CONDENSING BOILER TECHNOLOGY

MODULE IV

The present Module has been developed within the framework of the LEONARDO DA VINCI
project SERVITEC (D/97/2/00655/PI/II.1.1.b/FPC). An Internet version of the module as well as
further information about the SERVITEC project are freely accessible on the Internet at
[Link]
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Preface

Condensing boiler technology is a modern environment protecting technology which is becoming

more and more important and popular in the sanitary, heating and air-conditioning sector. For this
reason, service technicians have to have a good knowledge of this new technology. The present
Module IV "Condensing boiler technology" addresses especially those service technicians who
already have a basic knowledge of the subject. A particular emphasis has been put on demonstrating
the service technicians as to how they can best explain the particularities of the technology to
interested customers. In addition, various exercises and learning objectives are provided with which
one can test his/her knowledge of the most important aspects of condensing boiler technology.
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TABLE OF CONTENTS

Part I Advising customers about condensing boiler technology

1. Customer conversation S. 3

2. Natural gas as the primary energy source for condensing boiler technology
and comparison of different fuels S. 4

3. Useable heat energy > 100% ? S. 9

4. Condensing boiler technology checklist S. 14

5. Condensing boiler technology based heating systems S. 17

Part II The ecological solution - oil and gas based condensing boiler technology

6. Differences between condensing boiler technology based systems

and conventional systems S. 18

7. Common design features of condensing boiler technology based systems S. 19

8. Different condensing boiler technology based system constructions/designs S. 20

9. Condensing boiler technology and water heating S. 24

10. Particularities of the exhaust gas system/transport S. 27

11. Transport and neutralisation of the condensate S. 30

12. Condensing boiler technology - some technical diagrams S. 35

13. Solutions for the exercises and learning objectives in part II S. 45

14. Demonstration model - condensing boiler technology S. 54

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Part I Advising customers about condensing boiler technology

1. Customer conversation

The customer in our example did not obtain the necessary prolongation of the operating permission
for his old fuel oil heating system anymore after the last check of the installation by the district
chimney sweep. The district chimney sweep came to the conclusion that the customer has to install a
new heating system.

"Your fuel oil heating system is already p

"Could you as an expert give me an advice in this situation ?"

"You should make an appointment

It all looks like I now can forget about buying a new car !
 4

After our customer has realised that the best solution would really be to buy a new heating system, he
decides to follow the advice of the district chimney sweep and makes an appointment with a company
that is a member of the local sanitary, heating and air-conditioning association. The selected company
sends one of its service technicians to the appointment with the customer.

The service technician meets the customer in his house. He

gets the following information from the service technician:

2. Natural gas as the primary energy source for condensing boiler technology and
comparison of different fuels

Various energy sources or fuels are used to produce the heat/thermal energy, heating and air-
conditioning systems need. In order to obtain the fuels, the raw materials of the fuels have to be
further processed, treated or refined accordingly.

Exercise 1

One can distinguish three different groups of fuels. Write down these three groups of fuels and give
some examples for each group.

Group Fuels Examples

1

In regard to this group classification it has to be considered that the fuels in each group are produced
in different qualities and with different technical characteristic values. For this reason, the owner of a
heating system has to first answer the following two questions:

 Which fuel should be used ?

 Which fuel quality is available ?

You as the service technician had been informed that in the house of the customer a pump based
warm water heating system with fuel oil burner is installed which has to be replaced because of its
age and technical defects. You also had been told that the house of the customer has a natural gas
connection and that the existing heating installation is also used to heat up drinking water. Equipped
with this information you start to prepare yourself appropriately in order to be able to advise the
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customer as good as possible about the most effective solution to replace his old heating system with
a new one.
Exercise 2

– Fill in the table the characteristic values of the different fuels.

– Describe the combustion process of natural gas. Distinguish between complete and incomplete
combustion in your explanations. Complete the "normal combustion" diagram below.
– Explain the technical terms of the diagram.
– Determine the Ho : Hu - ratio for all fuels (in [%]).

Note: Since we are dealing with a condensing boiler, all other fuels can be neglected.

Gas composition [in %]

Component City gas Gas piped Natural gas Natural gas
over a long L H
distance
Hydrogen H2 - -
Methane CH4
Carbon monoxide CO - -
Propane, butane, ethane
Carbon dioxide CO2
Nitrogen N2
Oxygen O2 - -

Values that express the combustion heat

Fuel Calorific Heating Theoretical air Carbon
value value requirement dioxide
Ho Hu Lmin [m3/kg] CO2max [%]
[kWh/kg] [kWh/kg]
Anthracite coal
Coke
Dry wood
Dry peat
Fuel oil EL
[kWh/m3] [kWh/m3] [m3/m3] [%]
Natural gas L
Natural gas H
City gas
Propane
Butane
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Combustion
(general)

Complete
combustion

Incomplete
combustion

Carbon dioxide CO2

Exhaust gas: ..................................

................ ................
................ ..................................
................
................ ................ ..................................

Useable heat =
.............................
feelable heat
.............................

Natural gas
CH4
(Methane)

.............................
.............................

Combustion gas
 7

Overview of selected technical terms

Term Symbol Unit Explanation
Calorific value HoN kWh/m3
(in the standard state)

Calorific value during HoB kWh/m3

operation

Heating value HuN kWh/m3

(in the standard state)

Heating value during HuB kWh/m3

operation

Relative density d -

Wobbe-Index WoN kWh/m3

(in the standard state)

Wobbe-Index WuN kWh/m3 see above

(in the standard state)
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Overview of selected technical terms

Term Symbol Unit Explanation
Operating B -
condition/state

Standard state N -

Actual air Lactual m3/m3

requirement

Theoretical air Lmin m3/m3

requirement

Air changes number  -

Condensing boiler technology based/heating value ratios of different fuels

Fuel Condensing Heating value Ratio Ho/Hu [-] Ratio Ho/Hu [%]
boiler technology Hu [kWh/kg]
based
Ho [kWh/kg]
Anthracite coal 9,48 9,24
Coke 8,25 8,21
Dry wood 4,76 4,33
Dry peat 4,17 3,69
Fuel oil EL 12,8 11,9
3
[kWh/m ] [kWh/m3] [-] [%]
Natural gas L 10,0 9,0
Natural gas H 11,1 10,0
City gas 5,0 4,5
Propane 28,1 25,9
Butane 37,0 34,1
The values for Ho and Hu are only exemplary and can differ slightly.
 9

Learning objective 1

Explain why gas is the preferred fuel at the moment for condensing boilers.

3. Useable heat energy > 100% ?

"I would recommend you to let install a new condensing boiler system. With such a

"Your explanations sound very convincing

So ...

... from the manufacturer information and documentations we know:

In order to convert 1 litre of water into steam, a heat energy of 0,63kWh is necessary.

The same quantity of heat energy is released during the condensation of steam to water. This energy can e.g
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From the combustion of 1m3 of natural gas a maximum of 1,7 litres of water (in the form of steam)
results.
Exercise 3

– Determine the amount of heat energy that results as so called "latent heat" from the combustion of
1m3 of natural gas in the form of steam in the exhaust.

– Calculate the heating value Hu for a condensing boiler technology based of Ho = 11,1kWh/m3.

– Complete the following sentence:

If one reduces the ....................................... by the ....................................., that is present in the

exhaust as "........................" energy as .................................. one obtains
the .....................................................

– Explain the following diagram showing the natural gas combustion process.

CO2

CH4 + 2O2

2H2O
 11

– Complete the graphical comparison (see below) of a modern conventional boiler and a
condensing boiler (both with natural gas supply).

Heat energy in the exhaust ga

Heat energy in the exhaust gas that can not be used with conventional burners.

Calorific value Calorific value

Heating value Heating value

Exhaust losses
11%
100% 100%
Exhaust losses

100% ........ %
9% 5%
.... % ........ %
Emission and stand by losses

1% 1%

Emission and stand by losses

.... % ........ %

Usable heat energy of a modern

Usable conventional
heat energy of
boiler
a condensing
(fuel: natural
boiler
ga
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– Discuss the diagram shown below in your group.

– Discuss the "harmfulness/toxicity" of the condensate from oil or gas powered condensing boilers.

Condensate from condensing boilers

Waste water from households

Oil (EL) Gas

0123456789101112

0123456789101112

acidic basic

Battery acid, gastric acid

Distilled water (neutral)

Not polluted rain water

Tap/drinking water

Lemon juice
Rain water
Sea water
Ammonia

Vinegar
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Learning objective 2

For the condensing boilers mostly natural gas is currently used as a fuel. The
reason for this is that the use of natural gas has two main advantages.
– Name and explain these two advantages.

Advantage I Advantage II

Basis for advantage I Basis for advantage II

– Service technicians have to consider the following four important aspects in regard to the use of
the heat energy from exhaust gases. Explain all four aspects.

Support of the exhaust gas removal

Humidity insensitive exhaust gas pipes

Condensate removal

Corrosion resistant construction

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4. Condensing boiler technology checklist

I think I have understood now what condensin
I hope that our customer know has understood what condensing boiler technology m

I have brought you a check list for condensing boiler technology.

CHECK IT
HEATING SYSTEM
1  Pay attention to the reverse running temperature - maximally 60°C. 
 Adapt the heating curve. 
 Plan the possible installation of a reverse running temperature limiter. 
2  Try to achieve a temperature spread between forerun and reverse running 
temperature of at least 15 Kelvin in the case of old installations.
 Speed/revolution adjusted pumps are recommendable. 
3  Pay attention to the heating areas - in case of new buildings maximally 
75/60°C.
4  No increase of the reverse running temperature. 
 Do not use mixers and bypass circuits. 
REGULATION AND CONTROL
5  The regulation and control of the systems has to be realised according to the 
new regulations for heating systems.
WATER HEATING
6  The dimension/size of the hot water storage tank has to be planned 
according to the daily water needs of the hot water consumers.
 Chose preferably hot water storage tanks with large heat exchanger areas. 
 Plan the time/automatic switch controlled loading (maximally two times per 
day).
INSTALLATION SPACE
7  The are no special requirements for condensing boilers. 
 The installation of boilers that use room air and that do not use room air has 
to be discussed with the chimney sweep.
 Examine the possibility of a roof installation. 
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EXHAUST GAS REMOVAL

8  All matters with regard to the handling of exhaust gases have to be 
discussed with the chimney sweep.
 Exhaust gas pipes have to be installed gas-thight and corrosion resistant. 
 Give the customer the operating permission. 
CONDENSATE REMOVAL
9  The transport of the condensate from the condensing boiler to the domestic 
drainage system should be realised with plastic pipes if possible.
10  The introduction of the condensate into the public drainage system has to be 
discussed with the local waste water authorities.
 Plan a neutralisation if necessary. 
FINANCIAL SUPPORT
11  Get information about possible financial support programmes offered by gas 
supply companies or corresponding public authorities for the installation of
modern heating systems.

Exercise 4

You study the checklist with the customer. Afterwards, he still has some questions left in regard to
the following technical terms in the list:

 Adapt the heating curve

 Pay attention to the temperature spread
 No reverse running temperature increase
 Do not use bypass circuits
 Pay attention to the new heating system regulations
 Distinguish between condensing boilers that use room air and devices that do not use room air
 Plan a neutralisation

Try to explain the customer these terms as good as possible using the table below as well as
corresponding manufacturer documentation and information.

1 Heating curve adaptation

Keyword: Diagram: Examples for heating curves (characteristic heating curves)
Boiler temperature [°C]

Weather-led forerun temperature

control or automatic boiler
temperature regulation
6

80 5
4
3
70
2
1
60

50
+20+15+10+50-5-10-15-20
Outside temperature [°C]
40

30

20
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2 Pay attention to the temperature spread

3 ... no reverse running temperature increase

Keyword:
Reverse running temperature limiter

4 ... do not use bypass circuits

Keywords:
Mixer/Bypass-circuit, minimum water throughput quantities
(Distinction between normal one-circuit systems, radiators or convector heaters, dual
circuit systems, radiators and underfloor heating systems)

5 Pay attention to the new regulation for heating systems

Keywords:
New buildings, old buildings, 1 January 1998 deadline

6 ... distinguish between condensing boilers that use room air and that do not use room
air
Devices that do use room air Devices that do not use room air

7 Plan a neutralisation if necessary

Keywords:
See your corresponding documentation, manuals and DIN 1986 T4
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5. Condensing boiler technology based heating systems

Learning objective 3

Condensing boilers work in relatively low temperature ranges. The ideal working
range for condensing boilers are forerun/reverse running temperatures of
40°C/30°C. So, the temperature spread is 10K.
But also heating systems with temperature ranges of 75°C/60°C or 55°C/40°C use
the advantages of condensing boiler technology.
The diagram below shows the temperature curves as a function of the outside
temperature for a heating system with 75°C/60°C:
– Explain this diagram.
– Explain why the reverse running temperature should maximally be 60°C.
– Explain in which way the diagram is changing with a system temperature of
55°C/40°C and what effects that will have on the heating system.
Boiler forerun temperature [°C]

90

80 Heating system 75°C/60°C

70

60
?
50

40

30

20

20151050-5-10-15-20
Outside temperature [°C]

Area 1Area 2Area 3

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Part II The ecological solution - oil and gas based condensing boiler technology

6. Differences between condensing boiler technology based systems and

conventional systems

After the customer has now received a lot of basic information from you about the new condensing
boiler technology he is about to make a purchase decision in favour of it. However, before he actually
buys anything he would like to know some more details about the available systems and the
particularities of the condensing boiler technology. Of course, you want to be able to answer these
questions and so you are preparing yourself accordingly.

I have learned now that condensing boilers make use of the heat energy the exhaust gas is contain

There are four main differences between conden

Condensing boiler technology requires that the

exhaust gases are removed in a special way,
Exhaust gas removal since because of the strong cooling of the
1 support
exhaust gases their buoyancy is not sufficient
anymore. For this reason, and in order to
guarantee a save transport of the exhaust gases,
their removal has to be supported with air fans.

The exhaust gases contain rests of humidity

Exhaust gas pipe which is condensing in the exhaust gas pipes.
2 insensitive to humidity For this reason, the exhaust gas pipes have to
be insensitive to humidity.

By using the heat energy of the exhaust gas

condensate results. This condensate has to be
Condensate removed according to the corresponding
3 removal regulations.

In order to avoid possible corrosion damages

of the system, the parts of the condensing
Construction boilers, of the exhaust gas removal system and
4 corrosion resistant of the condensate removal system have to be
corrosion resistant.
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7. Common design features of condensing boiler technology based systems

Besides the above mentioned special characteristics, condensing boiler technology based systems also
have some common characteristic features with regard to their construction or design.

Exercise 5

– Complete the diagram below.

– Fill in the empty fields of the diagram the technical terms and temperature specifications you find
below.
– Describe (in the table below) the three characteristic features of condensing boiler technology
based systems with regard to their construction/design. Use manufacturer information and data to
get the necessary information.

Technical terms and temperature specifications:

150°C, exhaust gas fan, first heat exchanger, 1200°C, adjusted exhaust gas system, condensate
removal, 40°C, combustion air fan, second heat exchanger (integrated or following)

BURNER ......................................................................
......................................................
...........................

.......... .......... ..........

......................................................

...................................................................... ..................................

.....................
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Characteristic constructional/design features of condensing boiler technology systems

Second heat exchanger

Mechanical exhaust gas removal

Condensate removal

8. Different condensing boiler technology based system constructions/designs

Most condensing boiler technology based systems have been developed based on already existing
systems. For this reason, many different condensing boiler technology based system
constructions/designs exist:

Exercise 6

The four diagrams below show four different construction designs of condensing boiler technology
based systems. In the table below you find components and groups of components belonging to the
four boiler systems. However, not all parts are needed for the different boilers.
– Fill in the part/component numbers into the right fields of the four boiler diagrams.
– In the boiler comparison table check the components and component groups of each boiler.
– Discuss the result of the boiler comparison table.

Components and groups of components belonging to the four different condensing

boiler technology based construction designs
1 Boiler 13 Second heat exchanger
2 Burner 14 Condensate drain
3 Combustion air 15 Water reservoir
4 Supply air fan 16 Condensate
5 Exhaust air fan 17 Condensate pump
6 Exhaust gas 18 Whirling system
7 Condensing exhaust gas 19 Condensate pipe
8 Gas supply 20 Starting fan/blower
9 Heating system forerun 21 Combustion air chamber
10 Heating system reverse running 22 Combustion chamber
11 Heat exchanger 23 Swing pipe
12 First heat exchanger 24 Condensing area
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Diagram of a condensing boiler system with Diagram of a condensing boiler system with
following heat exchanger (1st generation) integrated heat exchanger (2nd generation)

...... ...... ...... ...... ...... ......

......
......

......
......

...... ......

......
...... ......
......
...... ......
......
......
...... ...... ...... ...... ......
Diagram of a condensing boiler system with Diagram of a condensing boiler system with a
direct heat exchanger (so called "Recitherm- so called "pulsation burner"
Boiler")

...... ...... ...... ...... ...... ...... ...... ...... ...... ......
......
......

...... ......
......
......

...... ....../......
...... ......

......

...... ...... ...... ...... ...... ...... ......

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Boiler-comparison table
No Component/component Boiler with Boiler with Boiler with Boiler with
group following heat integrated direct heat pulsation
exchanger heat exchanger burner
exchanger
1 Boiler
2 Burner
3 Combustion air
 23

4 Supply air fan

5 Exhaust gas air fan
6 Exhaust gas
7 Condensing exhaust gas
8 Gas supply
9 Heating system forerun
10 Heating system reverse
running
11 Heat exchanger
12 First heat exchanger
13 Second heat exchanger
14 Condensate drain
15 Water tank
16 Condensate
17 Condensate pump
18 Whirling system
19 Condensate pipe
20 Starting fan/blower
21 Combustion air
chamber
22 Combustion chamber
23 Swing pipe
24 Condensing area

Learning objective 4

– Describe the differences between condensing boiler technology based systems

with integrated heat exchangers and with following heat exchangers.
 24

– Explain which burners are used for condensing boiler based systems. Get
corresponding information from manufacturers, colleagues, fellow students,
etc...

Learning objective 5

– Describe the particularities of a pulsation - condensing boiler system.

– Name the components and/or component groups all different types of

condensing boiler technology based systems have in common.

Learning objective 6

All the four different condensing boiler technology based systems fulfil the
requirement "support the removal of exhaust gases".
– Explain in which way.

Condensing boiler
systems with following
heat exchanger
 25

Condensing boiler
systems with integrated
heat exchanger

Condensing boiler
systems with direct heat
exchanger

Condensing boiler
systems with pulsation
burner

9. Condensing boiler technology and water heating

Many heating systems that are currently available on the market offer the possibility to heat water
using condensing boiler technology.
For the planning of heating systems and for the heating of water the following factors have to be
taken into consideration:

 simultaneous use of different taps

 hot water use
 hot water comfort
 pipe length (with or without circulation pipe)
 available installation space
 costs
 exchange/replacement of system components

These factors influence e.g. the following:

 integrated or separate storage for hot water

 small or big hot water storage

I also would like to realise the hot water heating with the new condensing boiler. Sh

In order to help you with this decision I brought a tab

 26

Exercise 7

– Think, decide and explain which boiler you would recommend the customer. (Note: Consider that
the existing old heating system has to be replaced. It is a one family household with five family
members living in a detached family house. There exists a relatively new, two years old hot water
storage tank.)

Table with manufacturer recommendations

Situation Condensing Condensing boiler
boiler with with separate
integrated storage
storage
("Combined
boiler")
Use of taps Only one main tap X 
Different main taps, but taping not X X
occurring simultaneously
Different main taps, taping occurring - X
simultaneously
Water needs, 1-person-household (central warm X 
comfort water heating for an apartment)
4-people-household (central warm  X
water heating for an apartment or a
single-family house)
Multiple users (central warm water - X
heating for a multi-family house)
Pipe length  8m (without circulation pipe) X X
 8m (with circulation pipe) - X
Installation Only very little space available X -/*
space needed Sufficient space available X X
Costs Cost saving solution X p
Exchange/ Combined system existing X -
replacement Storage tank existing - X
X = recommendable  = recommendable but with limitations - = not recommendable
*
: only with a small vertical storage
Exercise 8

– Calculate for a new condensing boiler system with storage-water heating (storage tank volume =
200l, storage water temperature = 60°C) the necessary quantity [l] of cold water (cold water
temperature = 10°C) if 80l of hot water are taken out of the storage tank for a bath with a warm
water temperature of 42°C. Use the following formula for your calculation:

m1  1  m 2  2 1Cold water temperature [°C]

m  2Warm water temperature [°C]
mm mMixed water temperature [°C]
m1Cold water quantity [kg]
m2Warm water quantity [kg]
mmMixed water quantity [kg]
 27

– 80l of hot water (60°C) are taken out of the above mentioned storage tank and 80l of cold water
with a temperature of 10°C are flowing back into the storage tank. Determine the mixed water
temperature in the storage tank.

– Calculate the necessary heating time [min] of the storage, given a condensing boiler power of
27kW and a boiler efficiency ratio of 97,5%, in order to heat the storage water up from 40°C to
60°C. Use the following formula for your calculation:

P  t    Q  c   Temperature difference (Water) [K]

tHeating time [h]
mWater quantity [kg]
PSupplied power [W]
Boiler efficiency ratio [-]
cSpecific heat capacity [Wh/kg K]

Exercise 9

– Draw a heating system with separate water storage on a DIN A4 paper in landscape format. The
system should be a weather-led system with automatically adjusting boiler temperature control
and with storage priority circuit/switching. The heat exchangers that exist in the house are
equipped with thermostats. The system should be installed without mixer. Use your table book or
manufacturer brochures in order to determine the device mass.
– Consider all necessary components and parts in your drawing.
– Also plan and draw in the connection of the regulation and control unit to the heating system
circulation as well as to the storage system circulation and to all other necessary components.
 28

10. Particularities of the exhaust gas system/transport

After we have decided to integrate the existing drinking water storage tank into the

What has to be changed in this regard ? Will the condensing

The old boiler notchimney
existing be connected
can b

Exercise 10

– Explain the differences between exhaust gas systems for room air dependently operating gas
devices and room air independently operating gas devices.

I think I will chose a room air independently operating conden

 29

In contrast to conventional gas heating systems condensing boiler systems work with significantly
lower temperatures. As a result:

 .... the exhaust gas transport can not be realised using the natural gas buoyancy (also see
explanations above).
 .... the exhaust gases are condensing and so humidity insensitive pipe materials have to be used.

Prior to their use these materials have to be examined and have to be approved with a test seal and
test report by the IfBt (Institute for Construction Technique). So far the following materials fulfil
those special requirements: Aluminium, polyvinylidenflorid (PVDF), polypropylene (PPS), rustproof
steel, borsilicum glas and refractory/fire clay.

The following table gives an overview over the areas of use of the different materials:

Material Temperature categories Exhaust gas

A B C temperature
  80°C   120°C   160°C limiter
Aluminium - - X no
Polyvinylidenflorid (PVDF) X - - yes
Polypropylene (PPS) - X - yes
Rustproof steel - - X no
Borsilicum glas - - X no
Refractory/fire clay - - X no

So, if one plans to continue to use the old chimney with a new condensi

Exercise 11

Because of the low exhaust gas temperatures of condensing boiler systems, the exhaust gas transport
can not be realised using the natural buoyancy of the gas.
– Give reasons for the modifications that are necessary because of this in contrast to the
conventional way to remove exhaust gases.
– Explain in more detail how the exhaust gas removal has to be realised with condensing boiler
systems.
 30

Exercise 12

Since the exhaust gases are condensing in the exhaust gas pipe, humidity insensitive materials have to
be used for the exhaust gas pipe.
– Explain and give reasons which installation has to be there in the case of exhaust gas pipes of
condensing boiler systems.

Exercise 13

The so called "concentric shaft arrangement" of the exhaust gas pipe is based on the countercurrent
principle (second possibility: "parallel shaft arrangement").
– Explain the terms "concentric" and "parallel shaft arrangement".
– Draw the two different pit arrangements.

Exercise 14

Condensing boiler systems that operate room air independently are so called "pressurised systems".
– Explain this principle.

11. Transport and neutralisation of the condensate

According to the "general waste water regulations" only waste water/sewage with a pH-value
between 6,5 and 8,5 can be introduced into the sewage system.
With gas based condensing boiler systems the pH-value is between approximately 3,8 and 5,4. This
range means that the condensate of the condensing process is an acid and so can not be introduced
into the sewage system without further treatment/processing.
In regard to its introduction also its composition and its quantity are important.

Depending on the origin of the natural gas its composition can differ. The following applies for
natural gas E (former natural gas H):
 31

100% Natural gas E = 93% CH4 + 4,9% CnHm + 1,1% N2 + 1% CO2

For natural gas LL (former natural gas L) the following applies:

100% Natural gas LL = 81,8% CH4 + 3,4% CnHm + 14% N2 + 0,8% CO2

In order to ensure a complete combustion, more air has to be supplied to the combustion process than
theoretically would be necessary. A complete combustion can be recognised by a bluish colouring of
the flame. An air-to-fuel ratio  ranging from 1,25 to 1,30 has proved to yield good results for natural
gas.
In the case of complete combustion the following chemical reaction is taking place in the natural gas
flame:

CH4 + 2O2  CO2 + 2H2O

Methane + Oxygen  Carbon dioxide + Water steam + Heat

The steam that is created during the combustion process condenses and is transmitting the heat energy
it contains to the heating water. The resulting condensate has to be removed. The obtained condensate
quantity depends on the condensing boiler design and the operating conditions. Theoretically, the
combustion of 1 m³ of natural gas is resulting in 1,6 litres of condensate with a pH-value of 4,0 and
the combustion of 1 litre of fuel oil (EL) is resulting in 0,9 litre of condensate with a pH-value of 2,0.
Experience has shown however, that somewhat smaller quantities are resulting in practice. So, one
can say that as a rule of thumb approximately 1 litre of condensate is resulting from the combustion
of 1 m³ of natural gas (annual average). That means that e.g. with a natural gas consumption of
2500m3/year a condensate quantity of 2500l/year or 7l/day is obtained. This corresponds to only 1%-
2% of the total yearly and/or daily sewage quantity of a household.

With regard to the composition of the condensate, measurements have proved that the percentage of
elements like lead, chrome or nickel is well below the limits of the drinking water regulations (see
table below).

Substances/elements - Limit values of the drinking Condensate of a condensing

water quality water regulation boiler
mg/l g/l mg/l g/l
Lead 0,04 0,00004  0,002  0,000002
Chrome 0,05 0,00005  0,002  0,000002
Nickel 0,25 0,00025  0,002  0,000002
pH-value 6,9-9,5 3,8-5,4

Unfortunately, during further measurements and examinations some heavy metal elements were
found. The reasons for these findings were that metal heat exchangers had been used. So, only heat
exchangers made of ceramics, graphite or plastic should be used for these purposes.

Exercise 15

For the single-family house of a customer on average 3200 litres of fuel oil are needed per year for
room heating and drinking water heating. The customer now wants to switch to natural gas E (former
natural gas H).
 32

– Determine the average yearly condensate quantity that is resulting after switching to natural gas
(minimum and maximum).
– Determine the mean.
– Examine the condensate for lead, chrome and nickel elements by performing corresponding
measurements. Compare in a table the actual values found with the limit values of the drinking
water regulation (maximum tolerated value).
– Discuss the results.

Use the following formulas and values for your calculations:

Qa BaAnnual fuel need [m3/a; kg/a; l/a]

Ba  HuHeating value of fuel [kWh/m3; kWh/kg; kWh/l]
H u  ges
Substance density [kg/dm3]
Total system efficiency [-]
Hu Fuel oil EL= 11,6kWh/kg
Hu Natural gas E= 10,06kWh/m3 ... 11,58kWh/m3
Fuel oil= 0,86kg/dm3
Natural gas= 0,8kg/m3
Fuel oil system= 0,80
Condensing boiler system= 0,95

Value comparison table given an annual condensate quantity of

VK = ..................... l/a
Substances/ Maximum permitted (limit) Actual measured values of a
elements values according to the condensing boiler
drinking water regulation
mg/a g/a mg/a g/a
Lead
Chrome
Nickel

If the quantity of these measured elements the condensate is containing is still well
 33

Exercise 16

– Determine with the help of the information and documentation available to you the exact tolerated
limit values for the introduction of condensate into the public sewage system.
– Think about how the measured elements (e.g. lead, chrome, nickel) can get into the condensate.

11.1 Introduction/transport of the condensate without neutralisation

Like it already has been briefly mentioned above under certain conditions the introduction of
condensate into the public sewage system is possible without its neutralisation. One important
condition is that "...the pipes of the domestic drainage systems consist of materials that are resistant
to acid condensate." The following materials fulfil this condition:

 Stone pipes
 Hard-PVC-pipes
 PVC-pipes
 PE-HD-pipes
 34

 PP-pipes
 ABS/ASA-pipes
 Cast iron pipes with interior enamelling or internal coating
 Steel pipes with internal plastic coating
 Stainless steel pipes
 Borsilicum glass pipes

Furthermore, the particular regulations for building drainpipe systems have to be taken into
consideration. One also has to ensure that the drainpipes are supplied correctly with air so that the
required trap is not sucked empty.

11.2 Introduction/transport with prior neutralisation of the condensate

If a neutralisation of the condensate should be necessary, the boiler manufacturers normally offer
corresponding neutralisation systems for their condensing boilers. The size of these neutralisation
systems is varying depending on the boiler power and on the quantity of the condensate.
After the condensate has passed the neutralisation system its pH-value has been increased to 6,5 to 10
and it can be introduced into the public sewage system.
The function of the neutralisation system should be checked at least once per year with pH-paper
(litmus paper). Every second year the neutralisation medium (usually a granulate) should be replaced.
For large installations it usually makes more sense, and it is also more economical, to combine
neutralisation systems with corresponding dosing systems. Such systems add e.g. constant quantities
of liquid soda/sodium carbonate to the condensate.
The following diagram shows a neutralisation system and its possible integration into a condensing
boiler system.

Diagram: Example for a neutralisation system with magnesium oxide as neutralisation medium
 35

English translation of technical terms and sentences of the diagram above:

Stecker mit Anschluss zum Kessel-Regelgerät = Plug with connection to the boiler regulation device
Kondenswasserpumpe = Condensate pump
Ablauf Kondenswasser = Condensate drain/outlet
Förderhöhe 2m = Hoisting depth of 2 metres/2 metres difference in height
Druckschalter = Pressure switch
Kammer für neutralisiertes Kondenswasser = Chamber for neutralised condensate
(max. Volumen ca. 13 Liter) (maximum volume about 13 litres)
Magnesiumoxid-Neutralisationsmittel = Magnesium oxide as neutralisation medium
(max. Volumen ca. 7 Liter) (maximum volume about 7 litres)
Zulauf Kondenswasser = Condensate inflow/inlet

Diagram: Example for the possible installation of a neutralisation system

English translation of technical terms and sentences of the diagram above:

Gas-Brennwertkessel = Gas powered condensing boiler

Kondenswasser vom Brennwertkessel = Condensate of the condensing boiler
Neutralisationseinrichtung = Neutralisation system
Anschluss an das öffentliche Abwassernetz = Connection to the public sewage system
12. Condensing boiler technology - some technical diagrams

While you were giving me all these explanations I was drawing the diagram below a
 36

Diagram: Aspects that have to be considered for a successful use of condensing boiler technology

Fuel Regulation and control of the system

Gas Oil

al of heavy metal elements, condensation and neutralisation Boiler and exhaust gas heat exchanger

Condensing boiler technology use

Exhaust gas pipes and chimney Regulations, norms, legal requirements and local/municip

Hydraulic circuits and buffer

Heating
storage
system and medium heating temperature

Your overview is correct. It shows all relevant aspects of the condensing b

Or not ?

The condensing boiler technology is using the additional heat energy r

With regard to this subject I brought you some technical diagram

 37

Diagram: Relationship between the annual heating performance and the outside air temperature

Heating water temperature [°C]

Annual heating performance [%]

100 100
Annual heating performance curve
90 90
Heating water condensation temperature
80 80

70 70

60 60

50 50

40 40

30 30

20 20

10 10

0 0
-15-10-505101520

Outside air temperature [°C]

The following conclusions can be drawn from the diagram above:

– At an outside air temperature of –15°C, 100% of the boiler power is used.

– If the outside air temperature is –5°C, 93% of the boiler power is used.
– If the outside air temperature is 10°C, only about 10% of the boiler power is used.
– In order to determine the share of condensing boiler usage, the assumption is made that at a
heating water condensation temperature of 40°C the exhaust gases are cooling down below their
condensation temperature and so the use of the condensation heat energy becomes possible.

Diagram: Relationship between the annual heating performance and the outside air temperature with heating system
temperatures of 90°C/70°C
Heating water temperatu
Annual heating perform

100 100
Annual heating performance curve

90 90
Heating water condensation temperature

80 80
Heating system forerun
70 70

60 60
 38

The diagram shows that with the specified system temperatures a condensing boiler yield of about
30% of the annual heating system performance can be achieved.

Diagram: Relationship between the annual heating performance and the outside air temperature with heating system
temperatures of 70°C/50°C
Heating water temperatu
Annual heating perform

100 100
Annual heating performance curve
90 90
Heating water condensation temperature
80 80

70 Heating system forerun 70

60 60
 39

The diagram shows that with the specified system temperatures a high condensing boiler yield of
about 88% of the annual heating performance can be achieved.

Diagram: Relationship between the annual heating performance and the outside air temperature with heating system
temperatures of 40°C/30°C
Annual heating performan

Heating water temperatu

100 100
Annual heating performance curve
90 90
Heating water condensation temperature
80 80

70 Heating system forerun 70

60 60

50 50
 40

The diagram shows that with the specified system temperatures a condensing boiler yield of 100% of
the annual heating performance can be achieved.
That means that during the entire heating period a condensing boiler use is possible. It also means that
with the specified temperatures the most efficient condensing boiler use is accomplished.

Diagram: Relationship between water steam condensation temperature and CO2-concentration of different fuels
(according to DIN 4705)
Condensation temperatu

70

60

50 Exhaust gas

40

30
 41

Fuel values Hu CO2 max. Measurement example for natural gas

[kWh/kg] [kJ/kg] [Vol. %] The result of the measurement is 12% CO2
e.g.: in the
exhaust gas
Coke 29556 8,21 20,7 Measured condensation 58°C
temperature:
Fuel oil EL 42840 11,9 15,4 Measurement example for fuel oil
Natural gas 36000 10,0 12,0 The result of the measurement is 15,4% CO2
e.g.: in the
exhaust gas
City gas 16200 4,5 13,6 Measured condensation 52°C
temperature:
In the ATV-instructions M 251 the following formula is given to calculate the condensate quantity:

V  b  Q NB  v VMaximum condensate quantity [l/a]

QNBNominal heat energy load [kW]
bBurning time [h/a]
vSpecific condensate quantity [l/kWh]
in case of natural gas: v = 0,12l/kWh
 42

The following diagram shows an example for the efficiency of a condensing boiler that is working
with two different system temperatures. The efficiency difference between the two system
temperatures is very obvious.

Diagram: Relationship between partial load efficiency and system load

Partial load nominal efficiency [%]

112
System temperature 40/30°C
111

110

109

108

107

System temperature 75/60°C

106

105

104

103 0102030405060708090100110

System load [%]

102

101

100

99

98

97
12.1 Some examples for different condensing boiler technology based heating systems
96 with a drinking water heating circulation and one direct heating circulation (radiator heater)
Diagram: Heating system

95
 43

Diagram: Heating system with drinking water heating circulation, one direct heating circulation (radiator heater) and one
mixed heating circulation (under-floor heating)

Diagram: Heating system with drinking water heating circulation and two mixed heating circulations
(under-floor heating)

With the fuel oil powered system below an optimal condensing boiler use can be accomplished.

Diagram: Combined buffer storage with vacuum tube collectors and boiler with exhaust gas heat exchanger
(condensing boiler technology)
 44

Uh, I hope I did understand everything - I am not quite sure.

I had the same problems initially when I started studying condensin

 45

13. Solutions for the exercises and learning objectives in part II

Exercise 5

BURNER FIRST SECOND CORRESPONDING

1200°C 150°C HEAT 40°C EXHAUST GAS SYSTEM
HEAT
EXCHANGER EXCHANGER

CONDENSATE
disposal
 46

Constructional/design features of condensing boiler systems

Second heat exchanger The second heat exchanger was one of the first special
constructional features in the beginning of the
condensing boiler technology development. The
engineers had added an additional heat exchanger to a
conventional boiler in order to use the heat energy of
the exhaust gases. Today such a following or added
heat exchanger is still used for large high-performance
boilers.
Mechanical exhaust gas removal Condensing boiler systems make a mechanical exhaust
gas removal necessary since the exhaust gases do not
have sufficient natural buoyancy due to their low
temperatures. A mechanical exhaust gas transport is
normally realised with air fans or blowers.
Condensate removal Since in condensing boiler systems as well as in the
exhaust gas pipes the exhaust gases are condensing and
then are gathering in the lowest point of the system, it is
necessary to transport and to introduce the condensate
into the public sewage system with the help of
corresponding installations.

Exercise 6

Function of a condensing boiler system with Function of a condensing boiler system with
added/following heat exchanger integrated heat exchanger (2nd generation)
(1st generation)

12 24 13 7 10 5
...... ...... ...... ...... ...... ...... 4
3
......
......
11
8 ......
......

2 9
 47

Function of a condensing boiler system with Function of a condensing boiler system with
direct heat exchanger pulsation burner
(so called Recitherme-boiler)

3 9 7 24 6 18 19 3 20 2
...... ...... ...... ...... ...... ...... ...... ...... ...... ......
17
...... 21
......
8 22
...... ......
9
...... 23
......
10 7/24
......
6 16
...... ......
14
......

8 3 2 1 15 14 10
...... ...... ...... ...... ...... ...... ......

Boiler comparison table

No Component/component Boiler with Boiler with Boiler with Boiler with
group following heat integrated direct heat pulsation
exchanger heat exchanger burner
exchanger
1 Boiler X
2 Burner X X X X
3 Combustion air X X X X
4 Supply air fan X
 48

5 Exhaust gas air fan X

6 Exhaust gas X X X X
7 Condensing exhaust gas X X X
8 Gas supply X X X X
9 Heating system forerun X X X X
10 Heating system reverse X X X X
running
11 Heat exchanger X
12 First heat exchanger X X
13 Second heat exchanger X
14 Condensate drain X X X X
15 Water tank X
16 Condensate X X X
17 Condensate pump X
18 Whirling system X
19 Condensate pipe X
20 Starting fan/blower X
21 Combustion air X
chamber
22 Combustion chamber X
23 Swing pipe X
24 Condensing area X X X X

Learning objective 4

– Condensing boiler systems with added/following heat exchanger are usually

bigger than other boilers. Above all they are used when high boiler
performances are needed. It is necessary to position the heat exchanger behind
the boiler since the burner is located below the first heat exchanger. If a
condensation were to take place in this area, the condensate would drop on the
burner and could cause malfunctions.
In devices with integrated heat exchangers, the burner is normally located
above or at the side of the heat exchangers so that the condensate can not drop
on it.
 49

– The same atmospheric burners, blower burners and premix-burners that are
also used in conventional boiler systems are being used.

Learning objective 5

– A pulsation burner works with a special pulsating combustion process where

the gas-air-mixture is sucked into a spherical, closed combustion chamber. The
over-pressure developing in this combustion chamber presses the exhaust
gases in the heat exchangers located below. About 60 ignitions per second
(pulsation frequency) are resulting in a high exhaust gas speed which ensures
an good heat energy transmission to the heating water and so a very effective
use of the condensation heat. In contrast to other condensing boiler systems,
pulsation - condensing boilers do not need any mechanical exhaust gas
removal because of the combustion chamber over-pressure.

– Burner, combustion air, exhaust gas, condensing exhaust gas, gas supply,
heating system forerun, heating system reverse running, heat exchanger,
condensate, condensing area.

Learning objective 6

Condensing boiler with an exhaust gas fan

system with
added/following heat
exchanger
Condensing boiler with a supply air fan
system with integrated
heat exchanger
Condensing boiler with a combustion air fan (blower burner)
system with direct heat
exchanger
Condensing boiler with over-pressure in the combustion chamber
system with pulsation
boiler

Exercise 7

Since a 200l-storage tank for drinking water heating is existing, a boiler with separate storage
connection is recommendable.

Exercise 8

- m1 = [m2 * (2 - m)] / (m - 1)
m1 = [80kg * (60°C – 42°C)] / (42°C – 10°C)
m1 = 45kg 45l cold water

m = (m1 * 1 + m2 * 2) / mm
m = (80kg * 10°C + 120kg * 60°C) / 200kg
 50

Exercise 9

Heizkessel = Heating boiler

Speicherwassererwärmer = Storage water heater
Exercise 11

– The exhaust gas temperatures of conventional boiler systems are much higher than those of
condensing boiler systems. That means that the exhaust gases of conventional systems tend to
automatically move up because of their natural buoyancy.

– In order to remove the exhaust gases of condensing boiler systems, mechanical support
installations are necessary (with the exception of pulsation - condensing boilers): there either is a
fan installed in the exhaust gas pipe which sucks the exhaust gases out or there is a blower
integrated in the system which is pressing the exhaust gases out.
 51

Exercise 12

In the exhaust gas pipe there has to be a place where the condensate can be collected. Furthermore,
from this collection point on the exhaust gas pipe has to have a constant downward inclination, so
that the condensate can not collect itself in another place.

Exercise 13

– In the case of the concentric chimney arrangement, the exhaust gas pipe is completely surrounded
by inflowing combustion air. With the parallel chimney arrangement this is not the case.

- Diagram: Concentric and parallel exhaust gas systems

Concentric exhaust gas transport Parallel exhaust gas transport

Chimney cross-section Exhaust gas pipe

Area through which supply air is flowing in

Exercise 14

The combustion air supply pipes and/or the exhaust gas pipes have to be designed so that in the
exhaust gas pipes an over-pressure is being created whereas in the combustion air supply pipes a low-
pressure (see the diagram above: in the area where supply air is flowing in, there has to be a low-
pressure).

Exercise 15

Qa Oil = Ba * Hu * ges
Qa Oil = 3200l * 0,86kg/dm3 * 11,6kWh/kg * 0,80
Qa Oil = 25.538,56kWh

Ba Gas max. = 25.538,56kWh / (10,06kWh/m3 * 0,95)

Ba Gas max. = 2.672,24m3

Ba Gas min. = 25.538,56kWh / (11,56kWh/m3 * 0,95)

Ba Gas min. = 2.321,48m3

V Condensate = 2.322l/a ... 2.673l/a

 52

Value comparison table given an annual condensate quantity of

VK = ..................... l/a
Substances/ Maximum permitted (limit) Actual measured values of
elements values according to the condensing boiler systems
drinking water regulation
mg/a g/a mg/a g/a
Lead 100 0,100 <5 < 0,005
Chrome 125 0,125 <5 < 0,005
Nickel 625 0,625 <5 < 0,005

Important result of the discussion: The quantities of heavy metal elements that are going to be
introduced into the public sewage systems are well below the permitted limit values.

Exercise 16

– According to the ATV-instructions 251, May 1988 issue, it is permitted to introduce the
condensate of gas powered condensing boiler systems with a nominal heat energy load of 25kW
into the public sewage system without neutralisation. Furthermore, for gas-condensing boiler
systems with a nominal heat energy load of 25kW - 200kW a neutralisation of the condensate is
not necessary if the condensate is collected during the night and is then introduced during the day
into the public sewage system together with the domestic waste water.

– The condensate of condensing boiler systems that have a higher nominal heat energy load than
those mentioned above has to be neutralised in any case. The heavy metal elements that can be
measured in the condensate result from the metal components/parts of the boiler and other metal
installations. They become part of the condensate through the exhaust gas condensation process.

Technical parameters/characteristic values for fuels

 53

1)
Conversion factor: 1MJ = 0,2778kWh

English translation of technical terms and sentences in the table above:

Brennstoffgruppe = Fuel group

Brennstoff = Fuel
Wärmewert = Energy values
Verbrennungsluftbedarf = Combustion air requirement
Brennwert Ho = Calorific value
Heizwert Hu = Heating value
VLmin = Minimum air requirement for the stoichiometrical combustion
(complete combustion)
Feste Brennstoffe = Solid fuels
Anthrazit = Anthracite coal
Braunkohle = Brown coal
Braunkohlebriketts = Brown coal briquettes
Holz, luftgetrocknet = Wood, air-dried
Stroh, luftgetrocknet = Straw, air-dried
Torf, trocken = Dry peat
Zechenkoks = Coke
Flüssige Brennstoffe = Liquid fuels
Heizöl EL = Fuel oil EL
Heizöl S = Fuel oil S
Kerosin = Kerosene
Petroleum = Petroleum
Brennwert Ho,n = Calorific value in standard state/condition
Heizwert Hu,n = Heating value in standard state/condition
Ho,B = Calorific value in operating condition (Operating calorific value)
Hu,B = Heating value in operating condition (Operating heating value)
Gasfamilie (S) = Gas group (S)
Stadtgas = City gas
Ferngas = Gas supplied over long distances
Gasfamilie (N) = Gas group (N)
Erdgas H = Natural gas H
Erdgas L = Natural gas L
Gasfamilie (F) = Gas group (F)
Propan = Propane
Butan = Butane
Gasfamilie (L) = Gas group (L)
 54

Flüssiggas-Luft-Gemisch = Liquid gas-air-mixture

Erdgas-Luft-Gemisch = Natural gas-air-mixture

Operating heating Hu,B and operating calorific values H o,B are published by the corresponding gas
supply company. The operating heating value Hu,B is necessary for the adjustment of a gas burner
according to the so called "volumetric method".

Even if I had to try hard, my solutions are almost all correct.

I could not have done it any better.

14. Demonstration model - condensing boiler technology

During the project ZEBA has developed a demonstration model for condensing boiler technology
(see graphic below). The demonstration model can be used in practice-oriented initial and continuing
vocational training. With it students can easier understand the function of condensing boiler systems.
Also, frequently occurring errors can be simulated and test measurements be performed. On the
following pages the model and its function will be briefly presented.

Graphic: Demonstration model - condensing boiler technology

 55

14.1 Components

– Glass combustion chamber with integrated heat exchanger and condensate trap/collector
– Pipe set with couplings
– Flow meter
– Temperature measuring nipple
– Pressure-reducing valve 1/2 "
– Digital thermometer with holder for module rack
– Catalytic burner with gas bottle, inlet and fine flow control valve
– Small adjustable fan with voltage supply
– Module rack for desk-mounting, front and back can be further equipped (expandable)
– Diagrams with module pins, topic: condensing boiler technology

14.2 Structure

The model is delivered ready for operation. The following two graphics show the model components
and their arrangement.

Graphic: Condensing boiler model - Front view

 56

English translation of technical terms and sentences in the graphic above:

Schautafel = Diagram
Feinregulierventil = Fine flow control valve
Gasflasche = Gas bottle
Modulträger = Module rack
Glasbrennkammer = Glass combustion chamber
Digitalthermometer = Digital thermometer
Durchflußmesser = Flow meter
Abgasrohr mit Lüfter und = Exhaust gas pipe with fan and condensate trap/collector
Kondensatfalle
Kondensatfalle = Condensate trap/collector

Graphic: Condensing boiler model - Rear view

 57

English translation of technical terms and sentences in the graphic above:

Spannungsversorgung = Voltage supply

Druckminderer = Pressure-reducing valve
Kugelhahn = Ball cock/tap

14.3 Function

The ZEBA demonstration model shows how the condensing process in condensing boiler systems
works and also illustrates different energy balances.

The on top installed catalytic burner is operated with a propane/butane mixture. It is located in the
glass combustion chamber where only primary combustion air flows by the inlet nozzles of the
burner. In this way, a very calm catalytic combustion is achieved. The heat exchanger located below
is slowly being surrounded by the up-heated gases and extracts, at a corresponding reverse running
temperature, the humidity from the air in the burner.

Depending on the adjustment of the flow rate, coolant temperature and catalytic burner temperature a
corresponding efficiency results. The quantity of the obtained condensate clearly shows if those
adjustments were optimal. The gained condensation heat is supplied to the heat exchanger. The
condensate resulting at the glass heat exchanger drops into the condensate trap/collector and can be
removed through the ball cock/tap. The adjustable fan is removing the produced exhaust gases.

14.4 Preparing measures

Since the model is delivered completely assembled, it can be put into service in a relatively short
period of time.

After the model has been installed in a safe location and after it was checked if no parts are missing,
the modular pipes should be tied up again since it can happen that they have loosened during the
transport.

Afterwards the water circulation has to be connected (over a thermostat), the adjustment of the
pressure monitor has to be checked (max. 1 bar) and it has to be examined if the system is tight.
 58

The flow should be adjustable up to the maximum of the flow meter (25 l/H) using the ball cock/tap
located in the inlet (pressure-reducing valve adjustment). Possibly, the pipes and the glass combustion
chamber have to be adjusted to each other in order to guarantee a steady flow through the heat
resistant, soft silicone hoses at the connections of the heat exchanger. Now the feelers/sensors of the
digital thermometers can be introduced into the measuring connecting pieces. Those should be
moistened first with vaseline or silicone oil in order to preserve the rubber seals. The voltage supply
of the fan has to be attached on the back of the module rack and its two plugs have to be plugged in
with correct polarity/poling.

After the automatic controller has been connected to the mains (230V/50 Hz), one has to check the
rotation direction of the fan by switching it on and by adjusting it for the highest number of
revolutions. The air flow coming out of the exhaust gas pipe can be easily checked with the hand. If
the air flow should be directed to the inside (towards the heat exchanger), the polarity/poling of the
plugs is not correct and has to be changed.

The gas bottle has to be screwed into the fine flow control valve and then has to be hang up vertically
and firmly secured on the module rack with the valve pointing upward. The hose connection at the
burner may not be loosened. An examination on tightness also has to be performed here after
transport. This can be easily done by opening the fine flow regulation valve and by observing the
upward turned burner against the light. If a creation of reams/stains at the hose connection is
occurring, the connection has to be tied up before the device is started. The burner has to be held
upward (in burn direction) for this test since otherwise a creation of reams/stains through gas leakage
at the supply air openings of the primary combustion air may take place.
The condensate drainage possesses an adjustable drain valve/tap whose lock nut must be loosened at
the beginning and then has to be tied up again after some movements.

14.5 Measuring procedure - experimental/test setup

If all described preparing measures have been carried out, the condensing boiler demonstration model
is ready for use.

The automatic fan controller has to be switched on now and has to be adjusted to a medium number
of revolutions.

Burner start:

The burner has to be held upward with the catalytic fabric/tissue and then the gas supply has to be
opened. The fine flow control valve regulates very precisely. However, pressure changes are
normally occurring with a short time delay.
The gas can now be ignited. After the catalytic combustion has started - this can be easily recognised
by the disappearing flame and the following glow of the fabric/tissue - the burner has to be slowly
inserted into the glass combustion chamber and has to be centrically placed there.

Graphic: Burner adjustment

 59

Fine flow control valve Optimally Fine flow control valve

turn back open

The fan now has to be completely back-regulated. A minimum number of revolutions is factory
adjusted for safety reasons.

Depending on the adjusted/chosen starting values, the condensation starts after a short period of time
and a measuring protocol can be made and different test measurements can be performed.

The following two graphics show experimental/test setups with which one can perform different
measurements as a function of the flow. The last graphic shows an example for a measuring
protocol/report that has to be filled out by the students.

Graphic: Experimental/test setup

Graphic: Experimental/test setup

 60

English translation of technical terms and sentences in the graphic above:

Brennstoffgruppe = Fuel group

Gasgemisch = Gas mixture
Thermostat oder Einhandhebelmischer = Thermostat or lever mixer for the input
für eingangsseitige Temperaturwahl temperature selection
Warmwasser = Hot water
Kaltwasser = Cold water
Temperatur-Messstellen = Temperature measuring points
Durchflussmengenmesser = Flow meter
Druckminderer = Pressure reducer
Kugelventil = Ball valve
Abfluss = Drainage
Kondensatablauf = Condensate drain
Abgasaustritt = Exhaust gas outlet
Verbrennungsluftbedarf = Combustion air requirement
Brennwert Ho = Calorific value Ho
Heizwert Hu = Heating value Hu
 61

Graphic: Example for a measuring protocol/report

English translation of technical terms and sentences in the graphic above:

Schule = School
Messprotokoll - Brennwerttechnik- = Measuring protocol/report - Condensing boiler model
modell
Datum = Date
Klasse = Class
Name = Name
Versuch Nr. = Test/experiment number
Wassereintrittstemperatur = Water inflow temperature
Durchfluss l/h = Flow l/h
Abgastemperatur = Exhaust gas temperature
Eingangstemperatur = Input/start temperature
Ausgangstemperatur = Output temperature
Energie = Energy

14.6 Faults

The burner of the model is simple and normally will operate without any problems. If however the
components should not be firmly bolted, gas can leak out at other places than the nozzle. In this case
the supply pressure in the nozzle becomes too small and the gas flow can not carry enough oxygen
which leads to an incomplete combustion (soot formation).