STOKVIS ENERGY SYSTEMS R3600 Manuel d'instructions

Stokvis R3400/R3600 Boiler

Gas-Fired

Floor Standing

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: [email protected]

Website: www.stokvisboilers.com

420010567700 12/2013

Contents

Contents .................................................................. ...................................................... 2

Safety General regulation ............................................................................................ 3

Application ........................................................................................................3

Norms and regulations .............................. ...................................................... 3

Construction Layout of boiler ................................................................................................. 4

Operating principle ........................................................................................... 4

Technical data ......................................................................................................................... 5

Extent of delivery Standard boiler ............................................................................................... 13

Accessories .................................................................................................... 13

Installation Transport ........................................................................................................ 14

Removing the casing ...................................................................................... 16

Boiler installation ............................................................................................ 17

Connecting the boiler ..................................................................................... 18

Commissioning Water and hydraulic system ........................................................................... 20

Gas supply ..................................................................................................... 21

Condensate connection .................................................................................. 21

Flue and air intake connections ...................................................................... 21

Prepare boiler for first startup ......................................................................... 22

Combustion analysis ...................................................................................... 23

Air pressure switch ......................................................................................... 24

Check water flow ........................................................................................... 25

Check functionality of safety devices ............................................................. 26

Gas tightness check ....................................................................................... 26

Boiler shut down ............................................................................................. 26

Commissioning protocol ................................................................................. 27

Operating instructions Main menu (operating mode) ........................................................................ 28

Parameter menu(information/programming mode) ........................................ 28

Changing parameter values ........................................................................... 28

Maintenance Checklist .........................................................................................................29

Replacing the electrodes ................................................................................ 20

Cleaning the condensate receptacle .............................................................. 30

Cleaning and refilling the syphon ................................................................... 30

Water pressure and quality ............................................................................ 30

Water flow rate ............................................................................................... 30

Combustion analysis ...................................................................................... 30

Gas pressure .................................................................................................. 30

Gas tightness check ....................................................................................... 30

Safety devices ................................................................................................ 30

Maintenance protocol .....................................................................................

Lockouts ....................................................................................................................... 32

Sensor values ....................................................................................................................... 34

Declaration of Conformity ....................................................................................................................... 35

Safety

General regulations

Application

Norms and regulations

General regulations

This documentation contains important

information, which is a base for safe

and reliable installation, commissioning

and operation of the R3400/R3600 boil-

er. All activities described in this docu-

ment may only be excecuted by author-

ized companies.

Changes to this document may be ef-

fected without prior notice. We accept

no obligation to adapt previously deliv-

ered products to incorporate such

changes.

Only original spare parts may be used

when replacing components on the

boiler, otherwise warranty will be void.

Application

The R3400/R3600 boiler may be used

for heating and hot water production

purposes only. The boiler should be

connected to closed systems with a

maximum temperature of 100ºC (high

limit temperature), maximum setpoint

temperature is 90ºC.

Norms and regulations

When installing and operating the

R3400/R3600 boiler, all applicable

norms (european and local) should be

fulfilled:

Local building regulations for in-

stalling combustion air and flue gas

systems;

Regulation for connecting the boiler to

the electrical appliance;

Regulations for connecting the boiler

to the local gas network;

Norms and regulations according to

safety equipment for heating systems;

Any additional local laws/regulations

with regard to installing and operating

heating systems.

The R3400/R3600 boiler is CE ap-

proved and applies to the following

European standards:

92 / 42 / EEC

Boiler efficiency directive

90 / 396 / EEC

Gas appliance directive

73 / 23 / EEC

Low voltage directive

89 / 336 / EEC

EMC directive

EN 656

Gas-fired central heating boilers –

Type B boilers of nominal heat input

exceeding 70 kW but not exceeding

300 kW

EN 15417

Gas-fired central heating boilers -

Specific requirements for condensing

boilers with a nominal heat input

greater than 70 kW but not exceeding

1000 kW

EN 13836

Gas fired central heating boilers -

Type B boilers of nominal heat input

exceeding 300 kW, but not exceeding

1000 kW

EN 15502-1

Gas-fired central heating boilers -

Part 1: General requirements and

tests

EN 55014-1

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 1: Emission

EN 55014-2

Electromagnetic compatibility - Re-

quirements for household appliances,

electric tools and similar apparatus -

Part 2: Immunity - Product family

standard

EN 61000-3-2

Electromagnetic compatibility (EMC) -

Part 3-2: Limits - Limits for harmonic

current emissions (equipment input

current 16 A per phase)

EN 61000-3-3

Electromagnetic compatibility (EMC) -

Part 3-3: Limitation of voltage chang-

es, voltage fluctuations and flicker in

public low-voltage supply

systems, for equipment with rated

current 16 A per phase and not sub-

ject to conditional connection

EN 60335-1

Household and similar electrical appli-

ances - Safety - Part 1: General re-

quirements

EN 50165

Household and similar electrical appli-

ances - Safety - Part 2-102: Particular

requirements for gas, oil and solid-

fuel burning appliances having electri-

cal connections

Construction

Layout of boiler

Operating principle

Layout of boiler

The R3400/R3600 boiler consists of the

following main components:

1 Return water connection

2 Flue gas connection

3 Water flow switch

4 Safety valve

5 Flow water connection

6 Filling/draining valve

7 Top plate

8 Plenum

9 Burner

10 1st Heat exchanger

11 Gas filter

12 2nd Heat exchanger

13 Gastrain

14 Frame

15 180° Bend

16 Compensator

17 Flue gas connection

18 Condensate receptacle

19 Flue gas receptacle

20 Combustion chamber

21 Entry electrical connections

22 Syphon

23 Main gas valve

24 Fan

25 Electrical box

26 Control panel

27 Casing

28 Air inlet damper

29 Butterfly valve

30 Main mixing channel

31 Pilot gas valve

32 Pilot mixing channel

33 Boiler pump

34 3rd Heat exchanger (only R3600)

A Air

B Gas

C Flue gasses

D Condensate

Operating principle

The R3400/R3600 is a fully modulating

boiler. The control unit of the boiler

adapts the modulation ratio automati-

cally to the heat demand requested by

the system. This is done by controlling

the speed of the fan. As a result, the

Whirlwind mixing system will adapt the

gas ratio to the chosen fan speed, in

order to maintain the best possible

combustion figures and therewith the

best efficiency. The flue gases created

by the combustion are transported

downwards through

The KM628 control unit can control the

boiler operation based on:

fixed temperature (stand alone

operation);

weather compensated operation (with

optional controller);

with 0-10V external influence

(temperature or capacity) from a buil-

ding management system.

the boiler and leave at the back side

into the chimney connection.

The return water from the system en-

ters the boiler in the lower section,

where is the lowest flue gas tempera-

ture in the boiler. In this section con-

densation takes place. The water is

being transported upwards through the

boiler, in order to leave the boiler at the

top (burner) section. The cross flow

working principle (water up, flue gas

down) ensures the most efficient com-

bustion results.

Technical data

Technical data R3401 - R3405

R3401 R3402 R3403 R3404 R3405

Nominal heat output at 80-60ºC max/min kW 656/164 733/183 857/213 971/242 1084/270

Nominal heat output at 75-60ºC max/min kW 657/164 734/183 858/213 972/242 1085/270

Nominal heat output at 40/30ºC max/min kW 663/181 741/202 867/236 981/268 1095/298

Nominal heat input Hi max/min* kW 702/176 784/196 917/229 1038/260 1159/290

Efficiency at 80/60ºC % 93.5

Efficiency at 40/30ºC % 94.5

Annual efficiency (NNG 75/60ºC) % 100.0

Annual efficiency (NNG 40/30ºC) % -

Standstill losses (Twater = 70ºC) % 0.2

Max. condensate flow l/h -

Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 64.5/16.2 71.9/18.0 84.1/21.0 95.2/23.8 106.3/26.6

Gas consumption L-gas max/min (8,34 kWh/m3) m3/h 84.3/21.1 94.0/23.5 109.9/27.4 124.4/31.2 139.0/34.8

Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 54.9/13.8 61.2/15.3 71.6/17.9 81.1/20.3 90.5/22.6

Gas pressure H-gas mbar 20 35

Gas pressure L/LL-gas mbar 25 35

Gas pressure LPG mbar 30/50

Maximum gas pressure mbar 100

Flue gas temperature at 80/60ºC max/min ºC 165/70

Flue gas temperature at 40/30ºC max/min ºC 135/60

Flue gas quantity max/min* m3/h 1423/356 1580/395 1848/462 2091/523 2334/584

CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3

CO2 level main burner liguid gas P max/min % 11.0/11.0

CO2 level pilot burner natural gas H/E/L/LL max/min % 10.0/10.2

CO2 level pilot burner liguid gas P max/min % 11.0/11.2

NOx level max/min mg/kWh 61.4/22.0

CO level max/min mg/kWh 9.8/3.3

Max. permissible flue resistance max/min Pa 150

Water volume l 50 53 70 75 80

Water pressure max/min bar 6/1

Max. water temperature (High limit thermostat) ºC 100

Maximum temperature setpoint ºC 90

Nominal water flow at dT=20K m3/h 28.5 31.6 37.0 41.8 46.8

Hydraulic resistance at nominal water flow kPa 46 53 36 43 50

Electrical connection V 400

Frequency Hz 50

Mains connection fuse A 16 20

IP class - IP20

Power consumption boiler (excl. pump) W 900 900 1270 1270 1270

Power consumption 3-step pump (optional) W

Weight (empty) kg 675 740 840 950 1070

Noise level at 1 meter distance dB(A) 64

Ionisation current minimum µA 6

PH value condensate - 3.2

CE certification code - CE-0063AR3514

Water connections - DN65 PN16 DN80 PN16

Gas connection - R 2” DN65 PN16

Flue gas connection mm 300 350 400

Air intake connection (for room sealed use) mm 250 300 355

Condensate connection mm 40

980 1010 1020 1450 1500

Technical data

Technical data R3406

R3406

Nominal heat output at 80-60ºC max/min kW 1196/298

Nominal heat output at 75-60ºC max/min kW 1197/298

Nominal heat output at 40/30ºC max/min kW 1209/329

Nominal heat input Hi max/min* kW 1279/320

Efficiency at 80/60ºC % 93.5

Efficiency at 40/30ºC % 94.5

Annual efficiency (NNG 75/60ºC) % 100.0

Annual efficiency (NNG 40/30ºC) % -

Standstill losses (Twater = 70ºC) % 0.2

Max. condensate flow l/h -

Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 117.3/29.3

Gas consumption L-gas max/min (8.34 kWh/m3) m3/h 153.4/38.4

Gas consumption LPG. max/min (12.8 kWh/kg) kg/h 99.9/25.0

Gas pressure H-gas mbar 35

Gas pressure L/LL-gas mbar 35

Gas pressure LPG mbar 30/50

Maximum gas pressure mbar 100

Flue gas temperature at 80/60ºC max/min ºC 165/70

Flue gas temperature at 40/30ºC max/min ºC 135/60

Flue gas quantity max/min* m3/h 2578/645

CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3

CO2 level main burner liguid gas P max/min % 11.0/11.0

CO2 level pilot burner natural gas H/E/L/LL max/min % 10.0/10.2

CO2 level pilot burner liguid gas P max/min % 11.0/11.2

NOx level max/min mg/kWh 61.4/22.0

CO level max/min mg/kWh 9.8/3.3

Max. permissible flue resistance max/min Pa 150

Water volume l 85

Water pressure max/min bar 6/1

Max. water temperature (High limit thermostat) ºC 100

Maximum temperature setpoint ºC 90

Nominal water flow at dT=20K m3/h 51.6

Hydraulic resistance at nominal water flow kPa 58

Electrical connection V 400

Frequency Hz 50

Mains connection fuse A 20

IP class - IP20

Power consumption boiler (excl. pump) W 1270

Power consumption 3-step pump (optional) W 1500

Weight (empty) kg 1200

Noise level at 1 meter distance dB(A) 64

Ionisation current minimum µA 6

PH value condensate - 3.2

CE certification code - CE-0063AR3514

Water connections - DN80 PN16

Gas connection - DN65 PN16

Flue gas connection mm 400

Air intake connection (for room sealed use) mm 355

Condensate connection mm 40

Technical data

Dimensions R3401 - R3406

Dimensions R3401 R3402 R3403 R3404 R3405 R3406

L mm 2265 2265 2653 2653 2658 2658

L1 mm 595 595 610 615 615 770

L2 mm 700 700 1166 1166 1166 1166

L3 mm 108 108 88 88 88 88

H mm 1355 1355 1355 1355 1355 1355

H1 mm 1125 1125 1570 1420 1155 1377

B mm 1330 1330 1130 1130 1330 1330

B1 mm 1160 1210 1003 1053 1203 1253

B2 mm 665 665 565 565 665 665

B3 mm 170 120 127 77 127 77

B4 mm 1146 1146 946 946 1146 1146

B5 mm 115 65 115 65 115 65

D mm 300 350 350 400 400 400

W DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16

G R R 2" R 2" R 2" R 2" DN65 PN16 DN65 PN16

Technical data

Technical data R3600 - R3605 Standard

R3600 R3601 R3602 R3603 R3604 R3605

Nominal heat output at 80-60ºC max/min kW 572/142 639/182 747/212 846/241 945/269 1043/297

Nominal heat output at 75-60ºC max/min kW 576/144 643/184 753/215 852/243 952/272 1050/300

Nominal heat output at 40/30ºC max/min kW 602/159 672/203 786/237 890/268 994/300 1097/331

Nominal heat input Hi max/min* kW 585/146 653/187 764/218 865/247 966/276 1066/305

Efficiency at 80/60ºC % 97.8

Efficiency at 40/30ºC % 102.9

Annual efficiency (NNG 75/60ºC) % 105,1

Annual efficiency (NNG 40/30ºC) % 109,8

Standstill losses (Twater = 70ºC) % 0,3

Max. condensate flow l/h -

Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 53.7/13.4 59.9/17.1 70.1/20.0 79.4/22.7 88.6/25.3 97.8/27.9

Gas consumption L-gas max/min (8,34 kWh/m3) m3/h 70.3/17.6 78.3/22.4 91.6/26.2 103.7/29.6 115.8/33.1 127.8/36.5

Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 45.7/11.4 51.0/14.6 59.7/17.1 67.6/19.3 75.5/21.6 83.3/23.8

Gas pressure H-gas mbar 20

Gas pressure L/LL-gas mbar 25

Gas pressure LPG mbar 30/50

Maximum gas pressure mbar 100

Flue gas temperature at 80/60ºC max/min ºC 85/65

Flue gas temperature at 40/30ºC max/min ºC 59/36

Flue gas quantity max/min* m3/h 969/242 1076/307 1258/359 1424/407 1590/454 1756/502

CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3 10.0/9.3

CO2 level main burner liguid gas P max/min % 11.0/11.0 11.0/11.0

CO2 level pilot burner natural gas H/E/L/LL max/min % - 10.0/10.2

CO2 level pilot burner liguid gas P max/min % - 11.0/11.2

NOx level max/min mg/kWh 32.3/18.8 11.5/19.5

CO level max/min mg/kWh 8.2/10.9 27.3/6.5

Max. permissible flue resistance max/min Pa 100 150

Water volume l 69 73 97 104 110 117

Water pressure max/min bar 6/1

Max. water temperature (High limit thermostat) ºC 100

Maximum temperature setpoint ºC 90

Nominal water flow at dT=20K m3/h 24,7 27,6 32,2 36,5 40,8 45,0

Hydraulic resistance at nominal water flow kPa 48 56 38 45 53 60

Electrical connection V 400

Frequency Hz 50

Mains connection fuse A 10 16 20

IP class - IP20

Power consumption boiler (excl. pump) W 420 900 1270

Power consumption speed controlled pump (optional) W

Weight (empty) kg 810 890 1040 1150 1280 1410

Noise level at 1 meter distance dB(A) 64

Ionisation current minimum µA 6

PH value condensate - 3.2

CE certification code - CE-0063AR3514

Water connections - DN65 PN16 DN80 PN16

Gas connection - R 2” DN65 PN16

Flue gas connection mm 300 350 400

Air intake connection (for room sealed use) mm 250 300 355

Condensate connection mm 40

471 616 561 661 867 956

Power consumption 3-step pump (optional) W 940 980 1020 1400 1450 1500

Technical data

Dimensions R3600 - R3605 Standard

Dimensions R3601 R3602 R3603 R3604 R3605

L mm 2265 2653 2653 2658 2658

L1 mm 595 610 610 615 615

L2 mm 590 1166 1166 1166 1166

L3 mm 198 88 88 88 88

H mm 1405 1405 1405 1405 1405

H1 mm 1175 1450 1450 1205 1427

B mm 1330 1130 1130 1330 1330

B1 mm 1210 1003 1053 1203 1253

B2 mm 665 565 565 665 665

B3 mm 120 127 77 127 77

B4 mm 1146 946 946 1146 1146

B5 mm 65 115 65 115 65

D mm 300 350 350 400 400

W1 DN DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16

G R R 2" R 2" R 2" DN65 PN16 DN65 PN16

R3600

1958

595

700

108

1355

970

1230

1110

615

120

1046

100

300

DN65 PN16

R 2"

D1 mm 250 250 300 300 355 355

W2 DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels STOKVIS ENERGY SYSTEMS Chaudière

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS REX F Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R6000 LMS Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R2000 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOPAK R2000 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R2700 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R600 Series Manuel d'instructions

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R6142 Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R30 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ARES Tec 150 Manuel d'instructions

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOPLATE H1 Guide de l'utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R6000 Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R600 Series Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOPLATE H1 Guide de l'utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R3500 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R600 Series Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R1 Series Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R2700 Manuel du propriétaire

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOPLATE H1 Guide de l'utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS R601 Manuel d'instructions

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS Evolution Series Manuel utilisateur

STOKVIS ENERGY SYSTEMS

STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Manuel utilisateur

Manuels Chaudière populaires d'autres marques

Vaillant

Vaillant uniSTOR VIH SW GB 500 BES Manuel utilisateur

Radijator

Radijator BIO max 23.1 Manuel utilisateur

Brunner

Brunner BSV 20 Manuel utilisateur

Buderus

Buderus Logamax GB062-24 KDE H V2 Manuel utilisateur

Potterton

Potterton 50e Fiche technique

UTICA BOILERS

UTICA BOILERS TriFire Manuel utilisateur

Joannes

Joannes LADY Series Manuel

ECR International

ECR International UB90-125 Manuel d'instructions

Froling

Froling FHG Turbo 3000 Manuel utilisateur

Froling

Froling P4 Pellet 8 - 105 Manuel utilisateur

U.S. Boiler Company

U.S. Boiler Company K2 Manuel utilisateur

Henrad

Henrad C95 FF Manuel utilisateur

NeOvo

NeOvo EcoNox EF 36 Manuel utilisateur

Potterton

Potterton PROMAX SL 12 Manuel utilisateur

Eco Hometec

Eco Hometec EC 25 COMPACT Manuel utilisateur

Viessmann

Viessmann VITODENS 200 Mode d’emploi

Baxi

Baxi Prime 1.24 Manuel utilisateur

REXNOVA

REXNOVA ISA 20 BITHERMAL Manuel utilisateur