YEAR ROUND MAXIMUM CONDENSING BOILER - Atlantic Boilers · Heating boilers – special requirements for oil fired room sealed units DIN 18 160-1 Supplement 3 Chimneys DIN EN 12 828:2003

ATLANTIC 2000 - boilerplant sales ACM ATLANTIC - commissioning and maintenance ATLANTIC 4422 – spares

Atlantic 2000 Registered in England Company No: 1477687 Vat Reg No: 306 0653 89

PO BOX 11, ASHTON UNDER LYNE, OL6 7TR T: 0161 621 5960 E: [email protected] www.atlanticboilers.com

BK SERIESYEAR ROUND MAXIMUM CONDENSING BOILER

burning diesel oil, kerosene, natural gas or liquid petroleum gas

OPERATING & MAINTENANCE MANUALBK50 - BK70 - BK100

90% and above A A

86% - 90% B

82% - 86% C

78% - 82% D

74% - 78% E

70% - 74% F

Below 70% G

1

Contents

1 Overview – laws, regulations and standards 2

2 Information 42.1 Identification(label) �� 42.2 Warningsymbols �� 42.3 Importantinformation �� 5

2.3.1 Updatingservice ��52.3.2 Actuality ��52.3.3BKFullyCondensingBoiler ��52.3.4 Abouttheseoperatinginstructions ��5

2.4 Validity �� 52.5 Applicability �� 52.6 Liabilitylimitations �� 5

3 Safety instructions 73.1 Generalinformation �� 73.2 Safetyguidelines �� 7

3.2.1 Riskoffrostdamage ��83.2.2 Corrosion,boilerdamage ��8

3.3 Norms,regulations �� 83.4 Operationandmonitoring �� 8

3.4.1 Burnerfaults/remoteunlocking ��93.4.2 Maintenance(servicing) ��9

3.5 Safetyinstallations �� 93.5.1 Water-sidesafetyinstallations��93.5.2 Gas-sidesafetyinstallations ��93.5.3 Labelandoperatinginstructions ��93.5.4 Additionalsafetyinstallations ��9

3.6 Wastedisposalandenvironmentalprotection �� 10

4 Function and description 114.1 Functionandoperatingprinciple �� 114.2 Boilerdescriptionanddimensions �� 11

4.2.1 Trialrun,productioncontrol,qualityassurance ��11

4.2.2 Operatingcharacteristics,adjust-ment ��11

4.2.3 Materials �� 124.2.4 Safetyinstallations �� 124.2.5 Fluegassystem �� 124.2.6 Combustionair �� 124.2.7 Reservoir–servicewaterheater � 13

4.3 Unintendeduse �� 134.4 Technicaldata �� 14

5 Delivery – transportation to installation site 16

5.1 Safetyinstructions �� 165.2 Unloading,useofhoist �� 165.3 Completenessofdelivery �� 16

6 Installation and connection 176.1 FullyCondensingBoiler �� 176.2 Electricalconnection �� 176.3 Condensatedrainage �� 186.4 Handingoverandservicing

instructions �� 18

7 Cleaning 207.1 Cleaningofcombustionchamber

andboiler �� 207.2 Cleaningoffluegaspasses �� 217.3 Cleaningoffluegaspassesbox

(open) �� 217.4 Wetcleaning–neutralizationbox

andplasticheatexchanger �� 23

8 Terminal assignment and le-gend to Conform 6.0 26

9 Spare parts BK50, BK70 and BK100 28

10 ECconformitycertification 32

11 Guarantee 33

12 Notes 34

BK50/BK70 BK100

2

Overview–laws,regulationsandstandards

1 Overview – laws, regulations and standards

General information:Transportation,installation,mountingandelectri-calconnectionsshouldbedonebyacompetentperson.Hebearsresponsibilityforaproperimplementationoftheseworks.

BeforeinstallationoftheFullyCondensingBoiler,itisnecessarytoobtainpermissionofthelocalheatingequipmentinspectionboardorothercompetentauthorities.

Inordertopreventpenetrationofoxygenintotheclosedheatingsystem,itisadvisabletoperformasystemdivisionbetweenthefloorheatingandtheheatingsystembymeansofaheatexchanger.Itisadvisabletoinstallatemperaturesensorforthefloorheatingsystem,inordertoprotectpipesandfloorcoveringfromoverheating.

Sincecorrespondingregulationsvaryindifferentfederallands,werecommend,beforeboilerins-tallation,toconductconsultationswithcompetentauthoritiesandthelocalheatingequipmentins-pectionboard.Combustionairsupplyshouldbeperformedinsuchawayastoexcludesuctionoffluegasesfromheatingsystemsworkingonliquidorsolidfuels.

Thecombustionairsuppliedtotheunitshouldbefreefromchemicalsubstancessuchasfluorine,chlorineorsulphur.Thesesubstancesarecon-tainedinsprays,solventsandcleaningagents.Theymaycause,inspecificcases,corrosionofsomeunitcomponentsparticularlyinchimneys.Beforetheunitisputintooperation,itisneces-sarytocheckwithcompetentauthoritieswhethercondensateneutralizationisrequired.

Ifanychangesinthecontrolsystemoritssepa-rateitemsaremade,thentheguarantee,incaseofpossiblesubsequentdamages,shallbeinva-lid.Itisrecommendedtoinstallasafetyvalvewith“H”identificationintotheheatingcircuit.Themaximumpressureofthedischargepipeis3bars.Ifthedischargepipeofthesafetyvalveflowsintotheseweragenetwork,itisnecessarytointegrateadraintrap.

92/42/EWGEfficiencyguidelines

2006/95/EGElectricalequipmentdesignedforusewithincer-tainvoltagelimits

DIN EN 267:2011-02Fan-assistedoilburner

DIN EN 676:2003 + A2:2008Automaticforceddraughtburnersforgaseousfuels

DIN EN 677:1998-08Gas-firedcentralheatingboilers

DIN EN 14 471:2005Chimneys–systemchimneyswithplasticflueliners

DIN EN 15 034:2007-01Chapters 4.3.1 and 4.4Heatingboilers–condensingheatingboilersforfueloil

DIN EN 15 035:2007-05Chapters 6.1, 6.3.1, 6.3.3.1Heatingboilers–specialrequirementsforoilfiredroomsealedunits

DIN 18 160-1 Supplement 3Chimneys

DIN EN 12 828:2003Safety-relatedequipmentofheatingsystems

2006/42/EGMachineguidelines

DIN EN 303-1:2003-12Chapters 4.1.5.10 to 4.1.5.12Condensingheatingboilerswithfan-assistedburner

DIN EN 303-2:2003/12Chapters 3.2 to 3.5 andAppendices A and B

DIN EN 303-3:2004-10Chapters 5.4 to 5.5

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Overview–laws,regulationsandstandards

DIN EN 304:2004/01Condensingheatingboilers–testcodeforhea-tingboilerswithfan-assistedoilburners

1 BImSchV (22.03.2010)Regulationonsmallfurnaces

ATV A 251Removalofcondensatefromchimneys

DIN EN 60 335-1:2010

DIN EN 60 335-2-102:2010Safetyofhouseholdandsimilarelectricalappli-ances

2004/108/EGElectromagneticcompatibility

Furthermore, for installation in Austria the following norms and regulations are valid:• ÖVE–Rulesandlocalrules

• Art.15aB-VG

• FAnlG–LawonfurnacesdatedJune12,2011

Switzerland:• Swissprovisions(BAFU)andcertificateofconformityforoilandgas(LRVArticle20)

• Environmentalprotectionlaw

• Waterprotectionact

• Waterprotectionordinance

• Recommendationforsewagedrainagefromcondensingheatingsystems

• SVGWgasguidelines

• SVGWwaterguidelines

• Recommendationconcerningtheminimumchimneyheight(aboveroof)

• VKFfireprotectionregulations

• SWKIguidelines

• SEVandESTIrulesI

BK50/BK70 BK100

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Information

2 Information

2.1 Identification(label)

Product Id. Nr.Heating outputFlue gas temperatureMax. operation temperatureMax. operation overpressureWater contentElectrical connectionProtection classInstallation typeDegree of efficiencyCountry of destination

Unit category

Boiler number

0085

Oil

Giersch (G)Produkt ID-Nr.CE-0032BQ2719

CE0035CM10333 - 49 kW47°C / 54°C100°C3 bar110 l230 V~/50 Hz/350 WIP40C13/C33/C43/C53/C63/C8399%DE, AT, BE, CH, CZ, FR,GB, PL, SE, SK, LUsee identification plategasburnersee boiler base in front left

Giersch (GBZ)DIN CERTCO Reg.Nr.5G1049/11S

UNIT BK50 fully condensing boiler with fan

Gas

Weishaupt (WG) 33 - 49 kWWeishaupt (W)Produkt ID-Nr.CE-0036 0362/05

Produkt ID-Nr.CE-0085AU0353

MHG (M)Produkt ID-Nr.CE-0032BR2740

Firing capacity

33 kW 41 kW 49 kW Set on kW


Unit category

boiler number

Oil



Gas




DIN CERTCO Reg.Nr.5G1034/08

Giersch (GL)

0085


Firing capacity


Unit category

Boiler number

Oil



Gas




DIN CERTCO Reg.Nr.5G1034/08

Giersch (GL)

95 kW

0085

Firing capacity


2.2 WarningsymbolsIntheseoperatinginstructionsthefollowingwar-ningsymbolsareused:

Disregardingtheinstructionsmarkedwiththissymbolmayresultinadangerforpersonsandpropertydamage.

Attention

Thissymbolspecifiesinformationrelatedtoboileroperationaswellastocorrespondingorganizationalandtechnicalissues.

Information

5

Information

2.3 Important information

Careshouldbetakentoensurethat,depen-dingonthefuelandboilertype,theapprop-riateoperatingmodeisselected(SeeOpe-ratinginstructionforConform6.0andInitialcommissioningmanual).Failuretocomplywiththisprovisionwillresultinexpirationoftheguaranteeontheboilerbody!Withoutthesubmittedcommissioningreport,theguaranteeagreementwiththecompanyshallnotenterintoforce.

Information

Inordertopreventpenetrationofoxygenintotheclosedheatingsystem,itisrecommendedtoperformsystemseparationbetweenthefloorheatingandtheheatingsystem,bymeansofaheatexchanger.

2.3.1 Updating serviceTheseoperatinginstructionsarenotsubjecttomodifications!Themanufacturerreservestherighttomakeatanytimemodificationsandimprovementsintermsoffurthertechnicaldevelopment,toalltechnicaldata,informationandimages.AnyclaimsforafreemodificationorimprovementofalreadydeliveredFullyCondensingBoilersareexcluded.

2.3.2 ActualityAllreferencestolaws,regulations,guidelines,normsetc.mentionedintheseoperatinginstruc-tions,arecorrectasoftheperiodoftheinstruc-tions’drafting(may2012).

2.3.3 BK Fully Condensing BoilerThecopyrightfortheseoperatinginstructionsremainswiththecompany.

2.3.4 AbouttheseoperatinginstructionsForreasonsofclarity,theseoperatinginstruc-tionsdonotcontainalldetailedinformationwithregardtopossibleconstructionalandequip-mentversionsoftheFullyCondensingBoilerinquestion.Atthesametime,itisnotpossibletoforeseeeveryimaginablecaseofinstallation,configuration,operationand/ormaintenance.Intheeventyouwillrequireadditionalinformationorsomespecificproblemswillarisethatarenotaddressedindetailintheseoperatinginstruc-tions,pleasereferforinformationtoacompetentheatinginstallationcompanyordirectlyto thecompany.

2.4 ValidityTheseoperatinginstructionsarevalidonlywithrespecttotheFullyCondensingBoilermarkedwiththeproductionnumber(SeeLabel).Whenmakingrequestsandorderingspareparts,ple-asealwaysstatethesemodel(factory)numbers!TheseoperatinginstructionscontaininformationabouttheFullyCondensingBoileranditsitemsofequipment,insofarasthesebelongtothescopeofdelivery.Statementsaboutequipmentnotbelongingtothescopeofdeliveryareinten-dedpurelyforinformationalpurposes.Alegalclaimforthisequipment(options)isexcluded.Shouldmaterialsofthethird-partymanufacturersbeattachedtotheseoperatinginstructions(ope-ratinginstructionsofthirdparties),sothecompanycannotassumeanyliabilityfortheircorrectness,validity,technicaldataetc.

2.5 ApplicabilityAllinformationprovidedhereinwithrespecttotheworksafetyandenvironmentalprotectioncorrespondswithEU/ECregulationsand/orwiththeEquipmentSafetyAct(GSG)oftheFederalRepublicofGermany!Thecustomer/operatorshould,underhisorherownresponsibility• Considerthelaws,regulations,rules,gui-delines,technicalinstructionsetc.specifiedabove,asabasisforsafehandlingandmaintenance,

• Measuretheircompliancewiththelocalregulations,and

• independentlyinstallandadjustadditionalaccessoriesprescribedbythelocalcom-petentauthoritiesandcarryoutappropriateworksandmeasuresusingtheresourcesofaspecialistcompany.

2.6 LiabilitylimitationsThecompanytakesnoresponsibilityfordamagestothedeliveredFullyCondensingBoi-lercausedbythefollowingreasons:• Ignoranceoforfailuretocomplywiththeseoperatinginstructions.

• Insufficientlyqualifiedmaintenancestafforinadequatelyinstructedservicepersonnel.

• Naturalwearandtear!FordetailsseeDIN31051Part4,EN13306„Maintenanceterms“.

• FaultyornegligenthandlingoftheFullyCondensingBoilerand,inparticular,omis-sionoftakingmeasuresastosafeandproper

BK50/BK70 BK100

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Information

◦ Installationandcommissioning, ◦ Operationandmonitoring,and ◦ Maintenance(servicing).

• Defectiveinstallationworksand/ordefectiveelectricalinstallation.

• Chemical,electrochemicalorelectricalinflu-ences.

• Forsubstantialthird-partyproducts,theliabilityofthecompanyislimitedtotheassignmentofliabilityclaimstowhichthecompanyisentitledagainstthesupplierofthethird-partyproducts.

Priortoeachcommissioningandmaintenancecycle,thefurnaceshouldbecheckedforgassidemalfunctionsandleakproofness.

Attention

7

Safetyinstructions

TheoperatinginstructionsshouldbepositionedvisiblyadjacenttotheFullyCondensingBoiler.Theconnectionandadjustmentoftheheatingsystemshouldbeperformedbyaqualifiedplum-ber.Theheatingtechnicianshouldfamiliarizetheoperator(s)oftheFullyCondensingBoilerwithitsfunctionsandservicing!IntheeventofanyfaultsordisturbancesintheoperationoftheFullyCondensingBoiler,pleasenotifytheheatingins-tallationcompany!

If you smell gas, there is a risk of explosion• Avoidopenfireandsparkformation(forexamplewhenturningonandoutlightsandelectricalappliances)

• Closetheshut-offgasvalveandnotifytheheatinginstallationcompany

If you smell exhaust fumes, there is a risk of poisoning• Switchofftheunit

• Opendoorsandwindows

• Notifytheheatinginstallationcompany

Ifthereisariskoffire• Immediatelyputoftheheatingemergencyswitch(incaseitisoutsidetheinstallationroom)

• Closetheshut-offgasvalve

• Intheeventofafire,usethesuitablefireextinguisher(fireclassBpursuanttoDIN14406)

Dimensionaldistancesfromtheboilertocom-bustibleitemsormaterialsshouldcorrespondtolocalfireprotectionnormsbuttheyshouldbeatleast200mm(seeFig.1).Otherwise,thereisdangerofafire.

3 Safety instructions

3.1 General informationTheseoperatinginstructionsarevalidexclusivelyforthetheFullyCondensingBoiler.Thestaffinchargeofinstallation,commissioningormain-tenanceshouldreadtheoperatinginstructionspriortostartingtheseworks.Therequirementscontainedintheseoperatinginstructionsmustbeadheredto.Intheeventofanon-compliancewiththeoperatinginstructions,theguaranteeclaimvis-à-visthecompanyshallexpire.

3.2 Safety guidelines

ForaproperandreliableoperationoftheFullyCondensingBoiler,itisnecessarytoobservethefollowingsafetyguidelines.

Attention

• Installation,commissioningandmainte-nanceoftheFullyCondensingBoilershouldbeperformedonlybyqualifiedandtrainedpersonnel.

• Workswithelectricalcomponents(forexample,adjustment)aretobeperformedonlybyqualifiedelectricians.

• Duringinstallationofelectricalequipment,theprovisionsofVDE(GermanAssociationforElectrical,Electronic&InformationTech-nologies)andofthelocalelectricitysupplycompanyarerelevant.

• TheFullyCondensingBoilermaybeope-ratedonlywithinthepowerrangeindicatedinthetechnicaldocumentationofthecom-panyandoftheburnermanufacturer.

• TheintendeduseoftheFullyCondensingBoilercomprisesitsexclusiveuseforhotwaterheatingsystemspursuanttoDINEN304andDINEN303-3.

• Itisstrictlyprohibitedtobypassorinanywayremoveorswitchoffcontrol,safetyandmonitoringequipment.

• TheFullyCondensingBoilermaybeopera-tedonlywhenitssystemsareintechnicallyperfectcondition.

• Malfunctionsanddefectswhichaffectsafety(ormayaffectit)shouldbefixedinapromptandexpertmanner.

• Defectivepartsandcomponentsmustbereplacedonlywithoriginalsparepartsofthecompany.

BK50/BK70 BK100

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Safetyinstructions

combustion,underassistanceofaspecializedinstallingcompany.If,afteracleaning,repeateddustexposureshallstillbepossible,(forexample,duetospongychimneyjoints),taketheappropriatemeasures(forexample,cleanthechimney).

ModificationofthegasheatingsystemTheoperatormayundernocircumstancesmakechangesintheheater,pipesforgas,electricity,water,airsupplyandfluegas.Theseworksmaybeperformedonlybyahea-tingtechnician,toeliminatetheabovementionedhazards.

3.3 Norms, regulations• Theboilermustbeservicedinregularinter-vals.Werecommendtoconclude,forthispurpose,amaintenancecontract.

• TheFullyCondensingBoilersmaybeins-talledandoperatedonlyintheboilerandinstallationroomsasrequiredbylocalregu-lationsandguidelines(FeuAO)withrespecttofurnaces.

• ForAustriaarealsorelevanttheprovisionsoftheAustrianGasandWaterIndustryAssociationÖVGWTRGas(G1),BuildingregulationslawB-VG,Art.15AandalsotheLawonfurnacesFAnlG.

• Swissregulations(BAFU)andtheDeclara-tionofConformityforoilandgas(LRVArt.20)

BurnersFullyautomatedfan-assistedoilburnerspursu-anttoDINEN267.Fullyautomatedfan-assistedgasburnerspursuanttoDINEN676.Duringthecommissioningoftheburner,theappropriateoperatinginstructionsoftheburnerareessential.Astothecommissioningoftheburner,seecorre-spondingoperatingandassemblyinstructions.FuelELheatingoilpursuanttoDIN51603.NaturalgasinaccordancewiththeCodeofPracticeoftheGermanTechnicalAssociationforGasandWater(DVGW)G260/Iandalsopursu-anttolocalnorms.

3.4 Operation and monitoringPutintooperationtheFullyCondensingBoileronlyafterallworksrelatedtoinstallationandconnectionarecompletedand/oraftercomple-tionofpossiblepreventivemaintenancemeasu-res.Duringtheinitialcommissioningitisneces-sarytomonitortheautomaticprocessofcontrol

Fig. 1: Alateraldistanceofminimum600mmshouldbemaintainedeitherontheleftorontherightsideoftheboiler.

Aconnectinglineshouldbeleadtothechimneyasshortaspossibleandascending.Thisistheonlywaytoensuretheoptimumperformance.Thepipesshouldbecarefullysealed!Ifthefluepipesarenotproperlysealed,thefluegasmayescapeandcausetheriskofsuffocation.Itisadvisabletousethefluepipebendswithcleaningopenings,tobeabletocleanthefluepipes.

3.2.1 Risk of frost damageTheFullyCondensingBoilerandstoragewaterheaterarefrostprotectedthroughthecontrollingsystem.Sincetherisk(forexample,duringalong-lastingelectricalpoweroutage)offrostdamagecannotbeexcluded,theFullyConden-singBoilersandstoragewaterheatersshouldbeonlyinstalledinthefrost-protectedrooms.If,duringlongshutdownperiodsandwithinopera-tiveheatingsystem,theriskoffrostdangershallremain,aheatingtechnicianshouldemptytheFullyCondensingBoiler,reservoirandheatingsystem,inordertopreventwater-piperupturescausedbyfrost.

3.2.2 Corrosion,boilerdamageThecombustionairmustbefreefromdust(forexample,depositedsolidfuelsorconstructiondust)aswellasfromhalogenatedhydrocarbons(contained,forexample,inspraycans,solvents,washingandcleaningagents,paintsorglues).Otherwisepittingcorrosionoftheboilerbodyispossible.Ifthecombustionairisbeingsuckedinfrominoperativefireplaceorshaft,itisnecessarytoremoveresidualsofformeroilorsolidfuel

9

Safetyinstructions

thepowersupplyandonlybyaskilledelectri-cian.Beforecommencementofanyworksontheelectricalequipment,makesurethatthevoltageiscompletelyswitchedoff.Damaged,burned,frayedcablesaswellaslooseanduntightcableconnectionsmustbeimmediatelyreplacedbyaskilledelectrician.Intheeventofadefectivefuse,theymustbereplacedonlywiththeoriginalfuseswithprescri-bedamperage.

3.5 Safety installations

ThecommissioningoftheFullyCondensingBoilerwithoutaproperlyfunctioningsafetyinstallation(orwithanimproperlyfunctioningsafetyinstallation),isnotpermitted.

Attention

3.5.1 Water-side safety installationsSafetyinstallationspursuanttoDIN12828suchasthesafetyvalve,safetytemperaturelimiterandtemperaturecontrolleraredescribedindetail.

3.5.2 Gas-side safety installationsTothesesafetyinstallationsbelongsthefluegassafetytemperaturelimiter(STL).

3.5.3 LabelandoperatinginstructionsThelabelmustnotberemovedfromtheBKFullyCondensingBoiler;itshouldbekeptinawellreadablecondition.(Theoperatinginstruc-tionsmustbeplacedvisiblyinthesameroomwheretheboilerislocated).

3.5.4 Additional safety installationsThesesafetyinstallationsinclude,amongotherequipment.• Furnaceemergencyswitch

• Heatingoillockingdeviceinthefurnace

• Impermeablecovers/grillsinconformitywithDINEN294onthefluegassystem(uponarrangementasanoutdoorchimney)andontheairsupplyconnectionshouldbeinstalledbyatechnician,underhisownresponsibility,incompliancewithlocalregu-lationsandguidelines(FeuAO).

TheBKFullyCondensingBoilerservesexclu-sivelyforheatgenerationandalsoforwaterheatingpursuanttoDIN12828.Theflowtem-peratureismaximum80°C,thetechnicaldataofvariousboilertypesareindicatedonthecor-respondinglabels.Onlythoseliquidorgaseous

functionsandtocheckthetightnessoftheFullyCondensingBoileranditsconnections.

IntheeventofunusualoperatingperformanceinthefunctioningoftheFullyCondensingBoiler,forexample,malfunctionsorfaultsinenergysupply,theunitmustbeimmediatelyshutoff.

Attention

Determinethecauseoftheproblemorfaultandfixitinasafeandsecuremanner.Startre-commissioningonlyaftercompleteeliminationoffaults.

3.4.1 Burner faults/remote unlockingIncaseofaburnerdefectorfault,theredpushbuttoninthecontrolpanelwillflash.Pressthebuttonshortlytounlocktheburner.Shouldtheburnerfaultreappear,callaqualifiedspecialist.

Fig. 2: Donotpressthepushbuttonduringnormalburneroperation!

Pushbuttonofremoteunlocking

3.4.2 Maintenance (servicing)Itisstronglyrecommendedtoconsider,duringeachinspectionand/orscheduledmaintenanceworks,suggestionswithrespecttocausesoffaultsduetosuperfluousmeasuresand,inparti-cular,toboileropening,mostlyunnecessary.AllconnectionsattheFullyCondensingBoi-ler,burner,controlpaneletc.arepluggableorscrewable.WhenreplacingsafetyinstallationsmakesurethatthenewcomponentscorrespondtotheoriginalpartsandaretestedinconformitywithDINEN14597orDIN12828.Use only genuine components and parts deli-veredbythecompany!Duringanyoperations,refrainfromusingexces-siveforce–ifitgoesbeyondwhatisnecessarytoconnectordisconnectboltedconnections–thereisariskofmaterialdamage!Itisnotallowedtomoistentheplasticcompo-nents(secondaryheatexchanger,fluegassystem,hoses,sealsetc.)withoils,solvents,cleaningagentsorotherchemicalsubstances.Allworksontheelectricalequipmentshouldbeperformedonlyafterhavingdisconnecteditfrom

BK50/BK70 BK100

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Safetyinstructions

non-recyclableresiduesshouldbedisposedofpursuanttotheGermanWasteManagementLaw(AbfG).Duringdisposalworks,usesafetygloves.

fuelsthatareindicatedintheorderconfir-mationmaybeusedasworkingmaterials.Thedefinitionismadeincompliancewith1.BImSchV(1stFederalGermanrulingonemissi-onscontrol)condensingboilers:theseareheatgeneratorswhichutilizebycondensation,asaresultoftheirdesign,theheatofvaporizationofwatervapourcontainedinfluegases.Thisdefini-tiondifferentiatestheheatgenerationwithutiliza-tionoftheheatofvaporizationofwatervapourinfluegasesfromtheheatgeneratorswithoutsuchutilization.

3.6 Waste disposal and environmen-tal protection

Thefollowingsubstanceswhichmayoriginateduringmaintenanceandrepairworksshouldbedisposedof–underpersonalresponsibilityoftheheatingtechnician:• Sediments,forexample,afterabreakdown

• Heatingoilrests

• Cleaningagentsandconsumables

• Solidwaste(replacedcomponents)ofalltypes

Alldisposalworksshouldbeconductedasprescribed,alsopursuantto1.BImSchVandGermanWasteManagementLaw(AbfG)andincompliancewiththeprovisionsoftheWaterResourcesAct(WHG)aswellaswithlocalandregionalregulations.Liquidwastesuchaspotentialtoxicsubstancescapableofendangeringgroundwater(WHG)shouldbecollectedinspecialclosedcontainersandallocatedfortheproperdisposal.Donotallowworkingmaterials(heatingoil)toinfiltrateintothegroundorseweragesystem.PotentialoilleakagesshouldbeimmediatelyboundinconformitywiththeAccidentpreventionregulations(UVV1.)orwipedout.Duringdisposal(dismantling/scrapping)oftheboiler,itscomponentsshouldbedividedinaccordancewiththeirmaterials.Aftercompletecleaningandemptyingoftheneu-tralizationboxandduringsubsequentdismant-ling,thefollowingmaterialsmayberecovered:• Metals,steel,malleableiron

• Insulationmaterials,mineralwool

• Plastics:polypropylene,PVC,cableinsula-tion

• electrical/electroniccomponentsThecomponentsshouldbecollectedsepa-rately,inaccordancewiththematerials;the

11

Functionanddescription

ofelectrical/electronicmeasuringandcontroldevices.Maximumambienttemperature: 40°CMinimumambienttemperature: 1°CTheinductedcombustionairshouldbedust-freeandofnormalquality(temperature,humidityetc.).TheBKFullyCondensingBoilerisoperativeandreliableprovidedthatitisusedproperly,theagreedoperationaldataareadheredtoandonlyprescribedfuelsareused.Itisnecessarytotakeintoconsiderationpossiblemalfunctions,if:• installation,adjustmentandsubsequenttrialoperationwerenotcarriedoutproperly.

• itisimpossibletomaintaintheover-pres-sureinthefurnace(resistanceinthefluegassystemorduringthefluegassuction).

• theheatexchangerwasnotfilledwithwateronthegassidepriortocommissioningorafteralongoperationalstandstill.

• thefueldoesnotcorrespondtotheusualspecifications.

• thesafetyinstallations,notwithstandingtheprohibitiononalterations,weremisplacedorbridged.

• theelectricalconnectiondataandnet-workconditionsdonotcorrespondtothemanufacturer’sdata.

• thefurnacewasputintooperationimmedi-atelyafterorduringfillingoftheheatingoilstoragetanks.

4.2 Boiler description and dimensi-ons

4.2.1 Trial run, production control, qua-lity assurance

TheinstallationoftheFullyCondensingBoilermustbeperformedbyaqualifiedstaff(aheatingtechnicianandanelectrician).Withoutthecom-missioningreport,theguaranteeagreementwiththecompanyshallnotcomeintoeffect.Thenintroductiontotheunit,trialrunandhando-vertotheoperatortakeplace.

4.2.2 Operating characteristics, adjust-ment

TheBKFullyCondensingBoilerisfittedwiththefullyautomaticelectroniccontrolsystemwhich

4 Function and description

4.1 Function and operating principleInthefurnaceoftheBK FullyCondensingBoiler,thecombustionheatfromoilorgasistransferredtothecombustionchamberwashedroundbytheboilerwaterandtotheprimaryheatexchangerwhichisconnectedtothecombustionchamberfromthewaterside.Thehotfluegasesarrivethen,undertemperaturesbelow85°C–thatis,abovethedewpoint–intothesecondaryheatexchangerandtheyarecooleddown,inaccordancewiththeexternalairtemperature,toabout30°C–48°C.Thedewpointofthefluegasistherebynotreachedandbothsensibleandlatent(hidden)heatisdelivered,throughsteamcondensation,tothesecondaryheatexchangerortothecombustionairpassingthroughitincounterflow.Thefluegasarrives,afterflowingthroughthesecondaryheatexchanger(counterflow)withverylowtemperaturetothefluegaspipe.Thefreshairnecessaryforcombustionissuckedinthroughtheannulargapoutsidethefluegaspipe(roomsealedoperation).Therequirednegativepressureisgeneratedbytheburnerfan.Priortoentryintothecombustionchamber,thecom-bustionairispreheatedinthesecondaryheatexchangeragainstthefluesgases,thuscontribu-tingtothehighefficiency.Thecondensateaccumulatedinthesecondaryheatexchangercontainsthemostpollutantsfromthecombustionfluegases.Itaccumulatesinthesecondaryheatexchangerandisthenfedthroughapipeconnectiontotheneutraliza-tionbox.Thecondensatepassesthroughthemineralgranulateandisthen,intheneutralizedcondition,dischargedintoawastewaterpipeorsewagesystem.Owingtotemperaturemonitoringwiththesafetytemperaturelimiter(STL)andtheimplementationofstandards,thefunctionoftheBKFullyCon-densingBoilerisself-retainingoverthewholecombustiongaspath.

Theworkswhicharenotdescribedintheseoperatinginstructionsarereservedtothestaffofthemanufacturer.

Information

Functional criteriaTheambientconditionsintheinstallationroomoftheBKFullyCondensingBoilermustnotexceedthenormalvaluesfortheoperation

BK50/BK70 BK100

12


• controlstheoperatingperformanceincon-formitywiththeheatdemandoftheheatinginstallation,and

• assafetycircuit,canshutdowntheintheeventofanymalfunctionsonthewaterorgasside.

• Thepressuretransmitterservesforthefunregulationandcontrol.

TheConform 6.0controlsystemisintegra-tedintheFullyCondensingBoiler.Whenstudyingtheinformationintheseoperatinginstructions,pleasealwayscomparetheindica-tedtypedesignationwiththedataonthecontrolpanelofthedeliveredboiler.

Thesystemhasintegratedfunctionsfor:Boiler temperatureTheboilertemperatureismaintainedbywayofswitchingtheburneron/off–atsome55°Cto80°C,butalways>55°C(seealsotheoperatinginstructionsofthecontrolsystem).HeatingcircuittemperatureThetemperatureattheheatingcircuitflowisregulatedthroughcontrolsystemtothepreselec-tedvalue.Itispossible,byvirtueoftheoperatingsoftware,atanytimetolowerortopredeterminetheheatingcircuittemperature(operatingmodeselection).Service water temperatureThewatertemperatureintheseparatereservoirforservicewaterheating(reservoiroption)ismaintainedbywayofswitchingon/offtherespec-tiveservicewaterpumpatthelevelpresetinthecontrolsystem.Thisprocessisinterruptedifthereturnboilertemperaturefallsbelow50°C(boilerprotection).Flue gas temperatureThefluegastemperatureismonitoredbytheSTL90°Clocatedinthesecondaryheatexchanger.AmbienttemperatureregulationTheambienttemperatureandthetemperatureoftheheatingcircuitflowarerecordedbysen-sorsanditiscompared,bymeansofthecontrolsystem,withthepredeterminedheatingcircuittemperatureandthesetbacktemperature;ifnecessary,itisbeingcorrected.

4.2.3 MaterialsThecomponentsofthe BK FullyCondensingBoilercorrespondtothematerialrequirementsandthetestprotocol.• Theprimaryheatexchanger

◦ SteelS235JR

◦ ConnectingpiecesofseamlesstubesinaccordancewithDIN1629

• Thesecondaryheatexchanger � PP/PP

• Thermalinsulation/outercover ◦ 3-sidedmineralwool80mm ◦ Front–mineralwool40mmwithcoatingintegratedintothefrontdoor

◦ Boilercasing–steelplate1,25mm,scre-wedtogetherandpowder-coated.

4.2.4 Safety installationsTheBK FullyCondensingBoilerisfittedpur-suanttoDINEN304andDINEN303withthefollowingsafetyinstallations.• Safetytemperaturelimiter(STL)boiler100°C.ThisSTLmonitorstheboilertempe-rature.

• Safetytemperaturelimiter,heatexchanger90°Cprotectsfromexcessivefluegastem-peraturetransfer.Whenapre-settempera-turethresholdisreached,thetemperaturelimitersshutdowntheheatgeneratorandlockit.Re-startingisonlypossiblewiththehelpofatool.

• ThesafetytemperaturelimitersaretestedandmarkedinaccordancewithDIN EN 14 597�

4.2.5 Flue gas systemThefluegassystemisusedtoremoveresiduallow-pollutionfluegaseswiththetemperatureof<60°C(monitoredbyatemperaturesensor)outsidethebuilding,overtheroof.Itismarkedwithitsownlabelcontaininginformationaboutthemanufacturerandtheapprovalnumber.Thefluegassystemshouldbeinstalledbyeffortsofalocallyapprovedheatinginstallercompany,withtheuseofpipesandfittingsmadeofplasticcerti-fiedforapplicationinconstructionandconnectedtothefluegasconnectingpieceoftheFullyCon-densingBoiler.Thecombustiongaspathoftheboilercorres-pondstothebasicstandards.

4.2.6 CombustionairThecombustionairistakendirectlyfromthefreeatmosphere;itispreheatinthesecondaryheatexchangerandsuppliedtotheburner.Ifthefluepipeisarrangedinaduct(unused,cleanedchimney),thentheremainingfreespaceinthisductisusedforcombustionairsupply.Inthecasethefreespacemaynotbeused,incompliancewiththelocalrequirements,sothe

13


4.3 Unintended useTheBKFullyCondensingBoilermaynotbeused:• forthefunctionsotherthanindicatedinChapter3.5.4.

• inothersystemconfiguration.

• withvaluesdifferentfromthoseindicatedonthelabel.

• withfuelsotherthanindicatedintheorderconfirmation(OC).

• withoutnegativepressureatthecombustiongaspathrequiredforoperatingpurposes.

Theriskforthepersons,theFullyCondensingBoilerandotherequipmentcarriestheheatingtechnicianortheoperatoroftheheatingsystem.

WithfluegasfanBoiler type BK50 BK70 BK100Fuel Heatingoil Gas Heatingoil Gas Heatingoil Gas

Fluegaspipe DN 80/125 80/125 80/125110/160

80/125110/160 110/160 110/160

Duct system

Pipelength(vertical) m 25 [28]28 [31]

15 [18]25 [28]

27 [40]30 [43]

27 [40]30 [43]

2030 [43] 20

30 [33]

Ductcross-section mm 135170

135170

135170

135170

170200

170200

Exterior wall system

Pipelength(vertical) m 25 [28]28 [31]

20 [23]30 [33]

40 [43]40 [43]

28 [31]40 [43] 40 [43] 30 [33]

AssessmentbasisConnectingpipeBK50,BK70,BK100: 100cmeffectiveheight,2,5moveralllength,3pipebends87°Exteriorwallsystem: AirsupplyoverconsolewithadditionalincomingairconnectionGeodeticinstallationheight: from1000mgenerallyonlywithfluegasfanWitheveryfurtherinstalledpipebend,thelengthofthefluegaswillbereducedby1m.ThistableisbasedonpracticalendurancetestsconductedbythecompanyandpartlyoncalculationsperformedbyCentrotecSystemtechnikGmbHcompany.

Flue gas pipe dimensions BK50, BK70 and BK100roomsealedheatingRSH[non-roomsealedheatingNRSH]

combustionairshouldbesuckedinthroughanopeningintheexternalwallandthecorrespon-dingpipeandthensuppliedtotheairinletofthesecondaryheatexchanger.Thecombustionairheatedfromcondensingfluegasesinthesecon-daryheatexchangercomesoutattheboilerfront-sidefromthesecondaryheatexchangerandpassesthroughaspiralhosetotheinletopeningoftherespectiveburner.

4.2.7 Reservoir – service water heaterTheconnectionoftheservicewaterheaterismadeattheinletandtheoutletoftheBKFullyCondensingBoiler.Aheatingtechnicianshouldinstallaservicewatercirculationpump.Therespectiveelectricalsocketsareavailableattheboilercontrolpanel(seecircuitdiagraminthedescriptionoftheConform6.0system).Asensorformeasuringtheservicewatertempera-tureisattachedtothecontrolsystem.

BK50/BK70 BK100

14


Fig. 3: Installationtypes(NRSH) B23,B33 (RSH) C13,C33,C43,C53,C63orC83pursuanttoDINEN15035

SupplyairFluegas

4.4 Technical dataTheoperatingdataforthedeliveredFullyCon-densingBoilermaybefoundonthelabelorintheorderconfirmation.ThepresentoperatinginstructionsareattachedtothedeliveredFullyCondensingBoilerinclu-dingtechnicaldata,dimensionsandinstructionswithregardtoinstallation,commissioningandmaintenance.

Boiler type BK50 BK70 BK100Fuel Heatingoil Natural

gasHeatingoil Natural

gasHeatingoil Natural

gasNominalheatoutput kW 33,0–49,0 33,0–49,0 50,0–70,0 50,0–70,0 71,0–120 71,0–120Firingcapacity kW 33,3–49,5 33,3–49,5 50,5–70,7 50,5–70,7 71,7–121 71,7–121CO2content* Vol.-% 13 9,5 13 9,5 13 9,5Fluegasmassflow g/s 14,9–22,1 13,9–20,6 22,5–31,5 21,0–29,4 32,0–54,0 29,8–50,4Fluegastemperature °C <48 <56 <48 <56 <48 <56Air-fluegas-systemØ mm 80/125 110/160 110/160Heatingwaterresis-tance(withΔT=20K) mbar 9,3 13,7 14

Residualconveyingpressureafterfan Pa 200 200 200

*CO2contentmeasuredinfurnace

Thethirdpartyoperatingmanualsand/orcir-cuitdiagramsoftheboilerequipment,controlsystems,supplementarydocumentation,expertassessmentsetc.shouldbetakenintoconsi-deration.Ifneeded,thesedocumentsmayberequesteddirectlyfromthe company.

15


Fig. 4: Boilerdimensions

Pos. Description BK50 BK70 BK100Watercapacity l 110 110 200Weight kg 470 470 746

1 Safetygroupconnection DN 25(1") 25(1") 25(1")2 heatinputpipe DN 32(5/4") 32(5/4") 50(2")3 heatoutputpipe DN 32(5/4") 32(5/4") 50(2")4 Fillinganddischargingcock DN 1/2" 1/2" 1/2"5 Expansiontankconnection DN 25(1") 25(1") 25(1")

7 Fluegasconnectionair-fluegas-system(AFGS)**

external-Ø mm 160 160 160internal-Ø mm 110 110 110

8 Condensatedrainage DN 40 40 40Allconnections-externalthread|**BK50:usereductionto125/80,BK70:ifnecessaryusereductionto125/80

Pos. Description BK50 BK70 BK100H1 Connectingdimensions,condensatedrainage mm 49 49 56H2 Connectingdimensions,AFGsystem mm 278 278 314H3 Connectiondimensionoptionalexpansiontank mm 471 471 576H4 Connectingdimensions,heatoutputpipe mm 1162 1162 1291H5 Connectingdimensions,heatinputpipe mm 1302 1302 1468H6 Overall height mm 1480 1480 1605

Overall height without casing mm 1480 1480 1605Overallheightwithoutcasing,withoutbase mm 1095 1095 1100

H7 Boilersupports(*height-adjustable) mm 20–40 20–40 20–40B1 Connectingdimensions,AFGsystem mm 232,5 232,5 335B2 Connectingdimensions,condensatedrainage mm 322,5 322,5 425B3 Connectiondimensions,filling/dischargingcock mm 452,5 452,5 580D1 Connectiondistanzposition4and5 mm 80 80 80B4 Connectingdimensions,safetygroup mm 322,5 322,5 425B5 Connectingdimensions,heatinputpipe mm 370,7 370,7 447D2 Connectiondistanzheater mm 140 140 177B6 Overall width mm 645 645 850

Overall width without casing mm 645 645 835L1 Connectingdimensions,AFGsystem mm 54 54 54L2 Connectingdimensions,safetygroup mm 377 377 339L3 Overall length mm 1520 1520 1710

Overall length without casing mm 1250 1250 1457Overalllengthwithoutcasing,withoutbase mm 1110 1110 1250

BK50/BK70 BK100

16

Delivery–transportationtoinstallationsite

5 Delivery – transportation to installation site

5.1 Safety instructionsDuringloadingorunloading,anytransportationtoinstallationsiteandalsoduringtemporarysto-rageorwarehousing,itisnecessarytocomplywithregulations,warningsandinstructionsrela-tedtosafetyguidelinesoftherespectivecountry.

5.2 Unloading, use of hoistTheBKFullyCondensingBoilerisbroughttoshippingcompletelyorpartiallyassembled.• Dangerofinjury!Manualunloadingortrans-portationofweights>35kg(ILO,Geneva)orone-timeliftingofmaximum>55kg(Acci-dentpreventionregulations/FederalMinistryofLabourandSocialAffairesofGermany)isforbidden.

• Foryourownsecurity,alwaysusesuitablehoistingdevicesand/orindustrialtrucksaswellasotherloadhandlingaccessorieswithadequateloadcapacity.BeforeloadingorunloadingtheFullyCondensingBoiler,takecaretoensuresufficientspaceforsecureplacingoftheboiler.

• Theloadhandlingaccessoriesmustbecarefullyattachedandsecured.Thereshouldbenodangerfromsuspendedloads!

• Fixingropesorstringstotheboilerequip-mentisforbidden!

• AlwayslifttheFullyCondensingBoileronlyvertically–neverpullitsidewards!

Neverstayorworkunderthesuspendedload.Mortaldanger!

Attention

TheBKFullyCondensingBoilershouldbehandled,duringunloading,transportationtoinstallationsiteortemporarystorage,withtheusualcareandprotectedagainstexternalroughtreatmentand/orfallingobjects.

5.3 Completeness of deliveryCheckthecompletenessofdeliveryimmediatelyuponitsreceipt(compareitwiththeorderconfir-mation/deliverynoteofthecompany).

Missingpartsshouldbepromptlyclaimedtothedeliveringtransportcompanyandthecompanynotified.

17

Installationandconnection

6.2 Electrical connectionThereliablemainsconnectionistobeperformedbyanexperiencedelectrician.

1� Thecharacteristicsofelectricalmainsshouldmeettherespectivelocalandnati-onallegalprovisions.

2� Aspowercables,chooseatleastonefle-xiblecablewithpolychloroprenecoating,inaccordancewith60245IEC45(forexample,NYM3x1,5m2).

3� Theearthwireshouldbelongerthanothercables.

Information

6 Installation and connection

6.1 Fully Condensing BoilerTheinstallationoftheFullyCondensingBoilershouldbecarriedoutunderconsiderationoftheactualinstallationguidelines.Inthiscase,itisnecessarytoinstallsafety-relatedequipmentinconformitywithDIN12828,forexample,asafetygroupmaximum3bar.Foroperationwithgasfanburners,thefollowingclassesofgasequipmentareutilized(pursuanttoDINEN437):

Thedistancesfromtheunittothewallsorcom-bustiblematerials(min.200mm)shouldmeetlocalfirepoliceregulations.Thelateraldistancesontheleftortherightsideoftheboilershouldbeminimum600mm,toensurethattheboilerdoorwiththeburnercouldbeeasilyswungout.Thefluegaspipemustbeleadtothechimneyasshortaspossibleandrising.Thefluegaspipesmustbecarefullysealedup!Itisrecommendedtousethefluegaspipeswithaninspectionope-ning,toenablecleaningandvisualinspectionofthefluegaspipes.TheFullyCondensingBoilerandthetankwaterheaterhavetostandhorizontallyorslightlyrisingtothebackinordertoensureacompletede-aeriation(usetheadjustablefeettolevelthem).

Country Classes of gas equip-ment

Gas connec-tion pressure

Germany I2ELL 20/25mbarAustria I2H 20mbarBelgium I2E+ 20/25mbarLuxembourg I2E 20mbarFrance I2E+ 20/25mbarSwitzerland I2H 20mbar

BK50/BK70 BK100

18


Fig. 6: Condensatetrap

siphon

siphon-likehopper

25mm

Boiler

6.4 Handingoverandservicing instructions

Itisessentialthattheinstallation,commissio-ningandmaintenanceoftheFullyCondensingBoilersarecarriedoutbyqualifiedandtrainedpersonnel.Duringtheinstallationandtrialrun,itisnecessarytocarefullychecktheconformityofsafetyinstallationswithDIN12828aswellasitsfunctioningandcorrectsettingandtoconfirmitinthecommissioningreport.Theheatingtechnicianshouldfamiliarizetheoperatorwiththeheatingunitanditsservicingandwithsafetyinstallationsandtheirfunctions!Theoperatormustplacetheoperatinginstruc-tionsfortheBK FullyCondensingBoilervisiblyinthesameroomwheretheboilerislocated�

Theoperatorisobligatedtoeliminatemal-functionsintheheatingunitand/oritssafety-relatedorelectricalequipmentonlybyqualifiedexperts.Moreover,hemustbeclearlyinformedabouttheinadmissibilityandpotentialdangerofimproperhandlingoftheunit.

Information

Theheatingtechnicianand/ortheoperatormustnotmakeduringinstallation,commissio-ningoroperationanychangesintheBKFullyCondensingBoiler,itssafety-relatedequip-mentorfactorysettings.

Attention

6.3 Condensate drainageThecondensateaccumulatedinthesecondaryheatexchangerisprocessedintheneutraliza-tionboxoftheBKFullyCondensingBoiler.Whendischargingthecondensateintosewageorwastewatersewer,itisnecessarytotakeintoaccountthewaterwayprescriptionsoftheres-pectivecountryandthestatutesoflocalwastedisposalcompanies!Theunitoperatormustobtaintheauthorization,bearinginmindtheAdvisoryleafletA-251„Condensationdisposalinchimneys”withpresentationoftheexpertassessment.Oninstallationofthesuppliedneu-tralizationbox,itisessentialtoannuallyloosenandrinsethegranulate.

Duringinstallationofthecondensatedrainagesystem,caremustbetakentoensurethatthecondensationwaterlevelof120mm(seeFig.5)isnotexceeded.Thecondensatedrainagesystemmaynotbealteredorclosed.ThesuppliedcondensatetrapDN40shouldbeplacedasclosetotheboileraspossible.Priortocommissioning,fillthesiphonwithwater.Ifinspecificsituationstheneutralizationboxisnotutilized,thecondensatedrainagesystemshouldbearrangedinsuchawaythatthesealingwaterheightisnotlessthan25mm(see.Fig.6).

Attention

Fig. 5: Condensatedrainage–thehighestlevel

120mm

19


Option 1 Neutralizationboxalignedwiththepermanentlycondensingboiler.

Option 2 Neutralizationboxatrightanglestothepermanentlycondensingboiler.

Option 3 Neutralizationboxparallelbeneaththepermanentlycondensingboiler(additionalHTtuberequired).

BK50/BK70 BK100

20

Cleaning

Step 2: Removethefasteningscrews/nuts(4pieces,widthacrossflats17)attheboilerdoorandopenthedoortogetherwiththeburner.Attention!Riskofburning–wearprotectivegloves!

Step 3: Removetheintakesocketattheplasticheatexchanger.

Step 4: Removethestainlesssteelinsert.Attention!Riskofburning–wearprotectivegloves!

7 Cleaning

Maintenanceandcleaningworksmayonlybecarriedoutbyauthorizedskilledpersonnel.

Attention

Ateachservicecheck-up,theFullyCondensingBoilershouldbeswitchedcurrentless(mainswitchoftheFullyCondensingBoilerandmainswitchoftheheatingsystem).Itisrecommendedtoplaceintheinstallationroom,asaprecautionarymeasure,asignboard:“Attention!Boilercleaning!Donotputonpower supply”.Pleaseuseduringtheseworksthepersonalsafetygeartoprotectyoureyes,breathingandhands.

7.1 Cleaningofcombustionchamberandboiler

Step 1: Removetheairintakehoseattheburnerandheatexchanger.Disconnecttheburnerplugandalsotheplug“Remoteunlocking“.

WhenopeningtheboilerdoorsduringthenextStep2,itisnecessarytoliftitovertheintakesocketoftheplasticheatexchanger!

Attention

21

Cleaning

7.3 Cleaningoffluegaspassesbox(open)

Step 1: Loosethethreescrewsontheinspectionlidattheleftorrightboilersideandremovethelid.

Step 2: Takeouttheinsulationinsert.

Step 3: Loosethetwowingnutsonthecleaningcover,donotunscrewthem.

Step 5: Cleanthecombustionchamberfromthetoptothebottomwiththespecialboilerbrush.Attention!Riskofburning–wearprotectivegloves!Sweepoutorvacuumawaytheresidues.

7.2 CleaningoffluegaspassesStep 1: RemovethetubulatorsfromthefluegaspassesonlywithBK50andBK70.Attention!Riskofburning–wearprotectivegloves!

Step 2: Cleaningofthefluegaspasseswithabrush.

BK50/BK70 BK100

22

Cleaning

Cleaningofthefluegaspassesbox(closing)Step 1: Closethecleaningcoveronthefluegaspas-sesbox.Putthethreadedpinwithaflatheadscrewdriverintoposition �

Step 2: Tightlyscrewthewingnut.

Step 3: Putintheinsulationinsert.Attachtheinspectionlidandcloseit.

Step 4: Putthethreadedpinswithaflatheadscrewdri-verintoposition andtakeoutthecleaningcover.

Step 5: Vacuumoutthefluegaspassesbox.Theabsor-berplateneedsnotberemoved.

23

Cleaning

Agranulateadditionwillberequiredattheear-liestafter1–2yearswhensome50%ofthegra-nulateareusedup.Afterapproximately4years,completereplacementofthegranulatewillberequired.Itisabsolutelyessentialtoloosenandrinsethegranulateannually.Cleaning

Fig. 8: overallviewoftheneutralizationboxwithsiphon

Step 1: Takeoffthesiphonbendandtheconnectiontubefromtheneutralizationboxandtheboiler.

Step 2: Rinsethesiphonbendandpipewithwater.

7.4 Wetcleaning–neutralizationboxand plastic heat exchanger

Whenthegranulatebecomescontaminatedorsolidified,theneutralizationeffectdrops(pollutantsinthecondensateareinsufficientlyreduced).Incertaincases,corrosiondamageonthewastewaterpipesystemcannotbeexcluded.

Information

Theneutralizationboxshouldberegularlymaintained(atleastonceinayear),particu-larlyiftheboilerisoil-fired.Washoutthefiltermaterialwithclearwater.Duringtheseworks,wearprotectiveglovesandsafetygoggles.Thecondensateresiduesmaybeetching.ObservetheprovisionsoftheattachedSafetydatasheet!

Attention

Fig. 7: neutralizationbox

1 Fill3kggranulateuniformlyintothemidd-lechamber.

2 Safetydischargedevice(limitsthewaterleveltomax.130mmintheeventofapumpfailure).Thereforeitisadvisabletoinstallcatchcontainerincombinationwithanelectronicalarmtransmitter(acces-sorieskit).Itwouldbepracticaltolayanattachedhosewithadownwardgradient.• Electricalfaultsensor036425• Condensatepump044958-01(notincludedindelivery)

12

BK50/BK70 BK100

24

Cleaning

Step 6: Pouroutthegranulateintoasuitablecontainer(atub).

Step 7: Cleantheneutralizationboxwithwater.

Step 9: Rinsethegranulatewithwater.

Step 3: Placeacontainerforcollectingrinsingwaterunderthecondensatedischargesystem.

Step 4: Rinsetheplasticheatexchangerwiththehelpofawaterhosewhiletheboilerdoorisopen,throughthefluegasopening.

Step 5: Opentheneutralizationbox.

25

Cleaning

Step 9: Refillthecleanedgranulateintotheneutraliza-tionbox.

Fillthegranulateonlyintothemiddlechamber(asshowninthepicture).

Information

Step 10: Againinstallthecoveroftheneutralizationbox

Step 11: Againconnecttheneutralizationboxtothecondensatedrainagesystem(bearinmindtheprovisionsofcl.6.4!).

Re-establishingofoperatingcondi-tion• Connectthecondensatedischargesystemwiththeneutralizationboxandthentothewastewatersystem.

• Filltheneutralizationboxwiththegranulateasdescribedabove(waterandgranulate).

• Mountthestainlesssteelcombustioncham-ber.

• Whenclosingthedoor,liftitovertheintakesockettightlysetupandfixitwiththenuts.

• Connecttheairintakehosetotheburnerandheatexchangerandplugtheconnec-torsoftheburnerandremoteunlocking.

Carryoutcleaningworksatleastonceayear.Whiledoingso,pleasekeepinmindtheappro-priateregulationsandnormsoftherespectivecountry,sewagewaterandwasteordinanceaswellasjobsafetyrulesandinstructions.

Information

Priortoeverycommissioningandduringeachmaintenanceinterval,pleasecheckthefurn-aceforpossiblegas-sidemalfunctionsandforleakproofness.

Attention

BK50/BK70 BK100

26

TerminalassignmentandlegendtoConform6.0

8 Terminal assignment and legend to Conform 6.0

01

23

45

67

89

Änderung Datum Name

Gepr.

Norm

Datum

Urspr.

Ers.d

Ers.f

Zust.

Bearb.

BU

Blatt

von

11

04.12.15

Regelung 6.0

40

41

42

47

48

49

50

43

44

45

46

51

52

53

54

55

5657

5859

0 - 10V

eBUS

eBUS

LN

N3

N4

N5

N6

14N

1615

N7

NL1

S3B4

T2T1

N

12

N

N

N

89

1011

1213

MP

1P

2P

3P

4P

5

+

-M1

+-M

2

+

-M3

T8T6

22

24 21

0 - 10V

P6

063936

A1

A2

12

14 11

Attention!Whenconnectinganexternalfeedingpump(P2),anadditionalrelay(Article060115)needtobeinterposed

27

TerminalassignmentandlegendtoConform6.0

Terminal as-signment

Standard assignment Designation

40 Nominalvalueoutput0–10V

41 eBus(controlpanel,servicetool,sequencecontroller,remotecontrol)

42Controlpanel Yes eBus(controlpanel,servicetool,sequencecontroller,remotecontrol)

43 Yes Servicewaterchargepump44 Yes Ambienttemperaturesensor

45 Buffertemperaturesensor,above(requiredforcascadeservice,buffermodeoperationandmixingcylinder)

46 Buffertemperaturesensor,centric/lower(Shutdownsensorfortricklecharging)

47 Yes* Secondarypre-flowsensor(*onlyforBK50–BK250)(notrequiredforcascadeservice,buffermodeoperationandmixingcylinder)

48 Yes Fluegastemperaturesensor49 Yes Boilertemperaturesensor50 Yes Boilerreturnflowtemperaturesensor51 Yes Flowtemperaturesensor,heatingcircuit152 Flowtemperaturesensor,heatingcircuit253 Collectorsensor54 Buffertemperaturesensor,lower/Collectorbuffersensor55 Nominalvalueinput0–10V

56/57 Yes 12VDCoutputpressuresensor(red/yellow/black)(notforBK20/BK30withoutfluegasfan)

59 Auxiliaryboilersensor

Terminal assignment Standard assignment Designation

L N Yes Mainsconnection1

(blue)(1)

2(brown)(3)

N(black)(2)

YesFluegasfan(notinthemodelBK20/BK30withoutfan)(Directconnection)(with4-poleWielandplug)

M

3 N Yes Servicewaterchargepump P1

4 N Yes FeedingpumpBK50–BK250electronic,constantspeed P2

5 N Yes CirculationpumpHC1 P36 N Yes Circulationpumpforservicewater P47 N CirculationpumpHC2 P5

8(black)

9(brown)

N(grey) Yes Internalmixer(8open+/9close-)

(BK50–BK250) M1

8 N Yes orinBK20/BK30solarpump/switchvalveoversolarpower

10 11 N Yes HC1mixer(10open+/11close-) M212 13 N HC2mixer(12open+/13close-) M3

14 N Yes Additionalrelay(Boilercirculationpump)(BK50–BK250)electronic,constantspeed P6

15 16 Yes STLboiler/fluegasL1 N T1 T2 S3 B4 Yes Burnerplug(1/2/gr/ye/3/4/5/6)

T8 T6 Burnerplugstage2(T6/T8)

(gr/ye)(gr/ye)

BK50/BK70 BK100

28

SparepartsBK50,BK70andBK100

9 Spare parts BK50, BK70 and BK100

29


OrdernumberBK50 BK70 BK100

1 BoilerBoilermountedwithfluegasfan 037667-11Boilerpre-mountedwithoutfluegasfan 051705-11 051705-11 051707-11

1�1 Boiler 042868-10 042868-10 037667-101�2 Sealing 050773 050773 0507741�3 Cleaningcovercomplete 050627 050627 050628

2 Casingparts2�1 Inspectionlid 050650 050650 0506502.2a Lockingspigot 041535 041535 0415352.2b Fixationplate 041534 041534 0415342.2c Retainingcam 041533 041533 0415332�2 Sideelementleft,frontpart 041977-10 041977-10 037307-102�3 Sideelementleft,rearpart 041979-10 041979-10 037309-102�4 Sideelementleft,lowerpart 041978-02 041978-02 037308-032�5 Rearpanel,upperpart 037282-10 037282-10 037313-102�6 Rearpanel,middlepart 037283-10 037283-10 037314-102�7 Rearpanel,lowerpart 037284-10 037284-10 037315-102�8 Faceplate 037285-03 037285-03 037316-032�9 Mountingpanel 042855-11 042855-11 042854-112�10 Sideelementright,frontpart 041980-10 041980-10 037310-102�11 Sideelementright,rearpart 041982-10 041982-10 037312-102�12 Frontcover 036866-10 036866-10 036862-102�13 Sideelementright,lowerpart 041981-02 041981-02 037311-032�14 Boilerdoorcasing 036863-10 036863-10 036859-102�15 Doorinsulation2�16 Combustionchamberinsert2�17 Coveratthefront 037278-03 037278-03 037305-032�18 Coverattheback 037279-10 037279-10 037306-10

3 Baseparts3�1 U-formholder 040337-01 040337-01 039973-013�2 Basesidepartright 040331-01 040331-01 039967-013�3 Basesidepartleft 040332-01 040332-01 039968-013�4 Basecross-beamhead 040335-01 040335-01 039971-013�5 Basecross-beamrear 040336-01 040336-01 039972-013�6 Anglebracketright 040333-01 040333-01 039969-013�7 Anglebracketleft 040334-01 040334-01 039970-013�8 Absorberframe 050598 050598 050599

4 Othersheet-metalparts4�1 Mountingbracketleft 040330-01 040330-01 039966-014�2 Mountingbracketleft 040329-01 040329-01 039965-01

**:withoutpicture

BK50/BK70 BK100

30



5 Component5�1 Heatexchanger 031662-02 031662-02 037420-025�2 Siliconsealstringforheatexchanger 044622 044622 0446245�3 Fluegasfanpre-assembled 031826-01 031826-01 031826-015�4 Protectivecoverformotoroffluegasfan 031124-01 031124-01 031124-015�5 Burner Seetheattachedburneroperating

instructions5�7 ConnectionpieceforAFGsystem 037340 037340 0373405�8 Boilersupports 035457 035457 0354575�10 Boilerdoor5�11 Collar 035459 035459 0354595�12 Collar 043462 043462 043462

6 Control,regulationelementsandsignallers6�1 Controlset** 041371-05 041371-05 041371-056�2 Control 042475-02 042475-02 042475-026�3 Frontpanel 042433-03 042433-03 042433-036�5 Safetytemperaturelimiter90°C 042314 042314 0423146�6 Safetytemperaturelimiter100°C 042315 042315 0423156�8 Powerbuttongreen0/1 042777 042777 0427776�9 Fuseholder(includingmicrofuseT10A5x20) 042776 042776 0427766�10 Controlunit 042476-01 042476-01 042476-016�11 Remoteunlockingpushbuttoncomplete 048252 048252 0482526�20 Differentialpressuretransmitterwithplug 042517 042517 0425176�21 Holdingbracket 042548 042548 0425486�22 Additionelrelay 060115 060115 0601156�23 Plug3/N(servicewaterchargepump)** 042576 042576 0425766�24 Plug4/N(feedingpump)** 042577 042577 0425776�25 Plug5/N(HC1circulationpump)** 042578 042578 0425786�26 Plug6/N(circulationpump)** 042579 042579 0425796�27 Plug8/9/N(internalmixer)** 042581 042581 0425816�28 Plug10/11/N(HC1mixer)** 042582 042582 0425826�29 Plug43(DHWtemperaturesensor)** 042623 042623 0426236�30 Plug44(ambienttemperaturesensor)** 042555 042555 0425556�31 Plug48(fluegastemperaturesensor)** 042626 042626 0426266�32 Plug49(boilertemperaturesensor)** 042627 042627 0426276�33 Plug50(boilerreturnsensor)** 042628 042628 0426286�34 Plug51(HC1sensor)** 042629 042629 0426296�35 DHWtemperaturesensor** 042474 042474 0424746�36 Fluegastemperaturesensor** 042474 042474 0424746�37 Boilertemperaturesensor** 042474 042474 0424746�38 Boilerreturntemperaturesensor** 042474 042474 042474**:withoutpicture

31



6�39 HC1sensor** 042473 042473 0424736�40 ambienttemperaturesensor** 042471 042471 0424716�41 Burnercable** 042780 042780 0427806�42 Burnercablestage2** 046312 046312 0463126�43 eBusconnectionline** 042784 042784 0427846�44 Omegaconnectionspring** 038749 038749 038749

8 Otherconnectionelements8�2 AirplastPVCspiralhose 051948 051948 0410598�3 Fillinganddischargingcock** 037339 037339 037339

9 Accessories9�1 Neutralizationboxwithoutpump** 035314-01 035314-01 035314-019�5 Pumpforneutralizationbox** 044958-01 044958-01 044958-019�6 Connenctionsetformixer 049884 049884 0498849�7 4waymixer 050345 050345 0503449�8 Servomotor 037338 037338 0446239�9 Circulationpump 063319 063319 0633209�10 Hydrolitfiltermaterial,bundle3kg** 031278 031278 0312789�11 HTsiphonangleDN4090° 035710 035710 0357109�12 HTrubbernippleNW50x30forsiphonangle** 035981 035981 0359819�13 Fluegaspassesbrush** 050716 050716 0507169�14 Boilerbrush** 050717 050717 0507179�15 Brushhandle** 050727 050727 050727**:withoutpicture

BK50/BK70 BK100

32

ECconformitycertification

10 ECconformitycertificationEG-KonformitätserklärungDéclaration de conformité CE 0035

33

Guarantee

6� ExclusionofguaranteeNoguaranteeshallbegranted,regardlessofthecontributoryreasons,fordamageinconsequenceof:• Accident,wilfuldamage,unauthorizeduse,fie,storm,hail,lightningorexplo-sion,

• Useofunsuitablefuels

• Actsofwarofanykind,

• Confiscationorstateintervention.Noguaranteeisgrantedforconsumables(oiljets,ignitionandionizationelectrodes).

7� ScopeTheguaranteeisonlyvalidwithinEurope,ingeographicsense.

8� OtherprovisionsTheWarranteeisadvisedthatthelegalrightsoftheconsumersarenotaffectedbythisguarantee.

11 GuaranteeFully Condensing Boilers BK50, BK70 and BK100

1� Wegranttodealers/craftsmenandconsu-mersaguaranteefordurabilityofgoods,incompliancewiththefollowingconditions,forthefollowingparts:• Boilerbody 2years

• PlasticheatexchangerPP 5years

• Plasticparts 5years

• Conform6.0controlsystem 2years

• Rotatingelectricalcomponents 2years

• Oilandgasfanburner 2years

2� Theguaranteebeginswiththedateofput-tingintooperationbutnolaterthan4weeksafterdeliverytoadealer/craftsmanandendsafterexpirationoftheperiodspecifiedincl.1.Withoutthesubmittedcommissio-ningreport,theguaranteeagreementwiththecompanyshallnotenterintoforce.Asthepartsarereplacedwithinthescopeofguarantee,theguaranteeendsafterdismounting.Forthenewlyinstalledparts,theperiodmentionedincl.1,beginswiththeinstallation.

3� ScopeoftheguaranteeTheguaranteeincludesthereplacementofpartscoveredbytheguarantee.Labourandtransportationcostsrelatedtotheinstalla-tionaswellascostsofdisposalbearstheWarrantee,asfaraslegallypermissible.

4� GuaranteehandlingTheWarranteeshouldinformthemanu-factureraboutanydamagecoveredbytheguarantee,immediatelyupondiscovery,withanexactdescriptionofit.Thedefectivepartshouldbesenttothemanufactureralongwiththereturnsform.

5� Guaranteeisgranted• Ifthecommissioningwascarriedoutbyatrainedspecialiststaffandthesignedcommissioningreportwassenttothemanufacturerimmediatelyaftercommis-sioning.

• Ifmaintenancewasmadeaccordingtotherules,inthementionedtimescale.

BK50/BK70 BK100

34

Notes

12 Notes

Notes and particularities

35

Notes


BK50/BK70 BK100

36

Notes


Any use, installation, maintenance that is not effected in accordance with the rules specified in the operating instructions, or unauthorized modifications to

the factory-made equipment design shall result in expiration of every guarantee claim.Otherwise our “Conditions of Sale and Delivery” shall apply.

Subject to technical change in terms of product improvement without notice.

Documents

YEAR ROUND MAXIMUM CONDENSING BOILER - Atlantic Boilers · Heating boilers – special requirements for oil fired room sealed units DIN 18 160-1 Supplement 3 Chimneys DIN EN 12 828:2003