STOKVIS ENERGY SYSTEMS ECONOFLAME R2200 Owner's manual

ECONOFLAME R2200
GAS FIRED BOILERS
INSTALLATION, OPERATION & MAINTENANCE
DOCUMENTATION
STOKVIS ENERGY SYSTEMS
96R WALTON ROAD
EAST MOLESEY
SURREY
KT8 0DL
TEL: [phone]
FAX: [phone]
E-MAIL: [email protected]
WEBSITE: www.stokvisboilers.com
22CV22D - 160703

22CV22D
II
Edition D, 12-12-2000
© 2000 STOKVIS
All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior permission in writing of STOKVIS.
We aim to achieve continuous improvement in our products. Therefore, specifications are
subject to change without prior notice.
Due to changes the product can deviate from the information specified in this document.
Therefore STOKVIS rejectsany responsibilityfor the differences between the
product delivered and the information mentioned in this document.

22CV22D III
R2200 TECHNICAL DATA
Type 2207 2210 2213 2216 2220 2224 2228
Heat output kW 81,3 116,4 151,5 186,7 233,9 280,9 328,5
Heat input kW 88,2 126,0 163,8 201,6 252,0 302,4 352,8
Maximum gas rate m /h 9,3 13,3 17,3 21,3 26,7 32,0 37,3
3
Gas pressure (inlet)
natural gas minimum mbar 20 20 20 20 20 20 20
natural gas maximum mbar 120 120 120 120 120 120 120
Water capacity dm 6,2 6,9 7.7 8,5 9,6 10,5 11,4
Maximumworkingpressure bar6666666
3
Gas connection (G) 1" 1¼” 1¼” 1¼” 1¼” 1½” 1½”
Water connection (W) DN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN65 PN6 DN65 PN6
Chimney diameter (D) mm 150 180 200 200 250 250 300
Safety valve connection ½” ½” ¾” ¾” 1" 1" 1"
blow-off ½” ½” ¾” ¾” 1¼” 1¼” 1¼”
standard setting bar 3333333
Electrical supply V 230 230 230 230 230 230 230
Frequency Hz 50 50 50 50 50 50 50
Fuse A 6666666
Max. electrical consumption boiler kW 0,10 0,10 0,12 0,12 0,15 0,15 0,15
pump maximumkW0,07 0,14 0,20 0,24 0,30 0,35 0,44
total kW 0,17 0,24 0,32 0,36 0,45 0,50 0,59
Boiler weight empty kg 165 200 245 285 340 375 440
Sizes height (H) mm 1440 1440 1440 1440 1440 1440 1440
width (B) mm 786 786 786 786 786 786 786
length (L) mm 1016 1226 1436 1646 1926 2206 2486
Table 1 Technical Data
22IP22/T0001EE
-Heat output measured at :60 - 80 C.
-Gas consumption at :1013 mbar, 15 C, dry.
- Gas specification:I.
2H
- Appliance category : B14
- Protection degree : IP20
22IP22/000103DE
Pump and by pass = option

22CV22D
IV
Fig. 1 Dimensions

22CV22D V
Dimensions
Type 2207 2210 2213 2216 2220 2224 2228
B mm 786 786 786 786 786 786 786
B1 mm 318 318 298 298 292 292 292
B2 mm 420 420 420 420 420 420 420
D mm 150 180 200 200 250 250 300
G 1" 1¼” 1¼” 1¼” 1¼” 1½” 1½”
H mm 1440 1440 1440 1440 1440 1440 1440
L mm 1016 1226 1436 1646 1926 2206 2486
L1 mm 153 153 163 163 174 174 174
WDN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN50 PN6 DN65 PN6 DN65 PN6
Table 2 Dimensions in mm
22CV22/T0002BE
Changes in specifications and dimensions
The manufacturer reserves the right to change the above mentioned dimensions without prior
notice. Because of manufacturing tolerances, the above mentioned dimensions can vary
slightly.
000003BE
The R2200 unit is also available as a left-handed model.
This means that the burner assembly can be removed from the left-hand side of the unit.
000004AN

22CV22D
VI
INDEX
1 INTRODUCTION ............................ 1
1.1 General ................................... 1
1.2 Supplier ................................... 1
1.3 This manual ................................ 1
1.4 Service.................................... 2
1.5 Reservation ................................ 2
2 DESCRIPTION ............................. 3
2.1 General information .......................... 3
2.2 Main components ............................ 4
2.3 Principleofregulation ........................ 7
2.4 Boilerprotection............................. 8
3 SAFETY................................... 9
4 DELIVERY AND TRANSPORT ................ 12
4.1 Delivery .................................. 12
4.2 Unitprotectivepackaging..................... 12
4.3 Transport ................................. 12
5 INSTALLATION............................ 14
5.1 Boilerroom................................ 14
5.1.1 Siting .................................... 14
5.1.2 Boilerroomventilation ...................... 14
5.2 Unit connections ........................... 15
5.2.1 Gas supply ................................ 15
5.2.2 Electrical supply ............................ 15
5.2.3 Hydraulic connections ....................... 16
5.2.4 Flues .................................... 17
5.3 Waterquality .............................. 18
5.4 Hydraulicsystem ........................... 19
5.4.1 Flow and resistance ......................... 19
5.4.2 Exampleshydraulicsystem ................... 23
6 COMMISSIONING.......................... 24
7 OPERATION AND FAULT INDICATION ........ 26
7.1 Control panel .............................. 26
7.2 Operation................................. 28
7.3 Boilerfailure............................... 29
8 MAINTENANCE ........................... 35
8.1 Safety.................................... 35
8.2 General information ......................... 35
8.3 Inspection ................................ 35
8.4 Cleaning .................................. 36
8.5 Replacing................................. 37
8.6 Service................................... 38
SUPPLEMENT ............................ 39

22CV22D 1
1 INTRODUCTION
1.1 General Through their unique construction, these central heating units
1.2 Supplier StokvisEconoflame boilersare sold throughout the United
1.3 This manual This documentation has been to aid the following target
renowned for their:
- high thermal efficiency
- environmental friendliness
- light weight and small dimensions
- durability
- low noise production
- large regulating range
- available with many different options.
Continual research and development means that Stokvis
remains at the forefront of boiler and water heater technology.
101001AE
Kingdom by:
Stokvis Energy Systems
96R Walton Road
East Molesey
Surrey KT8 0DL
Telephone: [phone]
Facsimile: 08707707767
For advice or more information with regard to our products
contact Stokvis.
22IP22/102001BE
groups:
- the consulting engineer
- the heating installer
- the service engineer
- the user.
Because these target groups require mostly similar information
and also specific information, our technical documentation has
been integrated to provide these target groups with the neces-
sary general and specific information to install, service and
operate this product.
The supplier (see 1.2) will be able to provide any further or
supplemental information.

22CV22D
2
1.4 Service For commissioning and assistance in maintenance matters,
1.5 Reservation It is the law that the installation be carried out by a competent
The following aspects will be explained:
- general description
- technical specifications
- necessary services for system design and unit installation
- example systems
- maintenance instructions.
Operating instructions for the user can be found on the unit.
See also chapter 7.
please contact your supplier’s service department. For more
details see section 1.2.
person. The boiler should be installed in accordance with the
British Standards and Codes of Practice referred to in this
manual, the Gas Safety (installation & use) Regulations 1994,
Building Regulations, Model Water Bye-laws and any Require-
ments of the Local Gas Supplier, Local Authority, Water and
Fire Authorities and I.E.E. Regulations.
Health & Safety at Work Act, 1974
Under Section 6 of the above Act, it is the duty of manufactur-
ers and suppliers of products for use at work to ensure, so far
as it is reasonable practicable, that such products are safe and
without risk to health when properly used and to make available
to users of such products adequate information about their safe
and proper operation.
Stokvis boilersshould onlybe used in the manner and pur-
pose for wich they were intended, and in accordance with the
recommendations detailed in this manual. Our heaters have
been designed, produced and inspected with safety in mind,
but there are certain basic precautions, wich should be taken by
the user and, in particular attention is drawn to the safety pre-
cautions in this manual and to the operating instructions on the
boiler.
It is imperative, therefore, that all persons who make use of our
heaters have all the information and instructions they require to
ensure that they are fully aware of any hazard, and that they
know both the purpose and correct manner of use of our heat-
ers.
The manufacturer can alter its products without any pre-
ceding notification and is therefore not obliged to adapt
earlier delivered products.
22CV22/150001BE

22CV22D 3
2 DESCRIPTION
2.1 General information The R2200 is a gas-fired boiler with an atmospheric burner with
The R2200 series is CE approved for the following countries:
HIGH/LOW/OFF regulation.
The R2200 is fitted with a 2-stage thermostat control working at
100% or approx. 50% boiler capacity.
The R2200 series of boilers are available in 8 types:
R2207, R2210, R2213, R2216, R2220, R2224 and R2228.
The last two digits of the type number indicate the number of
burner bars present in the burner assembly. The load at nett
calorific value is approx. 13 kW per burner.
All boiler types are fitted with a 9-pipe heat exchanger of the 2
pass type.
The use of extruded copper fin pipes in the heat exchanger
leads to higher efficiency.
Thermal radiation losses are minimized by the optimal con-
struction of the combustion chamber in which high-grade insu-
lation is integrated.
The advanced construction of the R2200 enables swift assem-
bly and disassembly, which simplifies maintenance and inspec-
tion.
The boiler conforms to the strongest European environ-
mental regulations.
The R2200 is fitted with a draught diverter and a flue gas ex-
tractor fan which results in a small chimney diameter.
The draught diverter is fitted with a pressure difference switch
for the monitoring of flue gas flow.
The R2200 has an electronic protection and ignition sys-
tem, indicated by E.
The thermostatic control version, using a 2-stage thermostat
to maintain constant flow temperature is indicated by a T.
The weather compensation version controlled by a simple to
operate digital regulator is indicated in the W version.
22CV22/210001BE
Appliance category B14.
Great Britain, the Netherlands, Belgium, France, Ireland and
Italy under Product Identification Number 0063AR3702.
22CV22/210003DE

22CV22D
4
Fig. 2 R2200
Fig. 3 Draught diverter
2.2 Main components
Draught diverter
The R2200 is fitted with a draught diverter with a flue gas
extractor fan. It is possible to connect the flue outlet connection
on the top cover with a standard flue pipe.
The inside of the draught diverter is made of aluminium.
The galvanized panel work is easily removed without the use of
any special tools by means of a click system.

22CV22D 5
Fig. 4 Combustion chamber
Fig. 5 Heat exchanger
Combustion chamber
The chassis consists of two side frames with steel supports.
Dura blanket type thermal insulation is sandwiched between the
vermiculite refractory blocks and front, rear and side panels of
the combustion chamber housing. These vermiculite refractory
blocks are mounted so as to allow freedom of expansion. The
refractory blocks backed with Dura blanket insulation form the
combustion chamber.
Heat exchanger
The heat exchanger (2-pass type) is mounted on the chassis.
To ensure proper heat transfer of the combustion gases, the fin
pipes are arranged side by side and expanded laterally into a
mounting plate. The baffles on the fin pipes optimize the effi-
ciency of the heat exchanger. The supply and return pipes
together with the steel water manifolds form the heat exchanger
and is pressure tested at 16 bar.

22CV22D
6
Fig. 6 Burner
Fig. 7 Gas train
Burner
The burner is mounted under the combustion chamber in the
chassis. The burner bars, mounted in the burner tray are manu-
factured from stainless steel. Each burner bar is supplied by its
own injector nozzle mounted on the gas manifold. A bottom
plate is mounted under the burner bars. This pre-mix burner
has a very low NO emission.
x
Gas train
The gas train consists of a two-stage gas valve, which is mount
ed on the gas distribution manifold.
22CV22/220001HE

22CV22D 7
2.3 Principle of regulation The flow temperature can be constant or influenced by weather
compensation. Several boilers can be connected by using
cascade switching. In order to reduce electricity consumption
both boiler and boiler pump can be switched off by the cascade
switch box.
22CV22/240001AE
Thermostatic control version (T)
The R2200 has a thermostatic temperature control, providing
constant flow temperature by using a 3-step thermostat.
Only two steps are used:
Ilow
III high
By omitting the second step, a specific switching differential is
created. The following options are therefore available:
A) + 3°C/ - 3°C step I-II
B) + 3°C/ - 6°C step I-III
22IP22/230002AE
Weather-compensated version (W)
The W option is a two stage fired boiler controller, for direct
weather compensated regulation. The flow temperature is
compared to the programmed heating curve. The regulator is
fully digital. All functions are easily read by using standard
symbols.
The regulator includes a clock with:
- 99 days holiday mode
- automatic summer/winter switching
- programmed for 8 years.
Standard functions
- boiler regulation
- heating circuit with sliding temperature control
- extra heating circuit regulation (via servo-valve)
- tap water priority switching
- protection against legionnaires disease
- pump kick
- pump switching
- protection against freezing
- unit return temperature protection
- unit emission control possibilities
- remote control.
As standard, the unit is supplied with a flow temperature sensor
and outside temperature sensor.
22CV22/230003GE

22CV22D
8
2.4 Boiler protection The R2200 is protected by the following systems:
minimum water flow switch
The water flow switch is installed in the flow and monitors
continuously the minimum water flow. If the flow falls below a
preset level, the burner is shut down. The water flow switch is
factory set and should not be adjusted.
high limit thermostat (E.C.O.)
In the event of failure of the control thermostat, a preset high
limit thermostat will shut down the burner.
pressure relief valve
The maximum operating pressure of the R2200 boiler is6bar.
The standard safety valve supplied is set to 3 bar. If a different
pressure setting is required this should be specified and will be
set at the factory.
flame failure control
Flame safeguard relay with alpha numeric read out flame
ionisation control. Internal memory for the purpose of:
- operating hours (high and low)
- cycling time
- historical lock outs.
flue gas flow control
In the event that the flue gas extractor fan fails or the flue gas
flow is lower than the preset level the pressure difference
switch will shut down the burner.
22CV22/240001FE

22CV22D 9
3SAFETY
Instruction of extreme importance in order to guarantee proper
Not following the operation procedures can cause serious
Electric shock hazard.
Useful information.
Installation requirements
Please read these requirements before commencing installa-
tion.
The product should be installed according to relevant codes of
practice as mentioned in the “Supplement”.
The installation procedure should only be used for heating
systems with a maximum water temperature of 100 °C.
22CV22/300001BE
We emphasize that you should always give priority to the above
mentioned standards and regulations and that the installation
regulations should be considered as an addition to these stan-
dards and regulations.
Explanation of the icons used in this manual
functioning of the boiler.
damage to the boiler, personal injuries or environmental pollu-
tion.
300002AE

22CV22D
10
Keep unauthorized people away from the installation. Do not
In addition to the information in this documentation, always
The installation should never be switched on with panels re-
Never remove or cover any of the instruction and warning
ous areas when working in the boiler room.
MAINTENANCE
Work on the electrical installation should only be carried out by
approved technicians and in accordance with the electro techni-
cal regulations.
Work on the gas and hydraulic systems should only be carried
out by approved technicians and in accordance with the safety
regulations for gas and hydraulic installations.
place any objects on the boiler. Keep away from the hot water
connections in order to prevent burns.
Always disconnect the boiler from the electric mains and close
the gas service cock in the gas supply pipe before commencing
maintenance and servicing operations.
Check the system for leaks afterwards.
follow the standard safety regulations to prevent accidents.
Cover panels should only be removed for maintenance and
servicing tasks. Replace all panels after completing these
maintenance and servicing tasks.
300003AE
Safety precautions
moved or when boiler protection devices are not operational.
300004AE
Instruction and warning stickers
stickers. They should always be legible throughout the life span
of the boiler.
Immediately replace any damaged or illegible stickers.
22IP22/300005AE
Modification
Modification of the installation should only be carried out after
obtaining prior written permission from the manufacturer.
300006AE
Danger of explosion
Follow the health and safety regulations for working in hazard-
22IP22/300007AE

22CV22D 11
Installation
The product should be installed according to relevant codes of
practice as mentioned in the “Supplement”.
Make sure that you follow all safety instructions properly.
22IP22/300008DE
Operation
In case of gas leakage, switch off the boiler and close the gas
service cock.
Open doors and windows, and notify the proper authorities.
Follow the instructions in the manual when you use the boiler
again.
22IP22/300009AE
Technical specifications
Do not exceed the specifications as layed down in the installa-
tion and maintenance instructions.
300010AE

22CV22D
12
4 DELIVERY AND TRANSPORT
4.1 Delivery Before delivery, the R2200 boiler is fully assembled and tested
4.2 Unit protective The boiler is mounted on a wooden pallet. For transportation
packaging the boiler is covered in a "heat-shrink" protective covering. The
4.3 Transport Refer to the technical specifications on weight and dimensions
when transporting the boiler.
- Incorrect moving or lifting of the boiler may cause damage to
in the factory. The R2200 is mounted on a pallet and covered in
a "heat-shrink" protective wrapper.
Check for damage after removing the boiler’s protective cover-
ing.
Check whether the boiler conforms to the order requirements.
Check whether the circuit diagram and gas-train diagram num-
ber is in accordance with the offer, order confirmation and the
data on the boiler’s data number plate.
22IP22/410001BE
panel-work is also covered in a protective polyethylene layer.
Before final installation in the boiler room the boiler must be
removed from the pallet and all protective coverings removed.
The protective coverings should be disposed of in a environ-
mentally friendly way. Contact your local authority.
22IP22/420001BE
WARNING:
the boiler
- Remove the protective covering after transport and after
installation in the boiler room.

22CV22D 13
Fig. 8 Moving
Fig. 9 Lifting
Using a crane
Pallet cart and/or forklift truck
When moving the boiler with a pallet cart or forklift truck, the
forks should be placed at a side of the boiler.
- Never swing the load over bystanders.
- Always use special lifting harnesses which should be placed
on the boiler
- Make sure that during lifting the harness does not damage
the draught diverter.
22IP22/430001AE

22CV22D
14
Fig. 10 Minimum dimensions
5 INSTALLATION
5.1 Boiler room The R2200 should be installed according to relevant codes of
5.1.1 Siting Install the boiler as close to the chimney as possible. A flue
To maintain ease of access and therefore ease of mainte-
5.1.2 Boiler room The product should be installed according to relevant codes of
ventilation practice as mentioned in the “Supplement”.
practice as mentioned in the “Supplement”.
22IP22/510001CE
base is not required.
nance, the following minimum dimensions are recommended
between the R2200 and the boiler room walls:
Front with control panel 1000 mm
Rear side with water connections 350 mm
Left-hand side 350 mm
Right-hand side due to burner 550 mm
In case of a left-handed model:
Left-hand side due to burner 550 mm
Right-hand side 350 mm
If these dimensions are not met, maintenance operations could
be seriously inhibited.
* Right-hand model (R): standard
Left-hand model (L): option.
22IP22/511001EE
22IP22/501001AE