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STOKVIS ENERGY SYSTEMS ECONOPAK R2000 Installation, Operation & Maintenance Documentation

Atmospheric gas fired hot water boilers
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ECONOPAK R2000
ATMOSPHERIC GAS FIRED
HOT WATER 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
20IP18B 220802

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Summary of Contents for STOKVIS ENERGY SYSTEMS ECONOPAK R2000

  • Page 1 ECONOPAK R2000 ATMOSPHERIC GAS FIRED HOT WATER 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...
  • Page 2 Edition B, 09-01-2002 © 2002 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 R2000 WATER HEATER TECHNICAL DATA Type R2017 R2022 R2028 R2034 R2041 R2048 R2056 R2066 R2077 R2090 R2105 R2122 Nominal heat output 57,7 74,6 95,8 116,7 139,1 162,7 190,7 222,1 261,1 309,0 361,0 425,0 Nominal heat input (nett. CV) 65,5 84,8 107,7 131,6 158,6 185,5 217,4 253,3 296,2 348,0 403,9 470,7 Gas consumption natural gas H ( m /h...
  • Page 4 Dimensions The R2000 unit is also available as a left-handed model. Top and side clearances are 600 mm MINIMUM. Fig. 1 Dimensions 20IP18B...
  • Page 5 R2000 ECONOPAK PLUS with BT 300 litre tank Fig. 2 Dimensions 300 litre tank R2000 ECONOPAK PLUS with BT 500 litre tank Fig. 3 Dimensions 500 litre tank 20IP18B...
  • Page 6 20IP18B...

  • Page 7: Table Of Contents

    INDEX R2000 Water Heater Technical data ... . . III Dimensions ....... IV Index .
  • Page 8 General ........31 Pre-lighting checks and dry run ....34 6.2.1 Check 1 .

  • Page 9: Introduction

    INTRODUCTION General Through their unique construction, these water heaters are renowned for their: - high thermal efficiency - environmental friendliness - light weight and small dimensions - durability - low noise production - large regulating range - available with many different options. Continual research and development means that Stokvis remains at the forefront of boiler and water heater technology.

  • Page 10: Service

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

  • Page 11: Description

    DESCRIPTION General information The R2000 series water heaters are atmospheric open flued, low thermal capacity gas-fired water heaters. These high efficiency water heaters are designed to provide hot water to various industrial and commercial applications where there can be varying demands and fluctuating loads. Several models are available with heat inputs from 65,5 kW to 470,7 kW and recovery rates from 1219 litres per hour to 8577 litres per hour, based upon a temperature rise of 44 K or 976...

  • Page 12: Main Components

    Main components Fig. 4 View of the R2000 series 1. Flue outlet socket 13. Burner bars 2. Draught diverter 14. Quick clamp (securing burner trolley 3. Air supply opening at both sides) 4. Connection box 15. Main gas valve 5. Servomotor (air damper/gas input) 16.
  • Page 13 Draught diverter The R2000 is fitted with a draught diverter. 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 plate mantle is easily removed without the use of any special tools by means of a click system.
  • Page 14 Heat exchanger The heat exchanger (type 2-pass) is mounted on the chassis. To ensure proper heat transfer of the combustion gases, the copper fin tubes are arranged side by side and expanded laterally into a mounting plate. The baffles on the copper fin tubes optimize the efficiency of the heat exchanger.
  • Page 15 Burner The burner is mounted under the combustion chamber in the chassis. The burner bars, mounted in the burner trolley are manufactured from stainless steel. Each burner bar is supplied by its own injector nozzle mounted on the gas manifold. Fig.

  • Page 16: Principle Of Regulation

    2.3 Principle of regulation Electronic Modulating version This type of boiler control regulation (indicated by the EM control option) uses a built-in PID regulator to maintain a con- stant flow temperature to within a minimum temperature devia- tion of +1 to -1 K. This system allows the user to fine-tune the reaction of the boiler to the heating system or application process.
  • Page 17 2.3.1 EM Control option Electronic Modulating version with outside temperature compensation and night-time temperature reduction This system (indicated by the EW control option) uses the above mentioned PID regulator to regulate the boiler. The “EW” control system maintains the advantages of the “EM” type boiler and adds to it the possibility of automatically changing the flow temperature according to the outside temperature and the required heating curve.
  • Page 18 Fig. 10 Heating curve slope * * * * HYS1+ + + + is the switch-on point for the burner, and * * * * HYS3+ + + + is the switch-off point. As already described, they act with the set shift relative to the weather-controlled Process data Parameter...

  • Page 19: Water Heater Protection

    Configuration level Parameter Display Factory setting Analog input 1, 2 and 3; setpoint changeover / shift C111 9930 Limit comparator; controller type; setpoint 1; locking C112 5010 Unit address; decimal place / unit signal for out-of-range C113 Measurement range start analog input 1 Measurement range analog input 1 Measurement range analog input 2 SCL2...

  • Page 20: Safety

    SAFETY Installation requirements Please read these requirements before commencing installa- tion. The product has to be installed by a recognized installer fully according to the current national and local demands, norms and standards. The installation procedure should only be used for heating systems with a maximum water temperature of 95 °C.
  • Page 21 Maintenance Work on the electrical installation should only be carried out by approved technicians and in accordance with the electro tech- nic 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 installations.
  • Page 22 Installation The water heater should be installed by a recognized installer in accordance with current regulations and the regulations of the local electric companies (see supplement). Make sure that you follow all safety instructions properly. Operation In case of gas leakage, switch off the water heater and close the gas service cock.

  • Page 23: Delivery And Transport

    DELIVERY AND TRANSPORT Delivery Before delivery, the R2000 water heater is fully assembled and tested in the factory. The R2000 is mounted on a pallet and covered in a "heat-shrink" protective wrapper. Check for damage after removing the water heater’s protective covering.
  • Page 24 Pallet cart and/or forklift truck When moving the water heater with a pallet cart or forklift truck, the forks should be placed at a front of the water heater. Fig. 12 Moving Using a crane - Never swing the load over bystanders. - Always use special lifting harnesses which should be placed on the water heater - Make sure that during lifting the harness does not damage...

  • Page 25: Installation

    INSTALLATION Boiler room Installation of the R2000 should only be carried out by a recog- nized installer in accordance with the current national and local demands, norms and standards (see supplement). 5.1.1 Siting Install the water heater as close to the chimney as possible. A plinth base is not required.

  • Page 26: Unit Connections

    Mechanical ventilation The supply of air by mechanical means shall be by mechanical inlet with natural of mechanical extractions, mechanical extract with natural inlet must not be used. The minimum flow rates with mechanical ventilation are as follows: Inlet Air (Combustion ventilation) - 1.1 m /s per 1000 kW total rated heat input.

  • Page 27: Hydraulic Connections

    Fig. 14 Electrical terminal block External control It is possible to externally control the unit. The following termi- nals on the terminal block have the following functions: common up signal down signal enable 0 - 10 VDC control signal (only available with EM control option) external main gas valve alarm signal (230 V)

  • Page 28: Water System

    5.2.3.1 Water system The following notes are of particular importance to these water heaters. A drain tap is fitted to the header at the connection end of the water heater to drain the content of the heat exchanger. The water connections are normally on het right hand side of the water heater but can be supplied on the left hand side by special order, i.e.
  • Page 29 Fig. 16 TP 50 - 60 Fig. 17 TP 50 - 120 Type Water flow rate Q Pressure drop H in in m /h meter water gauche R2017 14,5 R2022 14,0 R2028 13,5 R2034 19,5 R2041 19,0 R2048 18,5 R2056 18,0 3,35 R2066...

  • Page 30: Flues

    Type Grundfos Pump motor rating pump R2017 3N~ 400 V 0,92 A TP 50 -30 R2022 0,25 kW 1410 r.p.m. PN10 R2028 1N~ 230 V 1,58 A R2034 R2041 3N~ 400 V 1,18 A R2048 TP 50 -60 0,37 kW 1410 r.p.m.
  • Page 31 Average flue pipe resistance coefficients of various flue pipes. See also manufacturers information. ζ = 0,5 bend 90E (R/D= 1,0) ζ = 1,3 bend 90E (right angle) ζ = 0,5 bend 45E ζ = 2,0 T-piece ζ = 1,5 outlet Table 7 Average flue pipe resistance coefficients Flue condensation Flue gases transfer heat when they pass through the chimney.

  • Page 32: Water Temperature

    Where there is a risk of the water pressure falling below the minimum pressure a minimum pressure switch should be included which turns off the water heater. Under certain conditions and following a high demand it is possible for the water heater to condensate. It is necessary to maintain the water heater above the minimum condensation point of 36 °C.

  • Page 33: Water Quality

    User Single use or Temperature Demand in fill in litres in °C litres/minute Dwellings kitchen sink 13 - 15 40 - 60 12 - 18 basin 7 - 10 6 - 8 hand washing 6 - 8 shower 8 - 12 bath 100 - 150 12 - 18...
  • Page 34 Permanent hardness The permanent hardness consists of minerals contained in the water which are not deposited such as calcium sulphate and calcium silicate. These salts form permanent hardness or non carbonate hardness. Total hardness The total hardness is the sum of the temporary hardness and permanent hardness.

  • Page 35: Formula To Calculate Hot Water Requirements

    Standard factory setting 65 °C. For higher temperature requirements contact your supplier. They will make the necessary water quality measurements and advise you with regards to high temperature settings and the use of water softeners as required. Water hardness in Maximum pH Maximum operating temperature in °C...
  • Page 36 Number of Delivery G in Type of property Hot water Formula hot water litres/hour at units * to apply ** units * 60 °C for numbers of Houses hot water individual dwellings units*** 4 or 5 rooms, 1 bathroom 1 or 2 4 or 5 rooms, 2 bathrooms 2 or 3 1100...

  • Page 37: A Small Selection Of Applications

    A small selection of applications 5.8.1 Single temperature Without storage tank using sufficient recirculation system Only applicable in projects with a constant draw or small fluctu- ations without large peak load. Such as hotels without catering towards the tour operators, hospitals, chemical industry, food processing, dairy produce etc.

  • Page 38: Industrial Application

    5.8.3 Industrial application With storage tank 500 l + This type of system has many applications in areas with large water demand fluctuations and variable temperatures to be kept within small tolerances. Industrial applications such as carwash (removing of protective wax layer), photo and film processing, laboratories, plating processing, slaughterhouses etc.

  • Page 39: Commissioning

    COMMISSIONING General COMMISSIONING OF THE WATER HEATER MUST BE CARRIED OUT BY PROPERLY QUALIFIED AND AUTHOR- ISED PERSONNEL. OTHERWISE, THE GUARANTEE WILL BECOME VOID. Never deviate from the instructions in this manual. Flushing the system To prevent damage from rust, sealing compounds, sand, metal particles etc., the system must be flushed thoroughly, before the system is switched on.
  • Page 40 Adjusting the burner pressure The burner pressure must be adjusted when the water heater has been running for 20 minutes at high load (state of equilib- rium). Natural gas H (G20) Gas service pressure 20 mbar Nozzle diameter 1,8 mm minimum load (20 %) Type Burner...
  • Page 41 Liquid Propane Gas Gas service pressure 50 mbar Nozzle diameter 1 mm minimum load (20 %) Type Burner Pilot Air- Burner Cascade pressure pressure damper pressure start/min. opening 40 % ET EM only closed out/in (mbar) (mbar) (mm) (mbar) (mbar) R2017 13/18 R2022...

  • Page 42: Pre-Lighting Checks And Dry Run

    Pre-lighting checks The following is a list of appliance checks to be carried out. and dry run 6.2.1 Check 1 With the water heater gas inlet service cock closed and electricity supply switched off Ascertain from the gas supplier or the customer that the meter installation is operational.

  • Page 43: Check 3

    III) Check the setting of the modulating combustion air damper situated underneath the burners, there should be a gap of 4 mm (Natural gas) or 8 mm (LPG) with the damper in the fully closed position against the stops. Burner trolley assembly Fig.

  • Page 44: Live Run Check

    If no leak is found, this indicates that the 1st safety shut off valve is letting by and should be replaced (whole multi block on models R2017 and R2022). With test points 10/1 and 10/2 opened connect them together with a short piece of flexible tubing which incorporates a tee connection to the pressure gauge.
  • Page 45 system if there is air in the gas supply; although seven minutes must be allowed between each attempt to ensure that any gas has been dispersed from the com- bustion chamber). Press reset button to override water heater lockout. Carry out a) above and close the pilot manual cock once the pilot burner has ignited.

  • Page 46: Instructions To User

    Fig. 24 Measuring ionisation With the gas train cover closed switch on the water heater. Check for spillage of products of combustion from the draught diverter opening with a smoke detec- tor or other suitable apparatus, ensuring that any openable windows, doors etc., fitted in the water heater space are shut and any extraction fans are operating.
  • Page 47 Stress the importance of regular servicing for safe and efficient operation and that if a gas leak is detected to turn off the water heater at the gas service cock and to call the local gas supplier. Water heater failure In case of water heater failure the system will fall into lock-out.

  • Page 48: Operation And Fault Indication

    OPERATION AND FAULT INDICATION Function The water heater starts up in the sequence described below: Heat demand. Ignition of pilot flame. As soon as pilot flame is detected, an ionisation current will pass to the flame safeguard control box. The main gas valve opens and gas ignites over complete burner tray.

  • Page 49: Fault Indications

    If there is insufficient water flow the water heater will turn off and lock-out. Red lamps 2 and 5 on. Reset by pushing button If the flow temperature exceeds the high limit setting, the water heater will mechanically lock-out and switch off. Red lamp 2 on. When resetting by pushing button 3, lamp 4 TA will light.

  • Page 50: Fault Finding Table

    Fault finding table Fault Possible cause Solution Water heater does not No electrical supply to check whether switched attempt to light water heater indicator (1) is alight Check all external con- trols for continuity No heat demand Check control thermostat is set high enough Overheat control has Check whether indicator...
  • Page 51 Fault Possible cause Solution Pilot burner ignites but Check flame probe if damaged, replace water heater then goes to lock-out, indicator (2) Flame probe lead(s) not rectify alights. Main burners do connected or faulty not light Faulty connections to rectify main safety shut off val- ve(s) Faulty main safety shut...

  • Page 52: Maintenance

    MAINTENANCE Safety Always wear the proper protective clothing and shoes when servicing the water heater. Wearing jewelry and loose clothing can contribute to unsafe situations. General information In order to keep the R2000 in a safe working condition, the water heater should be inspected and serviced at least once every year and cleaned if necessary.

  • Page 53: Cleaning

    Burner tray The burner manifold and the gas regulator are connected by means of a coupling. Remove the burner for inspection as follows: 1 Close the gas service cock and disconnect the burner mani- fold and gas regulator. 2 Release the two brackets which attach the burner to the water heater frame.

  • Page 54: Regulation

    Servicing WARNING: ONLY COMPETENT PERSONS SHOULD CARRY OUT SERVICING ON THIS WATER HEATER IN ACCOR- DANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1984. Ensure that both gas and electrical supplies are switched off before carrying out any service operation. After carrying out any service operation it is important to check for gas soundness and re-commission the water heater as described in Section 6 - Commissioning.
  • Page 55 Water heater with burner trolley removed Fig. 27 R2000 with burner trolley removed 1 Flue outlet socket 2 Down draught diverter 3 Front and rear upper panels 4 Draught diverter air supply opening 5 Water heater heat exchanger 6 Combustion chamber 7 Combustion chamber insulation 20IP18B...
  • Page 56 Remove the down draught diverter by releasing two screws in either side and remove the flueway baffles from the top of the heat exchanger. Inspect the heat exchanger for deposits and clean if necessary, check condition of the copper fin tubes and fins and replace flueway baffles.
  • Page 57 Each burner bar can be withdrawn from its injector. With the burners removed check the injectors for any blockage and if necessary clean in spirit. Remove the air guides located beneath the burners and clean. Check the setting of the modulating combustion air damper.

  • Page 58: Component Replacement

    Check that the modulating combustion air/gas control linkages are in good working order and that there is no play in the gas control spindle. Replace the various panels on the top of the water heater including the down draught diverter, replace the burner trolley and clamp into position.
  • Page 59 To remove the pilot burner assembly, disconnect the wiring to the sensing electrode and the ignition electrode. Avoid damag- ing the electrodes. Replacement of the burner bars is described in section Servicing. Ensure that the burners are not damaged or warped. Injectors Remove the burner trolley and burner bars as described before.
  • Page 60 Upon replacement if components carry out the relevant portions of section 5 commissioning. Ignition generator Release the two fixings securing the top of the gas train cover at the front of the water heater and remove carefully in upward direction. Disconnect all of the plugs from the front electrical panel and remove the cover of the electrical panel by releasing two scre- ws at each end.
  • Page 61 Fin-tube replacement Remove the unit’s 18 O-rings. From the top of the heat exchanger remove two baffles, one on either side of the damaged finned-tube. On the side of the unit with the best access, remove the 4 bolts which attach the finned-tube mounting-plate (6) the unit’s fram- e.

  • Page 62: Service

    Fig. 31 Fin tube replacing Service For service and maintenance the service department of your supplier can be contacted. Stokvis Energy Systems. 96R Walton Road East Molesey Surrey. KT8 0DL tel.: 08707 707 747 fax: 08707 707 767 20IP18B...

  • Page 63: List Of Serviceable Parts

    LIST OF SERVICEABLE PARTS When ordering parts it is important to specify the model and serial number of the water heater. When ordering under war- ranty it is also necessary to specify the date of installation and commissioning. Part Manufacturer Article code nr Main gas valve (multibloc) model 2017 &...

  • Page 64: Supplement

    SUPPLEMENT Regulations and standards 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).
  • Page 65 20IP18B...

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