elco RENDAMAX 30 Operating Instructions Manual
Operating Instructions
only for authorised experts
RENDAMAX 30
01/2007 Art. No. 12 076 446
doc2030
Table of contents
Table of contents .................................................................................2
General information .................................................................................3
Conditions .................................................................................3
Warranty conditions .................................................................................3
Hot water quality .................................................................................4
Product description Components.............................................................5
Function description.................................................5
Extent of delivery......................................................5
Circuit diagram.........................................................6
Compact gas fitting ..................................................6
Technical data..........................................................7
Dimensions ..............................................................8
Information about system
integration Chimney Exhaust ....................................................9
Condensation pipes .................................................9
Assembly Preparations for the assembly................................10
Air / exhaust system...............................................11
Design variations....................................................12
Exhaust systems, ambient air dependent...............13
Example: exhaust system ......................................13
Installing the burner................................................14
Dismantling / assembling the cover ........................14
Burner connection, filling the system......................15
Electrical installation...............................................16
Set up Control measures...................................................17
Circulating pump ....................................................17
Control measures...................................................18
Gas fitting settings..................................................19
Switch field with operating field KM 628 .................20
Display in operating field KM628............................21
Maintenance and service Removing device covers ........................................22
Dismantling of the burner and gas fitting ................23
Cleaning.................................................................23
Maintenance instructions ...............................................................................24
List of error messages ...............................................................................25
Notes .................................................................................26
2
General information
Conditions
Warranty conditions
General information
Installation, set up, electrical connection and first operation are tasks for an
expert. He is responsible for the
correct implementation.
Information for the operator
The safety and function of the burner
are reliable if the unit is regularly
serviced by a heating expert. In order to
guarantee regular implementation, it is
recommended that a service contract
be concluded.
Conditions
Observe the following standards for a
safe, environmentally friendly and
energy-saving operation:
DIN 1988
- Drinking water systems in
properties, technical conditions for
construction and operation
DIN 18160 + EN 13 384
- Chimney
TRGI (DVGW G600)
- Technical regulations, gas
installation
ATV A 251
- Feeding condensation from
furnaces into public wastewater
systems
State building regulations
TRF
- Technical regulations, liquid gas
DVGW G688
- Burner technology
EN 12 831
- Regole per il calcolo del fabbiso gno di calore degli edifici
EN 12 828
- Technical safety equipment for
heating units with lead tempera tures of up to 95
o
C
- EnEV
- FeuVO
Before installation of the burner, the
consent of the gas supply company
and the district master chimney
sweep must be obtained.
Notes on our warranty conditions
We exclude our guarantee for damage
resulting from the following:
- Unsuitable or incorrect use or
operation
- Incorrect assembly ot set up by the
purchaser or third parties
- Connection of parts of other origin
- Operation of the unit with excess
pressure or outside the work’s
performance details
- Use of incorrect fuel
- Non-compliance with the infor mation in the operating instructions
and the labels attached to the
burner.
In Austria, the following also
applies:
- ÖVGW TR Gas (G1)
- ÖVGW TR Liquid gas (G2)
- ÖNORM H 5152
Furnaces, planning aids
- ÖNORM M 7443
Gas devices with atmospheric
burners Part 1, 3, 5, 7
- ÖNORM M 7457
Gas devices with mechanically
supported pre-mix burners
- ÖNORM H 5195
Hot water norm
- ÖVGW Guidelines
G1 - Technical guideline for the
erection of low pressure gas
systems
G2 - Technical guideline for the
erection of liquid gas systems
G41 - Gas furnaces, erection and
connection
G4 - Heating room guideline
- The device is licensed according
to Article 15a B-CG and according
to the Furnace Directive VO
(FAV 97)
- The local building regulations must
be observed
In Switzerland, the following also
applies:
- PROCAL
Heating materials supplier
association
- SVGW – gas guidelines G1:
Gas installations
Swiss gas and water association
- EKAS – Form, 1942:
Liquid gas guideline, part 2
- BUWAL
Federal Ministry for the Environ ment, Forest and Landscape
- VKF
Union of cantonal fire insurance
companies
- Water treatments
Observe the guidelines of
SWKI No. 97-1
Water treatments for heating
systems
In addition, the country-specific
directives and standards must be
observed.
3
Hot water quality
Hot water quality
The composition and quality of the
system water directly affect the performance of the overall system and the
life of the boiler.
Normally, mains water with a pH value
of 7-8 can be used for the first filling
and subsequent top-ups, provided that
the water is not strongly corrosive
(chlorine content > 150 mg/l) or is very
hard (>14odH; hardness range IV).
A drinking water analysis can be
requested from the appropriate water
supply company.
If the specific system volume is greater
than 20 litres / kW of heat output (e.g.
through the installation of a hot water
buffer tank), the maximum permitted
chalk deposit must be determined by
the filling and top-up water corresponding to the computation of VDI
guideline 2035. If necessary, the water
must be softened. No chemical anticorrosion substances must be used.
In Austria,
ÖNORM H 5195-1 also applies.
In Switzerland,
SWKI No. 97-1 also applies.
Unknown water quality and replacement systems
Frequently, substances and additives
are in hot water which impact on the
function and life of the burner.
Therefore, either
x heat the old system and then fully
empty before replacing,
or
x carefully rinse the heating system
after replacing. Ideally, the system
should be rinsed directly after the
first heating.
Underfloor heating
For old systems, underfloor heating
systems and if there is problematic
filling water, ELCO recommends fitting
a heat exchanger from the accessories.
Criterion Permissible value Effect of deviation
pH value 7 - 8 Danger of corrosion of boiler components and heating system
Hardness < 14 dH - Increased chalk deposits
- Limited life of boiler
Chlorine content < 150 mg/l Corrosion of alloyed materials
4
Product description
Components
Function description
Extent of delivery
1 Smoke gas exhaust connection
2 Air infeed
3 Smoke gas temperature sensor
4 Heat exchanger
5 Ignition transformer
6 Blower
7 Regulator
8 On / off switch
9 Automatic ventilator
10 Noise insulation (types 65 and 85)
11 Gas valve
12 Venturi tube
13 Boiler pump (outside the boiler on
types 100 and 120)
Product description
The burner RENDAMAX 30 is certified
with CE-0063BO3192 and therefore
corresponds to the following standards
and guidelines:
- DIN EN 677
- EN 60 335
- EN 55 014-1/2
- 90/396/EWG
- 89/336/EWG
- 73/23/EWG
- 92/42/EWG
- DIN EN 483
- DIN EN 297
- DIN EN 656
- The NOx limits required by 1
st
BlmSchV Section 7 (2) are met.
The burner RENDAMAX 30 is a system
with a closed combustion chamber
which is independent of ambient air.
The combustion air enters the device
through an air infeed system. The
burner is used for closed hot water
heating systems. The boiler output is
modulated to the current heating
requirements by the integrated
regulator.
Heat exchanger
The stainless steel heat exchanger is
made from flat spirals and ensures a
transfer of the exhaust gas’s heat to
the boiler water.
The condensation takes place in the
upper section of the heat exchanger.
The condensation is fed down in the
rear section of the heat exchanger.
The control and regulator unit
assumes the function of the automatic
firing device and regulator of the
modulating operation of the boiler and
the hot water preparation. A display
shows the operating status of the
boiler.
The automatic firing device controls
and monitors the safety function
process.
Extent of the delivery
x Burner with circuit diagram
x Documentation
Accessories
x VISTRON tank
x Flue systems
x Neutralisation unit / condensation
treatment
x Pump group
1
2
3
4
5
6
7
8
9
10
11
12
13
5
Product description
Circuit diagram
Compact gas fitting
Circuit diagram
The circuit diagram is integrated in the
burner with all the above operating
elements.
The system electronics KM628 offers:
- Management for modulating boiler
regulator
- Hot water preparation
Compact gas fitting
The compact gas fitting works as a gas
safety close valve and as regulator.
The regulator functions as a pneumatic
gas / air difference pressure regulator.
On the gas side, it controls the gas
pressure P
O
in the function of the
combustion air pressure P
L
.
If no air pressure is built up (P
L
= 0),
the gas valve remains closed. The gas/
air pressure ratio and thus also the gas
air volume ratio can be set and then/
remain almost constant over the set
load range.
Technical data
Safety close valve 2, class B/C
Mains power
Type 65-100 AC 24 V
Type 120 AC 230 V
Power consumption
Type 65-100 0,42 A
Type 120 0,09 A
Gas fitting incl. gas filter
1 Operating type
i Standby
q Automatic operation
F Summer operation
j Chimney sweep operation
2 Operating type selector
3 Fault display E
4 Lead temperature
5 Fault code (blinking)
6 Heating circuit status
C Night operation
B Day operation
(Blinking) Burner on
7 Service status
jI Service status minimum burner
output
jII Service status maximum burner
output
5 6 7 4 3 2
1
6
Product description
Technical data
RENDAMAX 30
65 85 100 120
Nominal heat output at 75o / 60o Max/Min kW 58,8/8,3 77,5/15,5 87,2/17,4 108,9/21,8
Nominal heat output at 40
o
/ 30oC kW 65,1/9,2 85,8/17,2 96,5/19,3 120,5/24,1
Nominal heat load kW 60,7/8,6 80,0/16,0 90,0/18,0 112,4/22,5
Standard efficiency 75
o
/ 60oC % 106,3 106,3 106,3 106,3
Standard efficiency 40
o
/ 30oC % 110,1 110,1 110,1 110,1
Operability losses T
K
= 70oC % < 0,3 < 0,3 < 0,3 < 0,3
Max. blower pressure Pa 140 140 140 200
Water content l 6,6 8,4 10,3 12,0
Max. permissible water pressure bar 6 6 6 6
Max. permissible lead temperature °C 90 90 90 90
Condensation volume at 40
o
C / 30oC ca. l/h 9,7 12,8 14,4 18,0
Gas connection value Natural gas
E/H* (Hi=10.9 kWh/m
3
)
m
3
/h 5,6 7,3 8,2 10,3
Natural gas LL (Hi=8.1 kWh/m
3
) m3/h 7,5 9,9 11,1 13,9
Liquid gas propane / butane
(Hi=12.8 kWh/kg)
kg/h 4,7 6,3 7,1 8,8
Min. gas flow pressure Natural gas
Liquid gas
mbar
mbar
20
50
20
50
20
50
20
50
Exhaust gas mass flow for natural gas g/s 31 41 46 58
Exhaust gas temperature net, T
V/TR
75/60 °C 70 70 70 70
Exhaust gas temperature net, T
V/TR
40/30 °C < 55 < 55 < 55 < 55
Gas category II2ELL3P / II2H3P
Exhaust gas value group G61 G61 G61 G61
Construction type - Exhaust gas systems
(B23; C13; C33; C43; C53; C63; C83)
All All All All
Ionisation flow min.
P$
15,0 15,0 15,0 15,0
Connections: Air/exhaust gas pipe (concentric) DN 80/125 110/150 110/150 110/150
Air/exhaust gas pipe (parallel) DN 80/80 100/100 100/100 100/100
Heating lead / heating reflux (inner / outer) DN 25/32 25/32 25/32 25/32
Gas connection DN 20 20 20 20
Condensation pipe connection mm 25 25 25 25
pH value condensation pH 3,0 3,0 3,0 3,0
Electric connection / power consumption 230 V / VAC
(*types 100 and 120 without boiler circuit pump)
W 230 255 130* 215*
CE ID number 0063BO3192
Weight, approx. kg 55 65 80 90
Nominal heat output at 80
o
/60oC kW 59,2 77,8 88,2 109,0
Efficiency at nominal output at 100%, 80
o
/60oC % 97,5 97,3 98 97,7
Efficiency at partial load 30%, 40
o
/30oC % 108,1 108,1 108,1 108,1
Operability losses at 70
o
C average K temp. % < 0,3 < 0,3 < 0,3 < 0,3
Auxiliary energy + integrated boiler circuit pump
(*types 100 and 120 without boiler circuit pump)
W 147 171 83* 137*
7
Product description
Dimensions
Type R30/65 R30/85 R30/100 R30/120
B1 mm 120 140 140 140
D mm 80 100 100 100
D1 mm 80 100 100 100
G R
3
/4" R
3
/4" R
3
/4" R
3
/4"
L mm 405 510 560 670
L1 mm 90 90 90 90
W R 1
1
/4" / Rp 1" R 11/4" / Rp 1" R 11/4" / Rp 1" R 11/4" / Rp 1"
8
Information about system integration
Chimney
Exhaust
Condensation pipes
Burner technology
In the burner technology, the residual
heat is removed from the exhaust gas
trough cooling and condensation and is
fed to the heating system. In this way,
a higher degree of efficiency is
achieved with low energy consumption.
Information for the chimney
Exhaust systems must be installed in
a shaft corresponding to DIN 18 160 /
Part 1.
Check the exhaust gas pipes before
assembling the burner
Dimensions only apply to the use of
the exhaust gas system made from
polypropylene (PP) DN 110/150.
The low exhaust gas temperatures
required usual exhaust gas pipes
specifically for burners.
Examples:
- Chimneys resistant to moisture
- Condensation-sealed inner dish
- Diameter of the connections
(sleeves) must be considered for
the minimum shaft cross-sections.
Roof heating central
Dependent on ambient air, max. pipe
length 4 m
Exhaust gas is extracted
- via a DIBT (D) or VKF (CH) – ÖTZ
(A) authorised and tested exhaust
pipe
- into the chimney
Pipes and pipe sections
- outside shafts, must be freely
accessible and checkable and
must be protected against frost
- inside shafts, must be rear
ventilated.
Exhaust pipes must be
- moisture resistant
- suitable for exhaust temperatures
below 40
o
C, and
- secure against over-pressure.
Recommendation:
Accessories, exhaust pipe set
Condensation pipes must not be
securely installed. The condensation
is trapped in a funnel and fed into the
sewage system.
Recommendation:
Accessories, neutralisation device
Note worksheet ATV A 251.
Exhaust pipes
Infeed / exhaust system
The applicable local provisions for the
design of the exhaust system must be
observed.
The burner can only be operated with
approved exhaust systems.
On site exhaust systems must be
resistant to moisture, corrosion and
sealed against condensation, and
satisfy static and operating requirements. Unhindered escape of the
exhaust gases must be guaranteed at
the chimney opening (chimneypot is
not recommended).
The connection between chimney and
burner must be fitted with a drop (3%)
so that the condensation escaping
through the exhaust system can flow
back from the exhaust pipe. This
connection should have as few bends
as possible.
Inspection openings must be planned
in the exhaust pipe in accordance with
official requirements. It is possible to
use an exhaust system not dependent
on ambient air.
Exhaust pipes
Horizontal pipes must be avoided in
order to prevent the development of
condensation. It must be ensured that
the various components are connected
to each other with proper seals.
45
o
bends should be used for the
assembly. The vertical parts must be
fixed with straps.
Condensation
The connection of the condensation
pipe (under boiler) must lead to the
exhaust pipe with drop.
It must also be guaranteed that there
is no risk of frost.
Installation example of separate
condensation pipe from the exhaust
gas pipe.
9
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