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Theory

Theory. Condensing. Water out of combustion air and combustion reaction is vaporised in flue gasses. This vaporised water condenses when flue gasses are cooled down below dew point. Point of condensation. Efficiency. 1 m 3 natural gas (G25) contains:. 31669 KJ/m 3 sensible heat.

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Theory

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  1. Theory R30 Training

  2. Condensing Water out of combustion air and combustion reaction is vaporised in flue gasses. This vaporised water condenses when flue gasses are cooled down below dew point. R30 Training

  3. Point of condensation R30 Training

  4. Efficiency 1 m3 natural gas (G25) contains: 31669 KJ/m3 sensible heat 3427 KJ/m3 latent heat Calorific value of gas is defined as the amount of heat which is released when combusting 1m3 of gas under constant pressure (101,325 kPa) and constant temperature (25°C = 298,15K). Nett calorific value of gas: the amount of heat which can be released when combusting 1m3 of gas without condensing (sensible heat)Hi = 31669 KJ/m3 Gross calorific value of gas: the amount of heat which can be released when combusting 1m3 of gas including condensing (sensible heat + latent heat)Hs = 35096 KJ/m3 R30 Training

  5. Efficiency R30 Training

  6. Nett efficiency The nett calorific efficiency is based on a historical decision, which says that a boiler has 100% efficiency when all the sensible heat is transferred without having any latent heat transfer from condensing: Maximum nett efficiency: R30 Training

  7. Gross efficiency The gross calorific efficiency is the real, practical efficiency and it can only be 100% when all the sensible + latent heat is transferred: Maximum gross efficiency: R30 Training

  8. Efficiency (example) Gas consumption = 10 [m3/hr] = 10/3600 [m3/sec] Nett Energy input = (10/3600) [m3/sec] * 31669 [kJ/m3] = 87,97 [kJ/sec] = 87,97 [kW] Gross Energy input = (10/3600) [m3/sec] * 35096 [kJ/m3] = 97,49 [kJ/sec] = 97,49 [kW] Output measured = 95,21 kW: R30 Training

  9. R30 R30/45 HR107 39 kW R30/65 HR107 59 kW R30/85 HR107 78 kW R30/100 HR107 88 kW R30/120 HR107 110 kW # = maximum capacity on 40/30 • Free modulating 14/20% - 100% • Low Nox • Premix principle R30 Training

  10. Dimensions R30 Training

  11. Construction (1) R30 Training

  12. Construction (2) R30 Training

  13. Connections Electrical 230V AC, 50 Hz L1, N, PE (Watch phase-neutral!) Gas ¾” outer thread Water 1¼” outer thread 1” inner thread Condensate drain Hose d = 25mm Siphon reachable from outside the boiler Flue/Air intake R30/45 and R30/65 80/80mm R30/85 up to R30/120 100/100mm Application category B23, C13, C33, C43, C53, C63, C83 R30 Training

  14. Gas & Water Gas pressure: Natural gas L (G25) 20-25 mbar Natural gas H (G20) 17-25 mbar Propane (G31) 30-50 mbar Propane with restriction ring: 45kW Ø 6,8mm 65+85kW Ø 6,0mm 100kW Ø 6,2mm 120kW Ø 8,0mm Water: Max. water pressure 6 bar Max. flow temperature 90°C Water quality (Chloride level + Water hardness) R30 Training

  15. Electrical Connections L1-N-Earth Power supply to boiler 1-3 Lockout input (230V 1A from boiler) 4-5 Enable (standby to automatic) except DHW 6-7 DHW sensor 8-9 External setpoint: 1-5Vdc  10°C - 90°C, < 1Vdc  P1 10-11 SCOM Bus connection, watch polarity: 10 is neutral, 11 is positive ST 1.1-1.2 OK signal, max. 230V 1A external ST 2.1-2.2 Outdoor sensor: frost protection and/or weather compensation with BM8 or E8 ST 9.3-9.4 Interlock input (24Vac 7mA from boiler) ST11.1-11.2 DHW load pump control R30 Training

  16. Wiring diagram 45-100kW R30 Training

  17. Wiring diagram 120kW R30 Training

  18. Mixing system 45-100kW R30 Training

  19. Mixing system 120kW R30 Training

  20. Heatexchanger R30 Training

  21. Heatexchanger Cooled fluegas outlet Condensation deflector Hot water manifold Cold water manifold Baffle + Insulation disc Condensate drain hole First exchange Heated combustion gas Second exchange/condensation R30 Training

  22. Gasvalve adjustmentR30 - 45/65/85/100kW First adjust maximum, then minimum!! Maximum load + - Minimum load - + R30 Training

  23. Gasvalve adjustmentR30 - 120kW First adjust maximum, then minimum!! Maximum load + - Minimum load - + R30 Training

  24. Combustion Settings Set boiler to service operation (max./min.) R30/45-65-85-120 Natural gas CO2,max = 8,8% ± 0,2% CO2,min = 8,2% ± 0,2% Propane CO2,max = 9,8% ± 0,2% CO2,min = 9,0% ± 0,2% R30/100 Natural gas CO2,max = 9,4% ± 0,2% CO2,min = 8,8% ± 0,2% Propane CO2,max = 10,4% ± 0,2% CO2,min = 9,4% ± 0,2% R30 Training

  25. Controller KM628 KM628-R500 without CXE expansion module: External temperature setpoint with 1-5V signal OK-signal potential free (max. 230V AC, 1A) Boiler enable contact 230V AC Outside sensor Sanitary hot water sensor (thermostat connection optional) Interlock input 24V AC Lockout input 230V AC Primary sanitary hot water pump control (230V AC, max. 1A) R30 Training

  26. Controller KM628 Other differences compared with KM628+CXE: sanitary hot water thermostat connection optional!!! No external gas valve connection No header sensor connection No alarm signal No capacity feedback R30 Training

  27. Controller: KM628-R500 1 Function 2 Function selector 3 Fault indication 4 Supply temperature 5 Malfunction code (flashing) Standby Automatic operation Summer operation Service operation min. Service operation max. R30 Training

  28. Parameter menu 1 Parameter indication  2 Optical I/O 3 Reset/Programming button 4 Alarm LED 5 Parameter/Value selector 6 Output status 7 Current/Desired parameter value 8 Fault/Parameter indication 9 Input status P1 Current/Setting supply temperature P2 Current/Setting DHW temperature P3 Desired supply temperature external *** P5 Current outside temperature P6 Current fluegas temperature P9 Current/Maximum boiler capacity P10 Password entry *** Desired boiler capacity (when using a KKM) R30 Training

  29. Lockouts 1 High limit thermostat (STB) has operated, boiler temperature has exceeded 100°C 2/3 Interlock input has been interrupted (gas pressure switch or external safety device) 4/5 Flame signal fault during ignition/operation 6 Temperature protection (STW) has operated, boiler temperature has exceeded 97°C 7 Fluegas temperature has exceeded 100C 11 Error in flame signal, a flame has been detected during startup 12 Flow temperature sensor is defective 13 Lockout input has been interrupted or fluegas sensor is defective 14 Hot water temperature sensor is defective 15 Outside temperature sensor is defective 24 Fan does not reach prepurge speed 25 Fan does not reach ignition speed 26 Fan does not stop 30 CRC-error in EEprom data group “boilerparameters” 31 CRC-error in EEprom data group “burnerparameters” 32 Fault in 24V circuit x.y. Internal failure KM recognised R30 Training

  30. Hydraulic Add-on’s R30 Training

  31. Cascade Systems Flue gas cascade system Hydraulic cascade system R30 Training

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