Installation and Operating Instruction
Installation and Operating Instruction
Installation and Operating Instruction
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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 />
www.bruns-heiztechnik.de • info@bruns-heiztechnik.de
<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