Atlantic Boilers BK50 Installation and operation manual

ATLANTIC 2000 - boilerplant sales ACM ATLANTIC - commissioning and maintenance ATLANTIC 4422 – spares
Atlanc 2000 Registered in England Company No: 1477687 Vat Reg No: 306 0653 89
PO BOX 11, ASHTON UNDER LYNE, OL6 7TR T: 0161 621 5960 E: technical@atlancboilers.com www.atlancboilers.com
BK SERIES
YEAR ROUND MAXIMUM CONDENSING BOILER
burning diesel oil, kerosene, natural gas or liquid petroleum gas
OPERATING & MAINTENANCE MANUAL
BK50 - BK70 - BK100
90% and above A A
86% - 90% B
82% - 86% C
78% - 82% D
74% - 78% E
70% - 74% F
Below 70% G

1
Contents
1 Overview – laws, regulations
and standards 2
2 Information 4
2.1 Identication(label)���������������������������� 4
2.2 Warningsymbols�������������������������������� 4
2.3 Importantinformation ������������������������� 5
2.3.1 Updatingservice �����������������������������5
2.3.2 Actuality�������������������������������������������5
2.3.3BKFullyCondensingBoiler����������5
2.3.4 Abouttheseoperatinginstructions��5
2.4 Validity������������������������������������������������ 5
2.5 Applicability ���������������������������������������� 5
2.6 Liabilitylimitations ������������������������������ 5
3 Safety instructions 7
3.1 Generalinformation���������������������������� 7
3.2 Safetyguidelines�������������������������������� 7
3.2.1 Riskoffrostdamage �����������������������8
3.2.2 Corrosion,boilerdamage����������������8
3.3 Norms,regulations����������������������������� 8
3.4 Operationandmonitoring������������������� 8
3.4.1 Burnerfaults/remoteunlocking �������9
3.4.2 Maintenance(servicing)������������������9
3.5 Safetyinstallations ����������������������������� 9
3.5.1 Water-sidesafetyinstallations���������9
3.5.2 Gas-sidesafetyinstallations �����������9
3.5.3 Labelandoperatinginstructions �����9
3.5.4 Additionalsafetyinstallations����������9
3.6 Wastedisposalandenvironmental
protection ����������������������������������������� 10
4 Function and description 11
4.1 Functionandoperatingprinciple������ 11
4.2 Boilerdescriptionanddimensions ��� 11
4.2.1 Trialrun,productioncontrol,
qualityassurance ��������������������������11
4.2.2 Operatingcharacteristics,adjust-
ment ����������������������������������������������11
4.2.3 Materials��������������������������������������� 12
4.2.4 Safetyinstallations ����������������������� 12
4.2.5 Fluegassystem��������������������������� 12
4.2.6 Combustionair����������������������������� 12
4.2.7 Reservoir–servicewaterheater � 13
4.3 Unintendeduse�������������������������������� 13
4.4 Technicaldata ���������������������������������� 14
5 Delivery – transportation to
installation site 16
5.1 Safetyinstructions���������������������������� 16
5.2 Unloading,useofhoist��������������������� 16
5.3 Completenessofdelivery����������������� 16
6 Installation and connection 17
6.1 FullyCondensingBoiler ������������������� 17
6.2 Electricalconnection ������������������������ 17
6.3 Condensatedrainage����������������������� 18
6.4 Handingoverandservicing
instructions��������������������������������������� 18
7 Cleaning 20
7.1 Cleaningofcombustionchamber
andboiler ����������������������������������������� 20
7.2 Cleaningofuegaspasses������������� 21
7.3 Cleaningofuegaspassesbox
(open)����������������������������������������������� 21
7.4 Wetcleaning–neutralizationbox
andplasticheatexchanger �������������� 23
8 Terminal assignment and le-
gend to Conform 6.0 26
9 Spare parts BK50, BK70 and
BK100 28
10 ECconformitycertication 32
11 Guarantee 33
12 Notes 34

BK50/BK70
BK100
2
Overview–laws,regulationsandstandards
1 Overview – laws, regulations
and standards
General information:
Transportation,installation,mountingandelectri-
calconnectionsshouldbedonebyacompetent
person.Hebearsresponsibilityforaproper
implementationoftheseworks.
BeforeinstallationoftheFullyCondensingBoiler,
itisnecessarytoobtainpermissionofthelocal
heatingequipmentinspectionboardorother
competentauthorities.
Inordertopreventpenetrationofoxygenintothe
closedheatingsystem,itisadvisabletoperform
asystemdivisionbetweentheoorheating
andtheheatingsystembymeansofaheat
exchanger.
Itisadvisabletoinstallatemperaturesensorfor
theoorheatingsystem,inordertoprotectpipes
andoorcoveringfromoverheating.
Sincecorrespondingregulationsvaryindifferent
federallands,werecommend,beforeboilerins-
tallation,toconductconsultationswithcompetent
authoritiesandthelocalheatingequipmentins-
pectionboard.Combustionairsupplyshouldbe
performedinsuchawayastoexcludesuction
ofuegasesfromheatingsystemsworkingon
liquidorsolidfuels.
Thecombustionairsuppliedtotheunitshouldbe
freefromchemicalsubstancessuchasuorine,
chlorineorsulphur.Thesesubstancesarecon-
tainedinsprays,solventsandcleaningagents.
Theymaycause,inspeciccases,corrosionof
someunitcomponentsparticularlyinchimneys.
Beforetheunitisputintooperation,itisneces-
sarytocheckwithcompetentauthoritieswhether
condensateneutralizationisrequired.
Ifanychangesinthecontrolsystemoritssepa-
rateitemsaremade,thentheguarantee,incase
ofpossiblesubsequentdamages,shallbeinva-
lid.Itisrecommendedtoinstallasafetyvalve
with“H”identicationintotheheatingcircuit.
Themaximumpressureofthedischargepipeis
3bars.Ifthedischargepipeofthesafetyvalve
owsintotheseweragenetwork,itisnecessary
tointegrateadraintrap.
92/42/EWG
Efciencyguidelines
2006/95/EG
Electricalequipmentdesignedforusewithincer-
tainvoltagelimits
DIN EN 267:2011-02
Fan-assistedoilburner
DIN EN 676:2003 + A2:2008
Automaticforceddraughtburnersforgaseous
fuels
DIN EN 677:1998-08
Gas-redcentralheatingboilers
DIN EN 14 471:2005
Chimneys–systemchimneyswithplasticue
liners
DIN EN 15 034:2007-01
Chapters 4.3.1 and 4.4
Heatingboilers–condensingheatingboilersfor
fueloil
DIN EN 15 035:2007-05
Chapters 6.1, 6.3.1, 6.3.3.1
Heatingboilers–specialrequirementsforoil
redroomsealedunits
DIN 18 160-1 Supplement 3
Chimneys
DIN EN 12 828:2003
Safety-relatedequipmentofheatingsystems
2006/42/EG
Machineguidelines
DIN EN 303-1:2003-12
Chapters 4.1.5.10 to 4.1.5.12
Condensingheatingboilerswithfan-assisted
burner
DIN EN 303-2:2003/12
Chapters 3.2 to 3.5 and
Appendices A and B
DIN EN 303-3:2004-10
Chapters 5.4 to 5.5

3
Overview–laws,regulationsandstandards
DIN EN 304:2004/01
Condensingheatingboilers–testcodeforhea-
tingboilerswithfan-assistedoilburners
1 BImSchV (22.03.2010)
Regulationonsmallfurnaces
ATV A251
Removalofcondensatefromchimneys
DIN EN 60 335-1:2010
DIN EN 60 335-2-102:2010
Safetyofhouseholdandsimilarelectricalappli-
ances
2004/108/EG
Electromagneticcompatibility
Furthermore, for installation in Austria the
following norms and regulations are valid:
• ÖVE–Rulesandlocalrules
• Art.15aB-VG
• FAnlG–LawonfurnacesdatedJune12,
2011
Switzerland:
• Swissprovisions(BAFU)andcerticateof
conformityforoilandgas(LRVArticle20)
• Environmentalprotectionlaw
• Waterprotectionact
• Waterprotectionordinance
• Recommendationforsewagedrainagefrom
condensingheatingsystems
• SVGWgasguidelines
• SVGWwaterguidelines
• Recommendationconcerningtheminimum
chimneyheight(aboveroof)
• VKFreprotectionregulations
• SWKIguidelines
• SEVandESTIrulesI

BK50/BK70
BK100
4
Information
2 Information
2.1 Identication(label)
Product Id. Nr.
Heating output
Flue gas temperature
Max. operation temperature
Max. operation overpressure
Water content
Electrical connection
Protection class
Installation type
Degree of efficiency
Country of destination
Unit category
Boiler number
0085
Oil
Giersch (G)
Produkt ID-Nr.
CE-0032BQ2719
CE0035CM103
33 - 49 kW
47°C / 54°C
100°C
3 bar
110 l
230 V~/50 Hz/350 W
IP40
C13/C33/C43/C53/C63/C83
99%
DE, AT, BE, CH, CZ, FR,
GB, PL, SE, SK, LU
see identification plate
gasburner
see boiler base in front left
Giersch (GBZ)
DIN CERTCO Reg.Nr.
5G1049/11S
UNIT BK50 fully condensing boiler with fan
Gas
Weishaupt (WG) 33 - 49 kWWeishaupt (W)
Produkt ID-Nr.
CE-0036 0362/05
Produkt ID-Nr.
CE-0085AU0353
MHG (M)
Produkt ID-Nr.
CE-0032BR2740
Firing capacity
33 kW 41 kW 49 kW Set on kW
Product Id. Nr.
Heating output
Flue gas temperature
Max. operation temperature
Max. operation overpressure
Water content
Electrical connection
Protection class
Installation type
Degree of efficiency
Country of destination
Unit category
boiler number
Oil
CE0035CM103
50 - 70 kW
47°C / 54°C
100°C
3 bar
110 l
230 V~/50 Hz/410 W
IP40
C13/C33/C43/C53/C63/C83
99%
DE, AT, BE, CH, CZ, FR,
GB, PL, SE, SK, LU
see identification plate
gasburner
see boiler base in front left
UNIT BK70 fully condensing boiler with fan
Gas
Weishaupt (WG) 50 - 70 kWWeishaupt (W)
Produkt ID-Nr.
CE-0036 0362/05
Produkt ID-Nr.
CE-0085AU0353
MHG (M)
Produkt ID-Nr.
CE-0032BR2740
DIN CERTCO Reg.Nr.
5G1034/08
Giersch (GL)
0085
50 kW 60 kW 70 kW Set on kW
Firing capacity
Product Id. Nr.
Heating output
Flue gas temperature
Max. operation temperature
Max. operation overpressure
Water content
Electrical connection
Protection class
Installation type
Degree of efficiency
Country of destination
Unit category
Boiler number
Oil
CE0035CM103
71 - 120 kW
47°C / 54°C
100°C
4 bar
200 l
230 V~/50 Hz/480 W
IP40
C13/C33/C43/C53/C63/C83
99%
DE, AT, BE, CH, CZ, FR,
GB, PL, SE, SK, LU
see identification plate
gasburner
see boiler base in front left
UNIT BK100 fully condensing boiler with fan
Gas
Weishaupt (WG) 71 - 120 kWWeishaupt (W)
Produkt ID-Nr.
CE-0036 0362/05
Produkt ID-Nr.
CE-0085AU0353
MHG (M)
Produkt ID-Nr.
CE-0032BR2740
DIN CERTCO Reg.Nr.
5G1034/08
Giersch (GL)
95 kW
0085
Firing capacity
71 kW 95 kW 120 kW Set on kW
2.2 Warningsymbols
Intheseoperatinginstructionsthefollowingwar-
ningsymbolsareused:
Disregardingtheinstructionsmarkedwiththis
symbolmayresultinadangerforpersonsand
propertydamage.
Attention
Thissymbolspeciesinformationrelatedto
boileroperationaswellastocorresponding
organizationalandtechnicalissues.
Information

5
Information
2.3 Important information
Careshouldbetakentoensurethat,depen-
dingonthefuelandboilertype,theapprop-
riateoperatingmodeisselected(SeeOpe-
ratinginstructionforConform6.0andInitial
commissioningmanual).Failuretocomply
withthisprovisionwillresultinexpirationof
theguaranteeontheboilerbody!Withoutthe
submittedcommissioningreport,theguarantee
agreementwiththecompanyshallnot
enterintoforce.
Information
Inordertopreventpenetrationofoxygeninto
theclosedheatingsystem,itisrecommended
toperformsystemseparationbetweentheoor
heatingandtheheatingsystem,bymeansofa
heatexchanger.
2.3.1 Updating service
Theseoperatinginstructionsarenotsubjectto
modications!
Themanufacturerreservestherighttomake
atanytimemodicationsandimprovementsin
termsoffurthertechnicaldevelopment,toall
technicaldata,informationandimages.Any
claimsforafreemodicationorimprovementof
alreadydeliveredFullyCondensingBoilersare
excluded.
2.3.2 Actuality
Allreferencestolaws,regulations,guidelines,
normsetc.mentionedintheseoperatinginstruc-
tions,arecorrectasoftheperiodoftheinstruc-
tions’drafting(may2012).
2.3.3 BK Fully Condensing Boiler
Thecopyrightfortheseoperatinginstructions
remainswiththecompany.
2.3.4 Abouttheseoperatinginstructions
Forreasonsofclarity,theseoperatinginstruc-
tionsdonotcontainalldetailedinformationwith
regardtopossibleconstructionalandequip-
mentversionsoftheFullyCondensingBoilerin
question.Atthesametime,itisnotpossibleto
foreseeeveryimaginablecaseofinstallation,
conguration,operationand/ormaintenance.In
theeventyouwillrequireadditionalinformation
orsomespecicproblemswillarisethatarenot
addressedindetailintheseoperatinginstruc-
tions,pleasereferforinformationtoacompetent
heatinginstallationcompanyordirectlyto the
company.
2.4 Validity
Theseoperatinginstructionsarevalidonlywith
respecttotheFullyCondensingBoilermarked
withtheproductionnumber(SeeLabel).When
makingrequestsandorderingspareparts,ple-
asealwaysstatethesemodel(factory)numbers!
Theseoperatinginstructionscontaininformation
abouttheFullyCondensingBoileranditsitems
ofequipment,insofarasthesebelongtothe
scopeofdelivery.Statementsaboutequipment
notbelongingtothescopeofdeliveryareinten-
dedpurelyforinformationalpurposes.Alegal
claimforthisequipment(options)isexcluded.
Shouldmaterialsofthethird-partymanufacturers
beattachedtotheseoperatinginstructions(ope-
ratinginstructionsofthirdparties),sothe
companycannotassumeanyliabilityfortheir
correctness,validity,technicaldataetc.
2.5 Applicability
Allinformationprovidedhereinwithrespectto
theworksafetyandenvironmentalprotection
correspondswithEU/ECregulationsand/orwith
theEquipmentSafetyAct(GSG)oftheFederal
RepublicofGermany!Thecustomer/operator
should,underhisorherownresponsibility
• Considerthelaws,regulations,rules,gui-
delines,technicalinstructionsetc.specied
above,asabasisforsafehandlingand
maintenance,
• Measuretheircompliancewiththelocal
regulations,and
• independentlyinstallandadjustadditional
accessoriesprescribedbythelocalcom-
petentauthoritiesandcarryoutappropriate
worksandmeasuresusingtheresourcesof
aspecialistcompany.
2.6 LiabilitylimitationsThe
companytakesnoresponsibilityfor
damagestothedeliveredFullyCondensingBoi-
lercausedbythefollowingreasons:
• Ignoranceoforfailuretocomplywiththese
operatinginstructions.
• Insufcientlyqualiedmaintenancestaffor
inadequatelyinstructedservicepersonnel.
• Naturalwearandtear!Fordetailssee
DIN31051Part4,EN13306„Maintenance
terms“.
• FaultyornegligenthandlingoftheFully
CondensingBoilerand,inparticular,omis-
sionoftakingmeasuresastosafeand
proper

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Information
◦ Installationandcommissioning,
◦ Operationandmonitoring,and
◦ Maintenance(servicing).
• Defectiveinstallationworksand/ordefective
electricalinstallation.
• Chemical,electrochemicalorelectricalinu-
ences.
• Forsubstantialthird-partyproducts,the
liabilityofthecompanyislimitedto
theassignmentofliabilityclaimstowhichthe
companyisentitledagainstthe
supplierofthethird-partyproducts.
Priortoeachcommissioningandmaintenance
cycle,thefurnaceshouldbecheckedforgas
sidemalfunctionsandleakproofness.
Attention

7
Safetyinstructions
Theoperatinginstructionsshouldbepositioned
visiblyadjacenttotheFullyCondensingBoiler.
Theconnectionandadjustmentoftheheating
systemshouldbeperformedbyaqualiedplum-
ber.Theheatingtechnicianshouldfamiliarizethe
operator(s)oftheFullyCondensingBoilerwith
itsfunctionsandservicing!Intheeventofany
faultsordisturbancesintheoperationoftheFully
CondensingBoiler,pleasenotifytheheatingins-
tallationcompany!
If you smell gas, there is a risk of explosion
• Avoidopenreandsparkformation(for
examplewhenturningonandoutlightsand
electricalappliances)
• Closetheshut-offgasvalveandnotifythe
heatinginstallationcompany
If you smell exhaust fumes, there is a risk of
poisoning
• Switchofftheunit
• Opendoorsandwindows
• Notifytheheatinginstallationcompany
Ifthereisariskofre
• Immediatelyputoftheheatingemergency
switch(incaseitisoutsidetheinstallation
room)
• Closetheshut-offgasvalve
• Intheeventofare,usethesuitable
reextinguisher(reclassBpursuantto
DIN14406)
Dimensionaldistancesfromtheboilertocom-
bustibleitemsormaterialsshouldcorrespond
tolocalreprotectionnormsbuttheyshouldbe
atleast200mm(seeFig.1).Otherwise,thereis
dangerofare.
3 Safety instructions
3.1 General information
Theseoperatinginstructionsarevalidexclusively
forthetheFullyCondensingBoiler.Thestaff
inchargeofinstallation,commissioningormain-
tenanceshouldreadtheoperatinginstructions
priortostartingtheseworks.Therequirements
containedintheseoperatinginstructionsmust
beadheredto.Intheeventofanon-compliance
withtheoperatinginstructions,theguarantee
claimvis-à-visthecompanyshallexpire.
3.2 Safety guidelines
ForaproperandreliableoperationoftheFully
CondensingBoiler,itisnecessarytoobserve
thefollowingsafetyguidelines.
Attention
• Installation,commissioningandmainte-
nanceoftheFullyCondensingBoilershould
beperformedonlybyqualiedandtrained
personnel.
• Workswithelectricalcomponents(for
example,adjustment)aretobeperformed
onlybyqualiedelectricians.
• Duringinstallationofelectricalequipment,
theprovisionsofVDE(GermanAssociation
forElectrical,Electronic&InformationTech-
nologies)andofthelocalelectricitysupply
companyarerelevant.
• TheFullyCondensingBoilermaybeope-
ratedonlywithinthepowerrangeindicated
inthetechnicaldocumentationofthecom-
panyandoftheburnermanufacturer.
• TheintendeduseoftheFullyCondensing
Boilercomprisesitsexclusiveusefor
hotwaterheatingsystemspursuantto
DINEN304andDINEN303-3.
• Itisstrictlyprohibitedtobypassorinany
wayremoveorswitchoffcontrol,safetyand
monitoringequipment.
• TheFullyCondensingBoilermaybeopera-
tedonlywhenitssystemsareintechnically
perfectcondition.
• Malfunctionsanddefectswhichaffectsafety
(ormayaffectit)shouldbexedinaprompt
andexpertmanner.
• Defectivepartsandcomponentsmustbe
replacedonlywithoriginalsparepartsofthe
company.

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Safetyinstructions
combustion,underassistanceofaspecialized
installingcompany.
If,afteracleaning,repeateddustexposureshall
stillbepossible,(forexample,duetospongy
chimneyjoints),taketheappropriatemeasures
(forexample,cleanthechimney).
Modicationofthegasheatingsystem
Theoperatormayundernocircumstancesmake
changesintheheater,pipesforgas,electricity,
water,airsupplyanduegas.
Theseworksmaybeperformedonlybyahea-
tingtechnician,toeliminatetheabovementioned
hazards.
3.3 Norms, regulations
• Theboilermustbeservicedinregularinter-
vals.Werecommendtoconclude,forthis
purpose,amaintenancecontract.
• TheFullyCondensingBoilersmaybeins-
talledandoperatedonlyintheboilerand
installationroomsasrequiredbylocalregu-
lationsandguidelines(FeuAO)withrespect
tofurnaces.
• ForAustriaarealsorelevanttheprovisions
oftheAustrianGasandWaterIndustry
AssociationÖVGWTRGas(G1),Building
regulationslawB-VG,Art.15Aandalsothe
LawonfurnacesFAnlG.
• Swissregulations(BAFU)andtheDeclara-
tionofConformityforoilandgas(LRVArt.
20)
Burners
Fullyautomatedfan-assistedoilburnerspursu-
anttoDINEN267.Fullyautomatedfan-assisted
gasburnerspursuanttoDINEN676.Duringthe
commissioningoftheburner,theappropriate
operatinginstructionsoftheburnerareessential.
Astothecommissioningoftheburner,seecorre-
spondingoperatingandassemblyinstructions.
Fuel
ELheatingoilpursuanttoDIN51603.
NaturalgasinaccordancewiththeCodeof
PracticeoftheGermanTechnicalAssociationfor
GasandWater(DVGW)G260/Iandalsopursu-
anttolocalnorms.
3.4 Operation and monitoring
PutintooperationtheFullyCondensingBoiler
onlyafterallworksrelatedtoinstallationand
connectionarecompletedand/oraftercomple-
tionofpossiblepreventivemaintenancemeasu-
res.Duringtheinitialcommissioningitisneces-
sarytomonitortheautomaticprocessofcontrol
Fig. 1: Alateraldistanceofminimum600mmshouldbe
maintainedeitherontheleftorontherightside
oftheboiler.
Aconnectinglineshouldbeleadtothechimney
asshortaspossibleandascending.Thisisthe
onlywaytoensuretheoptimumperformance.
Thepipesshouldbecarefullysealed!Ifthe
uepipesarenotproperlysealed,theuegas
mayescapeandcausetheriskofsuffocation.
Itisadvisabletousetheuepipebendswith
cleaningopenings,tobeabletocleantheue
pipes.
3.2.1 Risk of frost damage
TheFullyCondensingBoilerandstoragewater
heaterarefrostprotectedthroughthecontrolling
system.Sincetherisk(forexample,duringa
long-lastingelectricalpoweroutage)offrost
damagecannotbeexcluded,theFullyConden-
singBoilersandstoragewaterheatersshould
beonlyinstalledinthefrost-protectedrooms.If,
duringlongshutdownperiodsandwithinopera-
tiveheatingsystem,theriskoffrostdangershall
remain,aheatingtechnicianshouldemptythe
FullyCondensingBoiler,reservoirandheating
system,inordertopreventwater-piperuptures
causedbyfrost.
3.2.2 Corrosion,boilerdamage
Thecombustionairmustbefreefromdust(for
example,depositedsolidfuelsorconstruction
dust)aswellasfromhalogenatedhydrocarbons
(contained,forexample,inspraycans,solvents,
washingandcleaningagents,paintsorglues).
Otherwisepittingcorrosionoftheboilerbodyis
possible.Ifthecombustionairisbeingsuckedin
frominoperativereplaceorshaft,itisnecessary
toremoveresidualsofformeroilorsolidfuel

9
Safetyinstructions
thepowersupplyandonlybyaskilledelectri-
cian.
Beforecommencementofanyworksonthe
electricalequipment,makesurethatthevoltage
iscompletelyswitchedoff.Damaged,burned,
frayedcablesaswellaslooseanduntightcable
connectionsmustbeimmediatelyreplacedbya
skilledelectrician.
Intheeventofadefectivefuse,theymustbe
replacedonlywiththeoriginalfuseswithprescri-
bedamperage.
3.5 Safety installations
ThecommissioningoftheFullyCondensing
Boilerwithoutaproperlyfunctioningsafety
installation(orwithanimproperlyfunctioning
safetyinstallation),isnotpermitted.
Attention
3.5.1 Water-side safety installations
SafetyinstallationspursuanttoDIN12828such
asthesafetyvalve,safetytemperaturelimiter
andtemperaturecontrolleraredescribedin
detail.
3.5.2 Gas-side safety installations
Tothesesafetyinstallationsbelongstheuegas
safetytemperaturelimiter(STL).
3.5.3 Labelandoperatinginstructions
ThelabelmustnotberemovedfromtheBK
FullyCondensingBoiler;itshouldbekeptina
wellreadablecondition.(Theoperatinginstruc-
tionsmustbeplacedvisiblyinthesameroom
wheretheboilerislocated).
3.5.4 Additional safety installations
Thesesafetyinstallationsinclude,amongother
equipment.
• Furnaceemergencyswitch
• Heatingoillockingdeviceinthefurnace
• Impermeablecovers/grillsinconformity
withDINEN294ontheuegassystem
(uponarrangementasanoutdoorchimney)
andontheairsupplyconnectionshould
beinstalledbyatechnician,underhisown
responsibility,incompliancewithlocalregu-
lationsandguidelines(FeuAO).
TheBKFullyCondensingBoilerservesexclu-
sivelyforheatgenerationandalsoforwater
heatingpursuanttoDIN12828.Theowtem-
peratureismaximum80°C,thetechnicaldata
ofvariousboilertypesareindicatedonthecor-
respondinglabels.Onlythoseliquidorgaseous
functionsandtocheckthetightnessoftheFully
CondensingBoileranditsconnections.
Intheeventofunusualoperatingperformance
inthefunctioningoftheFullyCondensing
Boiler,forexample,malfunctionsorfaultsin
energysupply,theunitmustbeimmediately
shutoff.
Attention
Determinethecauseoftheproblemorfault
andxitinasafeandsecuremanner.Startre-
commissioningonlyaftercompleteeliminationof
faults.
3.4.1 Burner faults/remote unlocking
Incaseofaburnerdefectorfault,theredpush
buttoninthecontrolpanelwillash.Pressthe
buttonshortlytounlocktheburner.Shouldthe
burnerfaultreappear,callaqualiedspecialist.
Fig. 2: Donotpressthepushbuttonduringnormal
burneroperation!
Pushbuttonofremoteunlocking
3.4.2 Maintenance (servicing)
Itisstronglyrecommendedtoconsider,during
eachinspectionand/orscheduledmaintenance
works,suggestionswithrespecttocausesof
faultsduetosuperuousmeasuresand,inparti-
cular,toboileropening,mostlyunnecessary.
AllconnectionsattheFullyCondensingBoi-
ler,burner,controlpaneletc.arepluggableor
screwable.
Whenreplacingsafetyinstallationsmakesure
thatthenewcomponentscorrespondtothe
originalpartsandaretestedinconformitywith
DINEN14597orDIN12828.
Use only genuine components and parts deli-
veredbythecompany!
Duringanyoperations,refrainfromusingexces-
siveforce–ifitgoesbeyondwhatisnecessary
toconnectordisconnectboltedconnections–
thereisariskofmaterialdamage!
Itisnotallowedtomoistentheplasticcompo-
nents(secondaryheatexchanger,uegas
system,hoses,sealsetc.)withoils,solvents,
cleaningagentsorotherchemicalsubstances.
Allworksontheelectricalequipmentshouldbe
performedonlyafterhavingdisconnecteditfrom

BK50/BK70
BK100
10
Safetyinstructions
non-recyclableresiduesshouldbedisposedof
pursuanttotheGermanWasteManagementLaw
(AbfG).
Duringdisposalworks,usesafetygloves.
fuelsthatareindicatedintheorderconr-
mationmaybeusedasworkingmaterials.
Thedenitionismadeincompliancewith1.
BImSchV(1stFederalGermanrulingonemissi-
onscontrol)condensingboilers:theseareheat
generatorswhichutilizebycondensation,asa
resultoftheirdesign,theheatofvaporizationof
watervapourcontainedinuegases.Thisdeni-
tiondifferentiatestheheatgenerationwithutiliza-
tionoftheheatofvaporizationofwatervapourin
uegasesfromtheheatgeneratorswithoutsuch
utilization.
3.6 Waste disposal and environmen-
tal protection
Thefollowingsubstanceswhichmayoriginate
duringmaintenanceandrepairworksshouldbe
disposedof–underpersonalresponsibilityofthe
heatingtechnician:
• Sediments,forexample,afterabreakdown
• Heatingoilrests
• Cleaningagentsandconsumables
• Solidwaste(replacedcomponents)ofall
types
Alldisposalworksshouldbeconductedas
prescribed,alsopursuantto1.BImSchVand
GermanWasteManagementLaw(AbfG)and
incompliancewiththeprovisionsoftheWater
ResourcesAct(WHG)aswellaswithlocaland
regionalregulations.
Liquidwastesuchaspotentialtoxicsubstances
capableofendangeringgroundwater(WHG)
shouldbecollectedinspecialclosedcontainers
andallocatedfortheproperdisposal.
Donotallowworkingmaterials(heatingoil)to
inltrateintothegroundorseweragesystem.
Potentialoilleakagesshouldbeimmediately
boundinconformitywiththeAccidentprevention
regulations(UVV1.)orwipedout.
Duringdisposal(dismantling/scrapping)ofthe
boiler,itscomponentsshouldbedividedin
accordancewiththeirmaterials.
Aftercompletecleaningandemptyingoftheneu-
tralizationboxandduringsubsequentdismant-
ling,thefollowingmaterialsmayberecovered:
• Metals,steel,malleableiron
• Insulationmaterials,mineralwool
• Plastics:polypropylene,PVC,cableinsula-
tion
• electrical/electroniccomponents
Thecomponentsshouldbecollectedsepa-
rately,inaccordancewiththematerials;the

11
Functionanddescription
ofelectrical/electronicmeasuringandcontrol
devices.
Maximumambienttemperature: 40°C
Minimumambienttemperature: 1°C
Theinductedcombustionairshouldbedust-free
andofnormalquality(temperature,humidity
etc.).
TheBKFullyCondensingBoilerisoperative
andreliableprovidedthatitisusedproperly,the
agreedoperationaldataareadheredtoandonly
prescribedfuelsareused.
Itisnecessarytotakeintoconsiderationpossible
malfunctions,if:
• installation,adjustmentandsubsequenttrial
operationwerenotcarriedoutproperly.
• itisimpossibletomaintaintheover-pres-
sureinthefurnace(resistanceintheue
gassystemorduringtheuegassuction).
• theheatexchangerwasnotlledwithwater
onthegassidepriortocommissioningor
afteralongoperationalstandstill.
• thefueldoesnotcorrespondtotheusual
specications.
• thesafetyinstallations,notwithstandingthe
prohibitiononalterations,weremisplacedor
bridged.
• theelectricalconnectiondataandnet-
workconditionsdonotcorrespondtothe
manufacturer’sdata.
• thefurnacewasputintooperationimmedi-
atelyafterorduringllingoftheheatingoil
storagetanks.
4.2 Boiler description and dimensi-
ons
4.2.1 Trial run, production control, qua-
lity assurance
TheinstallationoftheFullyCondensingBoiler
mustbeperformedbyaqualiedstaff(aheating
technicianandanelectrician).Withoutthecom-
missioningreport,theguaranteeagreementwiththe
companyshallnotcomeintoeffect.
Thenintroductiontotheunit,trialrunandhando-
vertotheoperatortakeplace.
4.2.2 Operating characteristics, adjust-
ment
TheBKFullyCondensingBoileristtedwith
thefullyautomaticelectroniccontrolsystem
which
4 Function and description
4.1 Function and operating principle
InthefurnaceoftheBK FullyCondensing
Boiler,thecombustionheatfromoilorgasis
transferredtothecombustionchamberwashed
roundbytheboilerwaterandtotheprimaryheat
exchangerwhichisconnectedtothecombustion
chamberfromthewaterside.Thehotuegases
arrivethen,undertemperaturesbelow85°C–
thatis,abovethedewpoint–intothesecondary
heatexchangerandtheyarecooleddown,in
accordancewiththeexternalairtemperature,to
about30°C–48°C.Thedewpointoftheue
gasistherebynotreachedandbothsensibleand
latent(hidden)heatisdelivered,throughsteam
condensation,tothesecondaryheatexchanger
ortothecombustionairpassingthroughitin
counterow.
Theuegasarrives,afterowingthroughthe
secondaryheatexchanger(counterow)with
verylowtemperaturetotheuegaspipe.The
freshairnecessaryforcombustionissuckedin
throughtheannulargapoutsidetheuegaspipe
(roomsealedoperation).Therequirednegative
pressureisgeneratedbytheburnerfan.Prior
toentryintothecombustionchamber,thecom-
bustionairispreheatedinthesecondaryheat
exchangeragainsttheuesgases,thuscontribu-
tingtothehighefciency.
Thecondensateaccumulatedinthesecondary
heatexchangercontainsthemostpollutants
fromthecombustionuegases.Itaccumulates
inthesecondaryheatexchangerandisthen
fedthroughapipeconnectiontotheneutraliza-
tionbox.Thecondensatepassesthroughthe
mineralgranulateandisthen,intheneutralized
condition,dischargedintoawastewaterpipeor
sewagesystem.
Owingtotemperaturemonitoringwiththesafety
temperaturelimiter(STL)andtheimplementation
ofstandards,thefunctionoftheBKFullyCon-
densingBoilerisself-retainingoverthewhole
combustiongaspath.
Theworkswhicharenotdescribedinthese
operatinginstructionsarereservedtothestaff
ofthemanufacturer.
Information
Functional criteria
Theambientconditionsintheinstallationroom
oftheBKFullyCondensingBoilermustnot
exceedthenormalvaluesfortheoperation

BK50/BK70
BK100
12
Functionanddescription
• controlstheoperatingperformanceincon-
formitywiththeheatdemandoftheheating
installation,and
• assafetycircuit,canshutdowntheinthe
eventofanymalfunctionsonthewateror
gasside.
• Thepressuretransmitterservesforthefun
regulationandcontrol.
TheConform 6.0controlsystemisintegra-
tedintheFullyCondensingBoiler.
Whenstudyingtheinformationintheseoperating
instructions,pleasealwayscomparetheindica-
tedtypedesignationwiththedataonthecontrol
panelofthedeliveredboiler.
Thesystemhasintegratedfunctionsfor:
Boiler temperature
Theboilertemperatureismaintainedbywayof
switchingtheburneron/off–atsome55°Cto
80°C,butalways>55°C(seealsotheoperating
instructionsofthecontrolsystem).
Heatingcircuittemperature
Thetemperatureattheheatingcircuitowis
regulatedthroughcontrolsystemtothepreselec-
tedvalue.Itispossible,byvirtueoftheoperating
software,atanytimetolowerortopredetermine
theheatingcircuittemperature(operatingmode
selection).
Service water temperature
Thewatertemperatureintheseparatereservoir
forservicewaterheating(reservoiroption)is
maintainedbywayofswitchingon/offtherespec-
tiveservicewaterpumpatthelevelpresetinthe
controlsystem.Thisprocessisinterruptedifthe
returnboilertemperaturefallsbelow50°C(boiler
protection).
Flue gas temperature
Theuegastemperatureismonitoredby
theSTL90°Clocatedinthesecondaryheat
exchanger.
Ambienttemperatureregulation
Theambienttemperatureandthetemperature
oftheheatingcircuitowarerecordedbysen-
sorsanditiscompared,bymeansofthecontrol
system,withthepredeterminedheatingcircuit
temperatureandthesetbacktemperature;if
necessary,itisbeingcorrected.
4.2.3 Materials
Thecomponentsofthe BK FullyCondensing
Boilercorrespondtothematerialrequirements
andthetestprotocol.
• Theprimaryheatexchanger
◦ SteelS235JR
◦ Connectingpiecesofseamlesstubesin
accordancewithDIN1629
• Thesecondaryheatexchanger
 PP/PP
• Thermalinsulation/outercover
◦ 3-sidedmineralwool80mm
◦ Front–mineralwool40mmwithcoating
integratedintothefrontdoor
◦ Boilercasing–steelplate1,25mm,scre-
wedtogetherandpowder-coated.
4.2.4 Safety installations
TheBK FullyCondensingBoileristtedpur-
suanttoDINEN304andDINEN303withthe
followingsafetyinstallations.
• Safetytemperaturelimiter(STL)boiler
100°C.ThisSTLmonitorstheboilertempe-
rature.
• Safetytemperaturelimiter,heatexchanger
90°Cprotectsfromexcessiveuegastem-
peraturetransfer.Whenapre-settempera-
turethresholdisreached,thetemperature
limitersshutdowntheheatgeneratorand
lockit.Re-startingisonlypossiblewiththe
helpofatool.
• Thesafetytemperaturelimitersare
testedandmarkedinaccordancewith
DIN EN 14 597�
4.2.5 Flue gas system
Theuegassystemisusedtoremoveresidual
low-pollutionuegaseswiththetemperature
of<60°C(monitoredbyatemperaturesensor)
outsidethebuilding,overtheroof.Itismarked
withitsownlabelcontaininginformationabout
themanufacturerandtheapprovalnumber.The
uegassystemshouldbeinstalledbyeffortsofa
locallyapprovedheatinginstallercompany,with
theuseofpipesandttingsmadeofplasticcerti-
edforapplicationinconstructionandconnected
totheuegasconnectingpieceoftheFullyCon-
densingBoiler.
Thecombustiongaspathoftheboilercorres-
pondstothebasicstandards.
4.2.6 Combustionair
Thecombustionairistakendirectlyfromthe
freeatmosphere;itispreheatinthesecondary
heatexchangerandsuppliedtotheburner.
Iftheuepipeisarrangedinaduct(unused,
cleanedchimney),thentheremainingfreespace
inthisductisusedforcombustionairsupply.
Inthecasethefreespacemaynotbeused,in
compliancewiththelocalrequirements,sothe

13
Functionanddescription
4.3 Unintended use
TheBKFullyCondensingBoilermaynotbe
used:
• forthefunctionsotherthanindicatedin
Chapter3.5.4.
• inothersystemconguration.
• withvaluesdifferentfromthoseindicatedon
thelabel.
• withfuelsotherthanindicatedintheorder
conrmation(OC).
• withoutnegativepressureatthecombustion
gaspathrequiredforoperatingpurposes.
Theriskforthepersons,theFullyCondensing
Boilerandotherequipmentcarriestheheating
technicianortheoperatoroftheheatingsystem.
Withuegasfan
Boiler type BK50 BK70 BK100
Fuel Heatingoil Gas Heatingoil Gas Heatingoil Gas
Fluegaspipe DN 80/125 80/125 80/125
110/160
80/125
110/160 110/160 110/160
Duct system
Pipelength(vertical) m 25 [28]
28 [31]
15 [18]
25 [28]
27 [40]
30 [43]
27 [40]
30 [43]
20
30 [43] 20 30 [33]
Ductcross-section mm 135
170
135
170
135
170
135
170
170
200
170
200
Exterior wall system
Pipelength(vertical) m 25 [28]
28 [31]
20 [23]
30 [33]
40 [43]
40 [43]
28 [31]
40 [43] 40 [43] 30 [33]
Assessmentbasis
ConnectingpipeBK50,BK70,BK100: 100cmeffectiveheight,2,5moveralllength,3pipebends87°
Exteriorwallsystem: Airsupplyoverconsolewithadditionalincomingairconnection
Geodeticinstallationheight: from1000mgenerallyonlywithuegasfan
Witheveryfurtherinstalledpipebend,thelengthoftheuegaswillbereducedby1m.
Thistableisbasedonpracticalendurancetestsconductedbythecompanyandpartlyoncalculationsperformedby
CentrotecSystemtechnikGmbHcompany.
Flue gas pipe dimensions BK50, BK70 and BK100
roomsealedheatingRSH[non-roomsealedheatingNRSH]
combustionairshouldbesuckedinthroughan
openingintheexternalwallandthecorrespon-
dingpipeandthensuppliedtotheairinletofthe
secondaryheatexchanger.Thecombustionair
heatedfromcondensinguegasesinthesecon-
daryheatexchangercomesoutattheboiler
front-sidefromthesecondaryheatexchanger
andpassesthroughaspiralhosetotheinlet
openingoftherespectiveburner.
4.2.7 Reservoir – service water heater
Theconnectionoftheservicewaterheateris
madeattheinletandtheoutletoftheBKFully
CondensingBoiler.Aheatingtechnicianshould
installaservicewatercirculationpump.The
respectiveelectricalsocketsareavailableatthe
boilercontrolpanel(seecircuitdiagraminthe
descriptionoftheConform6.0system).A
sensorformeasuringtheservicewatertempera-
tureisattachedtothecontrolsystem.

BK50/BK70
BK100
14
Functionanddescription
Fig. 3: Installationtypes(NRSH) B23,B33
  (RSH) C13,C33,C43,C53,C63orC83pursuanttoDINEN15035
Supplyair
Fluegas
4.4 Technical data
TheoperatingdataforthedeliveredFullyCon-
densingBoilermaybefoundonthelabelorin
theorderconrmation.
Thepresentoperatinginstructionsareattached
tothedeliveredFullyCondensingBoilerinclu-
dingtechnicaldata,dimensionsandinstructions
withregardtoinstallation,commissioningand
maintenance.
Boiler type BK50 BK70 BK100
Fuel Heatingoil Natural
gas
Heatingoil Natural
gas
Heatingoil Natural
gas
Nominalheatoutput kW 33,0–49,0 33,0–49,0 50,0–70,0 50,0–70,0 71,0–120 71,0–120
Firingcapacity kW 33,3–49,5 33,3–49,5 50,5–70,7 50,5–70,7 71,7–121 71,7–121
CO2content* Vol.-% 13 9,5 13 9,5 13 9,5
Fluegasmassow g/s 14,9–22,1 13,9–20,6 22,5–31,5 21,0–29,4 32,0–54,0 29,8–50,4
Fluegastemperature °C <48 <56 <48 <56 <48 <56
Air-uegas-systemØ mm 80/125 110/160 110/160
Heatingwaterresis-
tance(withΔT=20K) mbar 9,3 13,7 14
Residualconveying
pressureafterfan Pa 200 200 200
*CO2contentmeasuredinfurnace
Thethirdpartyoperatingmanualsand/orcir-
cuitdiagramsoftheboilerequipment,control
systems,supplementarydocumentation,expert
assessmentsetc.shouldbetakenintoconsi-
deration.Ifneeded,thesedocumentsmaybe
requesteddirectlyfromthe company.

15
Functionanddescription
Fig. 4: Boilerdimensions
Pos. Description BK50 BK70 BK100
Watercapacity l 110 110 200
Weight kg 470 470 746
1Safetygroupconnection DN 25(1") 25(1") 25(1")
2heatinputpipe DN 32(5/4") 32(5/4") 50(2")
3heatoutputpipe DN 32(5/4") 32(5/4") 50(2")
4Fillinganddischargingcock DN 1/2" 1/2" 1/2"
5Expansiontankconnection DN 25(1") 25(1") 25(1")
7Fluegasconnectionair-uegas-system
(AFGS)**
external-Ø mm 160 160 160
internal-Ø mm 110 110 110
8Condensatedrainage DN 40 40 40
Allconnections-externalthread|**BK50:usereductionto125/80,BK70:ifnecessaryusereductionto125/80
Pos. Description BK50 BK70 BK100
H1 Connectingdimensions,condensatedrainage mm 49 49 56
H2 Connectingdimensions,AFGsystem mm 278 278 314
H3 Connectiondimensionoptionalexpansiontank mm 471 471 576
H4 Connectingdimensions,heatoutputpipe mm 1162 1162 1291
H5 Connectingdimensions,heatinputpipe mm 1302 1302 1468
H6 Overall height mm 1480 1480 1605
Overall height without casing mm 1480 1480 1605
Overallheightwithoutcasing,withoutbase mm 1095 1095 1100
H7 Boilersupports(*height-adjustable) mm 20–40 20–40 20–40
B1 Connectingdimensions,AFGsystem mm 232,5 232,5 335
B2 Connectingdimensions,condensatedrainage mm 322,5 322,5 425
B3 Connectiondimensions,lling/dischargingcock mm 452,5 452,5 580
D1 Connectiondistanzposition4and5 mm 80 80 80
B4 Connectingdimensions,safetygroup mm 322,5 322,5 425
B5 Connectingdimensions,heatinputpipe mm 370,7 370,7 447
D2 Connectiondistanzheater mm 140 140 177
B6 Overall width mm 645 645 850
Overall width without casing mm 645 645 835
L1 Connectingdimensions,AFGsystem mm 54 54 54
L2 Connectingdimensions,safetygroup mm 377 377 339
L3 Overall length mm 1520 1520 1710
Overall length without casing mm 1250 1250 1457
Overalllengthwithoutcasing,withoutbase mm 1110 1110 1250

BK50/BK70
BK100
16
Delivery–transportationtoinstallationsite
5 Delivery – transportation to
installation site
5.1 Safety instructions
Duringloadingorunloading,anytransportation
toinstallationsiteandalsoduringtemporarysto-
rageorwarehousing,itisnecessarytocomply
withregulations,warningsandinstructionsrela-
tedtosafetyguidelinesoftherespectivecountry.
5.2 Unloading, use of hoist
TheBKFullyCondensingBoilerisbroughtto
shippingcompletelyorpartiallyassembled.
• Dangerofinjury!Manualunloadingortrans-
portationofweights>35kg(ILO,Geneva)
orone-timeliftingofmaximum>55kg(Acci-
dentpreventionregulations/FederalMinistry
ofLabourandSocialAffairesofGermany)
isforbidden.
• Foryourownsecurity,alwaysusesuitable
hoistingdevicesand/orindustrialtrucksas
wellasotherloadhandlingaccessorieswith
adequateloadcapacity.Beforeloadingor
unloadingtheFullyCondensingBoiler,take
caretoensuresufcientspaceforsecure
placingoftheboiler.
• Theloadhandlingaccessoriesmustbe
carefullyattachedandsecured.There
shouldbenodangerfromsuspendedloads!
• Fixingropesorstringstotheboilerequip-
mentisforbidden!
• AlwayslifttheFullyCondensingBoileronly
vertically–neverpullitsidewards!
Neverstayorworkunderthesuspendedload.
Mortaldanger!
Attention
TheBKFullyCondensingBoilershouldbe
handled,duringunloading,transportationto
installationsiteortemporarystorage,withthe
usualcareandprotectedagainstexternalrough
treatmentand/orfallingobjects.
5.3 Completeness of delivery
Checkthecompletenessofdeliveryimmediately
uponitsreceipt(compareitwiththeorderconr-
mation/deliverynoteofthecompany).
Missingpartsshouldbepromptlyclaimedtothe
deliveringtransportcompanyandthe
companynotied.

17
Installationandconnection
6.2 Electrical connection
Thereliablemainsconnectionistobeperformed
byanexperiencedelectrician.
1� Thecharacteristicsofelectricalmains
shouldmeettherespectivelocalandnati-
onallegalprovisions.
2� Aspowercables,chooseatleastonee-
xiblecablewithpolychloroprenecoating,
inaccordancewith60245IEC45(for
example,NYM3x1,5m2).
3� Theearthwireshouldbelongerthan
othercables.
Information
6 Installation and connection
6.1 Fully Condensing Boiler
TheinstallationoftheFullyCondensingBoiler
shouldbecarriedoutunderconsiderationofthe
actualinstallationguidelines.Inthiscase,itis
necessarytoinstallsafety-relatedequipmentin
conformitywithDIN12828,forexample,asafety
groupmaximum3bar.
Foroperationwithgasfanburners,thefollowing
classesofgasequipmentareutilized(pursuant
toDINEN437):
Thedistancesfromtheunittothewallsorcom-
bustiblematerials(min.200mm)shouldmeet
localrepoliceregulations.Thelateraldistances
ontheleftortherightsideoftheboilershouldbe
minimum600mm,toensurethattheboilerdoor
withtheburnercouldbeeasilyswungout.
Theuegaspipemustbeleadtothechimneyas
shortaspossibleandrising.Theuegaspipes
mustbecarefullysealedup!Itisrecommended
tousetheuegaspipeswithaninspectionope-
ning,toenablecleaningandvisualinspectionof
theuegaspipes.
TheFullyCondensingBoilerandthetankwater
heaterhavetostandhorizontallyorslightlyrising
tothebackinordertoensureacompletede-
aeriation(usetheadjustablefeettolevelthem).
Country Classes of
gas equip-
ment
Gas connec-
tion pressure
Germany I2ELL 20/25mbar
Austria I2H 20mbar
Belgium I2E+ 20/25mbar
Luxembourg I2E 20mbar
France I2E+ 20/25mbar
Switzerland I2H 20mbar

BK50/BK70
BK100
18
Installationandconnection
Fig. 6: Condensatetrap
siphon
siphon-like
hopper
25mm
Boiler
6.4 Handingoverandservicing
instructions
Itisessentialthattheinstallation,commissio-
ningandmaintenanceoftheFullyCondensing
Boilersarecarriedoutbyqualiedandtrained
personnel.Duringtheinstallationandtrialrun,it
isnecessarytocarefullychecktheconformityof
safetyinstallationswithDIN12828aswellasits
functioningandcorrectsettingandtoconrmitin
thecommissioningreport.
Theheatingtechnicianshouldfamiliarizethe
operatorwiththeheatingunitanditsservicing
andwithsafetyinstallationsandtheirfunctions!
Theoperatormustplacetheoperatinginstruc-
tionsfortheBK FullyCondensingBoilervisibly
inthesameroomwheretheboilerislocated�
Theoperatorisobligatedtoeliminatemal-
functionsintheheatingunitand/oritssafety-
relatedorelectricalequipmentonlybyqualied
experts.Moreover,hemustbeclearlyinformed
abouttheinadmissibilityandpotentialdanger
ofimproperhandlingoftheunit.
Information
Theheatingtechnicianand/ortheoperator
mustnotmakeduringinstallation,commissio-
ningoroperationanychangesintheBKFully
CondensingBoiler,itssafety-relatedequip-
mentorfactorysettings.
Attention
6.3 Condensate drainage
Thecondensateaccumulatedinthesecondary
heatexchangerisprocessedintheneutraliza-
tionboxoftheBKFullyCondensingBoiler.
Whendischargingthecondensateintosewage
orwastewatersewer,itisnecessarytotakeinto
accountthewaterwayprescriptionsoftheres-
pectivecountryandthestatutesoflocalwaste
disposalcompanies!Theunitoperatormust
obtaintheauthorization,bearinginmindthe
AdvisoryleaetA-251„Condensationdisposal
inchimneys”withpresentationoftheexpert
assessment.Oninstallationofthesuppliedneu-
tralizationbox,itisessentialtoannuallyloosen
andrinsethegranulate.
Duringinstallationofthecondensatedrainage
system,caremustbetakentoensurethat
thecondensationwaterlevelof120mm(see
Fig.5)isnotexceeded.
Thecondensatedrainagesystemmaynotbe
alteredorclosed.
ThesuppliedcondensatetrapDN40shouldbe
placedasclosetotheboileraspossible.Prior
tocommissioning,llthesiphonwithwater.
Ifinspecicsituationstheneutralizationboxis
notutilized,thecondensatedrainagesystem
shouldbearrangedinsuchawaythatthe
sealingwaterheightisnotlessthan25mm
(see.Fig.6).
Attention
Fig. 5: Condensatedrainage–thehighestlevel
120mm

19
Installationandconnection
Option 1 Neutralizationboxalignedwiththepermanentlycondensing
boiler.
Option 2 Neutralizationboxatrightanglestothepermanently
condensingboiler.
Option 3 Neutralizationboxparallelbeneaththepermanently
condensingboiler(additionalHTtuberequired).