STOKVIS ENERGY SYSTEMS R40 Installation, Operation And Maintenance Manual
Gas-fired wall hung condensing boiler
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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
420010565400 12/2013
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Summary of Contents for STOKVIS ENERGY SYSTEMS R40
- 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...
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Page 2: Table Of Contents
Contents Contents ..............Safety General regulations ........Application ..........Norms and regulations ......Construction Layout of boiler .......... Operating principle ........Technical data ..............Extent of delivery Standard boiler .......... Accessories ..........Installation Boiler transport .......... Removing the casing ......... Boiler installation ........ -
Page 3: Safety General Regulations
Type C boilers of nominal heat input Household an similar electrical Application exceeding 70 kW, but not exceeding appliances: Particular requirements The R40 boiler may be used for heating 1000 kW for gas, oil and solid-fuel burning ap- and hot water production purposes ... -
Page 4: Construction Layout Of Boiler
Construction Layout of boiler Operating principle Layout of boiler The R40 boiler consists of the following main components: Casing Control panel Flue gas connection (+ test point) Air intake connection (+ test point) Flow water connection Return water connection Gas connection... -
Page 5: Technical Data
Technical data Nominal heat output at 80/60ºC max/min 45.7/7.7 60.8/10.1 81.1/13.4 92.9/15.6 111.6/18.7 132.2/23.3 Nominal heat output at 75/60ºC max/min 45.8/7.7 60.9/10.1 81.3/13.4 93.1/15.6 111.8/18.7 132.5/23.3 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 Nominal heat input Hi max/min 46.9/7.8 62.4/10.4 83.3/13.8... - Page 6 Technical data Dimensions R40/50 R40/85 R40/100 R40/120 R40/150 R40/65 R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2" R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2" R 3/4"...
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Page 7: Extent Of Delivery Standard Boiler
Plate heat exchanger (dT=10K/15K or dT=20K) incl. connection kit; The above accessories are specially designed for the R40 boiler and there- Low velocity header, suitable for with easy to install (plug and play). By dT=10K/15K and dT=20K incl. con- choosing a combination of the kits men- nection kit;... -
Page 8: Installation Boiler Transport
Installation Boiler transport Removing the casing Boiler transport The R40 boiler will be supplied as a complete unit being fully assembled and pre-tested. The packaging dimensi- on is 1050x572x575mm for boiler types 50-85 and 1185x674x665mm for boiler types 100-150, which makes it possible to transport all models through a normal door in one piece. -
Page 9: Boiler Installation
Installation Boiler installation Connecting the boiler Boiler installation The boiler should be positioned in a frost-proof boiler room. If the boiler room is on the roof, the boiler itself may never be the highest point of the instal- lation. When positioning the boiler, please note the recommended minimum clea- rance in the picture. - Page 10 Installation Connecting the boiler Flue gas connection (7) Electrical connection Regulations for the construction of flue The electrical connection must be gas systems are very different for each made by an authorized installer in country. It should be ensured that all accordance with the applicable national regulations with regard to flue national and local standards and re-...
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Page 11: Wiring Diagram - Boiler
Installation Wiring diagram - Boiler... -
Page 12: Wiring Diagram - Accessories
Installation Wiring diagram - Accessories... -
Page 13: Commissioning Water And Hydraulic System
VDI2035 standard. In the table you can find the nominal va- lues for filling and additional water for the R40 according to the the VDI2035. The table at the left gives an indication of the relation between the water quali-... -
Page 14: Gas Supply
Commissioning Gas supply Condensate connection Flue and air intake connections Gas supply Check the gas supply connection to the boiler for tightness. If any leakage is found, reseal the leakage before star- ting the boiler! Remove any air between the gas valve and the gas line. -
Page 15: Prepare Boiler For First Startup
Commissioning Prepare boiler for first startup Preparation for first startup Legend: On/off switch Open the gas supply; Return (ESC) Enable the power supply to the boiler; Room temperature control Confirmation (OK) Switch on the boiler with the on/off Manual mode switch (A);... -
Page 16: Combustion Analysis
Combustion check at full load for natural gas G20 / G25 Start the boiler in controller stop mode and go to 50% load. Now the boiler R40/50-150 operates at 50% load. Allow the boiler 8.5 ± 0.2 2, max to stabilise the combustion for 3 minutes. -
Page 17: Check Water Flow
(see table below for nominal data): = √(∆p / ∆p ) * q actual measured nominal nominal Water flow data R40/50 R40/65 R40/85 R40/100 R40/120 R40/150 Nominal flow rate ∆T at nominal flow rate [ºC] ∆p at nominal flow rate... -
Page 18: Check Functionality Of Safety Devices
Commissioning Check functionality of safety devices Gas tightness check Boiler shut down Check functionality of safety devices Gas tightness check All safety devices have to be checked Check the gas tightness of all sealed on good functioning. Safety devices on connections with an approved soap or a standard boiler are a water flow tem- electronic gas analyzer, for example:... -
Page 19: Commissioning Protocol
Commissioning Commissioning protocol Commissioning 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] Installati- Roof top Water pH Ground floor Water hardness [ºdH]... -
Page 20: Operating Instructions Controls
Operating instructions Controls Legend: On/off switch Return (ESC) Room temperature control Confirmation (OK) Manual mode Chimney sweeper mode Info mode Reset button Operation mode heating zone(s) Display Operation mode DHW Deaeration mode (E) Operation mode DHW (M) Confirmation (OK) (D) For switching on the DHW operation By pressing the manual mode button Return (ESC) (B) -
Page 21: Display / Programming
Operating instructions Display / Programming DHW mode selection Heating operation mode selection (Controller Stopp mode when pressing > 3 sec.) Display Info button Confirm 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 22: Overview Of Main Functions
Operating instructions = confirmation = cancel, return to main Overview of main functions menu 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 Confirm with OK button or wait 5 sec. -
Page 23: Maintenance Checklist
Maintenance Checklist Replacing the electrodes Maintenance of the boiler should be Replace the ignition and ionisation carried out by authorized personnel electrodes; only. Clean the condensate receptacle; Clean and refill the syphon; In order to ensure continued good and ... -
Page 24: Cleaning The Condensate Receptacle
Maintenance Cleaning the condensate receptacle Cleaning and refilling the syphon Inspection of combustion chamber Cleaning the condensate receptacle Disconnect the plug of the fluegas temperature sensor (1); Remove the condensate receptacle (2); Clean the receptacle; Mount the condensate receptacle; ... -
Page 25: Water Pressure And Quality
Maintenance Water pressure and quality Combustion analysis Gas tightness check Check if the water pressure and quality Check the combustion at full load and Check the tightness of all sealed con- meet the requirements. Consult the minumum load, correct the settings if nections with an approved soap or chapter “commissioning: water and necessary. -
Page 26: 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] Water ∆T full load [ºC]... -
Page 27: 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 possible cause. - Page 28 Lockouts Error Description of error code Configuration error collective message Internal error Parameterization error Unit manually locked Fan error LP error, does not close Error heating circuit flow switch LP error, does not open Alarm contact H1 or H4 active Alarm contact H2 (EM1, EM2 or EM3) or H5 active Alarm contact H6 active Alarm contact H3 or H7 active...
- Page 29 Lockouts Error Description of error code Solid fuel boiler pump Q10 not available Solid fuel boiler comparison sensor not available Solid fuel boiler address error Buffer return valve Y15 not available Puffer address sensor Primary controller / system pump address error Pressureless header address error Common flow sensor B10 not available Flow temperature 3 (heating circuit 3) supervision...
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Page 30: Sensor Values
Sensor values The diagrams show the sensor values NTC 10kΩ temperature sensor for all boiler sensors and optional sen- (flow, return, flue gas, DHW and header sensor) sors available in accessory kits. The diagrams contain average values, as all sensors are liable to tolerances. 60000 When measuring the resistance values, 55000... -
Page 31: 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 15420 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 34 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 420010565400 12/2013...
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