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Rendamax R2000 Series, Technical Documentation Manual

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Rendamax R2000 Series Technical Documentation Manual Download Page 4

 

4 

DOC2012/2000en 

 

 

 

7 

Operation 

and 

fault 

indication 

         37 

 7.1 

 Function              37 

 

7.2  

Regulation  

 

 

 

 

 

 

 

 

 

 

 

 

37 

 7.3 

 Control 

panel 

            37 

 7.4 

 Fault 

indications            38 

 

7.5  

Start-up 

 

 

 

 

 

 

 

 

 

 

 

 

 

39 

 

7.6  

Shut-down  

 

 

 

 

 

 

 

 

 

 

 

 

39 

 

7.7  

Warnings    

 

 

 

 

 

 

 

 

 

 

 

 

39 

 7.8 

 Fault 

finding 

table 

           40 

 
8  Maintenance    

 

 

 

 

 

 

 

 

 

 

 

 

 

42 

 

8.1  

Safety   

 

 

 

 

 

 

 

 

 

 

 

 

 

42 

 8.2 

 General 

information           42 

 

8.3  

Inspection   

 

 

 

 

 

 

 

 

 

 

 

 

42 

 8.4 

 Cleaning 

             43 

 

8.5  

Servicing   

 

 

 

 

 

 

 

 

 

 

 

 

43 

 8.6 

 Component 

replacement 

         47 

 

8.7  

Service  

 

 

 

 

 

 

 

 

 

 

 

 

 

49 

 

 

Notes   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

50 

Summary of Contents for R2000 Series

Page 1: ...00 FLOW CLIMA s r o Baarova 2 140 00 Praha 4 Czech Republic Tel 420 241 483 130 Fax 420 241 483 129 Hviezdoslavova 55 627 00 Brno Tel 420 548 213 005 Fax 420 548 213 016 rendamax rendamax cz www renda...

Page 2: ...wise 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 Due to changes...

Page 3: ...Safety 17 4 Delivery and transport 19 4 1 Delivery 19 4 2 Unit protective packaging 19 4 3 Transport 19 5 Installation 20 5 1 Boiler room 20 5 1 1 Siting 20 5 1 2 Boiler room ventilation 20 5 2 Unit c...

Page 4: ...7 7 3 Control panel 37 7 4 Fault indications 38 7 5 Start up 39 7 6 Shut down 39 7 7 Warnings 39 7 8 Fault finding table 40 8 Maintenance 42 8 1 Safety 42 8 2 General information 42 8 3 Inspection 42...

Page 5: ...2 Pressure relief valve connection relief connection standard setting bar 3 3 3 3 3 3 Electrical supply Frequency Fuse V Hz A 230 50 6 230 50 6 230 50 6 230 50 6 230 50 6 230 50 6 Max electrical cons...

Page 6: ...m3 h 20 2 7 7 23 5 8 9 27 5 10 5 32 3 12 3 37 4 14 3 43 6 16 6 Gas inlet pressure min max propane max mbar mbar mbar 17 25 50 17 25 50 17 25 50 17 25 50 17 25 50 17 25 50 Water volume Max working pre...

Page 7: ...12 2000en 7 Dimensions Drain and fill Safety valve Water flow switch STANDARD ALTERNATIVE Fig 1 Dimensions The R2000 unit is also available as a left handed model Top and side clearances are 600 mm MI...

Page 8: ...your supplier 1 3 This manual This documentation has been produced to aid the following target groups the consulting engineer the heating installer the service engineer the user Because these target g...

Page 9: ...preceding notification and is therefore not obliged to adapt earlier delivered products 2 Description 2 1 General information The R2000 series boilers are atmospheric open flued low thermal capacity g...

Page 10: ...Main gas valve 10 Gas connection 11 Electrodes 12 Sight glass 13 Burner bars 14 Quick clamp securing burner trolley at both sides 15 Main burner gas governor 16 Gas train cover 17 Filling and drain v...

Page 11: ...he use of any special tools Fig 3 Draught diverter Combustion chamber The chassis consists of two side frames with steel supports Dura blanket type thermal insulation is sandwiched between the vermicu...

Page 12: ...e 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 Burner The burner is mounted under...

Page 13: ...eral boilers can be connected by using cascade switching With the cascade switching option you can reduce gas and electricity consumption by switching off both boiler and boiler primary pump by the ca...

Page 14: ...EW Control option Electronic Modulating version with outside temperature compensation and night time temperature reduction This system indicated by the EW control option uses the above mentioned PID...

Page 15: ...e 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...

Page 16: ...q 0 0 999 9 Heating curve slope H 0 0 4 0 2 Parallel displacement 1 P 90 90 Factory setting 0 1 5 10 80 350 1 15 S 3 3 3 0 2 0 Configuration level Parameter Display Factory setting Analog input 1 2 an...

Page 17: ...of the control circuit and to the flame supervision unit displaying the status the symbol appearing above the reading mark indicates the firing sequence or lock out condition The pilot flame is super...

Page 18: ...autions The installation should never be switched on with panels removed or when boiler protection devices are not operational Instruction and warning stickers Never remove or cover any of the instruc...

Page 19: ...tation the boiler is covered in a heatshrink protective covering The panel work is also covered in a protective polyethylene layer Before final installation in the boiler room the boiler must be remov...

Page 20: ...ions are not met maintenance operations could be seriously inhibited 5 1 2 Boiler room ventilation The product has to be installed by a recognized installer fully according to the current national and...

Page 21: ...ignal 4 5 enable 6 No cascade signal 240 V M6 XU6 0 10 VDC control signal only available with EM EW control option 32 No external main gas valve A No alarm signal 240 V remove jumper Pump switching Th...

Page 22: ...urers information bend 90 R D 1 0 bend 90 right angle bend 45 T piece outlet 0 5 1 3 0 5 2 0 1 5 Table 3 Average flue pipe resistance coeffi cients Flue condensation Flue gases transfer heat when they...

Page 23: ...n to oxygen and nitrogen hydrogen and methane have also been detected Oxygen promotes corrosion Corrosion products together with other pollutants form a sludge deposit magnetite which causes pitting u...

Page 24: ...e shows an example of a hydraulic system System pressure is calculated using the following formula p p exp H Rk p water flow temperature p exp pressure expansion vessel H pump head Rk pressure loss bo...

Page 25: ...041 R2048 R2056 R2066 R2077 R2090 R2105 R2122 5 5 5 6 7 8 9 10 12 13 14 16 22 24 26 36 44 58 66 92 135 150 190 260 6 6 5 7 8 9 10 11 12 14 15 16 18 30 35 40 55 70 85 110 130 180 220 250 310 9 11 14 19...

Page 26: ...able high temperature as a result of which the high limit thermostat may lock out the boiler Such a problem may also occur if all flow governors close simultaneously The flow governors should therefor...

Page 27: ...7 Fig 15 R2000 unit with outside temperature compensation 5 4 2 Examples hydraulic system Fig 16 R2000 unit with outside temperature compensation heating zone regulation and hot water priority switchi...

Page 28: ...feed Below 60 60 150 150 300 300 600 Above 600 25 mm 1 32 mm 1 38 mm 1 50 mm 2 63 mm 2 19 mm 25 mm 1 32 mm 1 38 mm 1 59 mm 2 See Technical data table for individual boiler outputs Table 6 Vent pipes a...

Page 29: ...ice Low velocity vertical headers for single and multiple boiler circuits are as option direct available Fig 17 R2000 units with constant flow temperature and cascade switching with a zero loss header...

Page 30: ...free of any such deposits after flushing the system Water heating system fill the system up to the standard set pressure bleeding the system switch on all pumps and check for correct direction of rota...

Page 31: ...opening closed mm Cascade in mbar R2017 10 4 3 5 90 1 5 7 5 R2022 10 4 3 5 90 1 5 7 5 R2028 10 4 3 5 90 1 5 7 5 R2034 10 4 3 5 90 1 5 7 5 R2041 10 4 3 5 90 1 5 7 5 R2048 10 4 3 5 90 1 5 7 5 full load...

Page 32: ...R2017 40 11 90 6 28 R2022 40 11 90 6 28 R2028 40 11 90 6 28 R2034 40 11 90 6 28 R2041 40 11 90 6 28 R2048 40 11 90 6 28 full load 100 Burner pressure 40 ET out mbar 13 18 13 18 13 18 13 18 13 18 13 1...

Page 33: ...r gas pipework and the mains supply VI Check the electrical components are of the correct voltage range particularly low voltage ancillary controls VII Check the pump motor current and adjust the star...

Page 34: ...action fans when applicable V Check the correct connection and operation of any external controls VI With the control thermostat on a high setting turn on the on off switch at the boiler control panel...

Page 35: ...2022 11 If no leak is found this indicates that the 2nd safety shut off valve is letting by and should be replaced whole multi block on models R2017 and R2022 a Disconnect the electrical connections t...

Page 36: ...west contact in the plug B see fig 21 Connect the red wire C of the A meter with the lowest contact in the ionisation socket D The ionisation of the pilot burner must show a minimum of 5 A during 10 s...

Page 37: ...er starts up in the sequence described below Heat demand Ignition of pilot flame As soon as pilot flame is detected an ionisation current will pass to the flame safeguard control box The main gas valv...

Page 38: ...thermostat cap nut see sticker high limit thermo stat with a 17 mm ring spanner See fig 19 Press a screwdriver against the green peg until a light click is heard Lamp 4 turns off Refit capnut Refi tup...

Page 39: ...egulator as required 7 5 Start up A To turn off for short periods switch boiler off by using the power switch 1 B For long periods switch the pump off and after 6 minutes close the main gas cock and m...

Page 40: ...system Control panel fuse blown Check fuse Faulty control box Change box Air modulating damper cycles no ignition spark and boiler then goes to lockout indicator 2 alights HT lead disconnected or faul...

Page 41: ...lty Rectify Faulty connections to main safety shut off valve s Rectify Faulty main safety shut off valves Change valves Faulty control box Check ionisation current as per instructions Replace Boiler o...

Page 42: ...nger can also be inspected Check for dirt and sooting For cleaning the heat exchanger refer to chapter Cleaning After removing the burner the combustion chamber and the underside of the heat exchanger...

Page 43: ...ver and check for leaks 8 4 Cleaning 43 WARNING ONLY COMPETENT PERSONS SHOULD CARRY OUT SERVICING ON THIS BOILER IN ACCORDANCE WITH THE GAS SAFETY INSTALLATION AND USE REGULATIONS 1984 Ensure that bot...

Page 44: ...anel covering the electrical controls Both the right hand and left hand upper side panels can now be removed by lifting upwards and off their lower locating pegs The front and rear upper panel can als...

Page 45: ...ectrodes are correctly positioned as shown in Fig 26 If the position or gaps are not correct the electrodes must not be bent In that case the electrodes have to be replaced Remove the down draught div...

Page 46: ...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 Re connect the electrical con...

Page 47: ...reverse order of removal Gas train including gas train components Release the fi xings securing the top of the gas train cover at the front of the boiler and remove carefully in upward direction Ensu...

Page 48: ...t right hand side panel of the boiler and its fixing screws can be accessed via the control panel Re connect any electrical connections in accordance with the separate supplied wiring diagrams Replaci...

Page 49: ...the removal procedure NOTE It is very important that the tensioning bars are correctly tensioned This is done by measuring the compression of the tensioning washers The compression varies depending on...

Page 50: ...DOC2012 2000en 50 Notes...

Page 51: ...DOC2012 2000en 51 Notes...

Page 52: ...Rendamax bv 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 Service...

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