R600 - Central heating boiler Elco - Free user manual and instructions

Frequently Asked Questions - R600 Elco

USER MANUAL R600 Elco

Operation and Installation manual for authorized technicians only

Operation and Installation manual for authorized technicians only

elco

R 600

Contents

Contents	2
Safety	General regulations	3
	Application	3
Norms and regulations	3
Construction	Layout of boiler	4
	Operating	principle
Technical data		5
Extent of delivery	Standard boiler	7
	Accessories	7
Installation	Boiler transport	8
	Removing	the casing
	Boiler installation	10
	Connecting the boiler	11
Commissioning	Water and hydraulic system	13
	Gas	supply
	Condensate	connection
Flue and air intake connections	14
Prepare boiler for first startup	15
	Combustion	analysis
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
Water flow rate	25
	Combustion	analysis
	Gas pressure	25
	Gas tightness check	25
	Safety devices	25
	Maintenance protocol	26
Lockouts		27
Sensor values		30
Declaration of Conformity		31

General regulations Application Norms and regulations

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 executed 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 100^ (high limit temperature), maximum setpoint temperature is 90^ .

Norms and regulations

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

• Local building regulations for installing 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.

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 70kW but not exceeding 300kW
EN 15420 Gas-fired central heating boilers - Type C boilers of nominal heat input exceeding 70kW but not exceeding 1000 kW
EN 15417 Gas-fired central heating boilers - Specific requirements for condensing boilers with a nominal heat input greater than 70kW but not exceeding 1000 kW
- EN 13836 Gas fired central heating boilers - Type B boilers of nominal heat input exceeding 300kW but not exceeding 1000kW
- 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

Additional national standards

Germany:

• RAL - UZ 61 / DIN 4702-8

Switzerland:

Layout of boiler Operating principle

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 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.

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.

R601 R602	R603	R604	R605	R606	R607
Nominal heat output at 80-60°C 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 75-60°C 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 40/30°C 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	5 388.0/8	0.5 485.0/8	0.5 550.0/8	0.5
Efficiency at 80/60°C %		98.0
Efficiency at 40/30°C %		103.9
Annual efficiency (NNG 75/60°C) %		106.8
Annual efficiency (NNG 40/30°C) %		110.4
Standstill losses (Twater = 70°C) % 0.21	0.18	0.17	0.16		0.15	0.14	0.13
Max. condensate flow	l/h	11	15	19	22		30
Gas consumption H-gas max/min (10,9 kWh/m3)	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
Gas consumption L-gas max/min (8,34 kWh/m3)	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
Gas consumption LL-gas max/min (8,34 kWh/m3)	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
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
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 80/60°C max/min °C		78/61
Flue gas temperature at 40/30°C max/min °C		56/30
Flue gas quantity max/min*	m3/h	238/40	318/69	397/69	477/69	636/134	795/134
CO2 level natural gas H/E/L/LL max/min	%	10.2/9.4
CO2 level liquid 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
Water volume	I	27	31	35	61		68
Water pressure max/min	bar	8/1
Max. water temperature (High limit thermostat)	°C	100
Maximum temperature setpoint	°C	90
Nominal water flow at dT=20K	m3/h	6.1	8.1	10.2	12.2	16.3	20.4
Hydraulic resistance at nominal water flow	kPa	10	18	28	15	27	42
Electrical connection	V	230/400
Frequency	Hz	50
Mains connection fuse	A	10
IP class	-	IP20
Power consumption boiler max/min (excl. pump)	W	158/43	200/35	230/35	260/35	470/61	650/61
Power consumption 3-step pump (optional)	W	170/90	190/120	380/210	380/210	530/300	720/380
Power consumption speed controlled pump (opt)	W	180/10	180/10	435/25	435/25	450/25	800/35
Power consumption bypass pump (optional)	W	55/35	85/65	170/90	170/90	190/120	460/225
Weight (empty)	kg	295	345	400	465	535	590
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"
Flue gas connection	mm	150	150	200	200	250	250
Air intake connection (for room sealed use)	mm	130	150	150	150	200	200
Condensate connection	mm	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.

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
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	770
B2 mm	225	235	235	235	215	215	215	215
B3 mm	260	260	260	310	310	310	310	310
B4 mm	260	260	260	490	490	490	490	490
B5 mm	130	130	130	245	245	245	245	245
D1 mm (Diam.)	130	150	150	150	200	200	200	200
D2 mm (Diam.)	150	150	200	200	250	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"	R 1 1/2"

1 Electrical connections
2 Gas supply
3 Water supply
4137Mgaten gatn (Gp) 187.5
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.

Standard boiler Accessories

Standard boiler

A boiler delivery package contains the

following components:

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. connection kit;
• Speed controlled pump incl. connection kit;
• Safety valve, manometer and deaerator (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 possible 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);

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

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.

Boiler transport

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

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
Burner/1st heat exchanger assembly Weight [kg]	86	100	112	135	158	181	198
Length [mm]	735	885	1035	735	885	1035	1185
Width [mm]	400	400	400	680	680	680	680
Height [mm]	321	321	321	321	321	321	321
2nd/3rd heat exchanger assembly Weight [kg]	90	103	116	150	170	198	219
Length [mm]	735	885	1035	735	885	1035	1185
Width [mm]	400	400	400	680	680	680	680
Height [mm]	244	244	244	244	244	244	244
Condensate receptacle	Weight [kg]	7	9	10	11	12	13
Length [mm]	589	739	889	589	739	889	1039
Width [mm]	385	385	385	665	665	665	665
Height [mm]	225	225	225	225	225	225	225
Frame	Weight [kg]	15	16	17	17	18	19
Length [mm]	990	1140	1350	1100	1320	1470	1620
Width [mm]	624	624	624	724	724	724	724
Height [mm]	335	335	335	335	335	335	335
Front U-frame with electronic board Weight [kg]	11	11	11	12	12	12	12
Length [mm]	628	628	628	728	728	728	728
Width [mm]	1304	1304	1304	1304	1304	1304	1304
Height [mm]	202	202	202	202	202	202	202

Removing the casing

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:

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.

Connecting the boiler

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.

Connecting the boiler

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 horizontal ways with a minimum angle of 3^

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 3mm 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).

Commissioning

Water and hydraulic system

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.

Boiler output [kW]	Max. sum of alkaline earths \( \left\lbrack {\mathrm{{mol}}/{\mathrm{m}}^{3}}\right\rbrack \)	Max. total hardness \( \left\lbrack {{\mathrm{d}}^{ \circ }\mathrm{H}}\right\rbrack \)
50 - 200 2.0 11.2
200 - 600 1.5 8.4

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 50mg / l . Entry of oxygen by diffusion should be prevented at all times. Damage to the heat exchanger because of oxygen diffusion will not be taken under warranty.

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.

Concentrate Ca(HCO3)2		Capacity of installation Q (kW)
		150	200	250	300	400	500	600
mol/m3 d°H Maxim		um 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	7.8
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

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.

9.4

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.

Minimum operating pressure [bar]	Flow temperature [°C]
>1.5	90
>1.0	80

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

Gas supply

Condensate connection

Flue and air intake connections

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.

Commissioning

Prepare boiler for first startup

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
1 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 (O);
• 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 Stop mode can be stopped by pushing the control mode button (I) >3 Sek.

Commissioning

Combustion analysis

Combustion check at full load Start the boiler in controller stop mode and go to full load operation (100%) 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 increasing 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 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 minimum 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.

Combustion settings for natural gas G20 / G25
R601-R607
CO2 max %	10.2 ± 0.2
COmax	ppm	< 30

Combustion settings for LPG G31
Convert boiler before operation (see conversion kit instruction)
R601-R607
CO2,max %	11.9 ± 0.2
COmax	ppm	< 30

Combustion settings for natural gas G20 / G25
R601-R607
CO2,min %	9.4 ± 0.2
COmin	ppm	<

Combustion settings for LPG G31
Convert boiler before operation (see conversion kit instruction)
R601-R607
CO2, min %	10.0 ± 0.2
COmin	ppm	<

Commissioning

Check water flow

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):

$$ \mathrm {q} _ {\text {a c t u a l}} = \left(\Delta \mathrm {T} _ {\text {n o m i n a l}} / \Delta \mathrm {T} _ {\text {m e a s u r e d}}\right) ^ {*} \mathrm {q} _ {\text {n o m i n a l}} [ \mathrm {m} ^ {3} / \mathrm {h} ] $$

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^ p_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):

$$ \mathrm {q} _ {\text {a c t u a l}} = \sqrt {\left(\Delta \mathrm {p} _ {\text {m e a s u r e d}} / \Delta \mathrm {p} _ {\text {n o m i n a l}}\right) ^ {*} \mathrm {q} _ {\text {n o m i a l}} \left[ \mathrm {m} ^ {3} / \mathrm {h} \right]} $$

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
ΔT at nominal flow rate [°C]	20
Δp at nominal flow rate [kPa]	10 18 28	15 27 42	55

Commissioning

Check functionality of safety devices Gas tightness check Boiler shut down

1 23

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.

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 () . 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.

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 A ) in between the ionisation electrode and its electrical connection. The ionisation current should always be above 1.2 A , in normal conditions it will be 6 A 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 (0)
• 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.

Commissioning protocol

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 [d°H] Basement		☐	☐
Water chloride [mg/l]		Other:	☐
Water ΔT full load [°C]	Hydrau-Plated heat exo	Low velocity header	☐
Water Δpboiler [kPa]		hanger	☐
Water flow [m3/h]		Bypass boiler	☐
Pump setting [-]		Other:	☐
Safety devices
High limit setting [°C]	Water flow sensor checked		☐
Temp. limiter setting [°C]	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	[m3/h]	[m3/h]	[m3/h]
Gas pressure [mbar]	[mbar]	[mbar]
CO2	[%]	[%]	[%]
O2	[%]	[%]	[%]
CO	[ppm]	[ppm]	[ppm]
NOx	[ppm]	[ppm]	[ppm]
Tatmospheric	[°C]	[°C]	[°C]
Tfluegas	[°C]	[°C]	[°C]
Twater, flow	[°C]	[°C]	[°C]
Twater, return	[°C]	[°C]	[°C]
Ionisation current	[μA]	[μA]	[μA]
Ptan	[mbar]	[mbar]	[mbar]
Ptop panel	[mbar]	[mbar]	[mbar]
Pcombustion chamber	[mbar]	[mbar]	[mbar]
Remarks

Operating instructions

Controls

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 temperature
for changing settings when programming.

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 abd the mixing valves are no longer controlled, the burner setpoint is 60^ (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.

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
1 Operation mode heating zone(s)
L Display
M Operation mode DHW

Deaeration mode (E)

By pressing the manual mode button longer than 3 seconds, the automatic hydraulicdeaeration is activated.Duringdeaeration the system is put in standby

$$ \bigcirc $$

The pumps are switched on and off for several times.

Afterdeaeration, 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.

Display / Programming

Heating to comfort setpoint Info level activated

Heating to reduced setpoint Programming activated

Heating for frost protection setpoint Heating tempo switched off

Process running - please wait ECO function active

Burner operating (only oil / gas boiler)

Error messages

INFO

Info level activated

PROG

Programming activated

Heating temporarily switched off

ECO

ECO function active

Holiday function active

Reference to heating circuit

Maintenance / special operation

No.

Parameter number

Programming

Enduser

choose
- confirm
choose
- confirm
- change value + - with wheel
- confirm
- 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

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 ESC	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 ESC	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
Auto	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 OK Turn wheel +/-\Press button OK Press button ESC Press button OK	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

Maintenance

Checklist

Replacing the electrodes

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 system:
• 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 minimum load with a combustion analyzer;
• Check the gas pressure to the boiler;
• Check the tightness of all sealed connections 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 electrode (1) and ionisation electrode (2) as shown on the picture.

Maintenance

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

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 position when the cleaning is finished;
• Connect the plug of the fluegas temperature sensor.

Cleaning and refilling the syphon

• Remove the syphon (4) from the condensate connection;
• Clean and fill it with fresh water;
• Mount the syphon back in the original position.

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 inspection opening;
• Inspect the combustion chamber (7), clean if necessary;
• Mount the cover and radiation panel back in original position.

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 Protocol

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 [d°H]
Water chloride [mg/l]
Water ΔT full load [°C]
Water Δpboiler [kPa]
Water flow [m3/h]
Pump setting [-]
Safety devices
High limit setting [°C]		Water flow sensor checked ☐
Temp. limiter setting [°C]		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	[m3/h]	[m3/h]	[m3/h]
Gas pressure [mbar]	[mbar]	[mbar]
CO2	[%]	[%]	[%]
O2	[%]	[%]	[%]
CO	[ppm]	[ppm]	[ppm]
NOx	[ppm]	[ppm]	[ppm]
Tatmospheric	[°C]	[°C]	[°C]
Tfluegas	[°C]	[°C]	[°C]
Twater, flow	[°C]	[°C]	[°C]
Twater, return	[°C]	[°C]	[°C]
Ionisation current	[μA]	[μA]	[μA]
pfan	[mbar]	[mbar]	[mbar]
Ptop panel	[mbar]	[mbar]	[mbar]
Pcombustion chamber	[mbar]	[mbar]	[mbar]
Remarks

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.

Error code	Description of error
0	No error
10	Outside temperature sensor error
20	Boiler temperature 1 sensor error
25	Solid fuel boiler temperature (wood) sensor error
26	Common flow temperature sensor error
28	Flue gas temperature sensor error
30	Flow temperature 1 sensor error
31	Flow temperature 1 cooling 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
68	Room temperature 3 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
78	Dynamic pressure switch
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
117	Upper pressure limit H1, H4, H5, H6 or H7 (exceeded)
118	Critical lower pressure limit H1, H4, H5, H6 or H7 (crossed)
119	Error pressure switch
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
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
169	Sitherm Pro system error
170	Error water pressure sensor primary side
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
176	Upper pressure limit H2 (EM1, EM2 or EM3) (exceeded)
177	Critical lower pressure limit H2 (EM1, EM2 or EM3) (crossed)
178	Limit thermostat heating circuit 1
179	Limit thermostat heating circuit 2
183	Unit in parameterization mode
193	Pump supervision error after flame on
195	Maximum refill time per charging cycle exceeded
196	Maximum refill time per week exceeded
215	Fault fan air diverting valve
216	Fault boiler
217	Fault sensor
218	Pressure supervision
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
321	Instantaneous water heater outlet temperature sensor error
322	Upper pressure limit H3 (exceeded)
323	Critical lower pressure limit H3 (crossed)
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
349	Buffer return valve Y15 not available
350	Puffer address sensor
351	Primary controller / system pump address error
352	Pressureless header address error
353	Common flow sensor B10 not available
371	Flow temperature 3 (heating circuit 3) supervision
372	Limit thermostat heating circuit 3
373	Extension module 3 error (collective error)
374	Sitherm Pro calculation
375	BV stepper motor
376	Drift test limit value
377	Drift test prevented
378	Repetition counter internal error elapsed
379	Repetition counter extraneous light elapsed
380	Repetition counter loss of flame during operation elapsed
381	Repetition counter no flame during TSA elapsed
382	Repetition counter fan error elapsed
383	No repetition permitted
384	Extraneous light
385	Mains undervoltage
386	Fan speed has lost valid range
387	LP error
388	DHW error no function
426	Feedback flue gas damper
427	Configuration flue gas damper
429	Dynamic water pressure to high
430	Dynamic water pressure to low
431	Sensor primary heat exchanger
432	Functional earth not connected
433	Temperature primary heat exchanger to high

NTC 10kΩ temperature sensor (flow, return, flue gas, DHW and header sensor)

NTC 1kΩ temperature sensor (outdoor sensor)

The diagrams show the sensor values for all boiler sensors and optional sensors available in accessory kits. The diagrams contain average values, as all sensors are liable to tolerances.

When measuring the resistance values, the boiler should always be switched off. Measure close to the sensor, in order to avoid value deviations.

Declaration of Conformity

Rendamax BV, Hamstraat 76, 6465 AG Kerkrade (NL), Declares that the product

R600

Is in conformity with the following standards:

EN 298

EN 656

EN 15420

EN 55014-1/-2

EN 61000-3-2 /-3

EN 60 335-1/-2

And in accordance with the guidelines of directives:

92/42/EEC (boiler efficiency directive)

2009/142/EEC (gas appliance directive)

73/23/EEC (low voltage directive)

2004/108/EEC (EMC directive)

This product is designated with CE number:

CE-0063BS3840

Kerkrade, 22-04-2010

R 600

92/42/EWG (boiler efficiency directive)

2009/142/EWG (gas appliance directive)

73/23/EWG (low voltage directive)

2004/108/EWG (EMC directive)

-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 70kW but not exceeding 300kW
- EN 15420 Gas-fired central heating boilers - Type C boilers of nominal heat input exceeding 70kW but not exceeding 1000 kW
EN 15417 Gas-fired central heating boilers - Specific requirements for condensing boilers with a nominal heat input greater than 70kW but not exceeding 1000 kW
- EN 13836 Gas fired central heating boilers - Type B boilers of nominal heat input exceeding 300kW but not exceeding 1000kW
- 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 and similar electrical appliances - Safety: Particular requirements for gas, oil and solid-fuel burning appliances having electrical connections

Minimum operating pressure [bar]	Flow temperature [°C]
>1.5 90
>1.0 80

Hydraulisch system

92/42/EEC (boiler efficiency directive)

2009/142/EEC (gas appliance directive)

73/23/EEC (low voltage directive)

2004/108/EEC (EMC directive)

-2004/108/EEC Directive EM

EN656

Raccordements hydrauliques

Pression hydraulique

M Touche "selectionecs"

Fonction "purge" (E)

2004/108/EWG (directive EMC)

ELCO Netherlands / Rendamax B.V.

NL-6465AGKerkrade

ELCO Belgium n.v./s.a.

B-1731 Zellik

ELCO Italia S.p.A.

I-31023 Resana