STOKVIS ENERGY SYSTEMS ECONOFLAME R40 User manual

ECONOFLAME R40
GAS FIRED
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
02/2011.2012.09.01.AC DOC1078/XXXXXXXX

Contents
2
Contents .................................................................. 2
Safety General regulations ................................... 3
Application ................................................. 3
Norms and regulations .............................. 3
Construction Layout of boiler .......................................... 4
Operating principle .................................... 4
Technical data .................................................................. 5
Extent of delivery Standard boiler .......................................... 7
Accessories ............................................... 7
Installation Boiler transport .......................................... 8
Removing the casing ................................. 8
Boiler installation ....................................... 9
Connecting the boiler ................................ 9
Commissioning Water and hydraulic system ...................... 11
Gas supply ................................................ 12
Condensate connection ............................. 12
Flue and air intake connections ................. 12
Prepare boiler for first startup .................... 12
Combustion analysis ................................. 14
Check water flow ...................................... 15
Check functionality of safety devices ........ 16
Gas tightness check .................................. 16
Boiler shut down ........................................ 16
Commissioning protocol ............................ 17
Operating instructions Controls .................................................... 18
Display / Programming .............................. 19
Overview of main functions ....................... 20
Maintenance Checklist .................................................... 21
Replacing the electrodes ........................... 21
Cleaning the condensate receptacle ......... 22
Cleaning and refilling the syphon .............. 22
Inspection of combustion chamber ............ 22
Water pressure and quality ....................... 23
Water flow rate .......................................... 23
Combustion analysis ................................. 23
Gas pressure ............................................. 23
Gas tightness check .................................. 23
Safety devices ........................................... 23
Maintenance protocol ................................ 24
Lockouts .................................................................. 25
Sensor values .................................................................. 28
Declaration of Conformity .................................................................. 29

Safety
General regulations
Application
Norms and regulations
3
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

Construction
Layout of boiler
Operating principle
4
Layout of boiler
The R40 boiler consists of the following
main components:
1 Casing
2 Control panel
3 Flue gas connection (+ test point)
4 Air intake connection (+ test point)
5 Flow water connection
6 Return water connection
7 Gas connection
8 Syphon
9 Input for wiring
10 Connection for safety valve
11 Connection for fill/drain valve
12 Manometer
13 Fan
14 Gas valve
15 Ignition and ionisation electrodes
16 Heat exchanger
17 Inspection window
18 Ignition transformer
19 Electrical input connections
20 Controller
21 Condensate receptacle
Operating principle
The R40 is a fully modulating boiler.
The control unit of the boiler adapts the
modulation ratio automatically to the
heat demand requested by the system.
This is done by controlling the speed of
the fan. As a result, the Whirlwind
mixing system will adapt the gas ratio to
the chosen fan speed, in order to
maintain the best possible combustion
figures and therewith the best efficiency.
The flue gases created by the
combustion are transported downwards
through the heat exchanger
The LMS14 control unit can control the
boiler operation based on:
Boiler control (stand alone operation);
weather compensated operation
(with optional outdoor sensor);
with 0-10V external influence
(temperature or capacity) from a
building management system.
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.
2
4
1
3
5 6
8 7 9
10 11
12
13
14
15
16
17
18
19
20
21
2

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 H-Gas mbar 20 20 20 20 20
Gas pressure G25 L-Gas mbar 25 25 25 25 25
Gas pressure G31 LPG 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
CO2 level G20/G25 max/min % 8.5/8.5 8.5/8.5 8.7/8.5 8.7/8.5 8.7/8.5
CO2 level 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 8.0/1.5 8.0/1.5 8.0/1.5 8.0/1.5 8.0/1.5
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) 56/50 56/50 56/50 56/50 56/50
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 data
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

Extent of delivery
Standard boiler
Accessories
7
Standard boiler
A boiler delivery package contains the
following components:
Extension module AGU2.550 for
heating zone control or external gas
valve and/or room fan control in
combination with an alarm signal.
For each boiler a maximum of 3
AGU2.550 modules (2x heating zone,
1x ext. gas valve / room fan in
combination with alarm) can be
integrated in the boiler;
Additional RVS63 heating zone
controller, when controlling more than
2 zones (incl. wall hung box, all
necessary sensors and sockets and
connection material for bus
communication).
The above accessories are specially
designed for the R40 boiler and
therewith easy to install (plug and play).
By choosing a combination of the kits
mentioned above, you can create your
own complete system solution. Ask your
supplier for more detailed information.
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
Accessories
Additional to the boiler, the following
accessories can be ordered:
Standard 3-step pump incl.
connection kit;
Speed controlled pump incl.
connection kit;
Safety valve, fill/drain valve and
connection for expansion tank;
Set with water (2x) and gas (1x)
cocks;
Gas filter incl. connection kit;
Min. gas pressure switch;
Plate heat exchanger (dT=10K/15K
or dT=20K) incl. connection kit;
Low velocity header, suitable for
dT=10K/15K and dT=20K incl.
connection kit;
Plug & play cascade kit (see Modupak
cascade manual for more details);
Extension module AGU2.551 for
0-10V control of a modulating pump
and/or boiler capacity feedback to a
building management system;
Electrical connection for external gas
valve and/or room fan.

Installation
Boiler transport
Removing the casing
8
Boiler transport
The R40 boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The packaging
dimension is 1050x572x575mm for boiler
types 65-85 and 1185x674x665mm for
boiler types 100-150, which makes it
possible to transport all models through
a nomal door in one piece.
The R40 can be transported with a
crane, but it has to be ensured that the
boiler is packed and fixed on a pallet.
The straps must be connected to the
pallet.
Removing the casing
Remove the casing before installing the
boiler, in order to avoid damage to the
casing parts. Removing the casing is
done as shown on the pictures.
1
2
3
4

Installation
Boiler installation
Connecting the boiler
9
Boiler installation
The boiler should be positioned in a
frost-proof boiler room. If the boiler
room is on the roof, the boiler itself may
never be the highest point of the
installation.
When positioning the boiler, please
note the recommended minimum clea-
rance in the picture. When the boiler is
positioned with less free space, mainte-
nance activities will be more difficult.
Connecting the boiler
This chapter will explain how to make
all connections to the boiler with regard
to:
Hydraulic connections
Condensate drain connection
Gas connection
Flue gas connection
Air intake connection
Electrical connection
The boiler should always be connected
in such a way, that the system applies
to all relevant standards and regulati-
ons (European, national and local).
It's the responsibility of the installer to
ensure that all standards and
regulations are respected.
Hydraulic connections (1,2,3,4)
The boiler should always be connected
in such a way, that water flow through
the boiler can be ensured at all times.
Connect the flow (1) and return (2)
connection of the system tension free
to the boiler connections.
The boiler contains a connection
possibility for an (optional) kit with safety
valve, fill/drain valve and an expansion
tank connection. The safety valve must
be connected to the flow connection (3)
of the boiler, the fill/drain valve and
expansion tank connection must be
connected to the return connection (4).
The (optional) pump kit should be
mounted directly to the return
connection (2) of the boiler, before
connecting to the system.
Condensate connection (5)
After filling with water, the syphon
(included in delivery) should be
installed to the connection (5) at the
bottom of the boiler. Connect the hose
to the draining system in the boiler room.
The connection to the draining system
should always be done with an open
connection, in order to avoid a flooding
of the boiler in case of a blocked drain.
Gas connection (6)
The gas connection must be made by
an authorized installer in accordance
with the applicable national and local
standards and regulations.
Connect the gas line from the system
tension free to the gas connection (6) of
the boiler. A gas cock should be
mounted directly behind the boiler.
A gas filter can be mounted directly on
the gas connection of the boiler.
1 2
5 6
3 4

Installation
Connecting the boiler
10
Flue gas connection (7)
Regulations for the construction of flue
gas systems are very different for each
country. It should be ensured that all
national regulations with regard to flue
gas systems are respected.
Connect the flue gas system to the flue
gas connection (7) of the boiler, use
flue gas systems with seamless connec-
tions only. It’s not necessary to make a
separate condensate drain for the flue
gas system, as the condensate will be
drained via the syphon of the boiler.
Please note the following issues:
It’s recommended to use stainless
steel or PPS flue gas systems
The diameter of the flue gas system
must be chosen by calculation
according to the national regulations
Construct the flue gas system as
short as possible (for maximum
length see Options manual)
Construct horizonal ways with a
minimum angle of 3º
Air intake connection (8)
The air intake can be connected in
case of room sealed installation. The
diameter should be calculated according
to the national regulations, together
with the flue gas system. The total
resistance of both systems should never
overcome the maximum permissible
resistance of the fan inside the boiler
(see also chapter: Technical data).
Electrical connection
The electrical connection must be
made by an authorized installer in
accordance with the applicable
national and local standards and
regulations.
For the power supply it’s necessary
to use a mains isolator switch with a
contact opening of at least 3 mm
within the boiler room. This switch
can be used to switch off the power
supply for maintenance purposes.
All cables should be lead through the
cable glands (9) at the bottom of the
boiler into the electro panel (10).
Connect all wires to the terminals
according to the wiring diagram of the
boiler (enclosed in map in boiler
packaging).
8
7
10
9
Outside sensor mounting
If an outside sensor (accessory) is
connected to the boiler, the sensor
should be positioned as shown on the
drawing.

Commissioning
Water and hydraulic system
11
Water quality
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
Minimum operating
pressure
[bar]
Flow tempe-
rature
[ºC]
> 1.5 90
> 1.5 80
Water pressure
Open the valves to the system. Check
the water pressure in the system. If the
water pressure is too low (see table
below), increase the pressure up to at
least the minimum required water
pressure in the table.
Filling can eventually be done via the
(optional) fill and drain valve (2) on the
return connection (1) of the boiler.
Hydraulic system
Check if the boiler is hydraulically
connected to the system in such way,
that water flow can be secured at all
times during burner operation. The water
flow is supervised by ∆T-protection in the
boiler and a lack of flow will lead to a
direct burner stop and lockout of the
boiler.
Commissioning of the boiler should be
carried out by authorized personnel
only. Failure to respect this condition
makes the guarantee void. A protocol
of the commissioning should be filled
out (see end of this chapter for example
of commissioning protocol).
This chapter explains the
commissioning of the boiler with the
standard boiler controller. When an
additional system controller is installed,
please refer to its manual for
commissioning the controller.
In installations with higher water
volumes, it’s necessary to respect the
maximum filling and additional volumes
with corresponding hardness values as
stated in the german VDI2035 standard.
In the table you can find the nominal
values for filling and additional water for
the R40 according to the the VDI2035.
The table at 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.
1
2

Commissioning
Gas supply
Condensate connection
Flue and air intake connections
12
Gas supply
Check the gas supply connection to the
boiler for tightness. If any leakage is
found, reseal the leakage before
starting the boiler!
Remove any air between the gas valve
and the gas line. This can be done at
the test point (1) at the gas pressure
switch. Don’t forget to close the test
point afterwards!
Check the gas type and values with the
local gas company, in order to know for
which gas type the boiler should be
commissioned.
Consult the conversion kit instruction if
the boiler is to be installed with natural
gas L or LPG.
Condensate connection
Remove the syphon (2) from the
condensate connection. Fill it with water
and place it back in the original
position. Make sure the syphon is filled
before starting the boiler, in
order to prevent flue gases discharging
through the condensate connection!
Flue and air intake connections
Check whether the flue and air intake
systems are made according to the
national and local regulations.
Installations which don’t comply with the
regulations, are not allowed to be
commissioned.
Make sure that all connections are free.
The size of flue gas and air intake
connections may not be reduced.
1
2

Commissioning
Prepare boiler for first startup
13
M
H
B C D E F
I
L
G
A
Legend:
A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I Operation mode heating zone(s)
L Display
M Operation mode DHW
Preparation for first startup
Open the gas supply;
Enable the power supply to the boiler;
Switch on the boiler with the on/off
switch (A);
Make sure the boiler is in standby
mode (K);
Check the pump operation: make
sure the pump runs in the right
direction;
Release all air from the pump motor.
It‘s recommended to put the boiler on
50% load after the first startup, as this
is the best starting point to do a proper
combustion analysis. This can be done
with the following procedure:
Push button I >3 Sec, the boiler goes
into controller Stop mode.
Push the Info button (G), the actual
boiler load (%) appears in the display;
Choose "set up" (confirm with OK
button), now the boiler load can be
changed by rotating the wheel (C)
and confirming the 50% setting with
the OK button.
After checking the combustion values
(see next page), the controller Stop
mode can be stopped by pushing the
control mode button (I) >3 Sec.
A

Commissioning
Combustion analysis
14
Combustion check at full load
Start the boiler in controller stop mode
and go to 50% load. Now the boiler
operates at 50% load. Allow the boiler
to stabilise the combustion for 3
minutes. Then increase the boiler load
step by step up to 100%. Check the
gas pressure on the inlet of the gas
valve while increasing the boiler load:
the gas pressure should never go
below the minimum required value 
see technical data. When an (optional)
minimum gas pressure switch is
connected, this must be set to 75% of
the required gas pressure.
Check the combustion settings via the
test point in the chimney connection
(1). If necessary, correct the settings
with the small adjustment screw at the
top of the gas valve (2).
Combustion check at minimum load
Switch the boiler to minimum load (0%).
Check the combustion settings the
same way as described for full load. If
necessary, correct the settings with the
large adjustment screw at the top of the
gas valve (3).
Combustion check at 50% load
An additional reference check of
combustion values at 50% load is
recommended in order to check if the
gas valve is set in such way, that the
modulating behaviour is normal. The
CO2value should be in between the
settings of full load and minumum load.
CO value should be equal to full load
and minimum load values.
Make sure that the boiler is set to
automatic operation and controller stop
mode is disabled after the combustion
test is finished.
1
2 3
Combustion settings max. load
for natural gas G20 / G25
R40/100-150
CO2, max % 8.7±0.2
COmax ppm < 70
R40/65-85
CO2, max % 8.5±0.2
COmax ppm < 70
Combustion settings min. load
for natural gas G20 / G25
R40/65-150
CO2, min % 8.5 ± 0.2
COmin ppm < 30

Commissioning
Check water flow
15
qactual = (∆Tnominal / ∆Tmeasured) * qnominal [m3/h]
Check water flow
The water flow through the boiler can
be checked with two different methods
shown below.
∆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 10K and 20K for secure boiler
operation. An indication of the actual
flow rate can be found with the
following calculation (see table below
for nominal data):
qactual = √(∆pmeasured / ∆pnominal) * qnominal [m3/h]
∆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:
1.0*Δpnom ≤ ∆P ≤ 4.0*∆pnom . An
indication 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 [ºC] 20
∆p at nominal flow rate [kPa] 16 29 15 22 34

Commissioning
Check functionality of safety devices
Gas tightness check
Boiler shut down
16
Flow temperature sensor (1)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 20.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Return temperature sensor (2)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 40.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Flue gas temperature sensor (3)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 28.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Ionisation electrode (4)
Remove electrical connection from the
ionisation electrode while the boiler is
running, the boiler will go in lockout no.
128. The boiler will try to restart. With
the electrical connection removed, the
restart will result in lockout no. 133.
When the connection is already
mounted, the restart will be successful.
Measuring the ionisation current can
be done by mounting a multi-meter (set
to µA) in between the ionisation
electrode and its electrical connection.
The ionisation current should always
be above 1.2 µA, in normal conditions
it will be 6 µA and above.
Check functionality of safety devices
All safety devices have to be checked
on good functioning. Safety devices on
a standard boiler are a water flow
temperature sensor, water return
temperature sensor, flue gas
temperature sensor and ionisation
electrode. These devices can be checked
as described below.
Gas tightness check
Check the gas tightness of all sealed
connections with an approved soap or
electronic gas analyzer, for example:
Test points;
Bolt connections;
Gaskets of mixing system, etc.
Boiler shut down
When the boiler will not be used for
longer periods, shut down the boiler by
following procedure:
Switch the boiler in standby operation
(K);
Switch off the boiler with the on/off
switch (5);
Disable power supply to the boiler by
deactivating the mains isolator switch
in the boiler room;
Close the gas supply to the boiler.
1
2
3
4
5

Commissioning
Commissioning protocol
17
Commissioning Protocol R40
Project
Boiler type Project
Serial number Address
Year City
Nominal load (Hi) [kW] Date
Nominal output (Hi) [kW] Engineer
System
Water pressure [bar] Installation: Roof top 
Water pH [-] Ground floor 
Water hardness [ºdH] Basement 
Water chloride [mg/l] Other: ......................... 
Water ∆T full load [ºC] Hydraulics: Low velocity header 
Water ∆pboiler [kPa] Plated heat exchanger 
Water flow [m3/h] Bypass boiler 
Pump setting [-] Other: ......................... 
Safety devices
High limit setting [ºC] Water flow sensor checked 
Temp. limiter setting [ºC] Fluegas sensor checked 
Min. gas pressure switch setting [mbar] Water flow switch checked 
Ignition time burner [sec]
Combustion analysis
100% load 50% load Min. load
Gas consumption [m3/h] [m3/h] [m3/h]
Gas pressure [mbar] [mbar] [mbar]
CO2 [%] [%] [%]
O2 [%] [%] [%]
CO [ppm] [ppm] [ppm]
NOx [ppm] [ppm] [ppm]
Tatmospheric [ºC] [ºC] [ºC]
Tfluegas [ºC] [ºC] [ºC]
Twater, flow [ºC] [ºC] [ºC]
Twater, return [ºC] [ºC] [ºC]
Ionisation current [µA] [µA] [µA]
pfan [mbar] [mbar] [mbar]
ptop panel [mbar] [mbar] [mbar]
pcombustion chamber [mbar] [mbar] [mbar]
Remarks

Operating instructions
Controls
18
Confirmation (OK) (D)
Return (ESC) (B)
These buttons are used for program-
ming in combination with the wheel.
By pressing the ESC button it‘s possible
to go back one level, changed values
are not taken over by the controller.
By pressing the OK button it‘s possible
to arrive in the next level or confirm
changed values.
Manual mode (E)
This button is used for switching the
boiler into manual mode. In manual
mode all pumps will run and the mixing
valves are no longer controlled, the
burner setpoint is 60°C (indicated by
spanner symbol).
On/off switch (A)
Position 0:
Boiler and connected electrical
components are no powered. Frost
protection is not secured.
Position I
Position I:
The boiler and connected electrical
components are powered and standby
for operation.
Operation mode DHW (M)
For switching on the DHW operation
(indication in display below DHW
symbol)
Operation mode heating zone(s) (I)
For setting 4 different heating modes:
Auto (clock): Automatic operation by
time programm
Comfort (sun): 24/7 heating in comfort
mode
Reduction (moon): 24/7 heating in
reduced mode
Standby: heating off, frost protection
activated.
Display (L)
Info mode (G)
Display possibility of following info
without influence on boiler control:
temperatures, operation mode
Heating / DHW, error code.
Room temperature control (C)
 for changing room comfort
temperature
 for changing settings when
programming.
Deaeration mode (E)
By pressing the manual mode button
longer than 3 seconds, the automatic
hydraulic deaeration is activated. During
deaeration the system is put in standby
mode
The pumps are switched on and off for
several times.
After deaeration, the boiler automatically
returns to normal operation.
Chimney sweeper mode (F)
Used for combustion analysis. By
pressing the button once again, or
automatically after 15 minutes, the
chimney sweeper mode will be deactiva-
ted (indicated by spanner symbol).
Reset button (H)
By shortly pressing the reset button a
burner lockout can be cancelled.
M
H
B C D E F
I
L
G
A
Legend:
A On/off switch
B Return (ESC)
C Room temperature control
D Confirmation (OK)
E Manual mode
F Chimney sweeper mode
G Info mode
H Reset button
I Operation mode heating zone(s)
L Display
M Operation mode DHW

19
Operating instructions
Display / Programming
- gewünschtes Menü
auswählen
- mit Taste OK bestätigen
- mit Taste ESC zurück
zur Grundanzeige
- gewünschte Benutzer-Ebene auswählen
- mit Taste OK bestätigen
- gewünschtes Menü auswählen
- mit Taste OK bestätigen
- mit Taste ESC zurück zur Grundanzeige
DHW mode selection
Heating operation mode selection
(Controller Stopp mode when
pressing > 3 sec.)
Display
Info button
Confirm
Manual mode
(Deaeration mode when pressing
> 3 sec.)
Chimney sweeper mode
Enduser
- choose menu
- confirm with OK button
- choose parameter
- confirm with OK button
- change value + - with wheel
- confirm with OK button
- return to main menu with ESC button
Commissioning Expert
- choose user level
- confirm with OK button
- choose menu
- confirm with OK button
- choose parameter
- confirm with OK button
- change value + - with wheel
- confirm with OK button
- return to main menu with ESC button
Programming
Select
(turn left/right)
Quit menu
Reset
Press OK (1x)
Press OK (1x)
Press INFO (4 sec.)
Default mode
(buttons)
Heating to comfort setpoint Info level activated
Heating to reduced setpoint Programming
activated
Heating for frost protection setpoint Heating
temporarily switched off
Process running – please wait ECO function
active
Burner operating (only oil / gas boiler)
Error messages
Info level activated
Programming activated
Heating temporarily switched off
ECO function active
Holiday function active
Reference to heating circuit
Maintenance / special operation
Parameter number

20
Operating instructions
Overview of main functions
Button Action Procedure Display / Function
Set room temperature
Zone 1 and zone 2
Actuate wheel left/right
Turn wheel
Confirm with OK button
or wait 5 sec.
or press
Comfort setpoint with blinking temperature
Blinking temperature in 0,5 °C steps from 10 to 30 °C
Comfort setpoint saved
Comfort setpoint cancelled
- after 3 sec. Main menu appears
Set room temperature for
zone 1 or zone 2
Zone 2 independent from zone 1
Actuate wheel left/right
Confirm with OK button
Actuate wheel left/right
Confirm with OK button
or wait 5 sec.
or press
Choose heating zone
Heating zone is chosen
Blinking temperature in 0,5 °C steps from 10 to 30 °C
Comfort setpoint saved
Comfort setpoint cancelled
- after 3 sec. Main menu appears
Switch on /off DHW ope-
ration
Press button DHW mode on / off
(see indication below DHW symbol)
- On: DHW mode by time program
- Off: no DHW operation
- Safety functions activated
Change heating operation
mode
Factory setting
Press button 1x
Press button 1x again
Press button 1x again
Automatic mode on, with:
- Heating by time program
- Temperature setpoint by heating program
- Safety functions activated
- Summer/Winter automatic switching activated
- ECO-functions activated
(see indication below operation symbol)
Continuous COMFORT heating on, with:
- Heating without time program by comfort setpoint
- Safety functions activated
Continuous REDUCED heating on, with:
- Heating without time programmby reduced setpoint
- Safety functions activated
- Summer/Winter automatic switching activated
- ECO-functions activated
Safety mode on, with:
- Heating off
- Temperature by frost protection
- Safety functions activated
Controller Stop mode Press button > 3 sec.
Press button > 3 sec. again
304: Controller Stop mode insert setpoint
after 3 sec. Main menu appears
Info display
Press button 1x
Press button 1x again
Press button 1x again
…..
Press button 1x
INFO Segment displayed
- Status Boiler - room temperature
- room temperature minimum
- Status DHW - room temperature maximum
- Status zone 1 - outside temperature
- Status zone 2 - outside temperature minimum
- outside temperature maximum
- Time / Date - DHW temperature 1
- Error indication - Boiler temperature
- Maintenance indication - Flow temperature
(Info display depends on configuration)
Back to main menu; INFO Segment disappears
Operation by manual
setpoint
Change factory setting
boiler temperature
Press button 1x
Press button
Press button
Turn wheel -/+
Press button
Press button
Press button
Manual mode on (spanner symbol appears)
- Haeting by fixed setpoint
(factory setting = 60 °C)
301: Manual mode insert setpoint?
blinking temperature
set value
Status boiler
Manual mode off (spanner symbol disappears)
Deaeration Press button > 3 sec.
Press button > 3 sec. again
312: Deaeration on
Deaeration off
Activate chimney sweeper
mode
Press button (< 3 sec.)
Press button again (< 3 sec.)
Chimney sweeper mode on
Chimney sweeper mode off
Temporary reduction of
reduced temperature on
QAA75
Press button
Press button again
Heating by reduced setpoint
Heating by comfort setpoint
RESET Reset button Press button (< 3 sec.)
Press button again > 3 sec.
Boiler manually blocked, no release
Boiler released, Alarm symbol disappears
= confirmation
= cancel, return to main
menu