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STOKVIS ENERGY SYSTEMS R40 EVO 60 Assembly Manual

Evolution series modupak cascade
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R40 (Evolution Range)
MODUPAK
CASCADE ASSEMBLY
MANUAL
STOKVIS ENERGY SYSTEMS
Unit 34 Central Park Estate
34 Central Avenue
West Molesey
Surrey
KT8 2QZ
Tel: 020 8783 3050
Fax: 020 8783 3051
E-Mail:
info@stokvisboilers.com
Website:
www.stokvisboilers.com
420010768400 04/2016 – Doc195-V1.0

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Summary of Contents for STOKVIS ENERGY SYSTEMS R40 EVO 60

  • Page 1 R40 (Evolution Range) MODUPAK CASCADE ASSEMBLY MANUAL STOKVIS ENERGY SYSTEMS Unit 34 Central Park Estate 34 Central Avenue West Molesey Surrey KT8 2QZ Tel: 020 8783 3050 Fax: 020 8783 3051 E-Mail: info@stokvisboilers.com Website: www.stokvisboilers.com 420010768400 04/2016 – Doc195-V1.0...

  • Page 3: Table Of Contents

    Contents Technical data ................... 4 Declaration of Conformity ................... 7 Cascade assembly General instructions ........... 8 Frame - line, wall mounted ......... 9 Frame - line, floor standing frame ....... 10 Frame - back to back, floor standing frame ....11 Collector ..............

  • Page 4: Technical Data

    Technical data R40 EVO R40 EVO R40 EVO R40 EVO R40 EVO R40 EVO Nominal heat output at 80/60°C max/min 56,5/15,5 65,5/15,6 75,3/19,4 92,9/18,7 111,9/22,5 130,4/26,2 Nominal heat output at 50/30°C max/min 60,4/17,2 70,0/17,2 79,7/21,2 98,9/20,6 118,5/24,8 137,8/28,9 Nominal heat output at 40/30°C max/min 60,5/17,3 70,0/ 17,4 79,7/21,5...
  • Page 5 Technical data R40 EVO R40 EVO R40 EVO R40 EVO R40 EVO R40 EVO IP class with Appliance Type B23(P) IP30 IP class with App. Type C13, C33, C43, C53, C63, C83, IPX4D Weight (empty) Weight (filled with water) Sound Power Level (LWA) μA Ionisation current...
  • Page 6 Technical data Side view Front view Back view Bottom view Dimensions R40 EVO R40 EVO R40 EVO 60/70/80 100/120 R1.¼ R1.½ R1.½ R1.¼ R1.½ R1.½ R¾...

  • Page 7: Declaration Of Conformity

    Declaration of Conformity Declaration of Conformity Elco BV, Hamstraat 76, 6465 AG Kerkrade (NL), Declares that the products R40 EVO Is in conformity with the following standards: EN 15502-1 EN 15502-2-1 EN 55014-1 / -2 EN 61000-3-2 /-3 EN 60 335-1/ -2 And in accordance with the guidelines of directives: 92 / 42 / EEC (boiler efficiency directive) 2009 / 142 / EEC (gas appliance directive)

  • Page 8: Cascade Assembly

    Cascade assembly General instructions The following pages show the most convenient way to install the complete cascade system, both for line and back to back solutions. The pictures show a cascade system with system connections to the right, but it’s also possible to make the system connections to the left.

  • Page 9: Frame - Line, Wall Mounted

    Cascade assembly Frame - line, wall mounted Mark the boreholes on the wall as displayed in the drawing. Drill the holes and place the plugs. NOTE: Before installing the boilers on the wall, please ensure that the wall is firm enough to carry the weight of the boilers (see technical data for weight indication by boiler type).

  • Page 10: Frame - Line, Floor Standing Frame

    Cascade assembly Frame - line, floor standing frame Place the frame on a clean and level surface. All parts are assembled and fastened with M8 hexagonal bolts (1) and washers (2) . The collector supports (3) and (4) are designed for both frame support as well as support for the hydraulic and gas collector tubes.

  • Page 11: Frame - Back To Back, Floor Standing Frame

    Cascade assembly Frame - back to back, floor standing frame Place the frame on a clean and level surface. All parts are assembled and fastened with M8 hexagonal bolts (1) and washers (2) . The collector supports (3) and (4) are designed for both frame support as well as support for the hydraulic and gas collector tubes.

  • Page 12: Collector

    Cascade assembly Collector Position the flow (1) and return (2) tubes, as well as the gas tube (3) on the collector supports (4 and 5). Place the gaskets (6) and the blind flanges (7) and assemble them with M16 bolts and nuts (8). NOTE: It’s important to check whether the collector tubes are placed in the right...

  • Page 13: Boilers

    Cascade assembly Boilers Place the boilers on the frame, make sure they are aligned properly.

  • Page 14: Insulation - Back Panel

    Cascade assembly Insulation - back panel Back panel boiler 1 (left): Cut off the extension pieces (1) of the back panel B. Place part F. Place part G. Place the back panel B in the cascade system. Back panel boiler 2 (right): For the second boiler follow step 2-4 as described for boiler 1 (NOTE: the insula- tion should NOT be cut!)

  • Page 15: Ispesl Kit (Italy Only)

    Cascade assembly ISPESL kit (Italy only) Position the ISPESL flow pipe (1) to the flow connection of the collector. Place the gasket (2) and assemble the pipe with M16 bolts and nuts (3). > 555 kW Repeat the same activities for the ISPESL return pipe (4).

  • Page 16: Gas Filter

    Cascade assembly Gas filter DN 65 Assemble the gas filter to the gas connection of the cascade collector as shown on the picture. DN 100 DN 65 If required by the situation, an extension pipe (optional) can be used to move the location of the gas filter a bit further from the cascade system.

  • Page 17: Low Loss Header

    Cascade assembly Low loss header Plate heat exchanger Low loss header Position the low loss header (1) to the flow and return connection of the collector. Place the gaskets (2) and assemble the header with M16 bolts and nuts (3). For the DN100 header (4), place the adapter kit (5) before assembling the header.

  • Page 18: Boiler Connection Kit - Line

    Cascade assembly Boiler connection kit - line The 1½” x 1¼” reducers (1) should only be used for hydraulic connection to boiler types 100-140 having 1½” connections. Boiler types 60-80 are equipped with 1¼” connections and therefore don’t need the reducers.

  • Page 19: Boiler Connection Kit - Back To Back

    Cascade assembly Boiler connection kit - back to back The 1½” x 1¼” reducers (1) should only be used for hydraulic connection to boiler types 100-140 having 1½” connections. Boiler types 60-80 are equipped with 1¼” connections and therefore don’t need the reducers.

  • Page 20: Boiler Pump - High Efficiency Speed Controlled

    Cascade assembly Boiler pump - high efficiency speed controlled The mechanical assembly of the boiler pumps is included in the assembly description of the boiler connection kits, see previous pages. The cable for electrical connection of the pump to the boiler is included in the pump delivery.

  • Page 21: Insulation - Front Panel

    Cascade assembly Insulation - front panel The front panel insulation is prepared for DN65 cascade systems. When using it on DN100 cascade systems, the wedges on the inside of the panel (1) should be cut before assembly. DN 100 Front panel assembly boiler 1 (left): Place front panel A.
  • Page 22 Cascade assembly Insulation - front panel Front panel assembly boiler 2 / 3 (right): Cut off the extension piece at the right hand side of the panel Place front panel A. Make sure that the snappersof back panel B fit correctly in the front panel A, both at top and bottom connection.

  • Page 23: Insulation - End Pieces

    Cascade assembly Insulation - end pieces When using the end pieces on a DN65 cascade system, the included inserts should be placed before assembly. End cover for left positioning: Place insert H into end cover D. Place insert I into end cover D. End cover for right positioning: Place insert H into end cover D.
  • Page 24 Cascade assembly Insulation - end pieces When using the end pieces on a DN65 cascade system, the included inserts should be placed before assembly. System side cover for left positioning: Place insert H over the top flange. Place insert I over the lower flange.

  • Page 25: Insulation - Connection Piece 2 Collectors

    Cascade assembly Insulation - connection piece 2 collectors For line configurations of more than 3 boilers and back to back configurations of more than 6 boilers, two collectors have to be connected. For fitting the insulation on such systems, a insulation connection piece K is required.

  • Page 26: Insulation - Back To Back Panel

    Cascade assembly Insulation - back to back panel The assembly of the insulation kits for the front boilers of a back to back cascade system is identical to the assembly of the insulation for line cascade systems, as described on the previous pages. The back boilers in a back to back cascade system can be insulated with the back to back insulation panel C.

  • Page 27: Air Inlet Cover

    Cascade assembly Air inlet cover Mount the air inlet cover A on the air inlet connection of each boiler. Boiler types 60-120 have a 100 mm air inlet connection, boiler type 140 has a 130 mm connection.

  • Page 28: Flue System - Line

    Cascade assembly Flue system - line The flue system should always be mounted with a light angle of minimum 3°, in order to enable a proper discharge of condensate from the flue system. To arrive to this angle, the vertical sections B from the boiler to the collector should be adapted to the actual boiler configuration.

  • Page 29: Flue System - Back To Back

    Cascade assembly Flue system - back to back The flue system should always be mounted with a light angle of minimum 3°, in order to enable a proper discharge of condensate from the flue system. To arrive to this angle, the vertical sections B from the boiler to the collector should be adapted to the actual boiler configuration.

  • Page 30: Controls

    Cascade assembly Controls MASTER The boilers can be managed by the integrated Master/Slave cascade management logic. To enable communication from one boiler to the other, the OCI345 communication modules should be connected. Contents of the kits are: Cascade kit MASTER 1x OCI345 communication module with connection material, 1x header sensor QAZ36 with 6m cable incl.

  • Page 31: Dimensions

    Dimensions DN65 line + low loss header Standard CASCADE DN 65 Number of boilers Total width 1672 2322 2972 3622 4272 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 65...

  • Page 32: Dn100 Line + Low Loss Header

    Dimensions DN100 line + low loss header Standard CASCADE DN 100 Number of boilers Total width 3407 4057 4707 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 100 Number of boilers...

  • Page 33: Dn65 Back To Back + Low Loss Header

    Dimensions DN65 back to back + low loss header Standard CASCADE DN 65 Number of boilers Total width 1672 2322 2972 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 65...

  • Page 34: Dn100 Back To Back + Low Loss Header

    Dimensions DN100 back to back + low loss header Standard CASCADE DN 100 Number of boilers Total width 2107 2757 3407 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 100...

  • Page 35: Dn65 Line + Plate Heat Exchanger

    Dimensions DN65 line + plate heat exchanger Standard CASCADE DN 65 Number of boilers Total width 1940 2590 3240 3890 4540 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 65...

  • Page 36: Dn65 Back To Back + Plate Heat Exchanger

    Dimensions DN65 back to back + plate heat exchanger Standard CASCADE DN 65 Number of boilers Total width 1940 2590 3240 ø D = 150mm B = 400 - 450 ø D = 200mm B = 350 - 400 Rear view Side view ISPESL (Italy only) CASCADE DN 65...

  • Page 37: Component Index

    Component index System components Picture Art. code Description DN65 DN100 Line Line 3590279 FRAME VERTICAL SUPPORT 3590280 FRAME HORIZONTAL SUPPORT 3590281 COLLECTOR SUPPORT LEFT 3590282 COLLECTOR SUPPORT RIGHT 3590283 FRAME FOOT 3590267 COLLECTOR GAS DN65 2B LINE / 4B 3590268 COLLECTOR GAS DN65 3B LINE / 6B 3590253 COLLECTOR FLOW/RETURN DN65...
  • Page 38 Component index System components Picture Art. code Description DN65 DN100 Line Line 3590257 COLLECTOR FLOW DN65 4B B2B 3590258 COLLECTOR RETURN DN65 4B B2B 3590259 COLLECTOR FLOW DN65 6B B2B 3590260 COLLECTOR RETURN DN65 6B B2B 3590261 COLLECTOR FLOW DN100 4B B2B 3590262 COLLECTOR RETURN DN100 4B B2B 3590263...
  • Page 39 Component index System components Picture Art. code Description DN65 DN100 Line Line 3590269 FLANGE KIT DN65 3590270 FLANGE KIT DN100 3590271 CONNECTION KIT 2 COLLECTORS DN65 3590272 CONNECTION KIT 2 COLLECTORS DN100 3590273 BLIND KIT FOR 1 BOILER 3590274 SPIROCROSS DN65 3590276 SPIROCROSS DN100 3590277...
  • Page 40 Component index System components Picture Art. code Description DN65 DN100 Line Line 3590198 EXPANSION VESSEL FLEXCON TOP 4/1,5 BAR 3590199 EXPANSION VESSEL FLEXCON TOP 8/1,5 BAR 3590298 GAS FILTER 2" INCL. CONNECTOR DN65 3590299 EXTENSION TUBE GAS 2" 3590300 GAS FILTER DN65 3590301 EXTENSION TUBE GAS DN65 3590303...

  • Page 41: Insulation

    Component index Insulation Controls Picture Art. code Description DN65 DN100 Line Line 3590418 CASC. INSULATION LINE 1 BOILER R40 EVO 3590419 CASC. INSULATION END PIECES RIGHT R40 EVO 3590420 CASC. INSULATION END PIECES LEFT R40 EVO 3590421 CASC. INSULATION MID CONN. PIECE R40 EVO 3590422 CASC.
  • Page 42 Component index Controls Picture Art. code Description DN65 DN100 Line Line 12081759 HEADER/HOT WATER SENSOR QAZ36 CABLE 6M 11002600 ZONE SENSOR QAD36.201 WITH 4M CABLE 12048253 ROOM CONTROLLER QAA75.610/101 12048264 ROOM CONTROLLER QAA78.610/301 WIRELESS 12048275 RECEIVER AVS71.390/109 WIRELESS 12048286 OUTDOOR SENSOR AVS13.399.201 WIRELESS 3590243 CASCADE KIT MASTER LMS...

  • Page 43: Flue System

    Component index Flue system Picture Art. code Description DN65 DN100 Line Line 3590313 CASCADE FLUE KIT BASIC DN150 LINE 3590314 CASCADE FLUE KIT EXTENSION DN150 LINE 3590315 CASCADE FLUE KIT BASIC DN200 LINE 3590316 CASCADE FLUE KIT EXTENSION DN200 LINE 3590317 CASCADE FLUE KIT BASIC DN150 3590318...

  • Page 44: Boiler Connection Kits

    Component index Boiler connection kits Picture Art. code Description Boiler type 80 100 120 140 3590284 CONNECTION KIT R40 EVO 70-80 LINE 3590285 CONNECTION KIT R40 EVO 100-140 LINE 3590286 CONNECTION KIT R40 EVO 70-80 B2B 3590287 CONNECTION KIT R40 EVO 100-140 B2B 3590288 CONNECTION KIT R40 EVO 70-80 LINE...

  • Page 45: Boiler Pumps

    Component index Boiler pumps Picture Art. code Description Boiler type 80 100 120 140 3590629 PUMP Yonos PARA 30/7,5 R40 EVO 3590630 PUMP Stratos PARA 30/1-9 R40 EVO 3590631 PUMP Stratos PARA 30/1-8 R40 EVO...

  • Page 46: Boiler Accessories

    Component index Boiler accessories Picture Art. code Description Boiler type 80 100 120 140 3590305 TAS GAS VALVE 3/4" 3590306 TAS GAS VALVE 1" 3590327 SAFETY VALVE TÜV 4 BAR R40 EVO 70-80 3590328 SAFETY VALVE TÜV 5 BAR R40 EVO 70-80 3590329 SAFETY VALVE TÜV 6 BAR R40 EVO 70-80...
  • Page 48 STOKVIS ENERGY SYSTEMS Unit 34 Central Park Estate 34 Central Avenue West Molesey Surrey KT8 2QZ Tel: 020 8783 3050 Fax: 020 8783 3051 E-Mail: info@stokvisboilers.com Website: www.stokvisboilers.com 420010768400 04/2016 – Doc195-V1.0...

This manual is also suitable for:

R40 evo 70R40 evo 80R40 evo 120R40 evo 140R40 evo 100

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