econoflame / econopak r300 heating / hot water boilers

ECONOFLAME / ECONOPAK R300
HEATING / HOT WATER 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
50CV02B&C
11/03/03
Edition 50CV02B, 17-06-2001
© 2001 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.
II
50CV02B
R300 TECHNICAL DATA
Type
R301
R302
R303
R304
R305
R306
R307
70
74
16
86
91
20
114
121
27
139
147
33
185
194
44
230
243
55
274
289
65
Nominal heat output
Nominal heat input (nett. CV)
Minimum heat output
kW
kW
kW
Gas consumption
natural gas H (10,9 kWh/m3)
propane (12,8 kWh/kg)
m3/h
kg/h
6,79
5,78
8,35
7,11
11,10
9,45
13,49
11,48
17,80
15,16
22,29
18,98
26,51
22,58
Gas inlet pressure
natural gas (min.)
natural gas (max.)
propane
mbar
mbar
mbar
17
25
50
17
25
50
17
25
50
17
25
50
17
25
50
17
25
50
17
25
50
Water capacity
Max. working pressure
dm3
bar
13
6
15
6
17
6
19
6
36
6
39
6
42
6
mm
mm
100
100
100
100
100
100
150
125
180
150
200
180
200
180
Flue connection
Air supply (option)
D
D1
Gas connection
G
Rp¾"
Rp¾"
Rp¾"
Rp¾"
R1"
R1½"
R1½"
Water connections
W
R1½"
R1½"
R1½"
R1½"
R2"
R2"
R2"
¾"
¾"
3
¾"
¾"
3
¾"
¾"
3
¾"
¾"
3
¾"
¾"
3
1"
1¼"
3
1"
1¼"
3
Safety valve
(option)
boiler connection
relief connection
standard setting
bar
Power supply
Frequency
Fuse
V
Hz
A
Max. electrical power consumption
unit
pump (option) maximum
total
W
W
W
135
245
380
135
245
380
370
245
615
370
245
615
370
380
750
370
380
750
370
380
750
Boiler weight, empty, ± 5 %
kg
120
140
160
180
250
270
290
Table 1
230 1N~ 230 1N~ 230 1N~ 230 1N~ 230 1N~ 230 1N~ 230 1N~
50
50
50
50
50
50
50
10
10
10
10
10
10
10
Technical data R300
50CV02B
III
DIMENSIONS R300
Fig. 1
IV
Dimensional sketch R500
50CV02B
Type
R301
R302
R303
R304
R305
R306
R307
B
mm
500
600
700
800
600
700
800
B1
mm
110
160
210
240
130
154
180
D
mm
100
100
100
150
180
200
200
D1
mm
100
100
100
125
150
180
180
Rp¾"
Rp¾"
Rp¾"
Rp¾"
R1"
R1½"
R1½"
G
H1
mm
160
160
160
176
197
197
197
H2
mm
238
250
325
347
320
330
365
H3
mm
943
943
874
874
900
900
900
L
mm
635
635
635
635
890
890
890
L1
mm
110
110
110
110
155
155
155
L2
mm
445
445
445
445
655
655
655
L3
mm
525
525
525
525
735
735
735
R1½"
R1½"
R1½"
R2"
R2"
R2"
W
Table 2
R1½"
Dimensions R300
Conditions applicable to table 1:
- Nominal capacity measured at
- Gas consumption at
- Gas category
- Gas pressure
- Appliance category
- Protection degree
:
:
:
:
60 - 80 °C.
1013 mbar, 15 °C, dry
II2H3P
The unit is adjusted during manufacture for a gas supply
pressure of 25 mbar.
: B23, C53, C33 or C63
: IP20
50CV02B
V
VI
50CV02B
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. 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.
IM/22 - Installation guide for high efficiency condensing boilers.
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.
New Water Regs -
50CV02B
The water supply (water fittings) Regulation 1999.
50CV02B
TABLE OF CONTENTS
R300 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . III
Dimensions R300 . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
1
1.1
1.2
1.3
1.4
1.5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stokvis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General restrictions . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
2
2.1
2.2
2.2.1
2.3
2.4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of principal components . . . . . . . . . . . . .
Boiler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
5
6
8
8
3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4
4.1
4.2
4.3
DELIVERY AND TRANSPORT . . . . . . . . . . . . . . . .
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
5
5.1
5.2
5.2.1
5.2.2
5.2.3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.4.1
5.3.4.2
5.3.5
5.3.5.1
5.3.5.2
5.3.6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . .
Water connections . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion air supply . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air supply pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate discharge . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
13
14
14
14
14
19
20
20
20
22
22
22
24
50CV02C
VII
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
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow rate and resistance . . . . . . . . . . . . . . . . . . . . .
Pump characteristics . . . . . . . . . . . . . . . . . . . . . . . .
Isolating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow protection . . . . . . . . . . . . . . . . . . . . . . . .
Water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler expansion tank . . . . . . . . . . . . . . . . . . . . . . . .
System expansion tank . . . . . . . . . . . . . . . . . . . . . .
Water pressure protection . . . . . . . . . . . . . . . . . . . .
Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . .
Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples of hydraulic systems . . . . . . . . . . . . . . . .
25
25
25
25
27
29
29
29
29
29
29
29
29
29
29
31
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
35
38
39
39
39
7
7.1
7.2
COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the burner and heat exchangers . . . . . . . .
Cleaning the filter/screen in the gas
combination block . . . . . . . . . . . . . . . . . . . . . . . . . .
Ionisation measurement . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
CONVERSION FORMULAE AND FACTORS . . . . . 46
SUPPLEMENT
Edition 50CV02C, 31-10-2001
© 2001 Stokvis
VIII
50CV02C
44
44
44
44
45
45
45
45
1
1.1
INTRODUCTION
Stokvis.
ISO9002
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 60 to 1200 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.
1.2
Supplier
1.3
This document
STOKVIS ENERGY SYSTEMS
96R Walton Road, East Molesey
Surrey KT8 0DL
Tel.: 08707 707 747
Fax: 08707 707 767
This documentation has been produced 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 necessary general and specific information to install, service and
operate this product.
The supplier (see 1.2) will be able to provide any further or
supplemental information.
50CV02C
1
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.
1.4
Service
1.5
General restrictions
The Stokvis service department is always
available for commissioning and for providing service and
maintenance. For details see 1.2.
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.
2
50CV02C
2
2.1
DESCRIPTION
General
The Econoflame R300 series are environmentally friendly
modulating gas fired heating boilers with variable outputs from
25 % to 100 % of maximum capacity.
The R300 series consists of 7 types in a range from 70 to
274 kW.
The units have an extremely low emission of NOx and CO, so
that this boiler satisfies the most stringent European requirements.
The R300 series have CE approval for all relevant European
countries. The series are registered under the product identification number 0063BL3345.
The boilers can be supplied either as a standard (category B23)
or a room sealed (categories C53, C33 or C63) appliances.
Working principle and construction
Air is blown into the appliance, as required, by a speed-controlled fan and is thoroughly mixed with gas in the correct proportions.
A temperature controller compares the desired water temperature with the temperature of the water flow. If required, the
controller will vary the speed of the fan and the fan will give a
speed feedback signal to maintain the correct heating capacity.
The gas/air mixture so formed is passed through the cooled
premix burner and is ignited. The premix burner is constructed
of finned bimetallic pipes (inside stainless steel, outside
aluminium) and steel water headers.
Heat transfer takes place in three heat exchangers. The first
heat exchanger is constructed from smooth stainless steel
pipes, while the second heat exchanger is fitted with laserwelded, stainless steel finned pipes. The third heat exchanger
is fitted with smooth stainless steel pipes.
All heat exchangers are fitted with steel profiled water headers
(stainless steel for water heater) which guarantee an optimum
water flow through the appliance.
The burner and the heat exchangers are connected in series.
The R300 units have a small water capacity so that it can
rapidly adjust to changing conditions. It can be installed without
any restrictions to the return water temperature. The necessary
water flow rate must be ensured by the boiler pump (optional).
50CV02C
3
Application possibilities
Because of its construction, the R300 unit is 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 = +2 °C – +90 °C), see 5.3.2 connection
terminals).
Fig. 2
4
The Econcoflame R300 standing model
50CV02C
2.2
Main components
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Casing
17
Air pressure switch
18
Control panel
19
Burner
20
Combustion chamber
21
First heat exchanger
22
Second heat exchanger
23
Third heat exchanger
24
Condensate receptacle
25
Flue attenuator
26
Condensate discharge trap (U-bend) 27
Flue gas discharge
Flow connection
A
Safety valve (option)
B
Gas connection
C
Adjusting feet
D
Fig. 3
Frame
Filling/drainage valve
Return connection
Water flow switch
Water headers
Ignition transformer
Connecting terminals
Distribution plate
Mixing chamber (internal)
Gas valve unit
Fan
Air
Gas
Flue gas
Condensate
General survey
50CV02C
5
2.2.1
Description of
principal components
The boiler is constructed from the following principal components:
Fan [27]
The DC fan, which is equipped with speed feedback, draws in
the combustion air and increases the air pressure. The speed
feedback signal is relayed to the regulator, which adjusts the
speed if need be.
Gas train
The principal component of the gas train is the main gas valve
[26]. 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. As an option, the unit can be equipped with a gas
filter.
Mixing chamber [30]
This area is used for the thorough mixing of the gas and the
combustion air. The chamber is situated inside the unit.
Burner [4]
After the gas/air mixture has been distributed over the burner
using a distribution plate, the mixture is burnt on the burner
surface such that the flame is directed downward. The burner is
both air and water-cooled. The water headers are constructed
of steel (stainless steel for water heater), and ensure a twopass flow through the burner.
Heat exchangers [6, 7 and 8]
The first heat exchanger is constructed of smooth stainless
steel pipes and transfers most of the combustion energy to the
system water. The second heat exchanger is constructed of
laser-welded, stainless steel finned pipes. The third heat
exchanger is constructed of smooth stainless steel pipes. The
second and third heat exchanger transfer the heat from the
combustion gasses to the system water. All water headers are
constructed of steel (stainless steel for water heaters), and
ensure a five-pass or three-pass flow through the heat
exchangers (depending on the type). The space between the
burner and the first heat exchanger constitutes the combustion
chamber.
Water headers [21]
The water headers are part of the burner and the heat
exchangers.
6
50CV02C
Water connections
These consist of a flow connection [13] and a return connection
[19]. Both of these connections are provided with a filling/drain
valve [18]. The connection for the optional safety valve [14] is
fitted on the supply line. The flow switch [20] is fitted on the
return line.
Boiler pump (optional)
The boiler pump must be mounted on the return connection to
the unit and can be directly connected electrically to the
appropriate terminals 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. As an
option, the pump is supplied as a separate item with the boiler.
Condensate receptacle [9]
A condensate receptacle is fitted underneath the last heat
exchanger. This receptacle is equipped with a condensate and
flue gas outlet.
Frame [17]
The frame is constructed from steel profile sections and is fitted
with vibration absorbing adjusting feet [16].
Casing [1]
The casing consists of easy-to-remove panels. Once the cover
has been opened (using tools), all other panels can be
removed without using tools.
The electrical section
This includes the control and safety circuits for the unit.
Connecting terminals [23]
The boiler power supply, the connecting terminals, the pump
connection and the pump relay are all fitted on top of the boiler.
The terminal strip is located under the cover, on the right hand
side.
50CV02C
7
2.3
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:
A
If the measured supply temperature is lower than the
desired temperature
B
As a result of “service operation” mode having been
selected (j)
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 fan, thus controlling the fan speed. Depending on the
quantity of air displaced by the fan, the proportional pressure
regulator will add the corresponding quantity of gas. In this way,
the boiler power is continuously modulated, enabling the boiler
to accurately follow the demand for heat. The fan is equipped
with a speed feedback, enabling an even more accurate control
behaviour.
Once the supply water temperature exceeds the desired value,
the unit will shut down. As soon as the supply water
temperature falls below the set value, the boiler re-starts.
2.4
Safety aspects
The boiler contains the following safety components:
- Flame protection (1x re-start)
- Water flow protection
- Maximum water temperature protection
- Gas valve test
- overload and underload protection.
If one of these components operates, this results in a lockout
fault. Lockout faults can only be cancelled by resetting the unit.
8
50CV02C
3
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 information included in this technical
manual.
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
followed this can result in serious damage to the installation,
personal injury or environmental damage.
Danger of electric shock.
Useful information.
50CV02C
9
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
undertaken 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, ensure that
all panels are replaced.
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.
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.
Modification
Modifications to the installation may only be carried out with the
written approval of the manufacturer.
10
50CV02C
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”.
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.
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
appropriate 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.
50CV02C
11
4
4.1
DELIVERY AND TRANSPORT
Delivery
The unit comes as standard fully assembled, tested and
packaged.
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.
4.2
Packaging
The unit is supplied in cardboard packaging on a pallet.
For transport, consult the technical details for dimensions and
weight.
4.3
Transport
Remove the packaging preferably after transportation and
positioning in the boiler room or remove the panels before
transporting the appliance. This is to prevent damage to the
casing panels.
Moving the appliance
A pallet truck or fork lift truck used at the front or side of the
unit.
Standard door width
The dimensions of the unit are such that after removing the
pallet, all types will fit through a standard width door opening of
80 cm (remove the outside panels of type R307).
Positioning
Once the boiler has been installed, it can be adjusted
horizontally using the adjusting feet. Subsequently, the water,
gas, condensate and electrical connections can be made.
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.
12
50CV02C
5
5.1
INSTALLATION
Regulations
The appliance must be installed by a recognised installer in
accordance with the applicable national and local specifications
and regulations (see Supplement).
Commissioning should be carried out by the service department
of your supplier.
5.2
Boiler room
5.2.1
General
5.2.2
Set up
- 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 so constructed that the space required for it is
small
- The range of applications for the boiler is that much greater
because of the possibility to supply it as a room sealed
appliance (see Section 5.3.4)
- Boiler types 1 - 3 can also be suspended on a wall using the
optional suspension bracket.
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:
- 250 mm at both sides
- 1000 mm at the front (space for free movement).
If you do not observe the recommended space requirements,
future maintenance might be more difficult.
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:
50CV02C
13
The unit itself may NEVER be the highest point of the
installation; 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.
5.2.3
Ventilation
The ventilation of the boiler room must satisfy the applicable
national and local standards and regulations (see Supplement).
With regard to ventilation, pay particular attention to the
following 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
c Fit inlet grills with a large width and a small height
d Ensure that the correct amount of high level ventilation exists
e If the air supply is inadequate, it may be necessary to fit a
mechanical means of providing adequate ventilation.
5.3
5.3.1
Connections
Gas connection
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.
The pressure of the gas supplied 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.
The loss of pressure in the connecting pipes must be such that,
at maximum boiler capacity, the pressure must never fall below
17 mbar for natural gas or 30 mbar for propane.
5.3.2
Electrical connection
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.
14
50CV02C
The electrical connections, the connection terminals and the
boiler pump relay are located underneath the cover, on the
right-hand side of the boiler. You can unlock the cover using a 4
mm socket wrench.
You must connect the unit using an all-pole main switch with a
contact opening of at least 3 mm.
The cables to be connected (power supply, control) enter the
appliance via the rear of the unit, using cable glands.
Fig. 4
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.
50CV02C
15
In order to prevent malfunctions occurring as a result of
inductive or high frequency signals, or static electricity,
screened cables must be employed for all low voltage and
control signals between the boiler and externally
connected units. The screening must be earthed at both
ends of the cable.
Electro-technical data
Type
R301
R302
R303
R304
R305***
R306***
R307***
Fan, control and
safety components
Pump (option)
Total
electrical
power
Power
consumption
consumption
(max)
** (max)
Supply*
1N~
Power
consumption
(max)
Supply*
1N~
V
W
V
W
W
230
230
230
230
230
230
230
135
135
370
370
370
370
370
230
230
230
230
230
230
230
245
245
245
245
380
380
380
380
380
615
615
750
750
750
Table 3 Electrotechnical data
*
tolerance on voltage: 230 V +10 % /-15 %
tolerance on frequency: 50 Hz ± 5 %
**
the stated pump power is based on the maximum power consumption
in pump speed 3
***
3-phase pump available as an option.
16
50CV02C
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 (= +2 °C – +90 °C) 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 temperatures
- 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. This E6 regulator can
be further extended with an optimizing controller for each group
(BM). The boiler is then directly weather-dependently
controlled.
KKM option
This is a boiler cascade manager permitting up to eight boilers
to be switched in cascade. The KKM also has the same
possibilities as the E6 option.
Connection terminals
The operation of the appliance can be influenced by externally
generated signals applied to the appropriate terminals.
Terminal Description
L1-N-E
Boiler power supply; must be fused at 10 A.
8-9
Domestic hot water primary pump control. This
output 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 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
50CV02C
17
months whilst continuing to provide domestic hot
water priority.
12 - 13
Operation signal. If a fault has occurred 3 times or
more within 6 minutes, the fault code will appear in
the display with a "3" and the operation signal falls
off (230 V, 50 Hz, 1 A, N.O.).
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
Interlock input (230 V). If the connection between
these terminals is interrupted, the boiler will be
deactivated and wait until the connection is restored
(after 6 minutes or if the same fault has occurred
three times within 6 minutes, this input will lock out).
20 - 21
Lockout input (230 V). If the connection between
these terminals is broken the boiler will enter the
fault mode. Reinstate 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
measure the temperature of a low velocity header.
35 - 36
Calorifier temperature sensor*. After a suitable
sensor has been connected it will be automatically
recognised when the power supply voltage is
switched on. The terminals 34 - 35 must not be
interconnected. 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).
37 - 38
External influence input (2 – 10 VDC = +10 °C – +90
°C)*. At voltages below 2 V the boiler will switch to
“constant supply temperature operation”.
39 - 40
External capacity output*. Only if programmed for fan
speed control. This signal provides information for a
capacity display. 0 – 100 % = 0 – 10 VDC. The
maximum current is 0.5 mA.
41 - 42
SCOM bus connection (make sure to use the correct
polarity).
43 - 44
Primary boiler pump control (0 – 10 V).
* In order to avoid faults caused by inductive currents, static
electricity or high frequency signals, the use of screened
cables is necessary.
18
50CV02C
5.3.3
Water connections
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.
Water connection supports
We recommend that the supply and return pipes be properly
supported using brackets to prevent mechanically overloading
the lines and to simplify maintenance.
The unit is a constant water flow appliance and is suitable for
use in both open vented (non-pressurised) systems and sealed
(pressurised) systems provided the minimum pressure
requirements, as per table 10, are met. The unit is optionally
fitted with a boiler pump 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 between the boiler and the low velocity header must
be chosen such that the remaining working head of the pump
(see table 8) will not be exceeded.
It is recommended that manually operated valves be fitted
between the water connections and the installation.
Connect the boiler pump on the return side, making sure to
keep a distance to the flow switch of at least 5 x d.
The boiler pump (optional) can be installed horizontally or
vertically.
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.
50CV02C
19
5.3.4
5.3.4.1
Combustion air
supply
General
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 should not
result in a pressure drop exceeding 1.8 mbar (180 Pa).
If the unit is used as a room sealed appliance, open Tees or
draught stabiliser are not permitted.
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 the resistance)
- stainless steel.
Fig. 5
Table 4
20
horizontal air supply
Type
Air supply diameter D1 (mm)
R301
R302
R303
R304
R305
R306
R307
100
100
100
125
150
180
180
Air supply connection
50CV02C
The connection to the air supply pipe is always mounted on the
back 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 300 mm above the roof and must be fitted with a rain cap.
The flue pipe opening must end at least 1000 mm above the
roof, assuming the roof to be flat.
Fig. 6
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.
Fig. 7
Distance between air inlet and flue gas outlet
To prevent undesirable condensate from forming, we strongly
recommend that you insulate the air-supply duct on the outside
to make it vapour tight.
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21
5.3.5
5.3.5.1
The Flue system
General
The flue system must be installed by a recognised installer in
accordance with the applicable national and local specifications
and regulations.
The flue pipe connection is at the back of the appliance and
has been designed for direct connection to a corrosion resisting
flue pipe.
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 > 83 %.
The following table lists all the flue gas data for all types.
Type
R301
R302
R303
R304
R305
R306
R307
Flue gas
temperature
at full
capacity
(approx.)
Flue gas quantity at full
capacity
Maximum
permissible
chimney
resistance
°C
m3/h
kg/s
mbar
. 135
. 135
. 135
. 135
. 135
. 135
. 135
130
161
214
261
345
430
513
0,033
0,040
0,053
0,065
0,086
0,106
0,127
1,8
1,8
1,8
1,8
1,8
1,8
1,8
Table 5 Flue gas data
Capacity
100 %
Flow temperature
80 °C
Return temperature
60 °C.
5.3.5.2
Chimney
Chimney length
Because the appliance is fitted with a “premix burner” with a
fan, an over-pressure is built up in the unit. This overpressure is
sufficient to overcome the resistance of the cooled burner, heat
exchangers, air intake and chimney up to a maximum of 1,8
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.
22
50CV02C
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.
The flue connection diameters of the units have been chosen
such that the speed of the flue gas will always be approximately
5 m/s. For the appliance there will be a maximum overpressure
of approximately 1.8 mbar (180 Pa) for the flue system.
Owing to their high resistance, bends with an R/D ratio smaller
than 1 should be avoided.
Calculation of the diameter and length
For calculating and checking the internal diameter of a flue
system with mechanical discharge, refer to the applicable
national and local regulations and specifications.
Type
Length of flue system in m
Diamete Diamete Diamete Diamete Diamete Diamete Diamete
r
r
r
r
r
r
r
80 mm 100 mm 130 mm 150 mm 180 mm 200 mm 250 mm
R301
9
68*
>256
R302
38*
200
R303
8*
64
210
70
150*
R304
R305
76
R306
110*
110
R307
160*
174*
Table 6 Length of flue system
The flue system lengths have been rounded down.
* Chimney diameter at the appliance.
These lengths are valid for boilers as open appliance.
For room sealed appliances these lengths are valid for the air
supply and flue together.
50CV02C
23
Losses in the chimney related to various chimney sections
expressed in metres of straight pipe. The total loss must be
subtracted from the maximum permitted chimney length given
in table 6.
Type
Diameter
in
mm
Elbow
90°
R/D =0,5
Elbow
90°
R/D = 1
Elbow
45°
R/D=0,5
90° Tee
R301
80
100*
130
4,0
4,9
3,2
3,2
1,2
1,4
1,6
4,0
4,9
6,2
R302
100*
130
4,9
3,2
3,2
1,4
1,6
4,9
6,2
R303
100*
130
150
4,9
3,2
3,2
3,6
1,4
1,6
1,8
4,9
6,2
7,5
R304
130
150*
3,2
3,2
3,6
1,6
1,8
6,2
7,5
R305
150
180*
3,6
4,6
1,8
2,3
7,5
9,0
R306
180
200*
4,6
4,8
2,3
2,6
9,0
10,1
R307
180
200*
250
4,6
4,8
6,2
2,3
2,6
3,1
9,0
10,1
12,4
Table 7 Chimney losses in metres of straight pipe
* Connection at boiler.
5.3.6 Condensate discharge
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. 8). 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
subsequent maintenance activities and inspections.
24
50CV02C
Fig. 8
5.4
5.4.1
Condensate discharge
Hydraulic system
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 R300 unit is a low water content boiler for which the water
flow rates must be within minimum and maximum values.
Tables 8 + 10 list 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).
5.4.2
5.4.2.1
Water flow
Flow rate and
resistance
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.
50CV02C
25
Type
Pump data
)T 22 K
Nominal Boiler- Grundfos
flow
resist
pump
rate
ance
type
m3/h
R301
2,72
R302
3,51
R303
4,52
R304
5,48
R305** 7,25
R306** 9,05
R307** 10,85
kPa
Pump
speed
UPS
17,0
25-80
23,5
25-80
30,0
32-80
30,0
32-80
20,0 32-120F
23,0 32-120F
32,0 32-120F
3
3
3
3
3
3
3
Head
at
Qnom.
Available
head at
Qnom.
Max.*
power consumption
kPa
kPa
W
66
58
52
45
75
65
52
49,0
34,5
22,0
15,0
55,0
42,0
20,0
245
245
245
245
380
380
380
Table 8 Water flow rate and pump data R300
* 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
** 3-phase pump available as an option.
The optional primary pump has been sized to have an optimum
duty when ∆T = 22 K. When running at ∆T’s less than this 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 ∆P measurement via the filling and drainage valve in
the supply and return pipe of the unit. The measured head can
be compared with the boiler resistance (table 8). At full capacity the water flow rate can be very accurately compared with
the ∆T, measured across the flow and return of the boiler.
The unit has a standard pump control. When the boiler is
enabled, the pump is switched on. When the enable signal is
re-moved, the pump will continue to run for several minutes.
This run on time is adjustable. The standard time is two
minutes.
When the system includes air heaters (ventilation, air
treatment), 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.
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 greater than that flowing through the primary circuit, a mixed
temperature 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
26
50CV02C
5.4.2.2
Pump characteristics
adjusted to obtain the desired temperature in the connected
circuits.
Fig. 9
Pump characteristic UPS 25-80
Fig. 10
Pump characteristic UPS 32-80
50CV02C
27
Fig. 11
Pump characteristic UPS 32-120F
Type
Pump speed
Pmax
W
I
(1 x 230 V) A
UPS 25-80
R301 - R302
1
2
3
140
210
245
0,63
0,92
1,04
UPS 32-80
R303 - R304
1
2
3
145
220
245
1,05
0,95
1,05
UPS 32-120F*
R305 - R307
1
2
3
320
340
380
1,55
1,65
1,75
Table 9a Electrical pump data
* 3-phase pump optionally available for types 5 - 7.
Type
Pump speed
Pmax
W
I
(1 x 230 V) A
UPS 32-80B
R301 - R304
1
2
3
145
220
245
1,05
0,95
1,05
UPS 32-120FB*
R305 - R307
1
2
3
320
340
380
1,55
1,65
1,75
Table 9b Electrical pump data bronze version for water heater
* 3-phase pump optionally available for types 5 - 7.
5.4.2.3
28
Isolating valves
It is recommended that manual valves be fitted between the
flow and return connections and the installation.
50CV02C
5.4.2.4
Valves
Mechanical non-return valve can be used. This is required so
as to avoid short-circuiting the appliance on the water side.
5.4.2.5
Water flow
protection
The unit is provided with water flow switch. This shuts the
appliance down in the event that the flow of water through the
appliance falls below the minimum required value.
5.4.3
Water pressure
5.4.3.1
Operating pressure
At a maximum supply temperature of 90 °C and a minimum
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.
Minimum operating pressure
in bar
Flow temperature
°C
>1,5
>1
90
80
Table 10 minimum operating pressures at nominal flow rate
5.4.3.2 Boiler expansion
tank
It is advisable to fit an expansion tank in the return pipe
between pump and the boiler isolating valve.
5.4.3.3System expansion
tank
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 velocity header.
5.4.3.4
Water pressure
protection
As an option, a 3 bar pressure relief valve can be supplied
(separately). Pressure relief valves adjusted between 3 and 6
bar, with increments of 1 bar, can also be supplied if necessary.
5.4.4
Water temperature
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.
5.4.5
Water quality
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.
50CV02C
29
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.
In general, 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
Moderately hard
approx. 160 - 250 ppm
Hard and very hard over
250
ppm.
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 ∆T = 20 K.
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 the pump. If a vertical
low velocity header is employed, the air separator should be
fitted above the header.
30
50CV02C
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. 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.
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.
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 requirements.
5.4.6
Examples of
hydraulic systems
The hydraulic systems shown are only examples. They must
not be employed in practice without professional analysis.
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
(approximately 0.5 m/s). The diameter of the low velocity
header can be determined using the formula:
ø =
Where:
Q
x 1,28
3600
v
ø = the diameter of the low velocity header in m
Q = the water flow rate in m3/h of the boiler circuit or
the secondary circuit, whichever is the greater
v = the speed in m/s.
50CV02C
31
Example of a low velocity header with isolating valves and an
expansion tank.
Fig. 12
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
separator 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 ∆T 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 that
the 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.
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.
32
50CV02C
Fig. 13
Boiler with vertically mounted low velocity header arranged with
right hand connections
Installations with weather dependent regulation and hot
water priority switching
The small water capacity of the boiler and the fast, accurate
boiler temperature regulation make the R300 unit ideal for use
as a boiler with hot water priority switching.
The boiler uses a simple temperature regulator without roomtemperature compensation. In order to determine the supply
water temperature and to compare this with the set heating
curve using an external temperature sensor, it is necessary to
keep the boiler pump operating continuously.
Switching the secondary pumps on and off without the use of a
building optimising system results in the temperature swings
being too large and a boiler and pump that are switched too
frequently. This increases the chances of wear and faults
occurring. In addition, it is likely that the operating efficiency will
be reduced.
Generally the hot water storage capacity is determined by peak
usage and operating cycle. In order to avoid shuttling between
central heating and hot water regulation and to keep the boiler
operating at high capacity, we advise the following:
- Minimum hot water storage capacity: 300 l/100 kW
- Maximum storage tank heating time: 20 minutes.
50CV02C
33
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.
Fig. 14
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.
When two 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 (TT)
must be mounted at the common flow pipe as indicated in the
drawing.
Fig. 15
34
Installation with more than one appliance
50CV02C
6
OPERATING INSTRUCTIONS
6.1
Function
6.2
Regulation
6.3
Control module
When a heating demand is received and before the boiler starts
up, the appliance must be pre-purged.
The fan supplies combustion air and has a modulating control.
A proportional controller in the gas valve (also modulating)
determines the required quantity of gas. Gas and air are
optimally mixed in the mixing chamber. Thereafter, the gas air
mixture is ignited on 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.
Depending on the heating demand, the unit will be started up
and shut down between 0% and 25% capacity and will be
continuously modulated between 25 % and 100 % capacity.
Lid closed
Fig. 16
1
2
3
4
5
Lid open
Control module
function
i standby
F automatic operation
summer operation
F
service operation min.
jI
jII service operation max.
function selector
fault indication E
supply temperature
malfunction code (flashing)
1
2
3
4
5
6
7
8
9
parameter indication
P1 current/setting boiler supply temp.
P2 current/setting domestic hot water
temperature
*P3 desired temperature
P5 current external temperature
P8 current low velocity header temp.
P9 current boiler capacity
P10 password entry for factory
settings
optical I/O
reset/programming push-button
alarm LED
parameter/value selector
output status
current/desired parameter value
fault/parameter indication
input status
* P3 set load (in combination with KKM)
50CV02C
35
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:K
standby
F
automatic
F
summer mode
jI
jII
service, low capacity
service, high capacity
the boiler switched off but frost protection is
active
the boiler can operate in heating or direct
hot water mode
the boiler will only react to a direct hot water
demand
the boiler will run at low capacity
the boiler will run at full capacity.
Information mode
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/setting flow temperature
P2
actual/setting direct hot water temperature (if used)
P3
setpoint temperature (* P3 set load in comb. with KKM)
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: H Flame Ionisation detected
SW Water flow switch in operating position
DW APS in operating position
RT Boiler enabled by BMS
Bus Data-bus detected.
Output indications: Power to Main Gas Valve
Power to Ignitor
Control signal to fan
Z Power to Primary Boiler Pump
F Power to Primary DHW Pump.
36
50CV02C
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)
- Push the Reset/Programming key (pos.3), the LED will light,
turn the rotary switch (pos.5) until the desired water flow
temperature has been reached
- Push the Reset/Programming key, the LED will go out
- Close the cover.
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
- Push the Reset/Programming key (pos.3), the LED will light,
turn the rotary switch until the desired Domestic Hot Water
flow temperature has been reached
- Push the Reset/Programming key, the LED will go out
- Close the cover.
50CV02C
37
6.4
Fault indications
A fault always results in a flashing E 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 has occurred 3 times or more within 6
minutes, the fault code will appear in the display with a "3"
above it. If the supplementary fault code "3" is present for 6
minutes or if a deactivating fault is detected for more than 6
minutes, a fault signal (terminals 12 - 13) will follow. The boiler
can be nevertheless in operation.
1
2/3
4
5
6
7
11
12
13
14
15
18
20
21
22
23
24
25
26
27
30
38
The high limit thermostat has operated. The boiler
temperature has exceeded 100 °C. Press the reset button.
The interlocking input has been interrupted. Correct the
external error and press reset.
Flame signal fault. No flame detected at burner start. One
restart possible. Correct fault and press reset.
Flames go out during operation. If this fault occurs 3 times
within 6 minutes, the fault will be lock out. Correct the fault
and press reset.
Temperature protection has operated. The boiler temp. has
exceeded the setting. Press reset.
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.
Flow temperature sensor is faulty. Correct fault.
Wiring of the CXE/EM extension module is defective.
Correct fault.
Hot water temp. sensor is defective. Correct fault.
External temp. sensor is defective. Correct fault.
Header temp. sensor is defective. Correct fault.
Error in the control of gas valve 1. After burner has stopped
a flame has been detected for a period of 5 seconds. This
in spite of the fact that valve has been sent a close signal.
Correct fault.
Error in the control of gas valve 2. After burner has stopped
a flame has been detected for a period of 5 seconds. This
in spite of the fact that valve has been sent a close signal.
Correct fault.
Air flow too low. The air pressure switch has not operated.
Press reset.
The air pressure switch has not switched off. Press reset.
The fan does not reach the set speed during pre-ventilating.
Correct fault.
The fan does not reach the set speed during ignition.
Correct fault.
The fan does not come to a standstill. Correct fault.
The air pressure switch switched off during operation.
CRC error in EEprom data group “Boiler”. Press reset.
50CV02C
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. Correct
fault.
X.Y. An internal fault has been detected during the self-test.
Press reset.
6.5
Start-up
6.6
Shut-down
6.7
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 q” using the
function selector (see also the operating instructions on the
boiler).
The unit can be shut down in three different ways:
A
The boiler continues to supply domestic hot water. Select
the F function with the function switch
B
The boiler is not operating and will only start up for
automatic frost protection. Select the i function using the
function selector
C
Shut down the boiler:
1 Switch off the boiler using the on/off switch on the
control panel
2 Close the gas valve.
The unit must be installed by a recognised installer. The
operating instructions must be strictly observed.
If the source of the fault cannot be found, the service
organisation 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.
50CV02C
39
7
COMMISSIONING
7.1
General
7.2
Commissioning
Commissioning must be carried out by skilled personnel.
Failure to observe this condition will invalidate the guarantee.
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 mg/l. If this concentration is
exceeded, 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 10 (Operating
pressures).
Check that there is a by-pass or a low velocity header fitted in
the hydraulic system. This is a requirement.
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.
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.
Check the chimney
Check the chimney. Ensure that the connection between the
appliance and the chimney is such that gasses cannot escape.
If necessary, apply an appropriate sealing tape.
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.
40
50CV02C
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.
Settings at full capacity
Guide value CO2
9,8 - 10,2 % for natural gas G20, G25
11,6 - 12,0 % for propane G31
Guide value CO
<15
<25
ppm for natural gas G20, G25
ppm for propane G31
Burner pressure = fan pressure – pressure above burner
P(vent)-P(bb)
type R301 - R302
1,5 ± 0,5 mbar
type R303 - R307
8,0 ± 2,0 mbar
Fig. 17
Burner pressure measurement
Measure the dynamic gas pressure at the supply side of the
gas valve. This must be at least 17 mbar for natural gas (30
mbar for propane or butane) 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 (∆T) between the flow and
return to the appliance at the water side. ∆T must be between
15 and 25 K at full capacity.
50CV02C
41
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:
Settings at minimum capacity
Guide value CO2
9,0 - 9,4 % for natural gas G20, G25
10,8 - 11,2 % for propane G31
Guide value CO
<15
<25
ppm for natural gas G20, G25
ppm for propane G31
Setting air pressure switch
type 3 - 7
0,5 ± 0,05 mbar
Burner pressure = fan pressure – pressure above burner
P(vent)-P(bb)
type 1 - 2
0,1 ± 0,05 mbar
type 3 - 7
0,7 ± 0,2 mbar
Adjusting the gas valve R301 - R302
An adjusting screw is located at the rear of the boiler which can
be used to adjust the gas volume (CO2 value).
Run the boiler at full load and check the CO2 value. Adjust if
necessary using the adjusting screw.
Adjusting the gas valve R303 - R307
If the CO2 values at minimum and/or full load appear to be
incorrect, you can adjust these using the V and N adjusting
screws on the gas valve.
Procedure: Run the boiler at full load (100%) and check the
CO2 value. Adjust, if necessary, using the V adjusting screw.
Then, run the boiler at minimum load and check the CO2 value
again. Adjust, if necessary, using the N adjusting screw.
Adjusting the air-pressure switch R301 and R302
In this example, the air-pressure switch is set at 80 % of the fan
speed when pre-ventilating.
Pre-ventilating takes place at 80 % of the max. speed (P9). The
air-pressure switch is set to 0.8 x 80 = 64 turn/min.
The actual switching moment can be read on the display.
Checking the air-pressure switch R303 - R307
Check the function ∆Pmin 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.
42
50CV02C
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:
Pvent
Pbb
Pvent-Pbb (measure separately!)
Pvh
∆T.
50CV02C
43
8
MAINTENANCE
8.1
Safety
8.2
General
During maintenance activities, always wear suitable clothing
and shoes. Consider your own safety, particularly in respect of
jewellery and loose clothing.
In order to ensure continued good and safe operation of the
appliance, this must be inspected 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 (option)
- Clean the fan blades
- Clean the condensate receptacle
- Clean the condensate trap and the drainage pipe from the
appliance
- 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 via a sight
glass
- Test the unit at the flue gas side for CO2 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 ∆T 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.
8.3
Procedure
a) Disconnect the power supply
b) Close the gas supply valve
- 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).
44
50CV02C
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 plate. Unscrew the trap
and clean it
- 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.
8.4
Cleaning the burner
and heat exchangers
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.
8.5
Cleaning the filter/
screen in the gas
combination block
In order to clean the filter/screen in the gas combination block,
this must first be removed.
8.6
Ionisation
measurement
8.7
Service
In order to carry out an ionisation measurement, a microammeter with a measuring range of 0 - 200 µA DC must be
connected in the ionisation circuit. In this way the ionisation
protection function can be checked. The nominal ionisation
current is between 10 and 25 µA.
The minimum ionisation current is 2.8 µA.
For service and maintenance the service department of your
supplier is always available.
STOKVIS ENERGY SYSTEMS
96 R WALTON ROAD, EAST MOLESEY
SURREY KT8 0DL
Tel.: 08707 707 747
Fax: 08707 707 767
50CV02C
45
9
CONVERSION FORMULAE AND FACTORS
Formulae
CO2 =
20,9 - measured O2
20,9
O2 = 20,9 -
x 11,7
measured CO2 x 20,9
11,7
11,7 % CO2 is the maximum CO2 percentage that is generated
by stoichiometric burning of G20 natural gas (H-gas).
Excess air N:
N =
20,9
x 0,914
20,9 - measured O2
N = 1 +
11,7
- 1
CO2 measured
or
x 0,914
Conversion factors
For NOx (N=1):
1 ppm = 2,05 mg/m3 = 1,759 mg/kWh = 0,498 mg/MJ
For CO (N=1):
1 ppm = 1,24 mg/m3 = 1,064 mg/kWh = 0,298 mg/MJ
Example:
Measured values for an environmentally friendly unit:
NOx = 15 ppm
CO2 = 10 %
What is the value for NOx according to the most usual standard
in mg/kWh for N=1?
O2 = 20,9 N =
10 x 20,9
= 3%
11,7
20,9
= 1,17
20,9 - 3
NOx (for N = 1 ) =
15,0 x 1,17 = 17,6 ppm
17,6 x 1,759 = 30,9 mg/kWh
46
50CV02C
W
kcal/h
Btu/h
1
1,163
0,293
0,86
1
0,252
3,41
3,97
1
Table 11 Conversion factors
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 298.15
K (25 °C) this amounts to 2442.5 kJ/kg (583.38 kcal/kg).
For non condensing boilers:
ηb = 90 -
ηo = 100 -
0,339
+ 0,008
CO2
0,377
+ 0,009
CO2
x ∆T
x ∆T
For condensing boilers:
As a result of condensation, the efficiency at the lower value
increases.
ηb = 90 -
0,339
+ 0,008 x ∆T + A (7,5 + 0,006 ∆T)
CO2
ηo/ηb=1,11
= Difference in temperature between the flue gasses and
the environmental temperature
ηb = Fuel efficiency at the upper calorific value
ηo = Fuel efficiency at the lower calorific value
CO2 = The volume of CO2 in the flue gas (%)
O2 = The volume of O2 in the flue gas (%)
A
= The quantity of condensed water in the appliance per
m3 gas in kg (kg/m3gas).
∆T
50CV02C
47
meg/l
°dH
°f
°e
mg
CaCO3/l
1
2.8
5
3.51
50
°dH
0.37
1
1.78
1.25
17.8
°f
0.2
0.56
1
0.7
10
°e
0.285
0.8
1.43
1
14.3
mg CaCO3/l
0.02
0.056
0.1
1.54
1
meg/l
Table 12 Conversion of degrees of hardness
1 degree English hardness (°e)
= 65 mg CaCO3/imp. gallon
1 Grain/US Gallon
= 0.958 °dH
1 milligramme equivalent per l (mval/l) = 2.8 °dH
1 ppm (parts per million) CaCO3
= 1 mg CaCO3/l
For information:
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 form one
place to another.
48
50CV02C
50CV02C
49
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