STOKVIS ENERGY SYSTEMS ECONOFLAME R30 Owner's manual

ECONOFLAME
R30
WALL MOUNTED
CONDENSING 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
DOC653/30CV02-151204

Edition 30CV02A, 18-11-2004
© 2004 Rendamax B.V.
All rights reserved.
No part of this publication may be copied and/or published by means of printing, photocopying, microfilming, or by electronic means, on
tape or in any other manner whatsoever without the prior permission of Rendamax B.V. in writing.
We are engaged in a constant effort to improve our products. As a result of this process, the products may deviate slightly from the
descriptions contained in the present document. Rendamax B.V. accepts no liability whatsoever for differences between the products
delivered and the information contained in the present document.
Doc653/30CV02A

Doc653/30CV02A
Table of contents
R30 Technical data 1
Dimensions R30 2
1 Introduction 3
1.1 Stokvis
1.2 The supplier
1.3 This document
1.4 Service
1.5 General restrictions 4
2 Description
2.1 General
2.2 Main components 6
2.2.1 Description of principal components
2.3 Boiler control 7
2.4 Safety aspects 8
3 Safety
4 Delivery and transport 9
4.1 Delivery
4.2 Packaging 10
4.3 Transport
5 Installation
5.1 Regulations
5.2 Installation area
5.2.1 General
5.2.2 Installation
5.2.3 Ventilation 11
5.3 Connections
5.3.1 Gas connection
5.3.2 Electrical connections
5.3.3 Water connections 14
5.3.4 Flue gas outlet and air inlet
5.3.4.1 Connection possibilities
5.3.4.2 Air inlet pipe 15
5.3.4.3 Flue gas outlet
5.3.4.4 Flue 16
5.3.5 Condensate drain 18
5.4 Hydraulic system
5.4.1 Water flow
5.4.4.1 Flow and resistance
5.4.1.2 Pump characteristics 19
5.4.1.3 Shut-off valves
5.4.1.4 Valves
5.4.1.5 Water flow protection device
5.4.2 Water pressure 20
5.4.2.1 Operating pressure
5.4.2.2 Boiler expansion vessel
5.4.2.3 System expansion vessel
5.4.2.4 Water pressure protection device

Doc653/30CV02A
5.4.3 Water temperature 20
5.4.4 Water quality
6 Operating instructions 21
6.1 Operation
6.2 Controls
6.3 Boiler module KM628 22
6.4 Fault signals 23
6.5 Setting into operation 25
6.6 Switching-off the appliance
6.7 Warnings
7 Commissioning
7.1 General
7.2 Commissioning 26
8 Maintenance 27
8.1 Safety
8.2 General
8.3 Procedure 28
8.4 Cleaning the burner and the heat exchanger
8.5 Cleaning the strainer of the gas combination block
8.6 Ionisation measurement
8.7 Service
9 Conversion formulae and factors 29

Doc653/30CV02A 1
R30 Technical data
Type R30/45 R30/65 R30/85 R30/100 R30/120
Nominal heat output (80/60oC)
Nominal heat output (40/30oC)
Heat input, gcv (Hs)
Heat input, ncv (Hi)
kW
kW
kW
kW
5.6-39.2
6.3-43.0
6.4-44.4
5.8-40.0
8.3-59.2
9.2-65.0
9.5-67.4
8.6-60.7
15.6-77.8
17.0-85.0
17.7-88.8
16.0-80.0
17.6-88.2
19.2-96.3
19.9-99.9
18.0-90.0
21.9-109.8
24.0-120.0
25.0-124.8
22.5-112.4
Gas consumption Natural gas H (10.9 kWh/m3)
Propane (24.65 kWh/m3)
Gas inlet pressure Natural gas (min./max.)
Propane (min./max.)
m3/h
m3/h
mbar
mbar
0.5-3.7
0.2-1.6
17/20
30/50
0.8-5.6
0.3-2.5
17/20
30/50
1.4-7.3
0.6-3.2
17/20
30/50
1.6-8.2
0.7-3.6
17/20
30/50
2.1-10.3
0.9-4.6
17/20
30/50
Maximum water temperature of central
heating system
Maximum operating pressure
Water content
Water resistance (∆T= 20°C)
Excess head of the boiler pump (∆T= 20°C)
°C
bar
litre
kPa
kPa
90
6
5.1
14
26
90
6
6.6
20
29
90
6
8.4
25
15
90
6
10.3
28
24
90
6
12.0
30
12
Connection for flue outlet D
Connection for air inlet D1
Gas connection G
Water connection W (int)
W (ext)
Condensate drain (∅outer)
mm
mm
mm
80
80
R3⁄4"
Rp1"
R11⁄4"
25
80
80
R3⁄4"
Rp1"
R11⁄4"
25
100
100
R3⁄4"
Rp1"
R11⁄4"
25
100
100
R3⁄4"
Rp1"
R11⁄4"
25
100
100
R3⁄4"
Rp1"
R11⁄4"
25
Electrical supply
Frequency
Fuse protection
V
Hz
A
230
50
6
230
50
6
230
50
6
230
50
6
230
50
6
Maximum power consumption (excl. pump)
Maximum power consumption (incl. pump)
Insulation
W
W
97
190
IPX4D
98
230
IPX4D
123
255
IPX4D
130
325
IPX4D
215
410
IPX4D
Boiler weight, empty, ± 5% kg 45 55 65 80 90
Table 1 Technical data R30

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Dimensions R30
G
50
L1 B1
D1 D
465
L
W W
232,5
62
81 81 70,5
896
40
870
12
162
Fig. 1 Dimensions of the R30
Type R30/45 R30/65 R30/85 R30/100 R30/120
B1 mm 120 120 140 140 140
D mm 80 80 100 100 100
D1 mm 80 80 100 100 100
GR
3⁄4"R 3⁄4"R 3⁄4"R 3⁄4"R 3⁄4"
L mm 340 405 510 560 670
L1 mm 74 90 90 90 90
WR1
1⁄4"/Rp 1" R 11⁄4"/Rp 1" R 11⁄4"/Rp 1" R 11⁄4"/Rp 1" R 11⁄4"/Rp 1"
Table 2 Dimensions of the R30
(We reserve the right to make changes without prior notification)
The data may deviate slightly due to fabrication tolerances.
Conditions applicable to table 1:
- Gas consumption at: 1013 mbar, 15°C, dry.
- Gas category: 22H3P
- Category of appliance: B23, C13, C33, C43, C53, C63, C83

Doc653/30CV02A 3
1 Introduction
1.1 Stokvis
Since its beginning in 1985, Stokvis has built up a strong reputation in the industry for the devel-
opment, production and marketing of gas fired, high efficiency boilers and water heaters in the
43-1200kW range.
Thanks to their unique design, these boilers differentiate themselves due to the following:
- High thermal output
- Environmentally friendly (they meet the most stringent environmental requirements)
- Low weight and compact size
- Durability
- Low noise level
- Broad control range
- Available in a wide range of models
Through active, market oriented research, Stokvis is again in a position to offer solutions for the
most challenging heating requirements.
1.2 The supplier
Stokvis will be happy to provide you with advice or more information concerning our products.
You will find our contact details on the cover of this documentation. You can of course always
obtain further information via www.stokvisboilers.com.
1.3 This document
The present documentation has been prepared with the following target groups in mind:
- The technical consultant
- The installer
- The maintenance technician
- The user
Stokvis has opted to make the technical documentation as comprehensive as possible in the form
of this book, in order to ensure that these target groups have all the information they need.
As the supplier we would be happy to help you in connection with any additional information that
you may require.
This document covers the following aspects relating to the boilers:
- General description
- Technical specifications
- Requirements for design and installation
- Maintenance instructions
The operating instructions for the user have been affixed to the appliance itself. You will also find
them in chapter 6.
1.4 Service
The Stokvis Service Department is always ready at hand to commission the appliance and provide
maintenance and service. Please refer to the cover for details.

4 Doc653/30CV02A
1.5 General restrictions
Stokvis products should always be used, installed and maintained in accordance with the statu-
tory requirements, specifications and standards applicable to these installations.
All the data, information and suggestions concerning its products provided by Stokvis are based
on careful study.
However, the use, installation and operation of the same are outside the control of Stokvis, and
neither Stokvis nor any other organisations associated with it, accept any liability for the same.
Changes may be incorporated without prior notice. Stokvis accepts no obligation to adapt previ-
ously delivered products to incorporate such changes.
2 Description
2.1 General
The Rendamax R30 wall mounted boilers are environmentally friendly gas fired heating boilers
with a modulation range between approximately 14% and 100% of their maximum output (types
85, 100 and 120: 20% to 100%). The R30 series consists of three models of boiler with an output
range of 43 to 120 kW. The appliances have low NOxand CO emission, which satisfy the most
stringent environmental requirements.
The R30 series has received CE Approval for all relevant European countries and has been regis-
tered under the Product Identification Number 0063BO3192.
The boilers may be used on both open (category B23) as well as room sealed (category C13, C33,
C43, C53, C63 or C83) systems.
As standard, the boiler is delivered fully wired, fully assembled, and tested.
Working principle and design
Air is drawn in as required, via a speed controlled fan. The zero pressure controller of the gas
valve measures the under pressure in the venturi and modulates the gas in response to this pres-
sure from the fan. The gas/air is then thoroughly mixed in the correct ratio and fired directly into
the burner.
A temperature controller compares the actual water flow temperature to the desired water tem-
perature. The controller interprets the load required and adjusts the fan speed. The fan sends a
speed feed-back signal, and the controller re-adjusts the speed as required.
The mixture of gas and air that is formed is then conveyed through the cylindrical stainless steel
burner for combustion.
The heat exchange takes place in a double heat exchanger block. The first heat exchanger is lo-
cated immediately next to the burner, while the second heat exchanger is connected downstream
(condenser). Both heat exchangers consist of several smooth pipes in the form of a coil. The two
heat exchangers are connected to each other using water distribution manifolds. The water is
circulated by the boiler pump. This pump will be in the boiler for types 45, 65 and 85 and external
for the types 100 and 120 (separate delivered).
The R30 boiler has a low water capacity. Due to this, rapid changes of the water temperature can
be achieved. It can be used without any return temperature protection. The installed pump pro-
vides the water flow rate required. This pump has three-stage modulation (types 45, 65 and 85).

Doc653/30CV02A 5
Application possibilities
The design of the R30 boiler makes it suitable for use in heating systems with:
- constant flow temperature;
- weather dependent set point adjustment;
- low temperature condensing system;
- external temperature control via building optimiser (0 - 5 Vdc = -10°C + 90°C, below 1Vdc the
boiler reverts back to the set temperature (P1), see 5.3.2 ‘connecting terminals’)
Fig. 2 The Stokvis R30

6 Doc653/30CV02A
1
2
3
4
5
6
7
14
15
16
17
18
19
20
8
9
10
11
12
13
21
Fig. 3 Overall view
2.2 Main components
1 Flue outlet connection 12 On/off switch
2 Air inlet connection 13 Condensate drain
3 Gas connection 14 Frame
4 Flow connection 15 Burner/ heat exchanger package
5 Automatic air vent 16 Water flow temperature sensor
6 Casing 17Gasvalve
7 Return connection 18 Venturi
8 Flue gas temperature sensor 19 Air intake silencer (tpes 45, 65 and 85)
9 Fan 20 Boiler pump (types 100 and 120 outside
10 Pressure Gauge the boiler)
11 Automatic boiler controller 21 Control panel
2.2.1 Description of principal components
The boiler is made of the following components:
Fan [9]
The fan pulls in and compresses the combustion air, drawn from inside the casing of the boiler.
The fan is a DC current fan equipped with a speed feed-back signal. This speed feed-back signal
is transmitted back to the controller, which makes the necessary corrections.
Gas train
The main component of the gas train is the gas valve [17]. The gas quantity is controlled according
to the quantity of air. The air quantity varies with the speed of the fan. The gas train is equipped
with a test point through which the gas pipe can be vented or the gas inlet pressure can be meas-
ured.

Doc653/30CV02A 7
Burner/heat exchanger package [15]
After the gas/air mixture has been correctly mixed, it flows into the burner via the inlet channel.
Due to the overpressure, the gas/air mixture is forced through the burner to the external surface
of the burner for combustion.
The heat exchanger is made of smooth stainless steel tubes in the form of coils. It essentially
consists of two parts; one part is located immediately next to the flame, where the major por-
tion of the heat transfer between the combustion gases and the water takes place. The other part
functions as a condenser for the flue gases, where the transfer of latent heat takes place.
Stainless steel water distribution manifolds ensure optimum water flow through the heat ex-
changer.
Water connections
These consist of a flow connection [4] and a return connection [7]. There is a water temperature
sensor [16] on the flow connection which, apart from controlling the burner load, also monitors
the water flow in the boiler. The latter is done in combination with the flue gas temperature sensor
[8].
Boiler pump [20]
The boiler pump of the types 45, 65 and 85 is located in the return connection of the boiler and
is electrically connected directly to the corresponding terminals in the control panel. The boiler
pump of the types 100 and 120 will be delivered separately and can be directly connected to the
return connection of the boiler. The capacity and the head of the pump are adequate to overcome
not only the boiler resistance but also some system resistance (see table 1). In the types 45, 65
and 85, the pump has three-stage modulation, depending on the load.
Condensate drain [13]
The boiler is equipped with a bottle trap. This bottle trap is located on the bottom side of the ap-
pliance and can be easily filled with water.
Frame [14]
The frame is the load bearing part of the boiler. All the components are installed on it.
Casing [6]
The casing can be removed easily as one unit. To do this, unscrew the 8 screws found on the top
and the bottom of the casing.
Electrical equipment
This comprises the control system and safety devices of the boiler. The connection terminals are
installed in a fully sealed enclosure behind the control panel [21]. This panel can be tilted through
90° after removing the control panel bolt. This provides access to all the electrical connections,
without the need to remove the casing.
2.3 Boiler control
If heat is required, the boiler will start, if all necessary conditions have been fulfilled and no
safety devices have been triggered. This heat requirement will arise if:
- The flow temperature of the boiler is less than the required flow temperature
- The manual option has been selected using selector switch set to: W1 or W2.
- The frost protection has been triggered independently of the operating conditions (K, q, t,
W1 or W2).
The integrated temperature controller adjusts the heat input inside the boiler by changing the fan
speed so that the desired temperature is reached and kept at a constant level. Depending on the
quantity of air displaced by the fan, a specific quantity of gas will be added. As a result, the boiler
capacity can be modulated seamlessly and the heat requirement can be accurately monitored. If
the flow temperature rises above the desired level together with any hysteresis, the boiler will
switch off. The boiler will start again as soon as the flow temperature falls below the desired
level.

8 Doc653/30CV02A
2.4 Safety aspects
The following safety devices are installed on the boiler:
- Temperature monitoring system
- High limit temperature monitoring system (STW)
- Limit temperature monitoring system (STB)
(both are adjustable)
- Frost protection system
- Using an external sensor, if the external temperature falls below 0°C
- Based on the flow temperature, if this is below 5°C and/or the domestic hot water tempera-
ture is below 10°C
- Flame monitoring by means of ionisation measurement
- Fan speed monitoring
- Flue gas temperature monitoring
- Flow monitoring using a combination of flow water temperature and flue gas sensor readings
If one of these safety systems is activated, the boiler will go to an interlocking or lockout fault and
will be switched off. Lockout faults can only be reset by pressing the reset button, after rectifying
the fault.
3 Safety
Installation specifications
Read the specifications before commencing with installation.
The equipment should be installed by a recognised installer in accordance with applicable na-
tional and local standards and specifications.
The installation should only be used for heating systems with a maximum water temperature of
90°C.
It is expressly stated that these installation specifications should be regarded as a supplement to
the above mentioned standards and specifications, which shall take priority over the information
contained in this technical documentation.
Icons used
yInstructions that are of essential importance for the correct functioning of the installation.
wIf the actions, operating procedures, etc. are not followed accurately, this may cause serious dam-
age to the installation, personal injury or damage to the environment.
vDanger of electrical shocks.
xUseful information.
Maintenance
Work on the electrical installation should only be carried out by a recognised installer in accord-
ance with the applicable electrical regulations.
Work on the gas equipment and hydraulic installation should only be done by personnel having
the required training, in accordance with the applicable safety rules and regulations for gas instal-
lations.
wKeep all unauthorised persons away from the installations.

Doc653/30CV02A 9
Do not place any objects on the boiler. Keep a safe distance from the hot water connection and the
flue, due to the danger of burns.
Before starting with any maintenance and service work, shut off the electrical supply and close
the gas valve to isolate the gas supply.
Check the entire installation for leakages after completing maintenance and service work.
xIn order to prevent accidents, please refer to the general safety requirements in addition to the
information contained in this technical documentation. All parts of the casing should be in place.
Casing parts may only be removed for maintenance and service purposes. After carrying out main-
tenance and service work, replace all the panels.
Safety devices
wThe installation should never be switched on with the casing panels removed or the safety de-
vices disabled.
Instructions and warning stickers
xInstruction and warning stickers affixed on the appliance should never be removed or covered up,
and should be maintained in a legible condition throughout the life of the appliance. Immediately
replace damaged or illegible instruction and warning stickers.
Modification
The appliance may only be modified with the written permission of the manufacturer.
Danger of explosion
While doing work in the boiler room, follow the applicable rules and regulations entitled ‘Working
in Areas Subject to Danger of Explosion’.
Installation
The appliance should be installed by a recognised installer in accordance with applicable national
and local standards and specifications.
Follow all the safety instructions precisely.
Operation
In case of a gas leakage: switch off the boiler and close the gas valve. Open doors and windows
and notify the relevant authorities.
When the appliance is restarted, follow the user instructions.
Technical specifications
The specifications contained in this technical documentation should not be exceeded.
4 Delivery and transport
4.1 Delivery
The boiler is delivered fully assembled, tested, and packed.
Check the boiler for damage after receipt.
Check whether the items delivered are correct and in accordance with the items ordered.

10 Doc653/30CV02A
4.2 Packaging
The boiler is delivered in suitable cardboard packaging.
The types 45, 65, 85 and 100 can be stacked up till two pieces. It’s not allowed to stack up the
type 120.
4.3 Transport
xRegarding transportation, refer to the technical data for dimensions and weights.
wThe packing should only be removed after transportation, or remove the panels before transpor-
tation. This is in order to prevent the panels from getting damaged.
Moving
Each boiler is packed in its own carton which has hand holed at both sides for lifting purposes.
Access requirements
The dimensions of the boiler are such that all the boiler types can be transported through a door
opening of 60 cm.
Mounting
Install the Stokvis R30 using a spirit level on a sufficiently sturdy wall using the suspension
bracket provided. A template has been provided in the packing box, on which the positions of the
fixing holes have been indicated.
Protection against frost
Boilers that are not used during the winter are in danger of freezing. Drain out the water from the
filling and drain valve.
5 Installation
5.1 Regulations
The appliance should be installed by a recognised installer in accordance with the applicable
national and local standards rules and regulations.
The commissioning should preferably be done by the Stokvis Service department to validate the
warranty.
5.2 Installation area
5.2.1 General
- Thanks to the design of the boiler, radiation losses are negligible
- Due to the low noise level, there is no need for additional sound insulation of the room
- Due to its compact design, very little installation space is required
- The location options for the boiler are increased because it is supplied suitable for both open
and room sealed operation (see chapter 5.3.4).
5.2.2 Installation
The following guidelines should be followed in order to optimise the installation of the boilers
- The device should be installed in a frost free room due to the risk of freezing of the condensate
drain. The built-in protection system is activated when the temperature of the central heating
water falls below 5°C
- Pay attention to the location and temperature sensitivity of the device.

Doc653/30CV02A 11
- Ensure that there is sufficient room around the device for maintenance and the replacement of
components if necessary
The recommended minimum clearance is as follows:
- 1000 mm to the front (free space for movement);
- 400 mm above;
- 250 mm below;
Since all the components can be accessed from the front, no minimum distance is required on
the left and right side. We however recommend a minimum distance of 100 mm in order to enable
easy opening of the casing.
5.2.3 Ventilation
The ventilation of the installation room should conform to the applicable national and local stand-
ards and regulations.
In connection with ventilation, keep in mind the following points:
a. Follow the applicable national and local standards and regulations concerning the dimensions
of the opening and the protection of the mechanical ventilation system if any
b. The air inlet openings should be in two walls facing each other
c. Use broad, low inlet grills
d. The ventilation outlet should be at high level as high as possible
e. In the case of insufficient air supply, it may be necessary to mechanically supply ventilation air.
5.3 Connections
5.3.1 Gas connection
The gas connection should be installed by a recognised installer in accordance with applicable
national and local standards and specifications.
The gas connection is located on the bottom of the appliance.
The pressure on the inlet side of the appliance should be reduced to 20 mbar for natural gas and
up to 50 mbar for propane, using a gas governor.
The pressure loss in the supply pipe should be such that the pressure never falls below 17 mbar
for natural gas and 30mbar for propane, when the appliance is at maximum load.
In order to guarantee that the gas valve works at all times, it is recommended that a gas filter is
installed in the gas pipeline. The gas filter can be ordered as an option to be supplied with the
boiler.
Install a gas isolating valve directly under the appliance.
5.3.2 Electrical connections
The electrical connections should be installed by a recognised installer in accordance with appli-
cable national and local standards and specifications.
The appliance is fully wired in accordance with the electrical diagrams delivered with the appli-
ance.
All the electrical connections are located behind the control panel. The control panel can be eas-
ily opened after removing the locking screw. The cables to be connected (supply, control) enter
through the bottom of the appliance via cable glands.

12 Doc653/30CV02A
Fig. 4 Connections of the R30
The appliance is suitable for a 230 V 50Hz power supply with live/neutral/earth. Other connect-
ing arrangements are only permissible if an isolating transformer is used. The appliance is phase
sensitive. The boiler can be switched on and off using the on/off switch on the control panel.
The installer should use a 2-pole main isolating switch with a contact opening of at least 3 mm in
the supply circuit to the boiler. With this, the entire boiler (including the boiler supply pump relay)
can be rendered volt free for maintenance work or in the case of failure.
In order to prevent faults due to electromagnetic fields, a screened cable should be used for the
bus connection and for all sensor and control signals between the boiler and all external connec-
tion units. The screening should be connected on both sides according to the EMC Directives.
Controls and options
The boilers are equipped with a modulating control system. The temperature can be controlled via
a 0-5 Vdc signal for example in response to external temperatures. If the voltage falls below 1 volt
the boiler reverts to the set point set on parameter P1. A hot water priority circuit also forms part
of the standard equipment, an additional sensor is required. Other options available on the boiler
can be supplied to extend this. The three following options are:
BME
A weather-dependent temperature controller with the following features:
- Programming of 3 heating periods with different room temperatures
- Adjustable night time boiler flow temperature reduction operation
- Choice between 2 weekly programmes
- Hot water priority circuit with 2 heat up periods
- Override for single hot water period during night time reduced flow temperature operation
- Optimum start time calculation
- Room temperature control with or without external temperature influence
- Option of internal (standard) or external room sensor (option)

Doc653/30CV02A 13
- Adjustable response of the flow temperature to sensed room temperature
- Calibration of the room sensor
- Delay to flow temperature compensation due to external temperature up to a maximum of
3 hours
- Holiday Programme
- Frost protection system based on external temperature or room temperature
- Remote activation via telephone if no external room sensor fitted (external relay required)
- Optimisation of compensation slope based on room temperature and external temperature
with optimum start time adjustment
- Hot water Anti-legionella bacteria function (65°C)
- Option of switching off internal room sensor
- 2-wired communication (scom-bus)
- Display in 6 different languages
- External display of KM628 functions with display of status, operating hours, number of starts,
degree of modulation and temperatures.
E6.1111
This is a control system for the weather dependent control of two secondary heating circuits. In
addition, a hot water circuit can also be controlled at two different Set Points. All the settings can
be made separately for each secondary circuit. This E6 controller can be further extended with an
optimisation controller system for each secondary group (BM). The weather dependent control of
the boiler is done indirectly by the E6.1111.
There are the following additional features to the BME:
- The maximum flow temperature can be set for each heating circuit
- The compensation slope can be manipulated with a parallel displacement to the desired flow
temperature of the boiler
- Time controlled hot water re-circulation pump
- Pump-kick function
- DCF receiver for internal clock (optional receiver required)
- Communication over a CAN-bus
- Integrated relay and sensor test
- Can be used in stand-alone operation
KKM
This is a boiler cascade manager with which up to 8 boilers can be connected in cascade and an
extra on/off boiler can be operated. The KKM also has the same functional features as the E6.1111.
Connecting terminals
Terminal: Description:
L1-N-Earth Supply for the boiler should be installed with 6A fuse protection. If miniature
circuit breakers are used, these should have C Rated characteristics.
1-3 Lockout circuit (230 Vac from boiler, 1A). If the connection between the two ter-
minals is broken, the boiler will immediately go into a lockout condition and will
remain out of operation until this connection is restored and has been reset using
the lockout reset button.
4-5 On/Off. By connecting the two terminals to each other, the boiler is switched
from the standby mode to the operating mode and can start when there is a heat
requirement. These terminals can be used for thermostatic functions for the
boiler. If the circuit is interrupted, the boiler goes into the stand-by mode, except
for hot water preparation.
6-7 A hot water temperature sensor can be connected to these terminals. These are
recognised automatically by the boiler controller when the supply voltage is
switched on. The reading from this sensor is used for controlling the hot water
temperature.
8-9 External flow temperature adjustment. A 0-5 Vdc (-10 to+90°C) analogue signal
can be applied at these terminals. If the voltage is less than 1 Vdc, it will change
over to the internal set flow temperature (set at P1).

14 Doc653/30CV02A
10-11 Connection terminals for the 2-wire bus signal (scom-bus). Pay attention to the
polarity: namely, terminal 10 is earth and 11 is positive.
ST 1.1-1.2 An OK-signal is available from these terminals (rated at 230 Vac, 1A). This circuit
is closed in normal operation and will be open if more than 2 identical faults
occur within 6 minutes (the display will show an error code with a “3” appearing
above it) or if a fault remains for more than 6 minutes.
ST 2.1-2.2 An outdoor sensor can be connected to these terminals. The automatic control
unit of the boiler will automatically detect this connection when the supply volt-
age is switched on. The reading from this sensor is used for frost protection and
for weather-dependent control of the flow temperature of the boiler when fitted
with the optional BME, E6.1111, or KKM
ST 9.3-9.4 Interlock circuit (230 Vac from boiler, 1A). If the connection between the two
terminals is broken, the boiler will go into a fault condition and remain out of
operation until this connection is restored.
Attention! If the situation lasts for more than 6 minutes, or if it occurs more than
twice within 6 minutes, the boiler will go into a lockout fault and remain out of
operation until this connection is restored and is reset using the reset button.
ST 11.1-11.2 Control for the hot water primary pump (230 Vac from boiler, 1A), of which termi-
nal 11.2 is the phase (L) wire and terminal 11.1 is the neutral (N) wire.
5.3.3 Water connections
It is recommended that the flow and return pipes are securely fixed with brackets. This prevents
damage and makes maintenance easier.
The boiler is an instantaneous boiler and is not suitable for use in open vented systems. In such
cases, a plate heat exchanger should be installed, with which system isolation can be achieved.
The capacity and head of the internal boiler pump is sufficient to overcome not only the boiler
resistance but also some system resistance (see table 1).
It is recommended that manually operated valves should be installed between the water connec-
tions and the installation.
In order to limit standby losses further, a motorised valve is sometimes installed in the flow or
return pipe work, or a mechanical non-return valve may be used for this purpose.
Standby losses can be further limited by switching off the boiler via the on/off control circuit.
5.3.4 Flue gas outlet and air inlet
5.3.4.1 Connection possibilities
During installation, a choice can still be made between a ‘room sealed’ and an ‘open’ version. The
standard eccentric connection can also be easily changed into a concentric connection.
The flue gas discharge outlet and air intake system should be installed by a recognised installer
according to applicable national and local standard and specifications.
• Type B23:
Open type appliance without draught stabiliser, air supply from the room, flue gas discharge
outlet above the roof.
• Type C13:
Room Sealed appliance, connected to a concentric air supply / flue discharge through the wall
• Type C33:
Room Sealed appliance, connected to a concentric air supply / flue discharge through the roof
• Type C43:
Room Sealed appliances in cascade, connected to a common concentric air supply / flue dis-
charge at the appliance.

Doc653/30CV02A 15
• Type C53:
Room Sealed appliance, connected to a separate air supply and flue discharge pipe, opening
into different pressure areas.
• Type C63:
Room Sealed appliance, sold without related connecting and/or discharge fittings
• Type C83:
Room Sealed appliances in cascade, connected to separate air supplies but common flue dis-
charge through the roof.
5.3.4.2 Air inlet pipe
The air supply pipe may be single wall, smooth or flexible, and be made of:
• plastic
• aluminium
• stainless steel
Always consider the large resistance when using flexible material.
Always consider condensate formation due to the suction of cold air.
Type Diameter of air inlet D1 (mm)
R30/45 80
R30/65 80
R30/85 100
R30/100 100
R30/120 100
Table 3 Diameter of air inlet
The connection for the air supply is on the top of the boiler.
The air supply pipe should be airtight. This is to prevent the suction of ‘false air’. Horizontal com-
ponents in the air supply should be installed sloping in the direction of the supply opening.
5.3.4.3 Flue gas outlet
The flue gas components may be single wall, smooth or flexible, and be made of:
• plastic
• aluminium
• stainless steel
Always consider the resistance when using flexible material.
Type Diameter of air inlet D (mm)
R30/45 80
R30/65 80
R30/85 100
R30/100 100
R30/120 100
Table 4 Diameter of flue gas outlet
The flue gas outlet is located on the top of the appliance and is designed for direct connection to a
corrosion resistant flue pipe.
The flue gas discharge pipe to be used should be airtight and watertight at the joints and connec-
tions, or should be seamless. Horizontal components in the flue pipe should be installed sloping
in the direction of the appliance (minimum 5 cm per meter).

16 Doc653/30CV02A
Due to the high efficiency, there may be condensate formation in the chimney even at high water
temperatures.
yThe condensate drain should never be blocked!
A direct connection to a brick chimney is not permissible, since the chimney losses must be less
than 17%.
The following table gives the flue gas data for all the types
Type Maximum flue gas tem-
perature at full load
Quantity of flue gas at
full load
Maximum permissible flue
resistance
°C m3/h kg/s mbar
R30/45 70 74 0.020 1.4
R30/65 70 113 0.031 1.4
R30/85 70 149 0.041 1.4
R30/100 70 168 0.046 1.4
R30/120 70 209 0.058 2.0
Table 5 flue gas data
Load 100%
Flow temperature 80 °C
Return temperature 60 °C
5.3.4.4 Flue
Flue length
Since the boiler is equipped with a “premix burner” with a fan, an overpressure is created in the
boiler. This overpressure is sufficient to overcome the resistance of the burner, the heat exchang-
er, and the chimney.
The back pressure outside the boiler depends on:
a. the resistance of the flue pipe
b. the degree of cooling of the combustion gases
c. the resistance of the discharge outlet
The degree of cooling of the combustion gases depends on the following:
a. the insulation value of the flue
b. the ambient temperature
c. the flue system and outlet
There is a maximum overpressure of around 1.4 mbar (140 pa) for the types 45, 65, 85, 100 and
2.0 mbar (200 pa) for the type 120 in the boiler for the flue gas discharge system.
Calculation of diameter and length
For the calculation and control of the inner diameter of a discharge system with mechanical dis-
charge, please refer to the applicable national and local standards and regulations.