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1. rr 20 eating Zone u u u u u y aan ua nasta Sa 20 Cascade CONG siete oo a ec ee 20 Contents Accessories Installation examples E w us cei en ee eee ene as ee ee eee eee eee 21 Dimensions single low loss 25 Dimensions single plate heat 26 7919 epee eee ce en areata eer ee oe ene ee 27 Modupak Cascade aa 29 Dimensions cascade DN65 line low loss header 30 Dimensions cascade DN100 line low loss 31 Dimensions cascade DN65 back 2 back low loss 32 Dimensions cascade DN100 back 2 back low loss 33 Dimensions cascade DN65 line plate heat 34 Dimensions cascade DN65 back 2 back plate heat 35 1 A C 1 direct heating Zone low loss header 36 2 A C 1 mixed heating Zone low lo
2. 98 Installation examples 2 5 B C 1 heating zone and sanitary hot water plate heat exchanger 2 5 B C 1 heating zone and sanitary hot water plate heat exchanger III I i ae L aji PORTIT OII Description e R40 with plate heat exchanger e Weather compensated control e 1 mixed heating zone e Sanitary hot water Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 47 Installation examples 4 5 B C 2 heating zones and sanitary hot water plate heat ex changer 4 5 B C 2 heating zones and sanitary hot water plate heat exchanger AV tae Description e R40 with plate heat exchanger e Weather compensated control e 2 mix
3. 76 40 9 7 dT 15K header type CB52 40L CB52 40L CB52 40L CB52 50L CB76 40H m3 h 3 5 4 5 3 6 4 7 kPa 8 7 44 7 20 0 19 4 16 8 dT 10K header type CB52 40L CB52 50L CB52 50L aie m3 h 5 2 6 8 0 9 6 5 6 2 5 6 5 Flue adapter parallel Flue adapter concentric The boiler is equipped with a flue con Concentric flue systems can be used nection of 100mm R40 65 120 or on the R40 65 120 by using a parallel 130mm R40 150 In case of using to concentric adapter 110mm or 125mm flue systems the Original adapter can be replaced as follows 100mm replaced by 110mm 130mm replaced by 125mm 24 Air inlet cover The inlet cover can be used to cover the air inlet connection of the boiler in non room sealed condition available in 100mm and 130mm Accessories Dimensions single low loss header R40 65 85 40 100 150 500 600 AX125 11 4 AX150 11 2 XCOSOF DN50 490 590 200 250 240 XCOSOF 25 Accessories Dimensions single plate heat exchanger R40 65 85 40 100 150 Plate heat exchanger CB52 40L CB52 50L CB52 40H CB52 50H 26 500 600 mm mm mm mm oo r E 250 300 466 466 519 519 490 590 am P G 1 1 4 G 1 1 4 G 2 G 2 Accessories Controls Extension module AGU2 551 The kit contains an AGU2 551 module fo
4. Accessories Dimensions cascade DN100 back 2 back low loss header Standard R40 DN 100 Number of boilers 3 4 5 6 7 8 Total width L mm 2107 2757 3407 D 150mm B 400 450 H mm 553 646 738 D 200mm B 350 400 H mm 616 709 801 a kane ee Dk i P DI I 4 i ES aaa i BS ISPESL Italy only R40 DN 100 Number of boilers 3 4 5 6 7 8 Total width L mm 2553 3203 3853 150mm 400 450 H mm 553 646 738 D 200mm B 350 400 H mm 616 709 801 Accessories Dimensions cascade DN65 line plate heat exchanger Standard R40 DN 65 Number of boilers 2 3 4 5 6 Total width L mm 1940 2590 3240 3890 4540 D 150mm B 400 450 H mm 553 646 738 831 924 D 200mm B 350 400 H mm 616 709 801 894 987 CB200 30M 92 CB200 50M 146 CB200 64M 184 AN O T Wop Pn O as Jeb dpa ISPESL Italy only R40 DN 65 Number of boilers 2 3 4 5 6 Total width L mm 2383 3033 3683 4333 4983 150mm 400 450 H mm 553 646 738 831 924 D 200mm B 350 400 H mm 616 709 801 894 987 Chall E Chall H 206 Accessories Dimensions cascade DN65 back 2 back plate heat exchanger Standard R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 1940 2590 3240 D 150mm B 400 450 H mm 553 646 738 D 200mm B 350 400 H mm 616 709 801 CB200 30M 92 CB200 BAS 146 yo is AL ISPESL Italy
5. max 3m horizontal flue Cascade collector line Cascade system For installing the R40 in cascade installations dedicated flue systems are defined and available in 150mm and 200mm diameter both for line and back 2 back installations The diameter of the horizontal collector and the vertical chimney depends on the total heat input of the installation and the vertical height of the chimney The table shows the maximum system input related to the vertical chimney length based on max 3m horizontal length after collector and diameter collector chimney Cascade collector back 2 back 14 Neutralisation General Neutralisation systems General The maximum amount of condensate Condensate created by the for each boiler type can be found in the R40 should be drained into the public chapter Technical data draining system The condensate PH is between 3 0 and 3 5 National and or local regulations have to be checked in order to find out whether the condensate should be neutralised before entering the public draining system Neutralisation systems The neutralisation systems can be placed in the bottom section of the boiler The delivery of the system contains the following components e Granulate for first filling e Connection hoses for inlet and outlet connection e Boiler connection adapter For the neutralisation two different systems are available Standard neutralisation system DN The
6. Antifreeze Antifreeze The R40 can be used with the antifreeze type Shell Antifreeze Concentrate The concentration of the antifreeze in the system affects the max capcity the boiler can work on The relation between antifreeze concentration and capacity reduction of the boiler can be found in the graph 11 Flue gas system Requirements and regulations Materials Flue gas data Requirements and regulations Materials Regulations for the construction of flue Exclusively materials which are heat gas systems are very different for each resistant and resistant to flue gases country It should be ensured that all and aggressive condensate may be national regulations with regard to flue used Recommended materials are gas systems are respected The most plastic PPS category T120 or stain important national norms can be found less steel Aluminium only thick wall in the chapter Norms can also be used in Germany only after consulting the chimney sweeper Pay attention to the following recommendations when dimensioning The R40 has an integrated high limit a flue gas system thermostat function for the flue gases Only approved flue gas material may When the fluegas temperature exceeds be used 90 C the burner is switched off With The flue gas system must be properly this function an additional external calculated to ensure a safe functioning safety device is not necessary of the system Flue gas sys
7. 0063CM35 76 Kerkrade 16 11 2010 Managing Director Technical description Standard boiler Boiler transport Boiler installation Standard boiler A boiler delivery package contains the following components Boiler fully assembled and tested Cardboard box on pallet Mounting bracket incl mounting material Cardboard box in boiler packaging Syphon for condensate connection Boiler transport The R40 boiler will be supplied as a complete unit being fully assembled and pre tested The packaging dimensi on is 1050x572x575mm for boiler types 65 85 and 1185x674x665mm for boiler types 100 150 which makes it possible to transport all models through a nomal door in one piece The R40 can be transported with a crane but it has to be ensured that the boiler is packed and fixed on a pallet The straps must be connected to the pallet 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 instalation 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 Norms and regulations Norms General regulations This documentation contains important information which is a base for safe and reliable installation commissioning and operation of the R40
8. 400 450 H mm 553 646 738 831 924 D 200mm B 350 400 H mm 616 709 801 894 987 7 Li I Fii i F r Ir 1 0 HI IL P u il ais sli TIR TR Accessories Dimensions cascade DN100 line low loss header Standard R40 DN 100 Number of boilers 4 5 6 Total width L mm 3407 4057 4707 D 150mm B 400 450 H mm 738 831 924 D 200mm B 350 400 H mm 801 894 987 560 660 va ISPESL Italy only R40 DN 100 Number of boilers 4 5 6 Total width L mm 3853 4503 5153 150mm 400 450 H mm 738 831 924 D 200mm B 350 400 H mm 801 894 987 af Beats ee ogo OE s DE zamm i O il DO Ei Accessories Dimensions cascade DN65 back 2 back low loss header Standard R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 1672 2322 2972 D 150mm B 400 450 H mm 553 646 738 D 200mm B 350 400 H mm 616 709 801 530 630 530 630 a Y j a if reir 1 li I J DN65 k EE 74 a all U i I ISPESL Italy only R40 DN 65 Number of boilers 2 3 4 Total width L mm 2115 2765 3415 D 150mm 400 450 H mm 553 646 738 D 200mm B 350 400 H mm 616 709 801
9. this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of a boiler room installed the roof the boiler may never be hydraulically connected at the highest point of the installation 49 Installation examples B C Boiler control via 0 10VDC plate heat exchanger B C Boiler control via 0 10VDC plate heat exchanger 52 2 sagen BBE Description e R40 with plate heat exchanger Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never
10. 50 mbar a pressure regulator should be fitted in the gas line The gas consumption and gas pressu res of the different gases can be found the chapter Technical data The following water quality levels must be respected at all times for warranty claiming Damage to the boiler due to poor water quality will not be taken under warranty 2 0 11 2 Boiler output Max sum of alkaline earths Max total hardness kW mol m Concentrate 2 mol m dH lt 0 5 lt 2 8 1 0 15 10 Capacity of installation Q kW 3 ees Maximum water volume Vmax m Combustion air The gas condensing boiler R40 can be used in both non roomsealed and roomsealed applications The com bustion air to the boiler shouldn t con tain high concentrations of dust and or halogen as they can damage the heat exchanger surface Especially in buil dings where chemicals are used the combustion air facility should prevent these chemicals to enter the boiler The different room sealed connection possibilities the R40 is approved for can be found in the chapter Flue gas system 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 wit
11. BP Fit Description e R40 with low loss header e Weather compensated control e 1 mixed heating zone Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation Installation examples 4 A C 2 heating zones low loss header 4 A C 2 heating zones low loss header RG2 QAAT5 WEFT ec Description e R40 with low loss header e Weather compensated control e 2 mixed heating zones Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This shou
12. Hydraulic resistance at nominal water flow 50 xan Po PD PD Power consumption boiler max min excl pump Power consumption 3 step pump optional Power consumption speed controlled pump opt w G 6 6 7 lonisation current minimum CE certification code Le CE 0063CM3576 Flue gas connection 100 Air intake connection for room sealed use 100 h 35 Gas consumption G20 max min 10 9 kWh m h 5 7 1 0 7 6 1 3 8 7 1 5 10 5 1 8 12 4 2 2 h lt 0 gt olo olo 0 09 mD 0 Q olo ta Q gt O D O 09 3 o gt lt a 3 gt 5 lt D Technical description Dimensions FRONT VIEW SIDE VIEW BACK VIEW aml oto s mooo Ri mu sum au erm Rte Rw Technical description Declaration of conformity Declaration of Conformity Rendamax BV Hamstraat 76 6465 AG Kerkrade NL Declares that the product R40 15 in conformity with the following standards EN 298 EN 483 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 2006 95 EEC low voltage directive 2004 108 EMC directive This product is designated with CE number CE
13. only R40 DN 65 Number of boilers 3 4 5 6 7 8 Total width L mm 2383 3033 3683 D 150mm B 400 450 H mm 553 646 738 200 50 400 616 709 801 00 30M 148 CB200 50 206 CB200 64M 244 epee Installation examples 1 A C 1 direct heating zone low loss header 1 A C 1 direct heating zone low loss header 52 M2 a i E RGI QUAATS AFFI STB i K X Description e R40 with low loss header e Weather compensated control e 1 direct heating zone Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 36 Installation examples 2 A C 1 mixed heating zone low loss header 2 A C 1 mixed heating zone low loss header 52 M2 gBaE3 84 QAATS
14. relay e Primary sanitary hot water pump control use of relay necessary when gt 1A e Interlock input e Lockout input e OK Alarm output signal e Boiler enable signal e 0 10VDC temperature or capacity setpoint programmable e Temperature control central heating via PID controller e Temperature control sanitary hot water hot water priority Boiler enable signal terminals X6 7 and X6 8 volt free The boiler enable signal is provided with a jumper from the factory When connecting to a volt free external signal the jumper must be removed Temperature or capacity setpoint terminals X6 1 and X6 2 0 10VDC The R40 can be controlled via a temperature or capacity setpoint The signal values are programmable from the factory the contact is programmed for temperature setpoint with settings as shown in the graphic When controlling the boiler via a capacity setpoint it s highly recommen ded to control the primary boiler pump with the internal pump control of the LMS14 boiler controller The minimum flow rate through the boiler must be respected at all times The nominal AT is 20K and should be at least within 15K 25K at full load to secure a Safe boiler operation e Weather compensation with optional outdoor sensor e Connection possibility for external gas valve and or room fan See chapter Accessories for combinations with an OK Alarm contact e Master Slav
15. standard neuirlisation system is used when the public draining connection is at lower level than the boiler syphon connection sai Wii Bal i 240 Width mm 300 Height mm Neutralisation system with pump HN The neutralisation system with pump is used when the public draining system is at higher level than the boiler syphon connection and the condensate needs to be transported to a higher level before draining is possible The built in pump of the neutralisation system takes care of the transport of the condensate HN1 5 HN2 5 HN2 7 rocco 80 750 Length im 640 640 400 400 Fa I sumption pump Pump head m Hydraulic connection Hydraulic resistance AT measurement Ap measurement m3 h AT measurement Check the temperature difference over the boiler AT flow return when the boiler is running on 100 load The nominal 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 follow ing calculation see table below for nominal data Qactual AT nominal AT measured Qnominal Ap measurement Check the pressure difference over the boiler Ap flow return when the boiler pump is running burner on is not required The nominal Ap for each boiler type can be found in the table below actual Ap must be within 0 35 Apnom lt Ap lt 1 75 Apnom indi cation of the actual flow rate can b
16. with the integrated boiler controller LMS14 e With the extension controller 2 additi onal heating zones can be controlled e The heating zone control can be extended up to 15 heating zones 52 Notes 55
17. SIT ORVIS ENERGY SYSTEMS ECONOFLAME R40 GAS FIRED WALL MOUNTED CONDENSING BOILERS INSTALLATION OPTIONS amp SYSTEMS DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 ODL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E MAIL info stokvisboilers com WEBSITE www stokvisboilers com 06 2011AC20111006 DOC2080GB Contents Gas condensing boiler R40 Technical description Norms and regulations Flue gas system Neutralisation Hydraulic connection Controls Modeli MOODUL 52252052 Sastrence ta Qs usuyku mah ub mia ha aD usa 4 Application pos ibililieSuuu nee 4 4 PSS 4 uuu xa 5 uw susu 6 Declaration COMMONMILY GE AIE La east os a age ek Sa a 7 Standard DONET S tasu Sau 8 BollerraliSbOrtux 8 Bollerinestallali i e 8 9 cen ee AS 10 Pausa hka 10 COMDUSUOM 10 VV ATCT uu uyu uyu uuu 10 NOISE DIOLS CTIOMN
18. VL Description e 2 x R40 with low loss header e Cascade control weather compensation e 2 mixed heating zones e Sanitary hot water Tips e Low loss duo headers are available for AT 15 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e n case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 41 Installation examples A C Boiler control via 0 10VDC low loss header A C Boiler control via 0 10VDC low loss header Description e R40 with low loss header Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positi
19. ZONES uA aan 52 a p secede E cea pa 53 Gas condensing boiler R40 Models and output Application possibilities Value propositions Description Models and output The wall hung gas condensing boiler R40 is available in 5 types within an output range from 61 until 132 kW Premix burner Stainless steel spiral heat exchanger double helix Speed controlled Whirlwind gas air mixing system LMS14 boiler management unit Application possibilities The gas condensing boiler R40 is applicable for all central heating systems built according to EN12828 In cascade applications max 8 boilers with LMS14 master slave cascade control the R40 can cover installations up to 1026 kW Preferred applications are central hea ting and sanitary hot water production in multi family buildings municipal and industrial buildings Value propositions e Unique high power wall hung boiler up to 142kW e Unequalled lifetime high efficiency gt 110 due to corrosion resistant stainless steel heat exchanger e Highest system flexibility easy planning and installation with Plug amp Play cascade accessories e Environmental friendly lowest emission values e Easy maintenance boiler design optimised for easy access on servicing Description The R40 is a fully modulating boiler The control unit of the boiler adapts the modulation ratio automa
20. a muya pastu 11 u uu 11 Requirements a 12 ak C 12 BE IE ie al umawa D Pa ee sassa ass Sans 12 DIMENSIONING single u 13 DIMeENSIGAING cascade y Shands a adobe un aa 14 suwa tiara AE A aie E ead 15 systems 15 riyaraulieTesislaneexuuuuuy um SD aie ade ee SQ HSE SG Las 16 AT HISdseiufelienl esaea uuu uns uum umasa banana 16 iimmmmmmcmmmm mmm m mm mmmmmmmmmmmmmmkmrmrmrmmrmrmrmrmmrmmmrmmmmmmmmmmmmmmmmmmmmH 16 Hydraulic CONNECTION into A 17 T m Sma m PTs ee 17 CAS CAG 18 Basic controls ANG A 19 Control by building system a 19 BONEr CMADIS SIGMA uz 19 Temperature Capacity setpoint 19 OK Alarm Output signal
21. ader The kit includes a low loss header wall mounting bracket and primary tubing incl connecting material The header integrates the following functionalities e Temperature balancing e De aeration e Dirt separation The low loss header can be used at dT 20K 15 or dT 10K Speed controlled pump R40 100 150 See below table for system selection Insulation for the low loss header is available as an option Dimension data can be found on page 25 Primary circuit 2 6 3 4 4 0 4 8 5 6 AX150 4 8 1 3 XCSOF 6 4 0 8 XCSOF 9 6 1 7 AX125 3 4 1 1 AX150 4 5 1 1 XCSOF 6 8 0 9 AX150 4 0 0 9 AX150 5 3 1 6 XCSOF 8 0 1 2 2 6 header type m3 h kPa header type m3 h kPa Secondary circuit AX150 5 6 1 7 XCSOF 7 5 1 1 XC50F 11 2 2 4 23 Accessories Plate heat exchanger The kit includes a plate heat exchanger wall mounting bracket and The plate heat exchanger is available See table for system selection is included in the delivery Dimensioning data can be found on page 26 Expansion vessel primary tubing incl connecting material for use at dT 20K dT 15K dT 10K Insulation for the plate heat exchanger Primary circuit 0 20 26 34 40 48 56 Secondary circuit 3 4 L 2 2 dT 20K header type CB52 40L CB52 40L CB52 40L CB52 50L m3 h 2 6 3 4 I kPa 5 1 8 5 5 8
22. and similar electrical appliances Particular requirements for gas oil and solid fuel burning appliances 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 Norms and regulations Maintenance Fuel Combustion air Water quality Maintenance Regular maintenance is necessary to secure a Safe and economical operation of the installation For the R40 one annual maintenance visit is recommended During this visit the proper functioning of the complete hea ting system should be checked as well Water quality The lifetime of the complete heating system is affected by the water quality Additional costs for water treatment of an installation are always lower than repairing costs for damage created by poor water quality 50 200 The gas condensing boiler R40 is applicable for natural gases G20 and G25 and for LPG G31 Factory settings are always done for G20 For other types of natural gas a correction can be made on the gas valve For LPG it s necessary to change the gas injector included in delivery before operating the boiler The R40 can work with gas pressures up to 50 mbar In case of a gas pressu re above
23. be hydraulically connected at the highest point of the installation 50 Installation examples B C E Boiler control via 0 10VDC cascade via plate heat exchanger B C E Boiler control via 0 10VDC cascade via plate heat exchanger 52 ES M 2 O El 3 a Master Gerdteadresse 6600 Segment Par 6601 Option Description e R40 with plate heat exchanger e Cascade control Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation Installation examples Extension 2 heating zones Extension 2 heating zones 52 M2 s gt Description e Weather compensated controller with wall hung box LOGON B e Extension of 2 heating zones Tips e The extension controller should always be used in combination
24. 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 accept 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 R40 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 100 C high limit temperature 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 installing combustion air and flue gas systems 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 R40 boiler is CE approved and applies to the following European standards 92 42 EEC Boiler efficiency directive 2009 142 EEC Gas appliance directive 2006 95 EEC Low voltage directive 2004 108 EEC EMC directive EN 483 Gas fired central heating boilers Type C boi
25. d controlled pump modulates the flow rate in the primary system in parallel with the burner load This ensures the lowest possible return temperature to the boiler for high efficiency usage Details of the available pump kits can be found in the chapter Accessories ay tu FA 51 0 17 Hydraulic connection Cascade Cascade The R40 is also available with Plug amp Play cascade solutions which are applicable for cascade installations up to 6 boilers in line and up to 8 boilers in back to back The cascade solutions are defined both with low loss header and plate heat exchanger Details of the cascade solutions can be found in the chapter Accessories Cascade 18 Controls Basic controls and connections Control by building management system Boiler enable signal Temperature or capacity setpoint Basic controls and connections The standard version of the R40 is equipped with a LMS14 boiler manage ment unit This controller controls both the burner safety operation and the temperature regulation of the boiler The 514 includes the following functions Control by building management system The R40 can be connected to a building management system This can be done by using one of the following connections e Electronic high limit thermostat e Electronic flue gas temperature limiter e Primary boiler pump control via
26. e found with the following calculation see table below for nominal data Qactual V APmeasured APnominal Qnominal Water flow data ee AT at nominal flow rate K Hydraulic resistance The hydraulic resistance depends on the flow rate through the boiler and the boiler type In the graph the resistance for a specific flow rate can be found The R40 is able to control a speed controlled pump via a 0 10VDC signal It makes the flow rate modulate in pa rallel with the burner load The mini mum flow rate to which the pump is allowed to modulate with the burner load is 30 of the nominal flow rate through the boiler The flow rate through the boiler can also be checked by calculation This can be done with a AT as well as a Ap measurement 16 Hydraulic connection Hydraulic connection into a system Single Hydraulic connection into a system The R40 must be connected in such a way that a minimum flow rate of 30 of the nominal flow rate can be ensured at all times independent from the flow rate in the secondary system The R40 can be used in single and cascade applications with low loss header or plate heat exchanger Single By using a low loss header or plate heat exchanger a minimum flow rate can be ensured at all times indepen dent from the flow rate in the secondary system The boiler pump is available as a standard 3 step or a speed controlled version The spee
27. e cascade control with optional BUS communication modules When additional control of secondary heating zones or cascade systems are required the R40 can be extended with different additional controls Explanation of these controls can be found in the next sections 19 Controls OK Alarm output signal Heating zone control Cascade control OK Alarm output signal terminals QX2 4 QX2 3 and QX2 4 230VAC or extension module AVS75 contact QX21 when combined with external gas valve and or room fan or gas leakage tester The boiler provides depending on its status and the setting of the relay factory setting alarm an OK or alarm signal at terminal 4 or 21 20 Heating zone control The R40 can be extended with an AVS75 controller for extended heating zone control The AVS75 enables weather compensated operation of one mixed heating zone For room temperature optimisation of each heating zone an additional room unit QAA75 can be connected via bus connection The values for the specific heating zone can then be displayed and changed on the room unit In case of heating systems with more than two heating zones an additonal kit with Logon G2Z2 controller in a wall hung box is available These kits can be used in a modular way up to a maximum of 8 heating zones See chapter Installation examples for more details regarding connections of pumps sensors etc Cascade control The R40 can be con
28. e switch The kit includes a minimum gas pressure switch connecting material and wiring The gas pressure switch needs to be connected inside the boiler 22 ISPESL gas valve Italy only The kit includes an ISPESL gas valve and connecting material The gas valve is approved according to the ISPESL requirements Wiring for room fan and or external gas valve The kit includes a wiring package for connecting a room fan and or external gas valve to the boiler The parameter settings of contact QX2 must be chan ged standard setting alarm signal When using this functionality in combi nation with an OK alarm signal an additional AGU2 550 clip in is necessary In this case the OK alarm signal must be connected to contact QX21 of the AGU2 550 module TAS gas valve Germany only The kit includes a TAS gas shut off valve Pump 3 step The kit includes a pump connecting material gaskets and electrical wiring See the graph for the residual pump head of the different boiler types next page Modulating pump The kit includes a modulating pump R40 65 85 PWM controlled R40 100 150 0 10V controlled connecting material gaskets and wiring See next page for the pump curves of the different boiler types Accessories Bae SESE ae Im ir IE ET 1200 1800 2400 3000 3600 4200 4800 5400 6000 l h 600 Speed controlled pump R40 65 85 NTT D PVT I a Low loss he
29. ed heating zones e Sanitary hot water Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 48 Installation examples 4 5 B C E 2 heating zones and sanitary hot water cascade via plate heat exchanger 4 5 B C E 2 heating zones and sanitary hot water cascade via plate heat exchanger gt 2 3izz 8 SE 2 Master Gerateadresse Par 6600 Ess Segment Par 6601 B8 T 23128 Description e 2 x R40 with plate heat exchanger e Cascade control weather compensation e 2 mixed heating zones e Sanitary hot water Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter e The primary circuit should be designed for AT 20K
30. es are available in 150mm and 200mm diameter both for line and back 2 back solutions See chapter Dimensioning cascade for more info on diameter selection and chimney dimensioning 0 250 kW 251 462 kW Please see the price list or online Primary circuit dT 20K m3 h 10 8 19 9 configurator for more info on these full Expansion vessel L a package solutions header type CB200 30M CB200 50M m3 h 10 8 19 9 kPa 9 0 12 6 header type CB200 30M CB200 50M Secondary circuit m3 h 14 3 26 5 kPa 20 0 21 3 header type CB200 30M CB200 64M m3 h 21 5 39 7 kPa 35 8 29 4 Accessories Besides the defined cascade packages the following components can be optionally added Gas filter Extension tube for gas filter Insulation kit collector Insulation kit low loss header ISPESL safety kit DN65 and DN100 Italy only 2nd ISPESL safety valve for systems gt 555kW Italy only e ISPESL gas valve Italy only e TAS gas valve Germany only e 150mm and 200mm flue material 29 Accessories Dimensions cascade DN65 line low loss header Standard R40 DN 65 Number of boilers 2 3 4 5 6 Total width L mm 1672 2322 2972 3622 4272 D 150mm B 400 450 H mm 553 646 738 831 924 D 200mm B 350 400 H mm 616 709 801 894 987 Ofc AD i II je m ISPESL Italy only R40 DN 65 Number of boilers 2 3 4 5 6 Total width L mm 2115 2765 3415 4065 4715 150mm
31. h 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 R40 according to the the VDI2035 The table on the left gives an indication of the relation between the water quality and the maximum water filling volume during the lifetime of the boiler Consult the original text of the VDI2035 for more detailed information Constant entry of oxygen in the instal lation should be avoided The system water pressure should be higher than the atmospheric pressure in all parts of the installation Underfloor heating components without oxygen diffusion barrier should never be used When they re used anyway a system separation e g with plate heat exchanger is compulsory Norms and regulations Noise protection Antifreeze Noise protection The gas condensing boiler R40 is equipped with a premix burner The noise level of this very quiet premix burner is extremely low in comparison to conventional gas burners Therefore no further measures have to be taken for noise protection in the boiler room Noise created by system components e g pumps should be taken care of with external measures in case of higher noise level requirements 50 40 30 20 Capacity reduction 10 15 20 25 30 35 40 45 50 55
32. ld be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 38 Installation examples 2 5 A C 1 heating zone and sanitary hot water low loss header 2 5 A C 1 heating zone and sanitary hot water low loss header il IRL gt FERREE ELELEE EEE ae Description e R40 with low loss header e Weather compensated control e 1 mixed heating zone e Sanitary hot water Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 39 Installation exa
33. lers of nominal heat input not exceeding 70 kW EN 15420 Gas fired central heating boilers Type C boilers of nominal heat input exceeding 0 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 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements EN 15502 1 Gas fired central heating boilers Part 1 General requirements and tests EN 55014 1 2000 Electromagnetic compatibility Requirements for household appliances electric tools and similar apparatus Part 1 Emission EN 55014 2 1997 Electromagnetic compatibility Requirements 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 subject to conditional connection EN 60335 1 2002 Household and similar electrical appliances Safety Part 1 General requirements EN 60335 2 102 2006 Household
34. ll be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation Installation examples 4 B C 2 heating zones plate heat exchanger 4 B C 2 heating zones plate heat exchanger i VV w V a x i pk Description e R40 with plate heat exchanger e Weather compensated control e 2 mixed heating zones Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 46 Fa 1
35. mples 4 5 A C 2 heating zones and sanitary hot water low loss header 4 5 A C 2 heating zones and sanitary hot water low loss header Description e R40 with low loss header e Weather compensated control e 2 mixed heating zones e Sanitary hot water Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 40 til j IRL La 2777727777 In Modul 2 Installation examples 4 5 A C E 2 heating zones and sanitary hot water cascade via low loss header 4 5 A C E 2 heating zones and sanitary hot water cascade via low loss header Master Gerateadresse Par 6600 1 Segment Par 6601 812 68 1 Ze t 77777727777777777777 i Option L EG LT
36. oned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 42 Installation examples A C E Boiler control via 0 10VDC cascade via low loss header A C E Boiler control via 0 10VDC cascade via low loss header Master Gerdteadresse Par 6600 Segment Par 6601 Description e 2 x R40 with low loss header e Cascade control Tips e Complete accessory kits with low loss header are available for AT 10 20K see chapter Accessories e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature in the header will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The header should be positioned close to the boiler to avoid a negative influence on the temperature control quality In case of a boiler room installed the roof the boiler may never be hydraulically connected at the highest point of the installation Option 43 Installation examples 1 B C 1 direct heating zone plate heat exchanger 1 B C 1 direct heating zone plate heat exchanger 52 MZ 3453 J QAATS HPF II Description e R40 with pla
37. r 0 10V pump control and or capacity feedback signal from the LMS14 to the building management system The output of the feedback signal is displayed in the graph below Extension module AGU2 550 The kit contains an AGU2 550 exten sion module incl communication cable to the LMS14 boiler management unit Maximum 3 AGU2 550 modules can be connected to one boiler module 1 and 2 for heating zone control module 3 for OK alarm signal when combined with external gas valve control Header hot water sensor QAZ36 Heating zone sensor QAD36 Outdoor sensor QAC34 The kit contains a header hot water The kit contains clamp sensor QAD36 The kit contains an outdoor sensor sensor QAZ36 with cable and a 1 2 with 4m cable QAC34 pocket 2 Accessories Controls Receiver wireless AVS71 The kit contains an AVS71 wireless receiver When connected to the boiler it can transmit data between wireless room units QAA78 and or wireless outdoor sensors QAC34 AVS13 Outdoor sensor wireless AVS13 The kit contains an outdoor sensor QAC34 and a wireless transmitter AVS13 The kit can be used in combination with a wireless receiver AVS71 to enable wireless communication between the outdoor sensor and the boiler Cascade kit MASTER The kit includes an OCI345 communication module and header sensor incl pocket Cascade kit SLAVE The kit includes an OCI345 Communication mod
38. ss header 37 4 A C 2 heating Zones low loss header 38 2 5 A C 1 heating zone and sanitary hot water low loss header 39 4 5 2 heating zones and sanitary hot water low loss header 40 4 5 A C E 2 heating zones and sanitary hot water cascade via low JOSS header RE a 41 A C Boiler control via 0 low loss header 42 A C E Boiler control 0 10VDC cascade via low loss 43 1 B C 1 direct heating zone plate heat exchanger 44 2 B C 1 mixed heating zone plate heat exchanger 45 4 B C 2 heating zones plate heat exchanger 46 2 5 B C 1 heating zone and sanitary hot water plate heat exchanger 47 4 5 B C 2 heating zones and sanitary hot water plate heat exchanger 48 4 5 B C E 2 heating zones and sanitary hot water cascade via plate heat exchanger a a 49 B C Boiler control via 0 10VDC plate heat exchanger 50 B C E Boiler control via 0 10VDC cascade via plate heat exchanger 51 Extension 2 heating
39. te heat exchanger e Weather compensated control e 1 direct heating zone Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger will be lower than the flow temperature of the boiler This should be taken in to consideration during the design stage e The plate heat exchanger should be positioned close to the boiler to avoid a negative influence on the temperature control quality e In case of a boiler room installed on the roof the boiler may never be hydraulically connected at the highest point of the installation 44 Installation examples 2 B C 1 mixed heating zone plate heat exchanger 2 B C 1 mixed heating zone plate heat exchanger 52 2 B4 ES _ Z 3 Ea Description e R40 with plate heat exchanger e Weather compensated control e 1 mixed heating zone Tips e Complete accessory kits with plate heat exchanger are available for AT 10 20K see chapter e The primary circuit should be designed for AT 20K this guarantees a high boiler efficiency e When the secondary circuit is designed for a AT smaller than 20K the flow temperature of the plate heat exchanger wi
40. tem components should be removable for maintenance purposes Horizontal flue gas ways must be mounted under an angle of 3 minimum A separate condensate drain for the chimney is not necessary as the condensate can enter the drain via the syphon connection of the boiler The R40 is certified for the flue gas systems B23 and B23P for France and C13 C33 C43 C53 C63 and C83 Flue gas data Boiler Nominal heat Nominal heat Flue gas Flue gas Flue gas Max permissible flue W ll el a a T1 12 Flue gas system Dimensioning single VERSION 1 Calculation base Total connection length in boiler room lt 1 5 m 2x 87 bend Maximum permissible height h of flue gas system m Boiler type 80 100 110 130 mm mm mm mm mm e fe VERSION 2 Calculation base Total connection length in boiler room lt 3 m 4x 87 bend 44 70 40 Maximum permissible height h of flue gas system m Boiler type 80 100 110 125 mm mm mm mm so ware _ 40 65 Concentric flue gas system Calculation base roof or wall terminal Maximum permissible length of flue gas system m Boiler type 4 bends 90 R40 65 R40 100 R40 120 Dimensioning When dimensioning a fl
41. tically 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 the best possible combustion figures and therewith the best efficiency The flue gases created by the combustion are transported downwards through the heat exchanger and leave the boiler at the top into the chimney connection The return water from the system enters the boiler in the lower section where is the lowest flue gas temperature in the boiler In this section condensation takes place The water is being transported upwards through the heat exchanger in order to leave the boiler at the flow connection The cross flow working principle water up flue gas down ensures the most efficient combustion results Technical description Technical data Efficiency at 80 60 C Efficiency at 40 30 C Annual efficiency NNG 75 60 C Annual efficiency NNG 40 30 C I 3 3 FE r 2 EE 3 4 8 Gas consumption G25 max min 8 34 kwh m 11 4 1 9 Gas consumption G31 max min 12 8 kWh kg 7 4 1 3 10 6 1 9 Gas pressure G20 2 20 2 25 5 50 30 50 30 50 30 50 Flue gas temperature at 80 60 max min Flue gas temperature at 40 30 C max min permissible fue resistance mamn Pa 1505 15005 15005 20015 2005 _ Watervoume 4 4 6 8 94 _ Max water temperature High limit thermostat
42. trolled in a cascade system of maximum 8 boilers This can be done by using the integrated Master Slave cascade functionality in combina tion with an optional BUS communicati on device OCI345 see chapter Accessories for more details The LMS14 includes an intelligent cascade control which allows free programming of boiler sequence after certain hours of operation See chapter Installation examples for more details regarding connections of pumps sensors etc Accessories Single For R40 single boiler installations a range of single accessories are defined The different accessory kits can be combined in order to build a primary system with low loss header or plate heat exchanger A description of the different accesso ries can be found on the following pages Safety valve The kit includes a TUV safety valve available in 3 4 5 or 6 bar drain valve and connection possibility to connect an expansion vessel Shut off valves The kit includes shut off valves for water 2x flow and return connection and gas 1x Gas filter The kit includes a gas filter and connecting material 21 Accessories ISPESL safety kit Italy only The kit includes a safety valve 4 5 bar drain valve connecting possibility for expansion vessel manometer thermometer maximum water pressure switch and thermostat All components are approved according to the ISPESL requirements Minimum gas pressur
43. ue gas system necessary to perform a calculation check of the flue gas system in order to verify if the choosen system is applicable The following table shows two examples of possible flue gas systems including the maximum possible height of the system These examples only give an indication of the possible heights but they cannot be used for Official flue gas layout calculation Each flue gas system must be calculated by an authorized company The maximum negative flue gas pressure which doesn t affect the burner modulation ratio is 30 Pa Higher negative pressure will lead to limitation of the burner modulation ratio The maximum horizontal flue gas way is 20 m With horizontal ways longer than 20 m a faultless burner start in cold condition can not be guaranteed Concentric flue gas system The R40 boiler models 65 85 100 and 120 can be connected to a concentric flue gas system Via a parallel to concentric adapter optional the boiler can be connected to e 100 150 concentric system from Muelink amp Grol e 110 150 concentric system from Skoberne See table for max permissible flue lengths 13 Flue gas system Dimensioning cascade Max boiler input kW by vertical chimney length and diameter collector chimney Chimney height Diameter 150 150mm _ s soo _ e _ 18 Calculation based
44. ule for the connection of slave boilers 28 LOGON B with wall hung box For control of additional 2 heating zones it s possible to connect a LOGON B controller with wall hung box The LOGON B enables the control of 2 heating zones and the control of a DHW recirculation pump The kit includes LOGON controller incl wall hung box and communication cable Room unit QAA75 The kit contains a QAA75 room unit which communicates with the boiler via BUS communication For each heating zone 75 can be connected Room unit QAA78 wireless The kit contains a QAA78 wireless room unit which communicates with the boiler via wireless BUS communica tion For each heating zone a QAA78 can be connected Accessories Cascade For the R40 a full range of cascade accessories are defined both for hydraulic and flue systems Hydraulic The hydraulic accessories are available for line solutions up to 6 boilers up to 793 kW with or without frame and back 2 back solutions up to 8 boilers up to 1058 kW The accessories are defined in two diameters depending on the required output DN65 up to 462 kW DN100 for higher outputs For DN65 a solution with plate heat exchanger also exists for different differential temperature In the table you ll find the secondary flow data for the different types of plate heat exchangers which are used Flue system For cascade flue systems a range of accessori

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