STOKVIS ENERGY SYSTEMS ECONOFLAME R40 User manual

ECONOFLAME R40
GAS FIRED
WALL MOUNTED
CONDENSING BOILERS
INSTALLATION, OPTIONS & SYSTEMS
DOCUMENTATION
STOKVIS ENERGY SYSTEMS
96R WALTON ROAD
EAST MOLESEY
SURREY
KT8 0DL
TEL: [phone]
FAX: [phone]
E-MAIL: [email protected]
WEBSITE: www.stokvisboilers.com
06/2011AC20111006 DOC2080GB

Contents
2
Gas condensing boiler R40 Models and output ................................................................................................. 4
Application possibilities.......................................................................................... 4
Value propositions ................................................................................................. 4
Description ............................................................................................................ 4
Technical description Technical data ....................................................................................................... 5
Dimensions ............................................................................................................ 6
Declaration of conformity ...................................................................................... 7
Standard boiler ..................................................................................................... 8
Boiler transport ...................................................................................................... 8
Boiler installation ................................................................................................... 8
Norms and regulations Norms .................................................................................................................... 9
Maintenance ........................................................................................................ 10
Fuel ..................................................................................................................... 10
Combustion air .................................................................................................... 10
Water quality ....................................................................................................... 10
Noise protection .................................................................................................. 11
Antifreeze ............................................................................................................ 11
Flue gas system Requirements and regulations ............................................................................. 12
Materials .............................................................................................................. 12
Flue gas data ....................................................................................................... 12
Dimensioning single ............................................................................................ 13
Dimensioning cascade ........................................................................................ 14
Neutralisation General................................................................................................................ 15
Neutralisation systems ........................................................................................ 15
Hydraulic connection Hydraulic resistance ............................................................................................ 16
∆T-measurement ................................................................................................. 16
∆p-measurement ................................................................................................. 16
Hydraulic connection into a system .................................................................... 17
Single .................................................................................................................. 17
Cascade .............................................................................................................. 18
Controls Basic controls and connections ........................................................................... 19
Control by building managemant system............................................................. 19
Boiler enable signal ............................................................................................. 19
Temperature or capacity setpoint ........................................................................ 19
OK/Alarm output signal ....................................................................................... 20
Heating zone control ........................................................................................... 20
Cascade control .................................................................................................. 20

Contents
3
Accessories Single .................................................................................................................. 21
Dimensions single - low loss header ................................................................... 25
Dimensions single - plate heat exchanger ........................................................... 26
Controls ............................................................................................................... 27
Modupak Cascade .............................................................................................. 29
Dimensions cascade - DN65 line + low loss header ............................................ 30
Dimensions cascade - DN100 line + low loss header .......................................... 31
Dimensions cascade - DN65 back-2-back + low loss header .............................. 32
Dimensions cascade - DN100 back-2-back + low loss header ............................ 33
Dimensions cascade - DN65 line + plate heat exchanger ................................... 34
Dimensions cascade - DN65 back-2-back + plate heat exchanger ..................... 35
Installation examples 1-A-C: 1 direct heating zone + low loss header .................................................. 36
2-A-C: 1 mixed heating zone + low loss header ................................................. 37
4-A-C: 2 heating zones + low loss header .......................................................... 38
2-5-A-C: 1 heating zone and sanitary hot water + low loss header .................... 39
4-5-A-C: 2 heating zones and sanitary hot water + low loss header ................... 40
4-5-A-C-E: 2 heating zones and sanitary hot water + cascade via
low loss header .................................................................................................. 41
A-C: Boiler control via 0-10VDC + low loss header ............................................ 42
A-C-E: Boiler control via 0-10VDC + cascade via low loss header ..................... 43
1-B-C: 1 direct heating zone + plate heat exchanger ......................................... 44
2-B-C: 1 mixed heating zone + plate heat exchanger ......................................... 45
4-B-C: 2 heating zones + plate heat exchanger .................................................. 46
2-5-B-C: 1 heating zone and sanitary hot water + plate heat exchanger ............ 47
4-5-B-C: 2 heating zones and sanitary hot water + plate heat exchanger .......... 48
4-5-B-C-E: 2 heating zones and sanitary hot water + cascade via
plate heat exchanger .......................................................................................... 49
B-C: Boiler control via 0-10VDC + plate heat exchanger .................................... 50
B-C-E: Boiler control via 0-10VDC + cascade via plate heat exchanger ............ 51
Extension 2 heating zones ................................................................................. 52
Norms ............................................................................................................................ 53

Gas condensing boiler R40
Models and output
Application possibilities
Value propositions
Description
4
Models and output
The wall hung gas condensing boiler
R40 is available in 5 types within an
output range from 61 until 132 kW.
Application possibilities
The gas condensing boiler R40 is
applicable for all central heating
systems built according to EN12828.
In cascade applications (max. 8 boilers
with LMS14 master/slave cascade
control) the R40 can cover installations
up to 1026 kW.
Preferred applications are central hea-
ting and sanitary hot water production
in multi-family buildings, municipal and
industrial buildings.
Value propositions
Unique high power wall hung boiler
up to 142kW
Unequalled lifetime high efficiency
>110% due to corrosion resistant
stainless steel heat exchanger
Highest system flexibility
easy planning and installation with
Plug & Play cascade accessories
Environmental friendly
lowest emission values
Easy maintenance
boiler design optimised for easy
access on servicing
Description
The R40 is a fully modulating boiler.
The control unit of the boiler adapts the
modulation ratio 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 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.
1
2
4
3
1 Premix burner
2 Stainless steel spiral heat exchanger (double helix)
3 Speed controlled Whirlwind gas/air mixing system
4 LMS14 boiler management unit

Technical description
Technical data
5
R40/65 R40/85 R40/100 R40/120 R40/150
Nominal heat output at 80-60ºC max/min kW 60.8/10.1 81.1/13.4 92.9/15.6 111.6/18.7 132.2/23.3
Nominal heat output at 75-60ºC max/min kW 60.9/10.1 81.3/13.4 93.1/15.6 111.8/18.7 132.5/23.3
Nominal heat output at 40/30ºC max/min kW 63.9/11.1 85.3/14.8 100.0/17.2 120.0/20.6 142.3/25.6
Nominal heat input Hi max/min kW 62.4/10.4 83.3/13.8 95.2/16.0 114.3/19.2 135.5/23.9
Efficiency at 80/60ºC % 97.4 97.4 97.6 97.6 97.6
Efficiency at 40/30ºC % 102.4 102.4 105.0 105.0 105.0
Annual efficiency (NNG 75/60ºC) % 106.2 106.2 106.2 106.2 106.2
Annual efficiency (NNG 40/30ºC) % >110 >110 >110 >110 >110
Standstill losses (Twater = 70ºC) % 0.20 0.20 0.20 0.20 0.20
Max. condensate flow l/h 3.5 4.8 6.4 7.7 9.1
Gas consumption G20 max/min (10,9 kWh/m3)m3/h 5.7/1.0 7.6/1.3 8.7/1.5 10.5/1.8 12.4/2.2
Gas consumption G25 max/min (8,34 kWh/m3)m3/h 7.5/1.2 10.0/1.7 11.4/1.9 13.7/2.3 16.3/2.9
Gas consumption G31 max/min (12,8 kWh/kg) kg/h 4.9/0.8 6.5/1.1 7.4/1.3 8.9/1.5 10.6/1.9
Gas pressure G20 mbar 20 20 20 20 20
Gas pressure G25 mbar 25 25 25 25 25
Gas pressure G31 mbar 30/50 30/50 30/50 30/50 30/50
Maximum gas pressure mbar 50 50 50 50 50
Flue gas temperature at 80/60ºC max/min ºC 76/63 76/63 76/63 76/63 76/63
Flue gas temperature at 40/30ºC max/min ºC 55/39 55/39 55/39 55/39 55/39
Flue gas quantity max/min m3/h 119/19 159/25 178/29 213/35 253/44
CO2level G20/G25 max/min % 8.5/8.5 8.5/8.5 8.7/8.5 8.7/8.5 8.7/8.5
CO2level G31 max/min % -/- -/- -/- -/- -/-
NOx level mg/kWh 39 39 39 39 39
CO level max/min mg/kWh 98/7 98/7 98/7 98/7 98/7
Max. permissible flue resistance max/min Pa 150/15 150/15 150/15 200/15 200/15
Water volume l 4.0 4.7 6.5 8.0 9.4
Water pressure max/min bar 6/1 6/1 6/1 6/1 6/1
Max. water temperature (High limit thermostat) ºC 100 100 100 100 100
Maximum temperature setpoint ºC 90 90 90 90 90
Nominal water flow at dT=20K m3/h 2.6 3.4 4.0 4.8 5.6
Hydraulic resistance at nominal water flow kPa 16 29 15 22 34
Electrical connection V 230 230 230 230 230
Frequency Hz 50 50 50 50 50
Mains connection fuse A 10 10 10 10 10
IP class - IPX4D IPX4D IPX4D IPX4D IPX4D
Power consumption boiler max/min (excl. pump) W 98/26 167/38 195/30 228/36 248/44
Power consumption 3-step pump (optional) W 150 205 150 210 385
Power consumption speed controlled pump (opt) W 124 124 130 130 130
Weight (empty) kg 60 68 80 90 97
Noise level at 1 meter distance dB(A) - - - - -
Ionisation current minimum µA 3 3 3 3 3
PH value condensate - 3.2 3.2 3.2 3.2 3.2
CE certification code -
Water connections - R1.1/4" R1.1/4" R1.1/2" R1.1/2" R1.1/2"
Gas connection - R3/4" R3/4" R1" R1" R1"
Flue gas connection mm 100 100 100 100 130
Air intake connection (for room sealed use) mm 100 100 100 100 130
Condensate connection mm 22 22 22 22 22
CE-0063CM3576

Technical description
Dimensions
6
Dimensions R40/65 R40/85 R40/100 R40/120 R40/150
B mm 490 490 590 590 590
B1 mm 140 140 140 140 190
B2 mm 245 245 295 295 295
D mm 500 500 600 600 600
H mm 810 810 950 950 950
W1 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"
W2 mm R 1 1/4" R 1 1/4" R 1 1/2" R 1 1/2" R 1 1/2"
G mm R 3/4" R 3/4" R 1" R 1" R 1"
F mm 100 100 100 100 130
A mm 100 100 100 100 130

Technical description
Declaration of conformity
7
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 / EEC (EMC directive)
This product is designated with CE number:
CE – 0063CM3576
Kerkrade, 16-11-2010
ing. G.A.A. Jacobs
Managing Director

Technical description
Standard boiler
Boiler transport
Boiler installation
8
Standard boiler
A boiler delivery package contains the
following components:
Component Pcs. Package
Boiler fully assembled and tested 1 Cardboard box on pallet
Mounting bracket incl. mounting material 1 Cardboard box in boiler packaging
Syphon for condensate connection 1 Cardboard box in boiler packaging
Conversion kit for propane incl. instruction 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 1 Map packed in cardboard box in boiler packaging
Boiler installation
The boiler should be positioned in a
frost-proof boiler room. If the boiler
room is on the roof, the boiler itself
may never be the highest point of the
instalation.
When positioning the boiler, please
note the recommended minimum clea-
rance in the picture. When the boiler is
positioned with less free space, mainte-
nance activities will be more difficult.
Boiler transport
The R40 boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The packaging dimensi-
on is 1050x572x575mm for boiler types
65-85 and 1185x674x665mm for boiler
types 100-150, which makes it possible
to transport all models through a
nomal door in one piece.
The R40 can be transported with a
crane, but it has to be ensured that the
boiler is packed and fixed on a pallet.
The straps must be connected to the
pallet.

Norms and regulations
Norms
9
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 such
changes.
Only original spare parts may be used
when replacing components on the
boiler, otherwise warranty will be void.
Application
The R40 boiler may be used for heating
and hot water production purposes
only. The boiler should be connected to
closed systems with a maximum
temperature of 100ºC (high limit
temperature), maximum setpoint
temperature is 90ºC.
Norms and regulations
When installing and operating the
boiler, all applicable norms (European
and local) should be fulfilled:
Local building regulations for
installing combustion air and flue gas
systems;
Regulation for connecting the boiler to
the electrical appliance;
Regulations for connecting the boiler
to the local gas network;
Norms and regulations according to
safety equipment for heating systems;
Any additional local laws/regulations
with regard to installing and operating
heating systems.
Additional national standards
Germany:
RAL - UZ 61 / DIN 4702-8
Switzerland:
SVGW
EKAS-Form. 1942: Flüssiggas-
Richtlinie Teil 2
Vorschriften der kantonalen Instanzen
(z.B. Feuerpoilizeivorschriften)
Netherlands:
GASKEUR BASIS
GASKEUR SV
GASKEUR HR107
Belgium:
HR TOP
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 requirements for condensing
boilers with a nominal heat input
greater than 70 kW but not exceeding
1000 kW
EN 50165
Electrical equipment of non-electric
appliances for household and similar
purposes - Safety requirements
EN 15502-1
Gas-fired central heating boilers -
Part 1: General requirements and
tests
EN 55014-1 (2000)
Electromagnetic compatibility -
Requirements for household appliances,
electric tools and similar apparatus -
Part 1: Emission
EN 55014-2 (1997)
Electromagnetic compatibility -
Requirements for household appliances,
electric tools and similar apparatus -
Part 2: Immunity - Product family
standard
EN 61000-3-2 (2000)
Electromagnetic compatibility (EMC) -
Part 3-2: Limits - Limits for harmonic
current emissions (equipment input
current 16 A per phase)
EN 61000-3-3 (2001)
Electromagnetic compatibility (EMC) -
Part 3-3: Limitation of voltage
changes, voltage fluctuations and
flicker in public low-voltage supply
systems, for equipment with rated
current 16 A per phase and not
subject to conditional connection
EN 60335-1 (2002)
Household and similar electrical
appliances - Safety - Part 1: General
requirements
EN 60335-2-102 (2006)
Household and similar electrical
appliances: Particular requirements
for gas, oil and solid-fuel burning
appliances having electrical
connections

Norms and regulations
Maintenance
Fuel
Combustion air
Water quality
10
Maintenance
Regular maintenance is necessary to
secure a safe and economical
operation of the installation. For the
R40, one annual maintenance visit is
recommended. During this visit, the
proper functioning of the complete hea-
ting system should be checked as well.
Water quality
The lifetime of the complete heating
system is affected by the water quality.
Additional costs for water treatment of
an installation are always lower than
repairing costs for damage created by
poor water quality.
Fuel
The gas condensing boiler R40
is applicable for natural gases G20 and
G25 and for LPG G31. Factory settings
are always done for G20. For other
types of natural gas, a correction can
be made on the gas valve. For LPG, it’s
necessary to change the gas injector
(included in delivery) before operating
the boiler.
The R40 can work with gas pressures
up to 50 mbar. In case of a gas pressu-
re above 50 mbar, a pressure regulator
should be fitted in the gas line.
The gas consumption and gas pressu-
res of the different gases can be found
in the chapter "Technical data".
Combustion air
The gas condensing boiler R40 can be
used in both non-roomsealed and
roomsealed applications. The com-
bustion air to the boiler shouldn’t con-
tain high concentrations of dust and/or
halogen, as they can damage the heat
exchanger surface. Especially in buil-
dings, where chemicals are used, the
combustion air facility should prevent
these chemicals to enter the boiler.
The different room sealed connection
possibilities the R40 is approved for,
can be found in the chapter "Flue gas
system".
The following water quality levels must
be respected at all times for warranty
claiming. Damage to the boiler due to
poor water quality will not be taken
under warranty.
The system should be filled with water
with a PH value between 8,0 and 9,5.
The chloride value of the water should
not exceed 50 mg/l. Entry of oxygen
by diffusion should be prevented at all
times. Damage to the heat exchanger
because of oxygen diffusion will not
be taken under warranty.
Boiler output
[kW]
Max. sum of alkaline earths
[mol/m3]
Max. total hardness
[ºdH]
50 - 200 2.0 11.2
200 - 600 1.5 8.4
Concentrate
Ca(HCO3)2
Capacity of installation Q (kW)
150 200 250 300 400 500 600
mol/m3 ºdH Maximum water (re)fill volume Vmax [m3]
≤0.5 ≤2.8 - - - - - - -
1.0 5.6 - - - - - - -
1.5 8.4 3 4 5 6 8 10 12
2.0 11.2 3 4 5 6 6.3 7.8 9.4
2.5 14.0 1.9 2.5 3.1 3.8 5.0 6.3 7.5
≥3.0 ≥16.8 1.6 2.1 2.6 3.1 4.2 5.2 6.3
In installations with higher water volu-
mes, it’s necessary to respect the maxi-
mum filling and additional volumes with
corresponding hardness values as sta-
ted in the german VDI2035 standard. In
the table you can find the nominal va-
lues for filling and additional water for
the R40 according to the the VDI2035.
The table on the left gives an indication
of the relation between the water
quality and the maximum water filling
volume during the lifetime of the boiler.
Consult the original text of the VDI2035
for more detailed information.
Constant entry of oxygen in the instal-
lation should be avoided. The system
water pressure should be higher than
the atmospheric pressure in all parts of
the installation. Underfloor heating
components without oxygen diffusion
barrier should never be used. When
they’re used anyway, a system
separation (e.g. with plate heat
exchanger) is compulsory.

Norms and regulations
Noise protection
Antifreeze
11
Noise protection
The gas condensing boiler R40 is
equipped with a premix burner. The
noise level of this very quiet premix
burner is extremely low in comparison
to conventional gas burners. Therefore
no further measures have to be taken
for noise protection in the boiler room.
Antifreeze
The R40 can be used with the
antifreeze type Shell Antifreeze
Concentrate. The concentration of the
antifreeze in the system affects the max.
capcity the boiler can work on. The relation
between antifreeze concentration and
capacity reduction of the boiler can be
found in the graph.
Noise created by system components
(e.g. pumps) should be taken care of
with external measures, in case of
higher noise level requirements.
0
10
20
30
40
50
10 15 20 25 30 35 40 45 50 55
Antifreeze [%]
Capacity reduction [%]

Flue gas system
Requirements and regulations
Materials
Flue gas data
12
Boiler
type
Nominal heat
output
Nominal heat
input
Flue gas
connection
CO2
level
Flue gas
temperature
Flue gas
quantity
Max. permissible flue
resistance
kW kW mm % ºC kg/s Pa
max min max min max min max min max min max min
R40/65 60.8 10.1 62.4 10.4 100 8.5 8.5 76 33 0.033 0.005 150 15
R40/85 81.1 13.4 83.3 13.8 100 0.044 0.007 150 15
R40/100 92.9 15.6 95.2 16.0 100
8.7 8.5 76 33
0.049 0.008 150 15
R40/120 111.6 18.7 114.3 19.2 100 0.059 0.010 200 15
R40/150 132.2 23.3 135.5 23.9 130 0.070 0.012 200 15
Requirements and regulations
Regulations for the construction of flue
gas systems are very different for each
country. It should be ensured that all
national regulations with regard to flue
gas systems are respected. The most
important national norms can be found
in the chapter "Norms".
Pay attention to the following
recommendations when dimensioning
a flue gas system:
Only approved flue gas material may
be used.
The flue gas system must be properly
calculated to ensure a safe functioning
of the system.
Flue gas system components should be
removable for maintenance purposes.
Horizontal flue gas ways must be
mounted under an angle of 3º
minimum.
A separate condensate drain for the
chimney is not necessary, as the
condensate can enter the drain via
the syphon connection of the boiler.
The R40 is certified for the flue gas
systems B23 (and B23P for France)
and C13, C33, C43, C53, C63 and
C83.
Materials
Exclusively materials, which are heat
resistant and resistant to flue gases
and aggressive condensate, may be
used. Recommended materials are
plastic (PPS, category T120) or stain-
less steel. Aluminium (only thick wall!)
can also be used (in Germany only
after consulting the chimney sweeper).
The R40 has an integrated high limit
thermostat function for the flue gases.
When the fluegas temperature exceeds
90ºC, the burner is switched off. With
this function, an additional (external)
safety device is not necessary.
Flue gas data

Flue gas system
Dimensioning single
13
Dimensioning
When dimensioning a flue gas system,
it’s necessary to perform a calculation
check of the flue gas system in order to
verify if the choosen system is
applicable.
The following table shows two
examples of possible flue gas systems,
including the maximum possible height
of the system. These examples only
give an indication of the possible
heights, but they cannot be used for
official flue gas layout calculation. Each
flue gas system must be calculated by
an authorized company.
The maximum negative flue gas
pressure, which doesn’t affect the
burner modulation ratio, is 30 Pa. Higher
negative pressure will lead to limitation
of the burner modulation ratio.
The maximum horizontal flue gas way
is 20 m. With horizontal ways longer
than 20 m, a faultless burner start in
cold condition can not be guaranteed.
VERSION 1
Calculation base:
Total connection length in boiler room ≤ 1.5 m;
2x 87°-bend
Maximum permissible height (h) of flue gas
system in m
Boiler type Ø 80
[mm]
Ø 100
[mm]
Ø 110
[mm]
Ø 125
[mm]
Ø 130
[mm]
R40/65 10 65
R40/85 30 51
R40/100 20 34 42 44
R40/120 32 54 68 70
R40/150 18 31 38 40
VERSION 2
Calculation base:
Total connection length in boiler room ≤ 3 m;
4x 87°-bend
Maximum permissible height (h) of flue gas
system in m
Boiler type Ø 80
[mm]
Ø 100
[mm]
Ø 110
[mm]
Ø 125
[mm]
Ø 130
[mm]
R40/65 6 61
R40/85 26 47
R40/100 16 30 38 40
R40/120 28 50 64 66
R40/150 14 27 34 36
Concentric flue gas system
Calculation base: roof or wall terminal
Boiler type 2 bends 90° 4 bends 90°
R40/65 5 2
R40/85 4 1
R40/100 3 -
R40/120 4 2
Maximum permissible length of flue gas
system in m
Concentric flue gas system
The R40 boiler models 65, 85, 100 and
120 can be connected to a concentric
flue gas system.
Via a parallel-to-concentric adapter
(optional) the boiler can be connected
to:
 100/150 concentric system from
Muelink&Grol;
 110/150 concentric system from
Skoberne.
See table for max. permissible flue
lengths.

Flue gas system
Dimensioning cascade
14
Cascade system
For installing the R40 in cascade
installations, dedicated flue systems are
defined and available in 150mm and
200mm diameter, both for line and back
-2-back installations.
The diameter of the horizontal collector
and the vertical chimney depends on
the total heat input of the installation
and the vertical height of the chimney.
The table shows the maximum system
input related to the vertical chimney
length (based on max. 3m horizontal
length after collector) and diameter
(collector/chimney).
Max. boiler input (kW) by vertical chimney length
and diameter (collector/chimney)
Diameter Chimney height
5m 15m 30m
150/150mm 327 313 288
150/200mm 450 412 370
200/200mm 530 500 482
200/250mm 697 675 646
200/300mm 855 835 797
Calculation based on max. 3m horizontal flue
Cascade collector line
Cascade collector back-2-back

Neutralisation
General
Neutralisation systems
15
General
Condensate, created by the
R40, should be drained into the public
draining system. The condensate PH is
between 3.0 and 3.5. National and/or
local regulations have to be checked, in
order to find out whether the
condensate should be neutralised before
entering the public draining system.
Type DN2 DN3
Applicable for [kW] 450 1500
Length [mm] 420 640
Width [mm] 300 400
Height [mm] 240 240
DN1
75
320
200
230
Type HN1.5 HN2.5
Applicable for [kW] 280 540
Length [mm] 410 640
Width [mm] 300 400
Height [mm] 290 240
Power con-
sumption pump
[W] 40 150
Pump head [m] 6 3
HN2.7
750
640
400
320
45
4
Neutralisation systems
The neutralisation systems can be
placed in the bottom section of the boiler.
The delivery of the system contains the
following components:
Granulate for first filling
Connection hoses for inlet and outlet
connection
Boiler connection adapter
For the neutralisation two different
systems are available:
Standard neutralisation system (DN)
The standard neutrlisation system is used, when the public draining connection is
at lower level than the boiler syphon connection.
Neutralisation system with pump (HN)
The neutralisation system with pump is used, when the public draining system is at higher level than the boiler syphon
connection and the condensate needs to be transported to a higher level before draining is possible. The built-in pump
of the neutralisation system takes care of the transport of the condensate.
The maximum amount of condensate
for each boiler type can be found in the
chapter "Technical data".

Hydraulic connection
Hydraulic resistance
∆T-measurement
∆p-measurement
16
Hydraulic resistance
The hydraulic resistance depends on
the flow rate through the boiler and the
boiler type. In the graph the resistance
for a specific flow rate can be found.
The R40 is able to control a speed
controlled pump via a 0-10VDC signal.
It makes the flow rate modulate in pa-
rallel with the burner load. The mini-
mum flow rate, to which the pump is
allowed to modulate with the burner
load, is 30% of the nominal flow rate
through the boiler.
The flow rate through the boiler can
also be checked by calculation. This
can be done with a ∆T as well as a ∆p
measurement.
R40/100-150
R40/65-85
∆T-measurement
Check the temperature difference over
the boiler (∆T flow-return) when the
boiler is running on 100% load. The
nominal ∆T is 20K and must be at least
between 15K and 25K for secure boiler
operation. An indication of the actual
flow rate can be found with the follow-
ing calculation (see table below for
nominal data):
∆p-measurement
Check the pressure difference over
the boiler (∆p flow-return) when the
boiler pump is running (burner on is
not required). The nominal ∆p for
each boiler type can be found in the
table below, actual ∆p must be within:
0.35*Δpnom ≤ ∆p ≤ 1.75*∆pnom. An indi-
cation of the actual flow rate can be
found with the following calculation
(see table below for nominal data):
Water flow data
R40/65 R40/85 R40/100 R40/120 R40/150
Nominal flow rate m3/h 2.6 3.4 4.0 4.8 5.6
∆T at nominal flow rate K 20
∆p at nominal flow rate kPa 16 29 15 22 34
qactual = (∆Tnominal / ∆Tmeasured) * qnominal qactual = √(∆pmeasured / ∆pnominal) * qnominal

Hydraulic connection
Hydraulic connection into a system
Single
17
Hydraulic connection into a system
The R40 must be connected in such a
way, that a minimum flow rate of 30%
of the nominal flow rate can be ensured
at all times, independent from the flow
rate in the secondary system. The R40
can be used in single and cascade
applications, with low loss header or
plate heat exchanger.
Single
By using a low loss header or plate
heat exchanger a minimum flow rate
can be ensured at all times, indepen-
dent from the flow rate in the secondary
system. The boiler pump is available as
a standard 3-step or a speed controlled
version. The speed controlled pump
modulates the flow rate in the primary
system in parallel with the burner load.
This ensures the lowest possible return
temperature to the boiler for high
efficiency usage.
Details of the available pump kits can
be found in the chapter "Accessories".
Single

Hydraulic connection
Cascade
18
Cascade
The R40 is also available with Plug &
Play cascade solutions, which are
applicable for cascade installations up
to 6 boilers in line and up to 8 boilers in
back-to-back.
The cascade solutions are defined both
with low loss header and plate heat
exchanger.
Details of the cascade solutions can be
found in the chapter "Accessories".
Cascade

Controls
Basic controls and connections
Control by building management system
Boiler enable signal
Temperature or capacity setpoint
19
Basic controls and connections
The standard version of the R40 is
equipped with a LMS14 boiler manage-
ment unit. This controller controls both
the burner safety operation and the
temperature regulation of the boiler.
The LMS14 includes the following
functions:
 Weather compensation (with optional
outdoor sensor)
 Connection possibility for external
gas valve and/or room fan. See
chapter "Accessories" for combinations
with an OK/Alarm contact
 Master/Slave cascade control (with
optional BUS communication
modules).
When additional control of secondary
heating zones or cascade systems are
required, the R40 can be extended with
different additional controls.
Explanation of these controls can be
found in the next sections.
Electronic high limit thermostat
Electronic flue gas temperature limiter
Primary boiler pump control (via
relay)
Primary sanitary hot water pump
control
(use of relay necessary when > 1A)
Interlock input
Lockout input
OK/Alarm output signal
Boiler enable signal
0-10VDC temperature or capacity
setpoint (programmable)
Temperature control central heating
via PID controller
Temperature control sanitary hot
water (hot water priority)
Control by building management
system
The R40 can be connected to a
building management system. This
can be done by using (one of) the
following connections:
0
20
40
60
80
100
0246810
[V]
[ºC]
Boiler enable signal, terminals X6-7
and X6-8 (volt free)
The boiler enable signal is provided
with a jumper from the factory. When
connecting to a (volt free!!!) external
signal, the jumper must be removed.
Temperature or capacity setpoint,
terminals X6-1 and X6-2 (0-10VDC)
The R40 can be controlled via a
temperature or capacity setpoint.
The signal values are programmable,
from the factory the contact is
programmed for temperature setpoint
with settings as shown in the graphic.
When controlling the boiler via a
capacity setpoint, it’s highly recommen-
ded to control the primary boiler pump
with the internal pump control of the
LMS14 boiler controller. The minimum
flow rate through the boiler must
be respected at all times. The
nominal ∆T is 20K and should be at
least within 15K-25K at full load to
secure a safe boiler operation.

Controls
OK/Alarm output signal
Heating zone control
Cascade control
20
Heating zone control
The R40 can be extended with an
AVS75 controller for extended heating
zone control. The AVS75 enables
weather compensated operation of one
mixed heating zone.
For room temperature optimisation of
each heating zone, an additional room
unit QAA75 can be connected via bus
connection. The values for the specific
heating zone can then be displayed
and changed on the room unit.
In case of heating systems with more
than two heating zones, an additonal kit
with Logon B G2Z2 controller in a wall
hung box is available. These kits can
be used in a modular way up to a
maximum of 8 heating zones.
See chapter "Installation examples" for
more details regarding connections of
pumps, sensors, etc.
Cascade control
The R40 can be controlled in a cascade
system of maximum 8 boilers. This can
be done by using the integrated Master/
Slave cascade functionality in combina-
tion with an optional BUS communicati-
on device OCI345 (see chapter
"Accessories" for more details).
The LMS14 includes an intelligent
cascade control, which allows free
programming of boiler sequence after
certain hours of operation.
See chapter "Installation examples" for
more details regarding connections of
pumps, sensors, etc.
OK/Alarm output signal, terminals
QX2-4, QX2-3 and QX2-4 (230VAC) or
extension module AVS75 (contact
QX21) when combined with external
gas valve and/or room fan or gas
leakage tester.
The boiler provides, depending on its
status and the setting of the relay
(factory setting = alarm) an OK or alarm
signal at terminal 4 (or QX21).