Rendamax R3600 Owner's manual

Rendama

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Technical documentation

R3400 R3500 R3600

Doc890/3456CV02B

Rendama

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Edition 3456CV02B, 03-02-2003

No part of this publication may be reproduced, stored in aretrieval system, or transmitted in any form or by any means, electronic, me-

chanical, photocopying, recording or otherwise, without the prior permission in writing of Rendamax B.V..

We aim to achieve continuous improvement in our products. Therefore, speciﬁ cations are subject to change without prior notice.

Doc890/3456CV02B

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Doc890/3456CV02B

Contents

R3400 Technical data 1

Dimensions R3400 2

R3500 Technical data 4

Dimensions R3500 5

R3600 Technical data 7

Dimensions R3600 8

1 Introduction 11

1.1 Rendamax

1.2 Supplier

1.3 This document

1.4 Service

1.5 General restrictions 12

2 Description

2.1 General

2.2 Main components 14

2.2.1 Description of principal components 15

2.3 Boiler control 16

2.4 Safety aspects

3 Safety 17

4 Delivery and transport 18

4.1 Delivery

4.2 Packaging

4.3 Transport

5 Installation 24

5.1 Regulations

5.2 Boiler room

5.2.1 General

5.2.2 Set up

5.2.3 Ventilation 25

5.3 Connections

5.3.1 Gas connection

5.3.2 Electrical connection 26

5.3.3 Water connections 29

5.3.4 Combustion air supply 30

5.3.4.1 General

5.3.4.2 Air supply pipe

5.3.5 The Flue system 32

5.3.5.1 General

5.3.5.2 Chimney 33

5.3.6 Condensate discharge 36

5.4 Hydraulic system 37

5.4.1 General

5.4.2 Water ﬂ ow

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5.4.2.1 Flow rate and resistance 37

5.4.2.2 Pump characteristics 39

5.4.2.3 Isolating valves 40

5.4.2.4 Valves

5.4.2.5 Water ﬂ ow protection

5.4.3 Water pressure

5.4.3.1 Operating pressure

5.4.3.2 Boiler expansion tank

5.4.3.3 System expansion tank

5.4.3.4 Water pressure protection

5.4.4 Water temperature 41

5.4.5 Water quality

5.4.6 Examples of hydraulic systems 42

6 Operating instructions 45

6.1 Function

6.2 Regulation

6.3 Control module

6.4 Fault indications 47

6.5 Start-up 48

6.6 Shut-down

6.7 Warnings

7 Commissioning

7.1 General

7.2 Commissioning

8 Maintenance 50

8.1 Safety

8.2 General

8.3 Procedure 51

8.4 Cleaning the burner and heat exchangers

8.5 Cleaning the ﬁ lter/screen in the gas combination block 52

8.6 Ionisation measurement

8.7 Service

9 Conversion formulae and factors

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R3400 Technical data

Type R3401 R3402 R3403 R3404 R3405 R3406

Nominal heat output

Nominal heat input (nett. CV)

Minimum heat input

kW

657

702

176

729

784

196

853

917

229

965

1038

260

1078

1159

290

1189

1279

320

Pilot burner kW 36 36 36 36 36 36

Gas consumption

natural gas H (10.9 kWh/m3)

propane (12.8 kWh/kg)

m3/h

kg/h

64.5

54.9

71.9

61.2

84.1

71.6

95.2

81.1

106.3

90.5

117.3

99.9

Gas inlet pressure

natural gas (min.)

natural gas (max.)

natural gas (max.) option

mbar

18

25

100

18

25

100

35

100

-

35

100

-

35

100

-

35

100

-

Water capacity

Max. working pressure

dm3

bar

50

6

53

6

70

6

75

6

80

6

85

6

Gas connection G Rp2" Rp2" Rp2" Rp2" DN65

PN6

DN65

PN6

Water connections W DN65

PN6

DN65

PN6

DN80

PN6

DN80

PN6

DN80

PN6

DN80

PN6

Flue connection D mm 300 350 350 400 400 400

Safety valve connection

relief connection

standard setting

11⁄4"

11⁄2"

3

11⁄4"

11⁄2"

3

11⁄2"

2"

3

11⁄2"

2"

3

11⁄2"

2"

3

2"

21⁄2"

3

Power supply

Frequency

Fuse

V

Hz

A

400 3N~

50

16

400 3N~

50

16

400 3N~

50

20

400 3N~

50

20

400 3N~

50

20

400 3N~

50

20

Max. electrical power

consumption unit

pump maximum

total

kW

0.90

1.15

2.05

0.90

1.15

2.05

1.27

1.15

2.42

1.27

1.50

2.77

1.27

1.50

2.77

1.27

1.50

2.77

Boiler weight, empty, ± 5 % kg 675 740 840 950 1070 1200

Dimensions height H

width B

length incl. connections L

mm

1355

1330

2265

1355

1330

2265

1355

1130

2653

1355

1130

2653

1355

1330

2658

1355

1330

2658

Table 1 Technical data R3400

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Dimensions R3400

Clearances

- 450 mm at one side

- 800 mm at the other side

- 450 mm at the rear

- 1000 mm at the front

Fig. 1 Dimensional sketch R3400

front view plan view

rear view

side view

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Type R3401 R3402 R3403 R3404 R3405 R3406

B mm 1330 1330 1130 1130 1330 1330

B1 mm 1160 1210 1003 1053 1203 1253

B2 mm 665 665 565 565 665 665

B3 mm 170 120 127 77 127 77

B4 mm 1146 1146 946 946 1146 1146

B5 mm 115 65 115 65 115 65

D mm 300 300 350 350 400 400

G Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6

H mm 1355 1355 1355 1355 1355 1355

H1 mm 1125 1125 1570 1420 1155 1462

L mm 2265 2265 2653 2653 2658 2658

L1 mm 595 595 610 615 615 770

L2 700 700 1166 1166 1166 1166

L3 mm10810888888888

W DN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Table 2 Dimensions R3400

(Changes may be introduced without notice)

As a result of manufacturing tolerances, there may be small variations in the dimensions.

Conditions applicable to table 1:

- Nominal capacity measured at: 60 - 80°C.

- Gas consumption at: 1013 mbar, 15°C, dry

- Gas category: 2

2H3P

- Appliance category: B23, C53, C33 of C63

- Protection degree: IP20

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1 Introduction

1.1 Rendamax

Since its beginning in 1968, Rendamax has built up a strong reputation in industry for the devel-

opment, production and marketing of gas-ﬁ red, high efﬁ ciency boilers in the 60 to 1200 kW range.

Through their unique construction, these central heating units are renowned for their:

- high thermal efﬁ ciency

- environmental friendliness

- light weight and small dimensions

- durability

- low noise production

- large regulating range

- available with many different options.

Continual research and development means that Rendamax remains at the forefront of boiler and

water heater technology.

1.2 Supplier

Rendamax boilers are sold by your supplier (see cover).

For advice or more information with regard to our products contact your supplier.

1.3 This document

This documentation has been to aid the following target

groups:

- the consulting engineer

- the heating installer

- the service engineer

- the user

Because these target groups require mostly similar information and also speciﬁ c information, our

technical documentation has been integrated to provide these target groups with the neces sary

general and speciﬁ c information to install, service and operate this product.

The supplier (see cover) will be able to provide any further or supplemental information.

The following aspects of the units are dealt with:

- General description

- Technical speciﬁ cations

- The facilities necessary for design and installation

- Installation examples

- Maintenance instructions

The operating instructions needed by the user are attached to the unit; these are also to be found

in Section 6.

1.4 Service

The supplier’s service department is always available for commissioning and for providing service

and maintenance. For details see cover.

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1.5 General restrictions

The application, installation and maintenance of Rendamax products must always be carried out

in accordance with the requirements (legal or otherwise), speciﬁ cations and standards applicable

to such installations.

All data, information and suggestions provided by Rendamax B.V. in relation to its products are

based on careful investigation. Nevertheless, neither Rendamax B.V. nor any other organisation

connected with Rendamax B.V. accepts any liability for application, installation or exploitation

that occurs outside its sphere of inﬂ uence.

Changes may be incorporated without prior notice.

Rendamax accepts no obligation to adapt previously deliv ered products to incorporate such

changes.

2 Description

2.1 General

The R3400/R3500/R3600 series are environmentally friendly modulat ing gas ﬁ red heating boilers

that can vary its output from 25% to 100% of its maximum capacity. The series R3400 consists of

6 types in a range from 657 to 1189 kW.

The series R3500 consists of 5 types in a range from 613 to 1000 kW. The series R3600 consists of

5 types in a range from 631 to 1031 kW.

The units have an extremely low emission of NOx and CO, so that this boiler satisﬁ es the most

stringent European require ments.

The R3400/R3500/R3600 series have CE approval for the following countries:

Austria, Belgium, Denmark, France, Germany, Ireland, Italy, The Netherlands, Spain and the

United Kingdom.

The series is registered under the product identiﬁ cation number 0063AR3514.

The units can be supplied either as a standard (category B23) or a room sealed (categories C53,

C33 or C63) appliance.

Working principle and construction

Air is blown into the appliance, as required, by a speed-con trolled fan and thoroughly mixed with

gas in the correct propor tions.

A temperature controller compares the desired water tempera ture with the temperature of the

water ﬂ ow and sends a signal to the frequency converter to maintain the correct heating capacity.

The gas/air mixture so formed is passed through a cooled premix burner and ignited. The premix

burner is constructed of ﬁ nned bimetallic pipes (internally from stainless steel and externally

from aluminium) with cast iron water headers.

Heat transfer takes place in two or three heat exchangers. The ﬁ rst heat exchanger is constructed

from smooth stainless steel pipes, while the second heat exchanger is ﬁ tted with laser welded,

stainless steel ﬁ nned pipes. Both heat exchangers are ﬁ tted with cast iron proﬁ led water distribu-

tion components (headers) which guarantee an optimum water ﬂ ow through the appliance.

The burner and the heat exchangers are connected in series.

At the R3600 a third heat exchanger is attached wich consists of one or more stainless steel ﬁ n

tube(s), switched in series, in form of a spiral. It is arranged on the back of the boiler on the ﬂ ue

gas collection chamber.

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The boiler pump ensures the water ﬂ ow quantity. The third heat exchanger is switched parallel to

the boiler and has a ﬂ ow of 5 - 10 % of the entire water ﬂ ow.

The R3400/R3500/R3600 units have a small water capacity so that it can rapidly adjust to chang-

ing conditions. It can be in stalled without any restrictions to the return water temperature. The

necessary water ﬂ ow rate is ensured by the standard pump delivered with the appliance.

Application possibilities

Because of its construction, the R3400/R3500/R3600 units are suitable for use in heating sys-

tems:

- With a constant supply temperature

- With a weather dependent heating demand

- With low temperature condenser systems

- With optimised condensation

- With control by means of building optimiser/compensator system (0-10 Vdc, see 5.3.2 connec-

tion terminals).

Fig. 4 The Econoﬂ ame R3600

* The R3400 and R3500 are identical with the exception of the third heat exchanger.

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2.2 Main components

1 Return connection 18 Condensate collection tank

2 Flue gas discharge R3600 or 19 Flue gas collection chamber

Flue attenuator 20 Combustion chamber

3 Water ﬂ ow switch 21 Electrical cable duct

4 Safety valve 22 Condensate discharge

5 Flow connection 23 Gas valve unit

6 Filling/drainage valve 24 Fan

7 Cover 25 Connection box

8 Distribution plate 26 Control panel

9 Burner 27 Casing

10 First heat exchanger 28 Air inlet damper

11 Gas ﬁ lter 29 Main mixing chamber

12 Second heat exchanger 30 Pilot gas valve

13 Gas train 31 Pilot mixing chamber

14 Frame 32 Boiler pump

15 Water circulation piping A Air

16 Flue gas discharge B Gas

17 Third heat exchanger R3600 C Flue gas

D Condensate

Fig. 5 General survey

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2.2.1 Description of principal components

The unit is constructed from the following principal compo nents:

Fan [24]

This consists of a fan casing, a fan impeller and an electric motor. The fan sucks in combustion air

and increases the air pressure.

Air inlet damper [28]

A specially developed air inlet damper ensures a low noise level. As an option, this can be provid-

ed with an air ﬁ lter or with an air inlet opening so that the appliance can function as a room sealed

appliance.

Gas train [13]

The principal component of the gas train is the main gas

valve/proportional pressure regulator [23]. The quantity of gas is adjusted in proportion to the

quantity of air being supplied. The quantity of air depends on the speed of the fan. The unit is ﬁ t-

ted with a gas ﬁ lter [11] as standard.

Mixing chamber [29 + 31]

This area is used for the thorough mixing of the gas and the combustion air. The unit is supplied

with a main mixing cham ber [29] and a pilot mixing chamber [31]. Both are connected to the fan.

Burner [9]

After the gas/air mixture has been distributed over the burner with the aid of a distribution plate

[8], the mixture is burned on the surface of the burner in such a way that the ﬂ ame is di rected

downward. The burner is air and water cooled. The water distribution components are made from

cast iron and have a proﬁ le that ensures that an optimum distribution and ﬂ ow are obtained.

Heat exchangers [10, 12 and 17]

The primary heat exchanger [10] is constructed from smooth stainless steel tubes. These transfer

most of the heat energy to the system water. The secondary heat exchanger [12], which consists

of laser welded stainless steel ﬁ nned tubes, transfers the remaining heat from the ﬂ ue gasses to

the system water. All the water distribution components are constructed from cast iron and have

a proﬁ le that ensures that optimum distribution and ﬂ ow are obtained. The space between the

burner and the secondary heat exchanger forms the combustion chamber.

At the R3600 a third heat exchanger [17] is attached wich consists of one or more stainless steel

ﬁ n tube(s), switched in series, in form of a spiral. It is arranged on the back of the boiler on the

ﬂ ue gas collection chamber.

The boiler pump ensures the water ﬂ ow quantity. The third heat exchanger is switched parallel to

the boiler and has a ﬂ ow of 5 - 10 % of the entire water ﬂ ow.

Water circulation pipes [15]

These pipes connect the burner to the heat exchangers.

Water connections

These consist of a ﬂ ow connection [5] and a return connection [1]. Both of these connections are

provided with a ﬁ lling/drain valve [6]. The ﬂ ow connection is also provided with a safety valve [4],

a ﬂ ow switch [3] and a temperature sensor.

Boiler pump [32]

The boiler pump is mounted on the return connection to the unit and is directly connected electri-

cally to the appropriate termi nals in the connection box. The capacity and the working head of the

pump is sufﬁ cient to overcome both the resistance of the boiler and some system resistance.

Flue gas collection chamber [19]

The stainless steel ﬂ ue gas collection chamber is mounted under the heat exchanger. This cham-

ber is provided with a ﬂ ue gas exhaust connection [16], a condensate drain connection [22] and an

inspection opening.

Frame [14]

The frame is constructed from steel proﬁ le sections. Vibration absorption dampers are supplied

separately and must be ﬁ tted after the unit has been placed in position.

The casing [27]

The casing consists of panels that can be removed easily without the aid of tools.

The electrical section

This includes the control and safety circuits for the unit.

Connection box [25]

The electrical power supply for the boiler, the terminals, the pump connections and the pump

relay are mounted in an easily accessible connection box. The supply cables can easily be fed to

the connection box via the cable duct inside the boiler [21].

2.3 Boiler control

The principle employed for the Boiler Management Unit is as follows: The boiler begins operating

on receipt of a heating demand. This heating demand is generated either:

A. If the measured supply temperature is lower than the desired temperature.

B. As a result of “manual operation” mode having been se lected (W1 or W2 ),

C. in standby mode, when the water temperature falls below the frost protection temperature.

After the unit has started up, the PID controller sends a signal to the frequency converter. This

converter controls the speed of the fan. Depending on the quantity of air moved by the fan, the

proportional pressure regulator ensures that the corresponding quantity of gas is added.

In this way the boiler capacity is continually adjusted and the boiler can accurately follow the

heating demand. If the boiler is operating at minimum capacity and the temperature of the supply

water rises above the desired value, the unit will be shut down. As soon as the temperature of the

supply water falls below the set value, the boiler will be re-started.

2.4 Safety aspects

The unit contains the following safety components:

- Flame protection on pilot and main burner (1x re-start)

- Water ﬂ ow protection

- Maximum water temperature protection

- Gas valve test

- Fan protection

- Boiler pump motor over-heating protection.

If one of these components operates, this results in a lockout fault. Lockout faults can only be

cancelled by resetting the unit.

The unit is ﬁ tted with a safety valve that opens at 3 bar.

3 Safety

Installation instructions

Read through these instructions carefully before starting the installation.

The appliance must be installed by a recognised installer in accordance with the applicable na-

tional and local regulations (see Supplement).

The installation may only be used for heating systems up to a maximum water temperature of

90°C.

It is expressly stated that these installation instructions must be seen as a supplement to the

above mentioned standards and regulations and that these standards and regulations must take

precedence over any information included in this technical manual.

Pictograms used in this manual

y An instruction that is essential for the correct functioning of the installation.

w If these operations, procedures, etc., are not accurately fol lowed this can result in serious damage

to the installation, personal injury or environmental damage.

v Danger of electric shock.

x Useful information.

Maintenance

Work on the electrical installation may only be carried out by an authorised installer in accordance

with the applicable electrical regulations.

Work on the gas and hydraulic installations may only be under taken by properly trained person-

nel in accordance with the safety regulations for gas installations.

w Keep unauthorised persons away from the installation. Do not place any objects on the unit.

Remain out of the area of the hot water connection and the chimney to avoid burns.

Before starting any maintenance or service activities, discon nect the electrical power supply and

close the gas supply valve.

After completing any maintenance or service activity, check the whole installation.

x As a supplement to the information provided in this technical manual, all applicable safety regula-

tions must be consulted to avoid accidents.

All panels forming part of the casing must be mounted. Panels may only be removed for main-

tenance or service purposes. After performing maintenance or service activities, ensure that all

panels are replaced.

Safety provisions

w The installation may never by switched on if any of the panels have been removed or if any of the

safety devices have been disabled.

Instruction and warning stickers

x None of the instruction and warning stickers attached to the installation may be removed or cov-

ered and during the whole of the lifetime of the installation they must remain legible.

Replace any damaged or unreadable instruction and warning stickers immediately.

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Modiﬁ cation

Modiﬁ cations to the installation may only be carried out with the written approval of the manufac-

turer.

Danger of explosion

When activities are being undertaken in the boiler room, always follow the applicable instructions

“Working in an area where there is a danger of explosion”.

Installation

The appliance must be installed by an authorised installer in accordance with the applicable na-

tional and local speciﬁ cations and regulations.

Carefully follow all the safety instructions.

Operation

In the event of a gas leak, switch off the unit and close the gas supply valve. Open doors and win-

dows and warn the appropri ate authorities.

When the installation is re-commissioned, always follow the instructions for use.

Technical speciﬁ cations

The speciﬁ cations listed in this technical manual cannot be ignored.

4 Delivery and transport

4.1 Delivery

The appliances are completely assembled, tested and covered in a “heat-shrink” protective cover-

ing.

After delivery and removal of the protective covering, check the appliance for damage.

Check that the equipment delivered is in accordance with the order and the delivery note.

On delivery, check the data plate for the correct boiler type and gas supply pressure.

4.2 Packaging

For transport purposes, the unit is mounted on wooden blocks, ﬁ tted with protective bumpers

and and covered in a “heat-shrink” protective covering.

4.3 Transport

x For transport, consult the technical details for dimensions and weight.

w Remove the covering preferably after transportation and posi tioning in the boiler room or remove

the panels before trans porting the appliance. This is to prevent damage to the casing panels.

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Doc890/3456CV02B 19

Moving the appliance

A pallet truck or fork lift truck with a minimum fork length of 1 m can be used at the side of the

unit.

Fig. 6 Moving the appliance

Rollers

After the wooden blocks have been removed, it is possible to move the appliance by rolling it over

tubes.

Fig. 7 Moving with the id of rollers

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Lifting

The ﬁ gure below shows how a unit can be safely lifted. To avoid damage to the panels, these

should ﬁ rst be removed. The wooden bars between the straps ensure that the unit will not be

damaged during lifting.

Fig. 8 Lifting

w Caution:

- Ensure that the lifting straps are of the correct quality!

- Never move the units over the heads of persons!

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Dismantling and reassembly

When the unit cannot be placed in position because of its dimensions or weight, the boiler may be

partially dismantled.

When it is necessary to perform extensive dismantling, we advise you to make early contact with

your supplier. The unit can be delivered in parts, each of which has been pretested.

We strongly advise you to have dismantling and reassembly activities carried out by the service

department of your

supplier.

Burner

Type L (mm) B (mm) H (mm) m (kg)

R3401 1010 1150 420 135

R3402 R3501 R3601 1010 1310 500 140

R3403 R3502 R3602 1420 1010 500 210

R3404 R3503 R3603 1420 1110 500 215

R3405 R3504 R3604 1420 1210 500 220

R3406 R3505 R3605 1420 1310 500 225

1st Heat exchanger

Type L (mm) B (mm) H (mm) m (kg)

R3401 1010 1150 160 120

R3402 R3501 R3601 1010 1310 160 135

R3403 R3502 R3602 1420 1010 160 180

R3404 R3503 R3603 1420 1110 160 185

R3405 R3504 R3604 1420 1210 160 190

R3406 R3505 R3605 1420 1310 160 195

2nd Heat exchanger

Type L (mm) B (mm) H (mm) m (kg)

R3401 1010 1150 160 135

R3402 R3501 R3601 1010 1310 160 150

R3403 R3502 R3602 1420 1010 160 200

R3404 R3503 R3603 1420 1110 160 200

R3405 R3504 R3604 1420 1210 160 210

R3406 R3505 R3605 1420 1310 160 210

Fig. 9 Dimensions and weights of burner and heat exchanger

Flue gas collection chamber

Type L (mm) B (mm) H (mm) m (kg)

R3401 1320 990 400 ‹25

R3402 R3501 R3601 1450 1070 400 ‹25

R3403 R3502 R3602 1950 770 400 ‹35

R3404 R3503 R3603 1950 870 400 ‹35

R3405 R3504 R3604 1950 970 400 ‹35

R3406 R3505 R3605 1950 1070 400 ‹35

Fig. 10 Dimensions and weights of the ﬂ ue gas collection chamber

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w R3600 only

3rd Heat exchanger

Type L (mm) B (mm) H (mm) m (kg)

R3601 585 800 411 60

R3602 585 610 411 60

R3603 585 690 411 60

R3604 585 780 686 90

R3605 585 780 686 90

Fig. 11 Dimensions and weights of the third heat exchanger

Frame

Type L (mm) B (mm) H (mm) m (kg)

R3401 1325 1165 460 50

R3402 R3501 R3601 1630 1266 500 60

R3403 R3502 R3602 2004 1066 500 70

R3404 R3503 R3603 2004 1066 500 70

R3405 R3504 R3604 2004 1266 500 70

R3406 R3505 R3605 2004 1266 500 70

Fig. 12 Dimensions and weights of the frame

Positioning

Once the unit is in the correct position, the wooden blocks must be removed. The vibration ab-

sorption dampers with spacers delivered with the unit must now be mounted as described in the

instructions delivered with them (see drawing). Thereafter, the water, gas, chimney, condensate

and electrical connections can be completed.

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Protection against frost

w If the unit is out of use during the winter months there is a danger of freezing. Drain the water

from the installation using the ﬁ lling/drainage valves.

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