Rendamax R3400 Guide

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Technical documentation
R3400 R3500 R3600
Doc890/3456CV02B

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Edition 3456CV02B, 03-02-2003
©2003 Rendamax B.V.
All rights reser ed.
No part of this publication may be reproduced, stored in aretrie al system, or transmitted in any form or by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior permission in writing of Rendamax B.V..
We aim to achie e continuous impro ement in our products. Therefore, specifi cations are subject to change without prior notice.
Doc890/3456CV02B

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Doc890/3456CV02B
Contents
R3400 Technical data 1
Dimensions R3400 2
R3500 Technical data 4
Dimensions R3500 5
R3600 Technical data 7
Dimensions R3600 8
1 Introduction 11
1.1 Rendamax
1.2 Supplier
1.3 This document
1.4 Serice
1.5 General restrictions 12
2 Description
2.1 General
2.2 Main components 14
2.2.1 Description of principal components 15
2.3 Boiler control 16
2.4 Safety aspects
3 Saety 17
4 Delivery and transport 18
4.1 Deliery
4.2 Packaging
4.3 Transport
5 Installation 24
5.1 Regulations
5.2 Boiler room
5.2.1 General
5.2.2 Set up
5.2.3 Ventilation 25
5.3 Connections
5.3.1 Gas connection
5.3.2 Electrical connection 26
5.3.3 Water connections 29
5.3.4 Combustion air supply 30
5.3.4.1 General
5.3.4.2 Air supply pipe
5.3.5 The Flue system 32
5.3.5.1 General
5.3.5.2 Chimney 33
5.3.6 Condensate discharge 36
5.4 Hydraulic system 37
5.4.1 General
5.4.2 Water fl ow

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5.4.2.1 Flow rate and resistance 37
5.4.2.2 Pump characteristics 39
5.4.2.3 Isolating al es 40
5.4.2.4 Val es
5.4.2.5 Water fl ow protection
5.4.3 Water pressure
5.4.3.1 Operating pressure
5.4.3.2 Boiler expansion tank
5.4.3.3 System expansion tank
5.4.3.4 Water pressure protection
5.4.4 Water temperature 41
5.4.5 Water quality
5.4.6 Examples of hydraulic systems 42
6 Operating instructions 45
6.1 Function
6.2 Regulation
6.3 Control module
6.4 Fault indications 47
6.5 Start-up 48
6.6 Shut-down
6.7 Warnings
7 Commissioning
7.1 General
7.2 Commissioning
8 Maintenance 50
8.1 Safety
8.2 General
8.3 Procedure 51
8.4 Cleaning the burner and heat exchangers
8.5 Cleaning the fi lter/screen in the gas combination block 52
8.6 Ionisation measurement
8.7 Serice
9 Conversion ormulae and actors

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R3400 Technical data
Type R3401 R3402 R3403 R3404 R3405 R3406
Nominal heat output
Nominal heat input (nett. CV)
Minimum heat input
kW
kW
kW
657
702
176
729
784
196
853
917
229
965
1038
260
1078
1159
290
1189
1279
320
Pilot burner kW 36 36 36 36 36 36
Gas consumption
natural gas H (10.9 kWh/m3)
propane (12.8 kWh/kg)
m3/h
kg/h
64.5
54.9
71.9
61.2
84.1
71.6
95.2
81.1
106.3
90.5
117.3
99.9
Gas inlet pressure
natural gas (min.)
natural gas (max.)
natural gas (max.) option
mbar
mbar
mbar
18
25
100
18
25
100
35
100
-
35
100
-
35
100
-
35
100
-
Water capacity
Max. working pressure
dm3
bar
50
6
53
6
70
6
75
6
80
6
85
6
Gas connection G Rp2" Rp2" Rp2" Rp2" DN65
PN6
DN65
PN6
Water connections W DN65
PN6
DN65
PN6
DN80
PN6
DN80
PN6
DN80
PN6
DN80
PN6
Flue connection D mm 300 350 350 400 400 400
Safety al e connection
relief connection
standard setting
11⁄4"
11⁄2"
3
11⁄4"
11⁄2"
3
11⁄2"
2"
3
11⁄2"
2"
3
11⁄2"
2"
3
2"
21⁄2"
3
Power supply
Frequency
Fuse
V
Hz
A
400 3N~
50
16
400 3N~
50
16
400 3N~
50
20
400 3N~
50
20
400 3N~
50
20
400 3N~
50
20
Max. electrical power
consumption unit
pump maximum
total
kW
kW
kW
0.90
1.15
2.05
0.90
1.15
2.05
1.27
1.15
2.42
1.27
1.50
2.77
1.27
1.50
2.77
1.27
1.50
2.77
Boiler weight, empty, ± 5 % kg 675 740 840 950 1070 1200
Dimensions height H
width B
length incl. connections L
mm
mm
mm
1355
1330
2265
1355
1330
2265
1355
1130
2653
1355
1130
2653
1355
1330
2658
1355
1330
2658
Table 1 Technical data R3400

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Dimensions R3400
Clearances
- 450 mm at one side
- 800 mm at the other side
- 450 mm at the rear
- 1000 mm at the front
Fig. 1 Dimensional sketch R3400
front view plan view
rear view
ide view

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Type R3401 R3402 R3403 R3404 R3405 R3406
B mm 1330 1330 1130 1130 1330 1330
B1 mm 1160 1210 1003 1053 1203 1253
B2 mm 665 665 565 565 665 665
B3 mm 170 120 127 77 127 77
B4 mm 1146 1146 946 946 1146 1146
B5 mm 115 65 115 65 115 65
D mm 300 300 350 350 400 400
G Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6
H mm 1355 1355 1355 1355 1355 1355
H1 mm 1125 1125 1570 1420 1155 1462
L mm 2265 2265 2653 2653 2658 2658
L1 mm 595 595 610 615 615 770
L2 700 700 1166 1166 1166 1166
L3 mm10810888888888
W DN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Table 2 Dimensions R3400
(Changes may be introduced without notice)
As a result of manufacturing tolerances, there may be small ariations in the dimensions.
Conditions applicable to table 1:
- Nominal capacity measured at: 60 - 80°C.
- Gas consumption at: 1013 mbar, 15°C, dry
- Gas category: 2
2H3P
- Appliance category: B23, C53, C33 of C63
- Protection degree: IP20

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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 de el-
opment, production and marketing of gas-fi red, high effi ciency boilers in the 60 to 1200 kW range.
Through their unique construction, these central heating units are renowned for their:
- high thermal effi ciency
- en ironmental friendliness
- light weight and small dimensions
- durability
- low noise production
- large regulating range
- a ailable with many different options.
Continual research and de elopment means that Rendamax remains at the forefront of boiler and
water heater technology.
1.2 Supplier
Rendamax boilers are sold by your supplier (see co er).
For ad ice or more information with regard to our products contact your supplier.
1.3 This document
This documentation has been to aid the following target
groups:
- the consulting engineer
- the heating installer
- the ser ice engineer
- the user
Because these target groups require mostly similar information and also specifi c information, our
technical documentation has been integrated to pro ide these target groups with the neces sary
general and specifi c information to install, ser ice and operate this product.
The supplier (see co er) will be able to pro ide any further or supplemental information.
The following aspects of the units are dealt with:
- General description
- Technical specifi cations
- The facilities necessary for design and installation
- Installation examples
- Maintenance instructions
The operating instructions needed by the user are attached to the unit; these are also to be found
in Section 6.
1.4 Service
The supplier’s ser ice department is always a ailable for commissioning and for pro iding ser ice
and maintenance. For details see co er.

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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), specifi cations and standards applicable
to such installations.
All data, information and suggestions pro ided by Rendamax B.V. in relation to its products are
based on careful in estigation. Ne ertheless, 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 infl uence.
Change may be incorporated without prior notice.
Rendamax accept no obligation to adapt previou ly deliv ered product to incorporate uch
change .
2 Description
2.1 General
The R3400/R3500/R3600 series are en ironmentally friendly modulat ing gas fi red heating boilers
that can ary its output from 25% to 100% of its maximum capacity. The series R3400 consists of
6 types in a range from 657 to 1189 kW.
The series R3500 consists of 5 types in a range from 613 to 1000 kW. The series R3600 consists of
5 types in a range from 631 to 1031 kW.
The units ha e an extremely low emission of NOx and CO, so that this boiler satisfi es the most
stringent European require ments.
The R3400/R3500/R3600 series ha e CE appro al for the following countries:
Austria, Belgium, Denmark, France, Germany, Ireland, Italy, The Netherlands, Spain and the
United Kingdom.
The series is registered under the product identifi cation number 0063AR3514.
The units can be supplied either as a standard (category B23) or a room sealed (categories C53,
C33 or C63) appliance.
Working principle and con truction
Air is blown into the appliance, as required, by a speed-con trolled fan and thoroughly mixed with
gas in the correct propor tions.
A temperature controller compares the desired water tempera ture with the temperature of the
water fl ow and sends a signal to the frequency con erter to maintain the correct heating capacity.
The gas/air mixture so formed is passed through a cooled premix burner and ignited. The premix
burner is constructed of fi nned bimetallic pipes (internally from stainless steel and externally
from aluminium) with cast iron water headers.
Heat transfer takes place in two or three heat exchangers. The fi rst heat exchanger is constructed
from smooth stainless steel pipes, while the second heat exchanger is fi tted with laser welded,
stainless steel fi nned pipes. Both heat exchangers are fi tted with cast iron profi led water distribu-
tion components (headers) which guarantee an optimum water fl ow through the appliance.
The burner and the heat exchangers are connected in series.
At the R3600 a third heat exchanger is attached wich consists of one or more stainless steel fi n
tube(s), switched in series, in form of a spiral. It is arranged on the back of the boiler on the fl ue
gas collection chamber.

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The boiler pump ensures the water fl ow quantity. The third heat exchanger is switched parallel to
the boiler and has a fl ow of 5 - 10 % of the entire water fl ow.
The R3400/R3500/R3600 units ha e a small water capacity so that it can rapidly adjust to chang-
ing conditions. It can be in stalled without any restrictions to the return water temperature. The
necessary water fl ow rate is ensured by the standard pump deli ered with the appliance.
Application po ibilitie
Because of its construction, the R3400/R3500/R3600 units are suitable for use in heating sys-
tems:
- With a constant supply temperature
- With a weather dependent heating demand
- With low temperature condenser systems
- With optimised condensation
- With control by means of building optimiser/compensator system (0-10 Vdc, see 5.3.2 connec-
tion terminals).
Fig. 4 The Econofl ame R3600
* The R3400 and R3500 are identical with the exception of the third heat exchanger.

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2.2 Main components
1 Return connection 18 Condensate collection tank
2 Flue gas discharge R3600 or 19 Flue gas collection chamber
Flue attenuator 20 Combustion chamber
3 Water fl ow switch 21 Electrical cable duct
4 Safety al e 22 Condensate discharge
5 Flow connection 23 Gas al e unit
6 Filling/drainage al e 24 Fan
7 Co er 25 Connection box
8 Distribution plate 26 Control panel
9 Burner 27 Casing
10 First heat exchanger 28 Air inlet damper
11 Gas fi lter 29 Main mixing chamber
12 Second heat exchanger 30 Pilot gas al e
13 Gas train 31 Pilot mixing chamber
14 Frame 32 Boiler pump
15 Water circulation piping A Air
16 Flue gas discharge B Gas
17 Third heat exchanger R3600 C Flue gas
D Condensate
Fig. 5 General sur ey

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Doc890/3456CV02B 15
2.2.1 Description o principal components
The unit is constructed from the following principal compo nents:
Fan [24]
This consists of a fan casing, a fan impeller and an electric motor. The fan sucks in combustion air
and increases the air pressure.
Air inlet damper [28]
A specially de eloped air inlet damper ensures a low noise le el. As an option, this can be pro id-
ed with an air fi lter or with an air inlet opening so that the appliance can function as a room sealed
appliance.
Ga train [13]
The principal component of the gas train is the main gas
al e/proportional pressure regulator [23]. The quantity of gas is adjusted in proportion to the
quantity of air being supplied. The quantity of air depends on the speed of the fan. The unit is fi t-
ted with a gas fi lter [11] as standard.
Mixing chamber [29 + 31]
This area is used for the thorough mixing of the gas and the combustion air. The unit is supplied
with a main mixing cham ber [29] and a pilot mixing chamber [31]. Both are connected to the fan.
Burner [9]
After the gas/air mixture has been distributed o er the burner with the aid of a distribution plate
[8], the mixture is burned on the surface of the burner in such a way that the fl ame is di rected
downward. The burner is air and water cooled. The water distribution components are made from
cast iron and ha e a profi le that ensures that an optimum distribution and fl ow are obtained.
Heat exchanger [10, 12 and 17]
The primary heat exchanger [10] is constructed from smooth stainless steel tubes. These transfer
most of the heat energy to the system water. The secondary heat exchanger [12], which consists
of laser welded stainless steel fi nned tubes, transfers the remaining heat from the fl ue gasses to
the system water. All the water distribution components are constructed from cast iron and ha e
a profi le that ensures that optimum distribution and fl ow are obtained. The space between the
burner and the secondary heat exchanger forms the combustion chamber.
At the R3600 a third heat exchanger [17] is attached wich consists of one or more stainless steel
fi n tube(s), switched in series, in form of a spiral. It is arranged on the back of the boiler on the
fl ue gas collection chamber.
The boiler pump ensures the water fl ow quantity. The third heat exchanger is switched parallel to
the boiler and has a fl ow of 5 - 10 % of the entire water fl ow.
Water circulation pipe [15]
These pipes connect the burner to the heat exchangers.
Water connection
These consist of a fl ow connection [5] and a return connection [1]. Both of these connections are
pro ided with a fi lling/drain al e [6]. The fl ow connection is also pro ided with a safety al e [4],
a fl ow switch [3] and a temperature sensor.
Boiler pump [32]
The boiler pump is mounted on the return connection to the unit and is directly connected electri-
cally to the appropriate termi nals in the connection box. The capacity and the working head of the
pump is suffi cient to o ercome both the resistance of the boiler and some system resistance.
Flue ga collection chamber [19]
The stainless steel fl ue gas collection chamber is mounted under the heat exchanger. This cham-
ber is pro ided with a fl ue gas exhaust connection [16], a condensate drain connection [22] and an
inspection opening.

Frame [14]
The frame is constructed from steel profi le sections. Vibration absorption dampers are supplied
separately and must be fi tted after the unit has been placed in position.
The ca ing [27]
The casing consists of panels that can be remo ed easily without the aid of tools.
The electrical ection
This includes the control and safety circuits for the unit.
Connection box [25]
The electrical power supply for the boiler, the terminals, the pump connections and the pump
relay are mounted in an easily accessible connection box. The supply cables can easily be fed to
the connection box ia the cable duct inside the boiler [21].
2.3 Boiler control
The principle employed for the Boiler Management Unit is as follows: The boiler begins operating
on receipt of a heating demand. This heating demand is generated either:
A. If the measured supply temperature is lower than the desired temperature.
B. As a result of “manual operation” mode ha ing been se lected (W1 or W2 ),
C. in standby mode, when the water temperature falls below the frost protection temperature.
After the unit has started up, the PID controller sends a signal to the frequency con erter. This
con erter controls the speed of the fan. Depending on the quantity of air mo ed by the fan, the
proportional pressure regulator ensures that the corresponding quantity of gas is added.
In this way the boiler capacity is continually adjusted and the boiler can accurately follow the
heating demand. If the boiler is operating at minimum capacity and the temperature of the supply
water rises abo e the desired alue, the unit will be shut down. As soon as the temperature of the
supply water falls below the set alue, the boiler will be re-started.
2.4 Sa ety aspects
The unit contains the following safety components:
- Flame protection on pilot and main burner (1x re-start)
- Water fl ow protection
- Maximum water temperature protection
- Gas al e test
- Fan protection
- Boiler pump motor o er-heating protection.
If one of these components operates, this results in a lockout fault. Lockout faults can only be
cancelled by resetting the unit.
The unit is fi tted with a safety al e that opens at 3 bar.

3 Saety
Installation instructions
Read through these instructions carefully before starting the installation.
The appliance must be installed by a recognised installer in accordance with the applicable na-
tional and local regulations (see Supplement).
The installation may only be used for heating systems up to a maximum water temperature of
90°C.
It is expressly stated that these installation instructions must be seen as a supplement to the
abo e mentioned standards and regulations and that these standards and regulations must take
precedence o er any information included in this technical manual.
Pictograms used in this manual
y An instruction that is essential for the correct functioning of the installation.
w If these operations, procedures, etc., are not accurately fol lowed this can result in serious damage
to the installation, personal injury or en ironmental damage.
v Danger of electric shock.
x Useful information.
Maintenance
Work on the electrical installation may only be carried out by an authorised installer in accordance
with the applicable electrical regulations.
Work on the gas and hydraulic installations may only be under taken by properly trained person-
nel in accordance with the safety regulations for gas installations.
w Keep unauthorised persons away from the installation. Do not place any objects on the unit.
Remain out of the area of the hot water connection and the chimney to a oid burns.
Before starting any maintenance or ser ice acti ities, discon nect the electrical power supply and
close the gas supply al e.
After completing any maintenance or ser ice acti ity, check the whole installation.
x As a supplement to the information pro ided in this technical manual, all applicable safety regula-
tions must be consulted to a oid accidents.
All panels forming part of the casing must be mounted. Panels may only be remo ed for main-
tenance or ser ice purposes. After performing maintenance or ser ice acti ities, ensure that all
panels are replaced.
Sa ety provisions
w The installation may ne er by switched on if any of the panels ha e been remo ed or if any of the
safety de ices ha e been disabled.
Instruction and warning stickers
x None of the instruction and warning stickers attached to the installation may be remo ed or co -
ered and during the whole of the lifetime of the installation they must remain legible.
Replace any damaged or unreadable instruction and warning stickers immediately.

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Modifi cation
Modifi cations to the installation may only be carried out with the written appro al of the manufac-
turer.
Danger o explosion
When acti ities are being undertaken in the boiler room, always follow the applicable instructions
“Working in an area where there is a danger of explosion”.
Installation
The appliance must be installed by an authorised installer in accordance with the applicable na-
tional and local specifi cations and regulations.
Carefully follow all the safety instructions.
Operation
In the e ent of a gas leak, switch off the unit and close the gas supply al e. Open doors and win-
dows and warn the appropri ate authorities.
When the installation is re-commissioned, always follow the instructions for use.
Technical specifi cations
The specifi cations listed in this technical manual cannot be ignored.
4 Delivery and transport
4.1 Delivery
The appliances are completely assembled, tested and co ered in a “heat-shrink” protecti e co er-
ing.
After deli ery and remo al of the protecti e co ering, check the appliance for damage.
Check that the equipment deli ered is in accordance with the order and the deli ery note.
On deli ery, check the data plate for the correct boiler type and gas supply pressure.
4.2 Packaging
For transport purposes, the unit is mounted on wooden blocks, fi tted with protecti e bumpers
and and co ered in a “heat-shrink” protecti e co ering.
4.3 Transport
x For transport, consult the technical details for dimensions and weight.
w Remo e the co ering preferably after transportation and posi tioning in the boiler room or remo e
the panels before trans porting the appliance. This is to pre ent damage to the casing panels.

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Doc890/3456CV02B 19
Moving the appliance
A pallet truck or fork lift truck with a minimum fork length of 1 m can be used at the side of the
unit.
Fig. 6 Mo ing the appliance
Roller
After the wooden blocks ha e been remo ed, it is possible to mo e the appliance by rolling it o er
tubes.
Fig. 7 Mo ing with the id of rollers

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Li ting
The fi gure below shows how a unit can be safely lifted. To a oid damage to the panels, these
should fi rst be remo ed. The wooden bars between the straps ensure that the unit will not be
damaged during lifting.
Fig. 8 Lifting
w Caution:
- Ensure that the lifting straps are of the correct quality!
- Ne er mo e the units o er the heads of persons!

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Dismantling and reassembly
When the unit cannot be placed in position because of its dimensions or weight, the boiler may be
partially dismantled.
When it is necessary to perform extensi e dismantling, we ad ise you to make early contact with
your supplier. The unit can be deli ered in parts, each of which has been pretested.
We strongly ad ise you to ha e dismantling and reassembly acti ities carried out by the ser ice
department of your
supplier.
Burner
Type L (mm) B (mm) H (mm) m (kg)
R3401 1010 1150 420 135
R3402 R3501 R3601 1010 1310 500 140
R3403 R3502 R3602 1420 1010 500 210
R3404 R3503 R3603 1420 1110 500 215
R3405 R3504 R3604 1420 1210 500 220
R3406 R3505 R3605 1420 1310 500 225
1t Heat exchanger
Type L (mm) B (mm) H (mm) m (kg)
R3401 1010 1150 160 120
R3402 R3501 R3601 1010 1310 160 135
R3403 R3502 R3602 1420 1010 160 180
R3404 R3503 R3603 1420 1110 160 185
R3405 R3504 R3604 1420 1210 160 190
R3406 R3505 R3605 1420 1310 160 195
2nd Heat exchanger
Type L (mm) B (mm) H (mm) m (kg)
R3401 1010 1150 160 135
R3402 R3501 R3601 1010 1310 160 150
R3403 R3502 R3602 1420 1010 160 200
R3404 R3503 R3603 1420 1110 160 200
R3405 R3504 R3604 1420 1210 160 210
R3406 R3505 R3605 1420 1310 160 210
Fig. 9 Dimensions and weights of burner and heat exchanger
Flue ga collection chamber
Type L (mm) B (mm) H (mm) m (kg)
R3401 1320 990 400 ‹25
R3402 R3501 R3601 1450 1070 400 ‹25
R3403 R3502 R3602 1950 770 400 ‹35
R3404 R3503 R3603 1950 870 400 ‹35
R3405 R3504 R3604 1950 970 400 ‹35
R3406 R3505 R3605 1950 1070 400 ‹35
Fig. 10 Dimensions and weights of the fl ue gas collection chamber

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w R3600 only
3rd Heat exchanger
Type L (mm) B (mm) H (mm) m (kg)
R3601 585 800 411 60
R3602 585 610 411 60
R3603 585 690 411 60
R3604 585 780 686 90
R3605 585 780 686 90
Fig. 11 Dimensions and weights of the third heat exchanger
Frame
Type L (mm) B (mm) H (mm) m (kg)
R3401 1325 1165 460 50
R3402 R3501 R3601 1630 1266 500 60
R3403 R3502 R3602 2004 1066 500 70
R3404 R3503 R3603 2004 1066 500 70
R3405 R3504 R3604 2004 1266 500 70
R3406 R3505 R3605 2004 1266 500 70
Fig. 12 Dimensions and weights of the frame
Positioning
Once the unit is in the correct position, the wooden blocks must be remo ed. The ibration ab-
sorption dampers with spacers deli ered with the unit must now be mounted as described in the
instructions deli ered with them (see drawing). Thereafter, the water, gas, chimney, condensate
and electrical connections can be completed.

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Protection against rost
w If the unit is out of use during the winter months there is a danger of freezing. Drain the water
from the installation using the fi lling/drainage al es.