STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Installation Manual Download Page 8

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Technical description

Standard boiler

Boiler transport

Boiler installation

Standard boiler

A boiler delivery package contains the

following components:

Component

Pcs.

Package

Boiler fully assembled and tested

Cardboard box on pallet

Mounting bracket incl. mounting material

Cardboard box in boiler packaging

Syphon for condensate connection

Cardboard box in boiler packaging

Conversion kit for propane incl. instruction

Cardboard box in boiler packaging

Operation and Installation manual

Map packed in cardboard box in boiler packaging

Spare parts list

Map packed in cardboard box in boiler packaging

Wiring diagram

Map packed in cardboard box in boiler packaging

Boiler installation

The boiler should be positioned in a

frost-proof boiler room. If the boiler

room is on the roof, the boiler itself

may

never be the highest point of the

insta

lation.

When positioning the boiler, please

note the recommended minimum clea-

rance in the picture. When the boiler is

positioned with less free space, mainte-

nance activities will be more difficult.

Boiler transport

The R40 boiler will be supplied as a

complete unit being fully assembled

and pre-tested. The packaging dimensi-

on is 1050x572x575mm for boiler types

65-85 and 1185x674x665mm for boiler

types 100-150, which makes it possible

to transport all models through a

mal door in one piece.

The R40 can be transported with a

cra

ne, but it has to be ensured that the

boiler is packed and fixed on a pallet.

The straps must be connected to the

pallet.

Summary of Contents for ECONOFLAME R40

Page 1: ...STALLATION OPTIONS SYSTEMS DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E MAIL info stokvisboilers com WEBSITE www stokvisboilers com 06 2011AC20111006 DOC2080GB ...

Page 2: ...protection 11 Antifreeze 11 Flue gas system Requirements and regulations 12 Materials 12 Flue gas data 12 Dimensioning single 13 Dimensioning cascade 14 Neutralisation General 15 Neutralisation systems 15 Hydraulic connection Hydraulic resistance 16 T measurement 16 p measurement 16 Hydraulic connection into a system 17 Single 17 Cascade 18 Controls Basic controls and connections 19 Control by bui...

Page 3: ...ne and sanitary hot water low loss header 39 4 5 A C 2 heating zones and sanitary hot water low loss header 40 4 5 A C E 2 heating zones and sanitary hot water cascade via low loss header 41 A C Boiler control via 0 10VDC low loss header 42 A C E Boiler control via 0 10VDC cascade via low loss header 43 1 B C 1 direct heating zone plate heat exchanger 44 2 B C 1 mixed heating zone plate heat excha...

Page 4: ...ler design optimised for easy access on servicing Description The R40 is a fully modulating boiler The control unit of the boiler adapts the modulation ratio automatically to the heat demand requested by the system This is done by controlling the speed of the fan As a result the Whirlwind mixing system will adapt the gas ratio to the chosen fan speed in order to maintain the best possible combusti...

Page 5: ... temperature at 40 30ºC max min ºC 55 39 55 39 55 39 55 39 55 39 Flue gas quantity max min m3 h 119 19 159 25 178 29 213 35 253 44 CO2 level G20 G25 max min 8 5 8 5 8 5 8 5 8 7 8 5 8 7 8 5 8 7 8 5 CO2 level G31 max min NOx level mg kWh 39 39 39 39 39 CO level max min mg kWh 98 7 98 7 98 7 98 7 98 7 Max permissible flue resistance max min Pa 150 15 150 15 150 15 200 15 200 15 Water volume l 4 0 4 7...

Page 6: ...90 490 590 590 590 B1 mm 140 140 140 140 190 B2 mm 245 245 295 295 295 D mm 500 500 600 600 600 H mm 810 810 950 950 950 W1 mm R 1 1 4 R 1 1 4 R 1 1 2 R 1 1 2 R 1 1 2 W2 mm R 1 1 4 R 1 1 4 R 1 1 2 R 1 1 2 R 1 1 2 G mm R 3 4 R 3 4 R 1 R 1 R 1 F mm 100 100 100 100 130 A mm 100 100 100 100 130 ...

Page 7: ...llowing standards EN 298 EN 483 EN 15420 EN 55014 1 2 EN 61000 3 2 3 EN 60 335 1 2 And in accordance with the guidelines of directives 92 42 EEC boiler efficiency directive 2009 142 EEC gas appliance directive 2006 95 EEC low voltage directive 2004 108 EEC EMC directive This product is designated with CE number CE 0063CM3576 Kerkrade 16 11 2010 ing G A A Jacobs Managing Director ...

Page 8: ...rd box in boiler packaging Boiler installation The boiler should be positioned in a frost proof boiler room If the boiler room is on the roof the boiler itself may never be the highest point of the instalation When positioning the boiler please note the recommended minimum clea rance in the picture When the boiler is positioned with less free space mainte nance activities will be more difficult Bo...

Page 9: ... R40 boiler is CE approved and applies to the following European standards 92 42 EEC Boiler efficiency directive 2009 142 EEC Gas appliance directive 2006 95 EEC Low voltage directive 2004 108 EEC EMC directive EN 483 Gas fired central heating boilers Type C boilers of nominal heat input not exceeding 70 kW EN 15420 Gas fired central heating boilers Type C boilers of nominal heat input exceeding 7...

Page 10: ...roved for can be found in the chapter Flue gas system The following water quality levels must be respected at all times for warranty claiming Damage to the boiler due to poor water quality will not be taken under warranty The system should be filled with water with a PH value between 8 0 and 9 5 The chloride value of the water should not exceed 50 mg l Entry of oxygen by diffusion should be preven...

Page 11: ...e boiler room Antifreeze The R40 can be used with the antifreeze type Shell Antifreeze Concentrate The concentration of the antifreeze in the system affects the max capcity the boiler can work on The relation between antifreeze concentration and capacity reduction of the boiler can be found in the graph Noise created by system components e g pumps should be taken care of with external measures in ...

Page 12: ...recommendations when dimensioning a flue gas system Only approved flue gas material may be used The flue gas system must be properly calculated to ensure a safe functioning of the system Flue gas system components should be removable for maintenance purposes Horizontal flue gas ways must be mounted under an angle of 3º minimum A separate condensate drain for the chimney is not necessary as the con...

Page 13: ...1 Calculation base Total connection length in boiler room 1 5 m 2x 87 bend Maximum permissible height h of flue gas system in m Boiler type Ø 80 mm Ø 100 mm Ø 110 mm Ø 125 mm Ø 130 mm R40 65 10 65 R40 85 30 51 R40 100 20 34 42 44 R40 120 32 54 68 70 R40 150 18 31 38 40 VERSION 2 Calculation base Total connection length in boiler room 3 m 4x 87 bend Maximum permissible height h of flue gas system i...

Page 14: ...nstallation and the vertical height of the chimney The table shows the maximum system input related to the vertical chimney length based on max 3m horizontal length after collector and diameter collector chimney Max boiler input kW by vertical chimney length and diameter collector chimney Diameter Chimney height 5m 15m 30m 150 150mm 327 313 288 150 200mm 450 412 370 200 200mm 530 500 482 200 250mm...

Page 15: ...n be placed in the bottom section of the boiler The delivery of the system contains the following components Granulate for first filling Connection hoses for inlet and outlet connection Boiler connection adapter For the neutralisation two different systems are available Standard neutralisation system DN The standard neutrlisation system is used when the public draining connection is at lower level...

Page 16: ...erature difference over the boiler T flow return when the boiler is running on 100 load The nominal T is 20K and must be at least between 15K and 25K for secure boiler operation An indication of the actual flow rate can be found with the follow ing calculation see table below for nominal data p measurement Check the pressure difference over the boiler p flow return when the boiler pump is running ...

Page 17: ...header or plate heat exchanger Single By using a low loss header or plate heat exchanger a minimum flow rate can be ensured at all times indepen dent from the flow rate in the secondary system The boiler pump is available as a standard 3 step or a speed controlled version The speed controlled pump modulates the flow rate in the primary system in parallel with the burner load This ensures the lowes...

Page 18: ...ade solutions which are applicable for cascade installations up to 6 boilers in line and up to 8 boilers in back to back The cascade solutions are defined both with low loss header and plate heat exchanger Details of the cascade solutions can be found in the chapter Accessories Cascade ...

Page 19: ...input Lockout input OK Alarm output signal Boiler enable signal 0 10VDC temperature or capacity setpoint programmable Temperature control central heating via PID controller Temperature control sanitary hot water hot water priority Control by building management system The R40 can be connected to a building management system This can be done by using one of the following connections 0 20 40 60 80 1...

Page 20: ...Installation examples for more details regarding connections of pumps sensors etc Cascade control The R40 can be controlled in a cascade system of maximum 8 boilers This can be done by using the integrated Master Slave cascade functionality in combina tion with an optional BUS communicati on device OCI345 see chapter Accessories for more details The LMS14 includes an intelligent cascade control wh...

Page 21: ...te heat exchanger A description of the different accesso ries can be found on the following pages Safety valve The kit includes a TÜV safety valve available in 3 4 5 or 6 bar drain valve and connection possibility to connect an expansion vessel Shut off valves The kit includes shut off valves for water 2x flow and return connection and gas 1x Gas filter The kit includes a gas filter and connecting...

Page 22: ...be connected inside the boiler Wiring for room fan and or external gas valve The kit includes a wiring package for connecting a room fan and or external gas valve to the boiler The parameter settings of contact QX2 must be chan ged standard setting alarm signal When using this functionality in combi nation with an OK alarm signal an additional AGU2 550 clip in is necessary In this case the OK alar...

Page 23: ... AX150 m3 h 2 6 3 4 4 0 4 8 5 6 kPa 0 6 1 1 0 9 1 3 1 7 dT 15K header type AX125 AX150 AX150 XC50F XC50F m3 h 3 5 4 5 5 3 6 4 7 5 kPa 1 1 1 1 1 6 0 8 1 1 dT 10K header type AX150 XC50F XC50F XC50F XC50F m3 h 5 2 6 8 8 0 9 6 11 2 kPa 1 5 0 9 1 2 1 7 2 4 Secondary circuit See below table for system selection Insulation for the low loss header is available as an option Dimension data can be found on ...

Page 24: ...10mm 130mm replaced by 125mm Flue adapter concentric Concentric flue systems can be used on the R40 65 120 by using a parallel to concentric adapter Air inlet cover The inlet cover can be used to cover the air inlet connection of the boiler in non room sealed condition available in 100mm and 130mm R40 65 R40 85 R40 100 R40 120 R40 150 Primary circuit dT 20K m3 h 2 6 3 4 4 0 4 8 5 6 dT 20K header t...

Page 25: ... R40 65 85 R40 100 150 Accessories Dimensions single low loss header 25 ...

Page 26: ...te heat exchanger A B ø P CB52 40L mm 105 466 G 1 1 4 CB52 50L mm 129 466 G 1 1 4 CB52 40H mm 124 519 G 2 CB52 50H mm 153 519 G 2 R40 65 85 R40 100 150 Accessories Dimensions single plate heat exchanger 26 ...

Page 27: ...ontrol Extension module AGU2 551 The kit contains an AGU2 551 module for 0 10V pump control and or capacity feedback signal from the LMS14 to the building management system The output of the feedback signal is displayed in the graph below Outdoor sensor QAC34 The kit contains an outdoor sensor QAC34 Header hot water sensor QAZ36 The kit contains a header hot water sensor QAZ36 with 6m cable and a ...

Page 28: ...VS13 The kit contains an outdoor sensor QAC34 and a wireless transmitter AVS13 The kit can be used in combination with a wireless receiver AVS71 to enable wireless communication between the outdoor sensor and the boiler Cascade kit MASTER The kit includes an OCI345 communication module and header sensor incl pocket Cascade kit SLAVE The kit includes an OCI345 communication module for the connectio...

Page 29: ...200mm diameter both for line and back 2 back solutions See chapter Dimensioning cascade for more info on diameter selection and chimney dimensioning Please see the price list or online configurator for more info on these full package solutions Accessories Besides the defined cascade packages the following components can be optionally added Gas filter Extension tube for gas filter Insulation kit co...

Page 30: ...rs 2 Total width L mm 1672 ø D 150mm B 400 450 H mm 553 ø D 200mm B 350 400 H mm 616 3 2322 646 709 4 2972 738 801 5 3622 831 894 6 4272 924 987 R40 DN 65 Number of boilers 2 Total width L mm 2115 ø D 150mm B 400 450 H mm 553 ø D 200mm B 350 400 H mm 616 3 2765 646 709 4 3415 738 801 5 4065 831 894 6 4715 924 987 ...

Page 31: ... 31 R40 DN 100 Number of boilers 4 5 6 Total width L mm 3407 4057 4707 ø D 150mm B 400 450 H mm 738 831 924 ø D 200mm B 350 400 H mm 801 894 987 R40 DN 100 Number of boilers 4 5 6 Total width L mm 3853 4503 5153 ø D 150mm B 400 450 H mm 738 831 924 ø D 200mm B 350 400 H mm 801 894 987 ...

Page 32: ...r 32 R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 1672 2322 2972 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 R40 DN 65 Number of boilers 2 3 4 Total width L mm 2115 2765 3415 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 ...

Page 33: ...3 R40 DN 100 Number of boilers 3 4 5 6 7 8 Total width L mm 2107 2757 3407 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 R40 DN 100 Number of boilers 3 4 5 6 7 8 Total width L mm 2553 3203 3853 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 ...

Page 34: ...lers 2 Total width L mm 1940 ø D 150mm B 400 450 H mm 553 ø D 200mm B 350 400 H mm 616 3 2590 646 709 4 3240 738 801 5 3890 831 894 6 4540 924 987 R40 DN 65 Number of boilers 2 Total width L mm 2383 ø D 150mm B 400 450 H mm 553 ø D 200mm B 350 400 H mm 616 3 3033 646 709 4 3683 738 801 5 4333 831 894 6 4983 924 987 ...

Page 35: ...r 35 R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 1940 2590 3240 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 2383 3033 3683 ø D 150mm B 400 450 H mm 553 646 738 ø D 200mm B 350 400 H mm 616 709 801 ...

Page 36: ...oiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of a boiler room installed on the roof t...

Page 37: ...oiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of a boiler room installed on the roof t...

Page 38: ...ned for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of...

Page 39: ...e primary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the tempe...

Page 40: ...The primary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the tem...

Page 41: ...ssories The primary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on...

Page 42: ...is guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of a boiler room i...

Page 43: ...be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In...

Page 44: ...igned for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperat...

Page 45: ...gned for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperatu...

Page 46: ...for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature co...

Page 47: ...imary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negativ...

Page 48: ...primary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negat...

Page 49: ...ter Accessories The primary circuit should be designed for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boi...

Page 50: ...uarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality In...

Page 51: ...igned for T 20K this guarantees a high boiler efficiency When the secondary circuit is designed for a T smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperat...

Page 52: ...troller with wall hung box LOGON B Extension of 2 heating zones Tips The extension controller should always be used in combination with the integrated boiler controller LMS14 With the extension controller 2 additi onal heating zones can be controlled The heating zone control can be extended up to 15 heating zones ...

Page 53: ...Notes 55 ...

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STOKVIS ENERGY SYSTEMS ECONOFLAME R40, Installation Manual

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