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Theory - PowerPoint PPT Presentation

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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.

R30 Training


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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R30 Training

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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R30/45 HR107 39 kW

R30/65 HR107 59 kW

R30/85 HR107 78 kW

R30/100 HR107 88 kW

R30/120 HR107 110 kW

# = maximum capacity on 40/30

  • Free modulating 14/20% - 100%
  • Low Nox
  • Premix principle

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construction 1
Construction (1)

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construction 2
Construction (2)

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Electrical 230V AC, 50 Hz

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

Gas ¾” outer thread

Water 1¼” outer thread

1” inner thread

Condensate drain Hose d = 25mm

Siphon reachable from outside the boiler

Flue/Air intake R30/45 and R30/65 80/80mm

R30/85 up to R30/120 100/100mm

Application category B23, C13, C33, C43, C53, C63, C83

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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: 45kW Ø 6,8mm

65+85kW Ø 6,0mm

100kW Ø 6,2mm

120kW Ø 8,0mm


Max. water pressure 6 bar

Max. flow temperature 90°C

Water quality (Chloride level + Water hardness)

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electrical connections
Electrical Connections

L1-N-Earth Power supply to boiler

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

4-5 Enable (standby to automatic) except DHW

6-7 DHW sensor

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

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

11 is positive

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

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

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

ST11.1-11.2 DHW load pump control

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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.)

R30/45-65-85-120 Natural gas CO2,max = 8,8% ± 0,2%

CO2,min = 8,2% ± 0,2%

Propane CO2,max = 9,8% ± 0,2%

CO2,min = 9,0% ± 0,2%

R30/100 Natural gas CO2,max = 9,4% ± 0,2%

CO2,min = 8,8% ± 0,2%

Propane CO2,max = 10,4% ± 0,2%

CO2,min = 9,4% ± 0,2%

R30 Training

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

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

4/5 Flame signal fault during ignition/operation

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

7 Fluegas temperature has exceeded 100C

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

12 Flow temperature sensor is defective

13 Lockout input has been interrupted or fluegas sensor is defective

14 Hot water temperature sensor is defective

15 Outside temperature sensor is defective

24 Fan does not reach prepurge speed

25 Fan does not reach ignition speed

26 Fan does not stop

30 CRC-error in EEprom data group “boilerparameters”

31 CRC-error in EEprom data group “burnerparameters”

32 Fault in 24V circuit

x.y. Internal failure KM recognised

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cascade systems
Cascade Systems

Flue gas cascade system

Hydraulic cascade system

R30 Training