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STOKVIS ENERGY SYSTEMS ECONOFLAME R2700 Installation, Operation & Maintenance Documentation

Gas fired condensing boilers
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See also: Installation, Operation & Maintenance Documentation
ECONOFLAME R2700/R2800/R2900
GAS FIRED CONDENSING 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
2789CV02B 180504

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Summary of Contents for STOKVIS ENERGY SYSTEMS ECONOFLAME R2700

  • Page 1 ECONOFLAME R2700/R2800/R2900 GAS FIRED CONDENSING 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...
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  • Page 12 <-- &9%...

  • Page 13: Table Of Contents

    INTRODUCTION ......1 Stokvis Energy Systems..... . . 1 Supplier .
  • Page 14 Hydraulic system ......36 5.4.1 General ........36 5.4.2 Water flow .

  • Page 15: Introduction

    - available with many different options. Continual research and development means that Stokvis remains at the forefront of boiler technology. Supplier STOKVIS ENERGY SYSTEMS. 96R Walton Road, East Molesey Surrey KT8 0DL Tel.: 08707 707 747 Fax: 08707 707 767...

  • Page 16: Service

    The following aspects of the units are dealt with: - General description - Technical specifications - The facilities necessary for design and installation - Installation examples - Maintenance instructions The operating instructions needed by the user are attached to the unit; these are also to be found in Section 6. Service The Stokvis service department is always available for commissioning and for providing service and...

  • Page 17: Description

    DESCRIPTION General The Econoflame R2700/R2800/R2900 are environmentally friendly modulating gas fired heating boilers that can vary its output from 25 % to 100 % of its maximum capacity. The R2700 series consists of 10 models in a range from 95 to 597 kW.
  • Page 18 The boiler pump ensures the water flow quantity. The third heat exchanger is switched parallel to the boiler and has a flow of 5 - 10 % of the entire water flow. The R2700/R2800/R2900 units have a small water capacity so that it can rapidly adjust to changing conditions.

  • Page 19: Main Components

    1 Return connection 19 Flue gas collection chamber Main components 2 Flue gas discharge R2900 or 20 Combustion chamber flue attenuator R2700 and R2800 21 Electrical cable duct 3 Water flow switch 22 Condensate discharge 4 Safety valve 23 Inspection opening 5 Inlet connection 24 Gas valve unit 6 Filling/drainage valve...

  • Page 20: Description Of Principal Components

    2.2.1 Description of The boiler is constructed from the following principal compo- principal components nents: Fan [25] This consists of a fan casing, a fan impeller and an electric motor. The fan sucks in combustion air and increases the air pressure.
  • Page 21 The boiler pump ensures the water flow quantity. The third heat exchanger is switched parallel to the boiler and has a flow of 5 - 10 % of the entire water flow. Water circulation pipes [15] These pipes connect the burner to the heat exchangers. Water connections These consist of a flow connection [5] and a return connection [1].

  • Page 22: Boiler Control

    Boiler control The principle employed for the Boiler Management Unit is as follows: The boiler begins operating on receipt of a heating demand. This heating demand is generated either: If the measured supply temperature is lower than the desired temperature. As a result of “manual operation”...

  • Page 23: Safety

    SAFETY Installation instructions Read through these instructions carefully before starting the installation. The appliance must be installed by a recognised installer in accordance with the applicable national and local regulations (see Supplement). The installation may only be used for heating systems up to a maximum water temperature of 90 °C.
  • Page 24 Maintenance Work on the electrical installation may only be carried out by an authorised installer in accordance with the applicable electrical regulations. Work on the gas and hydraulic installations may only be under- taken by properly trained personnel in accordance with the safety regulations for gas installations (see supplement).
  • Page 25 Danger of explosion When activities are being undertaken in the boiler room, always follow the applicable instructions “Working in an area where there is a danger of explosion”. Installation The appliance must be installed by an authorised installer in accordance with the applicable national and local specifications and regulations.

  • Page 26: Delivery And Transport

    DELIVERY AND TRANSPORT Delivery The appliances are completely assembled, tested and covered in a "heat-shrink" protective covering. After delivery and removal of the protective covering, check the appliance for damage. Check that the equipment delivered is in accordance with the order and the delivery note.
  • Page 27 Rollers After the wooden blocks have been removed, it is possible to move the appliance by rolling it over tubes. Fig. 7 Moving with the aid of rollers Lifting The figure below shows how a unit can be safely lifted. To avoid damage to the panels, these should first be removed.
  • Page 28 Dismantling and reassembly When the unit cannot be placed in position because of its dimensions or weight, the boiler may be partially dismantled. When it is necessary to perform extensive dismantling, we advise you to make early contact with your supplier. The unit can be delivered in parts, each of which has been pretested.
  • Page 29 Third heat exchanger Type L (mm) B (mm) H (mm) m (kg) R2900 only R2900 R2901 R2902 R2903 R2904 R2905 R2906 R2907 R2908 R2909 Fig. 11 Dimensions and weights of the third heat exchanger R2900 Frame Type L (mm) B (mm) H (mm) m (kg) R2700...
  • Page 30 Fig. 13 Mounting the vibration dampers Protection against frost If the unit is out of use during the winter months there is a danger of freezing. Drain the water from the installation using the filling/drainage valves. 2789CV02C...

  • Page 31: Installation

    INSTALLATION Regulations The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations (see Supplement). Commissioning should be carried out by the service department of your supplier, who can also determine the composition and quality of the system water.
  • Page 32 Installation on a roof When the appliance is installed on a roof or when the boiler room is the highest point in the system, the following protective measures are important: The unit itself may NEVER be the highest point of the in- stallation;...

  • Page 33: Ventilation

    5.2.3 Ventilation The ventilation of the boiler room must satisfy the applicable national and local standards and regulations (see Supplement). With regard to ventilation, pay particular attention to the follow- ing points: a Observe the applicable national and local standards and regulations for the dimensions of the openings and the pro- tection for any mechanical ventilation b Ensure that the air inlet openings are transversely placed in...
  • Page 34 This front panel can be simply removed by pulling the lower edge of the panel forward. Behind this panel are two cover plates which can be removed by unscrewing the M5 bolts. The terminal strip with the connection clamps are mounted behind the lower cover plate.
  • Page 35 Earth leakage trips can give problems when they are used in combination with frequency converters. In some countries this is actually forbidden. There are two reasons for this: a All rectifiers (not only frequency converters) can cause direct currents to flow in the mains power supply and which can reduce the sensitivity of the safety switch b The asymmetric loading caused by radio interference filters can result in the premature operation of the earth leakage...
  • Page 36 Electro-technical data Type Fan, control and Pump Total safety components electrical power Supply* Power Supply** Power consumption consumption consumption (max) (max) *** (max) R2700 0,33 0,19 0,52 **** R2701 0,33 0,19 0,52 **** R2702 0,37 0,40 0,77 R2703 0,37 0,40 0,77 R2704 0,33...
  • Page 37 Control and options The appliances are fitted with a proportional regulation system. This can be made temperature dependent with the aid of a 0 – 10 VDC (= +2 °C – +90 °C) signal. Also a domestic hot water priority circuit belongs to the standard equipment. In addition, the boiler regulating system can be extended by fitting one of the three options described below: BME option...
  • Page 38 ting the boilers to standby during the summer months whilst continuing to provide domestic hot water priority. Operating signal (230 V, 50 Hz, 1 A). The 230v ope- rating signal falls off if a fault has occurred more than twice within 6 minutes (the fault code will appear in the display with a "3") or if a fault is longer than 6 minutes active.

  • Page 39: Water Connections

    the use of a signal amplifier is recommended. 41 - 42 SCOM bus connection (use the correct polarity). 43 - 44 Primary boiler pump control (0 – 10 V = +2 °C – +90 °C). (Not available for R2700 series boilers). * the use of screened cables is recommended.

  • Page 40: Combustion Air Supply

    It is recommended that manually operated valves be fitted between the water connections and the installation. In order to limit the losses occurring in a non-operational boiler, a motorised valve is sometimes fitted in the flow or the return pipe or a mechanical non-return valve is used for this purpose. Standby losses can be reduced even further by shutting down the boiler via the “boiler enable”...
  • Page 41 Type Air supply diameter D (mm) (mm) (mm) R2700 R2701 R2800 R2900 R2702 R2801 R2901 R2703 R2802 R2902 R2704 R2803 R2903 R2705 R2804 R2904 R2706 R2805 R2905 R2707 R2806 R2906 R2708 R2807 R2907 R2709 R2808 R2908 R2809 R2909 Table 8 Air supply connection Fig.

  • Page 42: The Flue System

    Fig. 20 Heights of air inlet and flue gas discharge The relative horizontal difference between the flue pipe the air supply pipe must not be less than the width of the unit. Fig. 21 Distance between air inlet and flue gas outlet The formation of unwanted condensation must be avoided.
  • Page 43 Condensation forms because of the high boiler efficiency and the considerable degree of cooling of the flue gasses that takes place against the walls of the flue pipe. In order to reduce flue gas condensation as much as possible, the use of a double- walled and insulated flue pipe is recommended.

  • Page 44: Chimney

    Type Flue gas Flue gas quantity at full Maximum temperature capacity permissible at full chimney capacity resistance (approx.) °C m /h kg/s mbar R2700 0,047 R2701 0,059 R2702 0,071 R2703 0,089 R2704 0,109 R2705 0,149 R2706 0,187 R2707 0,222 R2708 1092 0,252 R2709...
  • Page 45 The back-pressure outside the unit depends on: a The resistance of the flue pipe b The degree of cooling of the burner system c The resistance of the discharge system. The degree of cooling of the flue gasses depends on: a the insulation value of the chimney b the local ambient temperature c the discharge system.
  • Page 46 Fig. 22b Chimney connection R2900 The R2700 and R2800 appliance must never be connected to a flue systems with a plastic lining (consult the applicable stan- dards and regulations). The maximum flue gas temperature at full capacity and with a water supply temperature of 80 °C will not exceed 170 °C for the R2700, 145 °C for the R2800 and 90 °C for the R2900.
  • Page 47 Maximum permitted flue system length in metres of smooth pipe. Standard flues only. Type Length of flue system in m Diameter Diameter Diameter Diameter Diameter Diameter 120 mm 150 mm 180 mm 200 mm 250 mm 300 mm R2700 R2701 R2702 R2703 R2704...
  • Page 48 Losses in the chimney related to various chimney sections expressed in metres of straight pipe. The total loss must be subtracted from the maxi- mum permitted chimney length given in table 10. Conversion for other types of accessories with different ζ (resistance coefficient) values can be simply accomplished by comparing with the stated losses at ζ=1.

  • Page 49: 5.3.6 Condensate Discharge

    ζ=1 Type Diameter Elbow Elbow Elbow 90° Tee 90° 90° 45° ζ=0,5 ζ=2 right angle R/D = 1 R2900 150* R2901 150* R2902 180* R2903 200* 10,1 R2904 200* R2905 250* 12,4 R2906 250* 12,3 R2907 250* 11,0 14,1 R2908 300* 14,8 11,1...

  • Page 50: Hydraulic System

    The connection to the drain must be arranged such that there is an open connection under the condensate discharge point on the appliance (see fig. 23). In addition, the discharge pipe must be fitted with a trap (U-bend) in accordance with the applicable regulations.

  • Page 51: Water Flow

    5.4.2 Water flow 5.4.2.1 Flow rate and The rate of water flow through the appliance must never fall resistance below the required minimum (otherwise the water flow switch will be activated and the appliance will be shut down). The use of valves, non-return valves, systems in which several appli- ances are connected to a common transport system, etc., must not interfere with the required water circulation.
  • Page 52 The primary pump has been sized to have an optimum duty when ∆T = 20 K. When running at ∆T’s less than 20 K the pump size should be checked to ensure suitability. The water flow rate can be adjusted with the aid of the built-in 3-speed pump control.

  • Page 53: 5.4.2.2 Pump Characteristics

    5.4.2.2 Pump characteristics UPS 32-60F UPS 32-120F Fig. 24 Pump char. UPS 32-60F Fig. 25 Pump char. UPS 32-120F UPS 40-120F UPS 50-120F Fig. 26 Pump char. UPS 40-120F Fig. 27 Pump char. UPS 50-120F UPS 65-120F Fig. 28 Pump char. UPS 65-120F 2789CV02C...

  • Page 54: Isolating Valves

    Type Pump Pmax Pmin n n n n speed 3x400 V UPS 32-60F 0,21 0,82 R2700 - R2701 0,23 0,88 R2800 - R2801 0,39 0,68 R2901 - R2901 UPS 32-120F 0,42 0,84 R2702 - R2704 0,47 0,86 R2802 - R2803 0,78 0,74 R2902 - R2903...

  • Page 55: Boiler Expansion Tank

    ∆ ∆ ∆ ∆ T at full load Minimum operating Flow temperature pressure in bar °C >1,5 >1 Table 14 minimum operating pressures 5.4.3.2 Boiler expansion It is advisable to fit an expansion tank in the return pipe be- tank tween pump and the boiler isolating valve.
  • Page 56 In the United Kingdom, water hardness is expressed in mg/litre (ppm) and is given the following divisions: Very soft less than Soft approx. 50 - 160 ppm Moderately hard approx. 160 - 250 ppm Hard and very hard over ppm. The system must contain soft to moderately hard water with a water hardness not exceeding 250 ppm with a sup- ply temperature of 80 °C and ∆...

  • Page 57: Examples Of Hydraulic Systems

    The chloride concentration must not exceed 200 mg/l. If this level is exceeded, the cause must be located. Compare the chloride concentration of the additional water with that of the system water. If this concentration is higher, this indicates evaporation if no chloride containing materials have been added.
  • Page 58 Example of a low velocity header with isolating valves and an expansion tank. Fig. 29 Installation with a low velocity header, isolating valves and expansion tank Mounting the low velocity header vertically has additional advantages: the upper section functions as an air separator and the lower section serves as a dirt separator.
  • Page 59 Fig. 30 Boiler with vertically mounted low velocity header arranged with right hand connections Fig. 31 Low velocity header with multiple heating circuits in a mixing control arrangement without a main pump Small installations (up to 200 kW) with weather dependent regulation and hot water priority switching.
  • Page 60 Switching the secondary pumps on and off without the use of a building optimization system results in the temperature swings being too large and a boiler and pump that are switched too frequently. This increases the chances of wear and faults occurring.
  • Page 61 Fig. 33 Installation with more than one appliance and making use of a low velocity header for two boilers Fig. 34 Low velocity header for two boilers 2789CV02C...

  • Page 62: Operating Instructions

    OPERATING INSTRUCTIONS Function When a heating demand is received and before the boiler starts up, the appliance must be pre-purged. Gas and air are optimally mixed in the mixing chamber. The fan supplies air for combustion, the quantity being regulated by the frequency controlled fan speed.

  • Page 63: Control Module

    Control module Lid closed Lid open Fig. 35 Control module 1 function 1 parameter indication i standby P1 current/setting boiler supply temp. F automatic operation P2 current/setting domestic hot water summer operation temperature service operation min. *P3 desired temperature service operation max. P5 current external temperature 2 function selector P8 current low velocity header temp.
  • Page 64 Information mode With the cover open and by turning the rotational switch (Pos. No 5) clockwise or anti-clockwise it is possible to read out certain information from the boiler management unit. There are 10 possibilities. An arrow at the bottom of the LCD display will indicate which parameter has been selected.

  • Page 65: Fault Indications

    Setting the flow temperature for Domestic Hot Water (cover open) N.B. Only applicable if the Direct Hot Water function is used with the BM-E expansion module. - Open the lid - Turn the rotational switch (pos.5) clockwise until the arrow at the bottom of the LCD display indicates parameter P2 - Press and hold the combined Reset/Programming key (pos.- 3) and at the same time turn the rotary switch until the desi-...

  • Page 66: Start-Up

    20 Error in the control of gas valve 1. After burner has stopped a flame has been detected for a period of 5 seconds. This in spite of the fact that valve 1 is closed. Correct the fault by cleaning the valve. 21 Error in the control of gas valve 2.

  • Page 67: Warnings

    Warnings The unit must be installed by a recognised installer. The operating instructions must be strictly observed. If the source of the fault cannot be found, the service organisation must be contacted. Never repair the appliance yourself. The condensate drain may never be modified or closed off. When a boiler is completely shut down in the winter period, there is a danger of freezing.

  • Page 68: Commissioning

    COMMISSIONING General Commissioning must be carried out by skilled personnel. Failure to observe this condition will invalidate the guarantee. Commissioning Water and the hydraulic system Take a sample of the water from the filling/drainage valve on the boiler and a sample of the make-up water. Determine the water hardness using the titration method.
  • Page 69 Check the operation of the appliance at full capacity Start up the appliance. Allow the appliance to operate at full capacity and to stabilise (approximately 3 minutes). At full capacity, the following settings must be checked and corrected if necessary using the butterfly valve on the mixing chamber, see fig.
  • Page 70 Check the appliance at minimum capacity Adjust the appliance to operate at minimum capacity. At minimum capacity the following settings must be checked and corrected if necessary only using the N-adjust skrew on the gas valve, see fig. 5 pos. 24. Settings at minimum capacity Natural gas: Guide value CO...

  • Page 71: Maintenance

    MAINTENANCE Safety During maintenance activities, always wear suitable clothing and shoes. Consider your own safety, particularly in respect of jewellery and loose clothing. General In order to ensure continued good and safe operation of the appliance, this must be inspected at least once per year. The following activities must be carried out (for an extensive description of these activities, see 8.3): - Renew the ignition and ionisation electrodes...

  • Page 72: Cleaning The Burner And Heat Exchangers

    In order to carry out the following activities, the panels must first be removed. - In order to clean the air inlet damper this must first be removed. Clean it with a vacuum cleaner. - For appliances installed in a dusty environment, the fan blades may become dirty.

  • Page 73: Cleaning The Filter/Screen In The Gas Combination Block

    Cleaning the filter/ In order to clean the filter/screen in the gas combination block, screen in the gas this must first be removed. combination block Kromschröder gas combination block 1 Close the gas supply valve to the boiler 2 Release the gas train by unscrewing the top bracket from the mixing system 3 Unscrew the four bolts securing the input flange 4 Remove the filter from the combination block...

  • Page 74: Service

    CO15 V/f rated frquency 70 Hz Service For service and maintenance the service department of your supplier is always available. STOKVIS ENERGY SYSTEMS. 96R Walton Road, East Molesey Surrey KT8 0DL Tel.: 08707 707 747 Fax: 08707 707 767 2789CV02C...

  • Page 75: Conversion Formulae And Factors

    CONVERSION FORMULAE AND FACTORS Formulae 20,9 - measured O x 11,7 20,9 measured CO x 20,9 = 20,9 - 11,7 11,7 % CO is the maximum CO percentage that is generated by stoichiometric burning of G20 natural gas (H-gas). Excess air N: 20,9 x 0,914 20,9 - measured O...
  • Page 76 kcal/h Btu/h 0,86 3,41 1,163 3,97 0,293 0,252 Table 15 Conversion factors 1 kcal = 4,187 kJ 1 kWh = 3,6 MJ Efficiency at the flue gas side The difference between upper and lower calorific values is the heat of evaporation of the combustion formed water. At 298.15 K (25 °C) this amounts to 2442.5 kJ/kg (583.38 kcal/kg).
  • Page 77 meg/l °dH °f °e CaCO /l meg/l 3.51 °dH 0.37 1.78 1.25 17.8 °f 0.56 °e 0.285 1.43 14.3 mg CaCO /l 0.02 0.056 1.54 Table 16 Conversion of degrees of hardness 1 degree English hardness (°e) = 65 mg CaCO /imp. gallon 1 Grain/US Gallon = 0.958 °dH 1 milligram equivalent per l (mval/l)
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  • Page 79 2789CV02C...

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