp
mode can be stopped by pushing the
control mode button (I) >3 Sek.

Commissioning

Combustion analysis

16

Combustion settings

for natural gas G20 / G25

R601-R607
CO

2, max

% 10.2 ± 0.2

CO

max

ppm < 30

Combustion settings

for LPG G31

Convert boiler before operation

(see coversion kit instruction)

R601-R607
CO

2, max

% 11.9 ± 0.2

CO

max

ppm < 30

Combustion check at full load

Start the boiler in controller stop mode
and go to 50% load. Now the boiler
operates at 50% load. Allow the boiler
to stabilise the combustion for 3
minutes. Then increase the boiler load
step by step up to 100%. Check the
gas pressure on the inlet of the gas
valve while increa-sing the boiler load:
the gas pressure should never go
below the minimum required value 
see technical data. Set the minimum
gas pressure switch (1) at 75% of the
required gas pressure.

Check the combustion settings via the
test point in the chimney connection(3).
If necessary, correct the settings with
the flat adjustment screw on the outlet
of the gas valve (2).

Combustion settings

for natural gas G20 / G25

R601-R607
CO

2, min

% 9.4 ± 0.2

CO

min

ppm < 30

Combustion settings

for LPG

G31

Convert boiler before operation

(see coversion kit instruction)

R601-R607
CO

2, min

% 10.0 ± 0.2

CO

min

ppm < 30

Combustion check at minimum load

Switch the boiler to minimum load (0%).
Check the combustion settings the
same way as described for full load. If
necessary, correct the settings with the
allen key adjustment screw on either
side of the gas valve (4).

Combustion check at 50% load

An additional reference check of com­bustion values at 50% load is recom­mended in order to check if the gas
valve is set in such way, that the modu­lating behaviour is normal. The CO

2

value should be in between the settings
of full load and minumum load. CO
value should be equal to full load and
minimum load values.

Make sure that the boiler is set to auto­matic operation and controller stop mo­de is disabled after the combustion test
is finished.

2

4

R601

R602 - R607

1

2
4

3

Commissioning

Check water flow

17

q

actual

= (∆T

nominal

/ ∆T

measured

) * q

nominal

[m3/h]

Water flow data
R601 R602 R603 R604 R605 R606 R607
Nominal flow rate [m

3

/h] 6.1 8.1 10.2 12.2 16.3 20.4 23.1

∆T at nominal flow rate [ºC] 20
∆p at nominal flow rate [kPa] 10 18 28 15 27 42 55

Check water flow

The water flow through the boiler can
be checked with two different methods
shown below.

∆T measurement

Check the temperature difference over
the boiler (∆T flow-return) when the
boiler is running on 100% load. The
nominal ∆T is 20K and must be at least
between 15K and 25K for secure boiler
operation. An indication of the actual
flow rate can be found with the follo­wing calculation (see table below for
nominal data):

q

actual

= √(∆p

measured

/ ∆p

nominal

) * q

nominal

[m3/h]

∆p measurement

Check the pressure difference over the
boiler (∆p flow-return) when the boiler
pump is running (burner on is not requi­red). The nominal ∆p for each boiler
type can be found in the table below,
actual ∆p must be within:

0.35*Δp

nom

≤ ∆P ≤ 1.75*∆p

nom

. An
indication of the actual flow rate can be
found with the following calculation (see
table below for nominal data):

Commissioning

Check functionality of safety devices
Gas tightness check
Boiler shut down

18

5
4

6

Flow temperature sensor (1)

Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 20.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.

Return temperature sensor (2)

Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 40.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.

Flue gas temperature sensor (3)

Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 28.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
.

Minimum gas pressure switch (5)

Close the gas cock when the boiler is in
standby position (

K). Open the test

point on the gas line (4) while measur­ing the gas pressure on the test point
of the gas pressure switch (5).
The boiler will go in lockout no. 2 when
the switch off setting is achieved. Close
both test points and open the gas cock.

Check functionality of safety devices

All safety devices have to be checked
on good functioning. Safety devices on
a standard boiler are a water flow tem­perature sensor, fluegas temperature
sensor, water flow switch minumum
gas pressure switch and ionisation
electrode. These devices can be
checked as described below.

Ionisation electrode (6)

Remove electrical connection from the
ionisation electrode while the boiler is
running, the boiler will go in lockout no.

128. The boiler will try to restart. With
the electrical connection removed, the
restart will result in lockout no. 133.
When the connection is already
mounted, the restart will be successful.

Measuring the ionisation current can
be done by mounting a multi-meter (set
to µA) in between the ionisation elec­trode and its electrical connection. The
ionisation current should always be
above 1.2 µA, in normal conditions it
will be 6 µA and above.

Gas tightness check

Check the gas tightness of all sealed
connections with an approved soap or
electronic gas analyzer, for example:

Test points
Bolt connections
Gaskets of mixing system, etc.

Boiler shut down

When the boiler will not be used for
longer periods, shut down the boiler by
following procedure:

Switch the boiler in standby operation

(K)

Switch off the boiler with the on/off

switch (7)

Disable power supply to the boiler by

deactivating the mains isolator switch
in the boiler room

Close the gas supply to the boiler.

7

1 2 3

Commissioning

Commissioning protocol

19

Commissioning Protocol R600

Project

Boiler type Project
Serial number Address
Year City
Nominal load (Hi) [kW] Date
Nominal output (Hi) [kW] Engineer
System
Water pressure [bar] Installati-

on:

Roof top



Water pH [-] Ground floor



Water hardness [dºH] Basement



Water chloride [mg/l] Other: .........................



Water ∆T full load [ºC] Hydrau-

lics:

Low velocity header



Water ∆p

boiler

[kPa] Plated heat exchanger



Water flow [m

3

/h] Bypass boiler



Pump setting [-] Other: .........................


Safety devices
High limit setting [ºC] Water flow sensor checked


Temp. limiter setting [ºC] Fluegas sensor checked


Min. gas pressure switch setting [mbar] Water flow switch checked


Ignition time burner [sec]

Combustion analysis

100% load 50% load Min. load

Gas consumption [m

3

/h] [m3/h] [m3/h]
Gas pressure [mbar] [mbar] [mbar]
CO

2

[%] [%] [%]

O

2

[%] [%] [%]
CO [ppm] [ppm] [ppm]
NOx [ppm] [ppm] [ppm]
T

atmospheric

[ºC] [ºC] [ºC]

T

fluegas

[ºC] [ºC] [ºC]

T

water, flow

[ºC] [ºC] [ºC]

T

water, return

[ºC] [ºC] [ºC]
Ionisation current [µA] [µA] [µA]
p

fan

[mbar] [mbar] [mbar]

p

top panel

[mbar] [mbar] [mbar]

p

combustion chamber

[mbar] [mbar] [mbar]

Remarks

Operating instructions

Controls

20

Confirmation (OK) (D)
Return (ESC) (B)

These buttons are used for program­ming in combination with the wheel.

By pressing the ESC button it‘s possible
to go back one level, changed values
are not taken over by the controller.

By pressing the OK button it‘s possible
to arrive in the next level or confirm
changed values.

Manual mode (E)

This button is used for switching the
boiler into manual mode. In manual
mode all pumps will run and the mixing
valves are no longer controlled, the bur­ner setpoint is 60°C (indicated by span­ner symbol).

On/off switch (A)

Position 0:
Boiler and connected electrical compo­nents are no powered. Frost protection
is not secured.

Position I

The boiler and connected electrical
components are powered and standby
for operation.

Operation mode DHW (M)

For switching on the DHW operation
(indication in display below DHW sym­bol)

Operation mode heating zone(s) (I)

For setting 4 different heating modes:
Auto (clock): Automatic operation by
time programm
Comfort (sun): 24/7 heating in comfort
mode
Reduction (moon): 24/7 heating in re­duced mode
Standby: heating off, frost protection
activated.

Display (L)

Info mode (G)

Display possibility of following info
without influence on boiler control:
temperatures, operation mode
Heating / DHW, error code.

Room temperature control (C)

 for changing room comfort tempe-

rature

 for changing settings when pro-

gramming.

Deaeration mode (E)

By pressing the manual mode button
longer than 3 seconds, the automatic
hydraulic deaeration is activated. During
deaeration the system is put in standby
mode

The pumps are switched on and off for
several times.
After deaeration, the boiler automatically
returns to normal operation.

Chimney sweeper mode (F)

Used for combustion analysis. By pres­sing the button once again, or automati­cally after 15 minutes, the chimney swee­per mode will be deactivated (indicated
by spanner symbol).

Reset button (H)

By shortly pressing the reset button a
burner lockout can be cancelled.

M

H

B C D E F

I

L

G

A

Legend:

A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I Operation mode heating zone(s)
L Display
M Operation mode DHW

21

Operating instructions

Display / Programming

- gewünschtes Menü

auswählen

- mit Taste OK bestätigen

- mit Taste ESC zurück
zur Grundanzeige

- gewünschte Benutzer-Ebene auswählen

- mit Taste OK bestätigen

- gewünschtes Menü auswählen

- mit Taste OK bestätigen

- mit Taste ESC zurück zur Grundanzeige

DHW mode selection

Heating operation mode selection
(Controller Stopp mode when
pressing > 3 sec.)
Display

Info button

Confirm
Manual mode
(Deaeration mode when pressing
> 3 sec.)

Chimney sweeper mode

Enduser

- choose menu

- confirm with OK button

- choose parameter

- confirm with OK button

- change value + - with wheel

- confirm with OK button

- return to main menu with ESC button

Commissioning Expert

- choose user level

- confirm with OK button

- choose menu

- confirm with OK button

- choose parameter

- confirm with OK button

- change value + - with wheel

- confirm with OK button

- return to main menu with ESC button

Programming

Select

(turn left/right)

Quit menu

Reset

Press OK (1x)

Press OK (1x)

Press INFO (4 sec.)

Default mode

(buttons)

Heating to comfort setpoint Info level activated
Heating to reduced setpoint Programming activated

Heating for frost protection setpoint Heating temporarily
switched off

Process running – please weit ECO function active

Burner operating (only oil / gas boiler)

Error messages

Info level activated

Programming activated
Heating temporarily switched off

ECO function active

Holiday function active

Reference to heating circuit

Maintenance / special operation
Parameter number

22

Operating instructions

Overview of main functions

Button Action Procedure Display / Function

Set room temperature

Zone 1 and zone 2

Actuate wheel left/right
Turn wheel
Confirm with OK button
or wait 5 sec.
or press

Comfort setpoint with blinking temperature
Blinking temperature in 0,5 °C steps from 10 to 30 °C

Comfort setpoint saved
Comfort setpoint cancelled

- after 3 sec. Main menu appears

Set room temperature for
zone 1 or zone 2

Zone 2 independent from zone 1

Actuate wheel left/right
Confirm with OK button
Actuate wheel left/right
Confirm with OK button
or wait 5 sec.
or press

Choose heating zone
Heating zone is chosen
Blinking temperature in 0,5 °C steps from 10 to 30 °C

Comfort setpoint saved
Comfort setpoint cancelled

- after 3 sec. Main menu appears

Switch on /off DHW ope­ration

Press button DHW mode on / off

(see indication below DHW symbol)

- On: DHW mode by time programm

- Off: no DHW operation

- Safety functions activated

Change heating operation
mode

Factory setting

Press button 1x

Press button 1x again

Press button 1x again

Automatic mode on, with:

- Heating by time programm

- Temperature setpoint by heating programm

- Safety functions activated

- Summer/Winter automatic switching activated

- ECO-functions activated
(see indication below operation symbol)
Continuous COMFORT heating on, with:

- Heating without time programm by comfort setpoint

- Safety functions activated
Continuous REDUCED heating on, with:

- Heating without time programm by reduced setpoint

- Safety functions activated

- Summer/Winter automatic switching activated

- ECO-functions activated
Safety mode on, with:

- Heating off

- Temperature by frost protection

- Safety functions activated

Controller Stop mode Press button > 3 sec.

Press button > 3 sec. again

304: Controller Stopp mode insert setpoint

after 3 sec. Main menu appears

Info display

Press button 1x
Press button 1x again
Press button 1x again
…..

Press button 1x

INFO Segment displayed

- Status Boiler - room temperature

- room temperature minimum

- Status DHW - room temperature maximum

- Status zone 1 - outside temperature

- Status zone 2 - outside temperature minimum

- outside temperature maximum

- Time / Date - DHW temperature 1

- Error indication - Boiler temperature

- Maintenance indication - Flow temperature
(Info display depends on configuration)
Back to main menu; INFO Segment disappears

Operation by manual
setpoint

Change factory setting
boiler temperature

Press button 1x

Press button
Press button
Turn wheel -/+
Press button
Press button
Press button

Manual mode on (spanner symbol appears)

- Haeting by fixed setpoint
(factory setting = 60 °C)

301: Manual mode insert setpoint?

blinking temperature
set value

Status boiler

Manual mode off (spanner symbol disappears)

Deaeration Press button > 3 sec.

Press button > 3 sec. again

312: Deaeration on
Deaeration off

Activate chimney sweeper

mode

Press button (< 3 sec.)
Press button again (< 3 sec.)

Chimney sweeper mode on
Chimney sweeper mode off

Temporary reduction of

reduced temperature on
QAA75

Press button
Press button again

Heating by reduced setpoint
Heating by comfort setpoint

RESET Reset button Press button (< 3 sec.)

Press button again > 3 sec.

Boiler manually blocked, no release
Boiler released, Alarm symbol disappears

= confirmation

= cancel, return to main
menu

Maintenance

Checklist
Replacing the electrodes

23

Maintenance of the boiler should be
carried out by authorized personnel
only.

In order to ensure continued good and
safe operation of the boiler, it should be
inspected at least once per year. A
maintenance protocol should be filled
out (see end of this chapter for example
of maintenance protocol).

Checklist

The following activities must be carried
out, see following paragraphs for an
extensive description of the main activi­ties:

Replace the ignition and ionisation

electrodes;

Clean the condensate receptacle;
Clean and refill the syphon;
Inspect the combustion chamber,

clean if necessary;

Check the water pressure of the sys-

tem;

Check the water quality of the system

water as well as supply water;

Check the water flow rate through the

boiler;

Check/correct the combustion values

at full and mimimum load with a com­bustion analyzer;

Check the gas pressure to the boiler;
Check the tightness of all sealed con-

nections and test points;

Check the functionality of all safety

devices;

Fill out a maintenance protocol.

Replacing the electrodes

The electrodes are positioned on the
right hand side of the boiler. Replace
the ignition elektrode (1) and ionisation
eclectrode (2) as shown on the picture.

2

1

Maintenance

Cleaning the condensate receptacle
Cleaning and refilling the syphon
Inspection of combustion chamber

24

5

6

7

Cleaning the condensate receptacle

Disconnect the plug of the fluegas

temperature sensor (1);

Remove the internal fluegas pipe (2)

of the boiler in order to create access
to the condensate receptacle;

Clean the receptacle (3);
Mount the fluegas pipe back in positi-

on when the cleaning is finished;

Connect the plug of the fluegas tem-

perature sensor.

Inspection of combustion chamber

The inspection opening is positioned on
the left hand side of the boiler.

Remove the radiation panel (5) from

the heat exchanger;

Remove the cover (6) from the in-

spection opening;

Inspect the combustion chamber (7),

clean if necessary;

Mount the cover and radiation panel

back in original position.

Cleaning and refilling the syphon

Remove the syphon (4) from the con-

densate connection;

Clean and fill it with fresh water;
Mount the syphon back in the original

position.

4

1

3

2

Maintenance

25

Water pressure and quality

Check if the water pressure and quality
meet the requirements. Consult the
chapter “commissioning: water and
hydraulic system” for more detailed
information.

Water flow rate

Check if the water flow rate through the
boiler is within the limits. Consult the
chapter “commissioning: check water
flow” for more detailed information.

Combustion analysis

Check the combustion at full load and
minumum load, correct the settings if
necessary. An additional reference
check at 50% load is recommended.
Consult the chapter “commissioning:
combustion analysis” for more detailed
information.

Gas pressure

Check the dynamic pressure of the gas
supply to the boiler, when the boiler is
running at full load. In case of a boiler
cascade, all boilers should be running
at full load. See technical data for re­quired values.

Gas tightness check

Check the tightness of all sealed con­nections with an approved soap or
electronic analyzer, for example:

Test points;
Bolt connections;
Gaskets of mixing system, etc.

Safety devices

Check the functionality and the settings
of all safety devices connected. Consult
the chapter “commissioning: Check
functionality of safety devices” for more
detailed information.

Maintenance

Maintenance Protocol

26

Maintenance Protocol R600

Project

Boiler type Project
Serial number Address
Year City
Nominal load (Hi) [kW] Date
Nominal output (Hi) [kW] Engineer
System
Water pressure [bar]
Water pH [-]
Water hardness [dºH]
Water chloride [mg/l]
Water ∆T full load [ºC]
Water ∆p

boiler

[kPa]

Water flow [m

3

/h]
Pump setting [-]
Safety devices
High limit setting [ºC] Water flow sensor checked



Temp. limiter setting [ºC] Fluegas sensor checked



Min. gas pressure switch setting [mbar] Water flow switch checked



Ignition time burner [sec]

Combustion analysis

100% load 50% load Min. load

Gas consumption [m

3

/h] [m3/h] [m3/h]
Gas pressure [mbar] [mbar] [mbar]
CO

2

[%] [%] [%]
O2 [%] [%] [%]
CO [ppm] [ppm] [ppm]
NOx [ppm] [ppm] [ppm]
T

atmospheric

[ºC] [ºC] [ºC]

T

fluegas

[ºC] [ºC] [ºC]

T

water, flow

[ºC] [ºC] [ºC]

T

water, return

[ºC] [ºC] [ºC]
Ionisation current [µA] [µA] [µA]
p

fan

[mbar] [mbar] [mbar]

p

top panel

[mbar] [mbar] [mbar]

p

combustion chamber

[mbar] [mbar] [mbar]

Remarks

27

In case of a lockout, a warning symbol ( ) and a flashing error code appears on the display. The cause of a fault should first
be determined and eliminated before the boiler is being reset. The table below shows all possible lockouts with indication of
possible cause.

Lockouts

Error
code

Description of error

0 No error
10 Outside temperature sensor error
20 Boiler temperature 1 sensor error
26 Common flow temperature sensor error
28 Flue gas temperature sensor error
30 Flow temperature 1 sensor error
32 Flow temperature 2 sensor error
38 Flow temperature primary controller sensor error
40 Return temperature 1 sensor error
46 Return temperature cascade sensor error
47 Common return temperature sensor error
50 DHW temperature 1 sensor error
52 DHW temperature 2 sensor error
54 DHW primary controller sensor error
57 DHW circulation temperature sensor error
60 Room temperature 1 sensor error
65 Room temperature 2 sensor error
70 Buffer storage tank temperature 1 sensor error
71 Buffer storage tank temperature 2 sensor error
72 Buffer storage tank temperature 3 sensor error
73 Collector temperature 1 sensor error
74 Collector temperature 2 sensor error
82 LPB address collision
83 BSB wire short-circuit
84 BSB address collision
85 BSB RF communication error
91 EEPROM error lockout information
98 Extension module 1 error (collective error)
99 Extension module 2 error (collective error)

100 2 clocktime masters (LPB)
102 Clocktime master without reserve (LPB)
103 Communication error
105 Maintenance message
109 Boiler temperature supervision
110 STB lockout
111 TW cutout
121 Flow temperature 1 (HC1) supervision
122

Flow temperature 2 (HC2) supervision

125 Pump supervision error
126 DHW charging supervision
127 Legionella temperature not reached

128 Loss of flame during operation
129 Fan error or LP error

130

Flue gas temperature limit exceeded

131

Burner fault

132 GP or LP error
133 No flame during safety time
146 Configuration error collective message

Lockouts

28

Error
code

Description of error

151 Internal error
152 Parameterization error
153 Unit manually locked
160 Fan error
162 LP error, does not close
164 Error heating circuit flow switch
166 LP error, does not open
171 Alarm contact H1 or H4 active
172 Alarm contact H2 (EM1, EM2 or EM3) or H5 active
173 Alarm contact H6 active
174 Alarm contact H3 or H7 active
178 Limit thermostat heating circuit 1
179 Limit thermostat heating circuit 2
183 Unit in parameterization mode
193 Pump supervision error after flame on
216 Fault boiler
217 Fault sensor
241 Flow sensor solar sensor error
242 Return sensor solar sensor error
243 Swimming pool temperature sensor error
270 Limit function
317 Mains frequency outside permissible range
320 DHW charging temperature sensor error
324 BX same sensors
325 BX / extension module same sensors
326 BX / mixing group same sensors
327 Extension module same function
328 Mixing group same finction
329 Extension module / mixing group same function
330 Sensor BX1 no function
331 Sensor BX2 no function
332 Sensor BX3 no function
333 Sensor BX4 no function
334 Sensor BX5 no function
335 Sensor BX21 no function (EM1, EM2 or EM3)
336 Sensor BX22 no function (EM1, EM2 or EM3)
337 Sensor BX1 no function
338 Sensor BX12 no function
339 Collector pump Q5 not available
340 Collector pump Q16 not available
341 Solar Collector sensor B6 not available
342 DHW sensor B31 not available
343 Solar integration not available
344 Solar controlling element buffer K8 not available
345 Solar controlling element swimming pool K18 not available
346 Solid fuel boiler pump Q10 not available
347 Solid fuel boiler comparison sensor not available
348 Solid fuel boiler address error