Rendamax Technical documentation R3400 R3500 R3600 Doc890/3456CV02B
Rendamax Edition 3456CV02B, 03-02-2003 ©2003 Rendamax B.V. All rights reserved. No part of this publication may be reproduced, stored in aretrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission in writing of Rendamax B.V.. We aim to achieve continuous improvement in our products. Therefore, specifications are subject to change without prior notice.
Rendamax Contents 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.2.1 2.3 2.4 3 R3400 Technical data 1 Dimensions R3400 2 R3500 Technical data 4 Dimensions R3500 5 R3600 Technical data 7 Dimensions R3600 8 Introduction Rendamax Supplier This document Service General restrictions 11 12 Description General Main components Description of principal components Boiler control Safety aspects 14 15 16 Safety 17 4 4.1 4.2 4.3 Delivery and transport Delivery Packaging Transport 18 5 5.1 5.2 5.2.1 5.2.2 5.
Rendamax 5.4.2.1 5.4.2.2 5.4.2.3 5.4.2.4 5.4.2.5 5.4.3 5.4.3.1 5.4.3.2 5.4.3.3 5.4.3.4 5.4.4 5.4.5 5.4.6 Flow rate and resistance Pump characteristics Isolating valves Valves Water flow protection Water pressure Operating pressure Boiler expansion tank System expansion tank Water pressure protection Water temperature Water quality Examples of hydraulic systems 37 39 40 6 6.1 6.2 6.3 6.4 6.5 6.6 6.
Rendamax R3400 Technical data Type R3401 R3402 R3403 R3404 R3405 R3406 Nominal heat output Nominal heat input (nett. CV) Minimum heat input kW kW 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) m3/h propane (12.8 kWh/kg) 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.) mbar natural gas (max.
Rendamax Dimensions R3400 front view plan view side view rear view Clearances - 450 mm at one side - 800 mm at the other side - 450 mm at the rear - 1000 mm at the front Fig.
Rendamax 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 Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6 G 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
Rendamax 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 - environmental friendliness - light weight and small dimensions - durability - low noise production - large regulating range - available with many different options.
Rendamax 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), specifications 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.
Rendamax The boiler pump ensures the water flow quantity. The third heat exchanger is switched parallel to the boiler and has a flow of 5 - 10 % of the entire water flow. The R3400/R3500/R3600 units have a small water capacity so that it can rapidly adjust to changing conditions. It can be installed without any restrictions to the return water temperature. The necessary water flow rate is ensured by the standard pump delivered with the appliance.
Rendamax 2.2 Main components 1 Return connection 2 Flue gas discharge R3600 or Flue attenuator 3 Water flow switch 4 Safety valve 5 Flow connection 6 Filling/drainage valve 7 Cover 8 Distribution plate 9 Burner 10 First heat exchanger 11 Gas filter 12 Second heat exchanger 13 Gas train 14 Frame 15 Water circulation piping 16 Flue gas discharge 17 Third heat exchanger R3600 Fig.
Rendamax 2.2.1 Description of principal components The unit is constructed from the following principal components: 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 provided with an air filter or with an air inlet opening so that the appliance can function as a room sealed appliance.
Frame [14] The frame is constructed from steel profile sections. Vibration absorption dampers are supplied separately and must be fitted 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.
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 national and local regulations (see Supplement). The installation may only be used for heating systems up to a maximum water temperature of 90°C.
Rendamax Modification Modifications to the installation may only be carried out with the written approval of the manufacturer. 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 national and local specifications and regulations. Carefully follow all the safety instructions.
Rendamax 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.
Rendamax Lifting The figure below shows how a unit can be safely lifted. To avoid damage to the panels, these should first be removed. The wooden bars between the straps ensure that the unit will not be damaged during lifting. Fig.
Rendamax 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.
Rendamax w R3600 only Type R3601 R3602 R3603 R3604 R3605 Fig. 11 L (mm) 585 585 585 585 585 3rd Heat exchanger B (mm) 800 610 690 780 780 m (kg) 60 60 60 90 90 Dimensions and weights of the third heat exchanger Type R3401 R3402 R3403 R3404 R3405 R3406 Fig.
Rendamax w Protection against frost 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 filling/drainage valves.
Rendamax 5 Installation 5.1 Regulations The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations. Commissioning should be carried out by the service department of your supplier, who can also determine the composition and quality of the system water. 5.2 Boiler room 5.2.1 General - The construction of the unit ensures that losses through radiation can be neglected.
Rendamax 5.2.3 y 5.3 5.3.1 Fig. 14 Roof installation Fig. 15 Loft installation Ventilation The ventilation of the boiler room must satisfy the applicable national and local standards and regulations.
Rendamax The gas connection is made at the rear of the boiler. Types R3401, R3402, the R3501 - R3505 and R3601 - R3605 are not suitable for immediate connection to a 100 mbar natural gas system (as option 100 mbar). The pressure of the gas sup-plied to the unit must be reduced to 25 mbar for natural gas or 50 mbar for propane with the use of a gas pressure regulator. From type R3403, all boilers are suitable for gas supply pressures of 100 mbar on natural gas.
Rendamax In accordance with the applicable standards and regulations, an emergency shut-off must be fitted outside the boiler room. In the event of a calamity, the power supply to the unit can be switched off. Earth leakage trips can give problems when they are used in combination with frequency converters. In some countries this is actually forbidden.
Rendamax BME (option) This is a weather-compensated regulator with the following possibilities: - Three on/off periods per day with three different temperatures - Night-time temperature reduction - Domestic hot water priority with time programming - Anti-legionella provision - Optimum start - Room-temperature sensor (can be switched off) - Two-wire communication bus connection - Multi-language display - External control E6 (option) This is a regulator with which two secondary groups can be weather-dependen
Rendamax 35 - 36 Calorifier temperature sensor*. After a suitable sensor has been connected it will be automatically recognised when the power supply voltage is switched on. The terminals 34 - 35 must not be interconnected. The purpose of this function, in comparison with the calorifier thermostat, is to make possible a night time temperature reduction and an anti- legionella switching (only with BME, E6 or KKM). External influence (2 - 10 VDC = +10°C - +90°C)*.
Rendamax w 5.3.4 5.3.4.1 In order to limit the losses occurring in a non-operational boiler, a motorised valve is sometimes fitted in the flow or the return pipe or a mechanical non-return valve is used for this purpose. Standby losses can be reduced even further by shutting down the boiler via the “boiler enable” terminals. A properly dimensioned low velocity header ensures that the natural flow through the boiler can be neglected.
Rendamax Fig. 19 Air supply connection The connection to the air supply pipe is always mounted on the top of the unit. Multiple units may not be connected to the same air supply or flue pipe. To prevent snow entering, the air supply pipe must extend at least 30 cm above the roof and must be fitted with a rain cap. The flue pipe opening must end at least 100 cm above the roof, assuming the roof to be flat. Fig.
Rendamax Fig. 21 Distance between air inlet and flue gas outlet The formation of unwanted condensation must be avoided. In the event that during the heating up period condensation occurs, the condensate must be able to flow back to the unit. Inspection of the air supply and flue pipe must be possible. The connection, exit position and height in relation to possible obstacles must comply with the applicable national and local standards and regulations (see Supplement). 5.3.5 5.3.5.
Rendamax Type Flue gas temperature at full capacity (approx.) Maximum permissible chimney resistance °C m3/h kg/s mbar R3401 R3402 R3403 R3404 R3405 R3406 165 165 165 165 165 165 1423 1580 1848 2091 2334 2578 0.330 0.367 0.428 0.485 0.541 0.598 1.5 1.5 1.5 1.5 1.5 1.5 R3501 R3502 R3503 R3504 R3505 155 155 155 155 155 1287 1505 1703 1901 2099 0.306 0.357 0.404 0.451 0.498 1.5 1.5 1.5 1.5 1.5 R3601 R3602 R3603 R3604 R3605 85 85 85 85 85 1076 1258 1424 1590 1756 0.306 0.357 0.404 0.451 0.
Rendamax chimney suspension draugt control draugt control fall ≥30/1000 mm collars min. 700 mm condensateopening Fig. 22a support Chimney connection R3400/R3500 chimney suspension draugt control draugt control fall ≥30/1000 mm collars condensateopening Fig. 22b w support Chimney connection R3600 The R3400 and R3500 appliance must never be connected to a flue sysytems with a plastic lining (consult the applicable standards and regulations).
Rendamax Maximum permitted flue system length in metres of smooth pipe. Standard flues only.
Rendamax Diameter in mm ζ=1 Elbow 90° R/D = 1 Elbow 90° right angle Elbow 45° ζ=0,5 90° Tee ζ=2 R3401 R3402 R3403 R3404 R3405 R3406 300* 350* 350* 400* 400* 400* 7.3 9.2 9.4 10.6 10.0 10.7 3.6 4.6 4.7 5.3 5.0 5.3 9.4 12.0 12.2 13.8 13.0 13.9 3.6 4.6 4.7 5.3 5.0 5.3 14.5 18.4 18.8 21.3 20.0 21.
Rendamax The connection to the drain must be arranged such that there is an open connection under the condensate discharge point on the appliance (see fig. 23). In addition, the discharge pipe must be fitted with a trap (U-bend) in accordance with the applicable regulations. Ensure that the distance between the condensate discharge point of the boiler trap and the drainage pipe is at least 5 mm. This provides the required open connection and simplifies any subsequent maintenance activities and inspections.
Rendamax Type ∆T 20 K Pump data Nominal flow rate Boilerresistance Grundfos Pump type m3/h kPa R3401 28.54 46 UPS 65-120F R3402 31.63 53 R3403 37.00 R3404 Pump speed Head at Qnom. Available Max.* head at power Qnom. consumption kPa kPa W 3 77 31 1.15 UPS 65-120F 3 69 16 1.15 36 UPS 65-120F 3 54 18 1.15 41.84 43 UPS 80-120F 3 70 27 1.50 R3405 46.75 50 UPS 80-120F 3 62 12 1.50 R3406 51.60 58 LM 80-160/162 - 70 12 1.50 R3501 26.
Rendamax For additional energy savings an optional speed controlled pump is available for the R3500 and R3600. For details of this, consult your supplier. 5.4.2.2 Pump characteristics UPS 80-120F UPS 65-120F Fig. 24 Pump char. UPS 65-120F Fig. 25 Pump char. UPS 80-120F LM 80-160/162 Fig. 26 Pump char.
Rendamax Type Pump speed Pmax W Pmin W I A 3x400 V cos φ UPS 65-120F R3401 - R3403 R3501 - R3503 R3601 - R3603 1 2 3 850 900 1150 440 460 600 1.35 1.45 2.15 0.91 0.90 0.77 UPS 80-120F R3404 - R3405 R3504 - R3505 R3604 - R3605 1 2 3 1000 1100 1500 710 760 960 1.65 1.80 2.75 0.87 0.88 0.79 LM 80-160/162 R3406 - 1500 - 4.05 0.79-0.70 Table 13 5.4.2.3 Isolating valves It is recommended that manual valves be fitted between the flow and return connections and the installation. 5.4.2.
Rendamax 5.4.4 Water temperature The maximum permissible temperature of the water flow can be set at 90°C. If the high limit thermostat functions at 100°C, the appliance shuts down and locksout and does not restart automatically when the temperature falls below the high limit temperature setting. 5.4.5 Water quality The composition and quality of the system water has a direct influence on the performance of the whole system and the life of the appliance.
Rendamax In order to guarantee a well functioning system and a long life, any suspended and corrosion producing particles must be removed with the aid of a well chosen and fitted filter system. The analysis of system water and the cleaning of filters must form part of the periodic inspection procedure. If there is an intention to add chemicals (such as inhibitors) to the water, contact must be made with the supplier. The supplier can provide advice on filter systems and other requirements.
Rendamax will react to this and will open the regulator func tions (valves, etc.) in the system. Generally, the temperature of the water supply from the boiler(s) will need to be corrected to obtain the desired temperature in the connected circuits. Systems with a separate flow header and a return header Flow headers in combination with return headers are often used in renovation projects. Several circuits operate with mixing valves or diverting valves.
Rendamax When two appliances are switched in cascade, it is advisable to employ this system. When appliances are controlled by a buil-ding optimising system using weather compensation or a compensating unit, the common flow temperature sensor must be mounted at the common flow pipe as indicated in the drawing. 44 Fig. 30 Installation with more than one appliance, without non-return valves and making use of a low velocity header for two boilers Fig.
Rendamax 6 Operating instructions 6.1 Function When a heating demand is received and before the boiler starts up, the appliance must be prepurged. Gas and air are optimally mixed in the mixing chamber. The fan supplies air for combustion, the quantity being regulated by the frequency controlled fan speed. A proportional controller determines (also by means of regulation) the required quantity of gas. Thereafter, the gas air mixture is ignited in min.
Rendamax Operating mode (cover closed) With the cover closed and by using the rotational switch (pos. No. 2) clockwise or anti-clockwise the boilers’ operating mode can be set.
Rendamax Setting the flow temperature for Domestic Hot Water (cover open) N.B. Only applicable if the Direct Hot Water function is used with the BM-E expansion module. - Open the lid - Turn the rotational switch (pos.5) clockwise until the arrow at the bottom of the LCD display indicates parameter P2 - Press the combined Reset/Programming key (pos.3). The LED will light. Turn the rotary switch (pos.5) until the desired water flow temperature has been reached - Press the combined Reset/Programming key.
Rendamax 6.5 Start-up 1 Open the gas valve. 2 Switch on the appliance using the on/off switch on the control panel. 3 Select the function “automatic operation q” using the func tion selector. (See also the operating instructions on the boiler). 6.6 Shut-down The appliance can be shut down in three different ways: A The boiler continues to supply domestic hot water. Select the F function with the function switch. B The boiler is not operating and will only start up for automatic frost protection.
Rendamax Check that there is a by-pass or a low velocity header fitted in the hydraulic system. This is a requirement. Check and bleed the pump Switch on the power supply to the boiler at the on/off switch and check the direction of rotation of the boiler pump after removing the end cap from the pump motor housing. If the direction of rotation is incorrect, two of the three phase connections must be swapped.
Rendamax Measure the gas pressure at the supply side of the gas valve. This must be at least 18 or 35 mbar (for natural gas) with the boiler operating at full capacity. When multiple appliances are installed in the boiler room, this pressure must be measured with all the appliances operating at full capacity. Check the temperature difference (∆T) between the flow and return to the appliance at the water side. ∆T must be between 15 and 25 K at full capacity.
Rendamax The following activities must be carried out (for an extensive description of these activities, see 8.3): - Renew the ignition and ionisation electrodes - Clean the air inlet damper - Clean the fan blades - Clean the flue gas collection chamber - Clean the condensate trap and the drainage pipe from the appliance - Clean the gas filter - Inspect all pressure measurement pipes and nipples.
Rendamax 8.5 Cleaning the filter/screen in the gas combination block Not applicable 8.6 Ionisation measurement In order to carry out an ionisation measurement, a micro-ammeter with a measuring range of 0 - 200 µA DC must be connected in the ionisation circuit. In this way the ionisation protec tion function can be checked. The nominal ionisation current is between 6 and 25 µA. The minimum ionisation current is 2.8 µA. 8.
Rendamax N= 20.9 = 1.17 20.9 − 3 NOx (for N = 1 ) = 15.0 x 1.17 = 17.6 ppm 17.6 x 1.759 = 30.9 mg/kWh W kcal/h Btu/h 1 1.163 0.293 0.86 1 0.252 3.41 3.97 1 Table 17 Conversion factors 1 kcal 1 kWh = 4.187 kJ = 3.6 MJ Efficiency at the flue gas side The difference between upper and lower calorific values is the heat of evaporation of the combustion formed water. At 298.15 K (25°C) this amounts to 2442.5 kJ/kg (583.38 kcal/kg). For non condensing boilers: 0.339 ηb = 90 − + 0.
Rendamax meg/l °dH °f °e mg CaCO3/l 1 2.8 5 3.51 50 °dH 0.37 1 1.78 1.25 17.8 °f 0.2 0.56 1 0.7 10 °e 0.285 0.8 1.43 1 14.3 mg CaCO3/l 0.02 0.056 0.1 1.54 1 meg/l Table 18 Conversion of degrees of hardness 65 mg CaCO3/imp. gallon 1 degree English hardness (°e) = 1 Grain/US Gallon = 0.958°dH 1 milligramme equivalent per l (mval/l) = 2.
