STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Installation Operation & Maintenance
- Type
- Installation Operation & Maintenance
Stokvis R40 Boiler
Gas-Fired
Wall Hung
Condensing
Installation, Operation & Maintenance
Manual
STOKVIS ENERGY SYSTEMS
96R Walton Road
East Molesey
Surrey
KT8 0DL
Tel: 020 8783 3050 / 0870 7707747
Fax: 020 8783 3051 / 0870 7707767
E-Mail: [email protected]
Website: www.stokvisboilers.com
420010685900 09/2015 ErP
4
Contents
General regulations ................................................................................................6
Application ............................................................................................................... 6
Norms and regulations ........................................................................................ 6
Informations for installer and maintenance service ................................. 7
Data plate ................................................................................................................. 8
Construction ...........................................................................................................9
Layout of boiler ...................................................................................................... 9
Operating principle ............................................................................................... 9
Technical data .........................................................................................................10
Product information ErP ....................................................................................... 11
Extent of delivery ...................................................................................................14
Standard boiler ....................................................................................................... 14
Accessories ............................................................................................................... 14
Installation ..............................................................................................................15
Boiler transport ....................................................................................................... 15
Removing the casing ............................................................................................. 15
Warnings before installation ............................................................................. 16
Boiler installation ................................................................................................... 17
Connecting the boiler .......................................................................................... 17
Air/Flue gas system ............................................................................................... 18
Air / Flue pipe data................................................................................................. 19
Air/Flue gas system dimensioning .................................................................. 21
Accessories ............................................................................................................... 22
Installation Instructions - coaxial - .................................................................. 23
Installation Instructions - twin pipe - ............................................................. 24
Installation of vertical flue terminals .............................................................. 25
Installation of horizontal flue terminals ........................................................ 26
Electrical connection .............................................................................................. 27
Wiring diagram - Boiler ....................................................................................... 28
Wiring diagram - Boiler (Legend) .................................................................... 29
Wiring diagram - Accessories ........................................................................... 30
5GB
Contents
Commissioning .......................................................................................................31
Water and hydraulic system .............................................................................. 31
Neutralisation systems ......................................................................................... 32
Gas supply ................................................................................................................ 33
Condensate connection ...................................................................................... 33
Flue and air intake connections ....................................................................... 33
First startup procedure ........................................................................................ 34
Combustion check ................................................................................................. 35
Combustion settings ............................................................................................ 35
Check water flow .................................................................................................... 36
Check safety devices ............................................................................................. 37
Boiler shut down .................................................................................................... 37
Commissioning Protocol ..................................................................................... 38
Controls ..................................................................................................................39
Display Programming .......................................................................................... 40
Overview of main functions ............................................................................... 41
Maintenance ...........................................................................................................42
Checklist .................................................................................................................... 42
Cleaning ..................................................................................................................... 43
Physical and chemical check .............................................................................. 44
Maintenance Protocol .......................................................................................... 45
Lockouts ..................................................................................................................46
Sensor Values..........................................................................................................48
Declaration of Conformity ....................................................................................49
Note .........................................................................................................................50
6
This documentation contains im-
portant information, which is a base
for safe and reliable installation,
commissioning and operation of the
boiler. All activities described in this
document may only be excecuted by
authorized companies.
Changes to this document may be
effected without prior notice. We ac-
cept no obligation to adapt previously
delivered products to incorporate
such changes.
Only original spare parts may be
used when replacing components on
the boiler, otherwise warranty will be
void.
Application
The boiler may be used for heating
and hot water production purposes
only. The boiler should be connected
to closed systems with a maximum
temperature of 100ºC (high limit
temperature), maximum setpoint
temperature is 90ºC.
Norms and regulations
When installing and operating the
boiler, all applicable norms (europe-
DQDQGORFDOVKRXOGEHIXO¿OOHG
Local building regulations for in-
VWDOOLQJ FRPEXVWLRQ DLU DQG ÀXH
gas systems;
Regulation for connecting the
boiler to the electrical appliance;
Regulations for connecting the
boiler to the local gas network;
Norms and regulations according
to safety equipment for heating
systems;
Any additional local laws/regula-
tions with regard to installing and
operating heating systems.
This boiler is CE approved and
applies to the following European
standards:
1992 / 42 / EEC%RLOHUHI¿FLHQF\
directive.
2004 / 108 / EEC EMC directive.
2014/68/EU PED directive,
art.4-3.
2006 / 95 / EEC Low voltage di-
rective.
2009 / 142 / EEC Gas appliance
directive.
2009/125/CE Energy related
Products.
811-813/2013 EU regulation
EN 15502-1 *DV¿UHG KHDWLQJ
boilers. General requirements
and tests.
EN 15502-2-1*DV¿UHGKHDWLQJ
ERLOHUV 6SHFL¿F VWDQGDUG IRU
type C and devices type B2, B3,
B5 with a nominal heat input not
exceeding 1000 kW.
EN 656:1999*DV¿UHGFHQWUDO
heating boilers. Type B boilers of
nominal heat input exceeding 70
kW, but not exceeding 300 kW.
EN 483:1999 *DV¿UHG FHQWUDO
heating boilers. Type C boilers of
nominal heat input not exceeding
70 kW.
EN 15420:2010*DV¿UHGFHQWUDO
heating boilers. Type C boilers of
nominal heat input exceeding 70
kW, but not exceeding 1000 kW.
EN 677:1998 *DV¿UHG FHQWUDO
KHDWLQJ ERLOHUV 6SHFL¿F UHTXL-
rements for condensing boilers
with a nominal heat input not
exceeding 70 kW.
EN 15417:2006 *DV¿UHGFHQWUDO
KHDWLQJ ERLOHUV 6SHFL¿F UHTXL-
rements for condensing boilers
with a nominal heat input greater
than 70 kW but not exceeding
1000 kW.
EN 60335-1 (2002) Household
and similar electrical appliances
6DIHW\3DUW*HQHUDOUHTXL-
rements.
EN 60335-2-102 (2006) Hou-
sehold an similar electrical ap-
SOLDQFHVSDUWLFXODUUHTXLUHPHQWV
for gas, oil and solid-fuel burning
appliances having electrical con-
nections.
EN 50165 Electrical equipment
of non-electric appliances for
household and similar purposes
- Safety requirements.
EN 55014-1 (2000) Electroma-
gnetic compatibility - Require-
ments for household appliances,
electric tools and similar appara-
WXV3DUW(PLVVLRQ
EN 55014-2 (1997) Electroma-
gnetic compatibility - Require-
ments for household appliances,
electric tools and similar appara-
WXV3DUW,PPXQLW\3URGXFW
family standard.
EN 61000-3-2 (2000) Electroma-
gnetic compatibility (EMC) - Part
/LPLWV/LPLWVIRUKDUPRQLF
current emissions (equipment in-
put current 16 A per phase).
EN 61000-3-3 (2001) Electro-
magnetic compatibility (EMC)
3DUW /LPLWDWLRQ RI YROWDJH
FKDQJHV YROWDJH ÀXFWXDWLRQV
DQG ÀLFNHU LQ SXEOLF ORZYROWDJH
supply systems, for equipment
with rated current 16 A per pha-
se and not subject to conditional
connection.
Additional national standards
Germany:
5$/8=',1
Switzerland
SVGW
Austria:
15a V-BG
General regulations
Application
Norms and regulations
7GB
General regulations
Informations for installer and maintenance service
The use of the appliance for purposes
RWKHU WKDQ WKRVH VSHFL¿HG LV VWULFWO\
forbidden. The manufacturer cannot
be held responsible for any damage
caused by improper, incorrect and
unreasonable use of the appliance or
by the failure to comply with the in-
structions given in this manual.
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other interventions must be carried
out in full conformity with the gover-
ning legal regulations and the instruc-
tions provided by the manufacturer.
,QFRUUHFW LQVWDOODWLRQ FDQ KDUP SHU-
sons, animals and possessions; the
manufacturing company shall not
be held responsible for any damage
caused as a result.
The boiler is delivered with protection
packaging. Once you have removed
all the packaging, make sure the ap-
pliance is intact and that no parts are
PLVVLQJ,IWKLVLVQRWWKHFDVHSOHDVH
contact your supplier.
Keep all packaging material (clips,
plastic bags, polystyrene foam, etc.)
out of reach of children as it may pre-
sent a potential hazard.
Before any maintenance or repair
work is performed on the boiler, make
sure you have disconnected it from
the electricity supply by switching the
external bipolar switch to the OFF
position.
All repairs, should only be performed
using original spare parts.
Information for the User
,QIRUPWKHXVHURQWKHPRGHRIRSHUD-
WLRQRIWKHV\VWHP6SHFL¿FDOO\GHOLYHU
to the user the instruction manuals,
informing him that they must be sto-
red with the appliance.
$OVRUHPLQGWKHXVHUWR
t Periodically check the water
pressure system and instruct him
on how to reintegrate and bleed.
t How to set the temperature and
the adjusters for a correct and
more economical management
of the system.
t To perform, according to legi-
slation, periodic maintenance
system.
t Do not change, in any case, the
settings for supply of air for com-
bustion and gas combustion.
t Pay attention to the warnings
contained in the user manual.
8
Symbols used on the data plate
Legend :
1 Brand
2Country of origin
3 Boiler model - Serial number
4 Commercial reference
5&HUWL¿FDWLRQQXPEHU
6 Destination country - Gas category
7 Gas setting
,QVWDOODWLRQW\SH
9 Electrical data
10 Factory settings
11 Maximum water pressure
12 Boiler type
13 12[FODVV(I¿FLHQF\
14 ,QSXWUDWLQJQRPLQDOKHDWLQJ
15 Power output heating
16 Gases which may be used
17 Ambient operating temperature
Max. central heating temperature
26-05-2015
S/N 0000000KE000000000000
00
100% min.
η η
= =
MAX MIN
Q(Hi)
P
P
60/80C
30/50C
gas
mbar
gas
mbar
gas
mbar
12
345
6
7
9
10
11
12
13
14
15
16
17
General regulations
Data plate
9GB
Operating principle
This is a fully modulating boiler.
The control unit of the boiler adapts
the modulation ratio automatically to
the heat demand requested by the
system. This is done by controlling
the speed of the fan.
As a result, the Whirlwind mixing
system will adapt the gas ratio to the
chosen fan speed, in order to maintain
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combustion are transported
downwards through the heat exchan-
ger and leave the boiler at the
top into the chimney connection.
The return water from the system
enters the boiler in the lower section,
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condensation takes place.
The water is being transpor-
ted upwards through the heat
exchanger, in order to leave the
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The LMS14 control unit can control
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boiler control (standalone opera-
tion);
weather compensated operation
(with optional outdoor sensor);
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(temperature or capacity) from a
building management system.
Layout of boiler
The boiler consists of the
following PDLQFRPSRQHQWV
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
19
20
21
22
Casing
Access door for Control panel
Flue gas connection (+ test point)
Air intake connection (+ test point)
Flow water connection
Return water connection
Gas connection
Condensate syphon
,QSXWIRUZLULQJ
Connection for safety valve
&RQQHFWLRQIRU¿OOGUDLQYDOYH
Manometer
Fan
Gas valve
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Heat exchanger
,QVSHFWLRQZLQGRZ
,JQLWLRQWUDQVIRUPHU
Electrical input connections
Controller
Condens tray
Control Panel
Construction
Layout of boiler
Operating principle
1
2
43
12
10
5
87 9 6
11
16
22
20
19
21
13
14
18
15
17
R40
10
Technical data
kW 45.7/7.6 60.8/10.1 81.1/13.4 92.9/15.6 111.6/18.7 132.2/23.3 56.4/10.1
kW 45.8/7.6 60.9/10.1 81.3/13.4 93.1/15.6 111.8/18.7 132.5/23.3 56.5/10.1
kW 48.0/8.4 63.9/11.1 85.3/14.8 100.0/17.2 120.0/20.6 142.3/25.6 59.3/11.1
kW 46.9/7.8 62.4/10.4 83.3/13.8 95.2/16.0 114.3/19.2 135.5/23.9 57.9/10.4
% 97.4 97.4 97.4 97.6 97.6 97.6 97.4
% 102.4 102.4 102.4 105.0 105.0 105.0 102,4
% 106.2
% >110
W 122
l/h 7,9 10,4 13,9 18,8 22,7 26,8 9,7
m³/h 4.3/0.7 5.7/1.0 7.6/1.3 8.7/1.5 10.5/1.8 12.4/2.2 5.3/1.0
m³/h 5.6/0.9 7.5/1.2 10.0/1.7 11.4/1.9 13.7/2.3 16.3/2.9 7.0/1.2
kg/h -/- -/- -/- -/- -/- -/- -/-
mbar 20
mbar 25
mbar -/- -/- -/- -/- -/- -/- -/-
mbar 50
°C 90
°C 76/63
°C 55/39
m³/h 89/14 119/19 159/25 178/29 213/35 253/44 111/19
% 8.5/8.5 8.5/8.5 8.5/8.5 8.7/8.5 8.7/8.5 8.7/8.5 8.5/8.5
% -/- -/- -/- -/- -/- -/- -/-
mg/kWh 39
mg/kWh 98/7
Pa 150/15 150/15 150/15 150/15 200/15 200/15 150/15
l 4.0 4.0 4.7 6.5 8.0 9.4 4.0
bar 8/1.5
°C 100
ºC 90
m³/h 1.9 2.6 3.4 4.0 4.8 5.6 2.4
kPa 9 16 29 15 22 34 14
V 230
Hz 50
A 10
- IP30
- IPX4D
W 100/25 100/25 100/25 214/38 214/38 221/43 100/25
W 75 75 90 90 130 130 75
kg 60 60 68 80 90 97 60
dB 62 62 66 66 68 67 62
µA 15 15 15 15 15 15 15
- 3.2 3.2 3.2 3.2 3.2 3.2 3.2
- CE-0063CM3576
- R1.1/4” R1.1/4” R1.1/4” R1.1/2” R1.1/2” R1.1/2” R1.1/4”
- R3/4” R3/4” R3/4” R1” R1” R1” R3/4”
mm 100 100 100 100 100 130
mm 100 100 100 100 100 130
mm 22
R40
4 50
R40
65
R40
85
R40
100
R40
120
R40
150
Nominal heat output at 80/60ºC max/min
Nominal heat output at 75/60ºC max/min
Nominal heat output at 40/30ºC max/min
Nominal heat input Hi max/min
Efficiency at 80/60ºC
Efficiency at 40/30ºC
Annual efficiency (NNG 75/60ºC)
Annual efficiency (NNG 40/30ºC)
Heat Loss (Pstby)
Max. condensate flow
Gas consumption G20 max/min (10,9 kWh/m3)
Gas consumption G25 max/min (8,34 kWh/m3)
Gas consumption G31 max/min (12,8 kWh/kg)
Gas pressure G20
Gas pressure G25
Gas pressure G31
Maximum gas pressure
Max. temperature flue gas (high limit)
Flue gas temperature at 80/60ºC max/min
Flue gas temperature at 40/30ºC max/min
Flue gas quantity max/min
CO2 level G20/G25 max/min
CO2 level G31 max/min
NOx level
CO level max/min
Max. permissible flue resistance max/min
Water volume
Water pressure max/min
Max. water temperature (High limit thermostat)
Maximum temperature setpoint
Nominal water flow at dT=20K
Hydraulic resistance at nominal water flow
Electrical connection
Frequency
Mains connection fuse
IP class with Appliance Type B23(P) **
IP class with App. Type C13, C33, C43, C53, C63, C83,
Power consumption boiler max/min (excl. pump)
Power consumption speed controlled pump (opt)
Weight (empty)
Sound Power Level (LWA) ***
Ionisation current average
pH value condensate
CE certification code
Water connections
Gas connection
Flue gas connection (DN)
Air intake connection (for room sealed use) (DN)
Condensate connection
** With appliance type B23(P) is mandatory to use the air inlet grille. For more information see pag.20
*** Room sealed
11 GB
Product information ErP
R40
Product information about the directive 2009/125/EG and regulation (EU) 813/2013
R40 Icon Unit 45/50 65 85 100 120 150
Condensing boiler - - Yes Yes Yes Yes Yes Yes
Low-temperature boiler - - No No No No No No
B1 boiler - - No No No No No No
Cogeneration space heater - - No No No No No No
Combination heater - - No No No No No No
ErP Heating
Rated heat boiler Prated kW 46 61 81 93 112 132
At rated heat output and high-tempera-
ture regime P4 kW 45.7 60.8 81.1 92.9 111.6 132.2
At 30 % of rated heat output and
lowtemperature regime 1) P1 kW 15.1 20.0 26.8 30.6 36.7 43.5
Seasonal space heating energy effi-
ciency Ks % 92 92 92 92 92 92
At rated heat output and high-temperatu-
re regime 2) K4 % 87.7 87.7 87.7 87.9 87.9 87.9
At 30 % of rated heat output and low
temperature regime 1) K1 % 96.5 96.5 96.5 96.5 96.5 96.5
Auxiliary electricity consumption
At full load elmax kW 0.100 0.100 0.214 0.214 0.214 0.221
At rated heat output and high-tempera-
ture regime elmin kW 0.025 0.025 0.038 0.038 0.038 0.043
At 30 % of rated heat output and
lowtemperature regime 1) PSB kW 0.003 0.003 0.003 0.003 0.003 0.003
Supplementary heater
Standby heat loss Pstby kW 0.122 0.122 0.122 0.122 0.122 0.122
Ignition burner power consumption Pign kW 0.000 0.000 0.000 0.000 0.000 0.000
Emissions of nitrogen oxides NOXmg/kWh 39 39 39 39 39 39
1) by return temperature 30°C
2) by return temperature and feed temperature (60-80°C)
12
Product data about the directive 2010/30/EU and regulation (EU) 813/2013
R40 45/50 65
Seasonal space heating energy efficiency class
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ȘV
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ȘV
Ș
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A
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A
Rated heat output Prated kW 46 61
Seasonal space heating energy
efficiency Ks % 92 92
Sound power level, indoors/ outdoors LWA dB 62 62
Important:
The installation, consisting of the boiler and all accessories including temperature control, together define the seasonal heating energy efficiency
Ks for the various models, as listed in the below table.
R40 45/50 65
Class VI, with use of components:
- R40
- Ambient temperature sensor QAA 75
(option)
- External temperature sensor QAC 34
Temperature controller contribution to
Ks: 4%
Ks % 92 + 4
=96
92 + 4
=96
Class V, with use of components:
- R40
- Ambient temperature sensor QAA 75
(option)
Temperature controller contribution to
Ks: 3%
Ks % 92 + 3
=95
92 + 3
=95
Class II, with use of components:
- R40
- External temperature sensor QAC 34
Temperature controller contribution to
Ks: 2%
Ks % 92 + 2
=94
92 + 2
=94
Product information ErP
R40
13 GB
Technical data
Dimensions R40/50
R40/65
R40/85 R40/100 R40/120 R40/145
B mm 490 490 590 590 590
B1 mm 140 140 140 140 190
B2 mm 245 245 295 295 295
D mm 500 500 600 600 600
H mm 810 810 950 950 950
W1 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"
W2 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"
G mm R 3/4" R 3/4" R 1" R 1" R 1"
F mm 100 100 100 100 130
A mm 100 100 100 100 130
B mm 490 490 590 590 590
B1 mm 140 140 140 140 190
B2 mm 245 245 295 295 295
D mm 500 500 600 600 600
H mm 950 950 950
W1 mm R1 1/4” R1 1/4” R1 1/2” R1 1/2” R1 1/2”
W2 mm R1 1/4” R1 1/4” R1 1/2” R1 1/2” R1 1/2”
G mm R3/4” R3/4” R1” R1” R1”
F (DN) mm 100* 100* 100* 100* 130**
A (DN) mm 100* 100* 100* 100* 130**
* DN 100 = Øint. 101±0.7 mm
** DN 130 = Øint. 131±0.7 mm
R40
45/50/65
R40-85 R40-100 R40-120 R40-150
Dimensions
FRONT VIEW SIDE VIEW BACK VIEW
BOTTOM VIEW
14
Standard boiler
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Accessories
Additional to the boiler, the following
DFFHVVRULHVFDQEHRUGHUHG
t Speed controlled pump incl. con-
nection kit;
t 6DIHW\YDOYH¿OOGUDLQ YDOYH DQG
connection for expansion tank;
t Set with water (2x) and gas (1x)
cocks;
t *DV¿OWHULQFOFRQQHFWLRQNLW
t Min. gas pressure switch;
t Plate heat exchanger
(dT=10K/15K or dT=20K) incl.
connection kit;
t Low velocity header, suitable for
dT=10K/15K and dT=20K incl.
connection kit;
t Plug & play cascade kit (see ca-
scade manual for more details);
t Extension module AGU2.551
for 0-10V control of a modula-
ting pump and/or boiler capacity
feedback to a building manage-
ment system;
t Electrical connection for external
gas valve and/or room fan.
t Extension module AGU2.550 for
heating zone control or external
gas valve and/or room fan con-
trol in combination with an alarm
signal. For each boiler a maxi-
mum of 3 AGU2.550 modules (2x
heating zone, 1x ext. gas valve
/ room fan in combination with
alarm) can be integrated in the
boiler;
t Additional RVS63 heating zone
controller, when controlling more
than 2 zones (incl. wall hung box,
all necessary sensors and so-
ckets and connection material for
bus communication).
The above accessories are specially
designed for the boiler and therewith
easy to install (plug and play). By
choosing a combination of the kits
mentioned above, you can create
your own complete system solution.
Ask Your supplier for more detailed
information
Extent of delivery
Standard boiler
Accessories
R40
Component Pcs. Package
Boiler fully assembled and tested 1 Cardboard box on pallet
Mounting bracket inc. mounting material 1 Together with manuals, in folding box inside boiler packaging
Syphon for condensate connection 1 ,QVLGHSDFNDJLQJ
Operation and installation manual 1 Map packed in cardboard box in boiler packaging
15 GB
Boiler transport
The boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The packaging dimen-
sion is 1050x572x575mm for boiler
W\SHV DQG [[PP
for boiler types
100-150, which makes it possible to
transport all models through a nor-
mal door in one piece.
The Boiler can be transported with a
crane, but it has to be ensured that
WKH ERLOHU LV SDFNHG DQG ¿[HG RQ D
pallet. The straps must be connected
to the pallet.
Removing the casing
Remove the casing before installing
the boiler, in order to avoid damage
to the casing parts. Removing the
casing is done as shown on the
pictures.
1
2
3
Installation
Boiler transport
4
16
Installation
Warnings before installation
,QVWDOODWLRQ¿UVWLJQLWLRQPDLQWHQDQFHDQGERLOHUUHSDLUPXVWEHSHUIRUPHGE\
TXDOL¿HGSHUVRQVDFFRUGLQJWRWKHQDWLRQDOLQVWDOODWLRQSURYLVLRQVDQGDQ\
requirements of the local authorities and public health agencies.
Before installing the appliance
%HIRUHFRQQHFWLQJWKHERLOHULWLV¿UVW
necessary to perform the following
RSHUDWLRQV
t Carefully wash the system piping
in order to remove any screw
thread or welding residues, or
any dirt which might prevent the
boiler from operating correctly;
t Make sure that the boiler is set
up for operation with the type of
gas available (read the informa-
tion on the packaging label and
on the boiler data plate);
t Make sure that there are no obsta-
FOHVLQVLGHÀXHH[KDXVWDQGWKDW
it does not contain any dischar-
ge from other appliances, unless
WKHÀXHLVPHDQW WR VHUYH PRUH
than one user (in accordance
with current legal requirements);
t Where there is already a con-
QHFWLRQWRH[LVWLQJÀXHH[KDXVWV
check that these exhausts have
been perfectly cleaned and are
without residues, because any
disconnection could obstruct the
passage of fumes and create po-
tentially dangerous situations;
t Make sure that, where unsuitable
ÀXHH[KDXVWVDUHDWWDFKHGWKH\
have been ducted;
t ,Q DUHDV ZLWK SDUWLFXODUO\ KDUG
water, limescale may build up on
the components inside the boiler
DQGUHGXFHLWVRYHUDOOHI¿FLHQF\
t ,QFDVHRILQVWDOODWLRQQHDUZDOO
sensitive to heat (for example
wood) make sure to protected it
by suitable insulation;
t Observe the clearance between
the wall on which the boiler is
installed and the hot parts on the
outside of the boiler.
WARNING!
1R LQÀDPPDEOH LWHPV VKRXOG EH
left near the boiler.
Make sure the installation site
and any systems to which the
appliance must be connected
are fully compliant with the
current applicable legislation.
Install the boiler respecting the
minimum distances from any
ÀDPPDEOHPDWHULDOV
If dust and/or aggressive
vapours are present in the room
in which it is to be installed, the
appliance must operate indepen-
dently of the air inside the room.
17 GB
Connecting the boiler
This chapter will explain how to
make all connections to the boiler
ZLWKUHJDUGWR
t Hydraulic connections
t Condensate drain connection
t Gas connection
t Flue gas connection
t Air intake connection
t Electrical connection
The boiler should always be
connected in such a way, that the
system applies to all relevant stan-
dards and regulations (European, na-
WLRQDODQGORFDO,W¶VWKHUHVSRQVLELOLW\
of the installer to ensure that all stan-
dards and regulations are respected.
Hydraulic connections (1,2,3,4)
The boiler should always be
connected in such a way,
WKDW ZDWHU ÀRZ WKURXJK KH ERLOHU
can be ensured at all times.
&RQQHFW WKH ÀRZ DQG UHWXUQ
connection of the system ten-
sion free to the boiler connections.
The boiler contains a connection
possibility for an (optional) kit with
VDIHW\ YDOYH ¿OOGUDLQ YDOYH DQG DQ
expansion tank connection. The
safety valve must be connected to
WKH ÀRZ FRQQHFWLRQ RI WKH ERL-
OHU WKH ¿OOGUDLQ YDOYH DQG H[SDQ-
sion tank connection must be con-
nected to the return connection (4).
The (optional) pump kit should be
mounted directly to the return
connection (2) of the boiler, before
connecting to the system.
Condensate connection (5)
$IWHU ¿OOLQJ ZLWK ZDWHU WKH V\SKRQ
(included in delivery) should be instal-
led to the connection (5) at the bottom
of the boiler. Connect the hose to the
draining system in the boiler room.
The connection to the draining system
should always be done with an open
FRQQHFWLRQLQRUGHUWRDYRLGDÀRRGLQJ
of the boiler in case of a blocked drain.
Gas connection (6)
The gas connection must be made
by an authorized installer in accor-
dance with the applicable national
and local standards and regulations.
Connect the gas line from the
system tension free to the gas connec-
tion (6) of the boiler. A gas cock should
be mounted directly behind the boiler.
$JDV¿OWHUFDQEHPRXQWHGGLUHFWO\
on the gas connection of the boiler.
Boiler installation
The boiler should be positioned in a
IURVWSURRI ERLOHU URRP ,I WKH ERLOHU
room is on the roof, the boiler itself
may never be the highest point of the
installation.
When positioning the boiler, please
note the recommended minimum
clearance in the picture. When the
boiler is positioned with less free
space, maintenance activities will be
PRUHGLI¿FXOW
x
x
x
x
x
x
Installation
Boiler installation
Connecting the boiler
3
16
5 2
4
18
boiler to evacuate the condensates.
When type B installation is used, the
room in which the boiler is installed
must be ventilated using a suitable
air inlet which complies with current
legislation.
,Q URRPV ZKHUH FRUURVLYH YDSRXUV
may be present (for example, laundry
rooms, hair studios, rooms where
galvanic processes take place, etc.) it
is important that type C installation is
used, with air for combustion drawn
IURPRXWVLGH,QWKLVZD\WKHERLOHULV
protected from the effects of corrosion.
When implementing coaxial
suction/exhaust systems the use of
authentic accessories is obligatory.
7KH ÀXH JDV H[KDXVW GXFWLQJ PXVW
not be in contact with or placed near
ÀDPPDEOH PDWHULDOV DQG PXVW QRW
cross building structures or walls
PDGHXVLQJÀDPPDEOHPDWHULDO
This Boiler has an integrated high
OLPLW WKHUPRVWDW IXQFWLRQ IRU WKH ÀXH
JDVHV :KHQ WKH ÀXH JDV WHPSH-
rature exceeds 90ºC, the burner is
switched off. With this function, an
additional (external) safety device is
not necessary.
When replacing an old boiler, the
YHQWLODWLRQ DQG ÀXH JDV H[KDXVW
system must always be replaced.
7KH ÀXH JDV H[KDXVW GXFWLQJ
joint should be created using a
male/female coupling and a seal.
Couplings should always be arranged
so that they go against the direction
RIWKHFRQGHQVDWHÀRZ
Flue gas connection (7)
The boiler is designed to operate in B
mode (by drawing air from the room)
and in C mode (by drawing air from
outside).
When installing an exhaust system
be careful when handling the seals,
LQRUGHUWRDYRLGÀXHJDVOHDNLQJLQWR
the air circuit.
&RQQHFW WKH ÀXH JDV V\VWHP WR WKH
ÀXHJDVFRQQHFWLRQRIWKHERLOHU
XVH ÀXHJDV V\VWHPV ZLWK VHDPOHVV
connections only.
,W¶VQRWQHFHVVDU\WRPDNHDVHSDUD-
WHFRQGHQVDWH GUDLQ IRUWKHÀXHJDV
system, as the condensate will be
drained via the syphon of the boiler.
The horizontal kit must be tilted with
a downward slope of 3° towards the
Air intake connection
The air intake can be connected in
case of room sealed installation.
The diameter should be calculated
according to the national regulations,
WRJHWKHU ZLWK WKH ÀXH JDV V\VWHP
The total resistance of both systems
should never overcome the maxi-
mum permissible resistance of the
fan inside the boiler (see also
FKDSWHU7HFKQLFDOGDWD
Installation
Air/Flue gas system
Requirements and regulations
Regulations for the construction of
ÀXH JDV V\VWHPV DUH YHU\ GLIIHUHQW
IRUHDFKFRXQWU\ ,W VKRXOG EH HQVX-
red that all national regulations with
UHJDUG WR ÀXH JDV V\VWHPV DUH UH-
spected.
Pay attention to the following recom-
mendations when dimensioning a
ÀXHJDVV\VWHP
2QO\DSSURYHGÀXHJDVPDWHULDOPD\
EH XVHG 7KH ÀXH JDV V\VWHP PXVW
be properly calculated to ensure a
safe functioning of the system.
Flue gas system components should
be removable for maintenance pur-
SRVHV+RUL]RQWDOÀXHJDVZD\VPXVW
be mounted under an angle of 3º mi-
nimum.
7KLV%RLOHULVFHUWL¿HGIRUWKHÀXH
gas systems B23(P), C13, C33, C43,
&&DQG&
Materials
Exclusively materials, which are heat
UHVLVWDQWDQGUHVLVWDQWWRÀXHJDVHV
and aggressive condensate, and CE
approved may be used.
,QSDUWLFXODUIRUÀXHJDVV\VWHPVHH
tab. on next page.
7
19 GB
Air / Flue pipe data
Concentric pipe nominal diam. Ø100/150
Tolerance female Ø internal
101 mm
150 mm
Single pipe nominal diam.
Ø100
Tolerance female Ø internal
101±0.7 mm
Ø130
Tolerance female Ø internal
131±0.7 mm
Material
PP (Concentric flue pipe) - Galva 0,4/Alluminium 1,3mm (Concentric air intake
pipe)
PP (single pipe)
Material seal EPDM black for corrosion class 1 / Viton for corrosion class 2
Heat resistance 0 W/m2K
Wall thickness 2.2 mm
Temperature class: T120
Pressure class: P1 max. 200Pa / H1 max. 5000Pa
Corrosion class: W1
Location class Concentric pipe: Only outside buildings / Single pipe: Only inside buildings
Fire rating class E
Outer wall class (Concentric pipe only) L0
Distance to combustible materials Concentric pipe: 00 mm / Single pipe: 30 mm
+1.0
- 0.5
+1.0
- 0.5
Installation
Air/Flue gas system
Flue Gas data
Boiler
type
Nominal heat
output
Nominal heat
input
Flue
gas
connection
(DN)
CO ഺ
Level
Flue gas
temperature
Flue gas
quantity
Max
permissible
ÀXH
resistance
kW kW mm % °C g/s Pa
R40 max min max min max min max min max min max min
45/50 45.7 7.7 46.9 100
76 33
26 4 150 15
65 10.1 62.4 10.4 100 35 6 150 15
13.4 100 47 7 150 15
100 92.9 15.6 95.2 16.0 100 52 9 150 15
120 111.6 114.3 19.2 100 62 11 200 15
150 132.2 23.3 135.5 23.9 130 74 12 200 15
20
Installation
Air/Flue gas system
Combustion air
drawn from the
room
B23
([WHUQDOÀXHJDVH[KDXVW$LUGUDZQIURPWKHURRP
Combustion
air intake from
outside
C13
Air/exhaust gas routing through outside wall in the same
pressure range.
Exhaust gas/fresh air supply system through outside wall.
The Terminal outlets from separate combustion and air supply
FLUFXLWVVKDOO¿WLQVLGHDVTXDUHRIFPIRUERLOHUVZLWKDKHDWLQ-
put to 70 kW and 100 cm with a heat input from 70 up to 100 kW.
C33
Flue gas exhaust and air suction duct from outside with roof ter-
minal in the same range of pressure.
The Terminal outlets from separate combustion and air supply
FLUFXLWVVKDOO¿WLQVLGHDVTXDUHRIFPDQGGLVWDQFHEHWZHHQ
WKHSODQHVRIWKHWZRRUH¿FHVVKDOOEHOHVVWKDQFPIRUERLOHUV
with a heat input below 70 kW.
A square of 100 cm and distance between the planes of the two
RUH¿FHVVKDOOEHOHVVWKDQFPZLWKDKHDWLQSXWDERYHN:
C43 ,QGLYLGXDORUVKDUHGÀXHJDVH[KDXVWDQGDLUVXFWLRQWKURXJKÀXH
ducting built into the building.
C53 Flue gas exhaust leading outside and air suction duct through
external wall not in the same range of pressure
C63
Air and exhaust connection to separate tested and supplied
air / exhaust pipes.
%DVHPHQWÀRRULQVWDOODWLRQ
Air and exhaust venting via exterior wall.
Exhaust venting through heat insulated exhaust pipe or moistu-
re-resistant pipe.
Exhaust line (standing air layer) at exterior wall.
The terminals for the supply of combustion air and for the eva-
cuation of combustion products shall not be installed on opposite
walls of the building.
C83 )OXHJDVH[KDXVWWKURXJKLQGLYLGXDORUVKDUHGÀXHGXFWLQJEXLOW
into the building. Air suction through external wall
21 GB
Dimensioning
:KHQ GLPHQVLRQLQJ D ÀXH JDV
system, it’s necessary to perform
D FDOFXODWLRQ FKHFN RI WKH ÀXH JDV
system in order to verify if the
choosen system is applicable.
The following table shows an
H[DPSOH RI SRVVLEOH ÀXH JDV
system, including the maximum
possible length of the system.
This example only give an
indication of the possible length, but
LWFDQQRWEHXVHGIRURI¿FLDOÀXHJDV
OD\RXW FDOFXODWLRQ (DFK ÀXH JDV
system has to be calculated by an
authorized company.
7KH PD[LPXP QHJDWLYH ÀXH JDV
pressure, which doesn’t affect the
burner modulation ratio, is 30 Pa.
Higher negative pressure will lead
to limitation of the burner modulation
ratio.
7KHPD[LPXPKRUL]RQWDOÀXHJDVZD\
is 20 m. With horizontal ways longer
than 20 m, a faultless burner start in
cold condition can not be guaranteed.
Installation
Air/Flue gas system dimensioning
7ZLQSLSHÀXHJDV
system
0D[LPXPSHUPLVVLEOHOHQJWKRIÀXHJDVV\VWHPLQP
Length reduction factor t PHWHUVSHUHDFKEHQG
t 1,5 meters per each 45/43° bend
&RQFHQWULFÀXHJDV
system
0D[LPXPSHUPLVVLEOHOHQJWKRIÀXHJDVV\VWHPLQP
Length reduction factor t PHWHUVSHUHDFKEHQG
t 1 meter per each 45/43° bend
&DOFXODWLRQEDVH
7RWDOFRQQHFWLRQOHQJWKLQERLOHUURRPP
[EHQG
%RLOHUW\SH
7+/
7+/
7+/
VER
&DOFXODWLRQEDVH
7RWDOFRQQHFWLRQOHQJWKLQERLOHUURRPP
[EHQG
Maximum permissible height (h) of flue gas
system in m
%RLOHUW\SH
TH-L 65 6 61
7+/
7+/
7+/
TH-L 145 14 27 34 36
TH-L 50 6 61
&DOFXODWLRQEDVHURRIRUZDOOWHUPLQDO
7+/
7KH7+,6,21/ERLOHUPRGHOV
DQGFDQEHFRQQHFWHGWRD
WR
0XHOLQN*URO
&DOFXODWLRQEDVH
7RWDOFRQQHFWLRQOHQJWKLQERLOHUURRPP
[EHQG
Maximum permissible height (h) of flue gas
system in m
%RLOHUW\SH
TH-L 65 10 65
7+/
TH-L 100 20 34 42 44
7+/
7+/
&DOFXODWLRQEDVH
7RWDOFRQQHFWLRQOHQJWKLQERLOHUURRPP
[EHQG
%RLOHUW\SH
7+/
7+/
7+/
TH-L 50 10 65
&DOFXODWLRQEDVHURRIRUZDOOWHUPLQDO
7+/
7KH7+,6,21/ERLOHUPRGHOV
DQGFDQEHFRQQHFWHGWRD
WR
0XHOLQN*URO
Ø80 Ø100 Ø120 Ø125 Ø130
Lmax
[m]
Lmax
[m]
Lmax
[m]
Lmax
[m]
Lmax
[m]
24 40
13 40
22 33
26 40 40
17 24 40 40
12 17 40
Equivalent length in m
Straight
pipe
Bend R=D
90°/87°
Bend R=D
45°/43°
Ø80 1 1.5 0.8
Ø100 1 1.8 0.9
Ø120 1 2 1
Ø125 1 2.2 1
Ø130 1 2.2 1
Ø 100 / 150
7
6
7
Equivalent length in m
Coaxial
pipe
Bend R=D
90°/87°
Bend R=D
45°/43°
Ø100/150 1.5 1
&RQFHQWULFÀXHJDVV\VWHP
7KH%RLOHUERLOHUPRGHOV
100 and 120 can be connected to a
FRQFHQWULFÀXHJDVV\VWHP
Via a parallel-to-concentric adap-
ter (optional) the boiler can be con-
QHFWHGWR
t 100/150 concentric system
6HHWDEOHIRUPD[SHUPLVVLEOHÀXH
lengths.
R40 45/50
R40 65
R40 85
R40 100
R40 120
R40 150
R40 45/50
R40 65
R40 85
R40 100
R40 120
22
PPUHSODFHGE\PP
Air inlet cover
The inlet cover must be used to co-
ver the air inlet connection of the
boiler in non room sealed condition,
available in 100mm and 130mm.
Types of boiler
Flue exhaust connection
coaxial connection of the boiler
to the suction/exhaust ducting
split connection of the boiler to
the exhaust ducting with air suc-
tion from outside.
The suction/exhaust ducting connec-
tion kits are supplied separately from
the appliance, according to different
installation solutions.
,IWKHUHLVDQ\ORVVRISUHVVXUHLQWKH
SLSLQJSOHDVHUHIHUWRWKHJDVÀXH
accessories catalogue.
Supplementary resistance must be
borne in mind during the sizing
process mentioned above.
For the calculation method, equiva-
lent length values and installation
H[DPSOHVSOHDVHUHIHUWRWKHJDVÀXH
accessories catalogue.
x
x
Installation
Air/Flue gas system
Accessories
Flue adapter concentric
&RQFHQWULFÀXHV\VWHPVFDQEHXVHG
on the R40 45-120, by using a paral-
lel to concentric adapter.
DN 100/150 = Øint101±0.3 / 151±0.3
DN 110/150 = Øint111 /151±0.5
Flue adapter parallel
7KH ERLOHU LV HTXLSSHG ZLWK D ÀXH
connection of 100mm (R40 45-120)
RUPP5,QFDVHRIXVLQJ
PPRUPPÀXHV\VWHPVWKH
original adapter can be replaced as
IROORZV
t 100mm replaced by 110mm;
DN 110 = Øint111
t 130mm replaced by 125mm.
DN 125 = Øint126
- 0.6
±0.3
- 0.6
+0.3
- 0.6
+0.3
100mm 45-120
130mm 150
x
x
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STOKVIS ENERGY SYSTEMS ECONOFLAME R40 Installation Operation & Maintenance
- Type
- Installation Operation & Maintenance
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