R3500 - Central heating boiler Elco - Free user manual and instructions

Frequently Asked Questions - R3500 Elco

USER MANUAL R3500 Elco

Operation and Installation manual for authorized technicians only

Contents	2
Safety	General regulation...3 Application...3 Norms and regulations...3
Construction	Layout of boiler...4 Operating principle...4
Technical data	5
Extent of delivery	Standard boiler...15 Accessories...15
Installation	Transport...16 Removing the casing...18 Boiler installation...19 Connecting the boiler...20
Commissioning	Water and hydraulic system...22 Gas supply...23 Condensate connection...23 Flue and air intake connections...23 Prepare boiler for first startup...24 Combustion analysis...25 Air pressure switch...26 Check water flow...27 Check functionality of safety devices...28 Gas tightness check...28 Boiler shut down...28 Commissioning protocol...29
Operating instructions	Main menu (operating mode) ...30 Parameter menu(information/programming mode) ...30 Changing parameter values ...30
Maintenance	Checklist...31 Replacing the electrodes...31 Cleaning the condensate receptacle...32 Cleaning and refilling the syphon...32 Water pressure and quality...32 Water flow rate...32 Combustion analysis...32 Gas pressure...32 Gas tightness check...32 Safety devices...32 Maintenance protocol...33
Lockouts	34
Sensor values	36
Declaration of Conformity	37

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 R3400/R3500/ R3600 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 R3400/R3500/R3600 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 R3400/R3500/R3600 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 R3400/R3500/R3600 boiler is CE approved and applies to the following European standards:

-92/42/EEC

Boiler efficiency directive

-90/396/EEC

Gas appliance directive

-73/23/EEC

Low voltage directive

-89/336/EEC

EMC directive

-EN656

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

-EN15417

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

-EN13836

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

-EN55014-1

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

• EN 55014-2

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

• EN 61000-3-2

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

• EN 61000-3-3

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

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

-EN50165

Household and similar electrical appliances - Safety - Part 2-102: 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 R3400/R3500/R3600 boiler consists of the following main components:

1 Return water connection

2 Flue gas connection

3 Water flow switch

4 Safety valve

5 Flow water connection

6 Filling/draining valve

7 Top plate

8 Plenum

9 Burner

10 1st Heat exchanger

11 Gas filter

12 2nd Heat exchanger

13 Gastrain

14 Frame

15 180^ Bend

16 Compensator

17 Flue gas connection

18 Condensate receptacle

19 Flue gas receptacle

20 Combustion chamber

21 Entry electrical connections

22 Syphon

23 Main gas valve

24 Fan

25 Electrical box

26 Control panel

27 Casing

28 Air inlet damper

29 Butterfly valve

30 Main mixing channel

31 Pilot gas valve

32 Pilot mixing channel

33 Boiler pump

34 3rd Heat exchanger (only R3600)

A Air
B Gas
C Flue gasses
D Condensate

Operating principle

The R3400/R3500/R3600 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 KM628 control unit can control the boiler operation based on:

• fixed temperature (stand alone operation);
• weather compensated operation (with optional controller);
  with 0-10V external influence (temperature or capacity) from a building management system.

Technical data R3401 - R3405

					R3401	R3402	R3
Nominal heat output at 80-60°C max/min kW 656	164	733/183	857/213	971/242	1084/270
Nominal heat output at 75-60°C max/min kW 657	164	734/183	858/213	972/242	1085/270
Nominal heat output at 40/30°C max/min kW 663	181	741/202	867/236	981/268	1095/298
Nominal heat input Hi max/min* kW 702/176	784/196	917/229	1038/260	1159/290
Efficiency at 80/60°C %	93.5
Efficiency at 40/30°C %	94.5
Annual efficiency (NNG 75/60°C) %		100.0
Annual efficiency (NNG 40/30°C) %		-
Standstill losses (Twater = 70°C)	%	0.2
Max. condensate flow	l/h	-
Gas consumption H-gas max/min (10,9 kWh/m3)	m3/h	64.5/16.2	71.9/18.0	84.1/21.0	95.2/23	8	106.3
Gas consumption L-gas max/min (8,34 kWh/m3)	m3/h	84.3/21.1	94.0/23.5	109.9/27.4	124.4/31	2	139.0
Gas consumption LPG. max/min (12,8 kWh/kg)	kg/h	54.9/13.8	61.2/15.3	71.6/17.9	81.1/20.3	90.5/22.6
Gas pressure H-gas	mbar	20		35
Gas pressure L/LL-gas	mbar	25		35
Gas pressure LPG	mbar	30/50
Maximum gas pressure	mbar	100
Flue gas temperature at 80/60°C max/min	°C	165/70
Flue gas temperature at 40/30°C max/min	°C	135/60
Flue gas quantity max/min*	m3/h	1423/356	1580/395	1848/462	2091/523	2334/584
CO2level main burner natural gas H/E/L/LL max/min	%	10.0/9.3
CO2level main burner liquid gas P max/min	%	11.0/11.0
CO2level pilot burner natural gas H/E/L/LL max/min	%	10.0/10.2
CO2level pilot burner liquid gas P max/min	%	11.0/11.2
NOx level max/min	mg/kWh	61.4/22.0
CO level max/min mg/kWh	9.8/3.3
Max. permissible flue resistance max/min	Pa	150
Water volume	I	50	53	70	75	80
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	28.5	31.6	37.0	41.8	46.8
Hydraulic resistance at nominal water flow	kPa	46	53	36	43	50
Electrical connection	V	400
Frequency	Hz	50
Mains connection fuse	A	16		20
IP class	-	IP20
Power consumption boiler (excl. pump)	W	900	900	1270	1270	1270
Power consumption 3-step pump (optional)	W	980	1010	1020	1450	1500
Weight (empty)	kg	675	740	840	950	1070
Noise level at 1 meter distance	dB(A)	64
Ionisation current minimum	μA	6
PH value condensate	-	3.2
CE certification code	-	CE-0063AR3514
Water connections	-	DN65 PN16		DN80 PN16
Gas connection	-	R 2"				DN65 PN16
Flue gas connection	mm	300	350		400
Air intake connection (for room sealed use)	mm	250	300		355
Condensate connection	mm	40

Technical R3406 - R3410

					R3406	R3407
Nominal heat output at 80-60°C max/min kW 1196/298		309/326	1496/373	1683/419	1870/466
Nominal heat output at 75-60°C max/min kW 1197/298		310/326	1498/373	1685/419	1872/466
Nominal heat output at 40/30°C max/min kW 1209/329		323/360	1512/412	1701/463	1890/515
Nominal heat input Hi max/min* kW 1279/320		1400/350	1600/400	1800/450	200/500
Efficiency at 80/60°C %		93.5
Efficiency at 40/30°C %		94.5
Annual efficiency (NNG 75/60°C) %			100.0
Annual efficiency (NNG 40/30°C) %			-
Standstill losses (Twater = 70°C) %			0,2
Max. condensate flow		l/h	-
Gas consumption H-gas max/min (10,9 kWh/m3)		m3/h	117.3/29.3	128.4/32.1	146.7/36.7	165.1/41.3
Gas consumption L-gas max/min (8,34 kWh/m3)		m3/h	153.4/38.4	167.9/42.0	191.8/48.0	215.8/54.0
Gas consumption LPG. max/min (12,8 kWh/kg)		kg/h	99.9/25.0	108.7/27.2	124.3/31.1	139.8/35.0
Gas pressure H-gas		mbar	35	50
Gas pressure L/LL-gas		mbar	35	50
Gas pressure LPG		mbar	30/50	50
Maximum gas pressure		mbar	100
Flue gas temperature at 80/60°C max/min		°C	165/70
Flue gas temperature at 40/30°C max/min		°C	135/60
Flue gas quantity max/min*		m3/h	2578/645	2825/706	3227/807	3631/908
CO2level main burner natural gas H/E/L/LL max/min		%	10.0/9.3
CO2level main burner liquid gas P max/min		%	11.0/11.0
CO2level pilot burner natural gas H/E/L/LL max/min		%	10.0/10.2
CO2level pilot burner liquid gas P max/min		%	11.0/11.2
NOx level max/min		mg/kWh	61.4/22.0
CO level max/min mg/kWh		9.8/3.3
Max. permissible flue resistance max/min		Pa	150
Water volume		I	85	97	109	116
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	51,6	56,1	64,1	72,1
Hydraulic resistance at nominal water flow		kPa	58	91	60	130
Electrical connection		V	400
Frequency		Hz	50
Mains connection fuse		A	20	C25
IP class		-	IP20
Power consumption boiler (excl. pump)		W	1270	1910	2330	2520
Power consumption 3-step pump (optional)		W	1500	4000		7500
Weight (empty)		kg	1200	1210	1525	1665
Noise level at 1 meter distance		dB(A)	64
Ionisation current minimum		μA	6
PH value condensate		-	3.2
CE certification code		-	CE-0063AR3514
Water connections		-	DN80 PN16	DN80 PN16
Gas connection		-	DN65 PN16		DN80 PN16
Flue gas connection		mm	400	450	500
Air intake connection (for room sealed use)		mm	355	-
Condensate connection		mm	40

R3408

Dimensions R3401 - R3406

Dimensions		R3401	R3402	R3403	R3404	R3405	R3406 58 770 1166 1166
L	mm	2265	2265	2653	2653	2658	26
L1	mm	595	595	610	615	615	88 1166 1166
L2	mm	700	700		1166	1166
L3	mm	108	108	88	88	88
H	mm	1355	1355	1355	1355	1355
H1	mm	1125	1125	1570	1420	1155
B	mm	1330	1330	1130	1130	1330
B1	mm	1160	1210	1003	1053	1203
B2	mm	665	665	565	565	665
B3	mm	170	120	127		77
B4	mm	1146	1146	946		946	1146
B5	mm	115	65	115	65	115	65
D	mm	300	350	350	400	400
W	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Dimensions R3407 - R3410

R3407 - R3408

R3409-R3410

Dimensions		R3407	R3408	R3409	R3410
L	mm	27	55	32	65
L2	mm	1	120	1	630
B	mm	15	30	13	30
B2	mm	1407	1	207	1
B3	mm	765	665	765	765
B4	mm	12	6.5	12	6.5
B5	mm	1406	1	206	1
B6	11	40	94	0	11
D	mm	450	450	500	500
W1	DN	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2	DN	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16

Technical data R3501 - R3505

					R3501	R3502
Nominal heat output at 80-60°C max/min kW 613	175	717/204	811/231	906/258	1000/285
Nominal heat output at 75-60°C max/min kW 613	175	717/204	812/231	907/258	1001/285
Nominal heat output at 40/30°C max/min kW 624	195	730/228	826/258	923/288	1018/319
Nominal heat input Hi max/min* kW 653/187	764/218	865/247	966/276	1066/305
Efficiency at 80/60°C %	93.8
Efficiency at 40/30°C %	95.5
Annual efficiency (NNG 75/60°C) %		102.2
Annual efficiency (NNG 40/30°C) %		-
Standstill losses (Twater = 70°C) %		0.3
Max. condensate flow l/h	-
Gas consumption H-gas max/min (10,9 kWh/m3)	m3/h	59.9/17.1	70.1/20.0	79.4/22.7	88.6/25	3 97.8/27
Gas consumption L-gas max/min (8,34 kWh/m3)	m3/h	78.3/22.4	91.6/26.2	103.7/29.6	115.8/33.1	127.8/36.5
Gas consumption LPG. max/min (12,8 kWh/kg)	kg/h	51.0/14.6	59.7/17.1	67.6/19.3	75.5/21.6	83.3/23.8
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	155/65
Flue gas temperature at 40/30°C max/min	°C	120/55
Flue gas quantity max/min*	m3/h	1287/368	1505/430	1703/487	1901/543	2099/60
CO2level main burner natural gas H/E/L/LL max/min	%	10.0/9.3
CO2level main burner liquid gas P max/min	%	11.0/11.0
CO2level pilot burner natural gas H/E/L/LL max/min	%	10.0/10.2
CO2level pilot burner liquid gas P max/min	%	11.0/11.2
NOx level max/min mg/kWh	11.5/19.5
CO level max/min mg/kWh	27.3/6.5
Max. permissible flue resistance max/min	Pa	150
Water volume	I	53	70	75	80	85
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	26.4	30.8	34.9	39.0	43.0
Hydraulic resistance at nominal water flow	kPa	37	25	30	35	40
Electrical connection	V	400
Frequency	Hz	50
Mains connection fuse	A	16		20
IP class	-	IP20
Power consumption boiler max/min (excl. pump)	W	900		1270
Power consumption 3-step pump (optional)	W	960	1000	1020	1400	1500
Power consumption speed controlled pump (optional)	W	394	375	523		557
Weight (empty)	kg	740	840	950	1070	1200
Noise level at 1 meter distance	dB(A)	64
Ionisation current minimum	μA 6
PH value condensate	- 3.2
CE certification code	-	CE-0063AR3514
Water connections	-	DN65 PN16	DN80 PN16
Gas connection	-	R 2"		DN65 PN16
Flue gas connection	mm	300	350		400
Air intake connection (for room sealed use)	mm	250	300		355
Condensate connection	mm	40

R3503

Dimensions R3501 - R3505

Dimensions		R3501	R3502	R3503	R3504	R3505
L	mm	2265	2653	2653	2658	2658
L1		mm	595	610	610	615
L2	mm	700	1166	1166	1166	1166
L3	mm	108	88	88	88	88
H		mm 1355	1355	1355	1355	1355
H1		mm 1125	1400	1400	1155	1155
B		mm 1330	1130	130	1330	1330
B1		mm 1210	1003	1053	1203	1253
B2	mm	665	565	565	665	665
B3	mm	120	127	77	127	77
B4	mm	1146	946	946	1146	1146
B5	mm	65	115	65	115	65
D		mm 300	350	350	400	400
W	DN	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Technical data R3600 - R3605 Standard

		R3600	R3601	R3602	R3603	R3604	R3605
Nominal heat output at 80-60°C max/min kW 572/142	639/182	747/212	846/241	945/269	1043/297
Nominal heat output at 75-60°C max/min kW 576/144	643/184	753/215	852/243	952/272	1050/300
Nominal heat output at 40/30°C max/min kW 602/159	672/203	786/237	890/268	994/300	1097/31
Nominal heat input Hi max/min* kW 585/146	653/187	764/218	865/247	966	1066/305
Efficiency at 80/60°C %	97.8
Efficiency at 40/30°C %	102.9
Annual efficiency (NNG 75/60°C) %		105,1
Annual efficiency (NNG 40/30°C) %		109,8
Standstill losses (Twater = 70°C) %		0,3
Max. condensate flow	l/h	-
Gas consumption H-gas max/min (10,9 kWh/m3)	m3/h	53.7/13.4	59.9/17.1	70.1/20.0	79.4/22.7	88.6	25.3 97
Gas consumption L-gas max/min (8,34 kWh/m3)	m3/h	70.3/17.6	78.3/22.4	91.6/26.2	103.7/29.6	115.8/33.1	127.8/36.5
Gas consumption LPG. max/min (12,8 kWh/kg)	kg/h	45.7/11.4	51.0/14.6	59.7/17.1	67.6/19.3	75.5/21.6	83.3/23.8
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	85/65
Flue gas temperature at 40/30°C max/min	°C	59/36
Flue gas quantity max/min*	m3/h	969/242	1076/307	1258/359	1424/407	1590/454	1756/502
CO2 level main burner natural gas H/E/L/LL max/min	%	10.0/9.3	10.0/9.3
CO2 level main burner liquid gas P max/min	%	11.0/11.0	11.0/11.0
CO2 level pilot burner natural gas H/E/L/LL max/min	%	-	10.0/10.2
CO2 level pilot burner liquid gas P max/min	%	-	11.0/11.2
NOx level max/min	mg/kWh	32.3/18.8	11.5/19.5
CO level max/min mg/kWh 8.2/10.9		27.3/6.5
Max. permissible flue resistance max/min	Pa	100	150
Water volume	I	69	73	97	104	110	117
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	24,7	27,6	32,2	36,5	40,8	45,0
Hydraulic resistance at nominal water flow	kPa	48	56	38	45	53	60
Electrical connection	V	400
Frequency	Hz	50
Mains connection fuse	A	10	16	20
IP class	-	IP20
Power consumption boiler (excl. pump)	W	420	900	1270
Power consumption 3-step pump (optional)	W	940	980	1020	1400	1450	1500
Power consumption speed controlled pump (optional)	W	471	616	561	661	867	956
Weight (empty)	kg	810	890	1040	1150	1280	1410
Noise level at 1 meter distance	dB(A)	64
Ionisation current minimum	μA	6
PH value condensate	-	3.2
CE certification code	-	CE-0063AR3514
Water connections	-	DN65 PN16	DN80 PN16
Gas connection	-	R 2"			DN65 PN16
Flue gas connection	mm	300	350		400
Air intake connection (for room sealed use)	mm	250	300		355
Condensate connection	mm	40

Dimensions R3600 - R3605 Standard

Dimensions	R36001	R3602	R3603	R3604		R3605
L mm	1958	2265	2653	2653		2658
L1	mm595	595	610	610		615
L2	mm 700	590	1166	1166		1166
L3 mm	108		198	88		88
H mm	1355	1405	1405	1405		1405
H1 mm	970	1175	1450	1450		1205
B mm	1230	1330	1130	1130		1330
B1 mm	1110	1210	1003	1053		1203
B2 mm	615	665	565	565		665
B3 mm	120	120	127	77		77
B4 mm	1046	1146	946	946		1146
B5 mm	100	65	115	65		115
D mm	300	300	350	350		400
D1 mm	250	250	300	300		355
W1 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

2658

1166

88

1405

1427

1330

1253

665

65

400

355

Technical data R3600 - R3605 Split system

		R3600	R3601	R3602	R3603	R3604	R3605
Nominal heat output at 80-60°C max/min kW 572/142		639/182	747/212	846/241	945/269	1043/297
Nominal heat output at 75-60°C max/min kW 576/144		643/184	753/215	852/243	952/272	1050/300
Nominal heat output at 40/30°C max/min kW 602/159		672/203	786/237	890/268	994/300	1097/31
Nominal heat input Hi max/min* kW 585/146		653/187	764/218	865/247	966/276	106/305
Efficiency at 80/60°C %		97.8
Efficiency at 40/30°C %		102.9
Annual efficiency (NNG 75/60°C) %			105,1
Annual efficiency (NNG 40/30°C) %			109,8
Standstill losses (Twater = 70°C) %			0,3
Max. condensate flow		l/h	-
Gas consumption H-gas max/min (10,9 kWh/m3)		m3/h	53.7/13.4	59.9/17.1	70.1/20	79.4/22.7	88.6/25.3
Gas consumption L-gas max/min (8,34 kWh/m3)		m3/h	70.3/17.6	78.3/22.4	91.6/26.2	103.7/29.6	115.8/33.1
Gas consumption LPG. max/min (12,8 kWh/kg)		kg/h	45.7/11.4	51.0/14.6	59.7/17.1	67.6/19.3	75.5/21.6
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	85/65
Flue gas temperature at 40/30°C max/min		°C	59/36
Flue gas quantity max/min*		m3/h	969/242	1076/307	1258/359	1424/407	1590/454
CO2level main burner natural gas H/E/L/LL max/min		%	10.0/9.3	10.0/9.3
CO2level main burner liquid gas P max/min		%	11.0/11.0	11.0/11.0
CO2level pilot burner natural gas H/E/L/LL max/min		%	-	10.0/10.2
CO2level pilot burner liquid gas P max/min		%	-	11.0/11.2
NOx level max/min		mg/kWh	32.3/18.8	11.5/19.5
CO level max/min mg/kWh 8.2/10.9			27.3/6.5
Max. permissible flue resistance max/min		Pa	100	150
Water volume		I	73	97	104	110	117
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	24,7	27,6	32,2	36,5	40,8
Hydraulic resistance at nominal water flow		kPa	48	56	38	45	53
Electrical connection		V	400
Frequency		Hz	50
Mains connection fuse		A	10	16	20
IP class		-	IP20
Power consumption boiler (excl. pump)		W	730	900	1270
Weight (empty)		kg	810	890	1040	1150	1280
Noise level at 1 meter distance		dB(A)	64
Ionisation current minimum		μA	6
PH value condensate		-	3.2
CE certification code		-	CE-0063AR3514
Water connections		-	DN65 PN16	DN80 PN16
Gas connection		-	R 2"		DN65 PN16
Flue gas connection		mm	300	350	400
Air intake connection (for room sealed use)		mm	250	300	355
Condensate connection		mm	40

Dimensions R3600 - R3605 Split system

Dimensions		R3600	R3601	R3602		R3603	R3604
L	mm		1958	2070		2443	2443
L2	mm		700	590	1166	1166	1166
L3	mm	108	198	88	88	88	88
H	mm	1355	1405	1405	1405	1405	1405
B	mm	1230	1330	1130	1130	1330	1330
B1	mm	1110	1210	1003	1053	1203	1253
B2	mm	615	665	565	565	665	665
B3	mm	120	120	127	77	127	77
B4	mm	1046	1146	946	946	1146	1146
B5	mm	100	65	115	65	115	65
D	mm	300	300	350	350	400	400
D1	mm	250	250	300	300	355	355
W1	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W3	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

R3605

2443

1166

Extent of delivery

Standard boiler

Accessories

Standard boiler

A boiler delivery package contains the

following components:

Component	Pcs.	Package
R3400/R3500/R3600 Boiler fully assembled and tested 1 Mo	ounted on	wooden blocks with wooden border, sealed in PE foil
Adjustable feet 4 Cardboard box on top of boiler		(on R3407-R3410 already fitted to boiler)
Syphon for condensate connection 1 Cardboard box on top of heatex	change	(under casing)
Operation and Installation manual 1 Map attached to back panel of the boiler
Wiring diagram 1 Map attached to back panel of the boiler

Accessories

On request it is possible to get various

options and/or accessories. Ask your

supplier for the possibilities.

Transport

Boiler transport

The R3400/R3500/R3600 boiler will be supplied as a complete unit being fully assembled and pre-tested. The boiler can be transported with a pallet truck (at least 1m wide), picking the boiler up 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 R3400/R3500/R3600 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			R3600	R340R3401 R3501 R3601	R3403 R3502 R3602	R3404 R3503 R3603	R3405 R3504 R3604	R3406 R3505 R3605
Burner m [kg]		135	135	140	210	215	220	225
	L [mm]	1010	1010	1010	1420	1420	1420	1420
	W [mm]	1150	1150	1310	1010	1110	1210	1310
	H [mm]	420	420	500	500	500	500	500
\( 1^{st}Heat exchanger m [kg] \)		120	120	135	180	185	190	195
	L [mm]	1010	1030	1010	1420	1420	1420	1420
	W [mm]	1150	1150	1310	1010	1110	1210	1310
	H [mm]	160	150	160	160	160	160	160
\( 2^{nd}Heat exchanger \)	m [kg]	135	135	150	200	200	210	210
	L [mm]	1010	1030	1010	1420	1420	1420	1420
	W [mm]	1150	1050	1310	1010	1110	1210	1310
	H [mm]	160	150	160	160	160	160	160
\( 3^{rd}Heat exchanger (only R3600 series) \)	m [kg]	-	135	150	200	200	210	210
	L [mm]	-	1030	1010	1420	1420	1420	1420
	W [mm]	-	1050	1310	1010	1110	1210	1310
	H [mm]	-	150	160	160	160	160	160
Frame H for R3600 in ( )	m [kg]	50	50	60	70	70	70	70
	L [mm]	1325	1325	1630	2004	2004	2004	2004
	W [mm]	1165	1165	1266	1066	1066	1266	1266
	H [mm]	460	360	500 (370)	500 (370)	500 (370)	500 (370)	500 (370)
Condensate receptacle m	[kg]	< 25	< 25	< 25	< 35	< 35	< 35	< 35
	L [mm]	1320	1320	1450	1950	1950	1950	1950
	W [mm]	990	990	1070	770	870	970	1070
	H [mm]	400	275	400	400	400	400	400

Transport

Component					R3407
Burner m [kg]		230	385	390	395
	L [mm]	1510	2050	2050	2050
	B [mm]	1400	1250	1350	1450
	H [mm]	600	600	620	620
\( 1^{st}Heat exchanger m [kg] \)		200	325	330	335
	L [mm]	1510	2050	2050	2050
	B [mm]	1425	1250	1350	1450
	H [mm]	150	150	150	150
\( 2^{nd}Heat exchanger \)	m [kg]	220	365	370	375
	L [mm]	1510	2050	2050	2050
	B [mm]	1425	1250	1350	1450
	H [mm]	150	150	150	150
Frame	m [kg]	80	120	120	120
	L [mm]	2010	2525	2525	2525
	B [mm]	1466	1266	1466	1466
	H [mm]	510	515	515	515
Condensate m [kg]		< 40	< 55	< 55	< 55
	L [mm]	2075	2600	2600	2600
	B [mm]	1175	975	1075	1175
	H [mm]	350	350	350	350

R3408

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 effect the exact height of all connections.

The R3407-R3410 are not supplied on wooden blocks, but on wheels. After positioning the boiler, the adjustable feet have to be set to the correct height. The wheels have to be removed. The connections to the boiler have to be made after the feet have been adjusted, as the adjustment will effect 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 (1, 3)
• Condensate drain connection (7)
  Gas connection (6)
• Flue gas connection (5)
  Air intake connection (only when using roomsealed, order separately) (2)
• Electrical connection (4)

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 (3) and return (1) connection of the system tension free to the boiler connections. If the boiler is used in a system with two return circuits (only R3600 series), the common return becomes the low temperature return, the 2nd return connection is the high temperature return (remove cap/ flange before connecting).

Condensate connection (7)

After filling with water, the syphon (included in delivery) should be installed to the connection at the bottom of the condensate receptacle. 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 (6)

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 (6) 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 (5)

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 (5) 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 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)

When using the boiler roomsealed. The air intake can be connected if the boiler was ordered as roomsealed. 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 (4)

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.

Cables can be inserted through the cable trays and glands at the back of the electrical panel at the front of the boiler.

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 \( \left\lbrack {{\mathrm{d}}^{0}\mathrm{H}}\right\rbrack \)
600 - 2000 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 50~mg / 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 R3400/R3500/R3600 according to the VDI2035.

Concentrate Ca(HCO3)2		Capacity of installation Q (kW)
		600	800	1000	1200	1400	1600	182000
mol/m3	d°H	Maximum water (re)fill volume V max[m3]
≤0.5	≤2.8	-	-		-	75.1	87.6	100.225.2
1.0	5.6	-	-	-	37.6	43.8	50.1	56.3
1.5	8.4	12.0	16.7	20.9	25.0	29.2	33.4	37.6
2.0	11.2	9.4	12.5	15.7	18.8	21.9	25.0	28.2
2.5	14.0	7.5	10.0	12.5	15.0	17.5	20.0	22.5
≥3.0	≥16.8	6.3	8.3	10.4	12.5	14.6	16.7	18.8

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.

122.7

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 tem- perature \( \left\lbrack {{}^{ \circ }\mathrm{C}}\right\rbrack \)
\( > {1.5}\;{90} \)
\( > {1.0}\;{80} \)

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.

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

Prepare boiler for first startup

• Open gas connection;
• Switch on mains isolator switch for power supply to the boiler;
• Switch on boiler with on/off switch (1)

Make sure the boiler remains in standby operation (2) use rotational switch (3);
- Check the pump operation: make sure that the direction of the rotation is correct;
- Remove any air from the pump by removing the end cap of the pump motor housing.

It's recommended to keep the boiler at 50% load for a while after the first startup, as this is the easiest base for starting the combustion analysis. This can be assured as follows:

• Open the lid of the boiler controller;
• Use rotational switch (3) for going to parameter P9 in the menu;
• Change P9 (5) into 50% (push programming button (4), change value with rotational switch (3), push programming button (4) to confirm);
• Close the lid of the boiler controller.

Combustion analysis

Combustion check at full load

Start the boiler at service mode for full load operation (A II). When you have reduced P9 to 50% (see previous chapter), the boiler will operate at 50% load. Allow the boiler to stabilise the combustion for 3 minutes. Then increase P9 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 50% of the required gas pressure.

First check the combustion values of the pilot burner using the measuring tube on the back of the boiler (3). If required the values can be corrected with the adjustment screw on the pilot gas valve (2).

Then check the combustion values of the main burner using a measuring point in the flue (4). If required the values can be corrected with the adjustment screw (V) on the main gas valve (5).

Pilot burner
Combustion settings for natural gas G20 / G25
All boilers
CO2,max %	10.0 ± 0.2
COmax	ppm	<
CO2,min %	10.2 ± 0.2
COmin	ppm	<

1000

1000

Pilot burner
Combustion settings for LPG G31
Parameter change required P19 : 100% ▲ 86%
All boilers
CO2, max %	11.0 ± 0.2
COmax	ppm	<
CO2, min %	11.2 ± 0.2
COmin	ppm	<

1000

1000

Combustion check at minimum load Switch the boiler to service mode for minimum load operation (I). Check the combustion settings the same way as described for full load. The combustion settings for the pilot burner can be adjusted using the adjustment screw on the pilot gas valve (6). The combustion settings for the main burner can be adjusted using the adjustment screw (N) on the main gas valve (7).

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 parameter P9 is set back to 100 and switch the boiler to automatic operation (O) after the combustion test is finished.

Main burner
Combustion settings for natural gas G20 / G25
All boilers
CO2 max %	10.0 ± 0.2
COmax	ppm	<
CO2, min %	9.3 ± 0.2
COmin	ppm	<

30

30

30

30

Main burner
Combustion settings for LPG G31
Parameter change required P19 : 100% ▶ 86%
All boilers
CO2, max %	11.0 ± 0.2
COmax	ppm	<
CO2, min %	11.0 ± 0.2
COmin	ppm	<

Commissioning

Air pressure switch

Adjustment Air pressure switch Connect a pressure gauge to the indicated measuring points on the switch (1). Start the boiler at service mode for minimum load operation (A I ) .Measure the pressure differential across the switch, this should be ≈ 0.8 mbar. Turn the dial on the switch (2) counterclockwise until the end. Reduce the setting on parameter P17 step by step until the pressure differential is 0.4 mbar. Slowly turn the dial on the switch clockwise until the boiler goes to lockout. Set P17 back to its original setting!! Reset the lockout. Restart the boiler and check if the switch contact closes at O.4 mbar (indicator at DW in display of the boiler controller (3). If required, repeat the above procedure.

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):

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

Flow rate R3401 - R3405 at ΔT 20K
	R3401	R3402	R3403	R3404	R3405
Nominal flow	[m³/h]	28.5	31.6	37.0	41.8	46.8
Δp at nom. flow	[kPa]	46	53	36	43	50

Flow rate R3406 - R3410 at ΔT 20K
	R3406	R3407	R3408	R3409	R3410
Nominal flow	[m³/h]	51,6	56,1	64,1	72,1	80,1
Δp at nom. flow	[kPa]	58	91	60	130	165

Flow rate R3501 - R3505 at ΔT 20K
	R3501	R3502	R3503	R3504	R3505
Nominal flow	[m³/h]	26,4	30,8	34,9	39,0	43,0
Δp at nom. flow	[kPa]	37	25	30	35	40

Flow rate R3600 - R3605 at ΔT 20K
	R3600	R3601	R3602	R3603	R3604		R3605
Nominal flow	[m³/h]	24,7	27,6	32,2	36,5	40,8	45,0
Δp at nom. flow	[kPa]	48	56	38	45	53	60

Commissioning

Check functionality of safety devices Gas tightness check Boiler shut down

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, water flow switch, minimum gas pressure switch and ionisation electrode. These devices can be checked as described below.

Water flow temperature sensor (1) Disconnect the plug from the sensor while the boiler is switched on. This should result in a lockout no. 12. The lockout should disappear as soon as the plug is placed back in position, the boiler will restart.

Water flow switch (2)

Close (slowly!) the valve in the flow connection to the system while the boiler is running on minimum load. When the valve is almost closed and the water flow is insufficient, the water flow switch will switch off and the boiler will go in lockout 40. Open the valve. A manual reset is necessary.

Minimum gas pressure switch (4)

Close the gas cock when the boiler is in standby position (6). Open the test point on the gas valve (3) 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.5. The boiler will try to restart. With the electrical connection removed, the restart will result in lockout no.4. 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 (6)
• 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 R3400/R3500/R3600
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-Placed 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]	Water flow switch checked		☐
Min. gas pressure switch setting [mbar]
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 pilot burner	[%]	[%]	[%]
O2 pilot burner	[%]	[%]	[%]
CO pilot burner [ppm]	[ppm]	[ppm]
NOx pilot burner	[ppm]	[ppm]	[ppm]
CO2 main burner	[%]	[%]	[%]
O2 main burner	[%]	[%]	[%]
CO main burner	[ppm]	[ppm]	[ppm]
NOx main burner	[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]
Parameter settings
P1 Setpoint temperature heating [°C]	P12 Boiler hysteresis [°C]
P2 Setpoint temperature DHW [°C]	P17 Fan speed min. load [‰]
P11 Maximum boiler setpoint [°C]	P19 Fan speed 100% load [‰]
Remarks

Operating instructions

Main menu (operating mode) Parameter menu (information/programming mode) Changing parameter values

The boiler controller has two menus: the main menu (operating mode) when the lid is closed, and the parameter menu (information/programming mode) when the lid is open. Both menus and possibilities are explained in the next paragraphs.

Main menu (operating mode) lid closed

With the lid closed and by using the rotational switch (1) clockwise or anticlockwise, the boilers' operating mode (2) can be set. The available modes are:

念 Standby mode (only frost protection)
Automatic operation mode (heating and DHW)
Summer mode (only DHW, no heating)
I Service mode minimum load
Service mode full load (limited by P9)

Besides the operating mode, the display also shows the actual water flow temperature (3) and, in case of a lockout, a warning triangle (4) combined with a lockout code (5). The explanation of the lockout codes can be found in chapter "Lockouts".

Parameter menu (information/programming mode) lid open

With the lid open and by using the rotational switch (1) clockwise or anticlockwise it's possible to read/change certain values/parameters from the boiler controller. An arrow at the bottom of the display (2) indicates which parameter has been selected. The available values/parameters are:

P1 Actual / setpoint water flow temperature [^ C]
P2 Actual/setpoint DHW temperature [^ C]
P3 Actual temperature/capacity setpoint for boiler [^o C]^*
P4
P5 Actual outside temperature [^ C] (if sensor is connected)
P6 Actual fluegas temperature [^ C]
P7
P8 Actual low velocity header temperature [^ C] (if sensor is connected)
P9 Actual / Limit boiler output [%]
P10 Password for advanced settings

• P3 shows the actual temperature setpoint of the boiler, either coming from P1/P2 or from an additional (weather compensated) controller or building management system (2-10V). When the boiler capacity is controlled via a cascade manager or building management system (2-10V), P3 shows the actual capacity setpoint of the boiler.

Behind the lid you find an optical I/O connection (6), a reset/programming button (7) and an alarm/programming LED (8). Besides the parameter values/ settings, the display also shows additional information with regard to input and output indications to and from the boiler:

Output indications

Power to main gas valve
Power to ignition transformer
Fan control signal
Power to primary boiler pump
Power to DHW pump/diverter valve

Input indications

Flame ionisation detected
SW Water flow switch active
DW Air pressure switch active
RT Boiler enabled**
Bus Bus communication active

**The boiler enable signal is equipped with a jumper in the standard delivery and therefore the boiler will normally be enabled. If a building management system is connected to provide the enable signal to the boiler (jumper should be removed), check the building management system if the boiler remains disabled.

Changing parameter values

For changing any parameters, in the example parameter P2 (DHW setpoint), the following procedure should be carried through:

• Open the lid (the arrow at the bottom of the display indicates parameter P1)

• Turn the rotational switch clockwise until the arrow indicates parameter P2

• Press the reset/programming button to select (the LED lights up)

• Turn the rotational switch until the desired DHW setpoint value has been reached
• Press the reset/programming button to confirm (the LED goes out)
• Close the lid.

The new value is now activated. All parameters can be changed by following the same procedure as described above.

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;
• 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 electrodes (2) as shown on the picture.

Maintenance

Cleaning the condensate receptacle Cleaning and refilling the syphon

Cleaning the condensate receptacle

• Remove the inspection hatch (2) to access the inside of the condensate receptacle;
  Clean the receptacle;
• Mount the inspection hatch.

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.

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.

Cleaning and refilling the syphon

• Remove the syphon (3) from the condensate connection;
• Clean and fill it with fresh water;
• Mount the syphon back in the original position.

Maintenance Protocol

Maintenance Protocol R3400/R3500/R3600
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 Δρboller [kPa]
Water flow [m3/h]
Pump setting [-]
Safety devices
High limit setting [°C]		Water flow sensor checked ☐
Temp. limiter setting [°C]		Water flow switch checked ☐
Min. gas pressure switch setting [mbar]
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 Pilot burner	[%]	[%]	[%]
O2 Pilot burner	[%]	[%]	[%]
CO Pilot burner	[ppm]	[ppm]	[ppm]
NOx Pilot burner	[ppm]	[ppm]	[ppm]
CO2 Main burner	[%]	[%]	[%]
O2 Main burner	[%]	[%]	[%]
CO Main burner	[ppm]	[ppm]	[ppm]
NOx Main burner	[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]
topanel	[mbar]	[mbar]	[mbar]
combustion chamber	[mbar]	[mbar]	[mbar]
Parameter settings
P1 Setpoint temperature heating [°C]		P12 Boiler hysteresis [°C]
P2 Setpoint temperature DHW [°C]		P17 Fan speed min. load [%]
P11 Maximum boiler setpoint [°C]		P19 Fan speed 100% load [%]
Remarks

In case of a lockout, a warning triangle () 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. In case the lockout appears more than twice within 6 minutes or maintains for longer than 6 minutes, the error code is added with a n^3 . The table below shows all possible lockouts and an indication of possible cause.

No.	Error type	Explanation	Possible solution
1	Lockout Water flow temperature has exceeded the high limit temperature setting (100°C).		Check if boiler is in automatic mode (K), Check if water flow through the boiler is sufficient, check if (P11+P12) < High limit setting (V9).
2	Interlock Gas pressure has dropped below minimum value of minimum gas pressure switch or additional safety device connected to the interlock input has been interrupted (during startup).		Check gas supply pressure / check function of additional safety device on interlock input.
3	Interlock Gas pressure has dropped below minimum value of minimum gas pressure switch or additional safety device connected to the interlock input has been interrupted (during operation).		Check gas supply pressure / check function of additional safety device on interlock input.
4	Lockout No flame ionisation signal detected during burner start.		Check phase/neutral of power supply (phase sensitivity!), check gas supply, check ignition spark, increase gas valve setting min. load (alan key screw).
5	Lockout Flame ionisation signal lost during operation. Check gas		gas supply pressure during operation, check gas valve setting via combustion analysis.
6	Interlock Water flow temperature has exceeded the temperature limiter setting (97°C).		Check if boiler is in automatic mode (Φ), check if water flow through the boiler is sufficient, check if (P11+P12) < Temp. limiter setting (V10).
7	Lockout External safety device connected to the lockout input has been interrupted.		Check the external safety devices (water pressure switches, safety thermostat, etc.)
11	Lockout Flame ionisation signal detected before burner start.		Check ionisation electrode, measure ionisation current when boiler is off, check wiring between ionisation electrode and boiler controller.
12	Interlock Water flow temperature sensor is defective.		Check resistance of sensor (see chapter "sensor values"), check wiring between water flow temperature sensor and boiler controller.
14	Interlock DHW temperature sensor (optional) is defective.		Check resistance of sensor (see chapter "sensor values"), check wiring between DHW temperature sensor and boiler controller.
15	Interlock Outside temperature sensor (optional) is defective.		Check resistance of sensor (see chapter "sensor values"), check wiring between outside temperature sensor and boiler controller.
18	Interlock Header temperature sensor (optional) is defective.		Check resistance of sensor (see chapter "sensor values"), check wiring between header temperature sensor and boiler controller.
20	Lockout Error gas valve V1, flame ionisation signal detected longer than 5 seconds after burner stop.	Check closing position of valve V1 within gas combi valve, replace gas valve.
21	Lockout Error gas valve V2, flame ionisation signal detected longer than 5 seconds after burner stop.	Check closing position of valve V2 within gas combi valve, replace gas valve.
22	Lockout	APS contact does not close during prepurge.	Check setting APS, check if fan is running.
23	Lockout APS contact remains closed when fan is off. Check setting APS
27	Lockout APS contact opens during operation. Check setting APS
30	Lockout CRC error in control system parameters (P11-P40).	Check parameter settings of P11-P40, change value of one parameter within P11-P40 (lockout disappears), change all parameters back to original settings.
31	Lockout CRC error in boiler safety parameters (V1-V16).	Check parameter settings of V1-V16, change value of one parameter within V1-V16 (lockout disappears), change all parameters back to original settings.
32	Interlock Power supply voltage to boiler controller is too low.	Check fuse of boiler controller, check power supply to boiler controller.
40	Lockout Water flow switch has been interrupted when pump being enabled.	Check pump operation, check water flow through the boiler, check functionality of water flow switch.
x.y.	Lockout (all) lockout codes which are not listed above) Internal lockout of boiler controller.	Press reset. Change boiler controller when lockout can not be reset or occurs more frequently.

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 products

R3400/3500/3600

are in conformity with the following standards:

EN 656

EN 15417

EN 13836

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)

90 / 396 / EEC (gas appliance directive)

73/23/EEC (low voltage directive)

89/336/EEC (EMC directive)

These products are designated with CE nr.:

CE-0063AR3514

Kerkrade, 10-06-2013

A.J.G. Schuiling

Plant Manager

Inhalt

Abmessungen R3600 - R3605 Split system

Abmessung		R3600	R3601	R3602	R3603	R3604	R3605
L	mm 19	58 20	70 24	43 24	43 24	43 24	43 1166 88 1166
L2	mm 700		590		1166	1166
L3	mm	108	198	88	88	88
H mm	1355	1405	1405	1405	1405	1405
B mm	1230	1330	1130	1130	1330	1330
B1 mm	1110	1210	1003	1053	1203	1253
B2 mm	615	665	565	565	665	665
B3 mm	120	120	127		77	127
B4 mm	1046	1146	946		946	1146
B5 mm	100	65	115	65	115	65
D mm	300	300	350	350	400	400
D1 mm	250	250	300	300	355	355
W1 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W3 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Lieferumfang

Standardausführung

Zubehör

Standard Ausführung

(boiler efficiency directive)

-90/396/EEC

(gas appliance directive)

-73/23/EEC

(low voltage directive)

-89/336/EEC

(EMC directive)

-EN656

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

-EN15417

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

-EN13836

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

-EN55014-1

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

• EN 61000-3-2

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

EN61000-3-3

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

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

-EN50165

Household and similar electrical appliances - Safety - Part 2-102: Particular requirements for gas, oil and solid-fuel burning appliances having electrical connections

Aanyullende nationale normen:

Duitsland:

• RAL - UZ 61 / DIN 4702-8

Zwitserland:

Afmetingen R3600 - R3605 Split system

Afmeting		R3600	R3601	R3602	R3603	R3604	R3605
L	mm	1958	2070	2443	2443	2443	2443
L2	mm	700		590	1166	1166	1166
L3	mm	108		198	88	88	88
H	mm	1355	1405	1405	1405	1405	1405
B	mm	1230	1330	1130	1130	1330	1330
B1		1110	1210	1003	1053	1203	1253
B2	mm	615	665	565	565	665	665
B3	mm	120	120	127	77	127	77
B4	mm	1046	1146	946	946	1146	1146
B5	mm	100	65	115	65	115	65
D	mm	300	300	350	350	400	400
D1	mm	250	250	300	300	355	355
W1	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W3	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Standaard toestel

Accessoires

Standaard toestel

92/42/EEC (boiler efficiency directive)

90 / 396 / EEC (gas appliance directive)

73/23/EEC (low voltage directive)

89/336/EEC (EMC directive)

17 Raccordement cheminee

18 Récipient de condensation

22 Raccordement condensation

23 Vanne gaz principale

24 Ventilateur

25 Boite électrique

Dimensions R3600 - R3605 Standard

Dimensions	R360601	R3602	R3603	R3604	R3605
L mm	1958	2265	2653	2653	2658	2658
L1	mr595	595	610	610	615	615
L2 mm	700	590	1166	1166	1166	1166
L3 mm	108	198	88	88	88	88
H mm	1355	1405	1405	1405	1405	1405
H1	mm 970	1175	1450	1450	1205	1427
B mm	1230	1330	1130	1130	1330	1330
B1 mm	1110	1210	1003	1053	1203	1253
B2 mm	615	665	565	565	665	665
B3 mm	120	120	127	77	127	77
B4 mm	1046	1146	946	946	1146	1146
B5 mm	100	65	115	65	115	65
D mm	mm300	300	350	350	400	400
D1 mm	250	250	300	300	355	355
W1 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2 DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Caracteristiques techniques R3600 - R3605 Split System

Dimensions R3600 - R3605 Split System

Dimensions		R3600	R3601	R3602	R3603	R3604	R3605
L	mm	1958	2070	2443	2443	2443	2443
L2	mm	700		590	1166	1166	1166
L3	mm	108		198	88	88	88
H	mm	1355	1405	1405	1405	1405	1405
B	mm	1230	1330	1130	1130	1330	1330
B1		1110	1210	1003	1053	1203	1253
B2		615	665	565	565	665	665
B3		120	120	127		77	127
B4	mm	1046	1146	946	946	1146	1146
B5	mm	100	65	115	65	115	65
D	mm	300	300	350	350	400	400
D1	mm	250	250	300	300	355	355
W1	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W3	DN	DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R	R 2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16

Raccordements hydrauliques

Pression hydraulique

89/336/EEC (directive EMC)

Dimensioni R3600 - R3605 systemd split

Dimensioni	R3600	R3601	R3602	R3603	R3604	R3605
L	mm 1958	2070	2443	2443	2443	2443
L2	mm 700		590		1166	1166
L3	mm 108		198	88	88	88
H	mm 1355	1405	1405	1405	1405	1405
B	mm 1230	1330	1130	1130	1330	1330
B1	mm 1110	1210	1003	1003	1203	1203
B2	mm 615	665	565	565	665	665
B3	mm 120	120	127	77	127	77
B4	mm 1046	1146	946	946	1146	1146
B5	mm 100	65	115	65	115	65
D	mm 300	300	350	350	400	400
D1	mm 250	250	300	300	355	355
W1	DN DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W2	DN DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
W3	DN DN65 PN16	DN65 PN16	DN80 PN16	DN80 PN16	DN80 PN16	DN80 PN16
G	R R2"	R 2"	R 2"	R 2"	DN65 PN16	DN65 PN16