STOKVIS ENERGY SYSTEMS ECONOFLAME R3500 Installation, Operation & Maintenance Documentation

ECONOFLAME

R3400/R3500/R3600SB

BOILERS

INSTALLATION

OPERATION & MAINTENANCE

DOCUMENTATION

STOKVIS ENERGY SYSTEMS

96R WALTON ROAD

EAST MOLESEY

SURREY

KT8 0DL

TEL: 08707 707 747

FAX: 08707 707 767

E-MAIL: [email protected]

WEBSITE: www.stokvisboilers.com

DOC2005/3456en.3456CV02A230611

I

.

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.

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Doc2005/3456en 1

R3400 Technical data

Type R3401 R3402 R3403 R3404 R3405 R3406

Nominal heat output

Nominal heat input (nett. CV)

Minimum heat input

kW

657

702

176

729

784

196

853

917

229

965

1038

260

1078

1159

290

1189

1279

320

Pilot burner kW 36 36 36 36 36 36

Gas consumption

natural gas H (10.9 kWh/m3)

propane (12.8 kWh/kg)

m3/h

kg/h

64.5

54.9

71.9

61.2

84.1

71.6

95.2

81.1

106.3

90.5

117.3

99.9

Gas inlet pressure

natural gas H (min/max)

natural gas H (max) option

propane (min/max)

mbar

18 – 25

100

30 – 50

18 – 25

100

30 – 50

35 – 100

30 – 50

35 – 100

30 – 50

35 – 100

30 – 50

35 – 100

30 – 50

Water capacity

Max. working pressure

dm3

bar

50

6

53

6

70

6

75

6

80

6

85

6

Gas connection G Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6

Water connections W DN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Flue connection D mm 300 350 350 400 400 400

Safety valve connection

relief connection

standard setting

11⁄4"

11⁄2"

3

11⁄4"

11⁄2"

3

11⁄2"

2"

3

11⁄2"

2"

3

11⁄2"

2"

3

2"

21⁄2"

3

Power supply

Frequency

Fuse

V

Hz

A

400 3N~

50

16

400 3N~

50

16

400 3N~

50

20

400 3N~

50

20

400 3N~

50

20

400 3N~

50

20

Max. electrical power

consumption unit

pump maximum

total

kW

0.90

1.15

2.05

0.90

1.15

2.05

1.27

1.15

2.42

1.27

1.50

2.77

1.27

1.50

2.77

1.27

1.50

2.77

Boiler weight, empty, ± 5 % kg 675 740 840 950 1070 1200

Dimensions height H

width B

length incl. connections L

mm

1355

1330

2265

1355

1330

2265

1355

1130

2653

1355

1130

2653

1355

1330

2658

1355

1330

2658

Table 1 Technical data R3400

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Dimensions R3400

Fig. 1 Dimensional sketch R3400

front view plan view

rear view

side view

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Type R3401 R3402 R3403 R3404 R3405 R3406

B mm 1330 1330 1130 1130 1330 1330

B1 mm 1160 1210 1003 1053 1203 1253

B2 mm 665 665 565 565 665 665

B3 mm 170 120 127 77 127 77

B4 mm 1146 1146 946 946 1146 1146

B5 mm 115 65 115 65 115 65

D mm 300 350 350 400 400 400

GRp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6

H mm 1355 1355 1355 1355 1355 1355

H1 mm 1125 1125 1570 1420 1155 1377

L mm 2265 2265 2653 2653 2658 2658

L1 mm 595 595 610 615 615 770

L2 700 700 1166 1166 1166 1166

L3 mm 108 108 88 88 88 88

WDN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Table 2 Dimensions R3400

(Changes may be introduced without notice)

As a result of manufacturing tolerances, there may be small variations in the dimensions.

Conditions applicable to table 1:

- Nominal capacity measured at: 60 - 80°C.

- Gas consumption at: 1013 mbar, 15°C, dry

- Gas category: 22H3P

- Appliance category: B23, C53, C33 of C63

- Protection degree: IP20

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R3500 Technical data

Type R3501 R3502 R3503 R3504 R3505

Nominal heat output

Nominal heat input (nett. CV)

Minimum heat input

kW

613

653

187

717

764

218

811

865

247

906

966

276

1000

1066

305

Pilot burner kW 30 30 30 30 30

Gas consumption

natural gas H (10.9 kWh/m3)

propane (12.8 kWh/kg)

m3/h

kg/h

59.9

51.0

70.1

59.7

79.4

67.6

88.6

75.5

97.8

83.3

Gas inlet pressure

natural gas H (min/max)

natural gas H (max) option

propane (min/max)

mbar

18 – 25

100

30 – 50

18 – 25

100

30 – 50

18 – 25

100

30 – 50

18 – 25

100

30 – 50

18 – 25

100

30 – 50

Water capacity

Max. working pressure

dm3

bar

53

6

70

6

75

6

80

6

85

6

Gas connection G Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6

Water connections W DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Flue connection D mm 300 350 350 400 400

Safety valve connection

relief connction

standard setting bar

11⁄4"

11⁄2"

3

11⁄4"

11⁄2"

3

11⁄2"

2"

3

11⁄2"

2"

3

11⁄2"

2"

3

Power supply

Frequency

Fuse

V

Hz

A

400 3N~

50

16

400 3N~

50

16

400 3N~

50

20

400 3N~

50

20

400 3N~

50

20

Max. electrical power

consumption unit

pump maximum

total

kW

0.90

1.15

2.05

0.90

1.15

2.05

1.27

1.15

2.42

1.27

1.50

2.77

1.27

1.50

2.77

Boiler weight, empty, ± 5 % kg 740 840 950 1070 1200

Dimensions height H

width B

length incl. connections L

mm

1355

1330

2265

1355

1130

2653

1355

1130

2653

1355

1330

2658

1355

1330

2658

Table 3 Technical data R3500

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Dimensions R3500

Fig. 2 Dimensional sketch R3500

front view plan view

rear view

side view

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Type R3501 R3502 R3503 R3504 R3505

B mm 1330 1130 1130 1330 1330

B1 mm 1210 1003 1053 1203 1253

B2 mm 665 565 565 665 665

B3 mm 120 127 77 127 77

B4 mm 1146 946 946 1146 1146

B5 mm 65 115 65 115 65

D mm 300 350 350 400 400

GRp2" Rp2" Rp2" DN65 PN6 DN65 PN6

H mm 1355 1355 1355 1355 1355

H1 mm 1125 1400 1400 1155 1155

L mm 2265 2653 2653 2658 2658

L1 mm 595 610 610 615 615

L2 mm 700 1166 1166 1166 1166

L3 mm 108 88 88 88 88

WDN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Table 4 Dimensions R3500

(Changes may be introduced without notice)

As a result of manufacturing tolerances, there may be small variations in the dimensions.

Conditions applicable to table 3:

- Nominal capacity measured at: 60 - 80°C.

- Gas consumption at: 1013 mbar, 15°C, dry

- Gas category: 22H3P

- Appliance category: B23, C53, C33 of C63

- Protection degree: IP20

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R3600SB Standard Technical Data

Type R3601SB R3602SB R3603SB R3604SB R3605SB

Nominal heat output kW 639 747 846 945 1043

Nominal heat input (net. CV) kW 653 764 865 966 1066

Minimum heat input kW 187 218 247 276 305

Pilot burner kW 30 30 30 30 30

Gas consumption Natural gas H (10,9 kWh/m3) m3/h 59.9 70.1 79.4 88.6 97.8

Propane (12,8 kWh/m3) m3/h 51.0 59.7 67.6 75.5 83.3

Gas inlet pressure Natural gas H

(min./max.) mbar 18-25 18-25 18-25 18-25 18-25

Propane (min./max.) mbar 30-50 30-50 30-50 30-50 30-50

Water capacity dm3 73 97 104 110 117

Max. working pressure bar 6 6 6 6 6

Gas connection G Rp2" Rp2" Rp2" DN65 PN16 DN65 PN16

Water connections W1

DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

W2

Flue connection D mm 300 350 350 400 400

Air supply connection (option) D1 mm 250 300 300 355 355

Safety valve Boiler connection 1¼" 1¼" 1½" 1½" 1½"

Relief connection 1½" 1½" 2" 2" 2"

Standard setting bar 3 3 3 3 3

Power supply V 400 3N~ 400 3N~ 400 3N~ 400 3N~ 400 3N~

Frequency Hz 50 50 50 50 50

Fuse A 1616 20 20 20

Max. electrical power consumption Unit kW 0.90 0.90 1.27 1.27 1.27

Pump kW 1.15 1.15 1.15 1.50 1.50

Total kW 2.05 2.05 2.42 2.77 2.77

Boiler weight, empty, ± 5% kg 890 1040 1150 1280 1410

Dimensions Height H mm 1405 1405 1405 1405 1405

Width W mm 1330 1130 1130 1330 1330

Length L mm 2265 2653 2653 2658 2658

Table 5 Technical data R3600SB Standard

Doc2005/3456en 57

Dimensions R3600SB Standard

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TJEFWJFX

SFBSWJFX

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

-

-

%

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







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#

#

8 8

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

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GSPOUWJFX

Fig. 34 Dimensions R3600 Standard

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Type R3601SB R3602SB R3603SB R3604SB R3605SB

Bmm1330 1130 1130 1330 1330

B1 mm 1210 1003 1053 1203 1253

B2 mm 665 565 565 665 665

B3 mm 120 127 77 127 77

B4 mm 1146 946 946 1146 1146

B5 mm 65 115 65 115 65

Dmm300 350 350 400 400

D1 mm 250 300 300 355 355

GmmRp2” Rp2” Rp2” DN65 PN6 DN65 PN6

Hmm1405 1405 1405 1405 1405

H1 mm 1175 1450 1450 1205 1427

Lmm2265 2653 2653 2658 2658

L1 mm 595 610 610 615 615

L2 mm 590 1166 1166 1166 1166

L3 mm 198 88 88 88 88

W1 mm DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

W2 mm DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6

Table 18 Dimensions R3600SB Standard

(Changes may be introduced without notice)

As a result of manufacturing tolerances, there may be small variations in the dimensions.

Conditions applicable to table 17:

- Nominal capacity measured at : 60 - 80°C

- Gas consumption at: 1013 mbar, 15°C, dry

- Gas category: 22H3p

- Appliance category: B23, C53, C33 or C63

- Protection degree: IP20

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XI

TABLE OF CONTENTS

R3400 Technical data ........................ I

Dimensions R3400 ........................... II

R3500 Technical data ........................ IV

Dimensions R3500 ........................... V

R3600SB Technical data ...................... VII

Dimensions R3600SB ........................ VIII

Table of contents ............................ XI

1 INTRODUCTION ............................ 1

1.1 Stokvis ...................................1

1.2 Supplier ................................... 1

1.3 This document .............................. 1

1.4 Service.................................... 2

1.5 General restrictions .......................... 2

2 DESCRIPTION ............................. 3

2.1 General ................................... 3

2.2 Main components ............................ 5

2.2.1 Description of principal components ............. 6

2.3 Boiler control ............................... 8

2.4 Safety aspects .............................. 8

3 SAFETY................................... 9

4 DELIVERY AND TRANSPORT .................12

4.1 Delivery ...................................12

4.2 Packaging .................................12

4.3 Transport ..................................12

5 INSTALLATION.............................17

5.1 Regulations ................................17

5.2 Boiler room.................................17

5.2.1 General ...................................17

5.2.2 Set up ....................................17

5.2.3 Ventilation .................................19

5.3 Connections ................................ 19

5.3.1 Gas connection .............................19

5.3.2 Electrical connection .........................19

5.3.3 Water connections ...........................24

5.3.4 Combustion air supply ........................25

5.3.4.1 General ...................................25

5.3.4.2 Air supply pipe ..............................26

5.3.5 The flue system .............................28

5.3.5.1 General ...................................28

5.3.5.2Chimney...................................31

5.3.6 Condensate discharge ........................33

3456CV02A

5.4 Hydraulic system ............................34

5.4.1 General ...................................34

5.4.2 Water flow .................................34

5.4.2.1 Flow rate and resistance ......................34

5.4.2.2Pump characteristics .........................36

5.4.2.3Isolating valves .............................37

5.4.2.4Valves ....................................37

5.4.2.5Water flow protection.........................37

5.4.3 Water pressure .............................38

5.4.3.1Operating pressure ..........................38

5.4.3.2 Boiler expansion tank ......................... 38

5.4.3.3 System expansion tank .......................38

5.4.3.4Water pressure protection ..................... 38

5.4.4 Water temperature...........................38

5.4.5 Water quality ...............................38

5.4.6 Examples of hydraulic systems .................40

6 OPERATING INSTRUCTIONS .................44

6.1 Function...................................44

6.2 Regulation .................................44

6.3 Control module ..............................44

6.4 Fault indications.............................47

6.5 Start-up ...................................48

6.6 Shut-down .................................48

6.7 Warnings ..................................48

7 COMMISSIONING........................... 49

7.1 General ...................................49

7.2 Commissioning .............................49

8 MAINTENANCE ............................52

8.1 Safety.....................................52

8.2 General ...................................52

8.3 Procedure .................................52

8.4 Cleaning the burner and heat exchangers .........53

8.5 Cleaning the filter/screen in the gas

combination block ...........................54

8.6 Ionisation measurement.......................54

8.7 Service....................................54

9 CONVERSION FORMULAE AND FACTORS ......55

SUPPLEMENT .............................58

Edition 3456CV02A, 12-01-2000

XII 3456CV02A

3456CV02A 1

1 INTRODUCTION

1.1 Stokvis.. Since its beginning in 1985, Stokvis has built up a strong

reputation in industry for the development, production and

ISO9002 marketing of gas-fired, high efficiency boilers and water heaters

STOKVIS ENERGY SYSTEMS

1.2 Supplier

1.3 This document

in the 45 to 1189 kW range.

Through their unique construction, these central heating units

and water heaters are renowned for their:

- high thermal efficiency

- environmental friendliness

- light weight and small dimensions

- durability

- low noise production

- large regulating range

- available with many different options.

Continual research and development means that Stokvis

remains at the forefront of boiler technology.

101001AE

96R WALTON ROAD

EAST MOLESEY

SURREY KT8 0DL

Tel.: 08707 707 747

Fax: 08707 707 767

2789CV02/120001EE

This documentation has been compiled to aid the following

target groups:

- the consulting engineer

- the heating installer

- the service engineer

- the user

Because these target groups require mostly similar information

and also specific information, our technical documentation has

been integrated to provide these target groups with the neces-

sary general and specific information to install, service and

operate this product.

The supplier (see 1.2) will be able to provide any further or

supplemental information.

3456CV02A

2

1.4 Service The Stokvis service department is always available for

1.5 General restrictions The application, installation and maintenance of Stokvis

The following aspects of the units are dealt with:

- General description

- Technical specifications

- The facilities necessary for design and installation

- Installation examples

- Maintenance instructions

The operating instructions needed by the user are attached to

the unit; these are also to be found in Section 6.

130001AE

commissioning and for providing service and maintenance. For

details see 1.2.

2789CV02/140001BE

products must always be carried out in accordance with the

requirements (legal or otherwise), specifications and standards

applicable to such installations.

All data, information and suggestions provided by Stokvis in

relation to its products are based on careful investigation.

Nevertheless, neither Stokvis nor any other organisation

connected with Stokvis accepts any liability for application,

installation that occurs outside its sphere of influence.

Changes may be incorporated without prior notice.

Stokvis accepts no obligation to adapt previously

delivered products to incorporate such changes.

2789CV02/150001CE

3456CV02A 3

2 DESCRIPTION

2.1 General The R3400/R3500/R3600SB are environmentally friendly modulat-

The R3400/R3500/R3600SB series have CE approval for the

ing gas fired heating boilers that can vary its output from 25% to

100% of its maximum capacity. The series R3400 consists of 6

types in a range from 657 to 1189 kW.

The series R3500 consists of 5 types in a range from 613 to

1000 kW. The series R3600SB consists of 5 types in a range from

639 to 1043 kW.

The units have an extremely low emission of NO and CO, so

x

that this boiler satisfies the most stringent European

requirements.

following countries:

Austria, Belgium, Denmark, France, Germany, Ireland, Italy,

The Netherlands, Spain and the United Kingdom.

The series is registered under the product identification number

0063AR3514.

The units can be supplied either as a standard (category B23)

or a room sealed (categories C53, C33 or C63) appliance.

Working principle and construction

Air is blown into the appliance, as required, by a speed-con-

trolled fan and thoroughly mixed with gas in the correct

proportions.

A temperature controller compares the desired water

temperature with the temperature of the water flow and sends

a signal to the frequency converter to maintain the correct

heating capacity.

The gas/air mixture so formed is passed through a cooled

premix burner and ignited. The premix burner is constructed of

finned bimetallic pipes (internally from stainless steel and

externally from aluminium) with cast iron water headers.

Heat transfer takes place in two or three heat exchangers. The

first heat exchanger is constructed from smooth stainless steel

pipes, while the second heat exchanger is fitted with laser

welded, stainless steel finned pipes. Both heat exchangers are

fitted with cast iron profiled water distribution components

(headers) which guarantee an optimum water flow through the

appliance.

The burner and the heat exchangers are connected in series.

3456CV02A

4

Fig. 4 The Econoflame R3600SB

On the R3600SB the 3rd heat exchanger is built from stainless

steel laser welded fin pipes and is placed directly below the

2nd heat exchanger. The boiler pump ensures the water flow

through the heat exchanger. The complete water flow over the

boiler goes through this 3rd heat exchanger as it is connected

in series with the other heat exchangers.

The R3400/R3500/R3600SB units have a small water capacity so

that they can rapidly adjust to changing conditions. They can be

installed without any restrictions to the return water temperature.

The necessary water flow rate is ensured by the standard pump

delivered with the appliance.

3456CV02/210002AE

Application possibilities

Because of its construction, the R3400/R3500/R3600SB units are

suitable for use in heating systems:

- With a constant supply temperature.

- With a weather dependent heating demand.

- With low temperature condenser systems.

- With optimised condensation.

- With control by means of building optimiser/compensator

system (0-10 Vdc, see 5.3.2 connection terminals).

34CV02/210003AE

*

* The R3400 and R3500 are identical with the exception of the third heat exchanger.

3456CV02A 5

Fig. 5 General survey

2.2 Main components 1 Return connection .18 Condensate collection tank

2 Flue attentuator 19 Flue gas collection chamber

20 Combustion chamber

3 Water flow switch 21 Electrical cable duct

4 Safety valve 22 Condensate discharge

5 Flow connection 23 Gas valve unit

6 Filling/drainage valve 24 Fan

7 Cover 25 Connection box

8 Distribution plate 26 Control panel

9 Burner 27 Casing

10 First heat exchanger 28 Air inlet damper

11 Gas filter 29 Main mixing chamber

12 Second heat exchanger 30 Pilot gas valve

13 Gas train 31 Pilot mixing chamber

14 Frame 32 Boiler pump

15 Water circulation piping A Air

16 Flue gas discharge B Gas

17 Third heat exchanger R3600SB C Flue gas

3456CV02/220001AE D Condensate

3456CV02A

6

2.2.1 Description of The unit is constructed from the following principal

principal components components:

Fan [24]

This consists of a fan casing, a fan impeller and an electric

motor. The fan sucks in combustion air and increases the air

pressure.

Air inlet damper [28]

A specially developed air inlet damper ensures a low noise

level. As an option, this can be provided with an air filter or with

an air inlet opening so that the appliance can function as a

room sealed appliance.

Gas train [13]

The principal component of the gas train is the main gas

valve/proportional pressure regulator [23]. The quantity of gas

is adjusted in proportion to the quantity of air being supplied.

The quantity of air depends on the speed of the fan. The unit is

fitted with a gas filter [11] as standard.

Mixing chamber [29 + 31]

This area is used for the thorough mixing of the gas and the

combustion air. The unit is supplied with a main mixing cham-

ber [29] and a pilot mixing chamber [31]. Both are connected to

the fan.

Burner [9]

After the gas/air mixture has been distributed over the burner

with the aid of a distribution plate [8], the mixture is burned on

the surface of the burner in such a way that the flame is di-

rected downward. The burner is air and water cooled. The

water distribution components are made from cast iron and

have a profile that ensures that an optimum distribution and

flow are obtained.

Heat exchangers [10, 12 and 17]

The primary heat exchanger [10] is constructed from smooth

stainless steel tubes. These transfer most of the heat energy to

the system water. The secondary heat exchanger [12], which

consists of laser welded stainless steel finned tubes, transfers

the remaining heat from the flue gasses to the system water. All

the water distribution components are constructed from cast

iron and have a profile that ensures that optimum distribution

and flow are obtained. The space between the burner and the

secondary heat exchanger forms the combustion chamber.

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STOKVIS ENERGY SYSTEMS ECONOFLAME R3500 Installation, Operation & Maintenance Documentation

STOKVIS ENERGY SYSTEMS ECONOFLAME R3500 Installation, Operation & Maintenance Documentation

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