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Related Manuals for Rendamax R2000 Series
Summary of Contents for Rendamax R2000 Series
- Page 1 TECHNICKÁ DOKUMENTACE R2000...
- Page 2 We aim to achieve continuous improvement in our products. Therefore, specifications are subject to change without prior notice. Due to changes the product can deviate from the information specified in this document. Therefore Rendamax B.V. rejects any responsibility for the differences between the product delivered and the information mentioned in this document.
- Page 3 Index R2000 Technical data R2017-R2048 R2000 Technical data R2056-R2122 Dimensions Introduction Rendamax Supplier This manual Service General restrictions Description General information Main components Principle of regulation 2.3.1 EM Control option 2.3.2 EW Control option Boiler protection Safety Delivery and transport...
- Page 4 Operation and fault indication Function Regulation Control panel Fault indications Start-up Shut-down Warnings Fault finding table Maintenance Safety General information Inspection Cleaning Servicing Component replacement Service Notes DOC2012/2000en...
- Page 5 R2000 Technical data R2017-R2048 Type R2017 R2022 R2028 R2034 R2041 R2048 Nominal heat output 57,7 74,6 95,8 116,7 139,1 162,7 Nominal heat input (nett. CV) 65,5 84,8 107,7 131,6 158,6 185,5 Gas consumption natural gas H 12,2 14,7 17,2 (10,9 kWh/m3) propane Gas inlet pressure (min.)
- Page 6 R2000 Technical data R2056-R2122 Type R2056 R2066 R2077 R2090 R2105 R2122 Nominal heat output 190,7 222,1 261,1 309,0 361,0 425,0 Nominal heat input (nett. CV) 217,4 253,3 296,2 348,0 403,9 470,7 Gas consumption natural gas H 20,2 23,5 27,5 32,3 37,4 43,6 (10,9 kWh/m3)
- Page 7 Dimensions STANDARD ALTERNATIVE The R2000 unit is also available as a left-handed model. Top and side clearances are 600 mm MINIMUM. Fig. 1 Dimensions DOC2012/2000en...
- Page 8 1 Introduction 1.1 Rendamax Since its beginning in 1968, Rendamax has built up a strong reputation in industry for the development, production and marketing of gas-fired, high efficiency boilers in the 60 to 1200 kW range. Through their unique construction, these central heating units are renowned for their: high thermal efficiency...
- Page 9 Rendamax boilers should only be used in the manner and purpose for wich they were intended, and in accordance with the recommendations detailed in this manual. Our heaters have been designed, produced and inspected with safety in mind, but there are certain basic precautions, wich should be taken by the user and, in particular attention is drawn to the safety precautions in this manual and to the operating instructions on the heater.
- Page 10 2.2 Main components Fig. 2 View of the R2000 series Flue outlet socket 13 Burner bars Draught diverter 14 Quick clamp (securing burner trolley at Air supply opening both sides) Connection box 15 Main burner gas governor Servomotor (air damper/gas input)
- Page 11 Draught diverter The R2000 is fi tted with a draught diverter. It is possible to connect the flue outlet connection on the top cover with a standard flue pipe. The inside of the draught diverter is made of aluminium. The galvanized plate mantle is easily removed without the use of any special tools. Fig.
- Page 12 Heat exchanger The heat exchanger (type 2-pass) is mounted on the chassis. To ensure proper heat transfer of the combustion gases, the copper fin tubes are arranged side by side and expanded laterally into a mounting plate. The baffles on the copper fin tubes optimize the efficiency of the heat exchanger. The supply and return pipes, together with the water manifolds, form the heat exchanger.
- Page 13 Combustion air damper A combustion air damper is situated underneath the burners. Fig. 7 Combustion air damper Gas train The principal components of the gas train are main governor and two main gas valves or combined main governor and main gas valve. The quantity of gas is adjusted in proportion of the quantity of air being supplied by the air damper opening.
- Page 14 Boiler temperature controller RWF40 A Process value (actual temperature) B Set point (temperature) C Burner enable (not applicable) D Mod. indicator (decrease fi re rate) E Mod. indicator (increase fi re rate) Two-stage firing (not applicable) G Limit comparator H Manual operation The keys K-L-M-N are used for displaying values and changing parameters in the temperature controllers confi guration.
- Page 15 Outside temperature (°C) Fig. 8 Parallel displacement of the heating curve Heating curve slope Slope H of the heating curve can be used to adjust the set- point in response to the outside temperature, as shown in the diagram. The common origin of the heating curves is set at (20°C/20°C). The effective range of the weather-adjusted setpoint is restricted by the setpoint limits SPH and SPL.
- Page 16 Process data Parameter Display Value range Factory setting Setpoint 1 SPL-SPH Setpoint 2 (option) SPL-SPH Digital setpoint shift (option) SPL-SPH Outside temperature (option) C111 Inputs Predefinition of external setpoint SP.E SPL-SPH Parameter level Parameter Display Value range Factory Advise setting Limit value of limit comparator -1999…+9999 digit Switching differential for limit comparator...
- Page 17 2.4 Boiler protection The R2000 is protected by the following systems: Water flow switch The water flow switch is installed in the flow manifold and monitors continuously the water flow. If the water flow falls below a preset level, the burner is shut down and go to lock-out. The water flow switch is factory set and should not be adjusted.
- Page 18 Maintenance Work on the electrical installation should only be carried out by approved technicians and in accordance with the electro technic regulations. Work on the gas and hydraulic systems should only be carried out by approved technicians and in accordance with the safety regulations for gas installations. Keep unauthorized people away from the installation.
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Page 19: Delivery And Transport
4 Delivery and transport 4.1 Delivery Before delivery, the R2000 boiler is fully assembled and tested in the factory. The R2000 is mounted on a pallet and covered in a “heat-shrink” protective wrapper. Check for damage after removing the boiler’s protective covering. Check whether the boiler conforms to the order requirements. -
Page 20: Installation
The main gas service cock and gas filter should be supplied by a qualified heating engineer. Install the main gas service cock and the gas filter as close to the boiler as possible. The R2000 series of boilers are suitable for connection to a 25 mbar gas network. DOC2012/2000en... - Page 21 The minimum supply pressure must never fall below 18 mbar. With a lower gas pressure it is possible that the boiler will not run at 100% capacity. At the same time the boiler can be more prone failures. Adjust the burner pressure with a supply pressure of 20 mbar before the boiler. 5.2.2 Electrical supply The product has to be installed by a recognized installer fully according to the current national and...
- Page 22 5.2.4 Flues Flue dimensions This section should be used for guidance only. A flue specialist should be contacted to rate a flue design. You can use the following flue dimensions to assist in flueing: Type Q flue m Chimney diameter mm R2017 R2022 R2028...
- Page 23 5.3 Water quality Corrosive elements in certain additives can attack the system, resulting in leakage; deposits of undesirable sediments can lead to damage to the boiler heat exchanger. For water hardness, a distinction must be made between: Temporary hardness This is also referred to as carbonate hardness. Deposits are formed at higher temperatures and are easy to remove.
- Page 24 5.4 Hydraulic system System pressure By system pressure we mean the water pressure measured at the heat exchanger in cold condition. With a correctly sized expansion system the system pressure will not change much under variable temperature conditions. 5.4.1 Flow and resistance The next figure shows an example of a hydraulic system.
- Page 25 Type Water flow rate versus pressure drop minimum flow rate nominal flow rate maximum flow rate pressure drop pressure drop pressure drop mbar mbar mbar R2017 R2022 R2028 R2034 R2041 R2048 R2056 R2066 R2077 R2090 R2105 R2122 Table 4 Water flow rate versus pressure drop Flow rate m Fig.
- Page 26 Positioning the pump and expansion vessel We advise that the pump should be mounted in the return pipe in the following order: expansion vessel, pump, boiler. If you mount the pump in the flow pipe, the lifespan of the pump will be reduced. Always connect the expansion vessel to the suction side of the boiler pump.
- Page 27 5.4.2 Examples hydraulic system Fig. 15 R2000 unit with outside temperature compensation Fig. 16 R2000 unit with outside temperature compensation (heating zone regulation and hot water priority switching is an option) DOC2012/2000en...
- Page 28 Boiler model By pass size R2017 - R2022 1“ R2028 - R2041 1½“ R2041 - R2090 2“ R2105 - R2122 2½“ Table 5 By pass size Open vent and cold feed An open vent pipe must be fitted in open systems not more than one meter along the flow pipe and must rise continuously by the shortest route to the venting point without valving and with frost protection where necessary.
- Page 29 Fig. 17 R2000 units with constant flow temperature and cascade switching with a zero loss header Condensing Non condensing Fig. 18 Condensing/non condensing unit cascade switching and a zero loss header These hydraulic systems are examples only and should not be used without specialist advice. Low velocity vertical headers, for single and multiple boiler circuits are as option direct available.
- Page 30 6 Commissioning 6.1 General COMMISSIONING OF THE BOILER MUST BE CARRIED OUT BY PROPERLY QUALIFIED AND AUTHORISED PERSONNEL. OTHERWISE, THE GUARANTY WILL BECOME VOID. Never deviate from the instructions in this manual. Flushing the system To prevent damage from rust, sealing compounds, sand, metal particles etc., the system must be flushed thoroughly, before the system is switched on.
- Page 31 Adjusting the burner pressure The burner pressure must be adjusted when the boiler has been running for 20 minutes at high load (state of equilibrium). Natural gas H (G20) Gas service pressure 20 mbar / Nozzle diameter 1,8 mm minimum load (20 %) Type Burner pressure Pilot pressure...
- Page 32 Liquid Propane Gas Gas service pressure 50 mbar Nozzle diameter 1 mm minimum load (20 %) Type Burner pressure Pilot pressure Air damper Burner pressure Cascade out start/min. opening closed 40% ET out (mbar) (mbar) (mm) (mbar) (mbar) R2017 13/18 6/28 R2022 13/18...
- Page 33 6.2 Pre-lighting checks and dry run The following is a list of appliance checks to be carried out. 6.2.1 Check 1 With the boiler gas inlet service cock closed and electricity supply switched off Ascertain from the gas supplier or the customer that the meter installation is operational. Ensure that the gas installation pipework up to and including the gas inlet service cock has been tested for gas soundness in accordance with IM/5 or BS 6891 as appropriate.
- Page 34 Burner trolley assembly modulating air damper gas valve adjustment screw burners 4 mm combustion air damper Fig. 20 Burner trolly assembly III) Check the setting of the modulating combustion air damper situated underneath the burners, there should be a gap of 4 mm (Natural gas) or 8 mm (LPG) with the damper in the fully closed position against the stops.
- Page 35 6.2.3 Check 3 With the electricity supply switched off check the gas train downstream of the gas inlet service cock as follows: Refer to Gas trains, fig. 28 for particular boiler model. 1. Ensure that gas service cock and pilot manual cock are closed. 2.
- Page 36 d) Connect a pressure gauge to the main burner manifold, test point 10/4 and re-connect the electrical connections from the main safety shut off valves into the front electrical panel. Switch the on/off switch to on and the boiler will ignite in the sequence described in a) above with the main burners igniting from the pilot burner at minimum rate.
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Page 37: Operation And Fault Indication
6.4 Instructions to user Upon satisfactory completion of commissioning hand the Technical documentation to the person responsible for the plant and explain the method of safe operation. Ensure that he/she is fully conversant with the starting, shut down, general operation and emergency shut down procedures. Explain the operation of the overheat control, by pressing button in right hand upper side panel, but stress that in case of repeated overheating of the boiler that the fault should be corrected by a competent person. - Page 38 Fig. 23 Additional control panel to the EM version with weather compensation including clock for night-time temperature reduction 7.4 Fault indications If there is insufficient water flow the boiler will turn off and lock- out. Red lamps 2 and 5 on. Reset by pushing button 3 If the flow temperature exceeds the high limit setting, the boiler will mechanically lock out and red lamp 2 illuminates.
- Page 39 7.5 Start-up Ensure that gas and electric supplies are connected. Start sequence: A Turn manual gas cock open B Turn the pumps on C Ensure that all hot water outlets are closed D Turn the supply voltage to the boiler on and turn the boiler on using the power switch 1 E In case of failure, observe type of failure, take necessary steps to rectify, refer to section 4 for details Set temperature regulator as required.
- Page 40 Fault finding table Fault Possible cause Solution Boiler does not attempt to light No electrical supply to boiler Check whether switched indicator (1) is alight Check all external controls for continuity No heat demand Check control thermostat is set high enough Overheat control has operated If lamp 2 is illuminated, press reset button...
- Page 41 Fault Possible cause Solution Pilot burner ignites but boiler then Check flame probe If damaged, replace goes to lock-out, indicator (2) alights. Main burners do not light Flame probe lead(s) not connected or Rectify faulty Faulty connections to main safety shut off Rectify valve(s) Faulty main safety shut off valves...
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Page 42: Maintenance
8 Maintenance 8.1 Safety Always wear the proper protective clothing and shoes when servicing the boiler. Wearing jewelry and loose clothing can contribute to unsafe situations. 8.2 General information In order to keep the R2000 in a safe working condition, the boiler should be inspected and serviced at least once every year and cleaned if necessary. - Page 43 8.4 Cleaning Before using chemicals and cleaning agents in the boiler, please contact your supplier for advise. Always read the instructions on the bottle of the cleaning agents before using them. Heat exchanger (external cleaning) Remove the baffles before cleaning the heat exchanger. Use compressed air when the heat exchanger is lightly soiled Use a stiff brush and soap when the heat exchanger is very dirty, do not allow the refractory brick-work to get wet.
- Page 44 Procedure Release the fixings securing the gas train cover at the front of the boiler and remove carefully in the upward direction. Disconnect all the plugs from the front electrical panel and release the quick clamps at either side of the burner trolley. The burner trolley can now be withdrawn from underneath the boiler. Release the fixing screw at the top of the right hand upper side panel covering the electrical controls.
- Page 45 Remove the down draught diverter by releasing two screws in either side and remove the fl ueway baffles from the top of the heat exchanger. Inspect the heat exchanger for deposits and clean if necessary, check condition of the copper fin tubes and fins and replace flueway baffl es. Check the condition of the boiler for any possible corrosion damage.
- Page 46 Fig. 26 Electrodes Check that the modulating combustion air/gas control linkages are in good working order and that there is no play in the gas control spindle. Replace the various panels on the top of the boiler including the down draught diverter, replace the burner trolley and clamp into position.
- Page 47 8.6 Component replacement Electrodes Remove the burner trolley as described earlier. Remove the insulation covered stainless steel channels and each burner as described at burner bars. Remove the air guide assembly(s) which are located under the burner bars and ensure the spark electrode is disconnected from the ignition generator. Remove the burner assembly frame complete from its location in the burner trolley.
- Page 48 Ignition generator Release the two fixings securing the top of the gas train cover at the front of the boiler and remove carefully in upward direction. Disconnect all of the plugs from the front electrical panel and remove the cover of the electrical panel by releasing two screws at each end.
- Page 49 Inspection of the headers and the fin-tube mounting plate mating surfaces Inspect the mating surfaces of the water header, flow/return manifolds and the fin-tube mounting plate. These should be clean, smooth and undamaged. O-ring replacement Fit new O-rings to all finned-tubes (article No. ARO020). Fitting and retensioning the water heater and flow/return manifold This is a reversal of the removal procedure.
- Page 50 Notes DOC2012/2000en...
- Page 51 Notes DOC2012/2000en...
- Page 52 Rendamax bv Service: Hamstraat 76 6465 AG Kerkrade Parkstad nr. 5007 P.O. Box 1035 6460 BA Kerkrade The Netherlands Tel. (+31) 45 5669 900 Fax (+31) 45 5669 910...
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