BURNS BOY III Guide de l'utilisateur

Stand 11/2009

Installation and

Operating Instruction

Gebr. Bruns GmbH

Hauptstraße 200

D 26683 Saterland

Tel.: + 49 (0) 44 92 / 92 46 0

Fax: + 49 (0) 44 92 / 71 41

BOY III

Condensing Gas Boiler

Table of contents

1 Introduction 4

1.1 Symbols used in this manual 4

1.2 Liability 4

1.3 Factory Warranty 4

2 Product Description 5

2.1 Product Description 5

2.2 Intended use 5

2.3 Equipment configuration BOY III Solo 6

2.4 Equipment configuration BOY III Combi 7

3 Regulations, Guidelines, Safety 8

3.1 Regulations and Guidelines 8

3.2 Safety Warning 9

3.2.1 What to Do if You Smell Gas 9

3.2.2 Risk of Poisoning 9

3.2.3 Risk of Freezing 10

3.2.4 Relief Valve 10

3.2.5 Aspirator 10

3.2.6 Pressure Compensating Tank for Drinking Water 11

3.2.7 Pressure Compensating Tank for the Heating System 11

3.2.8 Water Deficiency Safety Fuse 11

3.2.9 High Temperature cut out 11

3.2.10 Corrosion Protection 12

3.2.11 Installation Location Requirements 12

3.2.12 Minimum Safety Distances 12

4 Mounting/Installation 13

4.1 Shipment Contents 13

4.2 Mounting the Unit 14

4.2.1 General Instructions for Connection the Heating Unit 15

4.2.2 Connecting the Heating Unit (Supply and Return Lines) 15

4.2.3 Connecting for Drinking Water (BOY III Combi) 16

4.2.4 Connecting for Use with an External Reservoir 16

4.2.5 General Instructions for the Gas Connection 17

4.2.6 Connecting the Gas Main 17

4.2.7 General Instructions for Connecting the Gas Flue 18

4.2.8 Chimney Compatibility 18

4.2.9 Heating Duct Requirements 18

4.2.10 Maximum Length of Flue Ducts and Number of Directional Changes 18

4.2.11 Reducing the Maximum Delivery Height 18

4.2.12 Lighting Protection 18

4.2.13 Connecting the Unit to the Chimney 19

4.2.14 Installing the Emissions Connection to Central Roof Heating 21

4.2.15 Connecting the Condensed Water Drain 21

4.2.16 Neutralisation 21

4.2.17 General Instructions for the Electrical Connection 22

4.2.18 Electrical Connection 22

4.2.19 Pin Assignment on the Terminal Strip 23

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Table of contents

5 Start up 24

5.1 Filling and Ventilating the Heating System 24

5.2 Ventilating the Unit 24

5.3 Ventilating the Lower/Standing Reservoir (optional) 25

5.4 Start up 26

5.4.1 Performance of the Unit Test Routine upon Start up 26

5.5 (Pre) Setting the Boiler 26

5.5.1 CO2Boiler Settings 26

5.5.2 Gas Throughput Table / Connection Pressure 27

5.5.3 Changing Gas Types 27

6 Operating the Controls 28

6.1 Description of the Control Panel 28

6.2 LED Display Symbols 28

6.3 Controller Functions and Operating Status 29

6.3.1 Start up 29

6.3.2 Standby Mode 29

6.3.3 Flame Detector 29

6.3.4 Central Heating Mode 30

6.3.4.1 Operating the Central Heater 30

6.3.4.2 Anti-Cycling Central Heating 30

6.3.5 Drinking Water Mode 30

6.3.5.1 Operating the Drinking-Water Heater 30

6.3.5.2 Anti-Cycling Drinking-Water Heater 31

6.3.6 Changing the Set-point 31

6.3.6.1 Changing the Set-point for Central Heating 31

6.3.6.2 Changing the Set-point for the Drinking-Water Heater 31

6.3.7 Summer Mode 32

6.3.8 Chimney Sweep Mode 32

6.3.9 Installer Mode 32

6.3.10 Installer (+) Mode 33

6.3.10.1 Installer (+) Parameter List 34

7 Malfunctions and Errors 36

7.1 Error Mode 36

7.2 Error Code List 36

7.2.1 Shutdown Codes 36

7.2.2 Locking Codes 37

7.3 Error history Mode 39

7.4 Log Resistance Values for the Boiler and Reservoir Sensors 39

8 Maintenance 40

8.1 General Instructions for Maintenance 40

8.2 Cleaning the Condensed Water Siphon 40

8.3 Cleaning the Combustion Chamber 40

9 Technical Data 43

9.1 Circuit Diagram 43

9.2 Technical Data 44

10 Declaration of Conformity 46

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Introduction

1 Introduction

Dear customer,

We congratulate you on your decision to use the BOY III Condensing Gas Boiler. By

purchasing the BOY III, you have secured the most current level of innovation in boil-

er technology.

We will gladly answer any questions or provide any information you may need.

We thank you for your trust and hope you enjoy you BOY III Condensing Gas Boiler.

Gebr. BRUNS GmbH,

Your partner for heating technology

1.1 Symbols used in this manual

Failure to follow instructions marked with this symbol risks life and limb; a de-

fect in the unit is possible.

This Symbol denotes important Instructions and Information.

This symbol marks tasks to be fulfilled.

1.2 Liability

Gebr. Bruns GmbH is not liable for damages caused by not observing this in-

stallation and operating instruction.

1.3 Factory Warranty

We provide a factory warranty for the owner in accordance with the current condi-

tions and deadlines in the Gebr. Bruns GmbH’s general terms and conditions. The

warranty does not cover damages caused by normal wear and tear, insufficient water

quality, aggressive fumes or strong dust. Warranty work is performed exclusively by

the factory. We can, therefore, only reimburse you for expenses incurred for repairs

done during the warranty period if we have received a proper order and have

deemed it to be covered by the warranty.

- 4 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Product Description

2 Product Description

2.1 Product Description

The BOY III is a compact, wall-hanging condensing gas boiler that weighs very little.

The BOY III can be operated dependent or independent of compartment air. All of

the basic parts are inside the powder-coated steel-plated casing. The stainless steel

heat exchanger is designed for exhaust condensation operation and is very self-

cleaning. With its 1:5 modulation ratio, the force draught fan supported burner, de-

signed especially for gas boilers, is very efficient in its energy use and emissions.

The connections can be placed from below the unit. An atmospheric or temperature

sensor can be attached to the boiler controller. These sensors can, depending on

how they are set up, regulate up to two mixing valve circuit.

2.2 Intended use

The BOY III is a condensing gas boiler and is exclusively for use as a heating

unit for heating systems.

Any misuse is prohibited

- 5 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Fig. 1: Boy III

Product Description

2.3 Equipment configuration BOY III Solo

- 6 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Fig. 2: BOY III Solo

Burner Unit

Ionisation

Force Draught Fan

Relief Valve

Flow Sensor

Water Pressure Sensor

High Temperature

Sensor

Ignition Electrode

Automatic Firing Device

Gas Valve

Return Sensor

Circulation Pump

Product Description

2.4 Equipment configuration BOY III Combi

- 7 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Fig. 3: BOY III Combi

Burner Unit High Temperature

cut out

Ionisation

Force Draught Fan

Relief Valve

Flow Sensor

Water Pressure Sensor

Ignition Electrode

Automatic Firing Device

Gas Valve

Return Sensor

Circulation Pump

Plate Heat

Exchanger

Warm Water Sensor Circulation Sensor

Regulations, Guidelines, Safet

3 Regulations, Guidelines, Safety

3.1 Regulations and Guidelines

Regarding mounting, installation, and operation of the BOY III, the following laws, or-

dinances, regulations, norms and rules apply according to the current versions.

In other countries, the respective national regulations apply.

BImSchV Federal Emissions Protection Regulation

DIN 18160 Emissions Systems – Design and Operation

DIN 18380 Heating Systems and Central Water Heating Systems

DIN 1988 Teil 1 – 8 Technical Regulations for Drinking Water Installation

DIN 4753 Water heater and Water heating Systems for Drinking Wa-

ter and Domestic Use

DIN EN 12828 Water heating System Design

DIN EN 12831 Procedure for Calculating the Heating Load Norm

DIN EN 13384 Procedure for Calculating Emissions Systems – Heat and

Supply

DIN EN 267 Automatic Burner with Force Draught Fan for Liquid Fuels

DVGW G 631 Installation of Commercial Gas Consuming Appliances

DVGW G 634 Installation of Gas Units in Commercial Kitchens in Build-

ings

DVGW G 670 Gas Fire Locations and Mechanical Ventilation Systems

DVGW TRGI 86 Technical Regulations for Gas Installation

EnEG Energy Conservation Law

EnEV Energy Conservation Regulation

FeuVO Fire Regulations per State

VDE Rules and Regulations for Electro-Technical, Electronics,

and Information Technology

VDI 2035 Prevention of Damages in Water Heating Systems – Accu-

mulation of Stone in Drinking Water and Water Heating sys-

tems – Corrosive Water – Corrosive Emissions

This list may not be complete!

Before installing the condensing gas boiler BOY III, it is necessary to attain

approval from the Gas Supply Ordinance Board and the District Chimney

Sweep Foreman.

- 8 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet

3.2 Safety Warning

Attention: Electrical installation and initial operation may only be performed by

a licensed professional! This also pertains to maintenance, cleaning, and re-

pair.

●Do not use if system is damaged.

●Only original parts may be used.

●Changes and repairs made on one’s own authority are not allowed, as

such may result in damages to the unit or injury or death.

●When operated in a compartment air-dependent area, ventilation (in

and out) must not be obstructed. The intake of combustion air on the

top of the BOY III must be kept free of obstructions.

3.2.1 What to Do if You Smell Gas

Avoid open fire, smoking, turning on lights, or unplugging anything in rooms

that smell like gas. Under no circumstances should you use the telephone.

Close the gas meter valve! Have your installation technician show you where

the gas valve is and how to close it.

Do not use doorbells or light switches in other rooms.

If you smell gas, use a telephone in a neighbouring building or use a phone

booth. Mobile phones should also be used outside of the building.

Call the service department, even if you smell gas somewhere else.

Do not forget to warn housemates and neighbours and vacate the premises.

Secure the building against unauthorized entry.

Even if you aren’t sure if it is a gas smell, you should contact your energy pro-

vider as a precaution.

3.2.2 Risk of Poisoning

Never use water from the heating system as drinking water! It is contaminated with

deposits.

- 9 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

Regulations, Guidelines, Safet

3.2.3 Risk of Freezing

If the unit is at risk of freezing, it is necessary to be kept operational in conservation

mode (at minimum) and all radiator valves should be kept open. If you cannot heat

during freezing periods, turn off the system and empty the boiler, the warm water

storage tank and the radiators. The boiler must be secured against accidental activa-

tion when empty.

3.2.4 Relief Valve

The condensing gas boiler comes with a 2.5 bar relief

valve. The opening of the spring-loaded membranous

relief valve must be in a frost free area and must be eas-

ily accessible. The blow off pipe on the relief valve must

be implemented without the possibility of increasing

pressure while responding to the relief valve. Leaking

heater water should be safely siphoned off.

Operational readiness of the relief valve should be

checked from time to time. Fig. 4 Relief Valve

3.2.5 Aspirator

To ventilate the boiler with water in it, the

aspirator cap on the top of the unit must be

open by turning it two rotations to the left.

Fig. 5 Manual Quick-Aspirator

An additional automatic aspirator can be

found under the pump casing. This may

only be set by a licensed professional.

Fig. 6 Automatic Quick-Aspirator

- 10 -

Gebr. Bruns GmbH is not responsible for typographical errors or technical inaccuracies and reserves the right to make adjustments.

Gebr. Bruns GmbH •Hauptstraße 200 •26683 Saterland •Tel.: + 49 (0) 44 92 / 92 46-0 •Fax: + 49 (0) 44 92 / 71 41

www.bruns-heiztechnik.de •[email protected]

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