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<strong>Installation</strong> <strong>and</strong><br />

<strong>Operating</strong> <strong>Instruction</strong><br />

Gebr. Bruns GmbH<br />

Hauptstraße 200<br />

D 26683 Saterl<strong>and</strong><br />

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

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

BOY III<br />

Condensing Gas Boiler<br />

St<strong>and</strong> 11/2009


Table of contents<br />

1 Introduction 4<br />

1.1 Symbols used in this manual 4<br />

1.2 Liability 4<br />

1.3 Factory Warranty 4<br />

2 Product Description 5<br />

2.1 Product Description 5<br />

2.2 Intended use 5<br />

2.3 Equipment configuration BOY III Solo 6<br />

2.4 Equipment configuration BOY III Combi 7<br />

3 Regulations, Guidelines, Safety 8<br />

3.1 Regulations <strong>and</strong> Guidelines 8<br />

3.2 Safety Warning 9<br />

3.2.1 What to Do if You Smell Gas 9<br />

3.2.2 Risk of Poisoning 9<br />

3.2.3 Risk of Freezing 10<br />

3.2.4 Relief Valve 10<br />

3.2.5 Aspirator 10<br />

3.2.6 Pressure Compensating Tank for Drinking Water 11<br />

3.2.7 Pressure Compensating Tank for the Heating System 11<br />

3.2.8 Water Deficiency Safety Fuse 11<br />

3.2.9 High Temperature cut out 11<br />

3.2.10 Corrosion Protection 12<br />

3.2.11 <strong>Installation</strong> Location Requirements 12<br />

3.2.12 Minimum Safety Distances 12<br />

4 Mounting/<strong>Installation</strong> 13<br />

4.1 Shipment Contents 13<br />

4.2 Mounting the Unit 14<br />

4.2.1 General <strong>Instruction</strong>s for Connection the Heating Unit 15<br />

4.2.2 Connecting the Heating Unit (Supply <strong>and</strong> Return Lines) 15<br />

4.2.3 Connecting for Drinking Water (BOY III Combi) 16<br />

4.2.4 Connecting for Use with an External Reservoir 16<br />

4.2.5 General <strong>Instruction</strong>s for the Gas Connection 17<br />

4.2.6 Connecting the Gas Main 17<br />

4.2.7 General <strong>Instruction</strong>s for Connecting the Gas Flue 18<br />

4.2.8 Chimney Compatibility 18<br />

4.2.9 Heating Duct Requirements 18<br />

4.2.10 Maximum Length of Flue Ducts <strong>and</strong> Number of Directional Changes 18<br />

4.2.11 Reducing the Maximum Delivery Height 18<br />

4.2.12 Lighting Protection 18<br />

4.2.13 Connecting the Unit to the Chimney 19<br />

4.2.14 Installing the Emissions Connection to Central Roof Heating 21<br />

4.2.15 Connecting the Condensed Water Drain 21<br />

4.2.16 Neutralisation 21<br />

4.2.17 General <strong>Instruction</strong>s for the Electrical Connection 22<br />

4.2.18 Electrical Connection 22<br />

4.2.19 Pin Assignment on the Terminal Strip 23<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Table of contents<br />

5 Start up 24<br />

5.1 Filling <strong>and</strong> Ventilating the Heating System 24<br />

5.2 Ventilating the Unit 24<br />

5.3 Ventilating the Lower/St<strong>and</strong>ing Reservoir (optional) 25<br />

5.4 Start up 26<br />

5.4.1 Performance of the Unit Test Routine upon Start up 26<br />

5.5 (Pre) Setting the Boiler 26<br />

5.5.1 CO2 Boiler Settings 26<br />

5.5.2 Gas Throughput Table / Connection Pressure 27<br />

5.5.3 Changing Gas Types 27<br />

6 <strong>Operating</strong> the Controls 28<br />

6.1 Description of the Control Panel 28<br />

6.2 LED Display Symbols 28<br />

6.3 Controller Functions <strong>and</strong> <strong>Operating</strong> Status 29<br />

6.3.1 Start up 29<br />

6.3.2 St<strong>and</strong>by Mode 29<br />

6.3.3 Flame Detector 29<br />

6.3.4 Central Heating Mode 30<br />

6.3.4.1 <strong>Operating</strong> the Central Heater 30<br />

6.3.4.2 Anti-Cycling Central Heating 30<br />

6.3.5 Drinking Water Mode 30<br />

6.3.5.1 <strong>Operating</strong> the Drinking-Water Heater 30<br />

6.3.5.2 Anti-Cycling Drinking-Water Heater 31<br />

6.3.6 Changing the Set-point 31<br />

6.3.6.1 Changing the Set-point for Central Heating 31<br />

6.3.6.2 Changing the Set-point for the Drinking-Water Heater 31<br />

6.3.7 Summer Mode 32<br />

6.3.8 Chimney Sweep Mode 32<br />

6.3.9 Installer Mode 32<br />

6.3.10 Installer (+) Mode 33<br />

6.3.10.1 Installer (+) Parameter List 34<br />

7 Malfunctions <strong>and</strong> Errors 36<br />

7.1 Error Mode 36<br />

7.2 Error Code List 36<br />

7.2.1 Shutdown Codes 36<br />

7.2.2 Locking Codes 37<br />

7.3 Error history Mode 39<br />

7.4 Log Resistance Values for the Boiler <strong>and</strong> Reservoir Sensors 39<br />

8 Maintenance 40<br />

8.1 General <strong>Instruction</strong>s for Maintenance 40<br />

8.2 Cleaning the Condensed Water Siphon 40<br />

8.3 Cleaning the Combustion Chamber 40<br />

9 Technical Data 43<br />

9.1 Circuit Diagram 43<br />

9.2 Technical Data 44<br />

10 Declaration of Conformity 46<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Introduction<br />

1 Introduction<br />

Dear customer,<br />

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

purchasing the BOY III, you have secured the most current level of innovation in boiler<br />

technology.<br />

We will gladly answer any questions or provide any information you may need.<br />

We thank you for your trust <strong>and</strong> hope you enjoy you BOY III Condensing Gas Boiler.<br />

Gebr. BRUNS GmbH,<br />

Your partner for heating technology<br />

1.1 Symbols used in this manual<br />

Failure to follow instructions marked with this symbol risks life <strong>and</strong> limb; a defect<br />

in the unit is possible.<br />

This Symbol denotes important <strong>Instruction</strong>s <strong>and</strong> Information.<br />

This symbol marks tasks to be fulfilled.<br />

1.2 Liability<br />

Gebr. Bruns GmbH is not liable for damages caused by not observing this installation<br />

<strong>and</strong> operating instruction.<br />

1.3 Factory Warranty<br />

We provide a factory warranty for the owner in accordance with the current conditions<br />

<strong>and</strong> deadlines in the Gebr. Bruns GmbH’s general terms <strong>and</strong> conditions. The<br />

warranty does not cover damages caused by normal wear <strong>and</strong> tear, insufficient water<br />

quality, aggressive fumes or strong dust. Warranty work is performed exclusively by<br />

the factory. We can, therefore, only reimburse you for expenses incurred for repairs<br />

done during the warranty period if we have received a proper order <strong>and</strong> have<br />

deemed it to be covered by the warranty.<br />

- 4 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Product Description<br />

2 Product Description<br />

2.1 Product Description<br />

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

The BOY III can be operated dependent or independent of compartment air. All of<br />

the basic parts are inside the powder-coated steel-plated casing. The stainless steel<br />

heat exchanger is designed for exhaust condensation operation <strong>and</strong> is very selfcleaning.<br />

With its 1:5 modulation ratio, the force draught fan supported burner, designed<br />

especially for gas boilers, is very efficient in its energy use <strong>and</strong> emissions.<br />

The connections can be placed from below the unit. An atmospheric or temperature<br />

sensor can be attached to the boiler controller. These sensors can, depending on<br />

how they are set up, regulate up to two mixing valve circuit.<br />

2.2 Intended use<br />

Fig. 1: Boy III<br />

The BOY III is a condensing gas boiler <strong>and</strong> is exclusively for use as a heating<br />

unit for heating systems.<br />

Any misuse is prohibited<br />

- 5 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Product Description<br />

2.3 Equipment configuration BOY III Solo<br />

Burner Unit<br />

Ionisation<br />

Force Draught Fan<br />

Relief Valve<br />

Flow Sensor<br />

Water Pressure Sensor<br />

Fig. 2: BOY III Solo<br />

- 6 -<br />

High Temperature<br />

Sensor<br />

Ignition Electrode<br />

Automatic Firing Device<br />

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

Gas Valve<br />

Return Sensor<br />

Circulation Pump<br />

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Product Description<br />

2.4 Equipment configuration BOY III Combi<br />

Burner Unit High Temperature<br />

cut out<br />

Ionisation<br />

Force Draught Fan<br />

Plate Heat<br />

Exchanger<br />

Relief Valve<br />

Flow Sensor<br />

Water Pressure Sensor<br />

Fig. 3: BOY III Combi<br />

Warm Water Sensor Circulation Sensor<br />

- 7 -<br />

Ignition Electrode<br />

Automatic Firing Device<br />

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

Gas Valve<br />

Return Sensor<br />

Circulation Pump<br />

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Regulations, Guidelines, Safety<br />

3 Regulations, Guidelines, Safety<br />

3.1 Regulations <strong>and</strong> Guidelines<br />

Regarding mounting, installation, <strong>and</strong> operation of the BOY III, the following laws, ordinances,<br />

regulations, norms <strong>and</strong> rules apply according to the current versions.<br />

In other countries, the respective national regulations apply.<br />

BImSchV Federal Emissions Protection Regulation<br />

DIN 18160 Emissions Systems – Design <strong>and</strong> Operation<br />

DIN 18380 Heating Systems <strong>and</strong> Central Water Heating Systems<br />

DIN 1988 Teil 1 – 8 Technical Regulations for Drinking Water <strong>Installation</strong><br />

DIN 4753 Water heater <strong>and</strong> Water heating Systems for Drinking Water<br />

<strong>and</strong> Domestic Use<br />

DIN EN 12828 Water heating System Design<br />

DIN EN 12831 Procedure for Calculating the Heating Load Norm<br />

DIN EN 13384 Procedure for Calculating Emissions Systems – Heat <strong>and</strong><br />

Supply<br />

DIN EN 267 Automatic Burner with Force Draught Fan for Liquid Fuels<br />

DVGW G 631 <strong>Installation</strong> of Commercial Gas Consuming Appliances<br />

DVGW G 634 <strong>Installation</strong> of Gas Units in Commercial Kitchens in Buildings<br />

DVGW G 670 Gas Fire Locations <strong>and</strong> Mechanical Ventilation Systems<br />

DVGW TRGI 86 Technical Regulations for Gas <strong>Installation</strong><br />

EnEG Energy Conservation Law<br />

EnEV Energy Conservation Regulation<br />

FeuVO Fire Regulations per State<br />

VDE Rules <strong>and</strong> Regulations for Electro-Technical, Electronics,<br />

<strong>and</strong> Information Technology<br />

VDI 2035 Prevention of Damages in Water Heating Systems – Accumulation<br />

of Stone in Drinking Water <strong>and</strong> Water Heating systems<br />

– Corrosive Water – Corrosive Emissions<br />

This list may not be complete!<br />

Before installing the condensing gas boiler BOY III, it is necessary to attain<br />

approval from the Gas Supply Ordinance Board <strong>and</strong> the District Chimney<br />

Sweep Foreman.<br />

- 8 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Regulations, Guidelines, Safety<br />

3.2 Safety Warning<br />

Attention: Electrical installation <strong>and</strong> initial operation may only be performed by<br />

a licensed professional! This also pertains to maintenance, cleaning, <strong>and</strong> repair.<br />

● Do not use if system is damaged.<br />

● Only original parts may be used.<br />

● Changes <strong>and</strong> repairs made on one’s own authority are not allowed, as<br />

such may result in damages to the unit or injury or death.<br />

● When operated in a compartment air-dependent area, ventilation (in<br />

<strong>and</strong> out) must not be obstructed. The intake of combustion air on the<br />

top of the BOY III must be kept free of obstructions.<br />

3.2.1 What to Do if You Smell Gas<br />

Avoid open fire, smoking, turning on lights, or unplugging anything in rooms<br />

that smell like gas. Under no circumstances should you use the telephone.<br />

Close the gas meter valve! Have your installation technician show you where<br />

the gas valve is <strong>and</strong> how to close it.<br />

Do not use doorbells or light switches in other rooms.<br />

If you smell gas, use a telephone in a neighbouring building or use a phone<br />

booth. Mobile phones should also be used outside of the building.<br />

Call the service department, even if you smell gas somewhere else.<br />

Do not forget to warn housemates <strong>and</strong> neighbours <strong>and</strong> vacate the premises.<br />

Secure the building against unauthorized entry.<br />

Even if you aren’t sure if it is a gas smell, you should contact your energy provider<br />

as a precaution.<br />

3.2.2 Risk of Poisoning<br />

Never use water from the heating system as drinking water! It is contaminated with<br />

deposits.<br />

- 9 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Regulations, Guidelines, Safety<br />

3.2.3 Risk of Freezing<br />

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

mode (at minimum) <strong>and</strong> all radiator valves should be kept open. If you cannot heat<br />

during freezing periods, turn off the system <strong>and</strong> empty the boiler, the warm water<br />

storage tank <strong>and</strong> the radiators. The boiler must be secured against accidental activation<br />

when empty.<br />

3.2.4 Relief Valve<br />

The condensing gas boiler comes with a 2.5 bar relief<br />

valve. The opening of the spring-loaded membranous<br />

relief valve must be in a frost free area <strong>and</strong> must be easily<br />

accessible. The blow off pipe on the relief valve must<br />

be implemented without the possibility of increasing<br />

pressure while responding to the relief valve. Leaking<br />

heater water should be safely siphoned off.<br />

Operational readiness of the relief valve should be<br />

checked from time to time.<br />

3.2.5 Aspirator<br />

To ventilate the boiler with water in it, the<br />

aspirator cap on the top of the unit must be<br />

open by turning it two rotations to the left.<br />

An additional automatic aspirator can be<br />

found under the pump casing. This may<br />

only be set by a licensed professional.<br />

- 10 -<br />

Fig. 4 Relief Valve<br />

Fig. 5 Manual Quick-Aspirator<br />

Fig. 6 Automatic Quick-Aspirator<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Regulations, Guidelines, Safety<br />

3.2.6 Pressure Compensating Tank for Drinking Water<br />

In combination with a drinking water reservoir,<br />

a membranous pressure compensating<br />

tank that has been approved for filtering<br />

domestic-use water to drinking water is required.<br />

This tank should have ample space<br />

<strong>and</strong> must be installed externally in accordance<br />

with TRWI regulations. The size of the<br />

tank is dependent upon the volume of domestic-use<br />

water reservoir.<br />

3.2.7 Pressure Compensating Tank for the Heating System<br />

On the heater side, a membranous pressure<br />

compensating tank is required. This<br />

tank should have ample space <strong>and</strong> is to be<br />

installed externally. The size of the tank is<br />

dependent upon the volume of heating system’s<br />

water reservoir as well as the temperature<br />

requirements.<br />

Fig. 7 Pressure Compensating Tank for<br />

Drinking Water<br />

Fig. 8 Pressure Compensating Tank for the<br />

Heating System<br />

Setting the primary pressure of the pressure compensating tanks to the<br />

respective static levels is required <strong>and</strong> may only be performed by a licensed<br />

professional.<br />

3.2.8 Water Deficiency Safety Fuse<br />

A minimum circulation rate of 360 l/h is required. Furthermore, a water pressure<br />

sensor makes sure that at a system pressure of 0.6 bar, the system automatically<br />

shuts down. As soon as the water pressure returns to above 0.6 bar, the unit<br />

will turn itself back on automatically.<br />

3.2.9 High Temperature cut out<br />

The unit has a temperatur cut out with a melting fuse. This safety guard is only a protection<br />

against burning out of the heat exchanger. If this fuse is blown out, the complete<br />

heat exchanger has to be changed, because the baffle plate within, is most<br />

probably damaged.<br />

- 11 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Regulations, Guidelines, Safety<br />

3.2.10 Corrosion Protection<br />

The combustion air must be free of all corrosive elements – especially those containing<br />

fluoride <strong>and</strong> chloride such as those found in solvents <strong>and</strong> cleaning solutions, propellants<br />

an so on.<br />

When connecting a water heater to a floor heater with non-airtight plastic tubing (in<br />

accordance with DIN 4726), a heat exchanger must be used to separate the systems.<br />

To avoid corrosion damage in the heating system, heating water that fulfils the drinking<br />

water quality requirements in VDI guideline 2035 (Prevention of Damages in Water<br />

Heating Systems) must be used. Chemical additives are not to be used.<br />

3.2.11 <strong>Installation</strong> Location Requirements<br />

● When operated in a compartment air-dependent area, the unit must be housed<br />

in a room with clean combustion air. Under no circumstances should foreign<br />

substances such as pollen get inside the unit via the intake duct!<br />

● The installation location must be dry <strong>and</strong> frost free (0°C to 45°C).<br />

● The boiler room must be protected against small animals, vermin <strong>and</strong> pests.<br />

● When operated in a compartment air-dependent area, the boiler room must<br />

have a functioning ventilation <strong>and</strong> emission system.<br />

● Flammable material or liquids must not be stored or used near the boiler. Follow<br />

fire prevention guidelines!<br />

3.2.12 Minimum Safety Distances<br />

For optimal installation of the boiler,<br />

we recommend a lateral distance of<br />

200 mm from the walls <strong>and</strong> a vertical<br />

distance of 500 mm from the ceiling.<br />

Reducing these distances is allowed<br />

according to legal guidelines.<br />

The lateral distances should not fall<br />

below 100 mm.<br />

- 12 -<br />

200<br />

4 0 0<br />

Fig. 9 Minimum Safety Distances (mm)<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4 Mounting/<strong>Installation</strong><br />

4.1 Shipment Contents<br />

Please make sure the shipment is complete <strong>and</strong> undamaged before you begin<br />

with the installation!<br />

The delivery comes in a cardboard box.<br />

1<br />

Fig. 10 Shipment Contents<br />

Pos. Anzahl Bezeichnung<br />

1 1 Condensing Gas Boiler BOY III<br />

2 1 Atmospheric or Temperature Sensor (Optional)<br />

3 1 Pressure Gauge<br />

4 1 Control Keypad with Illuminated Display<br />

5 1 Wall Mounting Track<br />

6 2 Mounting Screws incl. Washers<br />

7 2 Plastic Expansion Studs<br />

8 1 <strong>Installation</strong> <strong>and</strong> Operation Manual<br />

- 13 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7


Mounting / <strong>Installation</strong><br />

4.2 Mounting the Unit<br />

The unit comes with a track for easy wall mounting. Before mounting the<br />

unit, please read the following requirements:<br />

• The wall must be stable enough to hold the unit.<br />

• An outlet with contact protection for electricity <strong>and</strong> a water drainage<br />

connection should both be in close proximity.<br />

• Make sure to check the wall for electrical wiring <strong>and</strong> water <strong>and</strong> gas pipes<br />

before drilling as they may get damaged.<br />

• To protect the boiler from contamination, place protective covers over<br />

all connections. Please remove these only at the appropriate installation<br />

stage.<br />

Next, measure the wall intended as the location<br />

of the unit. Follow the measurements of<br />

the unit <strong>and</strong> the minimum safety distances. If<br />

the unit is to be attached to an existing chimney,<br />

use the emissions connection, including<br />

the elbow as the point of reference.<br />

Mark the drilling positions for the mounting<br />

track <strong>and</strong> drill using an 8 mm bit.<br />

Place the plastic expansion studs in the wall<br />

<strong>and</strong> fasten the track to the wall with the<br />

screws. Use a level to make sure the track is<br />

straight <strong>and</strong> then screw it tightly to the wall.<br />

Hang the unit to the mounted track <strong>and</strong> make<br />

sure it is mounted firmly.<br />

Use the setting screws at the bottom of the<br />

back of the boiler to align it parallel to the wall.<br />

Check one more time with the level to make<br />

sure the boiler is straight.<br />

- 14 -<br />

3 2 0<br />

Fig. 11 Wall Track<br />

8 5<br />

Fig. 12 Wall Mount (mm)<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.1 General <strong>Instruction</strong>s for Connection the Heating Unit<br />

● Before connecting the boiler to the heating system, the heating system<br />

must be rinsed at a minimum of 3 times the flow capacity. The drinking<br />

water pipes must be rinsed at a minimum of 20 times its flow capacity.<br />

● In older systems, a filter must be placed in the heating circuit in the return<br />

supply line before the opening to the boiler.<br />

● Use only untreated tap water to fill <strong>and</strong> refill the heating system.<br />

● The pH value must be between 6 <strong>and</strong> 9.<br />

● Do not add any chemicals to the heating system’s water (e.g. anti-freeze,<br />

water softener, solutions to raise or lower the pH value, chemical<br />

additives <strong>and</strong>/or inhibitors). These can damage the boiler.<br />

● When using plastic pipes (e.g. in floor heaters), the pipes must be air<br />

<strong>and</strong> diffusion tight in accordance with DIN 4726/ 4729.<br />

● If the system’s plastic pipes are not in accordance with the norms, we<br />

recommend separating the boiler circulation system from the heating<br />

system with a (plate) heat exchanger or a filter mounted hydraulically<br />

in front of the boiler connection.<br />

● The temperature of the heating ducts <strong>and</strong> radiators can go up to 95 °C.<br />

4.2.2 Connecting the Heating Unit (Supply <strong>and</strong> Return Lines)<br />

There are flue cut-off devices that must be<br />

mounted directly under the boiler. These<br />

should have the respective diameters of the<br />

connections to which they belong. Permanently<br />

soldered or welded connections are not<br />

allowed.<br />

A separate line for filling <strong>and</strong> draining must be<br />

installed <strong>and</strong> easily accessible. If the line for<br />

filling <strong>and</strong> draining is not at the lowest point of<br />

the unit, an additional device must be installed<br />

so the system can be completely drained.<br />

Older systems <strong>and</strong> floor heating systems require<br />

a filter in the return line directly on the<br />

boiler.<br />

S R A K<br />

V L S V<br />

R L<br />

G<br />

Fig. 13 Connections: BOY III Solo<br />

S R A K<br />

V L W W S V<br />

K W R L<br />

G<br />

Fig. 14 Connections: BOY III Combi<br />

SR Siphon-Cleaning VL Supply WW Warm Water SV Drainage Safety Valve<br />

AK Condensation Drainage RL Return Flow KW Cold Water G Gas Connection<br />

- 15 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.3 Connecting for Drinking Water (BOY III Combi)<br />

The drinking water access must be<br />

equipped in accordance with DIN 1988<br />

<strong>and</strong> DIN 4753 to avoid dirt or germs that<br />

can contaminate the cold water network.<br />

The necessary parts <strong>and</strong> their configuration<br />

are shown in the diagram to the right.<br />

T W<br />

4.2.4 Connecting for Use with an External Reservoir<br />

1 2 3 4 5 6<br />

1 . C u t - o f f v a l v e<br />

2 . F i l t e r<br />

3 . P r e s s u r e r e g u l a t o r<br />

4 . C h e c k v a l v e<br />

5 . N o n e - r e t u r n e v a l v e<br />

6 . M a n o m e t e r c o n n e c t i o n<br />

T W . M a i n s d r i n k i n g w a t e r<br />

Fig. 15 Connection Schematic:<br />

Drinking Water Access<br />

If the unit is connected to an external reservoir, an expansion tank <strong>and</strong> a 10 bar relief<br />

valve must be installed to protect the heating system. The BOY III Solo requires an<br />

additional three-way redirecting valve installed in the return flow line directly on the<br />

boiler.<br />

Fig. 16 Three-way Redirecting Valve<br />

The connections on the three-way redirection<br />

valve are as follows:<br />

AB = Return Flow Line BOY III<br />

A = Reservoir Connection<br />

B = Heating Circuit Connection<br />

- 16 -<br />

These connections should never, under<br />

any circumstances, be interchanged!<br />

The three-way redirecting valve is<br />

already integrated in to the BOY III.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

1


Mounting / <strong>Installation</strong><br />

4.2.5 General <strong>Instruction</strong>s for the Gas Connection<br />

• The gas connection must be connected in accordance with the current<br />

regulations. <strong>Installation</strong> may only be performed by a licensed professional!<br />

• Make sure there is no open fire, flammable materials or the like in close<br />

proximity to the installation location. LIFE THREATENING DANGER!<br />

• Before installation, check to make sure the gas meter has adequate<br />

capacity. Take the usage of all household appliances into account.<br />

Let your energy provider know if your line does not have a high<br />

enough capacity.<br />

• Make sure the gas lines are clean. Clean the gas lines with high pressure<br />

or by knocking them clean before installation.<br />

• An approved shut-off valve with a fire protective faucet must be installed<br />

in front of the boiler.<br />

• Preferably, you can also install a gas filter to keep the gas control<br />

valve from getting dirty.<br />

4.2.6 Connecting the Gas Main<br />

Please follow these instructions during installation:<br />

• The main gas spigot must be shut off before the work begins. If the<br />

connection is older, make sure the spigot still closes to avoid uncontrolled<br />

gas leaking out.<br />

• Secure the line against accidental start up while you are working on<br />

the lines.<br />

• Make sure the fire protective faucet is mounted properly.<br />

• Before start up, make sure the entire gas line is sealed, especially at<br />

connection points. The gas faucet <strong>and</strong> the gas line may not exceed a<br />

maximum pressure of 150 mbar.<br />

• Ventilate the gas line after attaching to avoid malfunctions!<br />

• Ventilate the room well after installation to disperse any gas that may<br />

have escaped.<br />

- 17 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.7 General <strong>Instruction</strong>s for Connecting the Gas Flue<br />

Discuss regional guidelines for gas flue lines, cleaning openings <strong>and</strong> similar<br />

with the appropriate chimney sweep.<br />

4.2.8 Chimney Compatibility<br />

Heavily used <strong>and</strong> dirty chimneys are unsuitable for conducting combustion air (air<br />

supply through the chimney) <strong>and</strong> must be cleaned by a chimney sweep before use.<br />

If there are structural damages, such as brittle chimneys, soot build-up or the like, the<br />

chimney should be checked by a chimney sweep foreman to determine its stability. If<br />

cleaning the chimney isn’t possible, the unit can also be run through a concentric<br />

emissions pipe without being dependent upon compartment air. A compartment airdependent<br />

operating method is a possible alternative.<br />

Hooking up more than one or different types of boilers to one chimney should be approved<br />

by a chimney sweep foreman.<br />

4.2.9 Heating Duct Requirements<br />

Emission lines within buildings must be housed within their own ventilated ducts.<br />

The ducts must be made of non-flammable, form-holding materials. The duct’s fire<br />

resistance duration must be 90 minutes, in lower buildings, 30 minutes.<br />

4.2.10 Maximum Length of Flue Ducts <strong>and</strong> Number of Directional Changes<br />

Maximum length of<br />

Flue Duct<br />

Maximum Number of<br />

Directional Changes<br />

4.2.11 Reducing the Maximum Delivery Height<br />

Compartment air-dependent /Compartment air-independent<br />

Duct Layout Central Roof Heating<br />

21 m 4 m<br />

2 4<br />

When lengthening the connection lines by 1 m, the headroom of the emission lines is<br />

lowered by 1.5 m. Since the central roof heating system is limited to a total of 4.0 m,<br />

up to 4 directional changes can be installed. At an angle of 45°, the headroom is<br />

lowered by 0.5 m, at a 90° angle, by 1 m.<br />

4.2.12 Lighting Protection<br />

The chimney head cover must be into an existing lightning protection system <strong>and</strong> into<br />

a potential equalisation on the house. This should only be done by a licensed professional.<br />

- 18 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.13 Connecting the Unit to the Chimney<br />

Calculate the height of the opening for<br />

the emission pipe. Make sure to take<br />

headroom for the test connection <strong>and</strong> the<br />

revision T-piece (T-fitting) into account.<br />

m a x . 1 6 0 m m<br />

Ø 1 0 m m<br />

Fig. 18 Cross Section of the Duct<br />

Position the support bar according to the<br />

diagram to the right. The support bar<br />

must be level.<br />

- 19 -<br />

2 1 0 m m<br />

Fig. 17 BOY III with Emission Connection<br />

The opening for mounting the support bar<br />

should be made according to the diagram.<br />

Make sure the opening is no larger<br />

than160 mm x 160 mm; otherwise<br />

the cover will not be large enough.<br />

Drill the hole for the support bar with a 10<br />

mm bit. The support bar must be level.<br />

Fig. 19 Installing the Support Bar<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

Fig. 20 Insert the Emission Pipe into the Duct<br />

Mount the emission pipe between the unit<br />

<strong>and</strong> the support bar. The emission line to<br />

the unit must be placed at a slight downward<br />

slope, so condensation can flow<br />

back unhindered.<br />

Insert the pipe into the duct with a rope<br />

from above. The rope should stay taught<br />

at all times. Spacers should be placed<br />

every two meters after the collars.<br />

Place the support arc into the support<br />

bar.<br />

Fig. 21 Emission Connection - BOY III<br />

Follow the installation instructions for the respective emissions system!<br />

- 20 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.14 Installing the Emissions Connection to Central Roof Heating<br />

Measure the point where the emission<br />

pipe opening will be based on the position<br />

of the unit. Install the special feed<br />

through socket as appropriate for the<br />

space provided. Lead the emission pipe<br />

through the socket <strong>and</strong> connect it to the<br />

unit. Use the sleeves specially designed<br />

for the opening of the roofing paper in order<br />

to insure it is airtight. The emission<br />

line must be level.<br />

Fig. 22 Emissions Connection to Central<br />

Roof Heating<br />

Follow the installation instructions for the respective emissions system!<br />

4.2.15 Connecting the Condensed Water Drain<br />

Lay plastic piping (min. Ø 32 mm or larger that leads to the drain) app. 2 cm under<br />

the condensed water drain connection. Do not place a permanent connection on the<br />

siphon in the boiler as this hinders maintenance.<br />

4.2.16 Neutralisation<br />

• Fill the boiler siphon to avoid flue gases from escaping into the room.<br />

• The condensed water drain must not be sealed.<br />

• The emission pipe should have a minimum slope of 3 cm per meter<br />

<strong>and</strong> a maximum horizontal length of 5 meters.<br />

• Disposing of condensed water via rain gutters is not permitted.<br />

• Condensed water lines must be installed according to regulation.<br />

ATV Bulletin M 251 regulations <strong>and</strong> state provisions apply! A pH balancing system<br />

can be installed retroactively for the Bruns wall boiler. A neutralization system is required<br />

for boiler capacities exceeding 25 kW. Regional regulations for running condensed<br />

water into the canalisation system are a deciding factor. Neutralisation granulates<br />

must be checked yearly by the operator <strong>and</strong> if necessary, renewed.<br />

- 21 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

4.2.17 General <strong>Instruction</strong>s for the Electrical Connection<br />

• This should only be performed by a licensed professional!<br />

• Make sure the unit is disconnected from electricity before beginning!<br />

Life threatening danger!<br />

• In Germany, the VDE <strong>and</strong> local regulations must be followed when installing.<br />

• The condensing gas boiler must be connected to an emergency shut<br />

down switch.<br />

• All components must follow VDE regulations.<br />

• Attention! Life threatening danger! Connection to the main power supply<br />

(230V) should not be made until all remaining control components<br />

have been fully wired!<br />

4.2.18 Electrical Connection<br />

Remove the front cover from unit. To do<br />

this, remove the two screws at the bottom<br />

on the front of the unit. Hold the bottom<br />

of the cover <strong>and</strong> pull toward you.<br />

The front cover can then be pulled up<br />

<strong>and</strong> out.<br />

Remove the screws, 2 on top <strong>and</strong> 2 on<br />

the bottom of the terminal strip cover <strong>and</strong><br />

slide the cover out.<br />

- 22 -<br />

Remove the cover from the built-in slot in<br />

the controller.<br />

Screws<br />

Screws<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

1<br />

2


Mounting / <strong>Installation</strong><br />

1<br />

Screw<br />

Screw<br />

2<br />

You can lead additionally required cables<br />

into the unit through the cable opening on<br />

the bottom of the unit.<br />

Lay the cables as follows:<br />

• Lay current-carrying wires <strong>and</strong><br />

sensor leads separately. Use the<br />

lower clamp for the 230 V wire <strong>and</strong><br />

the upper clamp for the sensor<br />

lead <strong>and</strong> the bus line.<br />

• The clamps serve as stress relief.<br />

Make sure that the cables are long<br />

enough to be mounted without placing<br />

strain on them.<br />

4.2.19 Pin Assignment on the Terminal Strip<br />

Remove the two screws on the left of the<br />

operation panel. To open the panel, lift<br />

up lightly on the left side. You can then<br />

clap it open it to the right.<br />

Sensor Lead<br />

230 V Wires<br />

Make sure the electricity is disconnected before you begin!<br />

BOY III Combi comes with an integrated <strong>and</strong> preinstalled three-way valve<br />

- 23 -<br />

o r g o r w ew eo r w eg b l g r / gG e<br />

B W A F B U S 3 - W e Ng e t z<br />

V e n t i l<br />

N<br />

N<br />

B W<br />

= D H W S e n s o r<br />

A F<br />

= O u t d o o r T e m p . S e n<br />

B U S<br />

= H e a t i n g C o n t r o l l e r<br />

3 - W e g = e 3v -e W n t a i l y - V a l v e<br />

N e t z<br />

= G r i d c o n n e c t i o n ~ 2<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

L


Mounting / <strong>Installation</strong><br />

5 Start up<br />

5.1 Filling <strong>and</strong> Ventilating the Heating System<br />

The condensing gas boiler is not yet ready for operation!<br />

Fill the heating system to a maximum water pressure of1.5 bar!<br />

Ventilate the entire heating system via the installed ventilation valves on the<br />

radiators, floor heaters <strong>and</strong> so on. Keep the pressure at 1.5 bar while ventilating.<br />

5.2 Ventilating the Unit<br />

The gas line must be connected prior to<br />

ventilating the unit!<br />

Open the quick-aspirator on the pump<br />

app. two rotations. Wait until the air is<br />

gone from the quick-aspirator. Leave the<br />

aspirator open!<br />

- 24 -<br />

Activate the electrical supply by turning<br />

on the heater’s emergency switch. The<br />

unit’s circulating pump will then start up.<br />

Let the unit run with the gas main closed!<br />

Do not open the gas main! The unit will<br />

display an error code while the gas main<br />

is closed. Do not dejam!<br />

Open the manual aspirator on the top of<br />

the unit. Close this one as soon <strong>and</strong> the<br />

air is gone <strong>and</strong> water comes out.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

5.3 Ventilating the Lower/St<strong>and</strong>ing Reservoir (optional)<br />

To ventilate the heat exchanger’s heating<br />

coil in the lower/st<strong>and</strong>ing reservoir, you<br />

must operate the three-way valve manually.<br />

To do this, remove the safety splint<br />

from the three-way valve ...<br />

Press the valve pin into the valve with a<br />

pair of pliers. The valve is now set to<br />

drinking water mode. The air in the drinking<br />

water heating coil can thus dispel<br />

from the unit via the aspirator.<br />

Re-establish the gas supply by opening<br />

the gas main.<br />

- 25 -<br />

<strong>and</strong> pull the motor off the valve.<br />

After successfully ventilating the unit, replace<br />

the motor onto the valve.<br />

Dejam the condensing gas boiler by holding<br />

down the III button.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

5.4 Start up<br />

After successfully ventilating <strong>and</strong> dejamming the unit, it will start in drinking water<br />

mode (if available); otherwise it will start in hot water mode. To start in hot water<br />

mode or in drinking water mode, the unit requires a certain level of heat. This can be<br />

done by opening the thermostats on the radiators. If an error occurs during the start<br />

up phase, it will be shown on the display (see error code list).<br />

5.4.1 Performance of the Unit Test Routine upon Start up<br />

After turning on the unit, a manual reset of every 12/24 hours, the control unit will<br />

perform a start up test routine. The 12/24 hour reset is dependent upon whether or<br />

not the heating dem<strong>and</strong>s require it.<br />

No heating dem<strong>and</strong>s: The control unit will reset every 12 hours<br />

Heating dem<strong>and</strong>s: The control unit will reset every 24 hours<br />

During the start up test routine, the three-way valve, if there is one, is switched to<br />

drinking water heating mode <strong>and</strong> directly after back to central heating mode, regardless<br />

of the previous position of the valve. This way, one complete pass is made by<br />

the valve, which keeps the valve from seizing. The circulation pump is also turned on<br />

during the test routine.<br />

5.5 (Pre) Setting the Boiler<br />

5.5.1 CO2 Boiler Settings<br />

The unit must be in chimney sweep<br />

mode (Ch. 6.3.8) when setting the CO2-<br />

levels.<br />

The amount of CO2 in the unit can be set<br />

with the adjusting screw on the gas<br />

valve.<br />

With liquid gas, the starting load must be<br />

change from 50% up to 60%.<br />

The CO2 – content must lie between the following levels, regardless of load:<br />

Gas Type CO2-Wert<br />

Natural Gas 8,5 – 9,0 %<br />

Liquid Gas 10 – 10,5 %<br />

- 26 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Mounting / <strong>Installation</strong><br />

5.5.2 Gas Throughput Table / Connection Pressure<br />

Gas Type Load Area<br />

Gas Flow rate<br />

(l/min) Connection<br />

Pressure<br />

Min. Max.<br />

LL(L)-Gas 5,1 – 22,8 kW 11,6 50,1 20 mbar<br />

E(H)-Gas 5,1 – 22,8 kW 10,0 43,3 20 mbar<br />

Liquid Gas 5,1 – 22,8 kW 8,0 34,6 50 mbar<br />

Heating value: Natural Gas LL(L) = 8,83kWh/m³; Natural Gas E(H) = 10,22 kWh/m³; Liquid Gas = 12,78 kWh/m³<br />

The above gas type values may vary regionally. Please ask your energy provider for<br />

the heating values as necessary.<br />

5.5.3 Changing Gas Types<br />

Changing gas types does not require any adaptations to the unit. Simply adjust the<br />

CO2 Level (Ch. 5.5.1) to the respective gas type.<br />

- 27 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

6 <strong>Operating</strong> the Controls<br />

6.1 Description of the Control Panel<br />

T a s t4 e<br />

T a s t 5 e<br />

L E D 1 L E D 2 L E D 3<br />

T a s t e1 2 3<br />

I II III<br />

8.8.8.<br />

S e g m e Cn t B D<br />

T a s t 6e<br />

L E D 4 L E D 5<br />

P u n k t C B<br />

D<br />

6.2 LED Display Symbols<br />

T a s t 7e<br />

Taste 1<br />

Function Description<br />

Switch to summer mode/ Chimney sweep<br />

mode<br />

Taste 2 <strong>Installation</strong> Mode / <strong>Installation</strong> (+) Mode<br />

Taste 3 Dejamming/ End Mode/ Error Log<br />

Taste 4 Positive Set-point changes heating water<br />

Taste 5 Negative Set-point changes heating water<br />

Taste 6 Positive Set-point Changes Drinking Water<br />

Taste 7 Negative Set-point Changes Drinking Water<br />

LED 1 Summer Mode on / off<br />

LED 2 Display Installer / Installer (+) Mode<br />

LED 3 Display Error<br />

LED 4<br />

LED 5<br />

Segment<br />

B / C / D<br />

Heating Water Requirements on / off<br />

Anti-Cycling on / off<br />

Drinking Water Heating Dem<strong>and</strong>s on / off<br />

Anti-Cycling on / off<br />

Display Temperature, Parameters, Error<br />

Codes<br />

Punkt D Display Flame detector (Flame on / off)<br />

Symbol Meaning Symbol’s Reference Name<br />

Central Heating Central Heating-Symbol<br />

Drinking Water<br />

Domestic Hot Water<br />

DHW-Symbol<br />

Test Mode TM-Symbol<br />

Degrees Celsius Celsius-Symbol<br />

Index Index-Symbol<br />

Error E-Symbol<br />

Parameter Parameter-Symbol<br />

50 Normal Display for the Value 50<br />

150 Point Display for the Value 100<br />

25 Point Display for the Value 200<br />

Flame Last point shows that there is a flame<br />

- 28 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

6.3 Controller Functions <strong>and</strong> <strong>Operating</strong> Status<br />

In the followings sections, the control functions as well as the displays for the different<br />

operating modes will be described.<br />

6.3.1 Start up<br />

� If an external Open Therm controller or set-point calculator is installed,<br />

various settings can be made via the room controller/ set-point calculator.<br />

Follow the unit’s description<br />

● The symbols used here such as , are examples; they may differ<br />

from your display!<br />

After switching on the electrical supply, the software versions for the different components<br />

are shown in the following order during start up:<br />

Display Time<br />

Software Version MMI Display 2 Seconds<br />

Software Version CVBC (HuP) Display 2 Seconds<br />

Software Version CVBC (LuP) Display 2 Seconds<br />

Software Version CVBC (EEPROM) Display 2 Seconds<br />

6.3.2 St<strong>and</strong>by Mode<br />

In st<strong>and</strong>by mode, the ignition mechanism is turned off, the gas valve is closed <strong>and</strong><br />

the pump turns off when the cool-down is complete. If there is no active heating dem<strong>and</strong><br />

<strong>and</strong> no error code is displayed, the following information will be on the display.<br />

Display Display Element<br />

Central Heating Warm-up<br />

Temperature<br />

6.3.3 Flame Detector<br />

Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

When there is a flame, this is shown by a point display.<br />

Display Display Element<br />

Flame On Point Display D<br />

- 29 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

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<strong>Operating</strong> the Controls<br />

6.3.4 Central Heating Mode<br />

6.3.4.1 <strong>Operating</strong> the Central Heater<br />

If the thermostat closes or the optional Open Therm unit registers a heating dem<strong>and</strong>,<br />

the following information will be displayed.<br />

Display Display Element<br />

Central Heating Warm-up Temperature Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

Central Heating Dem<strong>and</strong> On LED 4 = On<br />

Central Heating Dem<strong>and</strong> Off LED 4 = Off<br />

6.3.4.2 Anti-Cycling Central Heating<br />

on / off<br />

When the central heating dem<strong>and</strong> is no longer present, the anti-cycling function is activated.<br />

When in this mode, the following information will be displayed.<br />

Display Display Element<br />

Central Heating Warm-up Temperature<br />

Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

Central Heating Anti-Cycling LED 4 = Blinking<br />

blinking<br />

When the heating dem<strong>and</strong> is over, no new heating dem<strong>and</strong>s will go through the unit<br />

for 90 seconds. This function lengthens the boiler’s life-span.<br />

6.3.5 Drinking Water Mode<br />

6.3.5.1 <strong>Operating</strong> the Drinking-Water Heater<br />

When there is a dem<strong>and</strong> on the drinking-water heater, the following information will<br />

be displayed.<br />

Display Display Element<br />

Drinking-water Temperature Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

Drinking-water Dem<strong>and</strong> On LED 5 = On<br />

Drinking water Dem<strong>and</strong> LED 5 = Off<br />

- 30 -<br />

on / off<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

6.3.5.2 Anti-Cycling Drinking-Water Heater<br />

When the dem<strong>and</strong> for drinking-water is over, the anti-cycling function is activated.<br />

When in this mode, the following information will be displayed<br />

Display Display Element<br />

Drinking-Water Temperature Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

Drinking-Water Heater Anti-Cycling LED 5 = Blinking<br />

blinking<br />

When the heating dem<strong>and</strong> is over, no new heating dem<strong>and</strong>s will go through the unit<br />

for 90 seconds. This function lengthens the boiler’s life-span.<br />

6.3.6 Changing the Set-point<br />

6.3.6.1 Changing the Set-point for Central Heating<br />

The set-point for heater water can be changed with<br />

the 4 <strong>and</strong> 5 buttons. When the heating water setpoint<br />

is changed, the following information will be<br />

displayed.<br />

Display Display Element<br />

Set-point, Central Heating Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

T a s t4 e<br />

L E D 4<br />

T a s t5 e<br />

blinking<br />

If the value is not changed within 5 Seconds, the display returns to the previous<br />

mode <strong>and</strong> the new set-point will be saved.<br />

6.3.6.2 Changing the Set-point for the Drinking-Water Heater<br />

The set-point for the drinking-water heater can be<br />

changed with the 6 <strong>and</strong> 7 buttons. When the drinking-water<br />

set-point is changed, the following information<br />

will be displayed.<br />

Display Display Element<br />

Set-point, Central Heating Segment B <strong>and</strong> C<br />

Celsius-Symbol Segment D<br />

T a s t 6e<br />

L E D 5<br />

T a s t 7e<br />

blinking<br />

If the value is not changed within 5 Seconds, the display returns to the previous<br />

mode <strong>and</strong> the new set-point will be saved.<br />

- 31 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

6.3.7 Summer Mode<br />

Summer mode can be activated by quickly pressing<br />

the 1 button (less than 1 second). In the table below,<br />

the information for summer mode status is<br />

shown.<br />

Display Display Element<br />

Summer mode On LED 1 = On<br />

Summer mode Off LED 1 = Off<br />

6.3.8 Chimney Sweep Mode<br />

Pressing the 1 button for 3-5 seconds until the display<br />

(E99) starts blinking. The unit will then run at<br />

max. capacity (100%). The capacity can be reduced<br />

to 0% with the 4 <strong>and</strong> 5 buttons.<br />

Display Display Element<br />

E-Symbol Segment B<br />

Display Code 99 Segment C <strong>and</strong> D<br />

T a s t e1<br />

L E D 1<br />

I<br />

T a s t e1<br />

L E D 1<br />

I<br />

on / off<br />

blinking<br />

T a s t4 e<br />

L E D 4<br />

T a s t5 e<br />

The chimney sweep function can be turned off by pressing the 3 button, or after 30<br />

min. the unit switches back to the normal heating mode automatically.<br />

6.3.9 Installer Mode<br />

The installer mode can be activated by quickly<br />

pressing the 2 (less than 1 second). In the table below,<br />

the respective information is shown.<br />

Display Display Element<br />

Index symbol alternates with the setpoint.<br />

After changing the set-point, it<br />

will appear after 2 seconds<br />

Segment B <strong>and</strong> C<br />

Value of the chosen index Segment B, C <strong>and</strong> D<br />

Installer Mode LED 2 = On<br />

In the following table (next page), the available information is shown.<br />

- 32 -<br />

T a s t e2<br />

L E D 2<br />

II<br />

alternating<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

on


<strong>Operating</strong> the Controls<br />

Set-point Information<br />

1 Actual flame current<br />

2 Actual supply temperature of the central heater<br />

3 Actual return flow of the central heater<br />

4 Actual temperature of the drinking-water<br />

5 Water pressure<br />

6 Type of use<br />

7 Actual temperature of the flame pipe or TTB<br />

8 Throughput speed of the drinking-water (Hz)<br />

9 Current control-set-point<br />

10 Current outside temperature (OTC-Temperature)<br />

The set-point can be raised by 1 by quickly pressing<br />

the 1 button (less than 1 second). When the<br />

counter has reached its highest value, it will drop<br />

T a s t e2<br />

down to 0. II<br />

Installer-mode is exited by quickly pressing the 3<br />

button (less than 1 second). The installer mode also<br />

has a time out function that exits the installer mode<br />

after one minute of inactivity. This function is also<br />

turned off if the electrical supply is interrupted.<br />

6.3.10 Installer (+) Mode<br />

T a s t e3<br />

The installer (+) mode can be activated by holding<br />

the 2 button for longer than 3 seconds. The displayed<br />

information’s format is shown in the following<br />

T a s t e2<br />

display. II<br />

Display Display Element<br />

Parameter symbol alternates with the<br />

index symbol. After changing the setpoint,<br />

it will appear after 2 seconds<br />

Segment B<br />

Parameter value for the chosen index Segment B, C <strong>and</strong> D<br />

Installer (+) Mode LED 2 = Blinking<br />

- 33 -<br />

L E D 2<br />

L E D 3<br />

III<br />

L E D 2<br />

alternating<br />

blinking<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

6.3.10.1 Installer (+) Parameter List<br />

The following values will be displayed <strong>and</strong> can be changed. Values with the symbol<br />

cannot be changed!<br />

Index Parameter Description Area<br />

1 CH Slope<br />

2<br />

CH Anticycle<br />

Time<br />

3 CH Kp<br />

4 CH Ki<br />

5 DHW Kp<br />

6 DHW Ki<br />

7<br />

Ignition<br />

Level<br />

8 Fan Kp<br />

9 Fan Ki<br />

11 CH set-point<br />

12<br />

13<br />

14<br />

CH Pump<br />

Overrun<br />

DHW setpoint<br />

CH max. capacity<br />

Central factor for the ascent/descent<br />

of the edge; defines the temperature<br />

rise in the warm-up<br />

cycle of the central heating dem<strong>and</strong><br />

Central heater anti-cycling time.<br />

During this period the CVBC will<br />

not accept any further central<br />

heating dem<strong>and</strong>s.<br />

Proportional control factor central<br />

heater<br />

Integral control factor central<br />

heater<br />

Proportional control factor for the<br />

drinking-water heater<br />

Integral control factor for the<br />

drinking-water heater<br />

Ignition level with which the boiler<br />

is ignited<br />

Proportional control factor for the<br />

fan controller<br />

Integral control factor for the fan<br />

controller<br />

The actual set-point of the<br />

central heater<br />

Pump overrun time for the central<br />

heater<br />

The actual set-point of the drinking-water<br />

heater<br />

The maximum capacity of the<br />

central heater<br />

- 34 -<br />

Default<br />

V1042 Esys2042<br />

0-60 °C/Min. 5 °C/Min 5 °C/Min<br />

0-900 sec. 90 Sec. 2 min.<br />

0-255 3 3<br />

0-255 95 95<br />

0-255 5 5<br />

0-255 95 95<br />

30-100 % 50% 33%<br />

0-255 13 13<br />

0-255 150 150<br />

30-80 °C 80 °C 70 °C<br />

1-20 Min. 7 Min. 7 Min.<br />

35-65 °C 60 °C 55 °C<br />

60-100% 90% 87%<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


<strong>Operating</strong> the Controls<br />

Index Parameter Description Area<br />

15<br />

16<br />

17<br />

18<br />

19<br />

DHW Pump<br />

Overrun<br />

CH Hysteresis<br />

DHW Hysteresis<br />

CH Max.<br />

Set-point<br />

Pump overrun time for the drinking-water<br />

heater<br />

Hysteresis of the central heater’s<br />

set-point during modulation<br />

Hysteresis of the drinking-water’s<br />

set-point during modulation<br />

Maximum value at which the<br />

central heater’s set-point may be<br />

set<br />

The values can be changed with the 6 <strong>and</strong> 7 buttons,<br />

respectively.<br />

When changing the value, the LED 3 will blink,<br />

which shows that the value can be confirmed by<br />

pressing the 3 button. If the value has not been<br />

confirmed within 5 seconds, the original value is restored<br />

<strong>and</strong> no new value will be saved.<br />

1-10 4-5<br />

Default<br />

V1042 Esys2042<br />

30-180 Sec. 30 Sec. 30 Sek.<br />

2-10 °C 3 °C 7 °C<br />

2-10 °C 7 °C 7 °C<br />

30-85 °C 85 °C 80 °C<br />

T a s t 6e<br />

L E D 5<br />

T a s t 7e<br />

T a s t e3<br />

L E D 3<br />

III<br />

LED blinkt<br />

Installer (+) mode will be exited after one 1 min. of inactivity. If LED 3 is off, installer<br />

(+) Mode can also be exited by quickly pressing the 3 button (less than 1 second).<br />

- 35 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Malfunctions <strong>and</strong> Errors<br />

7 Malfunctions <strong>and</strong> Errors<br />

7.1 Error Mode<br />

If there is an error the following information are displayed<br />

Display Display Element<br />

Error code Segment C <strong>and</strong> D<br />

E-Symbol Segment B<br />

Errors can be reset LED 3 = Blinking<br />

Errors that can correct themselves LED 3 = Off<br />

If the error can be reset, press the 3 button <strong>and</strong> it will reset.<br />

7.2 Error Code List<br />

T a s t e3<br />

L E D 3<br />

III<br />

blinking / off<br />

The error codes are split into two groups; shut down codes <strong>and</strong> blocking codes.<br />

7.2.1 Shutdown Codes<br />

Code Description Solution<br />

1<br />

2<br />

3<br />

5<br />

11<br />

26<br />

Shut off signal after the flame is out <strong>and</strong> all<br />

ignition attempts have failed.<br />

False flame signal. A flame signal is recognised<br />

without the gas valve being open.<br />

Excess temperature signal from the excess<br />

temperature thermostat. If the thermostat<br />

is open, it will cause an error to occur.<br />

Speedometer error. The controller requires<br />

a certain fan rotation, but is not receiving a<br />

(correct) speedometer signal.<br />

Check the gas supply <strong>and</strong> open any closed<br />

valves.<br />

Check the gas valve. If there is a flame, replace<br />

the gas valve. Check the ionization <strong>and</strong> replace<br />

as needed.<br />

Check the boiler settings (draft curve, max. Temperature,<br />

differential gap). Check the supply <strong>and</strong><br />

return flow sensors.<br />

Check the connection between the fan <strong>and</strong> the<br />

automatic firing device. Check the fan <strong>and</strong> replace<br />

as needed.<br />

Errors during the first temperature check.<br />

Initially, the pump’s controller will turn on to<br />

equalize the supply <strong>and</strong> return flows to with­ Check the supply <strong>and</strong> return flow temperatures.<br />

in 5 °C of each other. The sensors have Check the sensors <strong>and</strong> replace as needed.<br />

not reached the same values within app. 4<br />

minutes.<br />

The controller has lost the flame signal 4<br />

times within 240 sec. There is something<br />

wrong with the flame recognition’s reliability.<br />

- 36 -<br />

Check the ionisation <strong>and</strong> clean or replace as<br />

needed.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Malfunctions <strong>and</strong> Errors<br />

7.2.2 Locking Codes<br />

The boiler controller also recognises errors that may lead to the heating dem<strong>and</strong><br />

lockup, but does not recognise errors that may lead to a shutdown. If the error is resolved,<br />

it disappears, but will be recorded in the error log. The descriptions of these<br />

codes are as following:<br />

Code Description Solution<br />

30<br />

31<br />

32<br />

33<br />

34<br />

35<br />

Central heating sensor is not within normal<br />

parameters (short circuit). If the NTCsensor<br />

is not within normal parameters <strong>and</strong><br />

remains in this state for longer than 10 sec.,<br />

Check the supply sensor <strong>and</strong> replace the univer­<br />

a warning will be displayed. If the sensor<br />

sal sensor as needed.<br />

returns to normal parameters, the warning<br />

disappears. The warning causes the system<br />

to shut down. Heating dem<strong>and</strong>s are<br />

deactivated.<br />

Central heating sensor is not within normal<br />

parameters (line error). If the NTC-sensor is<br />

not within normal parameters <strong>and</strong> remains<br />

in this state for longer than 10 sec., a warn­<br />

Check the supply sensor <strong>and</strong> replace the univering<br />

will be displayed. If the sensor returns<br />

sal sensor as needed.<br />

to normal parameters, the warning disappears.<br />

The warning causes the system to<br />

shut down. Heating dem<strong>and</strong>s are deactivated.<br />

Domestic warm water sensor is not within<br />

normal parameters (short circuit). If the<br />

NTC-sensor is not within normal parameters<br />

<strong>and</strong> remains in this state for longer than Check the reservoir sensor. If no reservoir<br />

10 sec., a warning will be displayed. If the sensor is connected, check the resistance on the<br />

sensor returns to normal parameters, the end plate <strong>and</strong> replace as needed.<br />

warning disappears. The warning causes<br />

the system to shut down. Heating dem<strong>and</strong>s<br />

are deactivated.<br />

Domestic warm water sensor is not within<br />

normal parameters (line error). If the NTCsensor<br />

is not within normal parameters <strong>and</strong><br />

remains in this state for longer than 10 sec., Check the reservoir sensor. If no reservoir<br />

a warning will be displayed. If the sensor sensor is connected, check the resistance on the<br />

returns to normal parameters, the warning end plate <strong>and</strong> replace as needed.<br />

disappears. The warning causes the system<br />

to shut down. Heating dem<strong>and</strong>s are<br />

deactivated.<br />

This error is caused by the electrical supply<br />

being too low (less than 185 V alternating<br />

current).<br />

The power frequency shows a deviation of<br />

more than +/- 5 %.<br />

- 37 -<br />

Check the electrical current. If the electrical supply<br />

returns to normal, the error will disappear<br />

within 10 sec.<br />

Check the power frequency. If the power frequency<br />

returns to normal, the error will disappear.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Malfunctions <strong>and</strong> Errors<br />

Code Description Solution<br />

37 Water pressure is too low.<br />

41<br />

43<br />

44<br />

47<br />

Water pressure signal time out. The water<br />

pressure value is not being refreshed often<br />

enough.<br />

Central heating- return flow sensor is not<br />

within normal parameters (short circuit). If<br />

the NTC-sensor is not within normal parameters<br />

<strong>and</strong> remains in this state for longer<br />

than 10 sec., a warning will be displayed. If<br />

the sensor returns to normal parameters,<br />

the warning disappears. The warning<br />

causes the system to shut down. Heating<br />

dem<strong>and</strong>s are deactivated.<br />

Refill water (1.6 bar). Check the water pressure<br />

on the display <strong>and</strong> match it with the pressure<br />

gauge. If the difference is larger than 0.6 bar, replace<br />

the water pressure sensor.<br />

Remove the water pressure sensor <strong>and</strong> make<br />

sure the opening for the sensor is clear of obstructions.<br />

Clean as needed <strong>and</strong> install a filter in<br />

the heating circuit beneath the boiler.<br />

Check the water pressure sensor connection <strong>and</strong><br />

replace the universal sensor as needed.<br />

Check the return flow sensor <strong>and</strong> replace as<br />

needed.<br />

Central heating- return flow sensor is not<br />

within normal parameters (line error). If the<br />

NTC-sensor is not within normal parameters<br />

<strong>and</strong> remains in this state for longer than<br />

Check the return flow sensor <strong>and</strong> replace as<br />

10 sec., a warning will be displayed. If the<br />

needed.<br />

sensor returns to normal parameters, the<br />

warning disappears. The warning causes<br />

the system to shut down. Heating dem<strong>and</strong>s<br />

are deactivated.<br />

Combination error. Either the water pressure<br />

sensor or the supply sensor is defective<br />

or the cable has been interrupted.<br />

Check the universal sensor (water pressure <strong>and</strong><br />

supply sensors against the automatic firing<br />

device.<br />

All errors are recorded in the error log <strong>and</strong> organised in relation to the number of operation<br />

modes. The error codes 10-22 are not visible (they are part of the safety<br />

core).<br />

- 38 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Malfunctions <strong>and</strong> Errors<br />

7.3 Error history Mode<br />

The Error history mode can be activated by holding<br />

the 3 button longer than 3 seconds. The information’s<br />

displayed format is shown in the following<br />

T a s t e3<br />

table III<br />

Display Display Element<br />

E-Symbol alternating with the<br />

Index-Symbol<br />

Segment B<br />

Error code for the chosen index Segment C <strong>and</strong> D<br />

Error Log Mode LED 3 = Blinking<br />

L E D 3<br />

alternating<br />

blinking<br />

Error log mode can be exited by quickly pressing the 3 button (less than 1 second).<br />

Error log mode also has a time out function that exits the installer mode after 30<br />

minutes of inactivity. This function is also turned off if the electrical supply is interrupted.<br />

7.4 Log Resistance Values for the Boiler <strong>and</strong> Reservoir Sensors<br />

If there is an error in the boiler or reservoir sensors’ transmittal, it can be determined<br />

via the sensors’ resistance values.<br />

Temperature °C<br />

Nominal Value k<br />

RT 2333 640 6123<br />

Temperature °C<br />

Nominal Value k<br />

RT 2333 640 6123<br />

-40 309,5 35 8,055<br />

-35 229,4 40 6,653<br />

-30 171,7 45 5,524<br />

-25 129,7 50 4,609<br />

-20 98,82 55 3,863<br />

-15 75,94 60 3,253<br />

-10 58,82 65 2,752<br />

- 5 45,91 70 2,337<br />

0 36,10 75 1,994<br />

5 28,59 80 1,707<br />

10 22,97 85 1,467<br />

15 18,29 90 1,266<br />

20 14,72 95 1,096<br />

25 12,00 100 0,9522<br />

30 9,805<br />

- 39 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Maintenance<br />

8 Maintenance<br />

8.1 General <strong>Instruction</strong>s for Maintenance<br />

• Cleaning <strong>and</strong> maintenance should only be performed by a licensed<br />

professional.<br />

• Close all gas <strong>and</strong> heating <strong>and</strong> drinking water valves before beginning!<br />

• Make sure the unit is disconnected from electricity before beginning!<br />

8.2 Cleaning the Condensed Water Siphon<br />

The condensed water siphon should be cleaned in the following intervals:<br />

Yearly: the siphon connection on the bottom<br />

of the boiler. Make sure to have a<br />

collection container ready to collect the<br />

runoff condensed water. Clear obstructions<br />

<strong>and</strong> dirt from the siphon, replace<br />

the cover <strong>and</strong> test the water tightness of<br />

the connection.<br />

Every two years: completely remove <strong>and</strong><br />

clean the siphon. Remove the upper<br />

connection to the siphon <strong>and</strong> pull down<br />

on the siphon. Remove the siphon, with<br />

hose, from the boiler, disconnect it <strong>and</strong><br />

rinse thoroughly with clear water. Install<br />

the siphon by reversing this process.<br />

8.3 Cleaning the Combustion Chamber<br />

Clean the combustion chamber yearly.<br />

Remove the fan’s intake hose<br />

- 40 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Maintenance<br />

Use a flat spanner (SW 27) to remove<br />

the gas valve connection. Make sure the<br />

washer does not fall out of the connection.<br />

- 41 -<br />

Disconnect the ignition plug, ionisation<br />

<strong>and</strong> PE cable (ground) from the boiler.<br />

Use a flat spanner (SW 13) to remove<br />

the control unit’s securing screw.<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Maintenance<br />

Remove the control unit by pulling to the<br />

right.<br />

Carefully remove the burner. Carefully<br />

clean the heat exchange surfaces in the<br />

combustion chamber as well as the burner<br />

head with a nylon brush. Do not use a<br />

wire brush, sharp objects <strong>and</strong> so on!<br />

Remove the burner screws.<br />

nstall the components in reverse order. Make sure that all connections are screwed<br />

tight <strong>and</strong> well connected. Check to make sure the gas valve connection is airtight.<br />

The washer may need to be replaced.<br />

After successful maintenance, restart the unit. Make sure the unit is running<br />

free of errors after maintenance.<br />

- 42 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Technical Data<br />

9 Technical Data<br />

9.1 Circuit Diagram<br />

A u t o m a t i c F i r i n g D e v i c e S 4 9 6 5 C V B C C o n t r o l B o a r d M M I<br />

X 1 X 2 X 3 X 4 X 5<br />

X 1 X 1 2<br />

X 1 1<br />

G a s V a l v e<br />

2 3 4 5 6<br />

1<br />

1 2 3 4 5 6 7 8<br />

2 3<br />

2 3 4 5 6 1<br />

I g n i t i o n<br />

I o n i s a t i o n<br />

1<br />

1 2 3 4 5 6 7 8 9 1 0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6<br />

s w<br />

r o<br />

w e<br />

b l<br />

b l<br />

s w<br />

b l<br />

b r<br />

r o<br />

b l<br />

s w<br />

s w<br />

r o<br />

s w<br />

b r<br />

b l<br />

b l<br />

w e<br />

w e<br />

b r<br />

s w<br />

r o<br />

w e<br />

s w<br />

l i<br />

b r<br />

s w<br />

r o<br />

w e<br />

w e<br />

r o<br />

b l<br />

b l<br />

b r<br />

l i<br />

w e<br />

s w<br />

g r / g e<br />

Z 1<br />

Z 2<br />

s w<br />

w e<br />

F 1<br />

r o<br />

w e<br />

b l<br />

s w<br />

F 2<br />

F 3<br />

r o<br />

s w<br />

b l<br />

F 4<br />

b r<br />

s w<br />

- 43 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

M 2<br />

s w<br />

b l<br />

g r / g e<br />

M 1<br />

r o<br />

s w<br />

b r<br />

b r<br />

g r / g e<br />

b l<br />

g r / g e<br />

b r<br />

b r<br />

b l<br />

b l<br />

w e<br />

s w<br />

b r<br />

w e<br />

w e<br />

r o<br />

b r<br />

s w<br />

F 5 M 3<br />

Z 1 I g n i t i o n E l e c t r o d e<br />

Z 2 I o n i s a t i o n E l e c t r o d e<br />

F 5 D H W S e n s o r<br />

M 1 B l o w e r<br />

M 2 C i r c u l a t i n g P u m p<br />

M 3 T h r e e - W a y - V a l v e<br />

F 1 C o m b i S e n s o r ( w a t e r p r e s s u r e & t e m p e r a t u r e )<br />

F 2 E x h a u s t T C O<br />

F 3 F l o w M e t e r D H W<br />

F 4 T e m p e r a t u r S e n s o r ( r e t u r n )


Technical Data<br />

9.2 Technical Data<br />

2 1 0<br />

4 3<br />

1 0 8<br />

1 5 4<br />

2 0 5<br />

2 4 3<br />

1 6 5<br />

3 0 5<br />

3 9 5<br />

3 9 5<br />

8 5<br />

1 2 5<br />

850<br />

150<br />

20<br />

295<br />

- 44 -<br />

S R A K<br />

V L S V R L<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de<br />

G<br />

S R A K<br />

V L W WS V K W<br />

R L<br />

G


Technical Data<br />

BOY III Solo / Combi<br />

Width / Height / Depth mm 395 / 650 / 295<br />

Weight kg 35<br />

CE- number CE- 0045BRKD 1002<br />

Type of unit (licensed for...) B 23 & C 63x<br />

Preset gas type natural gas type LL<br />

Rated heating range of performance 50/30°C kW 5,1- 22,8<br />

Rated heating range of performance 80/60°C kW 4,6 - 20,1<br />

Rated heating load kW 4,8 - 21,8<br />

Degree of efficiency 50°/30°C % 106,3<br />

Max. capacity in warm water mode kW 24<br />

Continuous output of warm water L/ min 9,8<br />

Adjustment range for warm-up temperature °C 30<br />

Permitted operational temperature °C 90<br />

Permitted operational pressure bar 3<br />

Residual supply pressure Pa 100<br />

Unit water capacity L 3,5<br />

Emissions connection mm 80/125<br />

Emissions material PPs bis 120°C<br />

Emissions output oben<br />

HV / HR connection AG ¾“ flat sealing<br />

Gas connection IG ½“ flat sealing<br />

Natural gas connection pressure mbar 20<br />

Liquid gas connection pressure mbar 50<br />

Electrical connection V/Hz 230/50<br />

Emission Values Partial Load Full Load<br />

Emissions mass flow rate 80/60 °C g/s 1,87 7,98<br />

Emissions temperature 80/60 °C °C 68 76<br />

Residual headroom for air <strong>and</strong><br />

emissions system<br />

80/60 °C Pa 100 100<br />

Emissions mass flow rate 50/30 °C g/s 1,87 7,98<br />

Emissions temperature 50/30 °C °C 68 76<br />

Residual headroom for air <strong>and</strong><br />

emissions system<br />

50/30 °C Pa 100 100<br />

Natural gas CO2-content Vol.% 9,5 9,5<br />

Liquid propane CO2-content Vol. % 10,0 10,3<br />

- 45 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Technical Data<br />

10 Declaration of Conformity<br />

- 46 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Notes<br />

- 47 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Notes<br />

- 48 -<br />

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

Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de


Gebr. Bruns GmbH • Hauptstraße 200 • 26683 Saterl<strong>and</strong> •Tel.: + 49 (0) 44 92 / 92 46-0 • Fax: + 49 (0) 44 92 / 71 41<br />

www.bruns-heiztechnik.de • info@bruns-heiztechnik.de

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