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Rendamax R40 ECO Operating Manual

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Operating Manual
for authorized technicians only
R40 ECO
www.rendamax.com
9B.51.20.00 / 01.18
1

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Summary of Contents for Rendamax R40 ECO

  • Page 1 Operating Manual for authorized technicians only R40 ECO www.rendamax.com 9B.51.20.00 / 01.18...

  • Page 2: Table Of Contents

    Safety regulations General regulations ........Intended use ..........Standards and regulations ......Construction Product description / Functional description - R40 ECO ......Technical data Technical data / ERP data ......Dimensions ..........Delivery scope Standard version / Accessories ....Cascade / Cascade accessories ....

  • Page 3: Safety Regulations General Regulations

    EN 15420 (Requirements for gas- are excluded. fired systems – type C boiler 70 kW – 1000 kW) Intended use EN 15417 (Special requirements for The R40 ECO is a condensing and condensing gas-fired boilers 70 kW modulating gas boiler, which is – 1000 kW) The facility may only be operated by suspended from walls and is delivered...
  • Page 4 Product description R40 ECO 20 19...
  • Page 5 Legend: Product description Delivery scope heat exchanger 1 (All types OSS4) The R40 ECO is a condensing and The boiler, which has been assembled heat exchanger 2 (R40 ECO100: modulating gas boiler with one or two at the factory and is ready to use,...
  • Page 6 Product description R40 ECO hydraulic circuit diagram Burner A Burner B   Legend: 6 fan T1a secondary flow sensor (only 1 heat exchanger 1 (All types OSS4) 7 flue non-return valve OSS4) = burner A 8 automatic air vent T2 return sensor 2 heat exchanger 2 (R40 ECO100:...
  • Page 7 Product description Technical data ErP data Type R40 ECO Permit CE0063CM3648 Category II2H3P Heat exchanger type OSS4 OSS4 OSS4 OSS2 OSS4 Output Full load 80/60°C 60,1 95,0 120,0 40/30°C 65,0 102,3 129,3 Low load 80/60°C 14,8 17,6 40/30°C 16,6 19,6 Full load 80/60°C...

  • Page 8: Dimensions

    Product description Dimensions of R40 ECO Ceiling Individual flue: min. 400mm Collective flue: dependant on the selected flue system. Please contact the supplier Type R40 ECO Boiler connections Boiler height 1066 1066 1066 Type R40 ECO Boiler height with flue connection 1151 1151 1151 Flue gas nozzle concentric...
  • Page 9 R40 ECO boilers, specially constructed or selected for you should always use a low loss the R40 ECO boiler, which means they header adjusted to the set demand. are very easy to install (plug and play). Rendamax supplies 3 low loss...
  • Page 10 Product description R40 ECO Cascade Legend: Cascade possibilities 1 Air supply (for parallel flue The Rendamax R40 ECO cascade can connection) be mounted in 3 ways: 2 Flue/Air supply (concentric) 1430 3 Cascade manager Wall-mounted in line Accessories: All boilers alongside one another on...
  • Page 11 Product description R40 ECO Cascade accessories...
  • Page 12 Product description R40 ECO Cascade accessories Type R40 ECO Part no. Wall mounting rail for 2 boilers 3905023 Wall mounting rail for 3 boilers 3905024 L- post 3905022 I-post 3905021 Boiler frame 3905025 Header flow/return DN65 + gas DN50 2/4 3905017 Header flow/return DN100 + gas DN65 2/4 3905018 Header flow/return DN65 + gas DN50 3/6 3905019 Header flow/return DN100 + gas DN65 3/6 3905020 Low velocity header ≤ 452 kW DN65...

  • Page 13: Disassembly Of Panelling

    Boiler transport Boiler transport its packaging to a pallet. Loading belts should be attached to the pallet. The R40 ECO is a fully equipped compact heating system, which has Unpacking instructions are printed on been pre-set and tested at the factory.

  • Page 14: Installation

    The floor has to be flat and level and have sufficient deadweight capacity for the complete (filled) installation. The Rendamax R40 ECO cascade can be mounted in 3 ways: Wall-mounted in line All boilers alongside one another on the wall. Refer to page 15.

  • Page 15: Cascade Cascade Wall Mounted In Line

    Installation Cascade wall mounted in line A . Position the pipe work header D. Place the gas line in its intended against the wall. When using recess. When using several pipe several pipe work headers: couple work headers: couple the gas lines the pipe work headers and supplied using the supplied DN50/DN65 gaskets, M12 (DN65) or M16...

  • Page 16: Cascade Free-Standing In Line

    Installation Cascade free-standing in line A Position the pipe work header in D. Fit a mounting frame on the the required location. When using I-column using 3-x bolt M8x50mm. several pipe work headers: couple the pipe work headers using the Attention: mounting rail at the supplied gaskets, M12 (DN65) or top.

  • Page 17: Cascade Free-Standing Back-To-Back

    Installation Cascade free-standing back-to-back A. Position the pipe work header in D. Fit a mounting frame on the the required location. When using L-column using 3x bolt M8x50mm. several pipe work headers: couple Attention: mounting rail at the the pipe work headers with the supplied gaskets, M12 (DN65) or top.

  • Page 18: Connecting The Boiler

    The boiler is supplied with a 3 and 4 tightness. bar safety valve. Rendamax recommend fitting the 4 E. Fill the siphon with tap water and bar safety valve due to the control fit the siphon cup underneath the settings shutting the boiler off at 3.8 boiler.

  • Page 19: Cascade Accessories

    There are 3 low loss headers available: have to be fitted with blanking flanges. The blanking flanges come standard 3905048 with a fully configured delivery, Low loss header for 1 or 2 R40 ECO including bolts, spring washers and boilers to max. 200kW supplied gaskets. with automatic air vent, drain valve and pocket for temperature sensor 3905026 T10 Boiler connections are 4x 1 ½”,...

  • Page 20: Connecting 1 Or 2 Boilers

    Installation Cascade accessories Connecting 1 or 2 boiler boilers 1x R40 ECO boiler, wall hung 2x R40 ECO boilers, wall hung, max. 200kW 3/8” 1/2” 1x R40 ECO boiler, free-standing 2x R40 ECO boilers, free-standing, max. 200kW 1/2” Wall hung...

  • Page 21: Dimensions Headers, Low Loss Headers And Bends

    Installation Cascade accessories Dimensions headers, low loss headers and bends Dimensions low loss header DN65 until 452kW Dimensions main header G1/2” DN65 / DN100 G3/8” DN65 G1” DN65 DN65 L 2/4 places = 1398mm (DN65/DN100) L 3/6 places = 2098mm (DN65/DN100) DN65 Dimensions low loss header DN100 until 960kW Dimensions bend DN65 and DN100...

  • Page 22: Heating Water Quality

    If the regulations with regard to does not conform to the Rendamax The central heating installation must plastic piping are not observed, then requirements (see Table 1). be de-aerated properly, before it is warranty claims become null and taken into operation.

  • Page 23: Expansion Vessel

    When applying a DHW cylinder an expansion vessel. The expansion connected directly to the boiler vessel used has to comply with the (Rendamax cylinder connection water contents of the installation. with use of 3-way valve) the circuit between the three-way valve and the...

  • Page 24: Gas Line

    When the boiler has to be converted from natural gas to LPG, Rendamax provides special kits for this purpose. Special instructions are supplied with the kit. Following maintenance tasks always...

  • Page 25: Condensate Connection

    A fixed connection to the public sewer also check for leakproofness and the system is not permitted. equipment siphon is filled with water. All Rendamax wall hung gas fired condensing boilers contain a siphonic condensate trap to collect and release condensate. The amount of condensate formed is determined by the type of boilers and the water temperature produced by the boiler.
  • Page 26 Installation Hot water supply The hot water supply control can be Cylinder flow connection 1 1/2" internal thread connected to the Rendamax R40 ECO. Cylinder return connection 1" external thread For connection and settings refer to the Boiler Control chapter.

  • Page 27: Air- / Flue Gas Ducts

    In all cases, the concentric flue/air Flue gas connection national regulations. connection on the top of the boiler We recommend the use of Rendamax - The length of the flue gas system case is 80/125. When using 110/150 comprehensive range of flue gas must be kept as short as possible flue components, an allowance for components.
  • Page 28 Installation Connections Air- / flue gas ducts for individual boilers Parallel boiler connection The R40 ECO-boilers can be used both The boiler comes as standard with a in an “open” and in “closed” system. parallel connection for the flue gas outlet and air supply system.
  • Page 29 Installation Connections Air- / flue gas ducts - installation variants for individual boilers Ambient combustion air, ø80 PP Flue gas duct into the chimney, aspiration of air from the surroundings. End section of the waste gas duct above the roof. Flue gas duct into the chimney, aspiration of air from the surroundings.
  • Page 30 (outlet area 1). - Sufficient space above the boilers Large number of boilers Rendamax can supply a collective flue gas outlet system for the Rendamax You may opt for: R40 ECO. Refer to the following - Collective flue gas outlet under- chapters with regard to the various pressure possibilities and maximum pipe lengths - Collective flue gas outlet over- that can be used.
  • Page 31 Installation Connections Collective flue gas outlet under-pressure Diameter and venting lengths of the Dimensions cascade flue R40 ECO flue gas outlet/air supply: Open system, underpressure Open system, with under-pressure Output (P) kW at 80/60°C Type R40 ECO d = minimum diameter Ø in mm...
  • Page 32 Installation Connections Collective flue gas outlet over-pressure An installation with a collective Dimensions cascade flue R40 ECO flue gas outlet over-pressure in Open system, overpressure, parallel combination with individually Output (P) kW at 80/60°C Type R40 ECO d = minimum diameter Ø in mm controlled boilers (e.g.

  • Page 33: Electrical Connection

    Installation Electrical connection Electrical connection The electric diagram must be observed during all electrical connection works Electrical connections must be (see the following pages). carried out by an authorized electrical technician, and in conformity with valid national and local standards and A 230V -50Hz mains electrical supply regulations.
  • Page 34 The boiler has 4 socket blocks for all electrical connections. 1. High voltage supply (230V) 2. Voltage free switches (230V relays) 3. Low voltage sensors 4. Communication bus for cascaded R40 ECO boilers Front view Side view On/Off Error General...
  • Page 35 Installation Electrical connection 1. High voltage supply: 16 Connections Position Connection Application Max. On/Off Error General 230V~ 230V Open- signal purpose Therm On/Off 1, 2, 3 Live Neutral Earth Power for boiler. Power cable not 230V~ 230V Heat 13,5 230V 0-10Volt LWCO demand...

  • Page 36: External Controls On/Off - Opentherm

    When this is achieved the adviced to be connected. boiler modulates back to maintain the desired temperature and prevents over The Rendamax R40 ECO provides shoot. many possibilities to operate the boilers from external controls. If an OpenTherm controller of...
  • Page 37 Behaviour of connected external controls When using an OpenTherm or 0-10Volt control and a clock program is selected, the clock program of the R40 ECO will be ignored. - When an on/off control is connected and the thermostat is switched on manually before the pre-set switch-...

  • Page 38: Wiring Diagram

    Installation Electrical connection Wiring diagram T1a (OSS4) 6,3A T 6,3A T 20 10 20 10 6,3A T 6,3A T 10 1 10 1 10 1 18 9 18 9 18 9...
  • Page 39 Installation Electrical connection Wiring diagram Connections Item Art.nr. Description Main components Control unit with screen Burner A Control unit Circulation pump Ignition unit on gas block Ignition electrode Ignition cables Flow sensor T1 Water pressure sensor P1 Return sensor T2 Flow sensor T1a Burner B Control unit...
  • Page 40 Operation Description of display Open the flap by pushing right next of The boiler has a pilot-control. This the flap on the round button to reach control takes care of most of the the display and keybord. manual settings but also provides numerous settings to adjust the control exactly to the installation and user requirements.

  • Page 41: Operation Description Of Display And Keyboard

    Operation Description of display and keyboard Operational status - Standby Standby. Boiler is ready for operation. Standby - Vent.Phase Ventilation stage - Ignition phase Ignition stage - Burner lit CH Burner active for heating - Burner lit DHW Burner active for hot water - CH T >...
  • Page 42 Commissioning Start-up Turn the electrical supply on (heating After confirmation by OK and after the system does not have to be filled); automatic de-aeration programm has -- NC -- ended, you will see the standard read- During start-up, a blue screen is out “Good” showing the date and the displayed: time after the de-aerating program. Power Up Power Up Standard read-out:...

  • Page 43: Display Read-Out Boiler Addresses

    20.0 °C in °C) and water pressure (P in bar). 1.65 bar For R40 ECO boilers in cascade For R40 ECO boilers in cascade, the bus communication cables between the boilers must be connected (see section electrical connections). The master-boiler (address 01) should be set to how many boilers are actually connected.

  • Page 44: Basic Operations Selecting Programs

    Commissioning Basic operations Selecting programs Switching on the Heating, DHW and Pump program By switching on the functions ( and/or ) the boiler is turned on. Proceed as follows: From the standard display with illuminated display: 1. Press the right arrow button: Basic The display shows: Basic settings;...
  • Page 45 Commissioning Basic operations Setting the maximum flow temperature with On/Off-control P101 = 0 Basic Setting the maximum flow water temperature with connected outdoor sensor T4. Settings (starting with illuminated display): 1. Press the right arrow button: The display shows: Basic Settings; CH temp 2.

  • Page 46: Filling The Heating System

    Commissioning Filling the heating system When all boilers have been electrically Fill the heating system only commissioned as described above, with drinking water. Refer to the Water Quality chapter for quality then the heating system can be filled. Each boiler is fitted with a filling and requirements of the filling water. drain valve. The filling hose from the water tap is then connected to it. Water pressure Screen display Good...
  • Page 47 Commissioning Menu structure at Basic level Menu structure There are 2 setting levels 1. Basic level (manager/user): Blue screen 2. Setting level (Installer): Green screen With the illumination switched off, first press on one of the buttons to switch the illumination on and then continue with the setting.
  • Page 48 Commissioning Menu structure at Setting level Menu structure at Setting level With the illumination switched off, first press on one of the buttons to switch the illumination on and then continue with the setting. Having pressed the last button, the green illumination will switch off after 2 min.

  • Page 49: Clock Program Heating Line

    0-10Volt control and a clock hot water is set on continuous program is selected, the clock demand to prevent there being no program of the R40 ECO will be hot water available at starting up. ignored. The program can be adjusted to - When an on/off control is connected each individual situation.
  • Page 50 Parameters end users (blue screen) Basic display “dark” Overview of commissioning Press on one of the buttons to switch the illumination on (blue screen). parameters - Press the + or - button to go to the “Operational status” read-out The parameter lines with a grey Press arrow button to the right to go to the required menu (arrow to the low background only become visible at the goes back) technician level.
  • Page 51 Parameters technician (green screen) Basic display “dark” Overview of commissioning Press on one of the buttons to switch the illumination on (blue screen). parameters Press both arrow buttons for 2 seconds (green screen) The parameter lines with a grey - Press the + or - button to go to the “Operational status” read-out background only become visible at the Press arrow button to the right to go to the required menu (arrow to the low technician level.
  • Page 52 Parameters technician (green screen) Param Mode Parameter chapter PARA factory setting Description Range Cascade param. Cascade parameters P100 Domestic hot water facility 0: no DHW 1: Solo boiler with 3-way valve NOTE: 2: n.a. Option 6 and 8 not for Low 3: Solo boiler with cylinder loading pump P4 and 3-way valve Temerature systems, unless separately controlled...
  • Page 53 Parameters technician (green screen) Param Mode Parameter chapter PARA factory setting Description Range P252 Slope heating line (K-factor) 0,1 - 9,9 P256 Hysteresis Summer/Winter in °C (if T4 was detected) 0-10 P266 Switch on delay at heat demand in minutes 0-10 P267 Boiler sequence for boilers in cascade in hours...
  • Page 54 Number of running hours to go for maintenance interval Ignition Number of times ignition Faults Number of times in error Safety 02017005 Regul. 01018003 03018003 OEM par. 00018xxx xxx: 020 = R40 ECO 70, 080 = R40 ECO 100, 140 = R40 ECO 120...

  • Page 55: Activate Factory Settings

    Parameters Activate factory settings Do the following to reactivate factory settings (any changed settings, except from P108 and P121, will be lost): Activating the factory settings from user level only: Restore From the standard blue screen display: 1. Select using the right arrow button: Basic settings;...

  • Page 56: Commissioning Inspection And Maintenance

    Only in the case When replacing spare parts only of failures or replacement of the gas original Rendamax Service parts are unit, venturi and/or ventilator, does one to be used. For this purpose, please have to check and adjust the O...
  • Page 57 Gas pressure Press the right arrow button until This ends the procedure for burner A. Airflush is displayed; Press OK; Only for R40 ECO 100 and R40 ECO The screen displays Airflush off; 120: Press the return button 1x Only for R40 ECO 100 and R40 ECO...

  • Page 58: Co / Cco

    The O / CO check consists of 2 Step 1: O / CO check on full load Only for R40 ECO 100 and R40 ECO steps or, if necessary, 3 steps: The O or CO setting is preset at the 120:...
  • Page 59 L Display Step 2: O / CO check on low load Only for R40 ECO 100 and R40 ECO 120: Setting the low load Press the return button 1x The low load of the boiler can be set by...
  • Page 60 Commissioning Combustion analysis Settings on the gas valve (Step 3/3) Legend: A On/Off switch B Back button (ESC) C Plus button (value increase/change) D Confirmation button (OK) E Arrow button right (forward) F Chimney sweep function button G Arrow button left (backward)  ...

  • Page 61: Maintenance Repair Works

    Rendamax recommends leaving the maintenance or repair works have been carried out on the boiler. power switch switched on to ensure been carried out on the boiler.

  • Page 62: Maintenance Details

    In doing so, pay attention to the turning direction When carrying out maintenance works, (red check cams); only original Rendamax replacement parts may be used. CAUTION: Always interrupt the power supply, before carrying out maintenance or repair works on the boiler.

  • Page 63: Maintenance Details

    Maintenance Maintenance details Pull the complete ventilator unit If the cover/air box is heavily polluted and heat exchanger’s gas valve with dust, it is likely that the fan impeller forward; is also polluted. To clean the fan, it has Remove the burner cassette (18) to be removed from the upper tray and from the ventilator unit;...
  • Page 64 Maintenance Maintenance details Ignition electrode 6. Press the OK button; Replace the ignition electrode when 7. Press the right arrow button until: Flame necessary, but certainly every 4 years. Flame. This can be checked by reading out The ionization current is shown the ionization current.

  • Page 65: Counter Running Hours

    Maintenance Maintenance details Counter running hours Siphon Take the device back into operation and conduct a flue gas analysis (refer Place a collector (i.e. a bucket) to chapter Check O under the siphon to collect the dirty and aggressive condensate water. Wear protective clothing like latex gloves and safety glasses.

  • Page 66: Inspection Overview

    Maintenance Inspection overview Pos. Nr.: Inspection check list - R40 ECO Remarks Switch off power supply to the boiler and close the gas valve! √ √ Air box/Boiler cover √ 1.0.1 Remove boiler cover √ 1.0.2 Check boiler cover/air box sealing on wear √...

  • Page 67: Maintenance Overview

    Maintenance Maintenance overview Pos. Nr.: Maintenance check list - R40 ECO Remarks Switch off power supply to the boiler and close the gas valve! √ √ Air box/Boiler cover 1.0.1 √ Check cover on impurence and damage 1.0.2 Necessary cleaning √...

  • Page 68: Errors

    Errors (red screen) On the display, errors found are shown in the form of a message or blocking on a blue screen or an error on a red screen. Bx01sc01 Fan does not run on correct speed (Reset necessary). Blocking Fan defective.
  • Page 69 Maintenance Sensor resistance Sensor resistance Heating flow sensor Outdoor temperature sensor In the adjacent table contains a list of Heating return sensor values for all boiler sensors, and for the DHW sensor optional sensors that are contained in Flue gas sensor the accessory kits. NTC10k (25°C) NTC1k (25°C) These tables show average values,...

  • Page 70: System Water Additives

    System water additives The system water additives, which are In case of a wrong use, and if the listed in the table, have been released maximum concentration quantities are by the manufacturer and take into exceeded, then the guarantee for all consideration the indicated dosage components that come in contact with quantities.
  • Page 71 Declaration of Conformity Declaration of Conformity We, ELCO GmbH, Hohenzollernstrasse 31, D-72379 Hechingen declare under our responsibility that the product R40 ECO 70-100-120 is in conformity with the following standards: Gas Appliance Directive 2009/142/EC EN483: 2005 EN15420;2010 EN15417; 2007 EN 60335-2-102 :2006...
  • Page 72 Service: www.rendamax.com...

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