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Econoflame R3400/R3500/R3600SB Boilers Installation Operation

1. Fig 29 Installation with multiple appliances Hydraulic short circuit In order to avoid a short circuit over a non operating appliance we advise the use of non return valves These may be either mechanically or electrically operated valves see 5 4 2 4 28CV02 546007BE 3456CV02A Installations with multiple appliances without non return valves The total resistance of the system boiler isolating valves and pipework will be much greater than the resistance of the low velocity header The baffles X see fig 30 prevent undesirable circulation through the non operating boiler When 2 appliances are switched in cascade it is advisable to employ this system When appliances are controlled by a building optimising system using weather compensation or a compensating unit the common flow temperature sensor must be mounted at the common flow pipe as indicated in the drawing 28CV02 546008AE x
2. Fig 14 Roof installation i Ne gt SES PN a CAU f A Fig 15 Loft installation 3456CV02A 5 2 3 5 3 5 3 1 5 3 2 Ventilation Connections Gas connection Electrical connection The ventilation of the boiler room must satisfy the applicable national and local standards and regulations see supplement 523001BE 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 protection for any mechanical ventilation b Ensure that the air inlet openings are transversely placed in two opposite walls Fit inlet gratings with a large width and a small height Ensure that the correct amount of high level ventilation exists e Ifthe air supply is inadequate it may be necessary to fit a mechanical means of providing adequate ventilation 523002BE ao The gas connection must be made by a recognised installer in accordance with the applicable national and local standards and regulations see supplement The gas connection is made at the rear of the boiler Types R3401 R3402 R3501 R3505 and R3601SB R3605SB are not suitable for immediate connection to a 100 mbar natural gas system as option 100 mbar The pressure o
3. re 4 __ The Econoflame R3600SB The R3400 and R3500 are identical with the exception of the third heat exchanger 3456CV02A 2 2 Main components 1 Return connection 2 Flue attentuator 3 Water flow switch 4 Safety valve 5 Flow connection 6 Filling drainage valve 7 Cover 8 Distribution plate 9 Burner 10 First heat exchanger 11 Gas filter 12 Second heat exchanger 13 Gas train 14 Frame 15 Water circulation piping 16 Flue gas discharge 17 Third heat exchanger R3600SB 3456CV02 220001AE 18 Condensate collection tank 19 Flue gas collection chamber 20 Combustion chamber 21 Electrical cable duct 22 Condensate discharge 23 Gas valve unit 24 Fan 25 Connection box 26 Control panel 27 Casing 28 Air inlet damper 29 Main mixing chamber 30 Pilot gas valve 31 Pilot mixing chamber 32 Boiler pump A Air B Gas C Flue gas D Condensate al BR ON ON 0 11 12 13 14 15 16 17 18 Fig 5 General survey 3456CV02A 2 2 1 Description of The unit is constructed from the following principal principal components components Fan 24 This consists of a fan casing a fan impeller and an electric motor The fan sucks in combustion air and increases the air pressure Air inlet damper 28 A specially
4. Type R3401 R3402 R3403 R3404 R3405 R3406 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 Rp2 Rp2 Rp2 Rp2 DN65 PN16 DN65 PN16 mm 1355 1355 1355 1355 1355 1355 H1 mm 1125 1125 1570 1420 1155 1377 L mm 2265 2265 2653 2653 2658 2658 Li mm 595 595 610 615 615 770 L2 700 700 1166 1166 1166 1166 L3 mm 108 108 88 88 88 88 W DN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN8o PN6 Table2 Dimensions R3400 Changes may be introduced without notice As a result of manufacturing tolerances there may be small variations in the dimensions Conditions applicable to table 1 Nominal capacity measured at Gas consumption at Gas category Appliance category Protection degree DOC2005 3456en 3456CV02A19 10 09 60 80 C 1013 mbar 15 C dry ToH3P B23 C53 C33 of C63 IP20 DIM IV R3500 Technical data Type R3501 R3502 R3503 R3504 R3505 Nominal heat output kW 613 77 811 906 1000 Nominal heat input nett CV kW 653 764 865 966 1066 Minimum heat input kW 187 218 247 276 305 Pilot burner kW 30 30 30 30 30 Gas consumption natural gas H 10 9 kWwh m3 m3 h 59 9 704 79 4 88 6 97 8 propane 12 8 kwh kg kg h 51 0 59 7 67
5. llus 34 Pump characteristics o o oooo o 36 Isolating valves llle 37 Valves 1d a we TT A 37 Water flow protection o oooooooooo 37 Water pressure ada srta ari dati ca qo Eee 38 Operating pressure eaa dritte titre 38 Boiler expansion taMk o oooooccooooooo o 38 System expansion tank oooooooo ooo 38 Water pressure protection 38 Water temperature 25 0 sad ce heh n ce teta cen 38 Water quality 22 2 aurca ah d ated ARIAS 38 Examples of hydraulic systems 40 OPERATING INSTRUCTIONS 44 FUNCI N 33x ad aa A RUE CAE RACER 44 Regulation insere ere ee dae oem rei ins 44 Control module lt a re 44 Fault indications sea cas lee wee eee tk a 47 StartUp 2 5 ace cd aam gore dod ag ne Gh gid GR RAT Ga o y 48 SNUAOWN sensin ect tutt dete bab oh ded ees 48 WAFPIDIgS cure eei tnt ortnm dnd laa dh rid mx 48 COMMISSIONING eeeeess 49 General agat dates cates late uecatenz eaten eatem es 49 COMMISSIONING 6 53 594555463 ERE RR ERES 49 MAINTENANCE 2 2ccverebesebere bere bere bei 52 Safely s Piatt edie ee asia ed Sa tiea Rd fuos 52 General Pc 52 A ore dax E EIC Qd Y GO Oe 4 52 Cleaning the burner and heat exchangers 53 Cleaning the filter screen in the gas combination block ooo ooooooooo 54 lonisation measurement o oooocccoc 54 SEVICE n Le ace REI IER DUC Et
6. o o o occoo ee eee 5 2 2 1 Description of principal components 6 2 3 Boller contem gai recie etes tote AIO ERIS cada 8 2 4 Safety aspects uee eee aea custodie atu ADA 8 3 SAFETY catas a E aaa 9 4 DELIVERY AND TRANSPORT 12 4 1 BUITE A E E Es 12 4 2 Packa ing 54 3 quai dad or ao da 12 4 3 Transport 3 3415 1 42 303 128 eats UC QU QR AR Aa 12 5 INSTALLATION 6 iet Te s D e Rc Ps RP 17 5 1 FREQUIATIONS ia erg E Be aaa 17 5 2 Bolle TODITEs zs ree mere ida Gade mate 17 Scr Senmerall bs uc iub seas e Db ced daa d 17 NS RD 17 D23 Menu lO o2 2595 ct a o oc 19 5 3 CONNECIONS TL eee teeters 19 5 3 1 Gas connection gee cuu ceu etes ere Rus dadas aa de 19 5 3 2 Electrical connection o ooooooo ooo 19 5 3 3 Water connections 4 24 5 3 4 Combustion air supply ooooo 25 Dx General Z zdasestdu uec ei 25 5 3 4 2 Air supply pipe 34 sx assa aa aaa 26 5 3 5 The flue system Llluu s 28 53 0 General erea rs ees Sates 28 A O AA aea TR C RESTER EE 31 5 3 6 Condensate discharge o o o oooooooooo 33 3456CV02A XI XII 5 4 5 4 1 5 4 2 5 4 2 1 5 4 2 2 5 4 2 3 5 4 2 4 5 4 2 5 5 4 3 5 4 3 1 5 4 3 2 5 4 3 3 5 4 3 4 5 4 4 5 4 5 5 4 6 6 6 1 6 2 6 3 6 4 6 5 6 6 6 7 7 T 1 7 2 8 8 1 8 2 8 3 8 4 8 5 8 6 8 7 9 Hydraulic system oia es 34 Generals la 34 Water flow A ed SCRIBE t D IL te eG 34 Flow rate and resistance
7. 400 12 6 1 10 9 4 8 17 1 R3605SB 350 12 5 6 10 2 4 2 15 3 400 13 6 1 10 9 4 8 17 1 Table 11 Chimney losses in metres of straight pipe T5007BE Connection at boiler 3456CV02A 5 3 6 Condensate discharge AR Example A chimney 300 mm for an R3401 requires 5 m of straight pipe and 4 elbows 45 supplied by manufacturer x These elbows have an equivalent pipe length resistance of 3 7 m each table 11 The total losses will be equivalent to 5x1 5 m 4 x 3 7 148 m total 198 mof pipe The maximum allowed is 56 m this flue is acceptable table 10 Condensate that forms in the appliance must be discharged to a drain If there is no direct connection to a drain present a water collection tank with a pump and a level switch may be used so that the condensate can be pumped into a drain The discharge of condensate into roof guttering is not permitted The appliance is fitted with a water trap which prevents flue gasses from entering the boiler room 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 Ensure that the distance between the condensate discharge point of the boiler trap and the drainage pipe is at least 5 mm This provides the required open connection and simplifies any subsequ
8. 6 75 5 83 3 Gas inlet pressure natural gas H min max mbar 18 25 18 25 18 25 18 25 18 25 natural gas H max option mbar 100 100 100 100 100 propane min max mbar 30 50 30 50 30 50 30 50 30 50 Water capacity dm 53 70 75 80 85 Max working pressure bar 6 6 6 6 6 Gas connection G Rp2 Rp2 Rp2 DN65 PNI16 DN65 PN16 Water connections W DN65 PN6 DN80 PN6 DN8o PN6 DN80 PN6 DN80 PN6 Flue connection D mm 300 350 350 400 400 Safety valve connection 1 4 14 172 15 175 relief connction 15 15 2 2 2 standard setting bar 3 3 3 3 3 Power supply V 400 3N 400 3N 400 3N 400 3N 400 3N Frequency Hz 50 50 50 50 50 Fuse A 16 16 20 20 20 Max electrical power consumption unit kW 0 90 0 90 1 27 1 27 1 27 pump maximum kW 1 15 1 15 1 15 1 50 1 50 total kW 2 05 2 05 2 42 2 77 2 77 Boiler weight empty 5 96 kg 740 840 950 1070 1200 Dimensions height H mm 1355 1355 1355 1355 1355 width B mm 1330 1130 1130 1330 1330 length incl connections L mm 2265 2653 2653 2658 2658 Table 3 Technical data R3500 DOC2005 3456en 3456CV02A19 10 09 Dimensions R3500 front view Fig 2 Dimensional sketch R3500 plan view pu side view DOC2005 3456en 3456CV02A19 10 09 VL Type R3501 R3502 R3503 R3504 R3505 B mm 1330 1130 1130 1330 1330 B1 mm 1210 1003 10
9. 9 377 L CO 0 009 x AT 2 For condensing boilers As a result of condensation the efficiency at the lower value increases 0 339 0 008 X AT A 7 5 0 006 AT 2 ny 90 ny ny71 11 AT Difference in temperature between the flue gasses and the environmental temperature n Fuel efficiency at the upper calorific value n Fuel efficiency at the lower calorific value CO The volume of CO in the flue gas 96 O The volume of O in the flue gas 96 A The quantity of condensed water in the appliance per m gas in kg kg m 900001DE 3456CV02A megl l dH of e mg CaCOyl meg 1 2 8 5 3 51 50 dH 0 37 1 1 78 1 25 17 8 of 0 2 0 56 1 0 7 10 e 0 285 0 8 1 43 1 14 3 mg CaCOyl 0 02 0 056 0 1 1 54 1 Table 18 Conversion of degrees of hardness 1 degree English hardness e 1 Grain US Gallon 1 milligramme equivalent per mval l 1 ppm parts per million CaCO T9014AE For information 65 mg CaCO imp gallon 0 958 dH 2 8 dH 1 mg CaCO l The public water supply in general has a pH value of approximately 7 8 The temporary hardness will be 60 to 80 of the total hardness which can vary considerably from one place to another 900002BE 3456CV02A 57 SUPPLEMENT At the time of printing the following regulations and standards were taken into account British Standard 1 BS 5440 Parts 1 2 flueing and ventilation 2
10. BS 6644 Installation of gas fired water heaters 60 kW 2 MW 3 BS 6700 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages 4 BS 6891 Installation of low pressure gas pipework The following British Gas publications may be helpful IM 2 Purging procedures of non domestic gas installations IM 5 Soundness testing procedures for industrial and commercial gas installations IM 11 Flues for commercial and industrial gas installations IM 16 Guidance notes on the installation of gas pipework boosters and compressors Any other requirements currently in force The following regulations should also be taken into consideration Gas Safety Installation and Use Regulations Building Regulations Local fire regulations Regulations from the local gas distribution agency Local water bylaws 221P22 000002AE 3456CV02A
11. Moderately hard approx 160 250 ppm Hard and very hard over 250 ppm 545003AE The system must contain soft to moderately hard water with a water hardness not exceeding 250 ppm with a supply temperature of 80 C and AT 20 K 28CV02 545004AE Before the water is topped up the hardness and the chloride content of the water must be determined During the construction of larger installations one of the appliances may be operational New circuits may be regularly switched in which must occur together with the addition of fresh water In addition it can happen that because of leakage some circuits must be disconnected repaired and re filled In these circumstances the only appliance in operation often functions at full capacity and the chance of boiler scale formation is present For this reason the make up water must be softened To ensure proper functioning of the appliance and the system the use of water softeners is recommended Large stationary bubbles with widely different compositions can form at dead points in the system in addition to oxygen and nitrogen hydrogen and methane have also been detected Oxygen promotes corrosion Corrosion products together with other pollutants form a sludge deposit magnetite which causes pitting under the influence of oxygen The use of an air separator with an automatic de aerator is strongly recommended This should preferably be fitted in a horizontal section of the return pipe to
12. R3601 1010 1310 160 150 R3403 R3502 R3602 1420 1010 160 200 R3404 R3503 R3603 1420 1110 160 200 R3405 R3504 R3604 1420 1210 160 210 R3406 R3505 R3605 1420 1310 160 210 Fig 9 Dimensions and weights of burner and heat exchanger Flue gas collection chamber Type L mm B mm H mm m kg R3401 1320 990 400 25 R3402 R3501 R3601 1450 1070 400 25 R3403 R3502 R3602 1950 770 400 lt 35 R3404 R3503 R3603 1950 870 400 lt 35 R3405 R3504 R3604 1950 970 400 lt 35 R3406 R3505 R3605 1950 1070 400 lt 35 Fig 10 Dimensions and weights of the flue gas collection chamber 3456CV02A R3600SB only AN Third heat exchanger Type L mm B mm H mm m kg x R3601SB 1010 1310 160 150 c E R3602SB 1420 1010 160 200 s DRAWING NOT R36035B 1420 1110 160 200 A PS di R3604SB 1420 1210 160 210 R3605sB 1420 1310 160 210 Fd e Fig 11 Dimensions and weights of the third heat exchanger Frame Type L mm B mm H mm m kg R3401 1325 1165 460 50 Ww R3402 R3501 R3601 1630 1266 500 60 R3403 R3502 R3602 2004 1066 500 70 H R3404 R3503 R3603 2004 1066 500 70 R3405 R3504 R3604 2004 1266 500 70 x R3406 R3505 R3605 2004 1266 500 70 Fig 12 Dimensions and weights of the frame Positioning Once the unit is in the correct position the
13. Type Flue gas Flue gas quantity at full Maximum temperature capacity permissible at full capac chimney ity approx resistance e m h kg s mbar R3401 165 1423 0 330 1 5 R3402 165 1580 0 367 1 5 R3403 165 1848 0 428 1 5 R3404 165 2091 0 485 1 5 R3405 165 2334 0 541 1 5 R3406 165 2578 0 598 1 5 R3501 155 1287 0 306 1 5 R3502 155 1505 0 357 1 5 R3503 155 1703 0 404 1 5 R3504 155 1901 0 451 1 5 R3505 155 2099 0 498 1 5 R3601SB 85 1076 0 306 1 5 R3602SB 85 1258 0 357 1 5 R3603SB 85 1424 0 404 1 5 R3604SB 85 1590 0 451 1 5 R3605SB 85 1756 0 498 1 5 Table 9 Flue gas data Capacity 100 Flow temperature 80 C Return temperature 60 C 34CV01 T5005AN Chimney length Because the appliance is fitted with a premix burner with a fan an over pressure is built up in the unit This over pressure is sufficient to overcome the resistance of the cooled burner heat exchangers air intake and chimney upto a maximum of 1 5 mbar external to the boiler 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 535201CE 3456CV02A 29 30 A The flue connection diameters of the units have been chosen such that the speed of the flue gas will always be appro
14. between the boiler and the low velocity header must be chosen such that the remaining working head of the pump see table 12 will not be exceeded 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 terminals A properly dimensioned low velocity header ensures that the natural flow through the boiler can be neglected 28CV02 533003CE The unit can optionally be supplied as a room sealed appliance This simplifies the possibilities for installation within the building Guide lines and installation instructions The flue gas discharge and the air supply systems must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations The total resistance of the air supply and the flue may not result in a pressure drop exceeding 1 5 mbar If the unit is used as a room sealed appliance open tees or draught stabilisers are not permitted 3456CV02 534101BE 3456CV02A 25 26 5 3 4 2 Air supply pipe The air supply pipe may be single walled and constructed of plastic thin walled aluminium flexible aluminium take account of
15. boiler resistance table 12 At full capacity the water flow rate can be very accurately compared with the AT measured across the flow and return of the boiler 542102BN The unit has a standard pump control When the boiler is enabled the pump is switched on When the enable signal is removed the pump will continue to run on for several minutes This run on time is adjustable The standard time is 2 minutes 34CV02 542103BE 3456CV02A 35 5 4 2 2 Pump characteristics 36 When the system includes air heaters ventilation air treat ment it is usually desirable to have a small AT over these components Because of this the quantity of water flowing through the total secondary circuit is usually greater than that flowing through the boiler units The low velocity header must be dimensioned such that the water speed does not exceed 0 5 m s In this case the diameter of the header must be calculated for the water volume flowing through the secondary circuit When the water volume flowing through the secondary circuit is great er than that flowing through the primary circuit a mixed temper ature will exist which is lower than the desired temperature of the supply from the appliance The regulation system reacts to this and opens the control devices valves etc Usually the supply temperature from the boiler s must be adjusted to obtain the desired temperature in the connected circuits 542104DE For additional energy savings a
16. boiler will run at low capacity S amp I manual high capacity the boiler will run at full capacity Information mode cover open 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 The following parameters are readable Parameter P1 actual flow temperature P2 actual direct hot water temperature if used P3 set point temperature set load with KKM8 fitted P5 actual outside temperature if used P8 temperature at the low velocity header if used P9 actual boiler capacity P10 only for trained service engineers Summary of input and output indications cover open Input indications gt Flame lonisation detected SW Water flow switch in operating position DW APS in operating position RT Boiler enabled by BMS Bus Data bus detected Output indications Na Power to Main Gas Valve 4 Power to Ignitor C7 Control signal to fan Power to Primary Boiler Pump E Power to Primary DHW Pump 3456CV02A 45 46 Setting the flow temperature for Central Heating cover open Only applicable to boilers without weather compensated flow temperature or a 0 10 Volt control signal N B Only applicable if outside temperature compensation or a 0 10 V signal is not used Open the l
17. developed air inlet damper ensures a low noise level As an option this can be provided with an air filter or with an air inlet opening so that the appliance can function as a room sealed appliance Gas train 13 The principal component of the gas train is the main gas valve proportional pressure regulator 23 The quantity of gas is adjusted in proportion to the quantity of air being supplied The quantity of air depends on the speed of the fan The unit is fitted with a gas filter 11 as standard Mixing chamber 29 31 This area is used for the thorough mixing of the gas and the combustion air The unit is supplied with a main mixing cham ber 29 and a pilot mixing chamber 31 Both are connected to the fan Burner 9 After the gas air mixture has been distributed over the burner with the aid of a distribution plate 8 the mixture is burned on the surface of the burner in such a way that the flame is di rected downward The burner is air and water cooled The water distribution components are made from cast iron and have a profile that ensures that an optimum distribution and flow are obtained Heat exchangers 10 12 and 17 The primary heat exchanger 10 is constructed from smooth stainless steel tubes These transfer most of the heat energy to the system water The secondary heat exchanger 12 which consists of laser welded stainless steel finned tubes transfers the remaining heat from the flue gasses to the syst
18. ensure that all panels are replaced 300003DE Safety provisions The installation may never by switched on if any of the panels have been removed or if any of the safety devices have been disabled 300004DE Instruction and warning stickers None of the instruction and warning stickers attached to the installation may be removed or covered and during the whole of the lifetime of the installation they must remain legible Replace any damaged or unreadable instruction and warning stickers immediately 300005AE Modification Modifications to the installation may only be carried out with the written approval of the manufacturer 300006AE 3456CV02A 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 300007AE Installation The appliance must be installed by an authorised installer in accordance with the applicable national and local specifications and regulations Carefully follow all the safety instructions 300008BE Operation In the event of a gas leak switch off the unit and close the gas supply valve Open doors and windows and warn the appropri ate authorities When the installation is re commissioned always follow the instructions for use Technical specifications The specifications listed in this technical manual cannot be ignored 300009BE 3456CV02A 11 4 1 4 2
19. glass Test the unit at the flue gas side for CO and CO and correct these at both full and minimum capacity if necessary Check all the safety functions and make any necessary adjustments Measure the water temperature difference AT as a measure of the flow rate Check the water pressure Check the water quality hardness and chloride content Record all data Clean the outside of all the panels and ensure that these all have a smart appearance 820001AE a Disconnect the power supply b Close the gas supply valve 830001BE The ignition and ionisation electrodes are fitted at the rear of the appliance Remove the spark plug caps from the ignition and ionisation electrodes and inspect them for possible damage such as indications of burning or pollution renew the spark plug caps if damaged 3456CV02A 8 4 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 This will result in the air supply being reduced and the fan becoming unbalanced Clean the fan blades with a brush All loose dirt can be removed in this Way A trap is fitted under the condensate collection tank Unscrew the trap and clean it A gas filter is fitted at the start of the ga
20. observed If the source of the fault cannot be found the service organisa tion 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 Drain the water out with the aid of the filling drainage valve The user must never make any modifications to the appliance or the discharge system Annual checking and good maintenance are necessary in order to guarantee optimum performance 28CV02 670001BE 3456CV02A 7 1 7 2 General Commissioning COMMISSIONING Commissioning must be carried out by skilled personnel Fail ure to observe this condition will invalidate the guarantee 710001BE 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 The water hardness must be less than 250 ppm If the measured hardness is too high the water must be softened Determine the concentration of chloride in the system water This may never exceed 200 mgll If this concentration is ex ceeded the system must be flushed through and re filled with low chloride water Check the pressure of the system water This must have at least the minimum value given in table 14 Operating pressures Check that there is a bypass or a low velocity header fitted in the hyd
21. requirements Water analysis forms can be obtained from the supplier 545008BE The hydraulic systems shown are only examples They must not be employed in practice without professional analysis 546000AE Low velocity header The low velocity header must be dimensioned such that at full capacity the pressure difference between the supply to the flow and the return collector does not exceed 50 mmwg approxi mately 0 5 m s The diameter of the low velocity header can be determined using the formula Q 3600 V x 1 28 Where the diameter of the low velocity header in m Q the water flow rate in m h of the boiler circuit or the secondary circuit whichever is the greater v the speed in m s 28CV02 546001AE 3456CV02A Example of a low velocity header with isolating valves and an expansion tank eo A Fig 27 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 separa tor and the lower section serves as a dirt separator When air heaters for ventilation or air treatment are included in the system it is generally desirable to have a small AT over the air heaters Because of this the water flow rate through the whole secondary circuit is usually greater than that through the boilers The low velocity header must be so dimensioned such that the
22. the fault mode Re instate the connection and press the reset push button 30 31 External sensor After a suitable sensor has been connected it will be automatically recognised when the power supply is switched on 32 33 Low velocity header sensor This sensor can mea sure the temperature of a low velocity header This is used for the control of a speed controlled pump 35 36 Calorifier temperature sensor After a suitable sen sor has been connected it will be automatically re cognised when the power supply voltage is switched on The terminals 35 36 must not be intercon nected The purpose of this function in comparison with the calorifier thermostat is to make possible a night time temperature reduction and an anti legionella switching only with BME E6 or KKM 3456CV02A 23 5 3 3 24 Water connections 37 38 External influence 2 10 VDC 10 C 90 C At voltages below 2 V the boiler will switch to constant supply temperature operation 39 40 Output capacity signal This signal provides infor mation for a capacity display 0 100 1 10 VDC The maximum current is 0 5 mA For higher currents or long connecting wires 25 m the use of a signal amplifier is recommended 41 42 Bus connection 43 44 Primary boiler pump control 0 10 Vdc not applicable for R3400 series boilers 12 OK signal This output provides 230 V if everything is functioning normally If there is a boiler fault the termin
23. to provide any further or supplemental information 3456CV02A 1 1 4 1 5 Service General restrictions The following aspects of the units are dealt with General description Technical specifications The facilities necessary for design and installation nstallation examples Maintenance instructions The operating instructions needed by the user are attached to the unit these are also to be found in Section 6 130001AE The Stokvis service department is always available for commissioning and for providing service and maintenance For details see 1 2 2789CV02 140001BE The application installation and maintenance of Stokvis products must always be carried out in accordance with the requirements legal or otherwise specifications and standards applicable to such installations All data information and suggestions provided by Stokvis in relation to its products are based on careful investigation Nevertheless neither Stokvis nor any other organisation connected with Stokvis accepts any liability for application installation that occurs outside its sphere of influence Changes may be incorporated without prior notice Stokvis accepts no obligation to adapt previously delivered products to incorporate such changes 2789CV02 150001CE 3456CV02A 2 1 General CE DESCRIPTION The R3400 R3500 R3600SB are environmentally friendly modulat ing gas fired heating boilers that can vary its output fro
24. wooden blocks must be removed The vibration absorption dampers with spacers delivered with the unit must now be mounted as described in the instructions delivered with them see drawing Thereafter the water gas chimney condensate and electrical connections can be completed 3456CV02A 15 16 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 28CV01 430003DN 3456CV02A 5 1 5 2 5 2 1 5 2 2 Regulations Boiler room General INSTALLATION The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations see supplement 510001BE Commissioning should be carried out by the service department of your supplier who can also determine the composition and quality of the system water 28CV02 510002EE The construction of the unit ensures that losses through radiation can be neglected Because of the low noise level additional sound insulation of the boiler room is unnecessary Because of the position of the electrical components a plinth is not required The unit is constructed so that the space required for it is minimal The range of applications for the boiler is much greater due to the possibility of supp
25. 19 fab of e H n gt q gt y 4 zz pi p hd lt a WILL YUL Fig 30 Installation with more than one appliance without non return valves and making use of a low velocity header for 2 boilers Fig 31 Low velocity header for 2 boilers 3456CV02A 43 6 1 6 2 6 3 44 Function Regulation Control module OPERATING INSTRUCTIONS 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 A proportional controller determines also by means of regulation the required quantity of gas Thereafter the gas air mixture is ignited in min load on the pilot burner which is a part of the main burner After measuring the ionisation current the main gas valve will be opened and the ionisation measurement switches to the main burner The fan also ensures that the resulting flue gasses are subsequently removed The removal system for these gasses performs an essential function for the proper operation of the appliance The unit has no limits for return water temperature If this temperature is low condensation will be formed which will then be removed via the drainage system 34CV02 610001AE Depending on the heating demand the unit will be started up and shut down between 0 and 25 capacity and will be cont
26. 4 3 12 Delivery Packaging Transport A DELIVERY AND TRANSPORT 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 On delivery check the data plate for the correct boiler type and gas supply pressure 34CV02 410001BE For transport purposes the unit is mounted on wooden blocks fitted with protective bumpers and covered in a heat shrink protective covering 28CV02 420001BE For transport consult the technical details for dimensions and weight Remove the covering preferably after transportation and posi tioning in the boiler room or remove the panels before trans porting the appliance This is to prevent damage to the casing panels Moving the appliance A pallet truck or fork lift truck with a minimum fork length of 1 m can be used at the side of the unit Fig 6 Moving the appliance 3456CV02A 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 The wooden bars between the straps ensure that the unit will not be damaged d
27. 53 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 Rp2 Rp2 Rp2 DN65 PN16 DN65 PN16 H mm 1355 1355 1355 1355 1355 H1 mm 1125 1400 1400 1155 1155 L mm 2265 2653 2653 2658 2658 Li mm 595 610 610 615 615 L2 mm 700 1166 1166 1166 1166 L3 mm 108 88 88 88 88 W DN65 PN6 DN80 PN6 DN80 PN6 DN8o PN6 DN8o PN6 Table4 Dimensions R3500 Changes may be introduced without notice As a result of manufacturing tolerances there may be small variations in the dimensions Conditions applicable to table 3 Nominal capacity measured at Gas consumption at Gas category Appliance category Protection degree 60 80 C 1013 mbar 15 C dry ToH3P B23 C53 C33 of C63 IP20 DOC2005 3456en 3456CV02A19 10 09 R3600SB Standard Technical Data Type R3601SB R3602SB R3603SB R3604SB R3605SB Nominal heat output kW 639 747 846 945 1043 Nominal heat input net CV kW 653 764 865 966 1066 Minimum heat input 247 276 305 Pilot burner 30 30 30 Gas consumption Natural gas H 10 9 kWh m 79 4 88 6 97 8 Propane 12 8 kWh ms 67 6 75 5 83 3 ern i Natural gas H 18 25 18 25 18 25 Propane min max 30 50 30 50 30 50 Water capacity 104 110 117 Max working pressure 6 6 6 Gas connection G Rp2 DN65 PN16 DN65 PN16 Water connections W1 DN65 PN6 DN80 PN6 DN80PN6 DN80 PN6 DN80 PN6 W2 Flue connection D m
28. 600SB For details on this consult your supplier 3456CV02 542105AE 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 signal In addition the boiler regulating system can be extended by fitting one of the three options described below BME option This is a weather compensated regulator with the following possibilities Three on off periods per day with three different tempera tures Night time temperature reduction Domestic hot water priority with time programming Anti legionella provision Optimum start Room temperature sensor can be switched off Two wire communication bus connection Multi language display External control E6 option This is a regulator with which two secondary groups can be weather dependently controlled In addition domestic hot water temperature can also be regulated All the settings can be adjusted independently for each group The E6 regulator can be further extended with an optimizing controller for each group BM The boiler is then directly weather dependently con trolled KKM option This is a boiler cascade manager permitting up to eight boilers to be switched in cascade The KKM also has the same possi bilities as the E6 option 28CV02 532006CE 3456CV02A Connection terminals The operation of the appliance can be influenced by externally generated sign
29. 9 85 R3601SB 102 189 R3602SB 74 138 R3603SB js 108 184 R3604SB E 86 148 R3605SB EN 71 121 Table 10 Length of flue system The flue system lengths have been rounded down Chimney diameter at the appliance Not applicable 3456CV02 T5006BE Doc2005 3456en 31 32 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 resistance coefficient values can be simply accomplished by comparing with the stated losses at C71 Type Diameter 1 Elbow Elbow Elbow 90 Tee in 90 90 45 mm R D 1 0 R D 0 5 R D 0 5 R3401 300 7 3 5 0 9 6 3 7 14 1 R3402 350 9 2 5 6 10 2 4 2 15 3 R3403 350 9 4 5 6 10 2 4 2 15 3 R3404 400 10 6 6 1 10 9 48 17 1 R3405 400 10 0 6 1 10 9 4 8 17 1 R3406 400 10 7 6 1 10 9 4 8 17 1 R3501 300 10 5 0 9 6 3 7 14 1 350 11 5 6 10 2 4 2 15 3 R3502 300 9 5 0 9 6 3 7 14 1 350 11 5 6 10 2 4 2 15 3 R3503 350 11 5 6 10 2 4 2 15 3 400 12 6 1 10 9 4 8 17 1 R3504 350 11 5 6 10 2 4 2 15 3 400 12 6 1 10 9 4 8 17 1 R3505 350 12 5 6 10 2 4 2 15 3 400 13 6 1 10 9 4 8 17 1 R3601SB 300 10 5 0 9 6 3 7 14 1 350 11 5 6 10 2 4 2 15 3 R3602SB 300 9 5 0 9 6 3 7 14 1 350 11 5 6 10 2 4 2 15 3 R3603SB 350 11 5 6 10 2 4 2 15 3 400 12 6 1 10 9 4 8 17 1 R3604SB 350 11 5 6 10 2 4 2 15 3
30. H mm 1405 1405 1405 1405 1405 H1 mm 1175 1450 1450 1205 1427 L mm 2265 2653 2653 2658 2658 La mm 595 610 610 615 615 L2 mm 590 1166 1166 1166 1166 L3 mm 198 88 88 88 88 W1 mm DN65 PN6 DN8o PN6 DN8o PN6 DN8o PN6 DN8o PN6 W2 mm DN65 PN6 DN8o PN6 DN8o PN6 DN8o PN6 DN8o PN6 Table 6 Dimensions R3600SB Standard Changes may be introduced without notice As a result of manufacturing tolerances there may be small variations in the dimensions Conditions applicable to table 17 Nominal capacity measured at Gas consumption at Gas category Appliance category Protection degree 60 80 C 1013 mbar 15 C dry I2usp B23 C53 C33 or C63 IP20 DOC2005 3456en 3456CV02A19 10 09 IX DOC2005 en 3456CV02A19 10 09 TABLE OF CONTENTS R3400 Technical data I Dimensions R3400 0 000000 cee II R3500 Technical data 2452553 apd obe IV Dimensions R3500 cou cece E beh eed es V R3600SB Technical data VII Dimensions R3600SB lesen VIII Table of contents xz e s bare nd Oe Sate md Qe E eem male XI 1 INTRODUCTION 0 00 cee n n nm nm nh 1 1 1 STOKVIS eren a ds miu nie TL A EPA LL SEES 1 1 2 SUDDIIG scott cito dato delia des bs codo ea 1 1 3 Thus QOCHITIGEE nece cito DI weeps SI E DEED 2 1 1 4 DEMI RE PEDE ERE PPP ERN 2 1 5 General restrictions 1 A oo ys 2 2 DESCRIPTION 24 orar rat 3 2 1 General yA CE E A ER E 3 2 2 Main components
31. STOKVIS ENERGY SYSTEMS ECONOFLAME R3400 R3500 R3600SB BOILERS INSTALLATION OPERATION amp MAINTENANCE DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 ODL TEL 08707 707 747 FAX 08707 707 767 E MAIL info stokvisboilers com WEBSITE www stokvisboilers com DOC2005 3456en 3456CV02A19 10 09 2000 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 Therefore specifications are subject to change without prior notice Due to changes the product can deviate from the information specified in this document Therefore Stokvis rejects any responsibility for the differences between the product delivered and the information mentioned in this document 000002DE DOC2005 3456en 3456CV02A1 9 10 09 R3400 Technical data Type R3401 R3402 R3403 R3404 R3405 R3406 Nominal heat output kW 657 729 853 965 1078 1189 Nominal heat input nett CV kW 702 784 917 1038 1159 1279 Minimum heat input kW 176 196 229 260 290 320 Pilot burner kW 36 36 36 36 36 36 Gas consumption natural gas H 10 9 kwh m3 m3 h 64 5 71 9 84 1 95 2 106 3 117 3 propane 12 8 kwh kg kg h 54 9 61 2 71 6 81 1 90 5 99 9 G
32. TN min CI butterfly valve fo e o 5 restrictor n M plate Fig 33 Burner pressure measurement Measure the gas pressure at the supply side of the gas valve This must be at least 18 or 35 mbar for natural gas with the boiler operating at full capacity When multiple appliances are installed in the boiler room this pressure must be measured with all the appliances operating at full capacity Check the temperature difference AT between the flow and return to the appliance at the water side AT must be between 15 and 25 K at full capacity 3456CV02A 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 Pilot burner CO 96 10 2 0 2 Main burner CO 9 3 0 2 Main pilot burner CO ppm lt 30 lt 1000 Burner pressure mbar 0 7 0 1 Pian Pabove burner Table 16 Settings at minimum capacity Setting air pressure switch 0 4 0 05 mbar Check the function AP pressure switch by carefully placing a board for example a piece of strong cardboard in front of the supply opening to the fan and slowly slide the board so as to close off the opening until the boiler shuts down Adjusting the gas valve A butterfly valve i
33. ailable Max flow resis Pump type speed at head at power rate tance Qnom Qnom consumption m h kPa kPa kPa Ww R3401 28 54 46 UPS65120F 3 77 31 1 15 R3402 31 63 537 RA lt 3 69 16 1 15 R3403 37 00 BOs HES 69120F ag 54 18 1 15 R3404 41 84 43 UPS8020 7 3 70 27 1 50 R3405 46 75 Ds a ori 62 12 1 50 R3406 51 60 58 TP80 90 4 77 19 1 50 R3501 26 36 Ol e 3 80 43 1 15 R3502 30 83 25 e IS 72 47 1 15 R3503 34 87 30 Arana 9 60 30 1 15 R3504 38 96 357 EE 75 40 1 50 R3505 43 00 40 PS80120F 3 68 28 1 50 R3601SB 27 60 56 UPS65 120F 3 78 22 1 15 R3602sB 32 20 38 UPSS9 120P 3 67 29 1 15 R3603sB 36 50 45 UPS65 120F 3 57 12 1 15 R3604sB 40 80 53 YPS80 120F 3 71 18 1 50 R3605SB 45 00 60 TP 80 90 4 2 80 20 1 50 Table 12 Water flow rate and pump data The maximum power consumption of the pump is given for pump speed 3 The optimum operating point in relation to efficiency and minimum power consumption can be determined from the related pump curve 34CV02 T5001BE The primary pump has been sized to have an optimum duty when AT 20 K When running at AT 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 The water flow rate can be measured by making a dP measurement via the filling and drainage valve in the supply and return pipe of the unit The measured head can be compared with the
34. al will be voltage free In order to avoid faults caused by inductive currents static electricity or high frequency signals the use of screened cables is necessary 34CV02 532008BE The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations see supplement The flow and return connections are made at the rear of the unit Supports for water connections It is recommended that the flow and return pipes be properly supported This will avoid damage through overloading weight and simplifies maintenance Fig 17 Support The R3400 R3500 R3600SB units are constant water flow appli ances and are suitable for use in both open vented non pres surised systems and sealed pressurised systems provided the minimum pressure requirements as per table 14 are met 3456CV02A 5 3 4 5 3 4 1 A Combustion air supply General The unit is fitted with a boiler pump as standard which guarantees the required water circulation through the boiler The capacity and working head of the pump is sufficient to overcome both the resistance of the boiler and some resistance offered by the system The boiler pump is however not a system pump If the resistance of the system exceeds the available working head the boiler will be shut down by the flow switch In order to prevent this happening the length and diameter of the primary pipework
35. als applied to the appropriate terminals Terminal Description L1 L2 L3N E Boiler power supply must be fused at 16 20 A 8 9 Domestic hot water primary pump control This out put provides a voltage 230 V when the boiler is operational as a result of a domestic hot water heating demand 10 11 Boiler enable 230 V When these terminals are connected the DHW primary pump will be started and the boiler will be enabled When there is an open circuit between them the boiler will be shut down The pump will also stop after the set run on time These terminals can be used among other things for setting the boilers to standby during the summer months whilst continuing to provide domestic hot water priority 14 15 Control voltage for an external gas valve This output begins to provide 230 V before the boiler starts up the voltage ceases after the boiler shuts down This output can be used to open hydraulic valves or to operate boiler room ventilation 16 17 Calorifier thermostat 230 V When these terminals are interconnected the boiler will try to provide the set flow temperature programmed for the boiler This input only functions if terminals 34 35 are interconnected 18 19 Gas pressure 230 V If the connection between these terminals is broken the boiler will be shut down and will then wait until the connection is made again 20 21 Lockout input 230 V If the connection between these terminals is broken the boiler will enter
36. as inlet pressure natural gas H min max mbar 18 25 18 25 35 100 35 100 35 100 35 100 natural gas H max option mbar 100 100 propane min max mbar 30 50 30 50 30 50 30 50 30 50 30 50 Water capacity dm 50 53 70 75 80 85 Max working pressure bar 6 6 6 6 6 6 Gas connection G Rp2 Rp2 Rp2 Rp2 DN65 PN16 DN65 PN16 Water connections W DN65 PN DN65 PN6 DN8o PN6 DN8o PN6 DN8o PN6 DN8o PN6 Flue connection D mm 300 350 350 400 400 400 Safety valve connection 1 1 1 5 1 1 2 relief connection 15 1 5 2 2 2 21 2 standard setting 3 3 3 3 3 3 Power supply V 4003N 4003N 4003N 4003N 4003N 4003N Frequency Hz 50 50 50 50 50 50 Fuse A 16 16 20 20 20 20 Max electrical power consumption unit kW 0 90 0 90 1 27 1 27 1 27 1 27 pump maximum kW 1 15 1 15 1 15 1 50 1 50 1 50 total kW 2 05 2 05 2 42 2 77 2 77 2 77 Boiler weight empty 5 96 kg 675 740 840 950 1070 1200 Dimensions height H mm 1355 1355 1355 1355 1355 1355 width B mm 1330 1330 1130 1130 1330 1330 length incl connections L mm 2265 2265 2653 2653 2658 2658 Table 1 Technical data R3400 DOC2005 3456en 3456CV02A19 10 09 Dimensions R3400 front view plan view 1 side view Fig 1 Dimensional sketch R3400 II DOC2005 3456en 3456CV02A19 10 09
37. city header All appliances are fitted with a safety valve that opens at 3 bar As an option safety valves can be supplied with settings between 3 and 6 bar with increments of 1 bar The maximum permissible temperature of the water flow can be set at 90 C If the high limit thermostat functions at 100 C the appliance shuts down and locks out and does not re start automatically when the temperature falls below the high limit temperature setting The composition and quality of the system water has a direct influence on the performance of the whole system and the life of the appliance Unsuitable addition and use of chemicals water softeners oxygen binders de aerators aerators and water filters all increase the possibility of faults Corrosive elements in certain additives can attack the system resulting in leakage deposits of undesirable sediments can lead to damage to the boiler heat exchanger 545001AE 3456CV02A For water hardness a distinction must be made between a Temporary hardness This is also referred to as carbonate hardness Deposits are formed at higher temperatures and are easy to remove b Permanent hardness Minerals for example calcium sulphate dissolved in the water can be deposited as a function of very high surface temperatures 545002AE In the United Kingdom water hardness is expressed in mg litre ppm and is given the following divisions Very soft less than 50 ppm Soft approx 50 160 ppm
38. em water All the water distribution components are constructed from cast iron and have a profile that ensures that optimum distribution and flow are obtained The space between the burner and the secondary heat exchanger forms the combustion chamber 3456CV02A On the R3600SB the 3rd heat exchanger is built from stainless steel laser welded fin pipes and is placed directly below the 2nd heat exchanger The boiler pump ensures the water flow through the heat exchanger The complete water flow over the boiler goes through this 3rd heat exchanger as it is connected in series with the other heat exchangers 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 Both of these connections are provided with a filling drain valve 6 The flow connection is also provided with a safety valve 4 a flow switch 3 and a temperature sensor Boiler pump 32 The boiler pump is mounted on the return connection to the unit and is directly connected electrically to the appropriate termi nals in the connection box The capacity and the working head of the pump is sufficient to overcome both the resistance of the boiler and some system resistance Flue gas collection chamber 19 The stainless steel flue gas collection chamber is mounted under the heat exchanger This chamber is provided with a flue gas exhaust connection 16 a conde
39. ent maintenance activities and inspections 536001CE Fig 23 Condensate discharge 3456CV02A 33 5 4 5 4 1 5 4 2 34 5 4 2 1 Hydraulic system General Water flow Flow rate and resistance Although it is not the intention to provide a complete handbook covering the most divergent hydraulic systems the data is more extensive than would generally be provided in the case of conventional central heating boilers The R3400 R3500 R3600SB units are low water content boilers for which the water flow rates must be within minimum and maximum values deltaT 15 25 Table 12 14 lists the required relationship between the three parameters Q water flow P pressure and t temperature at maximum capacity Because of the high flow rate the appliance is less sensitive to water hardness Therefore the water hardness may not exceed 250 ppm with a supply temperature of 80 C see 5 4 5 Water quality 34CV02 541001CE The rate of water flow through the appliance must never fall 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 appliances are connected to a common transport system etc must not interfere with the required water circulation 542101AE 3456CV02A Type AT 20K Pump data Nominal Boiler Grundfos Pump Head Av
40. f the gas sup plied to the unit must be reduced to 25 mbar for natural gas or 50 mbar for propane with the use of a gas pressure regulator Types R3403 3406 are suitable for gas supply pressures of 100 mbar on natural gas The loss of pressure in the connecting pipes must be such that at maximum boiler capacity the pressure must never fall below 18 mbar for natural gas or 50 mbar for propane 34CV02 531001BE The electrical connections and provisions must comply with the applicable national and local standards and regulations see supplement The units are wired in accordance with the electrical diagram supplied with the appliance 532001AE The electrical connections the terminals and the boiler pump relay are mounted in a separate connection box behind the front panel extrusion profile fig 4 3456CV02A 19 20 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 The cables to be connected power supply control enter the appliance via the rear of the unit and pass via the cable duct at the inner right hand side to the connection box at the front of the unit The connection box is provided with cable glands and connection terminals The boiler pump is provided with thermal protection and a pump relay con
41. ff during operation 30 CRC error in EEprom data group Boiler Press reset 31 CRC error in EEprom data group Burner Press reset 32 Fault in 24 V circuit Correct fault 40 Error detected in the position of the flow switch The flow switch is tested under two conditions No heat demand pump stop flow switch must return in rest position Heat demand pump turns flow switch detects water flow Not adhering to the above conditions will give the error condition Correct fault X 5 An internal fault has been detected during the self test Press reset 2789CV021 630002EE 3456CV02A 47 6 5 6 6 6 7 48 Start up Shut down Warnings 1 Open the gas valve 2 Switch on the appliance using the on off switch on the control panel 3 Select the function automatic operation using the function selector See also the operating instructions on the boiler 28CV02 640001BE The appliance can be shut down in 3 different ways A The boiler continues to supply domestic hot water Select the function with the function switch B The boiler is not operating and will only start up for automatic frost protection Select the O function using the function selector C Shutdown the boiler 1 Switch off the boiler using the on off switch on the control panel 2 Close the gas valve 28CV02 660001BE The appliance must be installed by a recognised installer The operating instructions must be strictly
42. id the arrow at the bottom of the LCD display indicates parameter P1 press and hold the combined Reset Programming key pos 3 and at the same time turn the rotary switch pos 5 until the desired water flow temperature has been reached Release the Reset Programming key Close the cover N B The new temperature setting will only become active once the Reset Programming key has been released 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 desired Domestic Hot Water flow temperature has been reached Release the Reset Programming key Close the cover N B The new temperature setting will only become active once the Reset Programming key has been released 3456CV02A 6 4 Fault indications A fault always results in a flashing AA symbol and a fault code appearing in the display When a fault occurs the cause must always be found and corrected before the related protective function is reset If a fault occurs 3 times or more within half an hour the fault code will appear in the display with an additionally 3 above it The boiler can be nevertheless in operat
43. inuously modulated between 25 and 100 capacity 28CV02 620001AE Lid closed Lid open 5 43 98 7 6 21 320 21 E 1 1 gt ORTO ALARMIRESET v Y O 2 3 5 Fig 32 Control module 1 function 1 parameter indication standby P1 current setting boiler supply temp automatic operation P2 current setting domestic hot water summer operation temperature I manual operation min P3 desired temperature I manual operation max P5 current external temperature 2 function selector P8 current low velocity header temp 3 fault indication A P9 current boiler capacity 4 supply temperature P10 password entry for factory 5 malfunction code flashing settings 2 optical I O 3 reset programming push button 4 alarm LED 5 parameter value selector 6 output status 7 current desired parameter value 8 fault parameter indication 28CV02 630001CE 9 input status Desired load required by the KKM8 if fitted 3456CV02A Operating mode cover closed With the cover closed and by using the rotational switch pos No 2 clockwise or anti clockwise the boilers operating mode can be set The operating modes are standby the boiler switched off but frost protection is active automatic the boiler can operate in heating or direct hot water mode ar summer mode the boiler will only react to a direct hot water demand S amp I manual low capacity the
44. ion 1 The high limit thermostat has operated The boiler temperature has exceeded 100 C Press the reset button 2 3 The interlock input low gas pressure switch has been operated Correct the external error and press reset 4 5 lonisation fault Press reset amp Temperature protection has operated The boiler temperature has exceeded the setting Press reset 1 The lockout input has been interrupted Correct the external fault and press reset Error in flame signal A flame has been detected during start up Correct the fault and press reset i Flow temperature sensor is faulty Correct fault i3 Wiring of the CXE EM extension module is defective Correct fault Hot water temperature sensor is defective Correct fault 15 External temperature sensor is defective Correct fault i8 Header temperature sensor is defective Correct fault eU Error in the control of gas valve 1 After burner has stopped a flame has been detected for a period of 5 seconds This is 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 After burner has stopped a flame has been detected for a period of 5 seconds This is in spite of the fact that valve 2 is closed Correct the fault by cleaning the valve ce Air flow too low The air pressure switch has not operated Press reset 3 The air pressure switch has not switched off Press reset 21 The air pressure switch switched o
45. ity of gas is added In this way the boiler capacity is continually adjusted and the boiler can accurately follow the heating demand If the boiler is operating at minimum capacity and the temperature of the supply water rises above the desired value the unit will be shut down As soon as the temperature of the supply water falls below the set value the boiler will be re started 3456CV02 230001AE The unit contains the following safety components Flame protection on pilot and main burner 1x re start Water flow protection Maximum water temperature protection Gas valve test Fan protection Boiler pump motor over heating protection If one of these components operates this results in a lockout fault Lockout faults can only be cancelled by resetting the unit The unit is fitted with a safety valve that opens at 3 bar 34CV02 240001DE 3456CV02A Heeg 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 It is expressly stated that these installation instructions must be seen as a supplement to the above mentioned standards and regulations and that these standards and regulations must take precedence over any inf
46. lve can be used if it is controlled by the boiler using terminals 14 15 or alternatively a mechanical non return valve can be used This is required so as to avoid short circuiting the appliance on the water side The unit is provided with water flow protection This shuts the appliance down in the event that the flow of water through the appliance falls below the minimum required value This protection is implemented by means of a water flow switch 3456CV02A 37 5 4 3 Water pressure 5 4 3 1O0perating pressure Dx 5 4 3 2 Boiler expansion tank 5 4 3 3System expansion tank 5 4 3 4 Water pressure protection 5 4 4 Water temperature 5 4 5 Water quality 38 A At a maximum supply temperature of 90 C and a minimum water flow rate such as occurs at a AT of 20 K the minimum operating pressure must be greater than 1 5 bar The operating pressure must be measured with the pump switched off If a lower pressure is desired the maximum supply temperature must be adjusted accordingly Minimum operating Flow temperature AT pressure in bar C K gt 1 5 90 20 gt 1 80 20 Table 14 minimum operating pressures T5009AE It is advisable to fit an expansion tank in the return pipe between pump and the boiler isolating valve The size of the expansion tank is determined by the quantity of water in the system Our advice is to fit the system expansion tank at the neutral point centrally of the low velo
47. lying it as a room sealed appliance see Section 5 3 4 28CV02 521001BE Set up In order to avoid any difficulties the following rules apply to the boiler room a Install the appliance in a frost proof room b Pay particular attention to the positioning of the appliance to ensure protection from freezing and or high temperatures c Ensure that the boiler room is sufficiently large so that there is sufficient space on all sides of the unit to permit maintenance and possible replacement of components to be carried out The recommended minimum free space is 450 mmatone side 800 mmatthe other side 450 mmatthe rear 1000 mm at the front space for free movement If the distances are smaller this will make maintenance activities more difficult 28CV01 522001CE 3456CV02A 17 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 in other words the flow and return pipes from the boiler as seen from the boiler must first run upward before running down to the boiler Despite the fact that every unit is provided with water flow protection local authorities often require low water level protection to be fitted When multiple units are installed it is only necessary to fit one additional protective device 28CV02 522002CE
48. m 25 to 100 of its maximum capacity The series R3400 consists of 6 types in a range from 657 to 1189 kW The series R3500 consists of 5 types in a range from 613 to 1000 kW The series R3600SB consists of 5 types in a range from 639 to 1043 kW The units have an extremely low emission of NO and CO so that this boiler satisfies the most stringent European requirements The R3400 R3500 R3600SB series have CE approval for the following countries Austria Belgium Denmark France Germany Ireland Italy The Netherlands Spain and the United Kingdom The series is registered under the product identification number 0063AR3514 The units can be supplied either as a standard category B23 or a room sealed categories C53 C33 or C63 appliance Working principle and construction Air is blown into the appliance as required by a speed con trolled fan and thoroughly mixed with gas in the correct proportions A temperature controller compares the desired water temperature with the temperature of the water flow and sends a signal to the frequency converter to maintain the correct heating capacity The gas air mixture so formed is passed through a cooled premix burner and ignited The premix burner is constructed of finned bimetallic pipes internally from stainless steel and externally from aluminium with cast iron water headers Heat transfer takes place in two or three heat exchangers The first heat exchanger is constructed f
49. m 300 350 350 400 400 Air supply connection option D1 mm 250 300 300 355 355 Safety valve Boiler connection 11 2 11 2 1v Relief connection 2 2 25 Standard setting 3 3 3 Power supply 400 3N 400 3N 400 3N Frequency 50 50 50 Fuse 20 20 20 Max electrical power consumption Unit 1 27 1 27 1 27 Pump 1 15 1 50 1 50 Total 2 42 2 71 2 71 Boiler weight empty 5 1150 1280 1410 Dimensions Height H 1405 1405 1405 Width W 1130 1330 1330 Length L mm 2265 2653 2653 2658 2658 Table 5 Technical data R3600SB Standard DOC2005 3456en 3456CV02A19 10 09 VII Dimensions R3600SB Standard front view plan view side view rear view 990 540 420 Fig 3 Dimensions R3600 Standard VIII DOC2005 3456en 3456CV02A19 10 09 Type R3601SB R3602SB R3603SB R3604SB R3605SB 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 D1 mm 250 300 300 355 355 mm Rp2 Rp2 Rp2 DN65 PN16 DN65 PN16
50. must be able to flow back to the unit Inspection of the air supply and flue pipe must be possible The connection exit position and height in relation to possible obstacles must comply with the applicable national and local standards and regulations see supplement 534204BE The flue pipe connection is at the rear of the appliance and has been designed for direct connection to a corrosion resisting flue pipe 535101BE 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 Aluminium or stainless steel is strongly recommended Because a slight over pressure exists in the flue pipe during a cold start up flue pipes should preferably be constructed from seamless materials When the boiler functions as a high capacity boiler the high efficiency can lead to the formation of condensation in the chimney The condensate drain must never become blocked Direct connection to brick built stacks is not permitted because the combustion efficiency of the boiler is gt 83 The combus tion products at low flue gas temperatures will damage the stack The following table lists all the flue gas data for all types of boiler 535102bE 3456CV02A 5 3 5 2 Chimney
51. n optional speed controlled pump is available for the R3500 and R3600SB For details of this consult Stokvis 3456CV02 542105AE UPS 65 120F UPS 80 120F p Bem tg 100 7 ip to y 48 Q m h 0 0 40 50 60 Q m h TO 142 14 186 18 0 2 4 6 8 10 12 14Q Vs 20 Q Vs 40 0 10 2 30 40 50 60 48 Q mih Q men TMAO 9453 0497 TMAO 9449 0497 Fig 24 Pump char UPS 65 120F Fig 25 Pump char UPS 80 120F 3456CV02A 1 i RII n H 3 T 1 5 4 2 3 Isolating valves 5 4 2 4 Valves 5 4 2 5 Water flow protection T E Mp d re a a ecd A 46 60 55 Om EA i i i i NM imet 0B 84 Fig 26 Pump char TP80 90 4 Type Pump Pmax Pmin l cos Ww Ww A ee 3x400 V UPS 65 120F 1 850 440 135 091 Radot Ratos 2 90 460 145 090 R3601SB R36038B gt 1150 600 2 15 0 77 UPS 80 120F 1000 ies R3404 R3405 2 1100 760 1 80 0 88 R3504 R3505 1100 780 1 80 0 88 R3604SB R3605SB A TP80 90 4 R3406 1500 360 10 77 0 72 Table 13 Electrical data Tor pumps It is recommended that manual valves be fitted between the flow and return connections and the installation For R3400 R3500 R3600SB units connected in cascade a delayed motorised shut off va
52. nect the flue pipe directly to the flue attenuator The flue attenuator must always be free standing It must never be in contact with the walls of the chimney The flue pipe connected to the appliance must first rise vertically by 70 cm before either the diameter or the direction is changed The openings on the underside of the flue connection ring must never become blocked The free flow of condensate and any rain water must be guaranteed The flue connection is at the back of the appliance To ensure proper functioning of the appliance it is recom mended that a draught stabiliser be mounted in the flue system for the room sealed appliance this is not permitted Calculation of the diameter For calculating and checking the internal diameter of a flue system with mechanical discharge refer to the applicable national and local regulations and specifications Calculation of the length The lengths given in the following table are only intended for the further calculation of the total length The maximum vertical length may not exceed the flue length as indicated in table 10 Maximum permitted flue system length in metres of smooth pipe Standard flues only Type Length of flue system in m Diameter Diameter Diameter 300 mm 350 mm 400 mm R3401 58 108 R3402 47 88 R3403 34 64 R3404 kis 50 85 R3405 2 40 68 R3406 s 33 56 R3501 71 132 R3502 52 96 R3503 eis 75 129 R3504 ES 60 103 R3505 ig 4
53. nsate drain connection 22 and an inspection opening Frame 14 The frame is constructed from steel profile sections Vibration absorption dampers are supplied separately and must be fitted after the unit has been placed in position The casing 27 The casing consists of panels that can be removed easily without the aid of tools The electrical section This includes the control and safety circuits for the unit Connection box 25 The electrical power supply for the boiler the terminals the pump connections and the pump relay are mounted in an easily accessible connection box The supply cables can easily be fed to the connection box via the cable duct inside the boiler 21 34CV02 221001AE 3456CV02A 7 2 3 24 Boiler control Safety aspects 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 A Ifthe measured supply temperature is lower than the desired temperature B As a result of manual operation mode having been se lected amp C In standby mode when the water temperature falls below the frost protection temperature After the unit has started up the PID controller sends a signal to the frequency converter This converter controls the speed of the fan Depending on the quantity of air moved by the fan the proportional pressure regulator ensures that the corresponding quant
54. ormation included in this technical manual 300001DE Pictograms used in this manual An instruction that is essential for the correct functioning of the installation If these operations procedures etc are not accurately fol lowed this can result in serious damage to the installation personal injury or environmental damage Danger of electric shock Useful information 300002AE 3456CV02A 9 10 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 Keep unauthorised persons away from the installation Do not place any objects on the unit Remain out of the area of the hot water connection and the chimney to avoid burns Before starting any maintenance or service activities discon nect the electrical power supply and close the gas supply valve After completing any maintenance or service activity check the whole installation As a supplement to the information provided in this technical manual all applicable safety regulations must be consulted to avoid accidents All panels forming part of the casing must be mounted Panels may only be removed for maintenance or service purposes After performing maintenance or service activities
55. pe d tT GO aed 54 CONVERSION FORMULAE AND FACTORS 55 SUPPLEMENT i ssh a dci 58 Edition 3456CV02A 12 01 2000 3456CV02A 1 1 1 2 1 3 Stokvis ISO9002 Supplier This document INTRODUCTION Since its beginning in 1985 Stokvis has built up a strong reputation in industry for the development production and marketing of gas fired high efficiency boilers and water heaters in the 45 to 1189 kW range Through their unique construction these central heating units and 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 technology 101001AE STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 ODL Tel 08707 707 747 Fax 08707 707 767 2789CV02 120001EE This documentation has been compiled to aid the following target groups the consulting engineer the heating installer the service engineer the user Because these target groups require mostly similar information and also specific information our technical documentation has been integrated to provide these target groups with the neces sary general and specific information to install service and operate this product The supplier see 1 2 will be able
56. raulic system This is a requirement 28CV02 720001BE Check and bleed the pump Switch on the power supply to the boiler at the on off switch and check the direction of rotation of the boiler pump after removing the end cap from the pump motor housing If the direction of rotation is incorrect 2 of the 3 phase connections must be swapped Before the appliance is started up any air present must be bled out of the pump by removing the end cap from the pump motor housing This must be repeated after the appliance has been in operation for a short time 28CV02 720002AE Check the chimney Check the chimney Ensure that the connection between the appliance and the chimney is such that gassses cannot escape If necessary apply an appropriate sealing tape 28CV02 720003AE Bleed the gas pipework Open the gas valve Check that the gas piping is gas tight Remove any air between the gas valve and the appliance 28CV02 720004BE 3456CV02A 49 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 28CV02 720005AE Pilot burner CO 96 10 0 0 2 Main burner CO 96 10 0 0 2 CO ppm Main 30 Pilot 1000 Burner pressure mbar 9 01 Pian Pabove burner Table 15 Settings at full capacity EE
57. requency signals or static electricity screened cables must be employed for all low voltage and control signals between the boiler and externally con nected units The screening must be earthed at both ends of the cable Electro technical data Type Fan control and Pump Total safety components electrical power con Supply Power Supply Power sumption 230x1 N consumption 400x3 N consumption max max max V kW V kW kW R3401 230 0 90 400 1 15 2 05 R3402 230 0 90 400 1 15 2 05 R3403 230 1 27 400 1 15 2 42 R3404 230 1 27 400 1 50 2 77 R3405 230 1 27 400 1 50 2 77 R3406 230 1 27 400 1 50 2 77 R3501 230 0 90 400 1 15 2 05 R3502 230 0 90 400 1 15 2 05 R3503 230 1 27 400 1 15 2 42 R3504 230 1 27 400 1 50 2 77 R3505 230 1 27 400 1 50 2 77 R3601SB 230 0 90 400 1 15 2 05 R3602SB 230 0 90 400 1 15 2 05 R3603SB 230 1 27 400 1 15 2 42 R3604SB 230 1 27 400 1 50 2 77 R3605SB 230 1 27 400 1 50 2 77 Table 7 Electrotechnical data i tolerance on voltage 230 V 10 96 15 96 tolerance on frequency 50 Hz 5 96 v tolerance on voltage 400 V 10 15 96 the stated pump power is based on the maximum power consumption in pump speed 3 The pump curves can be used to determine the optimum operating point in relation to pump efficiency and power consumption 3456CV021 T5001DE 3456CV02A 21 For additional energy savings an optional speed controlled pump is available for the R3500 and R3
58. rom smooth stainless steel pipes while the second heat exchanger is fitted with laser welded stainless steel finned pipes Both heat exchangers are fitted with cast iron profiled water distribution components headers which guarantee an optimum water flow through the appliance The burner and the heat exchangers are connected in series 3456CV02A 3 On the R3600SB the 3rd heat exchanger is built from stainless steel laser welded fin pipes and is placed directly below the 2nd heat exchanger The boiler pump ensures the water flow through the heat exchanger The complete water flow over the boiler goes through this 3rd heat exchanger as it is connected in series with the other heat exchangers The R3400 R3500 R3600SB units have a small water capacity so that they can rapidly adjust to changing conditions They can be installed without any restrictions to the return water temperature The necessary water flow rate is ensured by the standard pump delivered with the appliance 3456CV02 210002AE Application possibilities Because of its construction the R3400 R3500 R3600SB units are suitable for use in heating systems With a constant supply temperature With a weather dependent heating demand With low temperature condenser systems With optimised condensation With control by means of building optimiser compensator system 0 10 Vdc see 5 3 2 connection terminals 34CV02 210003AE
59. s positioned on top of the mixing chamber During first commissioning the valve is set to limit the gas flow The CO value at minimum capacity can be set by adjusting the n screw on the gas valve The v adjuster screw is fixed and should not be adjusted If the appliance is checked in the manner indicated and corrected as necessary the following pressures at full capacity must be recorded for reference on the commissioning report note P P P vent Py measure separately vent vh AT 3456CV02 720006EE 3456CV02A 51 8 1 8 2 8 3 52 Safety General Procedure MAINTENANCE During maintenance activities always wear suitable clothing and shoes Consider your own safety particularly in respect of jewellery and loose clothing 810001AE In order to ensure continued good and safe operation of the appliance inspection must occur 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 Clean the air inlet damper Clean the fan blades Clean the flue gas collection chamber Clean the condensate trap and the drainage pipe from the appliance Clean the gas filter Inspect all pressure measurement pipes and nipples After removing the panels from the left hand side of the appliance ignition and burning can be observed from both front and rear via a sight
60. s train This filter can be cleaned as follows 1 Close the gas valve on the boiler 2 Unscrew the six bolts securing the cover to the gas filter 3 Carefully remove the filter element 4 Clean the filter element by shaking it When it is heavily polluted the filter element must be renewed Re assemble the filter Check for leaks soap solution O Ol Inspect all the pressure measurement pipes Ensure that these are securely fastened and tighten the connection nuts if necessary Inspect the screws in the measuring nipples renew the measuring nipples if they have become damaged In order to measure gas and air pressures and to perform measurements at the flue gas side calibrated test equipment must be employed All test data must be recorded on the applicable test forms 28CV02 830002EE The burner and the heat exchangers can be cleaned internally with suitable media For advice concerning suitable media consult the service department of your supplier 28CV02 840001CE 3456CV02A 53 8 5 8 6 8 7 54 Cleaning the filter screen in the gas combination block lonisation measurement Service Not applicable In order to carry out an ionisation measurement a micro am meter with a measuring range of 0 200 uA DC must be con nected in the ionisation circuit In this way the ionisation protection function can be checked The nominal ionisation current is between 6 and 25 pA The minimum ionisation curren
61. t is 2 8 pA 34CV02 860001CE For service and maintenance the service department of your supplier is always available 870001BE 3456CV02A CONVERSION FORMULAE AND FACTORS Formulae 20 9 measured O 20 9 measured CO x 20 9 11 7 CO x 11 7 O 20 9 11 7 CO is the maximum CO percentage that is generated by stoichiometric burning of G20 natural gas H gas Excess air N N2 209 x09144 or 20 9 measured O 11 7 N 1 CO measured 1 x 0 914 Conversion factors For NO N71 1 ppm 2 05 mg m 1 759 mg kWh 0 498 mg MJ For CO N71 1 ppm 1 24 mg m 1 064 mg kWh 0 298 mg MJ Example Measured values for an environmentally friendly unit NO 15 ppm CO 10 What is the value for NO according to the most usual standard in mg kWh for N21 10 x 20 9 O 209 396 N 20 9 2447 20 9 3 NO for N 1 15 0 x 1 17 17 6 ppm 17 6 x 1 759 30 9 mg kWh 3456CV02A 55 56 Ww kcal h Btu h 1 0 86 3 41 1 163 1 3 97 0 293 0 252 1 Table 17 Conversion factors T9013AE 1 kcal 7 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 15K 25 C this amounts to 2442 5 kJ kg 583 38 kcal kg For non condensing boilers 0 339 2 n 90 0 008 x AT o 0 377 100
62. the pump If a vertical low velocity header is employed the air separator should be fitted above the header 545005AE 3456CV02A 39 5 4 6 40 Examples of hydraulic systems The chloride concentration must not exceed 200 mgll 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 If chloride is present in high concentrations the water will be more aggressive due to among other things incorrectly regeneration of the water softener The system must then be flushed out and re filled with low chloride content water 545006CE To reduce the effects of unnecessary wear and blockages resulting from any pollution present we advise the use of a filter system with a mesh opening of 100 microns Always fit this in the return pipe of the secondary part of the system In order to guarantee a well functioning system and a long life any suspended and corrosion producing particles must be removed with the aid of a well chosen and fitted filter system The analysis of system water and the cleaning of filters must form part of the periodic inspection procedure 545007CE If there is an intention to add chemicals such as inhibitors to the water contact must be made with the supplier The supplier can provide advice on filter systems and other
63. the resistance 534201BE Fig 18 horizontal air supply Type R3401 R3501 R3601SB R3402 R3403 R3502 R3602SB R3503 R3603SB R3404 R3405 R3504 R3604SB R3406 R3505 R3605SB Air supply diameter mm D1 250 300 300 300 D2 355 355 355 mm 239 5 239 5 289 5 239 5 239 5 289 5 233 5 mm 359 359 266 266 266 266 266 Table 8 Air supply connection 3456CV01 T5004BN Fig 19 Air supply connection 3456CV02A The connection to the air supply pipe is always mounted on the top of the unit Multiple units may not be connected to the same air supply or flue pipe To prevent snow entering the air supply pipe must extend at least 30 cm above the roof and must be fitted with a rain cap The flue pipe opening must end at least 100 cm above the roof assuming the roof to be flat 534202CE Fig 20 Heights of air inlet and flue gas discharge The relative horizontal difference between the flue pipe and the air supply pipe must not be less than the width of the unit 534203CE Fig 21 Distance between air inlet and flue gas outlet 3456CV02A 27 5 3 5 5 3 5 1 28 The Flue system General The formation of unwanted condensation must be avoided In the event that during the heating up period condensation occurs the condensate
64. trol panel tranformer 230 24 15V frequency converter terminal strip with terminal functions cable glands boiler pump relay Fig 16 Connection box The appliance can be switched on and off with the switch on the control panel The power supply voltage cannot be removed from the boiler pump relay in this way The installer must fit a mains isolator switch in the power supply to the unit within the boiler room This can be used to switch off the power to the unit for maintenance purposes or in the event of a problem In accordance with the applicable standards and regulations an emergency shut off must be fitted outside the boiler room In the event of a calamity the power supply to the unit can be switched off 28CV02 532003BE 3456CV02A 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 trip which in turn will result in the unit being switched off 28CV02 532004CE In order to prevent malfunctions occurring as a result of inductive or high f
65. uring lifting Fig 8 Lifting CAUTION Ensure that the lifting straps are of the correct quality Never move the units over the heads of persons 3456CV02A 13 14 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 pre tested We strongly advise you to have dismantling and re assembly activities carried out by the service department of your supplier 34CV02 430002DE burner Type L mm B mm H mm m kg R3401 1010 1150 420 135 R3402 R3501 R3601 1010 1310 500 140 R3403 R3502 R3602 1420 1010 500 210 R3404 R3503 R3603 1420 1110 500 215 R3405 R3504 R3604 1420 1210 500 220 R3406 R3505 R3605 1420 1310 500 225 1 Heat exchanger Type L mm B mm H mm m kg R3401 1010 1150 160 120 R3402 R3501 R3601 1010 1310 160 135 R3403 R3502 R3602 1420 1010 160 180 R3404 R3503 R3603 1420 1110 160 185 R3405 R3504 R3604 1420 1210 160 190 R3406 R3505 R3605 1420 1310 160 195 2 Heat exchanger Type L mm B mm H mm m kg R3401 1010 1150 160 135 R3402 R3501
66. water speed does not exceed 0 5 m s In this case the diameter of the low velocity header must be calculated on the basis of the water flow through the secondary circuit Because the volume of the water in the secondary system is greater than that in the primary circuit boiler there will be a water circulation in the opposite direction to that of the primary circulation through the low velocity header A mixed temperature will then exist which is lower than the supply temperature from the boiler The regulation system will react to this and will open the regulator functions valves etc in the system Generally the temperature of the water supply from the boiler s will need to be corrected to obtain the desired temperature in the connected circuits 28CV02 546002BE Systems with a separate flow header and a return header Flow headers in combination with return headers are often used in renovation projects Several circuits operate with mixing valves or diverting valves In both cases a low velocity header or a bypass is necessary 28CV02 546003AE 3456CV02A 41 42 Fig 28 A boiler with vertically mounted low velocity header arranged with right hand connections Installations with multiple appliances For installations in which each appliance is fitted with a pump the pump is switched off after the boiler has been shut down 28CV02 546006BE o gt w o c gt gt w gt u ra
67. ximately 4 to 5 m s For the appliance there will be a maximum over pressure of approximately 1 5 mbar 150 Pa for the flue system see table 10 for lengths Owing to their high resistance bends with an R D ratio smaller than 1 should be avoided It may happen that these must be used in which case the chimney length must be calculated with the aid of table 11 We advise fitting the horizontal pipe section with a fall so that any condensate formed can be drained via the boiler 28CV02 535203CE chimney na suspension draught control A fall gt 30 1000 A collars draught control T 700 ai condensate 7 opening support Fig 22a Chimney connection R3400 R3500 chimney 9 suspension DRAWING NOT draught control A APEBICHEEN draught control A fall gt 30 1000 Dum FOR R3600SB collars condensate 7 opening support i A L Fig 22b Chimney connection R3600 not R3600SB The R3400 and R3500 appliance must never be connected to a flue sysytem with a plastic lining consult the applicable standards 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 R3400 160 C for the R3500 and 90 C for the R3600SB 3456CV02 535204CE 3456CV02A The R3400 R3500 and R3600SB are equipped with a flue attenuator Never con

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