Ecodense RT-65 One Installation guide

www.ecodense.com
ROOF TOPSERIES CONDENSING BOILER
INSTALLATION,OPERATING AND MAINTENANCE
MANUAL
ECODENSE RT-65One
ECODENSE RT-80One
ECODENSE RT-100One
ECODENSE RT-125One
ECODENSE RT-150One
ECODENSE RT-65Twin
ECODENSE RT-80Twin
ECODENSE RT-100Twin
ECODENSE RT-125Twin
ECODENSE RT-150Twin

06.06.2017 Rev. 00 1
DEAR USER,
TheRoofTop Series CondensingBoilersECODENSERT-65One,ECODENSE
RT-80One, ECODENSERT-100 One, ECODENSE RT-125One,ECODENSE RT-150
One, ECODENSERT-65 Twin,ECODENSE RT-80Twin,ECODENSERT-100Twin,
ECODENSE RT-125 Twin,ECODENSERT-150Twinareconstructedand manufactured
accordingtothemostadvancetechnological inventionsand thesafetyrules.Itiseasyto
useforourcustomers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyouencounteranyissuethat is notexplainedclearlyinthismanual oryoucould
not understand,please contact withour service department.
We thank youforchoosingECODENSE brand.
This OperatingManualisanintegralpartof thedeviceandmust bemaintainedin a
plasticdossierand hungat a clearlyvisible placebythedevice.
TERMO ISI S STEMLER SAN.VET C.A.Ş.
EsentepeMah.MilangazCad. No:75 K:3
KartalMonumentoPlaza
Kartal/ STANBUL/TÜRK YE
Tel: [phone]
Fax:[phone]
www.ecodense.com
e-mail:[e-mail]

06.06.2017 Rev. 00 2
CONTENTS
WARNINGS...............................................................................................................................................3
Warning Symbols andDescriptions........................................................................................................3
GeneralSafety Rules..............................................................................................................................4
TERMS OFWARRANTY.........................................................................................................................5
Out of Warranty Conditions....................................................................................................................5
GENERAL CHARACTERISTICSOF CONDENSINGBOILER.............................................................6
ECODENSERoofTop SeriesCondensing Boilersfor Outdoor Installation..........................................7
TechnicalSpecifications.........................................................................................................................7
BoilerSafety...........................................................................................................................................7
Standart Equipments...............................................................................................................................7
ECODENSERoofTop SeriesBoilerComponents.................................................................................8
CIRCUITSCHEMES...............................................................................................................................10
CLOSEDCIRCUITCOMPONENTS......................................................................................................13
BalanceTank........................................................................................................................................13
SizingTable ForExpansion Tank.........................................................................................................14
ExpansionTank....................................................................................................................................15
Manometer............................................................................................................................................15
Strainer .................................................................................................................................................15
Air Separator.........................................................................................................................................15
WATER QUALITY.................................................................................................................................16
TECHNICAL DATA................................................................................................................................17
Capacity Table......................................................................................................................................17
CondensingBoiler Dimensions............................................................................................................19
Noise Level...........................................................................................................................................19
INSTALLATION.....................................................................................................................................20
GeneralControls...................................................................................................................................20
STACKCONNECTIONS........................................................................................................................21
ASSEMBLY.............................................................................................................................................22
ECODENSEAssembly Instructions.....................................................................................................22
ECODENSESingle/CASCADEAssembly Instructions.......................................................................22
Assembly ofCondensingFluidDrain...................................................................................................22
ECODENSECONTROL INSTRUCTIONS BEFORE START-UP ........................................................23
ELECTRICALDIAGRAM......................................................................................................................24
COMMISSIONING..................................................................................................................................25
Before Commissioning.........................................................................................................................25
Checks During Commissioning ............................................................................................................25
ADJUSTINGCOMBUSTINPARAMATERS.........................................................................................26
Adjustment andMeasurement Points....................................................................................................26
AdjustingMinimumCapacity...............................................................................................................27
AdjustingMediumCapacity.................................................................................................................27
AdjustingMaximumCapacity..............................................................................................................28
AdjsutingTimeSchedule......................................................................................................................28
MAINTENANCE.....................................................................................................................................29
MonthlyMaintenance...........................................................................................................................29
Seasonal Maintenance...........................................................................................................................29
LISTOF ERRORCODE..........................................................................................................................30
SOLUTION RECOMMENDATIONSFORSOMEOFTHE PROBLEMS............................................34
AFTERSALES SERVICES.....................................................................................................................35
NOTES.....................................................................................................................................................36

06.06.2017 Rev. 00 3
WARNINGS
WarningSymbols andDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
GAZ HATTIN
ITEM ZLEY NZ.
CLEAN GAS LINE.
ЧИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegasline" warningongasline.
Carry inanupright position.Fragile Item.Protectagainstwater.

06.06.2017 Rev. 00 4
General Safety Rules
•All personnel engagedininstallation,disassembly,commissioning,operation,control,
maintenanceand repair should havereceived thenecessarytrainingandfullyread and understood
thismanual.
•Nochangesthat might damagethe safetyof the devicemustbemadebypersonsand/or
organizations onthe device.
•All operation,commissioning and installation works (except for burningadjustment) should be
carried out when thedeviceisnotoperating and after disconnecting the powersupply.
Noncompliancewith theserules may lead to seriousbodilyinjuriesand even death by electrical
shocksoruncontrolled flameformation.
•Repairs concerned withsafety elementsshould becarriedout only bythemanufacturing company.
•The deviceshouldnever be usedbychildren,mentally handicapped and inexperienced persons.
•Children mustnot be allowed to playwith the device.
•Keep the deviceaway fromexplosiveand flammable materials.
•Devicemustintakeair,and ventilationand air discharge holesmust notbe closed.
Ifyou sensegas leakage;
•Shutdownvalvesofall gasdevices.
•Open all doorsand windows.
•Donotturnonelectricdevices or donot turn themoffifthey areworking.
•Donotuseburner derived tools such as match andlighter.
•Informthe gascompany.
Do not store any inflammablematerialsinboiler room.
Wear hearingprotectorsifthereisnoiseinboiler room.
Incaseoffıreorother emergency;
Switchoff the mainswitch
Closethemain fuel shut-offvalveoutside the plant.
Takeappropriate actions

06.06.2017 Rev. 00 5
TERMS OF WARRANTY
Main and auxiliary equipmentandallcomponentsused in ECODENSERT-65One,ECODENSE
RT-80One,ECODENSERT-100 One ,ECODENSE RT-125One,ECODENSE RT-150 One,
ECODENSE RT-65Twin,ECODENSERT-80Twin,ECODENSE RT-100 Twin,ECODENSERT-125
Twin,ECODENSERT-150 Twin RoofTopSeriesCondensing Boilersare guaranteed for 1year by
TERMO ISI SSTEMLER A.Ş. starting fromthe date ofcommissioningunder the maintenance,
adjustment, operatingconditionsand relevant mechanic,chemical and thermal effectsexplainedherein.
Pleasenote that thiswarranty isonlyvalidifthedevice(s)is commissioned and maintained by our
authorizedservices.
Our company reserves the right to makeanymodificationson the product and all instructions
thereof for improvement purposes.
Out ofWarranty Conditions
•Any damage arising out oforin relation to customers’non-complianceto their responsibilities
with regardstoinstallation, commissioning,operation andmaintenance,
•Any damage arising out ofor inrelation to commissioning,repairsand maintenancecarried out by
unauthorized services,
•Any damage thatmayoccur during transportationorstorageofthe product,
•Not preserving the productinits original packaginguntiltheinstallationstage,
•Incorrectand poorelectrical connections,Failuresdue toincorrect voltage applications,frequent
repetition ofvoltage fluctuations,
•Any damagethat may occur as aresultofincorrect fuel usage or,foreign substancesinthe fuel
used or using ofthe productwithoutanyfuel,
•Any damage that mayoccur dueto foreignparticles entered into theproduct during installation
andoperation,
•Failuresdue toincorrectdeviceselection,
•Any damage tounitduetonatural disasters,
•Deviceswithoutany warranty certificates,
•Warranty Certificateswithoutthe stampand signature oftheauthorizeddealer or service,
•Devices with anyfalsificationonthewarranty certificate or without an originalserial number.
•The risks during transportation ofdevice undertheresponsibilityof customerbelong to the
customer.
•Presenceofmisuse faults areindicated in the reportsissued by authorized servicestations or our
authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

06.06.2017 Rev. 00 6
GENERALCHARACTERISTICS OF CONDENSING BOILER
ECODENSERT-65One,ECODENSE RT-80 One,ECODENSE RT-100 One ,ECODENSE RT-
125 One,ECODENSE RT-150One,ECODENSE RT-65 Twin,ECODENSE RT-80 Twin,ECODENSE
RT-100 Twin,ECODENSE RT-125Twin,ECODENSE RT-150 Twinare heatingdevices operating with
natural gasorLPGwith avery low suctionpower,andequipped with high-duty,premixcondensing
control systemwith micro-processor. The boiler iscomposedofaheat exchangerwith aluminumcooling
fins and asteel premix burnerequipped with ignition and ionization flamecontrol,modulatingfan and
gas valve.ECODENSERT-65 One,ECODENSE RT-80 One ,ECODENSERT-100 One,ECODENSE
RT-125 One,ECODENSE RT-150One,ECODENSERT-65 Twin,ECODENSE RT-80Twin,
ECODENSE RT-100Twin,ECODENSERT-125 Twin,ECODENSE RT-150 Twin aredesignedforuse
asstandaloneaswell ascascade.

06.06.2017 Rev. 00 7
ECODENSERoof Top SeriesCondensingBoilersfor OutdoorInstallation
ECODENSE RoofTop series condensing boilersoffersolution in hot waterproduction forrooftop
outdoor installation inmany applicationssuch as shopping centers,officebuildings,hospitals andhotels.
ECODENSE condensing boilers,when used as CASCADE,meet high-capacity energy requirementswith
line-up operation and alsoexpandthelife-cycleby ensuring equal aging inboilers.
Technical Specifications
•High efficiency withpremix condensing technologyand micro-flamemetal fibercoatedsteel burner,
•Provides energysaving through5:1modulating operation,
•10 different capacity optionbetween 65 kW-300kW inECODENSERT One/Twin series,
•Operation optionwithnaturalgasandLPG,
•Easyhydraulic and gas circuitconnections,
•Whenused as CASCADE,the panelon theboilers allowscontrolling 16 unit control for
ECODENSERTOne and8unitcontrolfor ECODENSERTTwinseries condensingboilers,
•Allows simplecontrol withilluminatedLCDpanel which provideseaseofuse; and error codesand
boiler information canbedisplayed on this panel,
•Daily and weekly operation schedule canbe programmed,
•Seasonal heat programcan be prepared duringsummerand winter times,
•Operation in lower noisevalues,
•Environmentally-friendly withlowerNOx and COemissionrates,
•Easyinstallation, operation and maintenance.
BoilerSafety
•When outdoortemperature goes below +4°C,the boilerautomaticallyprotectsitselfand prevents
fromfreezing.
•The boiler protects itself, whenthetemperature of flue gas exceeds theset valueduring operation,
•The boilerprotectsitself during unexpectedhigh temperatures with combustion space safety
thermostat.
StandartEquipments
•Primer hydraulic circuit circulating pump,
•Inlet andreturn collectorsinsize according toinstalled totalpower,
•Checkvalve ininletline andsafety valve inreturnlineoftheboiler,
•Ball valvesinbothinlet andreturn lines oftheboilers,
•Balance container with residue,dirtand airseparator return collectorsinsizeaccordingto total
installedpower,
•Gasdetector for thegas leakagecontrol,
•Pressuregaugeand ball valve in gasline,
•Thermometer inhydraulic circuits,
•Drain trap for eachboiler,
•Ventilation grills for the air inlet and outlet,
•Eye bolt for easytransport.

06.06.2017 Rev. 00 8
ECODENSERoofTop Series Boiler Components
ECODENSE WT 65 –ECODENSE WT 80
No. Material
1 Venturi 13 Reset
2 Flueoutlet 14 Control card
3 Gasvalve 15 Boiler body
4 Ignitiontransformer 16 Heater circuitreturn
5 Ignitionelectrode 17 Heater circuitsupply
6 Fan 18 Ionizationelectrode
7 Automaticair reliefcock 19 Condensingwater releaseoutlet
8 Water pressuresensor 20 Condensingwater trap
9 Water flowsensor 21 Gasinlet
10 Condensingwater collection tray 22 Burner
11 Control panel 23 Bulls eye
12 Start/Stop

06.06.2017 Rev. 00 9
ECODENSEWT100–ECODENSEWT125-ECODENSEWT150
No. Material
1 Venturi 13 Reset
2 Flueoutlet 14 Control card
3 Gasvalve 15 Boiler body
4 Ignitiontransformer 16 Heater circuitreturn
5 Ignitionelectrode 17 Heater circuitsupply
6 Fan 18 Ionizationelectrode
7 Automaticair reliefcock 19 Condensingwater releaseoutlet
8 Water pressuresensor 20 Condensingwater trap
9 Water flowsensor 21 Gasinlet
10 Condensingwater collection tray 22 Burner
11 Control panel 23 Bulls eye
12 Start/Stop

06.06.2017 Rev. 00 10
CIRCUIT SCHEMES

06.06.2017 Rev. 00 11

06.06.2017 Rev. 00 12

06.06.2017 Rev. 00 13
CLOSEDCIRCUITCOMPONENTS
BalanceTank
Balance Tank (Separator) must bevertical.
Advantages:
ØNohydraulic response occurs between the boilercircuitand the heating circuit.
ØBoilers and heatingzonesoperateundersuitablewater flow.
Sizing ofBalanceTank:
ØIn ordertoensurehealthy operation of thebalancetank, accurate sizing must bemade.
ØThe boiler’s exitwater temperature shouldbemeasured ontheupper partofbalance tank.
ØForthis,a½”muffshouldbe weldedontotank,andalsoanair reliefcock shouldbemounted.
ØDimensions shown in the picture represent minimumdimensionsrequired tobeapplied.

06.06.2017 Rev. 00 14
Sizing Table For ExpansionTank
SYSTEM
CAPACITY
ABHEXPANSION TANK
DIAMETER(D)
INLET &
OUTLET
DIAMETER(Ø)
kw
cm cm cm mm mm
65 33 38 48 100 50
90 38 44 55 125 50
115 42 47 59 125 50
130 47 54 68 150 65
170 54 62 77 150 65
230 59 67 84 200 80
345 72 82 103 200 80
460 83 95 119 250 100
575 93 106 133 250 100
690 102 116 145 300 125
805 110 126 157 300 125
920 118 134 168 350 150
1035 131 150 188 350 150
1150 138 157 197 400 200
1265 144 164 206 400 200
1380 150 171 214 450 200
1495 155 178 222 450 200
1610 162 185 230 450 200
1725 169 192 238 450 200

06.06.2017 Rev. 00 15
Expansion Tank
Expansiontankfore pressuresmust beadjustedaccordingtosystem. Expansion tank shouldbe
placed parallel tocircuitreturnline.
Manometer
Amanometer withcapacity ofatleast0to6barmustbeconnectedto system. Manometer shouldbe
placedto easily visible spot fromfillingpoint, preferably samepoint asexpansion tank.
Strainer
Any dirt or residue in circuit water causesdamagegot boiler and circuit components and decreases
efficiencyby reducing heattransfer. Inorder to prevent thisproblemastrainer mustbe connected to
circuit.
Air Separator
Theair in the waterdissolvesdueto increasing temperatureand flowin the circuit.Dissolvedair causes
cavitation, soundand efficiencyloss.Byusingan airseparator air isremoved fromthe system.

06.06.2017 Rev. 00 16
WATERQUALITY
1. Before connectionof condensing boilers any dirtand residue incircuit mustbecleaned.
2. Refined water mustbe used while addingwater toheating circuit duetoany lossinclosedcircuit.
3. Permittedwater hardnessforwater usedin water circuit must complywith VDI 2035 standard.
The limedissolved in water, settlesonhot surfaces and formsan insulationlayerwhen water
temperature rises.This preventsheattransferand high temperaturemightdamagetheheat
exchanger.If boiler water cycles through watercircuit,all circuit watermust meet above
requirements. If aplateheat exchanger separatesboiler water andheating circuit water,only the
water between boiler and heat exchanger must meet theserequirements.
In ordertoprevent calcification,propertiesofwater incircuitand wateradded mustbe asbelow:
Type Boiler Capacity
TotalWater
Hardness (°F)
Single 50-200 kW <20
Single 200-600 kW <15
Single >600kW <0,2
Cascade All capacities <0,2
*Volumeto capacity ratio of waterin circuit mustbehigherthan 20l/kW.Totalvolumeof first filled
water and additional watermustbelessthan volume of system.
Note: pH value ofunrefinedwater mustbe 7<pH<9.ThispH valuecanbe achievedafter filling the
circuit with main circuit waterwith pHvalue of7and air separation.pHvalueofrefinedwatermustbe
between7-8,5pH.

06.06.2017 Rev. 00 17
TECHNICAL DATA
Capacity Table
TYPE CAPACITY BOILER
NUMBER
GASINLET
PRESSURE
MAXIMUM
OPERATING
PRESSURE
kW - mbar bar
ECODENSERT-65One 65 1 21 6
ECODENSERT-80One 80 1 21 6
ECODENSERT-100 One 100 1 21 6
ECODENSERT-125 One 125 1 21 6
ECODENSERT-150 One 150 1 21 6
ECODENSERT-65Twin 130 2 21 6
ECODENSERT-80Twin 160 2 21 6
ECODENSERT-100 Twin 200 2 21 6
ECODENSERT-125 Twin 250 2 21 6
ECODENSERT-150 Twin 300 2 21 6

06.06.2017 Rev. 00 18
TECHNICAL SPECIFICATIONS Unit WT 65 WT 80 WT 100 WT 125 WT 150
Capacity
Maximum HeatingCapacity kW 65 80,0 100,0 125,0 150,0
MinimumHeatingCapacity kW 20 20,0 25,0 25,0 25,0
Maximum Thermal Output(80°C/ 60°C) kW 63,7 78,4 98,0 122,5 147,0
MinimumThermalOutlput(80°C / 60°C) kW 19,7 19,7 24,6 24,6 24,6
Maximum Thermal Output(50°C/ 30°C) kW 68 84,0 105,0 131,0 157,0
MinimumThermalOutput(50°C / 30°C) kW 21,5 21,5 26,8 26,8 26,8
Efficiency
Pmax. (80°C / 60°C) % 98,0% 98,0% 98,0% 98,0% 98,0%
Pmin. (80°C/ 60°C) % 98,5% 98,5% 98,4% 98,4% 98,4%
Pmax. (50°C / 30°C) % 104,6% 105,0% 105,0% 104,8% 104,7%
Pmin. (50°C / 30°C) % 107,5% 107,5% 107,2% 107,2% 107,2%
%30 (30°C) % 109,0% 109,0% 109,0% 109,0% 109,0%
Usage Water Circuit
Temperature AdjustmentRange with
ExternalStorageTank Usage °C
10-65 10-65 10-65 10-65 10-65
CentralHeatingCircuit
Maximum OperatingTemperature °C 90 90 90 90 90
Water Content Lt 5 5 7 7 9
Max.OperatingPressure bar 6 6 6 6 6
Min.OperatingPressure bar 0,8 0,8 0,8 0,8 0,8
GasSpecifications
GasType G20-G31 G20-G31 G20-G31 G20-G31 G20-G31
GasInlet Pressure (G20) mbar 21 21 21 21 21
GasInlet Pressure (G31) mbar 37 37 37 37 37
Combustion Data
Max.Fume Temperature (80°C / 60°C) °C 65 65 65 65 65
Min.Fume Temperature (80°C/ 60°C) °C 60 60 60 60 60
Max.Fume Temperature (50°C/ 30°C) °C 42 42 43 45 45
Min.Fume Temperature (50°C/ 30°C) °C 32 32 33 35 35
ElectricalSpecifications
Voltage& Frequency V/ Hz 230/50 230/50 230/50 230/50 230/50
Protection Class IP X5D X5D X5D X5D X5D
EnergyConsumption W 100 100 100 200 200
ElectricalFuse Amper 3 3 6 6 6
Hydraulic InstallationSpecifications
GasConnection inch 3/4'' 3/4'' 3/4'' 3/4'' 1''
CentralHeatingCircuit Inlet/Outlet inch 1'' 1'' 1'' 1'' 1''
General Specifications
NetWeight kg 50 50 55 55 64
ChimneyDiameter(Ø) mm 80/125 80/125 80/125 80/125 80/125
Nox Emission Class 5 5 5 5 5
G20 Natural Gas, G31LPG

06.06.2017 Rev. 00 19
CondensingBoilerDimensions
Device mustbe shippedinoriginal packaging!
Cleantheinside offuel line thoroughly beforeinstalling theburnerto thefuelline.Any
damagethat mayoccurdue to solid objects and metal particles fromthe fuel lineshall not be
coveredby ourcompany.
NoiseLevel
When thecondensing boileris in operation,themaximumnoise level releasedis<70 dBA.The
noiselevelvaluecorrespondstothevaluemeasuredwithsemi-anekoik(semi-unreflecting acoustic)room
testingaccording tothe product standards atthe timeofexpansionofthesmokerelease system,when the
condensing boiler operatesat the maximumheating power.