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Commissioning - Stokvis Industrial Boilers International Ltd

1. Error Description of error code 0 No error 10 Outside temperature sensor error 20 Boiler temperature 1 sensor error 26 Common flow temperature sensor error 28 Flue gas temperature sensor error 30 Flow temperature 1 sensor error 32 Flow temperature 2 sensor error 38 Flow temperature primary controller sensor error 40 Return temperature 1 sensor error 46 Return temperature cascade sensor error 47 Common return temperature sensor error 50 DHW temperature 1 sensor error 52 DHW temperature 2 sensor error 54 DHW primary controller sensor error 57 DHW circulation temperature sensor error 60 Room temperature 1 sensor error 65 Room temperature 2 sensor error 70 Buffer storage tank temperature 1 sensor error 71 Buffer storage tank temperature 2 sensor error 72 Buffer storage tank temperature 3 sensor error 73 temperature 1 sensor error 74 Collector temperature 2 sensor error 82 LPB address collision 83 BSB wire short circuit 84 BSB address collision 85 BSB RF communication error 91 EEPROM error lockout information 98 Extension module 1 error collective error 99 module 2 error collective error 100 2 clocktime masters LPB 102 master without reserve LPB 103 Communication error 105 Maintenance message 109 jBoiler temperature supervision 110 lockout 111 TW cutout 121 Flow temperature 1 HC1
2. Check water flow Check functionality of safety devices Gas tightness Boiler shut Commissioning protocol Gonttols ntc t Display Programming Overview of main functions Che cklisE denos neben Replacing the electrodes Cleaning the condensate receptacle Cleaning and refilling the syphon Inspection of combustion chamber Water pressure and quality Water flow rate Combustion analysis Gas Gas tightness Safety devices Maintenance protocol 13 14 14 14 16 17 18 18 19 20 21 22 23 23 24 24 25 25 25 25 25 26 27 30 31 Safety General regulations Application Norms and regulations General regulations This documentation contains important information which is a base for safe and reliable installation commissioning and operation of the R6000 boiler All activities described in this document may only be excecuted by authorized
3. mbar 0 mbar HA mbar Ptop panel mbar mbar mbar Pcombustion chamber mbar mbar mbar Operating instructions Controls Operation mode DHW M For switching on the DHW operation indication in display below DHW symbol Operation mode heating zone s I For setting 4 different heating modes Auto clock Automatic operation by time programm Comfort sun 24 7 heating in comfort mode Reduction moon 24 7 heating in reduced mode Standby heating off frost protection activated Display L Info mode G Display possibility of following info without influence on boiler control temperatures operation mode Heating DHW error code Room temperature control C e changing room comfort temperature e changing settings when programming 20 Confirmation OK D Return ESC B These buttons are used for program ming in combination with the wheel By pressing the ESC button it s possible to go back one level changed values are not taken over by the controller By pressing the OK button it s possible to arrive in the next level or confirm changed values Manual mode E This button is used for switching the boiler into manual mode In manual mode all pumps will run and the mixing valves are no longer controlled the bur ner setpoint is 60 C indicated by span ner symbol On off switch A Position 0 B
4. controller system pump address error 352 PPressureless header address error 353 Common flow sensor B10 not available 371 Flow temperature 3 heating circuit 3 supervision 372 thermostat heating circuit 3 373 Extension module 3 error collective error 386 speed has lost valid range 388 DHW error no function 426 Feedback flue gas damper 427 Configuration flue gas damper 431 Sensor primary heat exchanger 432 Functional earth not connected 433 Temperature primary heat exchanger to high Sensor values The diagrams show the sensor values for all boiler sensors and optional sensors available in accessory kits The diagrams contain average values as all sensors are liable to tolerances NTC 10 temperature sensor flow return flue gas DHW and header sensor When measuring the resistance values the boiler should always be switched off Measure close to the sensor in order to avoid value deviations Resistance Ohm 0 10 0 10 20 30 40 50 60 70 80 90 100 110 Temperature 2 NTC 1kQ temperature sensor outdoor sensor Resistance Ohm 0 10 Temperature C Declaration of Conformity Declaration of Conformity Rendamax BV Hamstraat 76 6465 AG Kerkrade NL Declares that the product R6000 Is in conformity with the following standards EN 298 EN
5. ging through the condensate connection Flue and air intake connections Check whether the flue and air intake systems are made according to the national and local regulations Installati ons which don t comply with the regula tions are not allowed to be commissio ned Make sure that all connections are free The size of flue gas and air intake connections may not be reduced 14 Commissioning Prepare boiler for first startup Sr TITOMmMoooOwWLY Legend On off switch Return ESC Room temperature control Confirmation Manual mode Chimney sweeper mode Info mode Reset button Operation mode heating zone s Display Operation mode DHW Preparation for first startup e Open the gas supply e Enable the power supply to the boiler e Switch on the boiler with the on off switch 1 e Make sure the boiler is in standby mode 0 e Check the pump operation make sure the pump runs in the right direction e Release all air from the pump motor It s recommended to put the boiler on 50 load after the first startup as this is the best starting point to do a proper combustion analysis This can be done with the following procedure e Push button gt 3 Sec the boiler goes into controller Stop mode e Push the Info button G the actual boiler load 96 appears in the display Choose set up confirm with OK button now the boiler load can be changed by rotating the whee
6. supervision 122 Flow temperature 2 HC2 supervision 125 Pump supervision error 126 DHW charging supervision 127 _ Legionella temperature not reached 128 Loss of flame during operation 129 Fan error or LP error 130 gas temperature limit exceeded 131 Burner fault 132 GP or LP error 133 No flame during safety time 146 Configuration error collective message Lockouts 28 Error Description of error code 151 Internal error 152 error 153 Unit manually locked 160 error 162 error does not close 164 Error heating circuit flow switch 166 error does not open 171 Alarm contact H1 or H4 active 172 contact H2 EM1 EM or or H5 active 173 Alarm contact H6 active 174 Alarm contact or H7 active 178 Limit thermostat heating circuit 1 179 Limit thermostat heating circuit 2 183 Unit in parameterization mode 193 supervision error after flame on 216 Fault boiler 217 Fault sensor 241 Flow sensor solar sensor error 242 Return sensor solar sensor error 243 Swimming pool temperature sensor error 270 Limit function 317 Mains frequency outside permissible range 320 DHW charging temperature sensor error 324 same sensors 325 extension module same sensors 326 mixing gr
7. the plug from the sensor while the boiler is switched on This should result in a lockout no 28 The lockout should disappear as soon as the plug is placed back in position the boiler will restart Minimum gas pressure switch 5 Close the gas cock when the boiler is in standby position Open the test point on the gas line 4 while measur ing the gas pressure on the test point of the gas pressure switch 5 The boiler will go in lockout no 2 when the switch off setting is achieved Close both test points and open the gas cock lonisation electrode 6 Remove electrical connection from the ionisation electrode while the boiler is running the boiler will go in lockout no 128 The boiler will try to restart With the electrical connection removed the restart will result in lockout no 133 When the connection is already mounted the restart will be successful Measuring the ionisation current can be done by mounting a multi meter set to in between the ionisation elec trode and its electrical connection The ionisation current should always be above 1 2 pA in normal conditions it will be 6 and above Gas tightness check Check the gas tightness of all sealed connections with an approved soap or electronic gas analyzer for example e Test points e Bolt connections e Gaskets of mixing system etc Boiler shut down When the boiler will not be used for longer periods shut down the boiler by f
8. to Preselected output 10V 3 In menu Configuration set the desired curve on parameters 5953 5956 Voltage value 1 for modulation F1 and voltage value 2 for modulation F2 Attention F1 and F2 units are in 1 10 percentage burner modulation DHW preparation with time program via thermostat DHW sensor and pump 3 way valve on Relay output QX3 1 Connect the thermostat DHW sensor B3 terminals 104 and 105 2 In menu Configuration set parameter 5730 DHW sensor to Thermostat or DHW sensor B3 3 In menu Domestic hot water set parameter 1620 Release to Time program 4 DHW 4 In menu Time program 4 DHW set parameter 560 Preselection to desired selection Mo Su Mo Fr Sa Su Mo 5 In menu Time program 4 DHW set parameters 561 566 phase on phase off to the desired heating periods 6 In menu Domestic hot water set parameter 1610 to the desired domestic hot water temperature max 65 C 7 Activate the DHW mode by pushing the left top button on the control panel A Maintenance Checklist Replacing the electrodes Maintenance of the boiler should be carried out by authorized personnel only In order to ensure continued good and safe operation of the boiler it should be inspected at least once per year A maintenance protocol should be filled out see end of this chapter for example of maintenance protocol Checklist The following activities must be carried out see following paragraphs for an extens
9. when the boiler pump is running burner on is not requi red The nominal Ap for each boiler type can be found in the table below actual Ap must be within 0 35 Apnom S AP lt 1 75 APnom An indication of the actual flow rate can be found with the following calculation see table below for nominal data Qactual V APmeasured APnominal Qnominal m h Water flow data R6142 R6190 R6237 Nominal flow rate AT at nominal flow rate Ap at nominal flow rate Commissioning Check functionality of safety devices Gas tightness check Boiler shut down Check functionality of safety devices All safety devices have to be checked on good functioning Safety devices on a standard boiler are a water flow tem perature sensor fluegas temperature sensor water flow switch minumum gas pressure switch and ionisation electrode These devices can be checked as described below Flow temperature sensor 1 Disconnect the plug from the sensor while the boiler is switched on This should result in a lockout no 20 The lockout should disappear as soon as the plug is placed back in position the boiler will restart Return temperature sensor 2 Disconnect the plug from the sensor while the boiler is switched on This should result in a lockout no 40 The lockout should disappear as soon as the plug is placed back in position the boiler will restart Flue gas temperature sensor 3 Disconnect
10. 0 Gas fired central heating boilers Type C boilers of nominal heat input exceeding 70 kW but not exceeding 1000 kw EN 15417 Gas fired central heating boilers Specific requirements for condensing boilers with a nominal heat input greater than 70 kW but not exceeding 1000 kW EN 13836 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 300 kW but not exceeding 1000 kW EN 15502 1 Gas fired central heating boilers Part 1 General requirements and tests EN 55014 1 2000 Electromagnetic compatibility Re quirements for household appliances electric tools and similar apparatus Part 1 Emission EN 55014 2 1997 Electromagnetic compatibility Re quirements for household appliances electric tools and similar apparatus Part 2 Immunity Product family standard EN 61000 3 2 2000 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment input current 16 A per phase EN 61000 3 3 2001 Electromagnetic compatibility EMC Part 3 3 Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply Systems for equipment with rated current 16 A per phase and not sub ject to conditional connection EN 60335 1 2002 Household and similar electrical appli ances Safety Part 1 General re quirements EN 60335 2 102 2006 Household an similar electrical appliances Pa
11. 202 Installation Removing the casing Boiler transport Remove the casing before transporting the boiler in order to avoid damage to the casing parts during transportation Removing the casing is done as fol lows Installation Boiler installation Boiler installation The boiler should be positioned in a frost proof boiler room If the boiler room is on the roof the boiler itself may never be the highest point of the instal lation When positioning the boiler please note the recommended minimum clea rance in the picture When the boiler is positioned with less free space mainte nance activities will be more difficult Once the boiler is in the correct positi on the wooden blocks 1 should be removed and the adjustable feet 2 with vibration absorption dampers should be adjusted to the right height Water and gas connections should be done after mounting the feet as they affect the exact height of all connecti ons Installation Connecting the boiler Connecting the boiler This chapter will explain how to make all connections to the boiler with regard to e Hydraulic connections e Condensate drain connection e Gas connection e Flue gas connection e Air intake connection under casing e Electrical connection The boiler should always be connected in such a way that the system applies to all relevant standards and regulati ons Eu
12. 656 EN 15420 EN 55014 1 2 EN 61000 3 2 3 EN 60 335 1 2 And in accordance with the guidelines of directives 92 42 EEC boiler efficiency directive 2009 142 EEC gas appliance directive 73 23 EEC low voltage directive 2004 108 EMC directive This product is designated with CE number CE 0063BS3840 Kerkrade 22 04 2010 Managing Director
13. H L LPG For type R6237 R6539 on gasses LL Gas min value is 1596 higher gt 68 Technical data 4 w2 a Electrical connections Gas supply Water supply Water return Cold Air Intake under casing Water 2nd return Hot Boiler water drain valve 1 2 Flue gas Outlet Condensate drain flexible hose 25mm diam R6380 6475 gt mm R DN DN65 PN16 R DN DN65 PN16 R R 1 1 2 Extent of delivery Standard boiler Accessories Standard boiler A boiler delivery package contains the following components Component Pcs Package Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border sealed in PE foil Adjustable feet 4 Syphon for condensate connection Cardboard box on top of heatexchanger under casing Mounted on frame of the boiler Conversion kit for natural gas L and propane incl instruction Cardboard box on top of heatexchanger under casing Operation and Installation manual Map attached to back panel of the boiler Spare parts list Map attached to back panel of the boiler Wiring diagram Map attached to back panel of the boiler Accessories Additional to the boiler the following accessories can be ordered e Standard 3 step pump incl connec tion kit e Speed controlled pump in
14. SI OKVIS ENERGY SYSTEMS ECONOFLAME R6000 LMS GAS FIRED CONDENSING BOILERS INSTALLATION OPERATION amp MAINTENANCE DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 ODL TEL 020 87833050 08707 707 747 FAX 020 87833051 08707 707 767 E MAIL info stokvisboilers com WEBSITE www stokvisboilers com DOC3070 R6000 BA Contents Contents Safety Construction Technical data Extent of delivery Installation Commissioning Operating instructions Maintenance Lockouts Sensor values Declaration of Conformity General Application een Norms and regulations Layout Operating principle Standard ACCeSSOLIGS ore ege Boiler Removing the Boiler installation Connecting the boiler Water and hydraulic system Gas SUpply i eer aie ee Condensate connection Flue and air intake connections Prepare boiler for first startup Combustion analysis
15. according to the the VDI2035 The table at the left gives an indication of the relation between the water quali ty and the maximum water filling volu me during the lifetime of the boiler Consult the original text of the VDI2035 for more detailed information Hydraulic system Check if the boiler is hydraulically con nected to the system in such way that water flow can be secured at all times during burner operation The water flow is supervised by the water flow switch in the boiler and a lack of flow will lead to a direct burner stop and lockout of the boiler Commissioning Gas supply Condensate connection Flue and air intake connections Gas supply Check the gas supply connection to the boiler for tightness If any leakage is found reseal the leakage before starting the boiler Remove any air between the gas valve and the gas line This can be done at the test point 1 at the gas pressure switch Don t forget to close the test point afterwards Check the gas type and values with the local gas company in order to know for which gas type the boiler should be commissioned Consult the conversion kit instruction if the boiler is to be installed with natural gas L or LPG Condensate connection Remove the syphon 2 from the con densate connection Fill it with water and place it back in the original positi on Make sure the syphon is filled before starting the boiler in order to prevent flue gases dischar
16. aline earths Max total hardness kW mol m d H 50 200 2 0 11 2 200 600 1 5 8 4 Concentrate Capacity of installation Q kW CARGOS 150 200 250 300 400 500 600 mol m d9H Maximum water re fill volume Vmax n 0 5 2 8 1 0 5 6 1 5 8 4 8 10 12 2 0 11 2 6 3 7 8 9 4 2 5 14 0 1 9 2 5 3 1 3 8 5 0 6 3 7 5 23 0 216 8 1 6 2 1 2 6 3 1 4 2 5 2 6 3 Water pressure Open the valves to the system Check the water pressure in the system If the water pressure is too low see table below increase the pressure up to at least the minimum required water pressure in the table Filling can be done via the fill and drain valve 2 on the return connection 1 of the boiler Minimum operating Flow tempe pressure rature bar PC gt 1 5 90 gt 1 0 80 Water quality The system should be filled with water with a PH value between 8 0 and 9 5 The chloride value of the water should not exceed 50 mg l Entry of oxygen by diffusion should be prevented at all times Damage to the heat exchanger because of oxygen diffusion will not be taken under warranty In installations with higher water volu mes it s necessary to respect the maxi mum filling and additional volumes with corresponding hardness values as sta ted in the german VDI2035 standard In the table you can find the nominal va lues for filling and additional water for the R6000
17. cl connec tion kit e Safety valve manometer and de aerator 3 4 5 or 6 bar incl connec tion kit e 2x max water pressure switch and 1 external high limit thermostat incl connection kit e Gas filter incl connection kit e Max gas pressure switch e External high limit thermostat incl connection kit e Gas valve leakage tester not possi ble for R6142 Controlled bypass incl pump incl connection kit e Plate heat exchanger dT 10K 15K or dT 20k incl connection kit e Low velocity header suitable for dT 10K 15K and dT 20K incl con nection kit e Duo header for connecting 2 boilers in cascade excl connection kit e Extension module AVS75 for heating zone control or external gas valve and or room fan control For each boiler a maximum of 3 AVS75 modules 2x heating zone 1x ext gas valve room fan can be inte grated in the boiler e Additional RVS63 heating zone con troller when controlling more than 2 zones incl wall hung box all neces sary sensors and sockets and con nection material for bus communica tion The above accessories are specially designed for the R6000 boiler and there with easy to install plug and play By choosing a combination of the kits men tioned above you can create your own complete system solution Ask your supplier for more detailed information Installation Boiler transport Boiler transport The R6000 boiler will be supplied as a complete
18. companies Changes to this document may be ef fected without prior notice We accept no obligation to adapt previously deliv ered 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 R6000 boiler may be used for heat ing and hot water production purposes only The boiler should be connected to closed systems with a maximum tem perature of 100 C high limit tempera ture maximum setpoint temperature is 90 C Norms and regulations When installing and operating the boiler all applicable norms european and local should be fulfilled e Local building regulations for install ing combustion air and flue gas sys tems e Regulation for connecting the boiler to the electrical appliance e Regulations for connecting the boiler to the local gas network e Norms and regulations according to safety equipment for heating systems e Any additional local laws regulations with regard to installing and operating heating systems The R6000 boiler is CE approved and applies to the following European standards 92 42 EEC Boiler efficiency directive 2009 142 EEC Gas appliance directive 73 23 Low voltage directive 2004 108 EEC EMC directive EN 656 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 70 kW but not exceeding 300 kW EN 1542
19. d and minumum load CO value should be equal to full load and minimum load values Make sure that the boiler is set to automatic operation and controller stop mode is disabled after the combustion test is finished Combustion settings for natural gas G20 G25 R6142 R6539 10 2 0 2 COmax ppm lt 30 Combustion settings for LPG G31 Convert boiler before operation see coversion kit instruction R6142 R6539 119502 COmax ppm lt 30 Combustion settings for natural gas G20 G25 R6142 R6539 9 4 0 2 COnin ppm 30 Combustion settings for LPG G31 Convert boiler before operation see coversion kit instruction R6142 R6539 COz mn 96 10 0 02 COnin ppm 30 Commissioning Check water flow Check water flow The water flow through the boiler can be checked with two different methods shown below AT measurement Check the temperature difference over the boiler AT flow return when the boiler is running on 100 load The nominal AT is 20K and must be at least between 15K and 25K for secure boiler operation An indication of the actual flow rate can be found with the follo wing calculation see table below for nominal data Qactual AT nominat AT measured Qnominal m h Ap measurement Check the pressure difference over the boiler Ap flow return
20. de off Temporary reduction of button Heating by reduced setpoint 3 amp reduced temperature on Press button again Heating by comfort setpoint QAA75 RESET heset button Press button 3 sec Boiler manually blocked no release 22 Press button again 3 sec Boiler released Alarm symbol disappears Various functions 22a Fixed boiler flow temp with external enable H5 terminals 111 and 112 1 Set operation mode of the controller HMI to comfort mode 3 2 In menu Configuration set parameter 5970 Function input to Room thermostat HC1 3 In menu Configuration set parameter 5971 Contact type H4 NC 4 In menu Heating circuit 1 set parameter 742 Flow temp setpoint room stat to the desired flow temperature Fixed boiler flow temp with time program and external enable H5 terminals 111 and 112 1 Set operation mode of the controller HMI to automatic mode Xt 2 In menu Configuration set parameter 5970 Function input to Room thermostat HC1 3 In menu Configuration set parameter 5971 Contact type H4 NC 4 In menu Heating circuit 1 set parameter 742 Flow temp setpoint room stat to the desired flow temperature 5 In menu Time program 1 set parameter 500 Preselection to the desired selection Mo Su Mo Fr Sa Su Mo 6 In menu Time program 1 set parameters 501 506 phase on phase off to the desired heating periods Weathercompensation on boile
21. ections e Gaskets of mixing system etc Safety devices Check the functionality and the settings of all safety devices connected Consult the chapter commissioning Check functionality of safety devices for more detailed information Maintenance Maintenance Protocol Maintenance Protocol R6000 Project Boiler type Project Serial number Year Address City Nominal load Hi Date Nominal output Hi System Engineer Water pressure Water pH Water hardness Water chloride Water AT full load Water ADboiler Water flow Pump setting Safety devices High limit setting Water flow sensor checked Temp limiter setting Fluegas sensor checked Min gas pressure switch setting Ignition time burner sec Combustion analysis Water flow switch checked Gas consumption 100 load 5096 load Min load Gas pressure CO Tatmospheric T water flow T water return lonisation current Ptop panel Pcombustion chamber 26 Lockouts In case of a lockout a warning symbol Q and a flashing error code appears on the display The cause of a fault should first be determined and eliminated before the boiler is being reset The table below shows all possible lockouts with indication of possible cause
22. in map attached to back panel of the boiler e It s recommended to use stainless steel or PPS fluegas systems e The diameter of the flue gas system must be chosen by calculation ac cording to the national regulations e Construct the flue gas system as short as possible for maximum length see planner documentation e Construct horizonal ways with a mini mum angle of 3 Air intake connection 3 The air intake can be connected in case of room sealed installation The cover 3 must be disassembled in order to connect the air intake piping to the connector inside the boiler The diame ter should be calculated according to the national regulations together with the flue gas system The total resistan ce of both systems should never over come the maximum permissible resis tance of the fan inside the boiler see also chapter Technical data Commissioning Water and hydraulic system Commissioning of the boiler should be carried out by authorized personnel only Failure to respect this condition makes the guarantee void A protocol of the commissioning should be filled out see end of this chapter for example of commissioning protocol This chapter explains the commissio ning of the boiler with the standard boi ler controller When an additional sys tem controller is installed please refer to its manual for commissioning the controller Boiler output Max sum of alk
23. installer in accordance with the applicable national and local standards and regulations Connect the gas line from the system tension free to the gas connection 1 of the boiler A gas cock should be moun ted directly behind the boiler A gas filter can be mounted directly on the gas connection of the boiler Flue gas connection 7 Regulations for the construction of flue gas systems are very different for each country It should be ensured that all national regulations with regard to flue gas systems are respected Connect the flue gas system to the flue gas connection 7 of the boiler use fluegas systems with seamless connec tions only It s not necessary to make separate condensate drain for the flue gas system as the condensate will be drained via the syphon of the boiler Please note the following issues Electrical connection The electrical connection must be madde by an authorized installer in accordance with the applicable national and local standards and regulations For the power supply it s necessary to use a mains isolator switch with a con tact opening of at least 3 mm within the boiler room This switch can be used to switch off the power supply for maintenance purposes 12 All cables should be lead through the cable gland 2 from the back of the boiler boiler into the electro panel 11 Connect all wires to the terminals according to the wiring diagram of the boiler enclosed
24. ion Safety functions activated Controller Stop mode Info display Press button gt 3 sec Press button gt 3 sec again Press button 1x Press button 1x again Press button 1x again Press button 1x 304 Controller Stopp mode after 3 sec Main menu appears insert setpoint INFO Segment displayed Status Boiler room temperature room temperature minimum room temperature maximum outside temperature outside temperature minimum outside temperature maximum DHW temperature 1 Error indication Boiler temperature Maintenance indication Flow temperature Info display depends on configuration Back to main menu INFO Segment disappears Status DHW Status zone 1 Status zone 2 Time Date Operation by manual setpoint Change factory setting boiler temperature Deaeration Press button 1x Press button Press button DOK Turn wheel Press button DOK Press button CJESC Press button Press button gt 3 sec Press button gt 3 sec again Manual mode on spanner symbol appears Heating by fixed setpoint factory setting 60 C 301 Manual mode blinking temperature set value insert setpoint Status boiler Manual mode off spanner symbol disappears 312 Deaeration on Deaeration off Activate chimney sweeper mode Press button lt 3 sec Press button again lt 3 sec Chimney sweeper mode on Chimney sweeper mo
25. ive description of the main activities e Replace the ignition and ionisation electrodes e Clean the condensate receptacle e Clean and refill the syphon e Inspect the combustion chamber clean if necessary e Check the water pressure of the sys tem e Check the water quality of the system water as well as supply water e Check the water flow rate through the boiler e Check correct the combustion values at full and mimimum load with a combustion analyzer e Check the gas pressure to the boiler e Check the tightness of all sealed connections and test points e Check the functionality of all safety devices e Fill out a maintenance protocol Replacing the electrodes The electrodes are positioned on the right hand side of the boiler Replace the ignition electrode 1 and ionisation electrode 2 as shown on the picture Maintenance Cleaning the condensate receptacle Cleaning and refilling the syphon Inspection of combustion chamber Cleaning the condensate receptacle e Disconnect the plug of the fluegas temperature sensor 1 e Remove the internal fluegas pipe 2 of the boiler in order to create access to the condensate receptacle e Clean the receptacle 3 e Mount the fluegas pipe back in positi on when the cleaning is finished e Connect the plug of the fluegas temperature sensor Cleaning and refilling the syphon e Remove the syphon 4 from the condensate connection e Clean and fil
26. l C and confirming the 5096 setting with the OK button After checking the combustion values see next page the controller Stop mode can be stopped by pushing the control mode button 1 23 Sec Commissioning Combustion analysis Combustion check at full load Start the boiler in controller stop mode and go to 50 load Now the boiler operates at 50 load Allow the boiler to stabilise the combustion for 3 minutes Then increase the boiler load step by step up to 100 Check the gas pressure on the inlet of the gas valve while increasing the boiler load the gas pressure should never go below the minimum required value gt see technical data Set the minimum gas pressure switch 1 at 75 of the required gas pressure Check the combustion settings via the test point in the chimney connection 3 If necessary correct the settings with the flat adjustment screw on the outlet of the gas valve 2 Combustion check at minimum load Switch the boiler to minimum load 0 Check the combustion settings the same way as described for full load If necessary correct the settings with the allen key adjustment screw on either side of the gas valve 4 Combustion check at 50 load An additional reference check of com bustion values at 50 load is recom mended in order to check if the gas valve is set in such way that the modu lating behaviour is normal The CO value should be in between the settings of full loa
27. l it with fresh water e Mount the syphon back in the original position Inspection of combustion chamber The inspection opening is positioned on the left hand side of the boiler e Remove the radiation panel 5 from the heat exchanger e Remove the cover 6 from the inspection opening e Inspect the combustion chamber 7 clean if necessary e Mount the cover and radiation panel back in original position Maintenance Water pressure and quality Check if the water pressure and quality meet the requirements Consult the chapter commissioning water and hydraulic system for more detailed information Water flow rate Check if the water flow rate through the boiler is within the limits Consult the chapter commissioning check water flow for more detailed information Combustion analysis Check the combustion at full load and minumum load correct the settings if necessary An additional reference check at 50 load is recommended Consult the chapter commissioning combustion analysis for more detailed information Gas pressure Check the dynamic pressure of the gas supply to the boiler when the boiler is running at full load In case of a boiler cascade all boilers should be running at full load See technical data for required values Gas tightness check Check the tightness of all sealed con nections with an approved soap or electronic analyzer for example e Test points e Bolt conn
28. max min kW 142 2 23 5 190 3 39 5 237 4 39 5 285 5 39 5 380 6 76 6 475 8 76 6 539 6 76 6 Nominal heat output at 40 30 C max min kW 150 7 26 7 201 6 45 2 251 4 45 1 302 3 45 2 403 1 87 7 503 9 87 7 571 5 87 7 Nominal heat input Hi max min kW 145 0 24 5 194 0 41 5 242 0 41 5 291 0 41 5 388 0 80 5 485 0 80 5 550 0 80 5 Efficiency at 80 60 C 98 0 Efficiency at 40 30 C 103 9 Annual efficiency NNG 75 60 C 106 8 Annual efficiency NNG 40 30 C 110 4 Standstill losses Twater 70 C 0 21 0 18 0 17 0 16 0 15 0 14 0 13 Max condensate flow 11 15 19 22 Gas consumption H gas max min 10 9 kWh m 13 3 2 3 17 8 3 8 22 2 3 8 26 7 3 8 35 6 7 4 44 5 7 4 50 5 7 4 Gas consumption L gas max min 8 34 kWh m 17 4 2 9 23 2 5 0 29 0 5 0 34 9 5 0 46 5 9 7 58 2 9 7 66 0 9 7 Gas consumption LL gas max min 8 34 kWh m m h 17 4 2 9 23 2 5 8 29 0 5 8 34 9 5 8 46 5 11 2 58 2 11 2 66 0 11 2 Gas consumption LPG max min 12 8 KWh kg kg h 11 3 1 9 15 2 3 2 18 9 3 2 22 7 3 2 30 3 6 3 37 9 6 3 43 0 6 3 Gas pressure H gas mbar 20 Gas pressure L LL gas mbar 25 Gas pressure LPG mbar 30 50 Maximum gas pressure mbar 100 Flue gas temperature at 80 60 C max min C 78 61 Flue gas temperature at 40 30 C max min C 56 30 Flue gas quantity max min m h 238 40 318 69 397 69 477 69 636 134 795 134 901 134 CO level natural gas H E L LL max min 10 2 9 4 CO level lig
29. oiler and connected electrical compo nents are not powered Frost protection is not secured Position The boiler and connected electrical components are powered and standby for operation Legend On off switch Return ESC Room temperature control Confirmation OK Manual mode Chimney sweeper mode Info mode Reset button Operation mode heating zone s Display Operation mode DHW zr TIQ9pnmoour Deaeration mode E By pressing the manual mode button longer than 3 seconds the automatic hydraulic deaeration is activated During deaeration the system is put in standby mode O The pumps are switched on and off for several times After deaeration the boiler automatically returns to normal operation Chimney sweeper mode F Used for combustion analysis By pres sing the button once again or automati cally after 15 minutes the chimney swee per mode will be deactivated indicated by spanner symbol Reset button H By shortly pressing the reset button a burner lockout can be cancelled Operating instructions Display Programming OO DHW mode selection Heating operation mode selection Controller Stopp mode when pressing gt 3 sec Display Info button Quit menu Confirm ES Manual mode Reset Deaeration mode when pressing gt sec Chimney sweeper mode Select turn left right Heating to comfort setpoint Info level activated Heating to reduced
30. ollowing procedure e Switch the boiler in standby operation 6 e Switch off the boiler with the on off switch 7 e Disable power supply to the boiler by deactivating the mains isolator switch in the boiler room e Close the gas supply to the boiler Commissioning Commissioning protocol Commissioning Protocol R6000 Project Boiler type Project Serial number Address Year Nominal load Hi City Date Nominal output Hi System Engineer Water pressure Water pH Water hardness Water chloride Installati on Roof top Ground floor Basement Water AT full load Water Water flow Pump setting Safety devices High limit setting Hydrau lics Low velocity header Plated heat exchanger Bypass boiler Water flow sensor checked Temp limiter setting Fluegas sensor checked Min gas pressure switch setting Water flow switch checked Ignition time burner Combustion analysis 100 load 50 load Min load Gas consumption m h m h mh Gas pressure mbar mbar mbar ppm ppm ppm ppm ppm ppm Tatmospheric Twater flow Twater return lonisation current Ptan
31. oup same sensors 327 Extension module same function 328 Mixing group same finction 329 Extension module mixing group same function 330 Sensor BX1 no function 331 Sensor BX2 no function 332 Sensor BX3 no function 333 Sensor BX4 no function 334 Sensor BX5 no function 335 Sensor BX21 no function EM1 EM2 or EM3 336 Sensor 22 no function EM1 EM2 or EM3 337 Sensor BX1 no function 338 Sensor BX12 no function 339 Collector pump Q5 not available 340 Collector pump Q16 not available 341 Collector sensor B6 not available 342 DHW sensor B31 not available 343 Solar integration not available 344 Solar controlling element buffer K8 not available 345 Solar controlling element swimming pool K18 not available 346 Solid fuel boiler pump Q10 not available 347 Solid fuel boiler comparison sensor not available 348 Solid fuel boiler address error Lockouts Error Description of error code 349 Buffer return valve Y15 not available 350 Puffer address sensor 351 Primary controller system pump address error 352 Pressureless header address error 353 Common flow sensor B10 not available 371 Flow temperature 3 heating circuit 3 supervision 372 thermostat heating circuit 3 373 Extension module 3 error collective error 349 Buffer return valve Y15 not available 350 Puffer address sensor 351
32. r flow temp with time program and external enable H5 terminals 111 and 112 1 Ensure that the resistor on terminals 106 and 107 has been removed and that the outdoor temp sensor QAC34 has been connected to these terminals 2 In menu Time program 1 set parameter 500 Preselection to the desired selection Mo Su Mo Fr Sa Su Mo 3 In menu Time program 1 set parameters 501 506 phase on phase off to the desired heating periods 4 In menu Heating circuit 1 set parameter 720 Heating curve slope and parameter 721 Heating curve displacement to the desired values External temperature setpoint via 0 10Vdc analogue signal H1 terminals 109 and 110 Function not active when setpoint lt 5 C Function active when setpoint gt 5 C 1 Ensure that the analogue 0 10Vdc signal has been connected correctly polarity 2 In menu Configuration set parameter 5950 Function input H1 to Consumer request VK1 10V 3 in menu Configuration set the desired curve on parameters 5953 5956 Voltage value 1 for temperature F1 and voltage value 2 for temperature F2 Attention F1 and F2 units are in 1 10 degrees External modulation setpoint via 0 10Vdc analogue signal H1 terminals 109 and 110 Function not active when Signal 0 15Vdc Function active when signal 2 0 2Vdc 1 Ensure that the analogue 0 10Vdc signal has been connected correctly polarity 2 In menu Configuration set parameter 5950 Function input H1
33. ropean national and local It s the responsibility of the installer to en sure that all standards and regulations are respected Hydraulic connections The boiler should always be connected in such a way that water flow through the boiler can be ensured at all times Connect the flow 4 and return 5 con nection of the system tension free to the boiler connections If the boiler is used in a system with two return cir cuits the common return becomes the low temperature return the 2nd return connection 6 is the high temperature return remove cap flange before con necting The optional accessory kit with safety valve manometer and deaerator should be mounted on the flow connec tion 4 of the boiler before connecting to the system The optional pump kit should be mounted directly to the return connecti on 5 of the boiler before connecting to the system Condensate connection 8 After filling with water the syphon included in delivery should be in stalled to the connection at the bottom of the condensate receptacle Lead the hose under the frame at the back of the boiler and connect it to the draining System in the boiler room The connec tion to the draining system should al ways be done with an open connection in order to avoid a flooding of the boiler in case of a blocked drain Installation Connecting the boiler Gas connection 1 The gas connection must be made by an authorized
34. rticular requirements for gas oil and solid fuel burning ap pliances having electrical connections Additional national standards Germany RAL UZ 61 DIN 4702 8 Switzerland SVGW EKAS Form 1942 Fl ssiggas Richtlinie Teil 2 Vorschriften der kantonalen Instanzen z B Feuerpoilizeivorschriften Netherlands GASKEUR BASIS GASKEUR SV GASKEUR HR107 Belgium HR TOP Construction Layout of boiler Operating principle Operating principle The R6000 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 mix ing system will adapt the gas ratio to the chosen fan speed in order to main tain the best possible combustion fig ures and therewith the best efficiency The flue gases created by the combus tion are transported downwards through the boiler and leave at the back side into the chimney connection 4 18 19 20 21 The return water from the system en ters the boiler in the lower section where is the lowest flue gas tempera ture in the boiler In this section con densation takes place The water is being transported upwards through the boiler in order to leave the boiler at the top burner section The cross flow working principle water up flue gas down ensures the most efficient com b
35. setpoint Programming activated c INFO PROG e o ECO Heating for frost protection setpoint Heating 0 0 A 2 8 8 temporarily switched off 0 1 2 No 2 0 0 xt Process running please w it ECO function active e e e o o lt Burner operating only oil gas boiler e 6 2253 Error messages e e e Info level activated Programming activated Heating temporarily switched off ECO function active Holiday function active Reference to heating circuit Maintenance special operation Parameter number Programming Default mode buttons Press OK 1x Press OK 1x Press INFO 4 sec Enduser Commissioning Expert choose menu choose user level confirm with OK button confirm with OK button choose parameter choose menu confirm with OK button confirm with OK button change value with wheel choose parameter confirm with OK button confirm with OK button return to main menu with ESC button change value with wheel confirm with OK button return to main menu with ESC button Operating instructions Overview of main functions DOK confirmation cancel return to main menu Button Action Set room temperature Procedure Zone 1 and zone 2 Actuate wheel left right Turn wheel Confirm with OK button or wait 5 sec press JESC Display Function Comfort setpoint with blinking temperature Blinking temperature in 0 5 C
36. steps from 10 to 30 C Comfort setpoint saved Comfort setpoint cancelled after 3 sec Main menu appears Qe Set room temperature for zone 1 or zone 2 Switch on off DHW ope ration Change heating operation mode Zone 2 independent from zone 1 Actuate wheel left right Confirm with OK button Actuate wheel left right Confirm with OK button or wait 5 sec or press Press button Factory setting Press button 1x Press button 1x again Press button 1x again Choose heating zone Heating zone is chosen Blinking temperature in 0 5 C steps from 10 to 30 C Comfort setpoint saved Comfort setpoint cancelled after 3 sec Main menu appears DHW mode off see indication below DHW symbol On DHW mode by time programm Off no DHW operation Safety functions activated Automatic mode on with Heating by time program Temperature setpoint by heating program Safety functions activated Summer Winter automatic switching activated ECO functions activated see indication below operation symbol Continuous COMFORT heating on with Heating without time program by comfort setpoint Safety functions activated Continuous REDUCED heating on with Heating without time program by reduced setpoint Safety functions activated Summer Winter automatic switching activated ECO functions activated Safety mode on with Heating off Temperature by frost protect
37. uid gas P max min 96 11 9 10 0 NOx level max min mg kWh 35 15 CO level max min mg kWh 14 8 Max permissible flue resistance max min Pa 160 10 160 10 200 10 200 10 200 10 250 10 250 10 Water volume 27 31 35 61 68 75 82 Water pressure max min bar 8 1 Max water temperature High limit thermostat C 100 Maximum temperature setpoint C 90 Nominal water flow at dT 20K m3 h 6 1 8 1 10 2 12 2 16 3 20 4 23 1 Hydraulic resistance at nominal water flow kPa 10 18 28 15 27 42 55 Electrical connection V 230 400 Frequency Hz 50 Mains connection fuse A 16 IP class IP20 Power consumption boiler max min excl pump Ww 158 43 200 35 230 35 260 35 470 61 650 61 770 61 Power consumption 3 step pump optional Ww 170 90 190 120 380 210 380 210 530 300 720 380 1150 600 Power consumption speed controlled pump opt 180 10 180 10 435 25 435 25 450 25 800 35 800 35 Power consumption bypass pump optional 55 35 85 65 170 90 170 90 190 120 460 225 470 280 Weight empty kg 295 345 400 465 535 590 650 Noise level at 1 meter distance dB A 59 lonisation current minimum uA 6 PH value condensate 3 2 CE certification code CE 0063BS3840 Water connections R2 DN65 PN16 Gas connection R3 4 R1 R1 R1 R1 1 2 R1 1 2 R1 1 2 Flue gas connection mm 150 150 200 200 250 250 250 Air intake connection for room sealed use mm 130 150 150 150 200 200 200 Condensate connection mm 40 40 40 40 40 40 40 min load on gasses
38. unit being fully assembled and pre tested The maximum width is 670mm for models R6142 R6237 and 770mm for models R6285 R6539 which makes it possible to transport all mo dels through a normal door in one pie ce The boiler can be transported with a pallet truck entering either from the front or from the side Whenever necessary the boiler can be dismantled into smaller parts for easier transport inside the building The table below shows the main dismantled parts with their weight and dimensions When the boiler has to be transported with a crane it is necessary to remove the casing before connecting the boiler to the crane Always connect the crane to the frame of the boiler by using straps 1 Hoisting belt 4x 2 Wooden retaining beam 2x 3 Hoisting belt position 4x Component R6142 R6190 6237 R6285 R6380 R6475 R6539 Burner 1st heat exchanger assembly Weight kg 86 100 112 135 158 181 198 Length mm 735 885 1035 735 885 1035 1185 Width mm 400 400 400 680 680 680 680 Height mm 321 321 321 321 321 321 321 2nd 3rd heat exchanger assembly Weight kg 90 Length mm 735 Width mm 400 Height mm 244 Condensate receptacle Weight kg 7 Length mm 589 Width mm 385 Height mm 225 Frame Weight kg 15 Length mm 990 Width mm 624 Height mm 335 Front U frame with electronic board Weight kg 11 Length mm 628 Width mm 1304 Height mm
39. ustion results Layout of boiler The R6000 boiler consists of the follow ing main components Casing Front panel Adjustable feet Control panel below cover Flue gas connection Air intake connection under casing 7 Gas connection 8 Flow water connection 9 1 Return water connection 0 2nd hot return water connection for split system use 11 Filling draining valve 12 Electrical input connections 13 Frame 14 Burner 1st heat exchanger assembly 15 2nd 3rd heat exchanger assembly 16 Water headers 17 Condensate receptacle 18 Whirlwind gas air mixing system 19 Fan 20 Gas valve 21 Gas pressure switch 22 Inspection opening 23 Ignition and ionisation electrodes 24 Syphon 25 Removable flue gas adapter The LMS14 control unit can control the boiler operation based on e Boiler control stand alone operation e Weather compensated operation with optional outdoor sensor e With 0 10V external influence temperature or capacity from a building management system Technical data R6142 R6190 R6237 R6285 R6380 R6475 R6539 Nominal heat output at 80 60 max min kW 142 1 23 3 190 1 39 5 237 2 39 5 285 2 39 5 380 2 76 6 475 3 76 6 539 0 76 6 Nominal heat output at 75 60

Commissioning - Stokvis Industrial Boilers International Ltd

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