STOKVIS ENERGY SYSTEMS ECONOFLAME R3500 Owner's manual

ECONOFLAME
R3400/R3500/R3600SB
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
DOC2005/3456en.3456CV02A230611

I
.
© 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 Stokvisrejectsany responsibilityfor the differences between the
product delivered and the information mentioned in this document.
000002DE
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Doc2005/3456en 1
R3400 Technical data
Type R3401 R3402 R3403 R3404 R3405 R3406
Nominal heat output
Nominal heat input (nett. CV)
Minimum heat input
kW
kW
kW
657
702
176
729
784
196
853
917
229
965
1038
260
1078
1159
290
1189
1279
320
Pilot burner kW 36 36 36 36 36 36
Gas consumption
natural gas H (10.9 kWh/m3)
propane (12.8 kWh/kg)
m3/h
kg/h
64.5
54.9
71.9
61.2
84.1
71.6
95.2
81.1
106.3
90.5
117.3
99.9
Gas inlet pressure
natural gas H (min/max)
natural gas H (max) option
propane (min/max)
mbar
mbar
mbar
18 – 25
100
30 – 50
18 – 25
100
30 – 50
35 – 100
30 – 50
35 – 100
30 – 50
35 – 100
30 – 50
35 – 100
30 – 50
Water capacity
Max. working pressure
dm3
bar
50
6
53
6
70
6
75
6
80
6
85
6
Gas connection G Rp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6
Water connections W DN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Flue connection D mm 300 350 350 400 400 400
Safety valve connection
relief connection
standard setting
11⁄4"
11⁄2"
3
11⁄4"
11⁄2"
3
11⁄2"
2"
3
11⁄2"
2"
3
11⁄2"
2"
3
2"
21⁄2"
3
Power supply
Frequency
Fuse
V
Hz
A
400 3N~
50
16
400 3N~
50
16
400 3N~
50
20
400 3N~
50
20
400 3N~
50
20
400 3N~
50
20
Max. electrical power
consumption unit
pump maximum
total
kW
kW
kW
0.90
1.15
2.05
0.90
1.15
2.05
1.27
1.15
2.42
1.27
1.50
2.77
1.27
1.50
2.77
1.27
1.50
2.77
Boiler weight, empty, ± 5 % kg 675 740 840 950 1070 1200
Dimensions height H
width B
length incl. connections L
mm
mm
mm
1355
1330
2265
1355
1330
2265
1355
1130
2653
1355
1130
2653
1355
1330
2658
1355
1330
2658
Table 1 Technical data R3400
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DN65 PN16
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Dimensions R3400
Fig. 1 Dimensional sketch R3400
front view plan view
rear view
side view
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Type R3401 R3402 R3403 R3404 R3405 R3406
B mm 1330 1330 1130 1130 1330 1330
B1 mm 1160 1210 1003 1053 1203 1253
B2 mm 665 665 565 565 665 665
B3 mm 170 120 127 77 127 77
B4 mm 1146 1146 946 946 1146 1146
B5 mm 115 65 115 65 115 65
D mm 300 350 350 400 400 400
GRp2" Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6
H mm 1355 1355 1355 1355 1355 1355
H1 mm 1125 1125 1570 1420 1155 1377
L mm 2265 2265 2653 2653 2658 2658
L1 mm 595 595 610 615 615 770
L2 700 700 1166 1166 1166 1166
L3 mm 108 108 88 88 88 88
WDN65 PN6 DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Table 2 Dimensions R3400
(Changes may be introduced without notice)
As a result of manufacturing tolerances, there may be small variations in the dimensions.
Conditions applicable to table 1:
- Nominal capacity measured at: 60 - 80°C.
- Gas consumption at: 1013 mbar, 15°C, dry
- Gas category: 22H3P
- Appliance category: B23, C53, C33 of C63
- Protection degree: IP20
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DN65 PN16
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R3500 Technical data
Type R3501 R3502 R3503 R3504 R3505
Nominal heat output
Nominal heat input (nett. CV)
Minimum heat input
kW
kW
kW
613
653
187
717
764
218
811
865
247
906
966
276
1000
1066
305
Pilot burner kW 30 30 30 30 30
Gas consumption
natural gas H (10.9 kWh/m3)
propane (12.8 kWh/kg)
m3/h
kg/h
59.9
51.0
70.1
59.7
79.4
67.6
88.6
75.5
97.8
83.3
Gas inlet pressure
natural gas H (min/max)
natural gas H (max) option
propane (min/max)
mbar
mbar
mbar
18 – 25
100
30 – 50
18 – 25
100
30 – 50
18 – 25
100
30 – 50
18 – 25
100
30 – 50
18 – 25
100
30 – 50
Water capacity
Max. working pressure
dm3
bar
53
6
70
6
75
6
80
6
85
6
Gas connection G Rp2" Rp2" Rp2" DN65 PN6 DN65 PN6
Water connections W DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Flue connection D mm 300 350 350 400 400
Safety valve connection
relief connction
standard setting bar
11⁄4"
11⁄2"
3
11⁄4"
11⁄2"
3
11⁄2"
2"
3
11⁄2"
2"
3
11⁄2"
2"
3
Power supply
Frequency
Fuse
V
Hz
A
400 3N~
50
16
400 3N~
50
16
400 3N~
50
20
400 3N~
50
20
400 3N~
50
20
Max. electrical power
consumption unit
pump maximum
total
kW
kW
kW
0.90
1.15
2.05
0.90
1.15
2.05
1.27
1.15
2.42
1.27
1.50
2.77
1.27
1.50
2.77
Boiler weight, empty, ± 5 % kg 740 840 950 1070 1200
Dimensions height H
width B
length incl. connections L
mm
mm
mm
1355
1330
2265
1355
1130
2653
1355
1130
2653
1355
1330
2658
1355
1330
2658
Table 3 Technical data R3500
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Dimensions R3500
Fig. 2 Dimensional sketch R3500
front view plan view
rear view
side view
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Type R3501 R3502 R3503 R3504 R3505
B mm 1330 1130 1130 1330 1330
B1 mm 1210 1003 1053 1203 1253
B2 mm 665 565 565 665 665
B3 mm 120 127 77 127 77
B4 mm 1146 946 946 1146 1146
B5 mm 65 115 65 115 65
D mm 300 350 350 400 400
GRp2" Rp2" Rp2" DN65 PN6 DN65 PN6
H mm 1355 1355 1355 1355 1355
H1 mm 1125 1400 1400 1155 1155
L mm 2265 2653 2653 2658 2658
L1 mm 595 610 610 615 615
L2 mm 700 1166 1166 1166 1166
L3 mm 108 88 88 88 88
WDN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Table 4 Dimensions R3500
(Changes may be introduced without notice)
As a result of manufacturing tolerances, there may be small variations in the dimensions.
Conditions applicable to table 3:
- Nominal capacity measured at: 60 - 80°C.
- Gas consumption at: 1013 mbar, 15°C, dry
- Gas category: 22H3P
- Appliance category: B23, C53, C33 of C63
- Protection degree: IP20
VI
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DN65 PN16
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DN65 PN16

R3600SB Standard Technical Data
Type R3601SB R3602SB R3603SB R3604SB R3605SB
Nominal heat output kW 639 747 846 945 1043
Nominal heat input (net. CV) kW 653 764 865 966 1066
Minimum heat input kW 187 218 247 276 305
Pilot burner kW 30 30 30 30 30
Gas consumption Natural gas H (10,9 kWh/m3) m3/h 59.9 70.1 79.4 88.6 97.8
Propane (12,8 kWh/m3) m3/h 51.0 59.7 67.6 75.5 83.3
Gas inlet pressure Natural gas H
(min./max.) mbar 18-25 18-25 18-25 18-25 18-25
Propane (min./max.) mbar 30-50 30-50 30-50 30-50 30-50
Water capacity dm3 73 97 104 110 117
Max. working pressure bar 6 6 6 6 6
Gas connection G Rp2" Rp2" Rp2" DN65 PN16DN65 PN16
Water connections W1
DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
W2
Flue connection D mm 300 350 350 400 400
Air supply connection (option) D1 mm 250 300 300 355 355
Safety valve Boiler connection 1¼" 1¼" 1½" 1½" 1½"
Relief connection 1½" 1½" 2" 2" 2"
Standard setting bar 3 3 3 3 3
Power supply V 400 3N~ 400 3N~ 400 3N~ 400 3N~ 400 3N~
Frequency Hz 50 50 50 50 50
Fuse A 161620 20 20
Max. electrical power consumption Unit kW 0.90 0.90 1.27 1.27 1.27
Pump kW 1.15 1.15 1.15 1.50 1.50
Total kW 2.05 2.05 2.42 2.77 2.77
Boiler weight, empty, ± 5% kg 890 1040 1150 1280 1410
Dimensions Height H mm 1405 1405 1405 1405 1405
Width W mm 1330 1130 1130 1330 1330
Length L mm 2265 2653 2653 2658 2658
Table 5Technical data R3600SB Standard

Doc2005/3456en 57
Dimensions R3600SB Standard
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Fig. 34Dimensions R3600 Standard
VIII
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58 Doc2005/3456en
Type R3601SB R3602SB R3603SB R3604SB R3605SB
Bmm1330 1130 1130 1330 1330
B1 mm 1210 1003 1053 1203 1253
B2 mm 665 565 565 665 665
B3 mm 120 127 77 127 77
B4 mm 1146 946 946 1146 1146
B5 mm 65 115 65 115 65
Dmm300 350 350 400 400
D1 mm 250 300 300 355 355
GmmRp2” Rp2” Rp2” DN65 PN6 DN65 PN6
Hmm1405 1405 1405 1405 1405
H1 mm 1175 1450 1450 1205 1427
Lmm2265 2653 2653 2658 2658
L1 mm 595 610 610 615 615
L2 mm 590 1166 1166 1166 1166
L3 mm 198 88 88 88 88
W1 mm DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
W2 mm DN65 PN6 DN80 PN6 DN80 PN6 DN80 PN6 DN80 PN6
Table 18 Dimensions R3600SB Standard
(Changes may be introduced without notice)
As a result of manufacturing tolerances, there may be small variations in the dimensions.
Conditions applicable to table 17:
- Nominal capacity measured at : 60 - 80°C
- Gas consumption at: 1013 mbar, 15°C, dry
- Gas category: 22H3p
- Appliance category: B23, C53, C33 or C63
- Protection degree: IP20
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XI
TABLE OF CONTENTS
R3400 Technical data ........................ I
Dimensions R3400 ........................... II
R3500 Technical data ........................ IV
Dimensions R3500 ........................... V
R3600SB Technical data ...................... VII
Dimensions R3600SB ........................ VIII
Tableofcontents ............................ XI
1 INTRODUCTION ............................ 1
1.1 Stokvis ...................................1
1.2 Supplier ................................... 1
1.3 Thisdocument .............................. 1
1.4 Service.................................... 2
1.5 General restrictions .......................... 2
2 DESCRIPTION ............................. 3
2.1 General ................................... 3
2.2 Main components ............................ 5
2.2.1 Description of principal components ............. 6
2.3 Boilercontrol ............................... 8
2.4 Safetyaspects .............................. 8
3 SAFETY................................... 9
4 DELIVERY AND TRANSPORT .................12
4.1 Delivery ...................................12
4.2 Packaging .................................12
4.3 Transport ..................................12
5 INSTALLATION.............................17
5.1 Regulations ................................17
5.2 Boilerroom.................................17
5.2.1 General ...................................17
5.2.2 Setup ....................................17
5.2.3 Ventilation .................................19
5.3 Connections ................................ 19
5.3.1 Gas connection .............................19
5.3.2 Electrical connection .........................19
5.3.3 Water connections ...........................24
5.3.4 Combustion air supply ........................25
5.3.4.1 General ...................................25
5.3.4.2 Air supply pipe ..............................26
5.3.5 Thefluesystem .............................28
5.3.5.1 General ...................................28
5.3.5.2Chimney...................................31
5.3.6 Condensate discharge ........................33
3456CV02A

5.4 Hydraulicsystem ............................34
5.4.1 General ...................................34
5.4.2 Waterflow .................................34
5.4.2.1 Flow rate and resistance ......................34
5.4.2.2Pumpcharacteristics .........................36
5.4.2.3Isolatingvalves .............................37
5.4.2.4Valves ....................................37
5.4.2.5Waterflowprotection.........................37
5.4.3 Waterpressure .............................38
5.4.3.1Operatingpressure ..........................38
5.4.3.2 Boiler expansion tank ......................... 38
5.4.3.3 System expansion tank .......................38
5.4.3.4Waterpressureprotection .....................38
5.4.4 Watertemperature...........................38
5.4.5 Waterquality ...............................38
5.4.6 Examplesofhydraulicsystems .................40
6 OPERATING INSTRUCTIONS .................44
6.1 Function...................................44
6.2 Regulation .................................44
6.3 Control module ..............................44
6.4 Faultindications.............................47
6.5 Start-up ...................................48
6.6 Shut-down .................................48
6.7 Warnings ..................................48
7 COMMISSIONING........................... 49
7.1 General ...................................49
7.2 Commissioning .............................49
8 MAINTENANCE ............................52
8.1 Safety.....................................52
8.2 General ...................................52
8.3 Procedure .................................52
8.4 Cleaning the burner and heat exchangers .........53
8.5 Cleaning the filter/screen in the gas
combinationblock ...........................54
8.6 Ionisationmeasurement.......................54
8.7 Service....................................54
9 CONVERSION FORMULAE AND FACTORS ......55
SUPPLEMENT .............................58
Edition 3456CV02A, 12-01-2000
XII 3456CV02A

3456CV02A 1
1 INTRODUCTION
1.1 Stokvis.. Since its beginning in 1985, Stokvis has built up a strong
reputation in industry for the development, production and
ISO9002 marketing of gas-fired, high efficiency boilers and water heaters
STOKVIS ENERGY SYSTEMS
1.2 Supplier
1.3 This document
in the 45 to 1189 kW range.
Through their unique construction, these central heating units
and water heaters are 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 technology.
101001AE
96R WALTON ROAD
EAST MOLESEY
SURREY KT8 0DL
Tel.: [phone]
Fax:[phone]
2789CV02/120001EE
This documentation has been compiled to aid the following
target 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.

3456CV02A
2
1.4 Service The Stokvis service department isalwaysavailable for
1.5 General restrictions The application, installation and maintenance of Stokvis
The following aspects of the units are dealt with:
- General description
- Technical specifications
- The facilities necessary for design and installation
- Installation examples
- Maintenance instructions
The operating instructions needed by the user are attached to
the unit; these are also to be found in Section 6.
130001AE
commissioning and for providing service and maintenance. For
details see 1.2.
2789CV02/140001BE
products must always be carried out in accordance with the
requirements (legal or otherwise), specifications and standards
applicable to such installations.
Alldata, information and suggestions provided by Stokvis in
relation to its products are based on careful investigation.
Nevertheless, neither Stokvis nor any other organisation
connected with Stokvis accepts any liability for application,
installation that occurs outside its sphere of influence.
Changes may be incorporated without prior notice.
Stokvis acceptsno obligation toadapt previously
delivered products to incorporate such changes.
2789CV02/150001CE

3456CV02A 3
2 DESCRIPTION
2.1 General The R3400/R3500/R3600SB are environmentally friendly modulat-
The R3400/R3500/R3600SB series have CE approval for the
ing gas fired heating boilers that can vary its output from 25% to
100% of its maximum capacity. The series R3400 consists of 6
types in a range from 657 to 1189 kW.
The series R3500 consists of 5 types in a range from 613 to
1000 kW. The series R3600SB consists of 5 types in a range from
639to 1043 kW.
The units have an extremely low emission of NO and CO, so
x
that this boiler satisfies the most stringent European
requirements.
following countries:
Austria, Belgium, Denmark, France, Germany, Ireland, Italy,
The Netherlands, Spain and the United Kingdom.
The series is registered under the product identification number
0063AR3514.
The units can be supplied either as a standard (category B23)
or a room sealed (categories C53, C33 or C63) appliance.
Working principle and construction
Air is blown into the appliance, as required, by a speed-con-
trolled fan and thoroughly mixed with gas in the correct
proportions.
A temperature controller compares the desired water
temperature with the temperature of the water flow and sends
a signal to the frequency converter to maintain the correct
heating capacity.
The gas/air mixture so formed is passed through a cooled
premix burner and ignited. The premix burner is constructed of
finned bimetallic pipes (internally from stainless steel and
externally from aluminium) with cast iron water headers.
Heat transfer takes place in two or three heat exchangers. The
first heat exchanger is constructed from smooth stainless steel
pipes, while the second heat exchanger is fitted with laser
welded, stainless steel finned pipes. Both heat exchangers are
fitted with cast iron profiled water distribution components
(headers) which guarantee an optimum water flow through the
appliance.
The burner and the heat exchangers are connected in series.

3456CV02A
4
Fig. 4 The Econoflame R3600SB
On the R3600SB the 3rd heat exchanger is built from stainless
steel laser welded fin pipes and is placed directly below the
2nd heat exchanger. The boiler pump ensures the water flow
through the heat exchanger. The complete water flow over the
boiler goes through this 3rd heat exchanger as it is connected
in series with the other heat exchangers.
The R3400/R3500/R3600SB units have a small water capacity so
that they can rapidly adjust to changing conditions. They can be
installed without any restrictions to the return water temperature.
The necessary water flow rate is ensured by the standard pump
delivered with the appliance.
3456CV02/210002AE
Application possibilities
Because of its construction, the R3400/R3500/R3600SB units are
suitable for use in heating systems:
- With a constant supply temperature.
- With a weather dependent heating demand.
- With low temperature condenser systems.
- With optimised condensation.
- With control by means of building optimiser/compensator
system (0-10 Vdc, see 5.3.2 connection terminals).
34CV02/210003AE
*
* The R3400 and R3500 are identical with the exception of the third heat exchanger.

3456CV02A 5
Fig. 5 General survey
2.2 Main components 1 Return connection .18 Condensate collection tank
2 Flue attentuator 19 Flue gas collection chamber
20 Combustion chamber
3 Water flow switch 21 Electrical cable duct
4 Safety valve 22 Condensate discharge
5 Flow connection 23 Gas valve unit
6 Filling/drainage valve 24 Fan
7 Cover 25 Connection box
8 Distribution plate 26 Control panel
9 Burner 27 Casing
10 First heat exchanger 28 Air inlet damper
11 Gas filter 29 Main mixing chamber
12 Second heat exchanger 30 Pilot gas valve
13 Gas train 31 Pilot mixing chamber
14 Frame 32 Boiler pump
15 Water circulation piping A Air
16 Flue gas discharge B Gas
17 Third heat exchanger R3600SB C Flue gas
3456CV02/220001AE D Condensate

3456CV02A
6
2.2.1 Description of The unit is constructed from the following principal
principal components components:
Fan [24]
This consists of a fan casing, a fan impeller and an electric
motor. The fan sucks in combustion air and increases the air
pressure.
Air inlet damper [28]
A specially developed air inlet damper ensures a low noise
level. As an option, this can be provided with an air filter or with
an air inlet opening so that the appliance can function as a
room sealed appliance.
Gas train [13]
The principal component of the gas train is the main gas
valve/proportional pressure regulator [23]. The quantity of gas
is adjusted in proportion to the quantity of air being supplied.
The quantity of air depends on the speed of the fan. The unit is
fitted with a gas filter [11] as standard.
Mixing chamber [29 + 31]
This area is used for the thorough mixing of the gas and the
combustion air. The unit is supplied with a main mixing cham-
ber [29] and a pilot mixing chamber [31]. Both are connected to
the fan.
Burner [9]
After the gas/air mixture has been distributed over the burner
with the aid of a distribution plate [8], the mixture is burned on
the surface of the burner in such a way that the flame is di-
rected downward. The burner is air and water cooled. The
water distribution components are made from cast iron and
have a profile that ensures that an optimum distribution and
flow are obtained.
Heat exchangers [10, 12 and 17]
The primary heat exchanger [10] is constructed from smooth
stainless steel tubes. These transfer most of the heat energy to
the system water. The secondary heat exchanger [12], which
consists of laser welded stainless steel finned tubes, transfers
the remaining heat from the flue gasses to the system water. All
the water distribution components are constructed from cast
iron and have a profile that ensures that optimum distribution
and flow are obtained. The space between the burner and the
secondary heat exchanger forms the combustion chamber.