Doc1078 R40 int1.pub - Stokvis Industrial Boilers International Ltd
Contents
1. Check functionality of safety devices Gas tightness check Boiler shut down Commissioning protocol 5 cuo ui eoi tete edax s Q Du indt aoe Display Programming Overview of main functions Checklisbu uu 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 DIeSSUIOG sce caesa ot u enda Fu odes Gas tightness check Safety devices Maintenance protocol 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 R40 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 su2. 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 extensive 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 DON T use water e Check the water pressure of the system 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 top 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 Cle
3. Reset NS D T k B C D E F 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 for changing room comfort temperature e for changing settings when programming 18 OK 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 burner setpoint is 60 C indicated by spanner symbol On off switch A Position O Boiler and connected electrical components are no powered Frost protection is not secured Position The boiler and connected electrical components are powered
4. boiler operation An indication of the actual flow rate can be found with the following calculation see table below for nominal data Qactual AT nominal AT measured Qnominal m h 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 1 0 Apnom S AP lt 4 0 Apnom An indication of the actual flow rate can be found with the following calculation see table below for nominal data Qactual man ADnominal nominal m h Water flow data AT 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 temperature sensor water return temperature sensor flue gas temperature sensor 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 resu
5. off fi ud No B B B te Process running please wait ECO function active i 0C Burner operating only oil gas boiler I Error messages INFO nfo level activated PROG Programming activated Heating temporarily switched off ECO function active 070 Holiday function active 12 Reference to heating circuit z a Maintenance special operation No Parameter number Programming Default mode Press OK 1x RENE Press INFO e Sec buttons Commissioning 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 Press OK 1x 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 19 GB Operating instructions Overview of main functions Zone 1 and zone 2 Actuate wheel left right Set room temperature Turn wheel Confirm with OK button or wait 5 sec or press CJESC Actuate wheel left right Set room temperature for Confirm with OK button zone 1 or zone 2 Actuate wheel left right Confirm with OK button or wait 5 sec or press CJESC Press button X3 Switch on off DHW ope ration Factory setting Press button 1x Change heating operation mode Press button 1x again Press button 1x again Controller mode as
6. 46 onfiguration error collective message 7A U U rr Umi 0 00 E E 28 30 32 38 40 46 OAT 8078 a ma 597 60 65 BEO MT ME CE IE RE 83 84 85 EUN 98 99 400 102 103 100 109 MEINE MEUM 122 EZA E 130 EE 132 146 Lockouts 26 a o Oo 5 o Error ipti code 151 nternal error 152 arameterization error 153 nit manually locked 160 an error 162 P error does not close 164 O gt gt TITI UGC A mis 3 NN 152 EES 160 162 164 rs l 172 Les 174 Laeire EE 216 Lo 241 F 333 336 33 O OO 4 AJO 339 ER O O gt G N 0 34 rror heating circuit flow switch 173 ic Wem i umm 241 low sensor solar sensor error 32 X extension module same sensors xtension module mixing group same function ensor BX4 no function ensor BX1 no function olar Collector sensor B6 not available 34 olar controlling element swimming pool K18 not available 171 172 174 178 imit thermostat heating circuit 1 179 imit thermostat heating circuit 2 nit in parameterization mode 193 ump supervision error after flame on 216 ault boiler 217 24 27 31 Mains frequency outside p
7. 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 R40 is a fully modulating boiler The control unit of the boiler adapts the modulation ratio automatically to the heat demand requested by the system This is done by controlling the speed of the fan As a result the Whirlwind mixing system will adapt the gas ratio to the chosen fan speed in order to maintain the best possible combustion figures and therewith the best efficiency The flue gases created by the combustion are transported downwards through the heat exchanger 4 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 Layout of boiler The R40 boiler consists of the following main components Casing Control panel Flue gas connection test point Air intake connection test point Flow water connection
8. Return water connection Gas connection Syphon Input for wiring 10 Connection for safety valve 11 Connection for fill drain valve 12 Manometer 13 Fan 14 Gas valve 15 Ignition and ionisation electrodes 16 Heat exchanger 17 Inspection window 18 Ignition transformer 19 Electrical input connections 20 Controller 21 Condensate receptacle 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 65 85 100 120 150 Gas consumption G20 max min 10 9 kWh m Gas consumption G25 max min 8 34 kWh m MEN INNER REEF HR gs THERME Gas pressure G20 H Gas Gas pressure G25 L Gas Maximum gas pressure Flue gas temperature at 80 60 C max min 76 63 Flue gas temperature at 40 30 C max min Flue gas quantity max min Ea Lia e Ss ee ee Max permissible ue resistance Pa 18618 15045 105 2005 20045 Watervoume rr 49 4 8 8 94 Max water temperature High limit thermostat Maximum temperature setpoint 90 9 9 9 9 _ Pos ID Po ID IPXD Weigntempy 6 6 9 9 9 Noise level at 1 meter distance CE 0063CM3576 Air intake connection for room sealed use 100 non room sealed room sealed lon
9. SIOKVIS ENERGY SYSTEMS ECONOFLAME R40 GAS FIRED WALL MOUNTED CONDENSING BOILERS INSTALLATION OPERATION amp MAINTENANCE DOCUMENTATION STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E MAIL info stokvisboilers com WEBSITE www stokvisboilers com 02 2011 2012 09 01 AC DOC1078 XXXXXXXX Contents Contents Safety Construction Technical data Extent of delivery Installation Commissioning Operating instructions Maintenance Lockouts Sensor values Declaration of Conformity General regulations ADDICION NE OR EN Norms and regulations Layout of Operating principle Standard boiler unu teca BOCOSSOLBS Sam Boiler transport Removing the Boiler installation Connecting the boiler Water and hydraulic system Gas SUPPI eT Condensate connection Flue and air intake connections Prepare boiler for first startup Combustion analysis Check water flow
10. 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 lt gt Deaeration mode 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 1 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 pressing the button once again or automatically after 15 minutes the chimney sweeper mode will be deactiva ted indicated by spanner symbol Reset button H By shortly pressing the reset button a burner lockout can be cancelled Operating instructions Display Programming QA DHW mode selection Heating operation mode selection Controller Stopp mode when pressing gt 3 sec Display Info button Quit menu 7 N 5 Confirm a Manual mode Reset Deaeration mode when pressing gt sec Chimney sweeper mode Select turn left right Heating to comfort setpoint Info level activated a Heating to reduced setpoint Programming m HE A GH activated INFO PROG ECO Heating for frost protection setpoint Heating 0 0 JP temporarily switched
11. aning the condensate receptacle e Disconnect the plug of the flue gas temperature sensor 1 e Remove the condensate receptacle 2 e Clean the receptacle e Mount the condensate receptacle e Connect the plug of the flue gas temperature sensor Cleaning and refilling the syphon e Remove the syphon 3 from the condensate connection e Clean and fill it with fresh water e Mount the syphon back in the original position Inspection of combustion chamber For inspection of the combustion chamber the mixing system and burner must be disassembled e Switch off the boiler and close the gas supply e Remove the electrical connection from the fan and gas valve 4 e Remove the electrical connection from the electrodes 5 e Undo the gas connection at the inlet of the gas valve 6 e Disassemble the top plate incl mixing system 7 e Remove the burner from the combustion chamber 8 e Inspect the combustion chamber and clean it with a vacuum cleaner if necessary e Assemble all components in opposite order e Open the gas supply and check all connections for gas leakage e Switch on the boiler 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 commis
12. boiler contains a connection possibility for an optional kit with safety valve fill drain valve and an expansion tank connection The safety valve must be connected to the flow connection 3 of the boiler the fill drain valve and expansion tank connection must be connected to the return connection 4 The optional pump kit should be mounted directly to the return connection 2 of the boiler before connecting to the system Condensate connection 5 After filling with water the syphon included in delivery should be installed to the connection 5 at the bottom of the boiler Connect the hose to the draining system in the boiler room The connection to the draining system should always be done with an open connection in order to avoid a flooding of the boiler in case of a blocked drain Gas connection 6 The gas connection must be made by an authorized 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 6 of the boiler A gas cock should be mounted directly behind the boiler A gas filter can be mounted directly on the gas connection of the boiler GB Installation Connecting 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 re
13. ch 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 boilers of nominal heat input not exceeding 70 kW EN 15420 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 requiremen
14. ch on the boiler with the on off switch A 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 9o appears in the display e Choose set up confirm with OK button now the boiler load can be changed by rotating the wheel C and confirming the 50 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 l gt 3 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 5096 load Allow the boiler to stabilise the combustion for 3 minutes Then increase the boiler load step by step up to 10096 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 When an optional minimum gas pressure switch is connected this must be set to 75 of the required gas pressure Check the combu
15. details e Extension module AGU2 551 for 0 10V control of a modulating pump and or boiler capacity feedback to a building management system e Electrical connection for external gas valve and or room fan e Extension module AGU2 550 for heating zone control or external gas valve and or room fan control in combination with an alarm signal For each boiler a maximum of 3 AGU2 550 modules 2x heating zone 1x ext gas valve room fan in combination with alarm can be integrated in the boiler e Additional RVS63 heating zone controller when controlling more than 2 zones incl wall hung box all necessary sensors and sockets and connection material for bus communication The above accessories are specially designed for the R40 boiler and therewith easy to install plug and play By choosing a combination of the kits mentioned above you can create your own complete system solution Ask your supplier for more detailed information Installation Boiler transport Removing the casing Boiler transport The R40 boiler will be supplied as a complete unit being fully assembled and pre tested The packaging dimension 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 strap
16. ead through the cable glands 9 at the bottom of the boiler into the electro panel 10 Connect all wires to the terminals according to the wiring diagram of the boiler enclosed in map in boiler packaging Outside sensor mounting If an outside sensor accessory is connected to the boiler the sensor should be positioned as shown on the drawing Commissioning Water and hydraulic system Commissioning of the boiler should be This chapter explains the carried out by authorized personnel commissioning of the boiler with the only Failure to respect this condition standard boiler controller When an makes the guarantee void A protocol additional system controller is installed of the commissioning should be filled please refer to its manual for out see end of this chapter for example commissioning the controller of commissioning protocol Boiler output Max sum of alkaline earths Max total hardness Water quality KW The system should be filled with water with a pH value between 8 0 and 9 5 Beers He The chloride value of the water should 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 volumes it s necessary to respect the maximum filling and additional volumes with corresponding hardness values as stated in the german VDI2035 standard In the table you can find the nom
17. ermissible range 32 DHW charging temperature sensor error 32 BX same sensors B 32 BX mixing group same sensors 32 Extension module same function ixing group same finction ensor BX1 no function ensor BX2 no function ensor BX3 no function ensor BX5 no function ensor BX21 no function EM1 EM2 or EM3 ensor BX22 no function EM1 EM2 or EM3 ensor BX12 no function ollector pump Q5 not available ollector pump Q16 not available HW sensor B31 not available olar integration not available olar controlling element buffer K8 not available olid fuel boiler pump Q10 not available olid fuel boiler comparison sensor not available olid fuel boiler address error 34 34 348 O gt 09 Lockouts Error Description of error code 351 Primary controller system pump address error 3 4 2 Limit thermostat heating circuit 373 Extension module 3 error collective error 351 Primary controller system pump address error 2 Limit thermostat heating circuit 373 Extension module 3 error collective error 3 433 Temperature primary heat exchanger to high 5 5 5 7 T T 5 5 5 T 8 8 2 2 3 3 27 GB Sensor values The diagrams show the sensor values NTC 10kO temperature sensor for all boiler sensors and optional flow return flue gas DHW and header sensor sensors available in accessory kits The diagrams contain average values as all sensors are liable to tolerance
18. gard to flue gas systems are respected Connect the flue gas system to the flue gas connection 7 of the boiler use flue gas systems with seamless connec tions only It s not necessary to make a 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 e ts recommended to use stainless steel or PPS flue gas systems e The diameter of the flue gas system must be chosen by calculation according to the national regulations e Construct the flue gas system as short as possible for maximum length see Options manual e Construct horizonal ways with a minimum angle of 3 Air intake connection 8 The air intake can be connected in case of room sealed installation The to the national regulations together with the flue gas system The total overcome the maximum permissible resistance of the fan inside the boiler see also chapter Technical data 10 diameter should be calculated according resistance of both systems should never Electrical connection The electrical connection must be made 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 contact opening of at least 3 mm within the boiler room This switch can be used to switch off the power supply for maintenance purposes All cables should be l
19. inal values for filling and additional water for the R40 according to the the VDI2035 o Capacity of installation Q KW The table at the left gives an indication a 3 2 f the relation between the water 200 300 o LTD ser ond ee ee eee el mol m Maximum water re fill volume Vmax m volume during the lifetime of the boiler Consult the original text of the VDI2035 for more detailed information 1 5 8 4 2 e s mie 2 5 14 0 1 9 2 9 3 1 3 8 5 0 6 3 7 5 Water pressure Filling can eventually be done via the Open the valves to the system Check optional fill and drain valve 2 on the the water pressure in the system If the return connection 1 of the boiler water pressure is too low see table below increase the pressure up to at Hydraulic system least the minimum required water Check if the boiler is hydraulically pressure in the table connected to the system in such way that water flow can be secured at all times during burner operation The water E flow is supervised by AT protection in the Minimum operating Flow tempe boiler and a lack of flow will lead to a P GSS IS rature direct burner stop and lockout of the bar PC boiler gt 1 5 L 906 7 165 80 J 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 star
20. isation current minimum PH value condensate ES a CE certification code Gas connection fo e D m Q O 5 5 D ct 5 o Flue gas connection GB Technical data FRONT VIEW SIDE VIEW BACK VIEW B om oto e s wo pere nine mu sum au me Rte Extent of delivery Standard boiler Accessories 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 1 Cardboard box in boiler packaging Operation and Installation manual 1 Map packed in cardboard box in boiler packaging Spare parts list 1 Map packed in cardboard box in boiler packaging Wiring diagram Map packed in cardboard box in boiler packaging Accessories Additional to the boiler the following accessories can be ordered e Standard 3 step pump incl connection kit e Speed controlled pump incl connection kit e Safety valve fill drain valve and connection for expansion tank e Set with water 2x and gas 1x cocks e Gas filter incl connection kit e Min gas pressure switch e Plate heat exchanger dT 10K 15K or 20 incl connection kit e Low velocity header suitable for dT 10K 15K and dT 20K incl connection kit e Plug amp play cascade kit see Modupak cascade manual for more
21. lt 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 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 lonisation electrode 4 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 uA in between the ionisation electrode and its electrical connection The ionisation current should always be above 1 2 uA in normal conditions it will be 6 UA 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 following procedure e Switch the boiler in standby operation e Switch off the boiler with the on off switch 5 e Disable power supply to the boiler by deactivating the mai
22. m 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 programmby reduced setpoint Safety functions activated summer Winter automatic switching activated ECO functions activated Safety mode on with Heating off Temperature by frost protection Safety functions activated 304 Controller Stop mode insert setpoint after 3 sec Main menu appears INFO Segment displayed Status Boiler room temperature room temperature minimum Status DHW room temperature maximum Status zone 1 outside temperature Status zone 2 outside temperature minimum outside temperature maximum Time Date DHW temperature 1 Error indication Boiler temperature Maintenance indication Flow temperature Info display depends on configuration Back to main menu INFO Segment disappears Manual mode on spanner symbol appears Haeting by fixed setpoint factory setting 60 C 301 Manual mode insert setpoint blinking temperature set value Status boiler Manual mode off Spanner symbol disappears Heating by reduced setpoint Heating by comfort setpoint Boiler manually blocked no release Boiler released Alarm symbol disappears
23. ns isolator switch in the boiler room e Close the gas supply to the boiler Commissioning Commissioning protocol Commissioning Protocol R40 Project Address ity Boiler type Serial number Year Nominal load Hi W J O Nominal output Hi Engineer System Water pressure bar Installation Water pH Ground floor Water hardness Basement Water chloride mg l mias Water flow m h Pump setting Bypass boiler L Water AT full load C Hydraulics Low velocity header Water kPa Plated heat exchanger Safety devices High limit setting C Water flow sensor checked Temp limiter setting C Fluegas sensor checked L Min gas pressure switch setting mbar Water flow switch checked L nion time burner Combustion analysis CO ppm NOx pp pp ppm atmospheric C C C C HA mbar 3 3 m m m 5 a a o m o o ma ma d water flow Thatar return lonisation current T mbar i i m bar Lu mba mba mbar Ptop panel mbar Pcombustion chamber mbar mbar Operating instructions Controls 0 4 6 12 16 20 24 ESC CLOS PUE BE E ma 2 lt m
24. ol A 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 0 Oo 5 h D o code oiler temperature 1 sensor error 30 low temperature 1 sensor error 32 38 low temperature primary controller sensor error 0 eturn temperature 1 sensor error 6 eturn temperature cascade sensor error T ommon 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 Room temperature 1 sensor error Room temperature 2 sensor error uffer storage tank temperature 1 sensor error uffer storage tank temperature 2 sensor error uffer storage tank temperature 3 sensor error 83 84 85 91 100 102 Clocktime master without reserve LPB 103 ommunication error 105 109 oiler temperature supervision 110 TB lockout IO 2 10 20 26 28 65 70 1 N UJ 72 73 74 82 o DD lt O 111 121 m3 low temperature 1 HC1 supervision low temperature 2 HC2 supervision 12 HW charging supervision 127 egionella temperature not reached 128 oss of flame during operation 9 130 lue gas temperature limit exceeded 131 urner fault 132 GP or LP error 133 o flame during safety time 1
25. po button gt 3 sec o 55 button gt 3 sec again Press button 1x Press button 1x again Press button 1x again Info display Press button 1x Operation by manual Press button 1x setpoint Change factory setting boiler temperature Press button Press button Turn wheel Press button Press button Press button Press button gt 3 sec 312 Deaeration on e button gt 3 sec again Deaeration off Activate chimney sweeper Press button lt 3 sec Chimney sweeper mode on mode Press button us lt 3 sec Chimney sweeper mode off Temporary reduction of Press button a T reduced temperature on Press button again QAA75 RESET Reset button Press button 3 sec Press button n gt 3 sec Zone 2 independent from zone 1 Choose heating zone WOK confirmation C JESC cancel return to main menu Comfort setpoint with blinking temperature Blinking temperature in 0 5 C steps from 10 to 30 C Comfort setpoint saved Comfort setpoint cancelled after 3 sec Main menu appears 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 on off see indication below DHW symbol On DHW mode by time program Off no DHW operation Safety functions activated Automatic mode on with Heating by time program Temperature setpoint by heating progra
26. s 60000 When measuring the resistance values the boiler should always be switched off Measure close to the sensor in order to avoid value deviations 55000 50000 45000 40000 35000 30000 25000 Resistance Ohm 20000 15000 10000 5000 0 10 0 10 20 30 40 50 60 70 380 90 100 110 Temperature C NTC 1kQ temperature sensor outdoor sensor 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 20 10 0 10 20 30 40 Resistance Ohm Temperature C 28 Declaration of Conformity Declaration of Conformity Rendamax BV Hamstraat 76 6465 AG Kerkrade NL Declares that the product R40 Is 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 number CE 0063CM3576 Kerkrade 16 11 2010 ing G A Managing Director 20 GB
27. s must be connected to the pallet Removing the casing Remove the casing before installing the boiler in order to avoid damage to the casing parts Removing the casing is done as shown on the pictures Installation Boiler installation Connecting the boiler 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 installation 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 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 e Electrical connection The boiler should always be connected in such a way that the system applies to all relevant standards and regulati ons European national and local It s the responsibility of the installer to ensure that all standards and regulations are respected Hydraulic connections 1 2 3 4 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 1 and return 2 connection of the system tension free to the boiler connections The
28. sioning 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 connections with an approved soap or electronic analyzer for example e Test points e Bolt connections 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 Protocol Maintenance Protocol R40 Nominal load Hj Um Water pH Water hardness Water chloride mg l Water AT full load C Water kPa Water flow m h Pump setting Safety devices I ih missing Temp Trier seira Min gas pressure switch setting mbar ie Combustion analysis T mba Sie mbar mbar I NOx mbar mbar mbar NO Lockouts In case of a lockout a warning symb
29. stion settings via the test point in the chimney connection 1 If necessary correct the settings with the small adjustment screw at the top 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 large adjustment screw at the top of the gas valve 3 Combustion check at 5096 load An additional reference check of combustion values at 50 load is recommended in order to check if the gas valve is set in such way that the modulating behaviour is normal The CO value should be in between the settings of full load 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 max load for natural gas G20 G25 R40 65 85 8 5 0 2 ms Hn E Rono 8 7 0 2 Combustion settings min load for natural gas G20 G25 E um R40 65 150 8 5 0 2 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 10K and 20K for secure
30. ting 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 Condensate connection Remove the syphon 2 from the condensate connection Fill it with water and place it back in the original position Make sure the syphon is filled before starting the boiler in order to prevent flue gases discharging 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 Installations which don t comply with the regulations are not allowed to be commissioned Make sure that all connections are free The size of flue gas and air intake connections may not be reduced 12 Commissioning Prepare boiler for first startup 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 lt o 4 6 12 16 20 H Br ESC OH qu E E x d Reset b 7 T k C D B E F Preparation for first startup e Open the gas supply e Enable the power supply to the boiler e Swit
31. ts 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 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
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