Summary of Contents for BURNS BOY III
- Page 1 Installation and Operating Instruction BOY III Condensing Gas Boiler Gebr. Bruns GmbH Hauptstraße 200 D 26683 Saterland Tel.: + 49 (0) 44 92 / 92 46 0 Fax: + 49 (0) 44 92 / 71 41 Stand 11/2009...
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Page 2: Table Of Contents
4.2.1 General Instructions for Connection the Heating Unit 4.2.2 Connecting the Heating Unit (Supply and Return Lines) 4.2.3 Connecting for Drinking Water (BOY III Combi) 4.2.4 Connecting for Use with an External Reservoir 4.2.5 General Instructions for the Gas Connection 4.2.6 Connecting the Gas Main... - Page 3 Table of contents Table of contents 5 Start up 5.1 Filling and Ventilating the Heating System 5.2 Ventilating the Unit 5.3 Ventilating the Lower/Standing Reservoir (optional) 5.4 Start up 5.4.1 Performance of the Unit Test Routine upon Start up 5.5 (Pre) Setting the Boiler 5.5.1 CO Boiler Settings 5.5.2 Gas Throughput Table / Connection Pressure...
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Page 4: Introduction
BOY III, you have secured the most current level of innovation in boil- er technology. We will gladly answer any questions or provide any information you may need. We thank you for your trust and hope you enjoy you BOY III Condensing Gas Boiler. Gebr. BRUNS GmbH, Your partner for heating technology Symbols used in this manual Failure to follow instructions marked with this symbol risks life and limb;... -
Page 5: Product Description
Fig. 1: Boy III Intended use The BOY III is a condensing gas boiler and is exclusively for use as a heating unit for heating systems. Any misuse is prohibited - 5 - Gebr. -
Page 6: Equipment Configuration Boy Iii Solo
Product Description Product Description Equipment configuration BOY III Solo Burner Unit High Temperature Sensor Ionisation Ignition Electrode Force Draught Fan Automatic Firing Device Gas Valve Relief Valve Return Sensor Flow Sensor Water Pressure Sensor Circulation Pump Fig. 2: BOY III Solo - 6 - Gebr. -
Page 7: Equipment Configuration Boy Iii Combi
Product Description Product Description Equipment configuration BOY III Combi Burner Unit High Temperature cut out Ionisation Ignition Electrode Force Draught Fan Automatic Firing Device Plate Heat Gas Valve Exchanger Relief Valve Return Sensor Flow Sensor Water Pressure Sensor Circulation Pump Fig. -
Page 8: Regulations, Guidelines, Safety
Regulations, Guidelines, Safety Regulations, Guidelines, Safety Regulations and Guidelines Regarding mounting, installation, and operation of the BOY III, the following laws, or- dinances, regulations, norms and rules apply according to the current versions. In other countries, the respective national regulations apply. -
Page 9: Safety Warning
● and out) must not be obstructed. The intake of combustion air on the top of the BOY III must be kept free of obstructions. 3.2.1 What to Do if You Smell Gas Avoid open fire, smoking, turning on lights, or unplugging anything in rooms that smell like gas. -
Page 10: Risk Of Freezing
Regulations, Guidelines, Safety Regulations, Guidelines, Safety 3.2.3 Risk of Freezing If the unit is at risk of freezing, it is necessary to be kept operational in conservation mode (at minimum) and all radiator valves should be kept open. If you cannot heat during freezing periods, turn off the system and empty the boiler, the warm water storage tank and the radiators. -
Page 11: Pressure Compensating Tank For Drinking Water
Regulations, Guidelines, Safety Regulations, Guidelines, Safety 3.2.6 Pressure Compensating Tank for Drinking Water In combination with a drinking water reser- voir, a membranous pressure compensat- ing tank that has been approved for filtering domestic-use water to drinking water is re- quired. -
Page 12: Corrosion Protection
Regulations, Guidelines, Safety Regulations, Guidelines, Safety 3.2.10 Corrosion Protection The combustion air must be free of all corrosive elements – especially those contain- ing fluoride and chloride such as those found in solvents and cleaning solutions, pro- pellants an so on. When connecting a water heater to a floor heater with non-airtight plastic tubing (in accordance with DIN 4726), a heat exchanger must be used to separate the sys- tems. -
Page 13: Mounting/Installation
The delivery comes in a cardboard box. Fig. 10 Shipment Contents Pos. Anzahl Bezeichnung Condensing Gas Boiler BOY III Atmospheric or Temperature Sensor (Optional) Pressure Gauge Control Keypad with Illuminated Display Wall Mounting Track Mounting Screws incl. Washers... -
Page 14: Mounting The Unit
Mounting / Installation Mounting / Installation Mounting the Unit The unit comes with a track for easy wall mounting. Before mounting the unit, please read the following requirements: • The wall must be stable enough to hold the unit. • An outlet with contact protection for electricity and a water drainage connection should both be in close proximity. -
Page 15: General Instructions For Connection The Heating Unit
A separate line for filling and draining must be Fig. 13 Connections: BOY III Solo installed and easily accessible. If the line for filling and draining is not at the lowest point of the unit, an additional device must be installed so the system can be completely drained. -
Page 16: Connecting For Drinking Water (Boy Iii Combi)
If the unit is connected to an external reservoir, an expansion tank and a 10 bar relief valve must be installed to protect the heating system. The BOY III Solo requires an additional three-way redirecting valve installed in the return flow line directly on the boiler. -
Page 17: General Instructions For The Gas Connection
Mounting / Installation Mounting / Installation 4.2.5 General Instructions for the Gas Connection • The gas connection must be connected in accordance with the current regulations. Installation may only be performed by a licensed profes- sional! • Make sure there is no open fire, flammable materials or the like in close proximity to the installation location. -
Page 18: General Instructions For Connecting The Gas Flue
Mounting / Installation Mounting / Installation 4.2.7 General Instructions for Connecting the Gas Flue Discuss regional guidelines for gas flue lines, cleaning openings and similar with the appropriate chimney sweep. 4.2.8 Chimney Compatibility Heavily used and dirty chimneys are unsuitable for conducting combustion air (air supply through the chimney) and must be cleaned by a chimney sweep before use. -
Page 19: Connecting The Unit To The Chimney
Make sure to take headroom for the test connection and the revision T-piece (T-fitting) into account. Fig. 17 BOY III with Emission Connection The opening for mounting the support bar should be made according to the dia- gram. - Page 20 Fig. 21 Emission Connection - BOY III Follow the installation instructions for the respective emissions system! - 20 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
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Page 21: Installing The Emissions Connection To Central Roof Heating
Mounting / Installation Mounting / Installation 4.2.14 Installing the Emissions Connection to Central Roof Heating Measure the point where the emission pipe opening will be based on the posi- tion of the unit. Install the special feed through socket as appropriate for the space provided. -
Page 22: General Instructions For The Electrical Connection
Mounting / Installation Mounting / Installation 4.2.17 General Instructions for the Electrical Connection • This should only be performed by a licensed professional! • Make sure the unit is disconnected from electricity before beginning! Life threatening danger! • In Germany, the VDE and local regulations must be followed when in- stalling. -
Page 23: Pin Assignment On The Terminal Strip
BOY III Combi comes with an integrated and preinstalled three-way valve - 23 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. -
Page 24: Start Up
Mounting / Installation Mounting / Installation Start up Filling and Ventilating the Heating System The condensing gas boiler is not yet ready for operation! Fill the heating system to a maximum water pressure of1.5 bar! Ventilate the entire heating system via the installed ventilation valves on the radiators, floor heaters and so on. -
Page 25: Ventilating The Lower/Standing Reservoir (Optional)
Mounting / Installation Mounting / Installation Ventilating the Lower/Standing Reservoir (optional) To ventilate the heat exchanger’s heating coil in the lower/standing reservoir, you must operate the three-way valve manu- ally. To do this, remove the safety splint from the three-way valve ... and pull the motor off the valve. -
Page 26: Start Up
Mounting / Installation Mounting / Installation Start up After successfully ventilating and dejamming the unit, it will start in drinking water mode (if available); otherwise it will start in hot water mode. To start in hot water mode or in drinking water mode, the unit requires a certain level of heat. This can be done by opening the thermostats on the radiators. -
Page 27: Gas Throughput Table / Connection Pressure
Mounting / Installation Mounting / Installation 5.5.2 Gas Throughput Table / Connection Pressure Gas Flow rate Connection (l/min) Gas Type Load Area Pressure Min. Max. LL(L)-Gas 5,1 – 22,8 kW 11,6 50,1 20 mbar E(H)-Gas 5,1 – 22,8 kW 10,0 43,3 20 mbar Liquid Gas... -
Page 28: Operating The Controls
Operating the Controls Operating the Controls Operating the Controls Description of the Control Panel Function Description Switch to summer mode/ Chimney sweep Taste 1 mode Taste 2 Installation Mode / Installation (+) Mode Taste 3 Dejamming/ End Mode/ Error Log Taste 4 Positive Set-point changes heating water Taste 5... -
Page 29: Controller Functions And Operating Status
Operating the Controls Operating the Controls Controller Functions and Operating Status In the followings sections, the control functions as well as the displays for the differ- ent operating modes will be described. If an external Open Therm controller or set-point calculator is installed, ... -
Page 30: Central Heating Mode
Operating the Controls Operating the Controls 6.3.4 Central Heating Mode 6.3.4.1 Operating the Central Heater If the thermostat closes or the optional Open Therm unit registers a heating demand, the following information will be displayed. Display Display Element Central Heating Warm-up Temperature Segment B and C Celsius-Symbol Segment D... -
Page 31: Anti-Cycling Drinking-Water Heater
Operating the Controls Operating the Controls 6.3.5.2 Anti-Cycling Drinking-Water Heater When the demand for drinking-water is over, the anti-cycling function is activated. When in this mode, the following information will be displayed Display Display Element Drinking-Water Temperature Segment B and C Celsius-Symbol Segment D Drinking-Water Heater Anti-Cycling... -
Page 32: Summer Mode
Operating the Controls Operating the Controls 6.3.7 Summer Mode Summer mode can be activated by quickly pressing the 1 button (less than 1 second). In the table be- low, the information for summer mode status is a s t e shown. -
Page 33: Installer (+) Mode
Operating the Controls Operating the Controls Set-point Information Actual flame current Actual supply temperature of the central heater Actual return flow of the central heater Actual temperature of the drinking-water Water pressure Type of use Actual temperature of the flame pipe or TTB Throughput speed of the drinking-water (Hz) Current control-set-point Current outside temperature (OTC-Temperature) -
Page 34: Installer (+) Parameter List
Operating the Controls Operating the Controls 6.3.10.1 Installer (+) Parameter List The following values will be displayed and can be changed. Values with the sym- bol cannot be changed! Default Index Parameter Description Area V1042 Esys2042 Central factor for the ascent/des- cent of the edge;... - Page 35 Operating the Controls Operating the Controls Default Index Parameter Description Area V1042 Esys2042 1-10 DHW Pump Pump overrun time for the drink- 30-180 Sec. 30 Sec. 30 Sek. Overrun ing-water heater CH Hyster- Hysteresis of the central heater’s 2-10 °C 3 °C 7 °C esis...
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Page 36: Malfunctions And Errors
Malfunctions and Errors Malfunctions and Errors Malfunctions and Errors Error Mode If there is an error the following information are displayed a s t e Display Display Element Error code Segment C and D E-Symbol Segment B Errors can be reset LED 3 = Blinking blinking / off Errors that can correct themselves... -
Page 37: Locking Codes
Malfunctions and Errors Malfunctions and Errors 7.2.2 Locking Codes The boiler controller also recognises errors that may lead to the heating demand lockup, but does not recognise errors that may lead to a shutdown. If the error is re- solved, it disappears, but will be recorded in the error log. The descriptions of these codes are as following: Code Description... - Page 38 Malfunctions and Errors Malfunctions and Errors Code Description Solution Refill water (1.6 bar). Check the water pressure on the display and match it with the pressure gauge. If the difference is larger than 0.6 bar, re- place the water pressure sensor. Water pressure is too low.
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Page 39: Error History Mode
Malfunctions and Errors Malfunctions and Errors Error history Mode The Error history mode can be activated by holding the 3 button longer than 3 seconds. The informa- tion’s displayed format is shown in the following a s t e table Display Display Element E-Symbol alternating with the... -
Page 40: Maintenance
Maintenance Maintenance Maintenance General Instructions for Maintenance • Cleaning and maintenance should only be performed by a licensed professional. • Close all gas and heating and drinking water valves before beginning! • Make sure the unit is disconnected from electricity before beginning! Cleaning the Condensed Water Siphon The condensed water siphon should be cleaned in the following intervals: Yearly: the siphon connection on the bot-... -
Page 41: Gebr. Bruns Gmbh • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71
Maintenance Maintenance Disconnect the ignition plug, ionisation and PE cable (ground) from the boiler. Use a flat spanner (SW 27) to remove the gas valve connection. Make sure the washer does not fall out of the connec- tion. Use a flat spanner (SW 13) to remove the control unit’s securing screw. - Page 42 Maintenance Maintenance Remove the control unit by pulling to the right. Remove the burner screws. Carefully remove the burner. Carefully clean the heat exchange surfaces in the combustion chamber as well as the burn- er head with a nylon brush. Do not use a wire brush, sharp objects and so on! nstall the components in reverse order.
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Page 43: Technical Data
Technical Data Technical Data Technical Data Circuit Diagram - 43 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41 •... -
Page 44: Technical Data
Technical Data Technical Data Technical Data 2 1 0 1 0 8 1 5 4 2 0 5 2 4 3 3 0 5 3 9 5 3 9 5 1 6 5 1 2 5 - 44 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. Gebr. - Page 45 Technical Data Technical Data BOY III Solo / Combi Width / Height / Depth 395 / 650 / 295 Weight CE- number CE- 0045BRKD 1002 Type of unit (licensed for...) B 23 & C 63x Preset gas type natural gas type LL Rated heating range of performance 50/30°C...
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Page 46: Declaration Of Conformity
Technical Data Technical Data Declaration of Conformity - 46 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41 •... - Page 47 Notes Notes - 47 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41 •...
- Page 48 Notes Notes - 48 - Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments. Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41 •...
- Page 49 Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41 • www.bruns-heiztechnik.de info@bruns-heiztechnik.de...