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STOKVIS ENERGY SYSTEMS R40 Installation Operation & Maintenance

Gas-fired wall hung condensing
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Download this manual See also: Operation & Installation Manual, Installation Manual
Stokvis R40 Boiler
Gas-Fired
Wall Hung
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:
info@stokvisboilers.com
Website:
www.stokvisboilers.com
420010685900 09/2015 ErP

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  • Page 1 Stokvis R40 Boiler Gas-Fired Wall Hung 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: info@stokvisboilers.com Website: www.stokvisboilers.com...

  • Page 2: Table Of Contents

    Contents General regulations ....................6 Application ....................... 6 Norms and regulations ..................6 Informations for installer and maintenance service ......... 7 Data plate ......................... 8 Construction ......................9 Layout of boiler ...................... 9 Operating principle ....................9 Technical data ......................10 Product information ErP ..................11 Extent of delivery ....................14 Standard boiler .......................
  • Page 3 Contents Commissioning .......................31 Water and hydraulic system ................31 Neutralisation systems ..................32 Gas supply ........................ 33 Condensate connection ..................33 Flue and air intake connections ............... 33 First startup procedure ..................34 Combustion check ....................35 Combustion settings .................... 35 Check water flow ....................

  • Page 4: General Regulations

    General regulations Application Norms and regulations This documentation contains This boiler is CE approved and EN 50165 Electrical equipment applies to the following European portant information, which is a base of non-electric appliances for for safe and reliable installation, standards: household and similar purposes commissioning and operation of the 1992 / 42 / EEC...

  • Page 5: Informations For Installer And Maintenance Service

    General regulations Informations for installer and maintenance service Information for the User The use of the appliance for purposes forbidden. The manufacturer cannot be held responsible for any damage to the user the instruction manuals, caused by improper, incorrect and informing him that they must be sto- unreasonable use of the appliance or red with the appliance.

  • Page 6: Data Plate

    General regulations Data plate Symbols used on the data plate Legend : Brand 26-05-2015 0000000KE000000000000 Country of origin Boiler model - Serial number Commercial reference Destination country - Gas category Q(Hi) Gas setting 60/80C 30/50C η η Electrical data 100% min.

  • Page 7: Construction

    Construction Layout of boiler Operating principle Layout of boiler The boiler consists of the following Casing Access door for Control panel Flue gas connection (+ test point) Air intake connection (+ test point) Flow water connection Return water connection Gas connection Condensate syphon Connection for safety valve Manometer...

  • Page 8: Technical Data

    Technical data Nominal heat output at 80/60ºC max/min 45.7/7.6 60.8/10.1 81.1/13.4 92.9/15.6 111.6/18.7 132.2/23.3 56.4/10.1 Nominal heat output at 75/60ºC max/min 45.8/7.6 60.9/10.1 81.3/13.4 93.1/15.6 111.8/18.7 132.5/23.3 56.5/10.1 Nominal heat output at 40/30ºC max/min 48.0/8.4 63.9/11.1 85.3/14.8 100.0/17.2 120.0/20.6 142.3/25.6 59.3/11.1 Nominal heat input Hi max/min 46.9/7.8...

  • Page 9: Product Information Erp

    Product information ErP Product information about the directive 2009/125/EG and regulation (EU) 813/2013 Icon Unit 45/50 Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater ErP Heating Rated heat boiler rated At rated heat output and high-tempera- 45.7 60.8 81.1 92.9...
  • Page 10 The installation, consisting of the boiler and all accessories including temperature control, together define the seasonal heating energy efficiency s for the various models, as listed in the below table. Class VI, with use of components: - R40 - Ambient temperature sensor QAA 75 92 + 4...
  • Page 11 Technical data FRONT VIEW SIDE VIEW BACK VIEW BOTTOM VIEW R40-85 R40-100 R40-120 R40-150 Dimensions R40/50 R40/85 R40/100 R40/120 R40/145 Dimensions 45/50/65 R40/65 R1 1/4” R1 1/4” R1 1/2” R1 1/2” R1 1/2” R1 1/4” R1 1/4” R1 1/2” R1 1/2”...

  • Page 12: Extent Of Delivery

    Extent of delivery Standard boiler Accessories Standard boiler Component Pcs. Package Boiler fully assembled and tested Cardboard box on pallet Mounting bracket inc. mounting material Together with manuals, in folding box inside boiler packaging Syphon for condensate connection Operation and installation manual Map packed in cardboard box in boiler packaging Accessories Extension module AGU2.550 for...

  • Page 13: Installation

    Installation Boiler transport Boiler transport boiler will be supplied as a complete unit being fully assembled and pre-tested. The packaging dimen- sion is 1050x572x575mm for boiler for boiler types 100-150, which makes it possible to transport all models through a nor- mal door in one piece.

  • Page 14: Warnings Before Installation

    Installation Warnings before installation requirements of the local authorities and public health agencies. Before installing the appliance with current legal requirements); Observe the clearance between Where there is already a con- the wall on which the boiler is installed and the hot parts on the check that these exhausts have necessary to perform the following outside of the boiler.

  • Page 15: Boiler Installation

    Installation Boiler installation Connecting the boiler Boiler installation The boiler should be positioned in a room is on the roof, the boiler itself may never be the highest point of the installation. When positioning the boiler, please note the recommended minimum clearance in the picture.

  • Page 16: Air/Flue Gas System

    Installation Air/Flue gas system Requirements and regulations Materials be mounted under an angle of 3º mi- nimum. Exclusively materials, which are heat Regulations for the construction of gas systems B23(P), C13, C33, C43, and aggressive condensate, and CE approved may be used. red that all national regulations with tab.

  • Page 17: Air / Flue Pipe Data

    Installation Air/Flue gas system Flue Gas data Flue Boiler Nominal heat Nominal heat Flue gas Flue gas permissible type output input connection Level temperature quantity (DN) resistance °C max min 45/50 45.7 46.9 10.1 62.4 10.4 13.4 92.9 15.6 95.2 16.0 111.6 114.3...
  • Page 18 Installation Air/Flue gas system Combustion air drawn from the room Air/exhaust gas routing through outside wall in the same pressure range. Exhaust gas/fresh air supply system through outside wall. The Terminal outlets from separate combustion and air supply put to 70 kW and 100 cm with a heat input from 70 up to 100 kW. Flue gas exhaust and air suction duct from outside with roof ter- minal in the same range of pressure.

  • Page 19: Air/Flue Gas System Dimensioning

    Ø80 Ø100 Ø120 Ø125 Ø130 Lmax Lmax Lmax Lmax Lmax system, it’s necessary to perform system in order to verify if the R40 45/50 choosen system applicable. R40 65 following table shows R40 85 R40 100 system, including maximum...

  • Page 20: Accessories

    Installation Air/Flue gas system Accessories Flue adapter concentric Types of boiler Flue exhaust connection on the R40 45-120, by using a paral- lel to concentric adapter. coaxial connection of the boiler ±0.3 ±0.3 DN 100/150 = Ø / 151 to the suction/exhaust ducting split connection of the boiler to ±0.3...

  • Page 21: Installation Instructions - Coaxial

    Installation Air/Flue gas system Installation Instructions - coaxial - Installation Cutting the pipe Take out the inner tube by turning Starting to assemble the pipes from ce must be carried out by a compe- it until it releases from its position the boiler.

  • Page 22: Installation Instructions - Twin Pipe

    Installation Air/Flue gas system Installation Instructions - twin pipe - Installation Cutting the pipe Take out the inner tube by turning Starting to assemble the pipes from ce must be carried out by a compe- it until it releases from its security the boiler.

  • Page 23: Installation Of Vertical Flue Terminals

    Installation Air/Flue gas system Warnings Installation is not damaged. owner to clean the opening regularly. Ensure while installation work is being carried out that no debris such Synthetic tile tar are allowed to remain in the air/ determine the type of weather terminal will positioned.

  • Page 24: Installation Of Horizontal Flue Terminals

    Installation Air/Flue gas system Before installing the terminal Part list: Wall plate or rosette Concentric bend ble damage. Locking bend (optional) Determine the proposed location Flue pipe Air inlet pipe Drill a hole through the wall of a Twin pipe connection. max.

  • Page 25: Electrical Connection

    Installation Electrical connection Electrical connection Connect all wires to the terminals The electrical connection must be according to the wiring diagram of the made by an authorized installer in boiler, see Wiring Diagram accordance with applicable It is mandatory connecting the boi- national and local standards and regulations.

  • Page 26: Wiring Diagram - Boiler

    Op. 01 Op. 02 Op. 03 Op. 04 F. 01 F. 02 Dp. 01 Op.05...

  • Page 27: Wiring Diagram - Boiler (Legend)

    Installation Wiring diagram - Boiler (Legend) Connection terminals XX and XX.1 Components X2.1 Gas Valve Op. 01 Load feedback (optional) L-N-PE Power supply boiler X2.3 Ignition transformer Op. 02 Alarm (optional) +10% -15% 50Hz Fuse 10A X2.3.1 Ionization electrode Op. 03 Zone 2 (optional) 1-2 Power supply EM Clipln...

  • Page 28: Wiring Diagram - Accessories

    Installation Wiring diagram - Accessories...

  • Page 29: Commissioning

    Commissioning Water and hydraulic system This chapter explains the commis- Commissioning of the boiler hould sioning of the boiler with the stan- be carried out by authorized person- dard boiler controller. When an nel only. Failure to respect this condi- additional system controller is in- tion makes the guarantee void.

  • Page 30: Neutralisation Systems

    Neutralisation Neutralisation systems Neutralisation systems General The neutralisation systems can be Condensate, created boiler should be drained into the placed in the bottom section of the boiler. public draining system. The con- The delivery of the system contains densate pH is between 3.0 and 3.5.

  • Page 31: Gas Supply

    Commissioning Gas supply Condensate connection Flue and air intake connections Gas supply Check the gas supply connection leakage is found, reseal the le- Remove any air between the gas valve and the gas line. This can be done at the test point (1) at the gas pressure switch.

  • Page 32: First Startup Procedure

    Commissioning First startup procedure Legend: A On/off switch B Return (ESC) C Room temperature control E Manual mode F Chimney sweeper mode H Reset button L Display M Operation mode DHW Initial procedures To guarantee safety and the correct operation of the appliance, the boiler Open the gas supply;...

  • Page 33: Combustion Check

    Start boiler controller for natural gas G20 / G25 stop mode and go to 50% load. R40 45-155 Now the boiler operates at 50% ± 0.2 load. Allow the boiler to stabili- ze the combustion for 3 minutes. Then increase the boiler load step by step up to 100%.

  • Page 34: Check Water Flow

    Commissioning be checked with two different me- thods shown below. Check the temperature difference the boiler is running on 100% load. at least between 10K and 20K for se- cure boiler operation. An indication of the following calculation (see table ) * q actual nominal...

  • Page 35: Check Safety Devices

    Commissioning Check safety devices Boiler shut down Check functionality of Gas tightness check safety devices Check the gas tightness of all sealed All safety devices have to be checked connections with an approved soap on good functioning. Safety devices or electronic gas analyzer, for temperature sensor, water return Test points;...

  • Page 36: Commissioning Protocol

    Commissioning Commissioning Protocol Commissioning Protocol Project Boiler type Project Serial number Adress Year City Nominal load (Hi) [kW] Date Nominal output (Hi) [kW] Engineer System Water pressure [bar] Installation: Roof top Water pH Ground floor Water hardness [°dH] Basement Water chloride [mg/l] Other:.......

  • Page 37: Controls

    Operating instructions Controls Legend: On/off switch Return (ESC) Room temperature control Manual mode Chimney sweeper mode Reset button Operation mode heating zone(s) Display Operation mode DHW Operation mode DHW (M) Deaeration mode (E) For switching on the DHW operation Return (ESC) (B) By pressing the manual mode button (indication in display below DHW These buttons are used for program-...

  • Page 38: Display Programming

    Operating instructions Display Programming DHW mode selection Heating operation mode selection (Controller Stop mode when pressing > 3 sec.) Display Info button Con rm Quit menu Manual mode (Deaeration mode when pressing Reset > 3 sec.) Chimney sweeper mode Select (turn left/right) Heating to comfort setpoint Info level activated Heating to reduced setpoint programming...

  • Page 39: Overview Of Main Functions

    Operating instructions = cancel, return to main menu Overview of main functions Button Action Procedure Display / Function Zone 1 and zone 2 Actuate wheel left/right Comfort setpoint with blinking temperature Set room temperature Turn wheel Blinking temperature in 0,5 °C steps from 10 to 30 °C Con rm with OK button or wait 5 sec.

  • Page 40: Maintenance

    Maintenance Checklist Maintenance of the boiler should be Replace the ignition and ionisa- Check the gas pressure to the carried out by authorized personnel tion electrodes; boiler; only. Clean the condensate receptacle; Check the tightness of all sealed connections and test points; Check the functionality of all sa- safe operation of the boiler, it should clean if necessary (DON’T use...

  • Page 41: Cleaning

    Maintenance Cleaning Cleaning the condens tray gas temperature sensor (1); Remove the condense tray (2); Clean the tray; Mount the condense tray; temperature sensor. Remove the syphon (3) from the condensate connection; Mount the syphon back in the ori- ginal position. Inspection of combustion chamber For inspection of the combustion...

  • Page 42: Physical And Chemical Check

    Maintenance Physical and chemical check Check physical and chemical water necessary. An additional reference check at 50% load is recommended. After some weeks of operation, check Consult the chapter commissioning: the main phisicals and chemicals combustion analysis for more detai- led information.

  • Page 43: Maintenance Protocol

    Maintenance Maintenance Protocol Maintenance Protocol R40 Project Boiler type Project Serial number Address Year City Nominal load (Hi) [kW] Date Nominal output (Hi) [kW] Engineer System Water pressure [bar] Water pH Water hardness [ºdH] Water chloride [mg/l] [ºC] [kPa] boiler...

  • Page 44: Lockouts

    Lockouts In case of a lockout, a warning symbol ( ) and a flashing error code appears on the display. The cause of a fault should first be determined and eliminated before the boiler is being reset. The table below shows all possible lockouts with indication of indication of possible cause "ERROR CODE"...
  • Page 45 Lockouts Repetition error counter exceeded Safety time for establishment of flame Safety time for establishment of flame exceeded exceeded BMU fault internal False polarity of the 230V power supply Parameterization error Reprogram PCB Unit manually locked Reset button pressed too long Fan speed threshold not reached Fan speed threshold not reached APS does not close...

  • Page 46: Sensor Values

    Sensor Values The diagrams show the sensor va- lues for all boiler sensors and optio- NTC 10k temperature sensor (flow, return, flue gas, DHW and header sensor) nal sensors available in accessory kits.The diagrams contain average values, as all sensors are liable to tolerances.

  • Page 47: Declaration Of Conformity

    Declaration of Conformity Declaration of Conformity Rendamax BV, Hamstraat 76, 6465 AG Kerkrade (NL), Declares that the product Is in conformity with the following standards: EN 298 EN 483 EN 15502-1 EN 15420 EN 55014-1 /-2 EN 55014-1 / -2 EN 61000-3-2 /-3 EN 61000-3-2 /-3 EN 60 335-1 /-2...

  • Page 48: Note

    Note...
  • Page 49 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: info@stokvisboilers.com Website: www.stokvisboilers.com 420010685900 09/2-15 ErP...

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