BURNS BOY III User guide

Stand 11/2009
Installation and
Operating Instruction
Gebr. Bruns GmbH
Hauptstraße 200
D 26683 Saterland
Tel.: + 49 (0) 44 92 / 92 46 0
Fax: + 49 (0) 44 92 / 71 41
BOY III
Condensing Gas Boiler

Table of contents
Table of contents
1 Introduction 4
1.1 Symbols used in this manual 4
1.2 Liability 4
1.3 Factory Warranty 4
2 Product Description 5
2.1 Product Description 5
2.2 Intended use 5
2.3 Equipment configuration BOY III Solo 6
2.4 Equipment configuration BOY III Combi 7
3 Regulations, Guidelines, Safety 8
3.1 Regulations and Guidelines 8
3.2 Safety Warning 9
3.2.1 What to Do if You Smell Gas 9
3.2.2 Risk of Poisoning 9
3.2.3 Risk of Freezing 10
3.2.4 Relief Valve 10
3.2.5 Aspirator 10
3.2.6 Pressure Compensating Tank for Drinking Water 11
3.2.7 Pressure Compensating Tank for the Heating System 11
3.2.8 Water Deficiency Safety Fuse 11
3.2.9 High Temperature cut out 11
3.2.10 Corrosion Protection 12
3.2.11 Installation Location Requirements 12
3.2.12 Minimum Safety Distances 12
4 Mounting/Installation 13
4.1 Shipment Contents 13
4.2 Mounting the Unit 14
4.2.1 General Instructions for Connection the Heating Unit 15
4.2.2 Connecting the Heating Unit (Supply and Return Lines) 15
4.2.3 Connecting for Drinking Water (BOY III Combi) 16
4.2.4 Connecting for Use with an External Reservoir 16
4.2.5 General Instructions for the Gas Connection 17
4.2.6 Connecting the Gas Main 17
4.2.7 General Instructions for Connecting the Gas Flue 18
4.2.8 Chimney Compatibility 18
4.2.9 Heating Duct Requirements 18
4.2.10 Maximum Length of Flue Ducts and Number of Directional Changes 18
4.2.11 Reducing the Maximum Delivery Height 18
4.2.12 Lighting Protection 18
4.2.13 Connecting the Unit to the Chimney 19
4.2.14 Installing the Emissions Connection to Central Roof Heating 21
4.2.15 Connecting the Condensed Water Drain 21
4.2.16 Neutralisation 21
4.2.17 General Instructions for the Electrical Connection 22
4.2.18 Electrical Connection 22
4.2.19 Pin Assignment on the Terminal Strip 23
Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Table of contents
Table of contents
5 Start up 24
5.1 Filling and Ventilating the Heating System 24
5.2 Ventilating the Unit 24
5.3 Ventilating the Lower/Standing Reservoir (optional) 25
5.4 Start up 26
5.4.1 Performance of the Unit Test Routine upon Start up 26
5.5 (Pre) Setting the Boiler 26
5.5.1 CO2Boiler Settings 26
5.5.2 Gas Throughput Table / Connection Pressure 27
5.5.3 Changing Gas Types 27
6 Operating the Controls 28
6.1 Description of the Control Panel 28
6.2 LED Display Symbols 28
6.3 Controller Functions and Operating Status 29
6.3.1 Start up 29
6.3.2 Standby Mode 29
6.3.3 Flame Detector 29
6.3.4 Central Heating Mode 30
6.3.4.1 Operating the Central Heater 30
6.3.4.2 Anti-Cycling Central Heating 30
6.3.5 Drinking Water Mode 30
6.3.5.1 Operating the Drinking-Water Heater 30
6.3.5.2 Anti-Cycling Drinking-Water Heater 31
6.3.6 Changing the Set-point 31
6.3.6.1 Changing the Set-point for Central Heating 31
6.3.6.2 Changing the Set-point for the Drinking-Water Heater 31
6.3.7 Summer Mode 32
6.3.8 Chimney Sweep Mode 32
6.3.9 Installer Mode 32
6.3.10 Installer (+) Mode 33
6.3.10.1 Installer (+) Parameter List 34
7 Malfunctions and Errors 36
7.1 Error Mode 36
7.2 Error Code List 36
7.2.1 Shutdown Codes 36
7.2.2 Locking Codes 37
7.3 Error history Mode 39
7.4 Log Resistance Values for the Boiler and Reservoir Sensors 39
8 Maintenance 40
8.1 General Instructions for Maintenance 40
8.2 Cleaning the Condensed Water Siphon 40
8.3 Cleaning the Combustion Chamber 40
9 Technical Data 43
9.1 Circuit Diagram 43
9.2 Technical Data 44
10 Declaration of Conformity 46
Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Introduction
Introduction
1 Introduction
Dear customer,
We congratulate you on your decision to use the BOY III Condensing Gas Boiler. By
purchasing the BOY III, you have secured the most current level of innovation in boil-
er technology.
We will gladly answer any questions or provide any information you may need.
We thank you for your trust and hope you enjoy you BOY III Condensing Gas Boiler.
Gebr. BRUNS GmbH,
Your partner for heating technology
1.1 Symbols used in this manual
Failure to follow instructions marked with this symbol risks life and limb; a de-
fect in the unit is possible.
This Symbol denotes important Instructions and Information.
This symbol marks tasks to be fulfilled.
1.2 Liability
Gebr. Bruns GmbH is not liable for damages caused by not observing this in-
stallation and operating instruction.
1.3 Factory Warranty
We provide a factory warranty for the owner in accordance with the current condi-
tions and deadlines in the Gebr. Bruns GmbH’s general terms and conditions. The
warranty does not cover damages caused by normal wear and tear, insufficient water
quality, aggressive fumes or strong dust. Warranty work is performed exclusively by
the factory. We can, therefore, only reimburse you for expenses incurred for repairs
done during the warranty period if we have received a proper order and have
deemed it to be covered by the warranty.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Product Description
Product Description
2 Product Description
2.1 Product Description
The BOY III is a compact, wall-hanging condensing gas boiler that weighs very little.
The BOY III can be operated dependent or independent of compartment air. All of
the basic parts are inside the powder-coated steel-plated casing. The stainless steel
heat exchanger is designed for exhaust condensation operation and is very self-
cleaning. With its 1:5 modulation ratio, the force draught fan supported burner, de-
signed especially for gas boilers, is very efficient in its energy use and emissions.
The connections can be placed from below the unit. An atmospheric or temperature
sensor can be attached to the boiler controller. These sensors can, depending on
how they are set up, regulate up to two mixing valve circuit.
2.2 Intended use
The BOY III is a condensing gas boiler and is exclusively for use as a heating
unit for heating systems.
Any misuse is prohibited
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]
Fig. 1: Boy III

Product Description
Product Description
2.3 Equipment configuration BOY III Solo
- 6 -
Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]
Fig. 2: BOY III Solo
Burner Unit
Ionisation
Force Draught Fan
Relief Valve
Flow Sensor
Water Pressure Sensor
High Temperature
Sensor
Ignition Electrode
Automatic Firing Device
Gas Valve
Return Sensor
Circulation Pump

Product Description
Product Description
2.4 Equipment configuration BOY III Combi
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]
Fig. 3: BOY III Combi
Burner Unit High Temperature
cut out
Ionisation
Force Draught Fan
Relief Valve
Flow Sensor
Water Pressure Sensor
Ignition Electrode
Automatic Firing Device
Gas Valve
Return Sensor
Circulation Pump
Plate Heat
Exchanger
Warm Water Sensor Circulation Sensor

Regulations, Guidelines, Safet
Regulations, Guidelines, Safet
3 Regulations, Guidelines, Safety
3.1 Regulations and Guidelines
Regarding mounting, installation, and operation of the BOY III, the following laws, or-
dinances, regulations, norms and rules apply according to the current versions.
In other countries, the respective national regulations apply.
BImSchV Federal Emissions Protection Regulation
DIN 18160 Emissions Systems – Design and Operation
DIN 18380 Heating Systems and Central Water Heating Systems
DIN 1988 Teil 1 – 8 Technical Regulations for Drinking Water Installation
DIN 4753 Water heater and Water heating Systems for Drinking Wa-
ter and Domestic Use
DIN EN 12828 Water heating System Design
DIN EN 12831 Procedure for Calculating the Heating Load Norm
DIN EN 13384 Procedure for Calculating Emissions Systems – Heat and
Supply
DIN EN 267 Automatic Burner with Force Draught Fan for Liquid Fuels
DVGW G 631 Installation of Commercial Gas Consuming Appliances
DVGW G 634 Installation of Gas Units in Commercial Kitchens in Build-
ings
DVGW G 670 Gas Fire Locations and Mechanical Ventilation Systems
DVGW TRGI 86 Technical Regulations for Gas Installation
EnEG Energy Conservation Law
EnEV Energy Conservation Regulation
FeuVO Fire Regulations per State
VDE Rules and Regulations for Electro-Technical, Electronics,
and Information Technology
VDI 2035 Prevention of Damages in Water Heating Systems – Accu-
mulation of Stone in Drinking Water and Water Heating sys-
tems – Corrosive Water – Corrosive Emissions
This list may not be complete!
Before installing the condensing gas boiler BOY III, it is necessary to attain
approval from the Gas Supply Ordinance Board and the District Chimney
Sweep Foreman.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet
Regulations, Guidelines, Safet
3.2 Safety Warning
Attention: Electrical installation and initial operation may only be performed by
a licensed professional! This also pertains to maintenance, cleaning, and re-
pair.
●Do not use if system is damaged.
●Only original parts may be used.
●Changes and repairs made on one’s own authority are not allowed, as
such may result in damages to the unit or injury or death.
●When operated in a compartment air-dependent area, ventilation (in
and out) must not be obstructed. The intake of combustion air on the
top of the BOY III must be kept free of obstructions.
3.2.1 What to Do if You Smell Gas
Avoid open fire, smoking, turning on lights, or unplugging anything in rooms
that smell like gas. Under no circumstances should you use the telephone.
Close the gas meter valve! Have your installation technician show you where
the gas valve is and how to close it.
Do not use doorbells or light switches in other rooms.
If you smell gas, use a telephone in a neighbouring building or use a phone
booth. Mobile phones should also be used outside of the building.
Call the service department, even if you smell gas somewhere else.
Do not forget to warn housemates and neighbours and vacate the premises.
Secure the building against unauthorized entry.
Even if you aren’t sure if it is a gas smell, you should contact your energy pro-
vider as a precaution.
3.2.2 Risk of Poisoning
Never use water from the heating system as drinking water! It is contaminated with
deposits.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet
Regulations, Guidelines, Safet
3.2.3 Risk of Freezing
If the unit is at risk of freezing, it is necessary to be kept operational in conservation
mode (at minimum) and all radiator valves should be kept open. If you cannot heat
during freezing periods, turn off the system and empty the boiler, the warm water
storage tank and the radiators. The boiler must be secured against accidental activa-
tion when empty.
3.2.4 Relief Valve
The condensing gas boiler comes with a 2.5 bar relief
valve. The opening of the spring-loaded membranous
relief valve must be in a frost free area and must be eas-
ily accessible. The blow off pipe on the relief valve must
be implemented without the possibility of increasing
pressure while responding to the relief valve. Leaking
heater water should be safely siphoned off.
Operational readiness of the relief valve should be
checked from time to time. Fig. 4 Relief Valve
3.2.5 Aspirator
To ventilate the boiler with water in it, the
aspirator cap on the top of the unit must be
open by turning it two rotations to the left.
Fig. 5 Manual Quick-Aspirator
An additional automatic aspirator can be
found under the pump casing. This may
only be set by a licensed professional.
Fig. 6 Automatic Quick-Aspirator
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet
Regulations, Guidelines, Safet
3.2.6 Pressure Compensating Tank for Drinking Water
In combination with a drinking water reser-
voir, a membranous pressure compensat-
ing tank that has been approved for filtering
domestic-use water to drinking water is re-
quired. This tank should have ample space
and must be installed externally in accord-
ance with TRWI regulations. The size of the
tank is dependent upon the volume of do-
mestic-use water reservoir. Fig. 7 Pressure Compensating Tank for
Drinking Water
3.2.7 Pressure Compensating Tank for the Heating System
On the heater side, a membranous pres-
sure compensating tank is required. This
tank should have ample space and is to be
installed externally. The size of the tank is
dependent upon the volume of heating sys-
tem’s water reservoir as well as the temper-
ature requirements.
Fig. 8 Pressure Compensating Tank for the
Heating System
Setting the primary pressure of the pressure compensating tanks to the
respective static levels is required and may only be performed by a li-
censed professional.
3.2.8 Water Deficiency Safety Fuse
A minimum circulation rate of 360 l/h is required. Furthermore, a water pressure
sensor makes sure that at a system pressure of 0.6 bar, the system automatically
shuts down. As soon as the water pressure returns to above 0.6 bar, the unit
will turn itself back on automatically.
3.2.9 High Temperature cut out
The unit has a temperatur cut out with a melting fuse. This safety guard is only a pro-
tection against burning out of the heat exchanger. If this fuse is blown out, the com-
plete heat exchanger has to be changed, because the baffle plate within, is most
probably damaged.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet
Regulations, Guidelines, Safet
3.2.10 Corrosion Protection
The combustion air must be free of all corrosive elements – especially those contain-
ing fluoride and chloride such as those found in solvents and cleaning solutions, pro-
pellants an so on.
When connecting a water heater to a floor heater with non-airtight plastic tubing (in
accordance with DIN 4726), a heat exchanger must be used to separate the sys-
tems.
To avoid corrosion damage in the heating system, heating water that fulfils the drink-
ing water quality requirements in VDI guideline 2035 (Prevention of Damages in Wa-
ter Heating Systems) must be used. Chemical additives are not to be used.
3.2.11 Installation Location Requirements
●When operated in a compartment air-dependent area, the unit must be hou-
sed in a room with clean combustion air. Under no circumstances should for-
eign substances such as pollen get inside the unit via the intake duct!
●The installation location must be dry and frost free (0°C to 45°C).
●The boiler room must be protected against small animals, vermin and pests.
●When operated in a compartment air-dependent area, the boiler room must
have a functioning ventilation and emission system.
●Flammable material or liquids must not be stored or used near the boiler. Fol-
low fire prevention guidelines!
3.2.12 Minimum Safety Distances
For optimal installation of the boiler,
we recommend a lateral distance of
200 mm from the walls and a vertic-
al distance of 500 mm from the ceil-
ing. Reducing these distances is al-
lowed according to legal guidelines.
The lateral distances should not fall
below 100 mm.
4 0 0
200
Fig. 9 Minimum Safety Distances (mm)
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4 Mounting/Installation
4.1 Shipment Contents
Please make sure the shipment is complete and undamaged before you be-
gin with the installation!
The delivery comes in a cardboard box.
Fig. 10 Shipment Contents
Pos. Anzahl Bezeichnung
11 Condensing Gas Boiler BOY III
21 Atmospheric or Temperature Sensor (Optional)
31 Pressure Gauge
41 Control Keypad with Illuminated Display
51 Wall Mounting Track
62 Mounting Screws incl. Washers
72 Plastic Expansion Studs
81 Installation and Operation Manual
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]
1
25
6
7
3
4

Mounting / Installation
Mounting / Installation
4.2 Mounting the Unit
The unit comes with a track for easy wall mounting. Before mounting the
unit, please read the following requirements:
•The wall must be stable enough to hold the unit.
•An outlet with contact protection for electricity and a water drainage
connection should both be in close proximity.
•Make sure to check the wall for electrical wiring and water and gas pi-
pes before drilling as they may get damaged.
•To protect the boiler from contamination, place protective covers over
all connections. Please remove these only at the appropriate installa-
tion stage.
Next, measure the wall intended as the loca-
tion of the unit. Follow the measurements of
the unit and the minimum safety distances. If
the unit is to be attached to an existing chim-
ney, use the emissions connection, including
the elbow as the point of reference.
Mark the drilling positions for the mounting
track and drill using an 8 mm bit.
Place the plastic expansion studs in the wall
and fasten the track to the wall with the
screws. Use a level to make sure the track is
straight and then screw it tightly to the wall.
Hang the unit to the mounted track and make
sure it is mounted firmly.
Use the setting screws at the bottom of the
back of the boiler to align it parallel to the wall.
Check one more time with the level to make
sure the boiler is straight.
320
Fig. 11 Wall Track
8 5
Fig. 12 Wall Mount (mm)
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4.2.1 General Instructions for Connection the Heating Unit
●Before connecting the boiler to the heating system, the heating system
must be rinsed at a minimum of 3 times the flow capacity. The drink-
ing water pipes must be rinsed at a minimum of 20 times its flow capa-
city.
●In older systems, a filter must be placed in the heating circuit in the re-
turn supply line before the opening to the boiler.
●Use only untreated tap water to fill and refill the heating system.
●The pH value must be between 6 and 9.
●Do not add any chemicals to the heating system’s water (e.g. anti-free-
ze, water softener, solutions to raise or lower the pH value, chemical
additives and/or inhibitors). These can damage the boiler.
●When using plastic pipes (e.g. in floor heaters), the pipes must be air
and diffusion tight in accordance with DIN 4726/ 4729.
●If the system’s plastic pipes are not in accordance with the norms, we
recommend separating the boiler circulation system from the heating
system with a (plate) heat exchanger or a filter mounted hydraulically
in front of the boiler connection.
●The temperature of the heating ducts and radiators can go up to 95 °C.
4.2.2 Connecting the Heating Unit (Supply and Return Lines)
There are flue cut-off devices that must be
mounted directly under the boiler. These
should have the respective diameters of the
connections to which they belong. Perman-
ently soldered or welded connections are not
allowed.
A separate line for filling and draining must be
installed and easily accessible. If the line for
filling and draining is not at the lowest point of
the unit, an additional device must be installed
so the system can be completely drained.
Older systems and floor heating systems re-
quire a filter in the return line directly on the
boiler.
S R A K
V L R L
S V
G
Fig. 13 Connections: BOY III Solo
S R A K
V L R L W W K W
S V
G
Fig. 14 Connections: BOY III Combi
SR Siphon-Cleaning VL Supply WW Warm Water SV Drainage Safety Valve
AK Condensation Drainage RL Return Flow KW Cold Water G Gas Connection
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4.2.3 Connecting for Drinking Water (BOY III Combi)
The drinking water access must be
equipped in accordance with DIN 1988
and DIN 4753 to avoid dirt or germs that
can contaminate the cold water network.
The necessary parts and their configura-
tion are shown in the diagram to the right.
1 2 3456
T W 1
1 . C u t - o f f v a l v e
2 . F i l t e r
3 . P r e s s u r e r e g u l a t o r
4 . C h e c k v a l v e
5 . N o n e - r e t u r n e v a l v e
6 . M a n o m e t e r c o n n e c t i o n
T W . M a i n s d r i n k i n g w a t e r
Fig. 15 Connection Schematic:
Drinking Water Access
4.2.4 Connecting for Use with an External Reservoir
If the unit is connected to an external reservoir, an expansion tank and a 10 bar relief
valve must be installed to protect the heating system. The BOY III Solo requires an
additional three-way redirecting valve installed in the return flow line directly on the
boiler.
Fig. 16 Three-way Redirecting Valve
The connections on the three-way redirection
valve are as follows:
AB = Return Flow Line BOY III
A = Reservoir Connection
B = Heating Circuit Connection
These connections should never, under
any circumstances, be interchanged!
The three-way redirecting valve is
already integrated in to the BOY III.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4.2.5 General Instructions for the Gas Connection
•The gas connection must be connected in accordance with the current
regulations. Installation may only be performed by a licensed profes-
sional!
•Make sure there is no open fire, flammable materials or the like in close
proximity to the installation location. LIFE THREATENING DANGER!
•Before installation, check to make sure the gas meter has adequate
capacity. Take the usage of all household appliances into account.
Let your energy provider know if your line does not have a high
enough capacity.
•Make sure the gas lines are clean. Clean the gas lines with high pres-
sure or by knocking them clean before installation.
•An approved shut-off valve with a fire protective faucet must be instal-
led in front of the boiler.
•Preferably, you can also install a gas filter to keep the gas control
valve from getting dirty.
4.2.6 Connecting the Gas Main
Please follow these instructions during installation:
•The main gas spigot must be shut off before the work begins. If the
connection is older, make sure the spigot still closes to avoid uncon-
trolled gas leaking out.
•Secure the line against accidental start up while you are working on
the lines.
•Make sure the fire protective faucet is mounted properly.
•Before start up, make sure the entire gas line is sealed, especially at
connection points. The gas faucet and the gas line may not exceed a
maximum pressure of 150 mbar.
•Ventilate the gas line after attaching to avoid malfunctions!
•Ventilate the room well after installation to disperse any gas that may
have escaped.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4.2.7 General Instructions for Connecting the Gas Flue
Discuss regional guidelines for gas flue lines, cleaning openings and similar
with the appropriate chimney sweep.
4.2.8 Chimney Compatibility
Heavily used and dirty chimneys are unsuitable for conducting combustion air (air
supply through the chimney) and must be cleaned by a chimney sweep before use.
If there are structural damages, such as brittle chimneys, soot build-up or the like, the
chimney should be checked by a chimney sweep foreman to determine its stability. If
cleaning the chimney isn’t possible, the unit can also be run through a concentric
emissions pipe without being dependent upon compartment air. A compartment air-
dependent operating method is a possible alternative.
Hooking up more than one or different types of boilers to one chimney should be ap-
proved by a chimney sweep foreman.
4.2.9 Heating Duct Requirements
Emission lines within buildings must be housed within their own ventilated ducts.
The ducts must be made of non-flammable, form-holding materials. The duct’s fire
resistance duration must be 90 minutes, in lower buildings, 30 minutes.
4.2.10 Maximum Length of Flue Ducts and Number of Directional Changes
Compartment air-dependent /Compartment air-independent
Duct Layout Central Roof Heating
Maximum length of
Flue Duct 21 m 4 m
Maximum Number of
Directional Changes 2 4
4.2.11 Reducing the Maximum Delivery Height
When lengthening the connection lines by 1 m, the headroom of the emission lines is
lowered by 1.5 m. Since the central roof heating system is limited to a total of 4.0 m,
up to 4 directional changes can be installed. At an angle of 45°, the headroom is
lowered by 0.5 m, at a 90° angle, by 1 m.
4.2.12 Lighting Protection
The chimney head cover must be into an existing lightning protection system and into
a potential equalisation on the house. This should only be done by a licensed profes-
sional.
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Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
4.2.13 Connecting the Unit to the Chimney
Calculate the height of the opening for
the emission pipe. Make sure to take
headroom for the test connection and the
revision T-piece (T-fitting) into account.
2 1 0 m m
Fig. 17 BOY III with Emission Connection
m a x . 1 6 0 m m
Ø 1 0 m m
Fig. 18 Cross Section of the Duct
The opening for mounting the support bar
should be made according to the dia-
gram. Make sure the opening is no lar-
ger than160 mm x 160 mm; otherwise
the cover will not be large enough.
Drill the hole for the support bar with a 10
mm bit. The support bar must be level.
Position the support bar according to the
diagram to the right. The support bar
must be level.
Fig. 19 Installing the Support Bar
- 19 -
Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]

Mounting / Installation
Mounting / Installation
Fig. 20 Insert the Emission Pipe into the Duct
Insert the pipe into the duct with a rope
from above. The rope should stay taught
at all times. Spacers should be placed
every two meters after the collars.
Place the support arc into the support
bar.
Mount the emission pipe between the unit
and the support bar. The emission line to
the unit must be placed at a slight down-
ward slope, so condensation can flow
back unhindered.
Fig. 21 Emission Connection - BOY III
Follow the installation instructions for the respective emissions system!
- 20 -
Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.
Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41
www.bruns-heiztechnik.de •[email protected]