STOKVIS ENERGY SYSTEMS R601 Gebrauchsanweisung

Stokvis R600 LMS Boiler

Gas-Fired

Floor Standing

Condensing

Installation, Operation & Maintenance

Manual

STOKVIS ENERGY SYSTEMS

96R Walton Road

East Molesey

Surrey

KT8 0DL

Tel: 020 8783 3050 / 0870 7707747

Fax: 020 8783 3051 / 0870 7707767

E-Mail: [email protected]

Website: www.stokvisboilers.com

420010567300 12/2013

Contents

Contents .................................................................. 3

Safety General regulations................................... 4

Application................................................. 4

Norms and regulations.............................. 4

Construction Layout of boiler.......................................... 5

Operating principle.................................... 5

Technical data .................................................................. 6

Extent of delivery Standard boiler.......................................... 8

Accessories............................................... 8

Installation Boiler transport.......................................... 9

Removing the casing................................. 10

Boiler installation....................................... 11

Connecting the boiler ................................ 12

Wiring diagram - Boiler.............................. 14

Wiring diagram - Accessories.................... 16

Commissioning Water and hydraulic system...................... 18

Gas supply ................................................ 19

Condensate connection............................. 19

Flue and air intake connections................. 19

Prepare boiler for first startup.................... 20

Combustion analysis................................. 20

Check water flow ...................................... 22

Check functionality of safety devices ........ 23

Gas tightness check.................................. 23

Boiler shut down........................................ 23

Commissioning protocol............................ 24

Operating instructions Controls .................................................... 25

Display / Programming.............................. 26

Overview of main functions ....................... 27

Maintenance Checklist.................................................... 28

Replacing the electrodes........................... 28

Cleaning the condensate receptacle......... 29

Cleaning and refilling the syphon .............. 29

Inspection of combustion chamber............ 29

Water pressure and quality ....................... 30

Water flow rate.......................................... 30

Combustion analysis................................. 30

Gas pressure............................................. 30

Gas tightness check.................................. 30

Safety devices........................................... 30

Maintenance protocol................................ 31

Lockouts .................................................................. 32

Sensor values .................................................................. 35

Declaration of Conformity .................................................................. 36

Safety

General regulations

Application

Norms and regulations

General regulations

This documentation contains important

information, which is a base for safe

and reliable installation, commissioning

and operation of the R600 boiler. All

activities described in this document

may only be excecuted by authorized

companies.

Changes to this document may be ef-

fected without prior notice. We accept

no obligation to adapt previously deliv-

ered products to incorporate such

changes.

Only original spare parts may be used

when replacing components on the

boiler, otherwise warranty will be void.

Application

The R600 boiler may be used for heat-

ing and hot water production purposes

only. The boiler should be connected to

closed systems with a maximum tem-

perature of 100ºC (high limit tempera-

ture), maximum setpoint temperature is

90ºC.

Norms and regulations

When installing and operating the boil-

er, all applicable norms (european and

local) should be fulfilled:

Local building regulations for in-

stalling combustion air and flue gas

systems;

Regulation for connecting the boiler to

the electrical appliance;

Regulations for connecting the boiler

to the local gas network;

Norms and regulations according to

safety equipment for heating systems;

Any additional local laws/regulations

with regard to installing and operating

heating systems.

The R600 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 656

Gas-fired central heating boilers –

Type B boilers of nominal heat input

exceeding 70 kW but not exceeding

300 kW

EN 15420

Gas-fired central heating boilers -

Type C boilers of nominal heat input

exceeding 70 kW, but not exceeding

1000 kW

EN 15417

Gas-fired central heating boilers -

Specific requirements for condensing

boilers with a nominal heat input

greater than 70 kW but not exceeding

1000 kW

EN 13836

Gas fired central heating boilers -

Type B boilers of nominal heat input

exceeding 300 kW, but not exceeding

1000 kW

EN 15502-1

Gas-fired central heating boilers -

Part 1: General requirements and

tests

EN 55014-1 (2000)

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 1: Emission

EN 55014-2 (1997)

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 2: Immunity - Product family

standard

EN 61000-3-2 (2000)

Electromagnetic compatibility (EMC) -

Part 3-2: Limits - Limits for harmonic

current emissions (equipment input

current 16 A per phase)

EN 61000-3-3 (2001)

Electromagnetic compatibility (EMC) -

Part 3-3: Limitation of voltage chang-

es, voltage fluctuations and flicker in

public low-voltage supply

systems, for equipment with rated

current 16 A per phase and not sub-

ject to conditional connection

EN 60335-1 (2002)

Household and similar electrical appli-

ances - Safety - Part 1: General re-

quirements

EN 60335-2-102 (2006)

Household an similar electrical

appliances: Particular requirements

for gas, oil and solid-fuel burning ap-

pliances having electrical connections

Construction

Layout of boiler

Operating principle

Layout of boiler

The R600 boiler consists of the follow-

ing main components:

1 Casing

2 Front panel

3 Adjustable feet

4 Control panel (below cover)

5 Flue gas connection

6 Air intake connection

(under casing)

7 Gas connection

8 Flow water connection

9 Return water connection

10 2nd (hot) return water connection

(for split system use), accessory

11 Filling/draining valve

12 Electrical input connections

13 Frame

14 Burner/1st heat exchanger

assembly

15 2nd/3rd heat exchanger assembly

16 Water headers

17 Condensate receptacle

18 Whirlwind gas/air mixing system

19 Fan

20 Gas valve

21 Gas pressure switch

22 Sight glass

23 Ignition and ionisation electrodes

24 Syphon

25 Removable flue gas adapter

Operating principle

The R600 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 mix-

ing system will adapt the gas ratio to

the chosen fan speed, in order to main-

tain the best possible combustion fig-

ures and therewith the best efficiency.

The flue gases created by the combus-

tion are transported downwards

through the boiler and leave at the back

side into the chimney connection.

The LMS14 control unit can control the

boiler operation based on:

Boiler control (stand alone operation);

weather compensated operation

(with optional outdoor sensor);

with 0-10V external influence

(temperature or capacity) from a buil-

ding management system.

The return water from the system en-

ters the boiler in the lower section,

where is the lowest flue gas tempera-

ture in the boiler. In this section con-

densation takes place. The water is

being transported upwards through the

boiler, in order to leave the boiler at the

top (burner) section. The cross flow

working principle (water up, flue gas

down) ensures the most efficient com-

bustion results.

1 5 4 2 7 6

3 8 12 9 10

14 22 23 18, 19, 20, 21 25

13 24 15 16 17 11

Technical data

R601 R602 R603 R604 R605 R606 R607

Nominal heat output at 80/60ºC max/min* kW 142.1/24.0 190.1/40.6 237.2/40.6 285.2/40.6 384.5/79.6 480.6/79.6 545.1/79.6

Nominal heat output at 75/60ºC max/min* kW 142.2/24.0 190.3/40.6 237.4/40.6 285.5/40.6 384.9/79.7 481.1/79.7 545.6/79.7

Nominal heat output at 40/30ºC max/min* kW 150.4/25.5 201.2/43.1 251.0/43.1 301.8/43.1 402.4/83.6 502.9/83.6 570.4/83.6

Nominal heat input Hi max/min* kW 145.0/24.5 194.0/41.5 242.0/41.5 291.0/41.5 388.0/80.5 485.0/80.5 550.0/80.5

Efficiency at 80/60ºC % 98.0 98.0 98.0 98.0 99.1 99.1 99.1

Efficiency at 40/30ºC % 103.7

Annual efficiency (NNG 75/60ºC) % 106.8

Annual efficiency (NNG 40/30ºC) % 110.4

Standstill losses (Twater = 70ºC) % 0.21 0.18 0.17 0.16 0.15 0.14 0.13

Max. condensate flow l/h 11 15 19 22 30 37 42

Gas consumption G20 max/min (10,9 kWh/m3)m3/h 13.3/2.3 17.8/3.8 22.2/3.8 26.7/3.8 35.6/7.4 44.5/7.4 50.5/7.4

Gas consumption G25 max/min (8,34 kWh/m3)m3/h 17.4/2.9 23.2/5.0 29.0/5.0 34.9/5.0 46.5/9.7 58.2/9.7 66.0/9.7

Gas consumption G31 max/min (12,8 kWh/kg) kg/h 11.3/1.9 15.2/3.2 18.9/3.2 22.7/3.2 30.3/6.3 37.9/6.3 43.0/6.3

Gas pressure G20 mbar 20

Gas pressure G25 mbar 25

Gas pressure G31 mbar 30/50

Maximum gas pressure mbar 50

Flue gas temperature at 80/60ºC max/min ºC 78/61

Flue gas temperature at 40/30ºC max/min ºC 56/30

Flue gas quantity max/min* m3/h 238/40 318/69 397/69 477/69 636/134 795/134 901/134

CO2level natural gas G20/G25 max/min % 10.2/9.4

CO2level G31 max/min % 11.9/10.0

NOx level max/min mg/kWh 35/15

CO level max/min mg/kWh 14/8

Max. permissible flue resistance max/min Pa 160/10 160/10 200/10 200/10 200/10 250/10 250/10

Water volume l 27 31 35 61 68 75 82

Water pressure max/min bar 8/1

Max. water temperature (High limit thermostat) ºC 100

Maximum temperature setpoint ºC 90

Nominal water flow at dT=20K m3/h 6.1 8.1 10.2 12.2 16.3 20.4 23.1

Hydraulic resistance at nominal water flow kPa 10 18 28 15 27 42 55

Electrical connection V 230/400

Frequency Hz 50

Mains connection fuse A 16

IP class - IP20

Power consumption boiler max/min (excl. pump) W 158/43 200/35 230/35 260/35 470/61 650/61 770/61

Power consumption speed controlled pump (opt) W 190/9 190/9 310/12 310/12 470/25 590/25 800/38

Power consumption bypass pump (optional) W 190/9 190/9 190/9 190/9 190/9 310/12 310/12

Weight (empty) kg 295 345 400 465 535 590 650

Noise level at 1 meter distance dB(A) 59

Ionisation current minimum µA 6

PH value condensate - 3.2

CE certification code - CE-0063BS3840

Water connections - R2" DN65 PN16

Gas connection - R3/4" R1" R1" R1" R1.1/2" R1.1/2" R1.1/2"

Flue gas connection mm 150 150 200 200 250 250 250

Air intake connection (for room sealed use) mm 130 150 150 150 200 200 200

Condensate connection mm 40 40 40 40 40 40 40

* min load on gasses G20, G25, G31. For type R602-R607 on gasses G25 (LL)-Gas min value is 15% higher.

Technical data

Dimension R601 R602 R603 R604 R605 R606 R607

L mm 1105 1260 1470 1220 1435 1585 1735

L2 mm 127.5 127.5 137.5 137.5 187.5 187.5 187.5

H mm 1480 1480 1500 1500 1500 1500 1500

H2 mm 1120 1130 1130 1150 1245 1245 1245

B mm 670 670 670 770 770 770 770

B2 mm 225 235 235 235 215 215 215

B3 mm 260 260 260 310 310 310 310

B4 mm 260 260 260 490 490 490 490

B5 mm 130 130 130 245 245 245 245

D1 mm (Diam.) 130 150 150 150 200 200 200

D2 mm (Diam.) 150 150 200 200 250 250 250

W1 R" / DN R2" R2" R2" DN65 PN16

W2 R" / DN R2" R2" R2" DN65 PN16

G R R 3/4" R 1" R 1" R 1" R 1 1/2"

1 Electrical connections

2 Gas supply

3 Water supply

4 Water return (Cold)

5 Air Intake (under casing)

6 Water 2nd return (optional)

7 Boiler water drain valve 1/2"

8 Flue gas Outlet

9 Condensate drain

flexible hose 25mm diam.

Extent of delivery

Standard boiler

Accessories

Standard boiler

A boiler delivery package contains the

following components:

The above accessories are specially

designed for the R600 boiler and there-

with easy to install (plug and play). By

choosing a combination of the kits men-

tioned above, you can create your own

complete system solution. Ask your

supplier for more detailed information.

Extension module AVS75 for heating

zone control or external gas valve

and/or room fan control.

For each boiler a maximum of 3

AVS75 modules (2x heating zone, 1x

ext. gas valve / room fan) can be inte-

grated in the boiler;

Additional RVS63 heating zone con-

troller, when controlling more than 2

zones (incl. wall hung box, all neces-

sary sensors and sockets and con-

nection material for bus communica-

tion).

Component Pcs. Package

Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border,

sealed in PE foil

Adjustable feet 4 Mounted on frame of the boiler

Syphon for condensate connection 1 Cardboard box on top of heatexchanger

(under casing)

Conversion kit for natural gas L and propane incl. instruction 1 Cardboard box on top of heatexchanger

(under casing)

Operation and Installation manual 1 Map attached to back panel of the boiler

Spare parts list 1 Map attached to back panel of the boiler

Wiring diagram 1 Map attached to back panel of the boiler

Accessories

Additional to the boiler, the following

accessories can be ordered:

Standard 3-step pump incl. connec-

tion kit;

Speed controlled pump incl. connec-

tion kit;

Safety valve, manometer and de-

aerator (3,4,5 or 6 bar) incl. connec-

tion kit;

2x max. water pressure switch and 1

external high limit thermostat incl.

connection kit;

Gas filter incl. connection kit;

Max. gas pressure switch;

External high limit thermostat incl.

connection kit;

Gas valve leakage tester (not possi-

ble for R601);

2nd Return connection for

Split System use;

Controlled bypass (incl. pump) incl.

connection kit;

Plate heat exchanger (dT=10K/15K or

dT=20K) incl. connection kit;

Low velocity header, suitable for

dT=10K/15K and dT=20K incl. con-

nection kit;

Duo header for connecting 2 boilers

in cascade (excl. connection kit);

Installation

Boiler transport

The R600 boiler will be supplied as a

complete unit being fully assembled

and pre-tested. The maximum width is

670mm for models R601-R603 and

770mm for models R604-R607, which

makes it possible to transport all mo-

dels through a normal door in one pie-

ce. The boiler can be transported with a

pallet truck, entering either from the

front or from the side.

Whenever necessary, the boiler can be

dismantled into smaller parts for easier

transport inside the building. The table

below shows the main dismantled parts

with their weight and dimensions.

When the boiler has to be transported

with a crane, it is necessary to remove

the casing before connecting the boiler

to the crane. Always connect the crane

to the frame of the boiler by using

straps.

Component R601 R602 R603 R604 R605 R606 R607

Burner/1st heat exchanger assembly Weight [kg]

Length [mm]

Width [mm]

Height [mm]

735

400

321

100

885

400

321

112

1035

400

321

135

735

680

321

158

885

680

321

181

1035

680

321

198

1185

680

321

2nd/3rd heat exchanger assembly Weight [kg]

Length [mm]

Width [mm]

Height [mm]

735

400

244

103

885

400

244

116

1035

400

244

150

735

680

244

170

885

680

244

198

1035

680

244

219

1185

680

244

Condensate receptacle

Weight [kg]

Length [mm]

Width [mm]

Height [mm]

589

385

225

739

385

225

889

385

225

589

665

225

739

665

225

889

665

225

1039

665

225

Frame

Weight [kg]

Length [mm]

Width [mm]

Height [mm]

990

624

335

1140

624

335

1350

624

335

1100

724

335

1320

724

335

1470

724

335

1620

724

335

Front U-frame with electronic board Weight [kg]

Length [mm]

Width [mm]

Height [mm]

628

1304

202

628

1304

202

628

1304

202

728

1304

202

728

1304

202

728

1304

202

728

1304

202

1 Hoisting belt (4x)

2 Wooden retaining beam (2x)

3 Hoisting belt position (4x)

Installation

Removing the casing

Boiler transport

Remove the casing before transporting

the boiler, in order to avoid damage to

the casing parts during transportation.

Removing the casing is done as fol-

lows:

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