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Summary of Contents for elco R3400
- Page 1 Operation and Installation manual for authorized technicians only R3400/R3500/R3600SB 08/2011 DOC3083...
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Page 2: Table Of Contents
Contents 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 ....................17 Accessories .................... -
Page 3: Safety General Regulation
European standards: Part 3-2: Limits - Limits for harmonic and reliable installation, commissioning current emissions (equipment input and operation of the R3400/R3500/ 92 / 42 / EEC current 16 A per phase) R3600SB boiler. All activities described Boiler efficiency directive ... -
Page 4: Construction Layout Of Boiler
34 3rd Heat exchanger (only R3600SB) Flue gasses Condensate Operating principle The R3400/R3500/R3600SB is a fully the boiler and leave at the back side The KM628 control unit can control the modulating boiler. The control unit of into the chimney connection. -
Page 5: Technical Data
Technical data Technical data R3401 - R3405 R3401 R3402 R3403 R3404 R3405 Nominal heat output at 80-60ºC max/min 657/164 729/182 853/213 965/241 1078/270 Nominal heat output at 75-60ºC max/min 658/164 734/182 858/213 972/242 1085/271 Nominal heat output at 40/30ºC max/min 663/180 741/201 867/235... - Page 6 Technical data Technical R3406 - R3410 R3406 R3407 R3408 R3409 R3410 Nominal heat output at 80-60ºC max/min 1189/297 1309/325 1496/372 1683/418 1870/465 Nominal heat output at 75-60ºC max/min 1197/298 1310/326 1498/373 1685/420 1872/467 Nominal heat output at 40/30ºC max/min 1209/329 1323/359 1512/411 1701/462...
- Page 7 Technical data Dimensions R3401 - R3406 Dimensions R3401 R3402 R3403 R3404 R3405 R3406 2265 2265 2653 2653 2658 2658 1166 1166 1166 1166 1355 1355 1355 1355 1355 1355 1125 1125 1570 1420 1155 1377 1330 1330 1130 1130 1330 1330 1160 1210...
- Page 8 Technical data Dimensions R3407 - R3410 R3407 - R3408 R3409 - R3410 Dimensions R3407 R3408 R3409 R3410 2755 3265 3265 3265 1120 1630 1630 1630 1530 1330 1530 1530 1407 1207 1357 1407 126.5 126.5 176.5 126.5 1406 1206 1406 1406 1140 1140...
- Page 9 Technical data Technical data R3501 - R3505 R3501 R3502 R3503 R3504 R3505 Nominal heat output at 80-60ºC max/min 613/174 717/203 811/230 906/258 1000/285 Nominal heat output at 75-60ºC max/min 613/174 717/203 812/231 907/259 1001/286 Nominal heat output at 40/30ºC max/min 624/195 730/227 826/258...
- Page 10 Technical data Dimensions R3501 - R3505 Dimensions R3501 R3502 R3503 R3504 R3505 2265 2653 2653 2658 2658 1166 1166 1166 1166 1355 1355 1355 1355 1355 1125 1400 1400 1155 1155 1330 1130 1130 1330 1330 1210 1003 1053 1203 1253 1146 1146...
- Page 11 Technical data Technical data R3600SB - R3605SB Standard R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB Nominal heat output at 80-60ºC max/min 572/142 639/182 747/212 846/240 945/269 1043/297 Nominal heat output at 75-60ºC max/min 573/142 640/182 749/212 848/241 947/269 1045/297 Nominal heat output at 40/30ºC max/min 602/158 672/203 786/236...
- Page 12 Technical data Dimensions R3600SB - R3605SB Standard Dimensions R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB 1958 2265 2653 2653 2658 2658 1166 1166 1166 1166 1355 1405 1405 1405 1405 1405 1175 1450 1450 1205 1427 1230 1330 1130 1130 1330 1330 1110 1210...
- Page 13 Technical data Technical data R3600SB - R3605SB Bypass R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB Nominal heat output at 80-60ºC max/min 572/142 639/182 747/212 846/240 945/269 1043/297 Nominal heat output at 75-60ºC max/min 573/142 640/182 749/212 848/241 947/269 1045/297 Nominal heat output at 40/30ºC max/min 602/158 672/203 786/236...
- Page 14 Technical data Dimensions R3600SB - R3605SB Bypass Dimensions R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB 1792 2070 2443 2443 2443 2443 1166 1166 1166 1166 1355 1405 1405 1405 1405 1405 1230 1330 1130 1130 1330 1330 1110 1210 1003 1053 1203 1253 1046...
- Page 15 Technical data Technical data R3600SB - R3605SB Split system R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB Nominal heat output at 80-60ºC max/min 572/142 639/182 747/212 846/240 945/269 1043/297 Nominal heat output at 75-60ºC max/min 573/142 640/182 749/212 848/241 947/269 1045/297 Nominal heat output at 40/30ºC max/min 602/158 672/203 786/236...
- Page 16 Technical data Dimensions R3600SB - R3605SB Split system Dimensions R3600SB R3601SB R3602SB R3603SB R3604SB R3605SB 1958 2070 2443 2443 2443 2443 1166 1166 1166 1166 1355 1405 1405 1405 1405 1405 1230 1330 1130 1130 1330 1330 1110 1210 1003 1053 1203 1253...
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Page 17: Extent Of Delivery Standard Boiler
A boiler delivery package contains the following components: Component Pcs. Package R3400/R3500/R3600SB Boiler fully assembled and tested Mounted on wooden blocks with wooden border, sealed in PE foil Adjustable feet Cardboard box on top of boiler Syphon for condensate connection... -
Page 18: Installation Transport
Installation Transport Boiler transport The R3400/R3500/R3600SB 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. - Page 19 Installation Transport Component R3407 R3408 R3409 R3410 Burner m [kg] L [mm] 1510 2050 2050 2050 B [mm] 1400 1250 1350 1450 H [mm] Heat exchanger m [kg] L [mm] 1510 2050 2050 2050 B [mm] 1425 1250 1350 1450 H [mm] Heat exchanger m [kg]...
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Page 20: Removing The Casing
Installation 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 fol- lows:... -
Page 21: Boiler Installation
Installation 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 instal- lation. When positioning the boiler, please 1000 note the recommended minimum clea- rance in the picture. -
Page 22: Connecting The Boiler
Installation Connecting the boiler Connecting the boiler This chapter will explain how to make all connections to the boiler with regard Hydraulic connections (1, 3) Condensate drain connection (7) Gas connection (6) Flue gas connection (5) ... - Page 23 Installation Connecting the boiler Gas connection (6) It’s recommended to use stainless The gas connection must be made by steel systems an authorized installer in accordance The diameter of the flue gas system with the applicable national and local must be chosen by calculation ac- standards and regulations.
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Page 24: Commissioning Water And Hydraulic System
VDI2035 standard. In the table you can find the nominal va- lues for filling and additional water for the R3400/R3500/R3600SB according to the the VDI2035. The table at the left gives an indication Concentrate... -
Page 25: Gas Supply
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 star- ting the boiler! Remove any air between the gas valve and the gas line. -
Page 26: Prepare Boiler For First Startup
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 use rotational switch (3);... -
Page 27: Combustion Analysis
Commissioning Combustion analysis Pilot burner Combustion check at full load Combustion settings Start the boiler at service mode for full for natural gas G20 / G25 load operation ( ). When you have All boilers reduced P9 to 50% (see previous chapter), the boiler will operate at 50% 10.0 ±... -
Page 28: Air Pressure Switch
Commissioning Air pressure switch Adjustment Air pressure switch Connect a pressure gauge to the indi- cated measuring points on the APS (1). Start the boiler at service mode for mi- nimum load operation (W1). Measure the pressure differential across the switch. -
Page 29: Check Water Flow
Commissioning Check water flow 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. -
Page 30: Check Functionality Of Safety Devices
Commissioning Check functionality of safety devices Gas tightness check Boiler shut down Check functionality of safety devices Ionisation electrode (6) All safety devices have to be checked Remove electrical connection from the on good functioning. Safety devices on ionisation electrode while the boiler is a standard boiler are a water flow tem- running, the boiler will go in lockout perature sensor, water flow switch mi-... -
Page 31: Commissioning Protocol
Commissioning Commissioning protocol Commissioning Protocol R3400/R3500/R3600SB Project Boiler type Project Serial number Address Year City Nominal load (Hi) [kW] Date Nominal output (Hi) [kW] Engineer System Water pressure [bar] Installati- Roof top Water pH Ground floor Water hardness [dºH]... -
Page 32: Operating Instructions Main Menu (Operating Mode)
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’... -
Page 33: Maintenance Checklist
Maintenance Checklist Replacing the electrodes Maintenance of the boiler should be Checklist carried out by authorized personnel The following activities must be carried only. out, see following paragraphs for an extensive description of the main activi- In order to ensure continued good and ties: safe operation of the boiler, it should be inspected at least once per year. -
Page 34: Cleaning The Condensate Receptacle
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. -
Page 35: Safety Devices
Maintenance Maintenance Protocol Maintenance Protocol R3400/R3500/R3600SB 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 [dºH] Water chloride [mg/l] Water ∆T full load [ºC]... -
Page 36: Lockouts
Lockouts In case of a lockout, a warning triangle (E) 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 “... - Page 37 Lockouts No. Error type Explanation Possible solution Lockout Error gas valve V1, flame ionisation signal detec- Check closing position of valve V1 within gas combi ted longer than 5 seconds after burner stop. valve, replace gas valve. Lockout Error gas valve V2, flame ionisation signal detec- Check closing position of valve V2 within gas combi ted longer than 5 seconds after burner stop.
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Page 38: Sensor Values
Sensor values The diagrams show the sensor values Water flow and fluegas temperature sensor (5kΩ NTC) for all boiler sensors and optional sen- sors 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. -
Page 39: Declaration Of Conformity
Declaration of Conformity Declaration of Conformity Rendamax BV, Hamstraat 76, 6465 AG Kerkrade (NL), declares that the products R3400/3500/3600SB 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... - Page 40 NL - 6465 AG Kerkrade ELCO Belgium n.v./s.a. B - 1731 Zellik ELCO Italia S.p.A. I - 31023 Resana ELCO UK / MHS Boilers ltd. UK - Basildon, Essex, SS15 6SJ ELCO France / Chaffoteaux SAS F - 93521 Saint-Denis Cedex...
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