Alutherm B 350-600
Installation, User and Service Manual | instructions for user
Page 1: ...Alutherm B 350 600 Installation User and Service Manual instructions for user ...
Page 2: ...r Depending on how your heating system is controlled this could be via an external timeclock thermostat switch or otherwise Once the boiler volt free enable contacts are closed the boiler will commence its starting sequence Boiler flow temperature The burner controller can adjust the flow temperature between 20 and 85 C The temperature setting can be changed using the control panel The installatio...
Page 3: ...ns on control panel 13 5 3 User menu 14 5 3 1 Parameter value setting 14 5 3 2 Parameters accessible by user 14 5 4 Installer technician menu 17 5 4 1 Parameters accessible by installer technician 17 5 5 Manual Chimney sweep mode 23 5 6 Disabling CH request 23 5 7 Service code 23 5 8 Tacho fan speed 23 5 9 Errors 23 5 10 ECO working mode 23 5 11 Holiday mode 23 5 12 Schedules for CH and DHW 23 5 1...
Page 4: ...ter inspection 47 8 ERRORS 48 8 1 General 49 8 2 DHW errors 49 8 3 CH errors 49 8 4 Errors hard and soft lockouts 50 9 ANNUAL INSPECTION MAINTENANCE 54 9 1 Service maintenance table 56 9 2 Tubing and fixation 57 9 3 Non return valve NRV in burnerhood Implemented soon 57 9 4 Torque table 58 Declaration of Conformity van Alutherm Heating 59 Note This manual is the translation of the original manufac...
Page 5: ...ector 10 Inspection cover 11 Air supply 12 Gas pipe 13 Air intake silencer 14 Overheat limiter 15 Gas valve 16 Fan 17 Flow 18 Flue gas NTC 19 Return 20 Exhaust 21 Syphon 22 Sump inspection cover 23 Return NTC 24 Fill and drain valve 25 Water pressure switch 26 Automatic air vent 27 Venturi 28 Boiler controller Maxsys 29 Terminal strip 30 Air pressure switch 31 Syphon pressure switch 1 2 4 3 5 6 7 ...
Page 6: ... G20 G25 3 9 3 9 3 9 3 9 3 CO2 content min load G25 G20 G25 3 9 1 9 1 9 1 9 1 CO2 content max load G25 3 90 0 10 0 30 3 90 0 10 0 30 3 90 0 10 0 30 3 90 0 10 0 30 CO2 content min load G25 4 30 0 35 0 20 4 30 0 35 0 20 4 30 0 35 0 20 4 30 0 35 0 20 CO2 content max load G25 3 3 95 0 10 0 35 3 95 0 10 0 35 3 95 0 10 0 35 3 95 0 10 0 35 CO2 content min load G25 3 4 35 0 35 0 25 4 35 0 35 0 25 4 35 0 3...
Page 7: ...ungs 230 VAC MBC 700 SE S02 MBC 700 SE S02 MBC 700 SE S02 MBC 700 SE S02 Venturi Honeywell VMU500A VMU500A VMU680 VMU680 Texi Burner round 130 mm Worgas 433 529 623 718 Silencer air inlet yes no no no Silencer flue gas round 250 mm L 300mm yes double yes single yes single yes single NTC 12 k L 50 3 3 3 3 NTC 12 k OTC optional optional optional optional Water low pressure sensor 1 6 0 8 bar WPS yes...
Page 8: ...ultiplied neither whole nor partly It may not be submitted for perusal to third parties either Blauwwater 1 5951 DB Belfeld T 0031 77 4752270 www dejatech nl Unit mm Projection PART NO CONFIDENTIAL COPYRIGHT DEJATECH DRAWN BY APPROVED BY NAME DATE MATERIAL REVISION TITLE SCALE 1 10 SHEET 1 OF 1 A0 WEIGHT Nieuwe mantel IM 7 8L 1550 5 6L 1430 103 126 162 50 588 1007 50 1264 1503 50 83 50 86 5 7 8L 1...
Page 9: ...om thermostat As standard the boiler is programmed for using an on off room thermostat The room thermostat has to be connected to the pin nrs 1 2 on the terminal strip Open Therm will be recognized if connected on 1 2 The desired flow temperature is adjustable but as standard is set to 85 C At CH heat request from the room thermostat and no DHW heat request present the CH pump is activated after 1...
Page 10: ...int value B OTC setpoint maximum maximum CH setpoint value C OTC weather cold external temperature value at which the maximum CH value will be used D OTC weather warm external temperature value at which the minimum CH value will be used E OTC warm weather shutdown external temperature value at which the CH demand will end In the user menu an eco setpoint reduction night reduction can be set Day we...
Page 11: ...at demand has finished the burner will turn off following a set post purge period The graph below illustrates this 4 2 6 Protection against insufficient flow through boiler Whentherequirementsof6 3 2arefulfilledtheboilerwillprotectitselfagainstinsufficientflow Thisisdonebycheckingthedifferenceintemperature between flow and return so called ΔT In a low flow scenario the ΔT will rise rapidly The ΔT ...
Page 12: ... advanced DHW settings DHW request to sensor Note The resistance of the NTC sensor must have a value of 12 kOhm at 25 C The 2 wires of the tank NTC sensor must be connected to numbers 7 and 8 on terminal strip C2 The set point temperature of the storage tank is adjustable default set at 60 C the flow temperature is DHW setpoint 20K Warning if a CH heat demand exists immediately after finishing the...
Page 13: ...n User and Service Manual instructions for user Heating Alutherm B 350 600 5 BOILER CONTROL 5 1 Control Panel The control panel has 12 buttons and a display as shown in the figure below 5 2 Push buttons on control panel Description of push button use ...
Page 14: ...e desired parameter By pressing the OK button R2 C2 the chosen option will be selected Onceanoptionhasbeenslecteditispossibletochange the parameters corresponding with the chosen option 5 3 1 Parameter value setting Pressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter Pressing the OK button R2 C2 will allow the chosen parameter to be modified This is shown below Th...
Page 15: ...on board scheduler 2 Scheduler set Select to set scheduler 1 Monday 2 Tuesday 3 Wednesday 4 Thursday 5 Friday 6 Saturday 7 Sunday 8 Monday Friday 9 Monday Sunday 10 Saturday Sunday Used to program on board scheduler On Off Eco 2 Domestic hot water Domestic hot water user settings 1 DHW set point Set the DHW temperature in case of a DHW with sensor this is the actual DHW temperature in case of DHW ...
Page 16: ...ime format 24 12 Hours is opened When selected ap propriate format screens jump to time entering screen 24 hours Select for 24 hours clock 12 hours Select for 12 hours clock 5 Restore factory data Pressing OK all the user settings will be restored to the original factory default settings See 1 6 Chimney sweeper Manual mode Hitting OK will force boiler to operate at of power Timeout 15 minutes Whil...
Page 17: ...ressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter group Pressing the OK button R2 C2 selects the chosen parameter group Pressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter subgroup Pressing the OK button R2 C2 selects the chosen parameter subgroup Once a parameter subgroup option has been chosen it is possible to change the param...
Page 18: ... by removing RT or bridge between terminal strip C2 1 2 4 OTC set point table Show in a table the link between external temperature and actual setpoint determined by the OTC parameter selection 5 OTC curve Show in a curve the link between external temperature and actual setpoint determined by the OTC parameter selection 4 CH pump settings Set pump usage related parameters 1 post pump time Set the ...
Page 19: ...eters 1 Ignition power Set power used when igniting burner 2 Delay siphon check Delay time to validate a syphon error 3 Number of boiler pump Pump and 3WayValve System with pump and 3 way valve Two pumps System with 2 pumps 4 Pump speed max Maximum of PWM pump speed 5 Pump speed min Minimum of PWM pump speed 6 Antilegionella Based on selection possible to enable disable Antilegionella protection E...
Page 20: ... Temp 18 0 10V input 19 Target power Will display the information shown in SUBMENU 2 When the line has a at the end of the line means that hitting OK when the line is highlighted will open a graph that shows the latest 120 variable values stored every 12 minutes 24 hour history 2 Lockout history Shows the list of recent errors Hitting OK on the high lighted error will open new screen that contains...
Page 21: ...DHW with thermostat this is the base boiler flow temperature 2 ECO set point reduction Invoke scheduler menu 3 Scheduler set Invoke scheduler menu 1 Enable disable on board scheduler Based on selection is possible to enable disable on board scheduler Enable Enable on board scheduler Disable Disable on board scheduler 2 Scheduler set Select to set scheduler 1 Monday 2 Tuesday 3 Wednesday 4 Thursday...
Page 22: ...ode 8 Cascade pump speed max Cascade pump full speed 9 Cascade pump min speed Cascade pump min speed 2 Cascade info 1 Cascade role Role of boiler in cascade mode MASTER SLAVE TERMINAL SLAVE If not in cascade mode STANDALONE 2 System temperature Cascade temperature value Hitting OK when highlighted will open graph that shows the latest 120 variable values stored every 12 minutes over the past 24 ho...
Page 23: ...10V setpoint The same principal is applicable for DHW see user menu 2 DOMESTIC HOT WATER under 2 ECO set point reduction 5 11 Holiday mode When the Holiday button R3 C3 is pressed a start and end date of a holiday period may be entered The desired flow temperature and the DHW temperature for this period can be set see user menu 3 HOLIDAY under 1 and 2 5 12 Schedules for CH and DHW For CH and DHW s...
Page 24: ...rs 5 Restore factory settings Reset to factory check settings 6 CHIMNEY SWEEPER OFF 0 100 7 DIAGNOSTICS 1 Boiler information Real time boiler status 2 Lockout history Overview lockout history Status boiler at time of lock block 1 ADVANCED CH SETTINGS 1 CH power set 1 Maximum power 100 0 100 100 2 Minimum power 0 0 100 0 2 CH temperatures 1 Absolute max temperature 90 20 90 80 Higher than 90 not al...
Page 25: ...7 25 off 2 ECO setpoint reduction 50 0 50 3 Scheduler set 1 Enable disable on board scheduler Enabled Disabled Enabled 2 Scheduler set Set time scheduler Time On ECO OFF 1 DHW setpoint NTC sensor 60 35 65 1 DHW setpoint Thermostated 80 35 85 2 ECO setpoint reduction 20 0 50 3 Scheduler set 1 Enable disable on board scheduler Enabled Disabled Enabled 2 Scheduler set Set time scheduler Time On ECO O...
Page 26: ...ust connection from the rear This water will then drain into the syphon and fill it 6 2 Frost protection The boiler is protected against frost If the boiler detects an NTC flow temperature below 8 ºC the CH pump will be activated If temperatures continues to fall the boiler will start at a flow temperature of 6 ºC and it will run on minimum load until the flow NTC senses a temperature of 15 C The ...
Page 27: ...pe Flow m3 h delta T 25 full load Flow m3 h delta T 30 Start 20 Flow m3 h delta T 30 part load B 350 11 7 3 5 1 9 B 425 14 6 3 4 2 4 B 510 17 5 4 3 2 9 B 600 20 5 6 1 3 4 We recommend to keep the minimum flow at least above 50 of the nominal flow in all cases When the actual flow is lower than nominal adjust the hysteresis to prevent hunting 15 56 100 190 5 L 15 50 115 200 6 L 15 50 120 217 7 L 10...
Page 28: ...of 0 1 mg ltr If the O2 content is lower than 0 02 mg ltr a higher conductivity llimit of 600 μs cm is allowed If the conductivity is higher than the values mentioned empty the system flush and fill with clean tap water preferably by adding the recommended cleaning products The water pressure must be higher than 0 8 bar The water quality must be checked on a regular basis at least once per year Th...
Page 29: ...f the gas valve ensure that there is no dirt in the gas pipework prior to commissioning 4 The maximum allowable inlet pressure for the gas valve is 50 mbar 5 Check the heat input of the boiler The load as given on the type plate should be checked 6 5 Air supply and flue gas connection Air connection All types have air connection ø 150 mm Flue gas connection ø 250 mm for all types Allowed Appliance...
Page 30: ...Pressure range P1 Condensate resistance W wet D Dry W The minimal combustion products temperature mass flow rate and CO2 are given in the table below Type Vol Flue Vol Air Vol Flue m3 h Vol Air m3 h CO2 T Fluegas ºC rho kg m3 B 350 350 68 88 76 9 1 30 1 12 B 425 425 85 110 95 9 1 30 1 12 B 510 510 102 132 115 9 1 30 1 12 B 600 600 119 154 134 9 1 30 1 12 The maximum allowed recirculation rate unde...
Page 31: ...pressure area within a plane of 1m2 6 5 4 Pressure drop calculations The first 90 bend must be mounted directly to the boiler and followed by the chimney silencer this bend is not part of the calculation as it is already taken into account Flue outlet and air supply calculations Total pressure drop available for flue outlet and air supply is given in the table below Air connection All types have a...
Page 32: ...iler type 1 2 3 4 5 6 7 8 Component 350 425 510 600 Pressure drop Pa Flue gas Pa Air Pa Flue gas Pa Air Pa Flue gas Pa Air Pa Flue gas Pa Air Pa Pipe length 1 m Ø 250mm 0 6 0 9 1 3 1 8 Pipe length 1 m Ø 150mm 4 2 6 5 9 4 12 7 Bend 90 Ø 250mm 5 3 8 3 12 0 16 3 Bend 90 Ø 150mm 16 2 25 3 36 5 49 7 Bend 45 Ø 250mm 3 4 5 2 7 5 10 3 Bend 45 Ø 150mm 6 9 10 7 15 4 21 0 Terminal C33 Ø250mm Ø250mm 20 8 32 5...
Page 33: ...p terminal Column 9 total pressure drop flue gas and air column 6 7 8 Finally add all together column 9 Total pressure drop must be lower than 250 Pa Intermodul 340 and Intermodul 425 or 300 Pa intermodul 510 and Intermodul 700 If the combined inlet outlet system exceeds the maximum allowed pressure this will result in a decrease of more than 5 of heat capacity This is not allowed All components m...
Page 34: ...ERM B 350 600 Installation User and Service Manual instructions for user Heating Alutherm B 350 600 APPLIANCE TYPE FLUEGAS OUTLET SUPPLY AIR INLET B23 ROOF TERMINAL ALU 250 B23 C33 ROOF TERMINAL ALU 250 350 C33 T PIECE 150 350 ...
Page 35: ...C33 41 012 31 94 T PIECE ALU 150 350 C33 41 012 31 90 PP Ø 150 mm ELBOW PP 150 90 41 007 03 31 ELBOW PP 150 45 41 007 03 32 EXTENSION PP 150x2000 41 007 03 24 EXTENSION PP 150x1000 41 007 03 22 EXTENSION PP 150x500 41 007 03 21 LEAF CATCHER AIR INLET GRILL ALU DN 150 x 180 41 007 54 36 GENERAL WALL BRACKET 250 40 045 22 35 WALL BRACKET 150 41 008 71 96 SEAL SIL 250 mm for DN250 ALU 40 045 18 15 SE...
Page 36: ...tundish and a U trap to the sewer Air inlet If PP material is used for the air inlet a minimum distance of 35 mm between exhaust and air inlet should be respected The minimum insert length of the sleeve leaf catcher or pipe must be 40 mm Flue exhaust A horizontal flue exhaust pipe must be installed with a fall of 3 50 mm per mtr downwards towards the boiler to allow condensate to flow back in the ...
Page 37: ...e equipped with a non clamping to allow minor movement bracket in between Vertical pipes should be bracketed equally divided with a maximum distance of 2 mtrs between the brackets In case of a chimney shaft first identify the flue outlet Check if the used shaft pipes are damaged or blocked The ends of the exhaust pipe should be at least 0 5 mtr above the shaft The last component before entering th...
Page 38: ...ip C2 and a short wire loop should be placed between the numbers 1 and 2 of strip C2 Finally from the technician menu advanced CH settings CH request select only OTC 7 If a storage tank is connected to the boiler the tank thermostat or the tank NTC should be connected to the numbers 7 and 8 on the strip C2 Select fom the technician menu advanced DHW settings DHW request type Note that a tank NTC s...
Page 39: ...ce Manual instructions for user Heating Alutherm B 350 600 General remarks Use the tube on the left side to guide the low voltage connections from C2 and C3 Use the 4 tubes on the right side to guide the 230 V connections from C1 Also see wiring diagram on next pages ...
Page 40: ...5 7 8 X15 D X01 D MT 2 MT 1 6 3 5 4 Tach PWM Fan 2 1 X05 1 2 3 4 C1 C1 D X05 1 5 4 3 2 61718 12 6 1 2 3 7 8 9 24 25 29 30 D X05 BC L 1 2 3 4 C2 N V1 V2 PE PE N 230V A P CH P DHW P A OT RT C P B B OTC 0 10Vdc DHW or SPS B B L ground pwm white yellow blue red brown white grey black red grey blue blue grey red grey black white green white green yellow green yellow green yellow PWM P grey grey grey gr...
Page 41: ...rature sensor NTC3 Domestic hot water sensor or switch NTC4 Outside temperature sensor NTC5 Flue gas temperature sensor NTC6 Cascade sensor WPS Waterpressure sensor APS Air pressure switch SPS Siphon pressure switch GPS Gas pressure switch GV Gas valve S Switch on off 3WV 3 way valve OT RT Open therm or room thermostat on OTC Outdoor temperature control 12K F Fuse SPS B Siphon pressure switch bloc...
Page 42: ... 600 6 6 2 NTC resistance table NTC resistance table Temperature C Resistance kΩ 30 20 98 200 15 75 900 10 58 800 5 45 900 0 36 100 5 28 600 10 22 800 15 18 300 20 14 700 25 12 000 30 9 800 35 8 050 40 6 650 45 5 520 50 4 610 55 3 860 60 3 250 70 2 340 75 1 940 80 1 410 85 1 470 90 1 260 95 1 100 100 950 105 110 115 120 ...
Page 43: ...res sure in the flue The air pressure switch P1 and P2 connected to the venturi checks the amount of air by means of a Δp measurement before startup 6 8 PC CONNECTION For information regarding connection of a PC to the boiler please contact your supplier P1 P2 P1 P2 P2 P1 P1 Venturi Sump SPS Syphon Pressure Switch Gas valve APS Air Pressure Switch Air inlet Restric on 90 mm P1 P2 P1 P2 P2 P1 P1 Ve...
Page 44: ...a heat demand 8 Just before ignition the control checks if the contacts of the gas pressure syphon pressure and water pressure switches are closed If not the boiler will block and the display will show E76 9 If gas water syphon pressure switches are closed the burner will be ignited 10 Perform a thorough check on flue gas joints for leakage 11 Check the heat input and the gas pressure at maximum l...
Page 45: ...nnex D with Wobbe index 43 46 45 3 MJ m3 dry 0 C Hs or 41 23 42 98 dry 15 C Hs This boiler can also be converted and re adjusted for category E I2E This means that the boiler is either is suitable for G gas and H gas or provable suitable is for G gas and provable can be made suitable for H gas as meant by Besluit van 10 Mei 2016 until changes in this document are made Countries Countries Category ...
Page 46: ...ning towards gives a higher CO2 percentage Note this offset adjustment is very sensitive half a turn 180 causes a change of approximately 1 CO2 Check on heat input In the table below the relationship between nominal input and fan speed and gasflow is given The nominal fans peed can be 5 due to adjustments in production If the gas flow is too low it may be due to an obstruction dirt in the air flue...
Page 47: ...ALUTHERM Boilers 47 ALUTERM B 350 600 Installation User and Service Manual instructions for user Heating Alutherm B 350 600 7 3 Gas valve filter inspection ...
Page 48: ...0 in the MAXSYS Also see electrical wiring diagram If there is 230 VAC present terminal connector C1 19 20 then the 230 V fuses F1 and F2 inside the Maxsys should be renewed Disconnect the boiler from the main 230V supply and remove the connectors from the Maxsys Notice for this it is not necessary to unscrew the Maxsys from the mounting plate Release the six security clips with a long thin screw ...
Page 49: ...errors Boiler does not respond to DHW heat request Check the storage tank NTC or thermostat and its wiring also see electrical wiring diagram Check if DHW is enabled using the control panel Insufficient DHW flow Dirty filters in taps Insufficient water pressure DHW temperature too low Tapping flow too high Temperature set point too low Leakage 3 way valve towards CH circuit 3 way valve not fully i...
Page 50: ...ain until a manual reset is performed eg max temp limit These errors can be found under column hard lockout code in the following table Following an error with a soft lockout the boiler will automatically resume normal operation after the cause of block is solved eg gas pressure too low They can be found under column soft lockout code in the following table The cause of error hard or soft lockout ...
Page 51: ...ly reset once flue temperature returns to normal range E8 Flame Circuit Error Flame circuit test failed 1 Turn boiler off 2 Check and clean the electrode 3 Check ignition and grounding cables are firmly connected E9 Gas valve circuit error Gas valve circuit test failed 1 Check the gas valve and wiring harness 2 If the problem persists replace the MAXSYS circuit board E 12 Internal Control Fault EE...
Page 52: ...or the wire harness 3 After fixing the problem reset the appliance and resume normal operation E 45 Flue Sensor Shorted A short circuit has been detected in the boiler flue temperature sensor circuit 1 Check flue temperature sensor and wiring harness for a short circuit 2 If necessary replace the sensor or the wire harness 3 After fixing the problem reset the appliance and resume normal operation ...
Page 53: ...s been detected in the outdoor temperature sensor circuit 1 Check outdoor temperature sensor and wiring for a short circuit 2 If necessary replace the sensor or the wire harness 3 After fixing the problem reset the appliance and resume normal operation E 94 Internal Display Fault Display memory error Turn unit off and on to resume normal operation E 95 Cascade CH Supply Sensor Error Supply sensor ...
Page 54: ...or leakages and correct if necessary Compare the heat input max and min with that measured at installation If the figures as mentioned in table chapter 9 1 are comparable the inspection is done If the heat input is now considerably lower then there is probably an obstruction in the air inlet or the flue outlet or in the boiler itself Switch off the boiler Disconnect from the mains electricity supp...
Page 55: ...ages and condensate leakages and correct eventually Check for in general for leakages and correct if necessary Note be carefull during maintenance not to damage seals Fill in the data in table 9 1 9 1 Service maintenance table When commissioning inspecting the boiler CO2 CO T flow T return ΔP air pressure switch and Psyphon pressure switch must be measured and the measured values must be written d...
Page 56: ...herm B 350 600 Date Gasflow m3 h or load kW CO2 CO ppm Tflow C Treturn C P air pressure switch mbar P syphon pressure switch mbar Installed Installed 1 year inspection Installed 2 year maintenance Installed 3 year inspection Installed 4 year maintenance Installed 5 year inspection 9 1 Service maintenance table ...
Page 57: ...r functioning of the boiler After reconnection of the tubing check for proper functioning of the boiler and also check the input and CO CO2 figures see 7 2 Also see detail in picture beneath Tubing and fixation 9 3 Non return valve NRV in burnerhood Implemented soon For cascade also read the cascade manual During maintenance the outer seal red part of the non return valve must be replaced Also che...
Page 58: ...m Inspection cover sump 4 Burnerhood on heat exchanger 30 Venturi on fan 12 Fan on burnerhood 7 Air inlet on fan 4 Gasvalve on fan 4 Electrode ignition 1 5 Electrode ionisation 1 5 Inspection cover on left hand side heat exchanger middle 5 Inspection cover on left hand side heat exchanger front 5 Inspection cover on left hand side heat exchanger back 5 Manifold return Manifold flow Connection PN f...
Page 59: ...ential requirements of the following European standards and directives Regulation Description Date Directive EU 2016 426 Regulation relating to appliances burning gaseous fuels 09 03 2016 2009 125 EC Ecodesign Directive implemented by EU regulation 813 2013 21 10 2009 2014 35 EU Low Voltage Directive 26 02 2014 2014 30 EU Electromagnetic Compatibility Directive 26 02 2014 Relevant harmonized stand...
Page 60: ...s errors and technical modifications Rev 1 Design by marcand nl Alutherm Heating B V Craenakker 3a 5951 CC Belfeld The Netherlands Telephone 31 0 77 303 19 76 E mail info aluthermheating nl Website www aluthermheating nl ...
