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

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R30 Training



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

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Point of condensation

Point of condensation

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1 m3 natural gas (G25) contains:

31669 KJ/m3 sensible heat

3427 KJ/m3 latent heat

Calorific value of gas is defined as the amount of heat which is released when combusting 1m3 of gas under constant pressure (101,325 kPa) and constant temperature (25°C = 298,15K).

Nett calorific value of gas: the amount of heat which can be released when combusting 1m3 of gas without condensing (sensible heat)Hi = 31669 KJ/m3

Gross calorific value of gas: the amount of heat which can be released when combusting 1m3 of gas including condensing (sensible heat + latent heat)Hs = 35096 KJ/m3

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Nett efficiency

Nett efficiency

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

Maximum nett efficiency:

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Gross efficiency

Gross efficiency

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

Maximum gross efficiency:

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Efficiency example

Efficiency (example)

Gas consumption = 10 [m3/hr] = 10/3600 [m3/sec]

Nett Energy input = (10/3600) [m3/sec] * 31669 [kJ/m3] = 87,97 [kJ/sec] = 87,97 [kW]

Gross Energy input = (10/3600) [m3/sec] * 35096 [kJ/m3] = 97,49 [kJ/sec] = 97,49 [kW]

Output measured = 95,21 kW:

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R30/45HR107 39 kW

R30/65HR107 59 kW

R30/85HR107 78 kW

R30/100HR107 88 kW

R30/120HR107110 kW

# = maximum capacity on 40/30

  • Free modulating 14/20% - 100%

  • Low Nox

  • Premix principle

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Construction 1

Construction (1)

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Construction 2

Construction (2)

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Electrical230V AC, 50 Hz

L1, N, PE (Watch phase-neutral!)

Gas¾” outer thread

Water1¼” outer thread

1” inner thread

Condensate drainHose d = 25mm

Siphon reachable from outside the boiler

Flue/Air intakeR30/45 and R30/6580/80mm

R30/85 up to R30/120100/100mm

Application categoryB23, C13, C33, C43, C53, C63, C83

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Gas water

Gas & Water

Gas pressure:

Natural gas L (G25)20-25 mbar

Natural gas H (G20)17-25 mbar

Propane (G31)30-50 mbar

Propane with restriction ring:45kWØ 6,8mm

65+85kWØ 6,0mm

100kWØ 6,2mm

120kWØ 8,0mm


Max. water pressure6 bar

Max. flow temperature90°C

Water quality (Chloride level + Water hardness)

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Electrical connections

Electrical Connections

L1-N-EarthPower supply to boiler

1-3Lockout input (230V 1A from boiler)

4-5Enable (standby to automatic) except DHW

6-7DHW sensor

8-9External setpoint: 1-5Vdc  10°C - 90°C, < 1Vdc  P1

10-11SCOM Bus connection, watch polarity: 10 is neutral,

11 is positive

ST 1.1-1.2OK signal, max. 230V 1A external

ST 2.1-2.2Outdoor sensor: frost protection and/or weather compensation with BM8 or E8

ST 9.3-9.4Interlock input (24Vac 7mA from boiler)

ST11.1-11.2DHW load pump control

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Wiring diagram 45 100kw

Wiring diagram 45-100kW

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Wiring diagram 120kw

Wiring diagram 120kW

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Mixing system 45 100kw

Mixing system 45-100kW

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Mixing system 120kw

Mixing system 120kW

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Cooled fluegas outlet

Condensation deflector

Hot water manifold

Cold water manifold

Baffle + Insulation disc

Condensate drain hole

First exchange

Heated combustion gas

Second exchange/condensation

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Gasvalve adjustment r30 45 65 85 100kw

Gasvalve adjustmentR30 - 45/65/85/100kW

First adjust maximum, then minimum!!

Maximum load

+ -

Minimum load

- +

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Gasvalve adjustment r30 120kw

Gasvalve adjustmentR30 - 120kW

First adjust maximum, then minimum!!

Maximum load

+ -

Minimum load

- +

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Combustion settings

Combustion Settings

Set boiler to service operation (max./min.)

R30/45-65-85-120Natural gasCO2,max = 8,8% ± 0,2%

CO2,min = 8,2% ± 0,2%

PropaneCO2,max = 9,8% ± 0,2%

CO2,min = 9,0% ± 0,2%

R30/100Natural gasCO2,max = 9,4% ± 0,2%

CO2,min = 8,8% ± 0,2%

PropaneCO2,max = 10,4% ± 0,2%

CO2,min = 9,4% ± 0,2%

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Controller km628

Controller KM628

KM628-R500 without CXE expansion module:

External temperature setpoint with 1-5V signal

OK-signal potential free (max. 230V AC, 1A)

Boiler enable contact 230V AC

Outside sensor

Sanitary hot water sensor (thermostat connection optional)

Interlock input 24V AC

Lockout input 230V AC

Primary sanitary hot water pump control (230V AC, max. 1A)

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Controller km6281

Controller KM628

Other differences compared with KM628+CXE:

sanitary hot water thermostat connection optional!!!

No external gas valve connection

No header sensor connection

No alarm signal

No capacity feedback

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Controller km628 r500

Controller: KM628-R500

1 Function

2 Function selector

3 Fault indication

4 Supply temperature

5 Malfunction code (flashing)


Automatic operation

Summer operation

Service operation min.

Service operation max.

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Parameter menu

Parameter menu

1 Parameter indication 

2 Optical I/O

3 Reset/Programming button

4 Alarm LED

5 Parameter/Value selector

6 Output status

7 Current/Desired parameter value

8 Fault/Parameter indication

9 Input status

P1 Current/Setting supply temperature

P2 Current/Setting DHW temperature

P3 Desired supply temperature external ***

P5 Current outside temperature

P6 Current fluegas temperature

P9 Current/Maximum boiler capacity

P10 Password entry

*** Desired boiler capacity

(when using a KKM)

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1High limit thermostat (STB) has operated, boiler temperature has exceeded 100°C

2/3Interlock input has been interrupted (gas pressure switch or external safety device)

4/5Flame signal fault during ignition/operation

6Temperature protection (STW) has operated, boiler temperature has exceeded 97°C

7Fluegas temperature has exceeded 100C

11Error in flame signal, a flame has been detected during startup

12Flow temperature sensor is defective

13Lockout input has been interrupted or fluegas sensor is defective

14Hot water temperature sensor is defective

15Outside temperature sensor is defective

24Fan does not reach prepurge speed

25Fan does not reach ignition speed

26Fan does not stop

30CRC-error in EEprom data group “boilerparameters”

31CRC-error in EEprom data group “burnerparameters”

32Fault in 24V circuit

x.y.Internal failure KM recognised

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Hydraulic add on s

Hydraulic Add-on’s

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Cascade systems

Cascade Systems

Flue gas cascade system

Hydraulic cascade system

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