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STOKVIS ENERGY SYSTEMS ECONOFLAME R2200 Installation, Operation & Maintenance Documentation

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ECONOFLAME R2200
GAS FIRED BOILERS
INSTALLATION, OPERATION & MAINTENANCE
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
22CV22D - 160703

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Summary of Contents for STOKVIS ENERGY SYSTEMS ECONOFLAME R2200

  • Page 1 ECONOFLAME R2200 GAS FIRED BOILERS INSTALLATION, OPERATION & MAINTENANCE 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...
  • Page 2 Edition D, 12-12-2000 © 2000 STOKVIS All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission in writing of STOKVIS. We aim to achieve continuous improvement in our products.
  • Page 3 R2200 TECHNICAL DATA Type 2207 2210 2213 2216 2220 2224 2228 Heat output 81,3 116,4 151,5 186,7 233,9 280,9 328,5 Heat input 88,2 126,0 163,8 201,6 252,0 302,4 352,8 Maximum gas rate m /h 13,3 17,3 21,3 26,7 32,0 37,3 Gas pressure (inlet) natural gas minimum mbar...
  • Page 4 Fig. 1 Dimensions 22CV22D...
  • Page 5 Dimensions Type 2207 2210 2213 2216 2220 2224 2228 1" 1¼” 1¼” 1¼” 1¼” 1½” 1½” 1440 1440 1440 1440 1440 1440 1440 1016 1226 1436 1646 1926 2206 2486 DN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN65 PN6 DN65 PN6 Table 2 Dimensions in mm...

  • Page 6: Table Of Contents

    INDEX INTRODUCTION ......1 General ........1 Supplier .

  • Page 7: Introduction

    Continual research and development means that Stokvis remains at the forefront of boiler and water heater technology. 101001AE Supplier StokvisEconoflame boilers are sold throughout the United Kingdom by: Stokvis Energy Systems 96R Walton Road East Molesey Surrey KT8 0DL Telephone: 08707707747 08707707767...

  • Page 8: Service

    The following aspects will be explained: - general description - technical specifications - necessary services for system design and unit installation - example systems - maintenance instructions. Operating instructions for the user can be found on the unit. See also chapter 7. Service For commissioning and assistance in maintenance matters, please contact your supplier’s service department.

  • Page 9: Description

    DESCRIPTION General information The R2200 is a gas-fired boiler with an atmospheric burner with HIGH/LOW/OFF regulation. The R2200 is fitted with a 2-stage thermostat control working at 100% or approx. 50% boiler capacity. The R2200 series of boilers are available in 8 types: R2207, R2210, R2213, R2216, R2220, R2224 and R2228.

  • Page 10: Main Components

    Main components Fig. 2 R2200 Draught diverter The R2200 is fitted with a draught diverter with a flue gas extractor fan. It is possible to connect the flue outlet connection on the top cover with a standard flue pipe. The inside of the draught diverter is made of aluminium. The galvanized panel work is easily removed without the use of any special tools by means of a click system.
  • Page 11 Combustion chamber The chassis consists of two side frames with steel supports. Dura blanket type thermal insulation is sandwiched between the vermiculite refractory blocks and front, rear and side panels of the combustion chamber housing. These vermiculite refractory blocks are mounted so as to allow freedom of expansion. The refractory blocks backed with Dura blanket insulation form the combustion chamber.
  • Page 12 Burner The burner is mounted under the combustion chamber in the chassis. The burner bars, mounted in the burner tray are manu- factured from stainless steel. Each burner bar is supplied by its own injector nozzle mounted on the gas manifold. A bottom plate is mounted under the burner bars.

  • Page 13: Principle Of Regulation

    2.3 Principle of regulation The flow temperature can be constant or influenced by weather compensation. Several boilers can be connected by using cascade switching. In order to reduce electricity consumption both boiler and boiler pump can be switched off by the cascade switch box.

  • Page 14: Boiler Protection

    Boiler protection The R2200 is protected by the following systems: minimum water flow switch The water flow switch is installed in the flow and monitors continuously the minimum water flow. If the flow falls below a preset level, the burner is shut down. The water flow switch is factory set and should not be adjusted.

  • Page 15: Safety

    SAFETY Installation requirements Please read these requirements before commencing installa- tion. The product should be installed according to relevant codes of practice as mentioned in the “Supplement”. The installation procedure should only be used for heating systems with a maximum water temperature of 100 °C. 22CV22/300001BE We emphasize that you should always give priority to the above mentioned standards and regulations and that the installation...
  • Page 16 MAINTENANCE Work on the electrical installation should only be carried out by approved technicians and in accordance with the electro techni- cal regulations. Work on the gas and hydraulic systems should only be carried out by approved technicians and in accordance with the safety regulations for gas and hydraulic installations.
  • Page 17 Installation The product should be installed according to relevant codes of practice as mentioned in the “Supplement”. Make sure that you follow all safety instructions properly. 22IP22/300008DE Operation In case of gas leakage, switch off the boiler and close the gas service cock.

  • Page 18: Delivery And Transport

    DELIVERY AND TRANSPORT Delivery Before delivery, the R2200 boiler is fully assembled and tested in the factory. The R2200 is mounted on a pallet and covered in a "heat-shrink" protective wrapper. Check for damage after removing the boiler’s protective cover- ing.
  • Page 19 Pallet cart and/or forklift truck When moving the boiler with a pallet cart or forklift truck, the forks should be placed at a side of the boiler. Fig. 8 Moving Using a crane - Never swing the load over bystanders. - Always use special lifting harnesses which should be placed on the boiler - Make sure that during lifting the harness does not damage...

  • Page 20: Installation

    INSTALLATION Boiler room The R2200 should be installed according to relevant codes of practice as mentioned in the “Supplement”. 22IP22/510001CE 5.1.1 Siting Install the boiler as close to the chimney as possible. A flue base is not required. To maintain ease of access and therefore ease of mainte- nance, the following minimum dimensions are recommended between the R2200 and the boiler room walls: Front with control panel...

  • Page 21: Unit Connections

    Unit connections 5.2.1 Gas supply The product should be installed according to relevant codes of practice as mentioned in the “Supplement”. 22IP22/501001AE Gas connection can be found at the rear of the boiler. Always mount a gas filter. The main gas service cock and gas filter should be supplied by a qualified heating engineer.

  • Page 22: Hydraulic Connections

    External control It is possible to externally control the unit. The following termi- nals on the terminal block have the following functions: 1st stage on-off 2nd stage high-low lock out, minimum gas pressure switch blocking, low water level protection outgoing alarm signal (230 V) blocking, high gas pressure switch outgoing cascade signal (230 V) * remove jumper.

  • Page 23: Flues

    5.2.4 Flues Flue gas volumes/dimensions You can use the following flue dimensions to assist in flueing: Type Q flue m /h Chimney Pressure loss diameter mm Pa/m 2207 2210 2213 2216 2220 2224 1145 2228 1336 Table 3 Flue gas amounts Heat input: 100 % Flow temperature:...

  • Page 24: Water Quality

    In areas with extreme hard water, precautions should be taken to control water hardness, ie. a water softener. Contact the service department of Stokvis Energy Systems for more infor- mation about the required water quality necessary for the R2200 series.

  • Page 25: Hydraulic System

    Hydraulic system System pressure By system pressure is meant, the water pressure measured at the heat exchanger in cold condition. With a correctly sized expansion system the system pressure will not change very much under variable temperature conditions. 22CV22/540001GE 5.4.1 Flow and resistance The next figure shows an example of a hydraulic system.
  • Page 26 Minimum and maximum water volume per hour A too low flow rate through the fin tubes can lead to cavitation. Also, a too high flow rate can cause erosion. To protect the heat exchanger from these two extremes, the flow rate (Q) should be set using the table below.
  • Page 27 Positioning the pump and expansion vessel We advise that the pump should be mounted in the return pipe in the following order: expansion vessel, pump, boiler. If you mount the pump in the supply pipe, the lifespan of the pump will be reduced. Always connect the expansion vessel to the suction side of the boiler pump.
  • Page 28 The primary circuit must have a low water volume. This enables faster heating and reduces the condensing time of the boiler after for example night time temperature reduction. The recommended maximum volume of the primary circuit per 100 kW installed boiler capacity is 200 litres. When the installation is switched off, the boilers must be switched off first.
  • Page 29 Fig. 16 R2200 units with constant flow temperature and cascade switching. R2800 HR R2200 VR Fig. 17 Condensing / non condensing unit cascade switching and a zero- loss header. These hydraulic systems are examples only and should not be used without specialist advice. 22CV22/542001AE 22CV22D...

  • Page 30: Commissioning

    COMMISSIONING COMMISSIONING OF THE BOILER MUST BE CARRIED OUT BY PROPERLY QUALIFIED AND AUTHORISED PERSON- NEL. OTHERWISE, THE GUARANTY WILL BECOME VOID. Never deviate from the instructions in this manual. Flushing the system To prevent damage from rust, sand, metal particles etc., the system must be flushed thoroughly, before the system is switched on.
  • Page 31 Fig. 18 Main gas valve adjustment The capacity of the R2200 is adjusted using the burner pres- sure method. The burner pressure can be read off a manome- ter connected to the pressure test point C on the outlet side of the main gas valve.

  • Page 32: Control Panel

    Boiler failure In case of boiler failure the boiler will lock out. Reset the boiler with the reset button on the control panel. Repeat this several times if necessary. If the boiler still does not start, refer to chapter ‘Boiler failure’. Measuring boiler ionisation In order to check ionisation a micro-ampere meter with a scale range from 0 to 50 µA DC should be used.

  • Page 33: Operation And Fault Indication

    OPERATION AND FAULT INDICATION Control panel On/Off switch 7 segment program step display Lock out reset button Pump selector switch (manual/automatic)* Central Alarm indicator Reset for 4-7-8-9-10-11* Minimum gas pressure fault* Maximum gas pressure fault* Water flow fault* Gas valve fault* Spare High limit thermostat reset Control thermostat (fig.

  • Page 34: Operation

    Display codes Boiler start-up codes: 0 Boiler in stand-by mode, ready for heat demand. 1 Pressure difference switch not open. Boiler remains in stand- by mode. 2 Boiler pre-purge, awaits closing of pressure difference switch. 3 Boiler pre-purge in progress, pressure difference switch closed.
  • Page 35 Fuses Electrical supply 230 VAC. Protects the controller and its peripherals (gas valve and fan). Display is off during interruption. Internal fuse. If this is blown, the controller must be replaced. Display is off during interruption. Internal fuse. If this is blown, the controller must be replaced. Flashing display numbers 4, 5 or 6.

  • Page 36: Boiler Failure

    In case of boiler failure, the cause of the problem should first be ascertained before resetting the boiler. If the source of the problem cannot be found then contact Stokvis Energy Systems. NEVER TRY TO REPAIR THE BOILER YOURSELF. Flame control An ionisation fault will cause the boiler to lock out.
  • Page 37 This is indicated by the 7-segment program display with a flashing 0. The fan will continue to run for several minutes. Resetting the maximum thermostat is done as follows: - Remove the internal hex-head cover on the control panel with a 17 mm spanner. - Push the green pin until you hear and feel a light click.
  • Page 38 Ignition attempts If the first attempt of igniting the burner is unsuccessful, a second attempt will follow. The ignition procedure: - The gas valve closes. - The ignition switches off. - The fan continues to run. - Pre-purge is followed by the second attempt. If this second attempt also fails, the controller will fall into lock out.
  • Page 39 Fault indication table (Indicated by the program display with a flashing number) Fault Possible cause Solution No fault indicated, yet No electrical voltage. Switch on electrical boiler does not start. voltage. Fuse in the burner Replace fuse. controller has blown. Burner controller is Replace burner defective.
  • Page 40 (Indicated by the program display with a flashing number) Fault Possible cause Solution Heat demand, boiler Pressure difference Set pressure differ- does not start. switch opened while ence switch. boiler running. Flue resistance too Set pressure differ- high. ence switch. See par.
  • Page 41 (Indicated by the program display with a flashing number) Fault Possible cause Solution Insufficient water flow. No water flow Switch on pump. through boiler. Reset using reset but- ton 3. Insufficient water flow. Check the water stop valves are open. Re- set using reset button Pump runs in wrong Change the electrical...

  • Page 42: Safety

    MAINTENANCE Safety Always wear the proper protective clothing and shoes when servicing the boiler. Wearing jewellery and loose clothing can contribute to unsafe situations. 22IP22/710001BE General information In order to keep the R2200 in a safe working condition, the boiler should be inspected at least once every year and cleaned if necessary.
  • Page 43 22IP22/830001AE Cleaning Before using chemicals and cleaning agents in the boiler, please contact Stokvis Energy Systems for advise. Always read the instructions on the bottle of the cleaning agents before using them. 22CV22D...

  • Page 44: Replacing

    Heat exchanger (external cleaning) Remove the baffles before cleaning the heat exchanger. - Use compressed air when the heat exchanger is lightly soiled. - Use a stiff brush and soap when the heat exchanger is very dirty. Protect refractory blocks against moisture. The heat exchanger may become heavily soiled (soot for example), when the instructions are not followed properly.

  • Page 45: Service

    22IP22/750001AE Service For service and maintenance the service department of Stokvis Energy Systems can be contacted. Stokvis Energy Systems 96R Walton Road East Molesey, Surrey KT8 0DL Telephone: 08707 707 747...

  • Page 46: Supplement

    SUPPLEMENT At the time of printing the following regulations and standards were taken into account: British Standard 1. BS 5440 - parts 1 + 2 (fluing and ventilation). 2. BS 6644 - Installation of gas fired water heaters (60 kW - 2 MW). 3.
  • Page 47 22CV22D...

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