BK20/BK30 Overview – laws, regulations and standards Overview – laws, regulations 92/42/EWG Efficiency guidelines and standards General information: 2006/95/EG Transportation, installation, mounting and electri- Electrical equipment designed for use within cer- cal connections should be done by a competent tain voltage limits person. He bears responsibility for a proper implementation of these works. DIN EN 267:2011-02 Fan-assisted oil burner Before installation of the Fully Condensing Boiler, it is necessary to obtain permission of the local DIN EN 676:2003 + A2:2008 heating equipment inspection board or other Automatic forced draught burners for gaseous competent authorities. fuels In order to prevent penetration of oxygen into the DIN EN 677:1998-08 closed heating system, it is advisable to perform Gas-fired central heating boilers...
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Overview – laws, regulations and standards DIN EN 304:2004/01 Condensing heating boilers – test code for hea- ting boilers with fan-assisted oil burners 1 BImSchV (22.03.2010) Regulation on small furnaces ATV A 251 Removal of condensate from chimneys DIN EN 60 335-1:2010 DIN EN 60 335-2-102:2010 Safety of household and similar electrical appli- ances 2004/108/EG Electromagnetic compatibility Furthermore, for installation in Austria the following norms and regulations are valid: • ÖVE – Rules and local rules •...
BK20/BK30 Information Information 2.2 Warning symbols In these operating instructions the following war- ning symbols are used: 2.1 Identification (label) Attention Disregarding the instructions marked with this UNIT BK20 fully condensing boiler with fan symbol may result in a danger for persons and Product Id. Nr. CE0035CM103 property damage. Heating output 15 - 21 kW Flue gas temperature 47°C / 54°C Max. operation temperature 100°C Max.
Information 2.3.4 About these operating instructions 2.6 Liability limitations For reasons of clarity, these operating instruc- The company takes no responsibility for tions do not contain all detailed information with damages to the delivered Fully Condensing Boi- regard to possible constructional and equip- ler caused by the following reasons: ment versions of the Fully Condensing Boiler in • Ignorance of or failure to comply with these question. At the same time, it is not possible to operating instructions. foresee every imaginable case of installation, • Insufficiently qualified maintenance staff or configuration, operation and/or maintenance. In inadequately instructed service personnel. the event you will require additional information or some specific problems will arise that are not • Natural wear and tear! For details see addressed in detail in these operating instruc- DIN 31 051 Part 4, EN 13 306 „Maintenance tions, please refer for information to a competent terms“. heating installation company or directly to the • Faulty or negligent handling of the Fully company. Condensing Boiler and, in particular, omis- 2.4 Validity sion of taking measures as to safe and proper These operating instructions are valid only with respect to the Fully Condensing Boiler marked ◦...
BK20/BK30 Safety instructions Safety instructions The operating instructions should be positioned visibly adjacent to the Fully Condensing Boiler. 3.1 General information The connection and adjustment of the heating These operating instructions are valid exclusively system should be performed by a qualified plum- for the BK Fully Condensing Boiler. The staff ber. The heating technician should familiarize the in charge of installation, commissioning or main- operator(s) of the Fully Condensing Boiler with tenance should read the operating instructions its functions and servicing! In the event of any prior to starting these works. The requirements faults or disturbances in the operation of the Fully contained in these operating instructions must Condensing Boiler, please notify the heating ins- be adhered to. In the event of a non-compliance tallation company! with the operating instructions, the guarantee claim vis-à-vis the company shall expire. If you smell gas, there is a risk of explosion 3.2 Safety guidelines •...
Safety instructions combustion, under assistance of a specialized installing company. If, after a cleaning, repeated dust exposure shall still be possible, (for example, due to spongy chimney joints), take the appropriate measures (for example, clean the chimney). Modification of the gas heating system The operator may under no circumstances make changes in the heater, pipes for gas, electricity, water, air supply and flue gas. These works may be performed only by a hea- ting technician, to eliminate the above mentioned hazards. 3.3 Norms, regulations • The boiler must be serviced in regular inter- vals. We recommend to conclude, for this purpose, a maintenance contract. Fig. 1: A lateral distance of minimum 600 mm should be maintained either on the left or on the right side • The Fully Condensing Boilers may be ins- of the boiler. talled and operated only in the boiler and installation rooms as required by local regu- A connecting line should be lead to the chimney lations and guidelines (FeuAO) with respect as short as possible and ascending. This is the to furnaces. only way to ensure the optimum performance. The pipes should be carefully sealed! If the • For Austria are also relevant the provisions flue pipes are not properly sealed, the flue gas of the Austrian Gas and Water Industry may escape and cause the risk of suffocation.
BK20/BK30 Safety instructions functions and to check the tightness of the Fully Before commencement of any works on the Condensing Boiler and its connections. electrical equipment, make sure that the voltage is completely switched off. Damaged, burned, Attention frayed cables as well as loose and untight cable connections must be immediately replaced by a In the event of unusual operating performance skilled electrician. in the functioning of the Fully Condensing In the event of a defective fuse, they must be Boiler, for example, malfunctions or faults in replaced only with the original fuses with prescri- energy supply, the unit must be immediately bed amperage. shut off. 3.5 Safety installations Determine the cause of the problem or fault and fix it in a safe and secure manner. Start re- Attention commissioning only after complete elimination of faults. The commissioning of the Fully Condensing Boiler without a properly functioning safety 3.4.1 Burner faults/remote unlocking installation (or with an improperly functioning In case of a burner defect or fault, the red push safety installation), is not permitted. button in the control panel will flash. Press the button shortly to unlock the burner. Should the 3.5.1 Water-side safety installations burner fault reappear, call a qualified specialist.
Safety instructions The definition is made in compliance with 1. During disposal works, use safety gloves. BImSchV (1st Federal German ruling on emissi- ons control) condensing boilers: these are heat generators which utilize by condensation, as a result of their design, the heat of vaporization of water vapour contained in flue gases. This defini- tion differentiates the heat generation with utiliza- tion of the heat of vaporization of water vapour in flue gases from the heat generators without such utilization. 3.6 Waste disposal and environmen- tal protection The following substances which may originate during maintenance and repair works should be disposed of – under personal responsibility of the heating technician: • Sediments, for example, after a breakdown • Heating oil rests • Cleaning agents and consumables • Solid waste (replaced components) of all types All disposal works should be conducted as prescribed, also pursuant to 1. BImSchV and German Waste Management Law (AbfG) and in compliance with the provisions of the Water Resources Act (WHG) as well as with local and regional regulations. Liquid waste such as potential toxic substances capable of endangering ground water (WHG) should be collected in special closed containers and allocated for the proper disposal.
BK20/BK30 Function and description Function and description of electrical/electronic measuring and control devices. Maximum ambient temperature: 40 °C 4.1 Function and operating principle Minimum ambient temperature: 1 °C In the furnace of the BK Fully Condensing The inducted combustion air should be dust-free Boiler, the combustion heat from oil or gas is and of normal quality (temperature, humidity transferred to the combustion chamber washed etc.). round by the boiler water and to the primary heat The BK Fully Condensing Boiler is operative exchanger which is connected to the combustion and reliable provided that it is used properly, the chamber from the water side. The hot flue gases agreed operational data are adhered to and only arrive then, under temperatures below 85 °C – prescribed fuels are used. that is, above the dew point – into the secondary It is necessary to take into consideration possible heat exchanger and they are cooled down, in malfunctions, if: accordance with the external air temperature, to • installation, adjustment and subsequent trial about 30 °C – 48 °C. The dew point of the flue operation were not carried out properly. gas is thereby not reached and both sensible and latent (hidden) heat is delivered, through steam •...
Function and description • controls the operating performance in con- ◦ Connecting pieces of seamless tubes in formity with the heat demand of the heating accordance with DIN 1629 installation, and • The secondary heat exchanger • as safety circuit, can shut down the in the PP/PP event of any malfunctions on the water or • Thermal insulation/outer cover gas side. ◦ 3-sided mineral wool 80 mm • The pressure transmitter serves for the fun ◦ Front – mineral wool 40 mm with coating regulation and control. integrated into the front door The Conform 6.0 control system is integra- ◦ Boiler casing – steel plate 1,25 mm, scre- ted in the Fully Condensing Boiler. wed together and powder-coated. When studying the information in these operating instructions, please always compare the indica- 4.2.4 Safety installations ted type designation with the data on the control The BK Fully Condensing Boiler is fitted pur- panel of the delivered boiler. suant to DIN EN 304 and DIN EN 303 with the following safety installations.
The connection of the service water heater is confirmation (OC). made at the inlet and the outlet of the BK Fully • without negative pressure at the combustion Condensing Boiler. A heating technician should gas path required for operating purposes. install a service water circulation pump. The The risk for the persons, the Fully Condensing respective electrical sockets are available at the Boiler and other equipment carries the heating boiler control panel (see circuit diagram in the technician or the operator of the heating system. description of the Conform 6.0 system). A sensor for measuring the service water tempera- ture is attached to the control system. Flue gas pipe dimensions BK20 and BK30 room sealed heating RSH [non-room sealed heating NRSH] With flue gas fan Boiler type BK20 BK30 Fuel Heating oil Heating oil Flue gas pipe 80/125 80/125 80/125 80/125 Duct system 18 [21]...
(RSH) C13, C33, C43, C53, C63 or C83 pursuant to DIN EN 15 035 4.4 Technical data with regard to installation, commissioning and maintenance. The operating data for the delivered Fully Con- The third party operating manuals and/or cir- densing Boiler may be found on the label or in cuit diagrams of the boiler equipment, control the order confirmation. systems, supplementary documentation, expert The present operating instructions are attached assessments etc. should be taken into consi- to the delivered Fully Condensing Boiler inclu- deration. If needed, these documents may be ding technical data, dimensions and instructions requested directly from the company. Boiler type BK20 BK30 Fuel Heating oil Natural gas Heating oil Natural gas Nominal heat output 15,0 – 21,0 15,0 – 21,0 22,0 – 32,0 22,0 – 32,0 Firing capacity 15,2 – 21,2 15,2 – 21,2 22,2 – 32,3 22,2 – 32,3 content* Vol.-%...
Delivery – transportation to installation site Delivery – transportation to installation site 5.1 Safety instructions During loading or unloading, any transportation to installation site and also during temporary sto- rage or warehousing, it is necessary to comply with regulations, warnings and instructions rela- ted to safety guidelines of the respective country. 5.2 Unloading, use of hoist The BK Fully Condensing Boiler is brought to shipping completely or partially assembled. • Danger of injury! Manual unloading or trans- portation of weights >35 kg (ILO, Geneva) or one-time lifting of maximum >55 kg (Acci- dent prevention regulations/Federal Ministry of Labour and Social Affaires of Germany) is forbidden. • For your own security, always use suitable hoisting devices and/or industrial trucks as well as other load handling accessories with adequate load capacity. Before loading or unloading the Fully Condensing Boiler, take care to ensure sufficient space for secure placing of the boiler. • The load handling accessories must be carefully attached and secured. There should be no danger from suspended loads! •...
BK20/BK30 Installation and connection Installation and connection 6.2 Electrical connection The reliable mains connection is to be performed by an experienced electrician. 6.1 Fully Condensing Boiler The installation of the Fully Condensing Boiler Information should be carried out under consideration of the actual installation guidelines. In this case, it is 1� The characteristics of electrical mains necessary to install safety-related equipment in should meet the respective local and nati- conformity with DIN 12 828, for example, a safety onal legal provisions. group maximum 3 bar. 2� As power cables, choose at least one fle- For operation with gas fan burners, the following xible cable with polychloroprene coating, classes of gas equipment are utilized (pursuant in accordance with 60245 IEC 45 (for to DIN EN 437): example, NYM 3x1,5 m Country Classes of Gas connec- 3� The earth wire should be longer than...
Installation and connection 6.3 Burner installation Step 1: Pull out above both wing flaps and turn them down. Step 2: Lead burner flange behind the insulation at the burner door and fasten it with four screws. Then hook the burner flange up and fix it. Step 3: Again hook up both wing flaps.
BK20/BK30 Installation and connection 6.4 Condensate drainage Boiler The condensate accumulated in the secondary siphon heat exchanger is processed in the neutraliza- tion box of the BK Fully Condensing Boiler. When discharging the condensate into sewage 25 mm or wastewater sewer, it is necessary to take into siphon-like account the waterway prescriptions of the res- hopper pective country and the statutes of local waste disposal companies! The unit operator must Fig. 6: Condensate trap obtain the authorization, bearing in mind the Advisory leaflet A-251 „Condensation disposal 6.5 Handing over and servicing in chimneys” with presentation of the expert assessment. On installation of the supplied neu- instructions tralization box, it is essential to annually loosen It is essential that the installation, commissio- and rinse the granulate. ning and maintenance of the Fully Condensing Boilers are carried out by qualified and trained Attention personnel. During the installation and trial run, it is necessary to carefully check the conformity of During installation of the condensate drainage safety installations with DIN 12 828 as well as its system, care must be taken to ensure that functioning and correct setting and to confirm it in the condensation water level of 120 mm (see the commissioning report.
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Installation and connection Option 1 Neutralization box aligned with the permanently condensing boiler. Option 2 Neutralization box at right angles to the permanently condensing boiler. Option 3 Neutralization box parallel beneath the permanently condensing boiler (additional HT tube required).
BK20/BK30 Cleaning Cleaning Step 2: Remove the fastening screws/nuts (4 pieces, Attention width across flats 17) at the boiler door and open the door together with the burner. Maintenance and cleaning works may only be Attention! Risk of burning – wear protective carried out by authorized skilled personnel. gloves! At each service check-up, the Fully Condensing Boiler should be switched currentless (main switch of the Fully Condensing Boiler and main switch of the heating system). It is recommended to place in the installation room, as a precautionary measure, a signboard: “Attention! Boiler cleaning! Do not put on power supply”. Please use during these works the personal safety gear to protect your eyes, breathing and hands. 7.1 Cleaning of combustion chamber Step 3: and boiler Remove the intake socket at the plastic heat exchanger. Step 1: Remove the air intake hose at the burner and heat exchanger. Disconnect the burner plug and also the plug “Remote unlocking“. Step 4: Remove the stainless steel insert.
Cleaning 7.3 Cleaning of flue gas passes box Step 5: Clean the combustion chamber from the top to (open) the bottom with the special boiler brush. Step 1: Attention! Risk of burning – wear protective Loose the screw on the inspection lid at the left gloves! or right boiler side and remove the lid. Sweep out or vacuum away the residues. 7.2 Cleaning of flue gas passes Step 2: Step 1: Take out the insulation insert. Remove turbulators from the flue gas passes. Attention! Risk of burning – wear protective gloves! Step 3: Step 2: Loose the wing nut on the cleaning cover, do not Cleaning of the flue gas passes with a brush. unscrew it.
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BK20/BK30 Cleaning Cleaning of the flue gas passes box Step 4: Put the threaded pin with a flat head screwdriver (closing) into position and take out the cleaning cover. Step 1: Close the cleaning cover on the flue gas pas- ses box. Put the threaded pin with a flat head screwdriver into position � Step 5: Vacuum out the flue gas passes box. The absor- ber plate needs not be removed. Step 2: Tightly screw the wing nut. Step 3: Put in the insulation insert. Attach the inspection lid and close it.
Cleaning 7.4 Wet cleaning – neutralization box A granulate addition will be required at the ear- liest after 1 – 2 years when some 50 % of the gra- and plastic heat exchanger nulate are used up. After approximately 4 years, Information complete replacement of the granulate will be required. It is absolutely essential to loosen and When the granulate becomes contaminated rinse the granulate annually. or solidified, the neutralization effect drops Cleaning (pollutants in the condensate are insufficiently reduced). In certain cases, corrosion damage on the wastewater pipe system cannot be excluded. Attention The neutralization box should be regularly maintained (at least once in a year), particu- larly if the boiler is oil-fired. Wash out the filter material with clear water. During these works, wear protective gloves and safety goggles. The condensate residues may be etching. Observe the provisions of the attached Safety data Fig. 8: overall view of the neutralization box with siphon sheet! Step 1: Take off the siphon bend and the connection tube from the neutralization box and the boiler. Step 2: Rinse the siphon bend and pipe with water. Fig.
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BK20/BK30 Cleaning Step 3: Step 6: Place a container for collecting rinsing water Pour out the granulate into a suitable container under the condensate discharge system. (a tub). Step 4: Step 7: Rinse the plastic heat exchanger with the help Clean the neutralization box with water. of a water hose while the boiler door is open, through the flue gas opening. Step 8: Rinse the granulate with water. Step 5: Open the neutralization box.
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Cleaning Step 9: Step 11: Refill the cleaned granulate into the neutraliza- Again connect the neutralization box to the tion box. condensate drainage system (bear in mind the provisions of cl. 6.4!). Information Re-establishing of operating condi- tion Fill the granulate only into the middle chamber (as shown in the picture). • Connect the condensate discharge system with the neutralization box and then to the waste water system. • Fill the neutralization box with the granulate as described above (water and granulate). • Mount the stainless steel combustion cham- ber. • When closing the door, lift it over the intake socket tightly set up and fix it with the nuts. • Connect the air intake hose to the burner and heat exchanger and plug the connec- tors of the burner and remote unlocking. Step 10: Information Again install the cover of the neutralization box Carry out cleaning works at least once a year. While doing so, please keep in mind the appro- priate regulations and norms of the respective country, sewage water and waste ordinance as well as job safety rules and instructions.
BK20/BK30 Terminal assignment and legend to Conform 6.0 Terminal assignment and legend to Conform 6.0 0 - 10V eBUS eBUS 0 - 10V Attention! When connecting an external feeding pump (P2), an additional relay need to be interposed (e.g. part no. 060115).
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Ambient temperature sensor Buffer temperature sensor, above (required for cascade service, buffer mode operation and mixing cylinder) Buffer temperature sensor, centric/lower (Shutdown sensor for trickle charging) Secondary pre-flow sensor (*only for BK50 – BK250) Yes* (not required for cascade service, buffer mode operation and mixing cylinder) Flue gas temperature sensor Boiler temperature sensor Boiler return flow temperature sensor Flow temperature sensor, heating circuit 1 Flow temperature sensor, heating circuit 2 Collector sensor Buffer temperature sensor, lower / Collector buffer sensor Nominal value input 0 – 10 V 12 V DC output pressure sensor (red/yellow/black) 56/57 (not for BK20/BK30 without flue gas fan) Auxiliary boiler sensor Standard Terminal assignment Designation assignment Mains connection Flue gas fan (not in the model BK20/BK30 without fan) (blue) (brown) (black) (Direct connection) (gr/ye) (gr/ye) (with 4-pole Wieland plug) Service water charge pump Feeding pump BK20/BK30 electronic, (pulsed PWM) BK50 – BK250 electronic, constant speed...
BK20/BK30 Spare parts BK20, BK30 Spare parts BK20, BK30...
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Spare parts BK20, BK30 Order number BK20 BK30 Boiler Boiler mounted with flue gas fan 051701-11 051703-11 Boiler pre-mounted without flue gas fan 051700-11 051702-11 1�1 Boiler 046302 046303 1�2 Sealing 041057 041057 1�3 Cleaning cover complete 041060 041060 Casing parts 2�1 Side element right 037138-03 037182-03 2�2 Inspection lid 041122-02 041122-02 2.2a Locking spigot 041535 041535 2.2b Fixation plate 041534 041534 2.2c...
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BK20/BK30 Spare parts BK20, BK30 Order number BK20 BK30 5�7 Boiler pedestal 035457 035457 5�8 Socket for negative pressure measurement 037222-01 037222-01 5�9 Circulation pump 063262 063292 5.9a PWM plug with 2 m cable 063292 063292 5�10 Shut-off valve 037528 037528 5�11 Boiler door 5�12 Silicon seal string for heat exchanger 035401 035401 Control, regulation elements and signallers 6�1 Control set** 041371-05 041371-05 6�2 Control 042475-02 042475-02 6�3...
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Spare parts BK20, BK30 Order number BK20 BK30 6�38 Burner cable** 042780 042780 6�39 Burner cable stage 2** 046312 046312 6�40 eBus connection line** 042784 042784 6�41 Omega connection spring** 038749 038749 Flue gas conduit 7�1 Flue gas conduit set for boilers with fan 036942-01 036942-01 7�2 KAS Standard PO DN 125/80 031973 031973 7�3 Flue gas conduit set for boilers without fan 036786-01 036786-01 7�8 Lip seal DN 100** 045604 045604 Other connection elements 8�1 Silicon hose**...
Guarantee 11 Guarantee 6� Exclusion of guarantee No guarantee shall be granted, regardless BK Fully Condensing Boilers BK20 and of the contributory reasons, for damage in BK30 consequence of: 1� We grant to dealers/ craftsmen and consu- • Accident, wilful damage, unauthorized mers a guarantee for durability of goods, in use, fie, storm, hail, lightning or explo- compliance with the following conditions, for sion, the following parts: • Use of unsuitable fuels • Boiler body 2 years • Acts of war of any kind, • Plastic heat exchanger PP 5 years • Confiscation or state intervention. • Plastic parts 5 years No guarantee is granted for consumables •...
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BK20/BK30 Notes Notes and particularities...
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Any use, installation, maintenance that is not effected in accordance with the rules specified in the operating instructions, or unauthorized modifications to the factory-made equipment design shall result in expiration of every guarantee claim. Otherwise our “Conditions of Sale and Delivery” shall apply. Subject to technical change in terms of product improvement without notice.
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