Rendamax R18 Series User manual

TECHNICKÁ DOKUMENTACE
R18
FLOW CLIMA, s. r. o.
Baarova 2, 140 00 Praha 4, Czech Republic
Tel.: [phone]
Fax: [phone]
Hviezdoslavova 55, 627 00 Brno
Tel.: [phone]
Fax: [phone]
[email protected]
www.rendamax.cz
www.flowclima.cz

2
Edition DOC2010, April 2007
2007 Rendamax
All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means,
electronic, mechanical, photocopying, recording or otherwise, without the prior permission in writing of Rendamax B.V.
We aim to achieve continuous improvement in our products. Therefore, specifications are subject to change without prior notice.
Due to changes the product can deviate from the information specified in this document. Therefore Rendamax B.V. rejects any
responsibility for the differences between the product delivered and the information mentioned in this document.
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Index
R18Technicaldata 5
Dimensions 6
1Introduction 7
1.1 Rendamax 7
1.2 Supplier 7
1.3 This manual 7
1.4 Service 7
1.5 General restrictions 8
2Description 8
2.1 General information 8
2.2 Main components 9
2.3 Principle of regulation 13
2.3.1EMControl 13
2.3.2 EW Control option 14
2.4 Boiler protection 17
3Safety 17
4 Delivery and transport 19
4.1 Delivery 19
4.2 Unit protective packaging 19
4.3 Transport 19
5Installation 20
5.1 Boilerroom 20
5.1.1Siting 20
5.1.2 Boiler room ventilation 20
5.2 Unit connections 20
5.2.1Gassupply 20
5.2.2Electricalsupply 21
5.2.3 Hydraulic connections 21
5.2.4 Boiler room ventilation 22
5.2.5 Air supply and ventilation 22
5.2.6Flues 23
5.3 Waterquality 24
5.4 Hydraulicsystem 25
5.4.1 Flow and resistance 25
5.4.2 Examples hydraulic system 27
6Commissioning 31
6.1 General 31
6.2 Pre-lighting checks and dry run 31
6.2.1Check1 31
6.2.2Check2 31
6.2.3Check3 33
6.3 Liveruncheck 34
6.4 Instructions to user 35

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7 Operation and fault indication 36
7.1 Function 36
7.2 Regulation 36
7.3 Control panel 36
7.4 Fault indications 37
7.5 Start-up 38
7.6 Shut-down 38
7.7 Warnings 38
8Maintenance 41
8.1 Safety 41
8.2 General information 41
8.3 Inspection 41
8.4 Cleaning 42
8.5 Servicing 43
8.6 Component replacement 45
8.7 Service 48
Notes 49

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R18 Technical data
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Type 132 154 180 210 244 280
Nominal heat output
Nominal heat input (nett. CV)
kW
kW
481
538
558
625
649
727
756
846
875
980
1002
1122
Gas consumption
natural gas H (10,9 kWh/m3)
propane
m3/h
m3/h
49,3
19,0
57,9
22,1
67,4
25,7
78,4
29,9
90,8
34,7
104,0
39,7
Gas inlet pressure (min.)
(max.)
propane (max.)
mbar
mbar
mbar
17
25
50
17
25
50
17
25
50
17
25
50
17
25
50
17
25
50
Water volume
Max. working pressure
dm3
bar
22,0
6
23,2
6
24,6
6
26,3
6
28,1
6
30,1
6
Flue connection D mm 450 500 550 600 650 700
Gas connection G 2" 2" 2" 2" DN65
PN16
DN65
PN16
Water connections W DN80
PN16
DN80
PN16
DN80
PN16
DN80
PN16
DN80
PN16
DN80
PN16
Pressure relief valve connection
relief connection
standard setting bar
1¼"
1½"
3
1¼"
1½"
3
1¼"
1½"
3
1½"
2"
3
1½"
2"
3
1½"
2"
3
Electrical supply
Frequency
Fuse
V
Hz
A
230
50
6
230
50
6
230
50
6
230
50
6
230
50
6
230
50
6
Max. electrical consumption kW 0,35 0,35 0,35 0,35 0,35 0,35
Dimensions B
H
L
mm
mm
mm
1430
1795
1461
1430
1795
1636
1430
1795
1842
1430
1795
2080
1400
1895
2350
1400
1895
2636
Weight, empty, ± 5 % kg 620 660 705 760 820 885
Table 1 Technical Data
- Heat output measured with: 60 - 80°C
- Gas consumption at: 1013 mbar, 15°C, dry
- Gas specification: 22H3P
- Appliance category: B11
- Protection degree: IP30
Changes in specifications and dimensions
The manufacturer reserves the right to change the above mentioned dimensions without prior notice.
Because of manufacturing tolerances, the above mentioned dimensions can vary slightly.

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Dimensions
Drain and fill ½“
Safety valve
Water flow switch
Flow Return
STANDARD ALTERNATIVE
The R18 unit is also available
as a left -handed model.
* Denotes minimum clearance for maintenance
Fig. 1 Dimensions

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1 Introduction
1.1 Rendamax
Since its beginning in 1968, Rendamax has built up a strong reputation in industry for the
development, production and marketing of gas-fired, high efficiency boilers in the 60 to 1200 kW
range.
Through their unique construction, these central heating units are renowned for their:
- high thermal efficiency
- environmental friendliness
- light weight and small dimensions
- durability
- low noise production
- large regulating range
- available with many different options
Continual research and development means that Rendamax remains at the forefront of boiler
and water heater technology.
1.2 Supplier
Rendamax boilers are sold by your supplier (see cover).
For advice or more information with regard to our products contact your supplier.
1.3 This manual
This documentation has been produced to aid the following target groups:
- the consulting engineer
- the heating installer
- the service engineer
- the user
Because these target groups require mostly similar information and also specific information, our
technical documentation has been integrated to provide these target groups with the necessary
general and specific information to install, service and operate this product.
The supplier (see cover) will be able to provide any further or supplemental information.
The following aspects will be explained:
- general description
- technical specifications
- necessary services for system design and unit installation
- example systems
- maintenance instructions
Operating instructions for the user can be found on the unit. See also chapter 7.
1.4 Service
The supplier’s service department is always available for commissioning and for providing service and
maintenance. For details see cover.

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1.5 General restrictions
The application, installation and maintenance of Rendamax products must always be carried out in accordance
with the requirements (legal or otherwise), specifications and standards applicable to such installations.
All data, information and suggestions provided by Rendamax B.V. in relation to its products are based on careful
investigation. Nevertheless, neither Rendamax B.V. nor any other organisation connected with Rendamax B.V.
accepts any liability for application, installation or exploitation that occurs outside its sphere of influence.
Changes may be incorporated without prior notice.
Rendamax accepts no obligation to adapt previously delivered products to incorporate such changes.
2 Description
2.1 General information
The R18 series boilers are atmospheric open flued, low thermal capacity gas-fired boilers. These high efficiency
boilers are designed to provide heating and hot water services for a wide variety of industrial and commercial
premises.
The R18 series of boilers are available in 6 types:
132, 154, 180, 210, 244 and 280.
The type number indicate the number of burner bars present in the burner assembly.
The load at nett calorific value is approximately 3,5 kW per burner.
All boiler types are fitted with an 18-tube heat exchanger of the 2 pass type.
The use of extruded copper fin pipes in the heat exchanger leads to higher efficiency.
Thermal radiation losses are minimised by the optimal construction of the combustion chamber in
which high-grade insulation is integrated.
The advanced construction of the R18 enables swift assembly and dismantle, which simplifies
maintenance and inspection.
All boilers have full sequence automatic control with overheat cut off, water flow switch, modulating turn
down on gas and combustion air (for improved efficiency at varying heat loads) and fault indicators.
The R18 has a PID temperatur regulator and electronic protection and ignition system indicator by the letters EM.
Appliance category B11.
The R18 series have CE approval for all relevant European countries. The series are registered
under the Product Identification Number 0063AQ6600.

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2.2 Main components
Fig. 2 View of the R18 series
1 Flue outlet socket
3 Draught diverter
6 Cover for electrical connection tray
7 Connection tray
11 Servomotor (air damper/gas input)
13 Modulating gas valve
15 Modulating air damper
19 Safety valve
20 Water fl ow switch
21 Pressure gauge/thermostat
22 Flow temperature sensor
23 Pilot governor
24 Gas governor
25 Main gas valve
26 Solenoid valve for pilot burner
27 Pressure test points
28 Temperature control unit
29 Safety system control box
30 Control panel
33 Gas connection
34 Water connections
35 Air deflector
36 Fill/drain cock
37 High limit thermostat

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1 Flue outlet socket
2 Deflector
3 Draught diverter
4 Air in-take
5 Heat exchanger
6 Connection tray
7 Combustion chamber
8 Sight glas
9 Burner assembly
10 Modulating gas valve
11 Servo motor
12 Front adjusment strew forc air damper
13 Linkage assembly
14 Adjusment screw
15 Lock screw for air damper
16 Rear adjustment screw for air damper
17 Modulating air damper
18 Air deflector
Fig. 3 Cross-section of the R18 series

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Draught diverter
The R18 is fitted with a draught diverter. It is possible to connect the flue outlet connection
on the top cover to a standard flue pipe.
The inside of the draught diverter is made of aluminium.
The galvanized plate mantle is easily removed.
Fig. 4 Draught diverter
Combustion chamber
The chassis consists of two side frames with steel supports. Dura blanket type thermal insulation is sandwiched
between the vermiculite refractory blocks and front, rear and side panels of the combustion chamber housing.
These vermiculite refractory blocks are mounted so as to allow freedom of expansion.
The refractory blocks backed with the Dura blanket insulation, form the combustion chamber.
Fig. 5 Combustion chamber

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Heat exchanger
The heat exchanger (type 2-pass) is mounted on the chassis. To ensure proper heat transfer of the combustion
gases, the copper fin tubes are arranged side by side and expanded laterally into a mounting plate.
The baffles on the copper fin tubes optimize the efficiency of the heat exchanger.
The supply and return pipes, together with the water manifolds, form the heat exchanger.
Burner
The burner is mounted under the combustion chamber in the chassis.
The burner bars, mounted in the burner trolley are manufactured from stainless steel.
Each burner bar is supplied by its own injector nozzle mounted on the gas manifold.
Fig. 7 Burner
Fig. 6 Heat Exchanger

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Combustion air damper
A combustion air damper is situated underneath the burners.
Fig. 8 Combustion air damper
Gas train
The principal components of the gas train are main governor and two main gas valves or combined main
governor and main gas valve. The quantity of gas is adjusted in proportion of the quantity of air being
supplied by the air damper opening. The pilot flame has a separate pilot line with pilot governor and gas
valve.
2.3 Principle of regulation
The flow temperature can be constant or weather compensated. Several boilers can be connected by using
cascade switching. With the EM Control option you can reduce electricity consumption, both boiler and boiler
primary pump can be switched off by the cascade control box.
2.3.1 EM Control Electronic Modulating version
This type of boiler control regulation (indicated by the EM control option) uses a built-in PID regulator to
maintain a constant flow temperature to within a minimum temperature deviation of +1 to -1 K.
This system allows the user to fine-tune the reaction of the boiler to the heating system or application
process. An added bonus with this “EM" control system is that it allows a Building Management system
to influence the flow temperature using a 0 - 10 VDC control signal. For electrical terminal functions
see par. 5.2.2

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Boiler temperature controller RWF40
A Process value (actual temperature)
B Set point (temperature)
C Burner enable (not applicable)
D Mod. indicator (decrease fire rate)
E Mod. indicator (increase fire rate)
F Two-stage firing (not applicable)
G Limit comparator
H Manual operation
The keys K-L-M-N are used for displaying
values and changing parameters in the
temperature controllers confi guration.
K Down key (reduce value)
L Up key (increase value)
M Programme key
N Exit key
Assignment of levels
All levels can be accessed from the basic
display via the «PGM» button, as shown in the diagram.
The upper actual value display (red) indicates the actual
value and the parameter values for the various levels.
The setpoint and the parameters are indicated in the lower
setpoint display (green).
1. After using «PGM» to step through all the parameters
of a level, an automatic return occurs after the last
parameter has been confirmed.
2.3.2 EW Control option
Electronic Modulating version with weather compensation and night-time temperature reduction
This system (indicated by the EW control option) uses the above mentioned PID regulator to regulate the
boiler. The “EW” control system maintains the advantages of the “EM” type boiler and adds to it the
possibility of automatically changing the flow temperature according to the outside temperature and the
required heating curve. The unit’s built-in week-clock also means that a night-time and weekend
temperature reduction is possible with a “EW” control system.
Weather-compensated setpoint shift
The RWF40 can be configured in such a way that, if a Ni1000 outside sensor (e.g. QAC22) is connected,
a weather-cmompensated setpoint shift is implemented. The minimum and maximum setpoint values can
be set by the lower setpoint limit SPL and the upper setpoint limit SPH. Parameter P can be used to
apply a parallel displacement to the heating curve.
Each RWF40 must have its own separate outside sensor connected (no parallel connection)!
BASIC DISPLAY
USER
LEVEL
PARAMETER LEVEL
CONFIGURATION
LEVEL
or time-out (approx. 30 s)

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HYS1 is the switch-on point for the burner, and HYS3 is the switch-off point.
As already described, they act with the set shift relative to the weather-controlled setpoint.
Fig. 9 Parallel displacement of the heating curve
Heating curve slope
Slope H of the heating curve can be used to adjust the set- point in response to the outside temperature, as shown
in the diagram. The common origin of the heating curves is set at (20°C/20°C). The effective range of the weather-
adjusted setpoint is restricted by the setpoint limits SPH and SPL.
Fig. 10 Heating curve slope
Boiler temperature setpoint (°C)
Outside temperature (°C)
Heating curve slope
Setpoint (°C)
H larger
H smaller
Outside temperature (°C)

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Process data
Parameter Display Value range Factory setting
Setpoint 1 1SP1 SPL-SPH 80
Setpoint 2 (option) 1SP2 SPL-SPH 0
Digital setpoint shift (option) 1dSP SPL-SPH 0
Outside temperature (option) 1tA C111 Inputs -
Predefinition of external setpoint 1SP.E SPL-SPH -
Parameter level
Parameter Display Value range Factory setting
Limit value of limit comparator 1AL -1999…+9999 digit 6
Switching differential for limit comparator 1HYSt 0…999.9 digit 1,5
Proportional band 1Pb.1 0.1…999.9 digit 10
Derivative time dt 0…9999 s40
Integral action time rt 0…9999 s30
Contact spacing 1db 0.0…999.9 digit 1
Actuator running time tt 10…3000 s15 s
Switch-on threshold burner/stage II 1H Y S 1 0.0…-199.9 digit -3
Switch-off level stage II 1H Y S 2 0.0… HYS3 digit 3
Upper switch-off threshold 1H Y S 3 0.0…999.9 digit 3
Response threshold q0.0…999.9 0
Heating curve slope H0.0…4.0 2
Parallel displacement 1P-90…+90 0
Configuration level
Parameter Display Factory setting
Analog input 1, 2 and 3; setpoint changeover / shift C111 9930
Limit comparator; controller type; setpoint 1; locking C112 5010
Unit address; decimal place / unit signal for out-of-range C113 0110
Measurement range start analog input 1 1SCL 0
Measurement range analog input 1 1SCH 100
Measurement range analog input 2 1SCL2 0
Measurement range analog input 2 1SCH2 100
Lower setpoint limit 1SPL 44
Upper setpoint limit 1SPH 90
Actual value correction, analog input 1 1OFF1 0
Actual value correction, analog input 2 1OFF2 0
Actual value correction, analog input 3 1OFF3 0
Filter time constant for digital filter, analog input 1dF1 1
1) These parameters are affected by the setting for the decimal place. With the above factory settings K6 contact
can be used as a limit thermostat. Weather compensation and Q64-Q63 have been activated, but not wired in.

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2.4 Boiler protection
The R18 is protected by the following systems:
Water flow switch
The water flow switch is installed in the flow manifold and monitors continuously the water flow.
As soon as the water flow stops, the burner is shut down and goes to lock-out.
The water flow switch is factory set and should only be adjusted authorized personnel.
High limit thermostat
In the event of failure of the control thermostat, a preset high limit thermostat will shut down the burner
and go to lock-out.
Pressure relief valve
The maximum operating pressure of the R18 boiler is 11 bar. The standard safety valve supplied is set to 3 bar.
If a different pressure setting is required this should be specified and will be set at the factory.
Gas burner control
The burner control unit provide control and supervision of the atmospheric burner.
The sequence controller is coupled to the spindle of the control circuit and to the flame supervision unit
displaying the status, the symbol appearing above the reading mark indicates the firing sequence or lock-out
condition. The pilot flame is supervised by ionisation current detection.
3 Safety
Installation requirements
Please read these requirements before commencing installation.
The product has to be installed by a recognized installer fully according to the current national and local
demands, norms and standards. The installation procedure should only be used for heating systems with a
maximum water temperature of 95°C. We emphasize that you should always give priority to the above
mentioned standards and regulations and that the installation regulations should be considered as an addition
to these standards and regulations.
Explanation of the icons used in this manual
Instruction of extreme importance in order to guarantee proper functioning of the boiler.
ENot following the operation procedures can cause serious damage to the boiler, personal injuries
or environmental pollution.
Electric shock hazard.
Useful information.

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Maintenance
Work on the electrical installation should only be carried out by approved technicians and in accordance
with the electro technic regulations.
Work on the gas and hydraulic systems should only be carried out by approved technicians and in
accordance with the safety regulations for gas installations.
Keep unauthorized people away from the installation. Do not place any objects on the boiler. Keep
away from the hot water connections in order to prevent burns.
Always disconnect the boiler from the electric mains and close the gas service cock in the gas supply
pipe before commencing maintenance and servicing operations.
Check the system for leaks afterwards.
In addition to the information in this documentation, always follow the standard safety regula-
tions to prevent accidents.
Cover panels should only be removed for maintenance and servicing tasks. Replace all panels
after completing these maintenance and servicing tasks.
Safety precautions
The installation should never be switched on with panels removed or when boiler protection
devices are not operational.
Instruction and warning stickers
Never remove or cover any of the instruction and warning stickers. They should always be legible
throughout the life span of the boiler.
Immediately replace any damaged or illegible stickers.
Modification
Modification of the installation should only be carried out after obtaining prior written permission from
the manufacturer.
Danger of explosion
Follow the health and safety regulations for working in hazardous areas when working in the boiler room.
Installation
The boiler should be installed by a recognized installer in accordance with current regulations and
the regulations of the local electric companies. Make sure that you follow all safety instructions properly.
Operation
In case of gas leakage, switch off the boiler and close the gas service cock. Open doors and windows,
and notify the proper authorities. Follow the instructions in the manual when you use the boiler again.
Technical specifications
Do not exceed the specifications as layed down in the installation and maintenance instructions.
E
E

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4 Delivery and transport
4.1 Delivery
Before delivery, the R18 boiler is fully assembled and tested in the factory. The R18 is protecd by a
wooden band and covered in a “heat-shrink” protective wrapper.
Check for damage after removing the boiler’s protective covering.
Check whether the boiler conforms to the order requirements.
Check whether the circuit diagram and gas-train diagram number is in accordance with the offer,
order confirmation and the data on the boiler’s data number plate.
4.2 Unit protective packaging
For transportation the R18 boiler is protected by a wooden band and covered in a “heat-shrink”
protective covering. The panel-work is also covered in a protective polyethylene layer.
Before final installation in the boiler room the boiler must be removed from the pallet and all
protective coverings removed.
The protective coverings should be disposed of in a environmentally friendly way.
Contact your local authority.
4.3 Transport
Refer to the technical specifications on weight and dimensions when transporting the boiler.
WARNING:
- Incorrect moving or lifting of the boiler may cause damage
- Remove the protective covering after transport and installation in the boiler room.
Pallet cart and/or forklift truck
When moving the boiler with a pallet cart or forklift truck, the forks should be placed at a back
of the boiler
E
Fig. 11 Moving

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Using a crane
- Never swing the load over bystanders.
- Always use special lifting harnesses which should be placed on the boiler.
- Make sure that during lifting the harness does not damage the draught diverter.
E
5 Installation
5.1 Boiler room
Installation of the R18 should only be carried out by a recognized installer in accordance with the current
national and local demands, norms and standards.
5.1.1 Siting
Install the boiler as close to the chimney as possible. A plinth base is not required.
To maintain ease of access and therefore ease of maintenance refer to clearances in figure 1.
If these dimensions are not met, maintenance operations could be seriously inhibited.
5.1.2 Boiler room ventilation
The product has to be installed by a recognized installer fully according to the current national
and local demands, norms and standards.
5.2 Unit connections
5.2.1 Gas supply
The product has to be installed by a recognized installer fully according to the current national
and local demands, norms and standards (see supplement).
Gas connection can be found at the side of the boiler.
We recommend the use of a gas filter.
The main gas service cock and gas filter should be supplied by a qualified heating engineer.
Install the main gas service cock and the gas filter as close to the boiler as possible.
The R18 series of boilers are suitable for connection to a 25 mbar gas network.
E
Fig. 12 Lifting