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Related Manuals for STOKVIS ENERGY SYSTEMS ECONOFLAME R3500
Summary of Contents for STOKVIS ENERGY SYSTEMS ECONOFLAME R3500
- Page 1 ECONOFLAME R3400/R3500/R3600SB BOILERS INSTALLATION OPERATION & MAINTENANCE DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL: 08707 707 747 FAX: 08707 707 767 E-MAIL: info@stokvisboilers.com WEBSITE: www.stokvisboilers.com DOC2005/3456en.3456CV02A230611...
- Page 2 © 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.
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Page 3: R3400 Technical Data
R3400 Technical data Type R3401 R3402 R3403 R3404 R3405 R3406 Nominal heat output 1078 1189 Nominal heat input (nett. CV) 1038 1159 1279 Minimum heat input Pilot burner Gas consumption natural gas H ( 64.5 71.9 84.1 95.2 106.3 117.3 10.9 kWh/m propane ( kg/h... -
Page 4: Dimensions R3400
Dimensions R3400 front view plan view side view rear view Fig. 1 Dimensional sketch R3400 Doc2005/3456en DOC2005/3456en.3456CV02A19/10/09 DOC2005/3456en.3456CV02A19/10/09 DOC2005/3456en.3456CV02A19/10/09... - Page 5 Type R3401 R3402 R3403 R3404 R3405 R3406 1330 1330 1130 1130 1330 1330 1160 1210 1003 1053 1203 1253 1146 1146 1146 1146 DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6 DN65 PN16 DN65 PN16 1355 1355 1355...
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Page 6: R3500 Technical Data
R3500 Technical data Type R3501 R3502 R3503 R3504 R3505 Nominal heat output 1000 Nominal heat input (nett. CV) 1066 Minimum heat input Pilot burner Gas consumption natural gas H ( 59.9 70.1 79.4 88.6 97.8 10.9 kWh/m propane ( kg/h 51.0 59.7 67.6... -
Page 7: Dimensions R3500
Dimensions R3500 front view plan view side view rear view Fig. 2 Dimensional sketch R3500 Doc2005/3456en DOC2005/3456en.3456CV02A19/10/09 DOC2005/3456en.3456CV02A19/10/09 DOC2005/3456en.3456CV02A19/10/09... - Page 8 Type R3501 R3502 R3503 R3504 R3505 1330 1130 1130 1330 1330 1210 1003 1053 1203 1253 1146 1146 1146 DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6 DN65 PN16 DN65 PN16 1355 1355 1355 1355 1355...
- Page 9 R3600SB Standard Technical Data Type R3601SB R3602SB R3603SB R3604SB R3605SB Nominal heat output 1043 Nominal heat input (net. CV) 1066 Minimum heat input Pilot burner Gas consumption Natural gas H 59.9 70.1 79.4 88.6 97.8 (10,9 kWh/m Propane 51.0 59.7 67.6 75.5 83.3...
- Page 10 Dimensions R3600SB Standard Fig. Dimensions R3600 Standard Doc2005/3456en VIII VIII DOC2005/3456en.3456CV02A19/10/09 DOC2005/3456en.3456CV02A19/10/09 VIII DOC2005/3456en.3456CV02A19/10/09...
- Page 11 Type R3601SB R3602SB R3603SB R3604SB R3605SB 1330 1130 1130 1330 1330 1210 1003 1053 1203 1253 1146 1146 1146 DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 Rp2” Rp2” Rp2” DN65 PN6 DN65 PN6 DN65 PN16 DN65 PN16 1405 1405 1405 1405 1405...
- Page 12 DOC2005/en.3456CV02A19/10/09...
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Page 13: Table Of Contents
TABLE OF CONTENTS R3400 Technical data ......I Dimensions R3400 ......II R3500 Technical data . - Page 14 Hydraulic system ......34 General ........34 5.4.1 Water flow .
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Page 15: Introduction
- available with many different options. Continual research and development means that Stokvis remains at the forefront of boiler technology. 101001AE Supplier STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL Tel.: 08707 707 747 Fax: 08707 707 767... -
Page 16: Service
The following aspects of the units are dealt with: - General description - Technical specifications - The facilities necessary for design and installation - Installation examples - Maintenance instructions The operating instructions needed by the user are attached to the unit; these are also to be found in Section 6. 130001AE The Stokvis service department is always available for Service... -
Page 17: Description
DESCRIPTION General The R3400/R3500/R3600SB are environmentally friendly modulat- ing gas fired heating boilers that can vary its output from 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. - Page 18 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.
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Page 19: Main Components
.18 Condensate collection tank Main components 1 Return connection 2 Flue attentuator 19 Flue gas collection chamber 20 Combustion chamber 3 Water flow switch 21 Electrical cable duct 4 Safety valve 22 Condensate discharge 5 Flow connection 23 Gas valve unit 6 Filling/drainage valve 24 Fan 7 Cover... -
Page 20: Description Of Principal Components
2.2.1 Description of The unit is constructed from the following principal components: principal 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 developed air inlet damper ensures a low noise level. - Page 21 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.
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Page 22: Boiler Control
Boiler control The principle employed for the Boiler Management Unit is as follows: The boiler begins operating on receipt of a heating demand. This heating demand is generated either: If the measured supply temperature is lower than the desired temperature. As a result of “manual operation”... -
Page 23: Safety
SAFETY Installation instructions Read through these instructions carefully before starting the installation. The appliance must be installed by a recognised installer in accordance with the applicable national and local regulations (see supplement). The installation may only be used for heating systems up to a maximum water temperature of 90 °C. - Page 24 Maintenance Work on the electrical installation may only be carried out by an authorised installer in accordance with the applicable electrical regulations. Work on the gas and hydraulic installations may only be under- taken by properly trained personnel in accordance with the safety regulations for gas installations (see supplement).
- Page 25 Danger of explosion When activities are being undertaken in the boiler room, always follow the applicable instructions “Working in an area where there is a danger of explosion”. 300007AE Installation The appliance must be installed by an authorised installer in accordance with the applicable national and local specifications and regulations.
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Page 26: Delivery And Transport
DELIVERY AND TRANSPORT Delivery The appliances are completely assembled, tested and covered in a "heat-shrink" protective covering. After delivery and removal of the protective covering, check the appliance for damage. Check that the equipment delivered is in accordance with the order and the delivery note. - Page 27 Rollers After the wooden blocks have been removed, it is possible to move the appliance by rolling it over tubes. Fig. 7 Moving with the aid of rollers Lifting The figure below shows how a unit can be safely lifted. To avoid damage to the panels, these should first be removed.
- Page 28 Dismantling and reassembly When the unit cannot be placed in position because of its dimensions or weight, the boiler may be partially dismantled. When it is necessary to perform extensive dismantling, we advise you to make early contact with your supplier. The unit can be delivered in parts, each of which has been pre-tested.
- Page 29 Third heat exchanger Type L (mm) B (mm) H (mm) m (kg) 1010 1310 R3601SB R3600SB only 1420 1010 R3602SB DRAWING NOT 1420 1110 R3603SB 1420 1210 R3604SB 1420 1310 APPLICABLE TO R3605SB R3600 SB Fig. 11 Dimensions and weights of the third heat exchanger Frame Type L (mm)
- Page 30 Fig. 13 Mounting the vibration dampers Protection against frost If the unit is out of use during the winter months there is a danger of freezing. Drain the water from the installation using the filling/drainage valves. 28CV01/430003DN 3456CV02A...
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Page 31: Installation
INSTALLATION Regulations The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations (see supplement). 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. - Page 32 Installation on a roof When the appliance is installed on a roof, or when the boiler room is the highest point in the system, the following protective measures are important: The unit itself may NEVER be the highest point of the in- stallation;...
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Page 33: Ventilation
5.2.3 Ventilation The ventilation of the boiler room must satisfy the applicable national and local standards and regulations (see supplement). 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. - Page 34 This front panel can be simply removed by pulling the lower edge of the panel forward. Behind this panel are two cover plates which can be removed by unscrewing the M5 bolts. The terminal strip with the connection clamps are mounted behind the lower cover plate.
- Page 35 Earth leakage trips can give problems when they are used in combination with frequency converters. In some countries this is actually forbidden. There are two reasons for this: a All rectifiers (not only frequency converters) can cause direct currents to flow in the mains power supply and which can reduce the sensitivity of the safety switch.
- Page 36 For additional energy savings an optional speed controlled pump is available for the R3500 and R3600SB. 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.
- Page 37 Connection terminals The operation of the appliance can be influenced by externally generated signals applied to the appropriate terminals. Terminal Description Boiler power supply; must be fused at 16/20 A. L1-L2-L3 N-E 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.
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Page 38: 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. -
Page 39: Combustion Air Supply
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. -
Page 40: Air Supply Pipe
The air supply pipe may be single-walled and constructed of: 5.3.4.2 Air supply pipe - plastic - thin-walled aluminium - flexible aluminium (take account of the resistance). 534201BE Fig. 18 horizontal air supply Type Air supply diameter (mm) (mm) (mm) R3601SB 239,5 R3401... - Page 41 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.
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Page 42: The Flue System
The formation of unwanted condensation must be avoided. In the event that during the heating up period condensation occurs, the condensate 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). - Page 43 Type Flue gas Flue gas quantity at full Maximum temperature capacity permissible at full capac- chimney ity (approx.) resistance °C m /h kg/s mbar R3401 1423 0,330 R3402 1580 0,367 R3403 1848 0,428 R3404 2091 0,485 R3405 2334 0,541 R3406 2578 0,598 R3501...
- Page 44 The flue connection diameters of the units have been chosen such that the speed of the flue gas will always be approximately 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).
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Page 45: Chimney
The R3400, R3500 and R3600SB are equipped with a flue attenuator. Never connect 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. - Page 46 Losses in the chimney related to various chimney sections expressed in metres of straight pipe. The total loss must be subtracted from the maxi- mum permitted chimney length given in table 10. Conversion for other types of accessories with different ζ (resistance coefficient) values can be simply accomplished by comparing with the stated losses at ζ=1.
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Page 47: 5.3.6 Condensate Discharge
Example: A chimney Ø 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: 5 x 1 14,8 m 4 x (3,7) -
Page 48: Hydraulic System
Hydraulic system 5.4.1 General 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). - Page 49 ∆ ∆ ∆ ∆ T 20 K Type Pump data Nominal Boiler- Grundfos Pump Head Available Max.* flow resis- Pump type speed head at power rate tance Qnom. Qnom. consumption m /h UPS 65-120F R3401 28,54 1,15 UPS 65-120F R3402 31,63 1,15 UPS 65-120F...
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Page 50: 5.4.2.2 Pump Characteristics
When the system includes air heaters (ventilation, air treat- ment), it is usually desirable to have a small ∆T 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. -
Page 52: Water Pressure
5.4.3 Water pressure At a maximum supply temperature of 90 °C and a minimum 5.4.3.1Operating pressure water flow-rate such as occurs at a ∆T 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. - Page 53 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.
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Page 54: Examples Of Hydraulic Systems
The chloride concentration must not exceed 200 mg/l. If this level is exceeded, the cause must be located. Compare the chloride concentration of the additional water with that of the system water. If this concentration is higher, this indicates evaporation if no chloride containing materials have been added. - Page 55 Example of a low-velocity header with isolating valves and an expansion tank. 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.
- Page 56 A boiler with vertically mounted low-velocity header Fig. 28 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 Fig.
- Page 57 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.
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Page 58: Operating Instructions
OPERATING INSTRUCTIONS Function When a heating demand is received and before the boiler starts up, the appliance must be pre-purged. Gas and air are optimally mixed in the mixing chamber. The fan supplies air for combustion, the quantity being regulated by the frequency controlled fan speed. - Page 59 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...
- Page 60 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 lid (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...
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Page 61: Fault Indications
A fault always results in a flashing E symbol and a fault code Fault indications 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"... -
Page 62: Start-Up
Start-up 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 q” using the function selector. (See also the operating instructions on the boiler). 28CV02/640001BE The appliance can be shut down in 3 different ways: Shut-down The boiler continues to supply domestic hot water. -
Page 63: Commissioning
COMMISSIONING General Commissioning must be carried out by skilled personnel. Fail- ure to observe this condition will invalidate the guarantee. 710001BE Commissioning Water and the hydraulic system Take a sample of the water from the filling/drainage valve on the boiler and a sample of the make-up water. Determine the water hardness using the titration method. - Page 64 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 10,0 ±...
- Page 65 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 10,2 ± 0,2 Main burner CO 9,3 ± 0,2 < 30 / <1000 Main/pilot burner CO [ppm] Burner pressure...
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Page 66: Maintenance
MAINTENANCE Safety During maintenance activities, always wear suitable clothing and shoes. Consider your own safety, particularly in respect of jewellery and loose clothing. 810001AE General 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. -
Page 67: Cleaning The Burner And Heat Exchangers
In order to carry out the following activities, the panels must first be removed: - In order to clean the air inlet damper, this must first be removed. Clean it with a vacuum cleaner. - For appliances installed in a dusty environment, the fan blades may become dirty. -
Page 68: Cleaning The Filter/Screen In The Gas Combination Block
Cleaning the filter/ Not applicable screen in the gas combination block Ionisation In order to carry out an ionisation measurement, a micro-am- measurement meter with a measuring range of 0 - 200 µA DC must be con- nected in the ionisation circuit. In this way the ionisation protection function can be checked. -
Page 69: Conversion Formulae And Factors
CONVERSION FORMULAE AND FACTORS Formulae 20,9 - measured O x 11,7 20,9 measured CO x 20,9 = 20,9 - 11,7 11,7 % CO is the maximum CO percentage that is generated by stoichiometric burning of G20 natural gas (H-gas). Excess air N: 20,9 x 0,914 20,9 - measured O... - Page 70 kcal/h Btu/h 0,86 3,41 1,163 3,97 0,293 0,252 Table 17 Conversion factors T9013AE 1 kcal = 4,187 kJ 1 kWh = 3,6 MJ Efficiency at the flue gas side The difference between upper and lower calorific values is the heat of evaporation of the combustion formed water. At 298.15K (25 °C) this amounts to 2442.5 kJ/kg (583.38 kcal/kg).
- Page 71 meg/l °dH °f °e CaCO /l meg/l 3.51 °dH 0.37 1.78 1.25 17.8 °f 0.56 °e 0.285 1.43 14.3 mg CaCO /l 0.02 0.056 1.54 Table 18 Conversion of degrees of hardness 1 degree English hardness (°e) = 65 mg CaCO /imp. gallon 1 Grain/US Gallon = 0.958 °dH 1 milligramme equivalent per l (mval/l)
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Page 72: Supplement
SUPPLEMENT At the time of printing the following regulations and standards were taken into account: British Standard Parts 1 + 2 (flueing and ventilation). 1. BS 5440 - 2. BS 6644 - Installation of gas fired water heaters (60 kW - 2 MW). 3. - Page 73 Addendum . Commissioning figures including LPG. Guide Values at Full Capacity: Main Burner CO 9.8-10.2% for Natural Gas G20, G25 10.8-11.2% for Propane G31 Pilot Burner CO 9.8-10.2% for Natural Gas G20, G25 10.8-11.2% for Propane G31 ≤30ppm Main Burner CO for Natural Gas G20, G25 ≤30ppm for Propane G31...
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