STOKVIS ENERGY SYSTEMS ECONOFLAME R6000 LMS User manual

ECONOFLAME R6000 LMS
GAS FIRED
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
DOC3070 R6000 BA

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................................. 9
Boiler installation....................................... 10
Connecting the boiler ................................ 11
Commissioning Water and hydraulic system...................... 13
Gas supply ................................................ 14
Condensate connection............................. 14
Flue and air intake connections................. 14
Prepare boiler for first startup.................... 15
Combustion analysis................................. 16
Check water flow ...................................... 17
Check functionality of safety devices ........ 18
Gas tightness check.................................. 18
Boiler shut down........................................ 18
Commissioning protocol............................ 19
Operating instructions Controls .................................................... 20
Display / Programming.............................. 21
Overview of main functions ....................... 22
Maintenance Checklist.................................................... 23
Replacing the electrodes........................... 23
Cleaning the condensate receptacle......... 24
Cleaning and refilling the syphon .............. 24
Inspection of combustion chamber............ 24
Water pressure and quality ....................... 25
Water flow rate.......................................... 25
Combustion analysis................................. 25
Gas pressure............................................. 25
Gas tightness check.................................. 25
Safety devices........................................... 25
Maintenance protocol................................ 26
Lockouts .................................................................. 27
Sensor values .................................................................. 30
Declaration of Conformity .................................................................. 31

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 R6000 boiler. All
activities described in this document
may only be excecuted by authorized
companies.
Changes to this document may be ef-
fected without prior notice. We accept
no obligation to adapt previously deliv-
ered 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 R6000 boiler may be used for heat-
ing and hot water production purposes
only. The boiler should be connected to
closed systems with a maximum tem-
perature of 100ºC (high limit tempera-
ture), 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 install-
ing combustion air and flue gas sys-
tems;
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 R6000 boiler is CE approved and
applies to the following European
standards:
 92 / 42 / EEC
Boiler efficiency directive
 2009 / 142 / EEC
Gas appliance directive
 73 / 23 / EEC
Low voltage directive
 2004 / 108 / EEC
EMC directive
EN 656
Gas-fired central heating boilers –
Type B boilers of nominal heat input
exceeding 70 kW but not exceeding
300 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 13836
Gas fired central heating boilers -
Type B boilers of nominal heat input
exceeding 300 kW, but not exceeding
1000 kW
EN 15502-1
Gas-fired central heating boilers -
Part 1: General requirements and
tests
EN 55014-1 (2000)
Electromagnetic compatibility - Re-
quirements for household appliances,
electric tools and similar apparatus -
Part 1: Emission
EN 55014-2 (1997)
Electromagnetic compatibility - Re-
quirements 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 sub-
ject to conditional connection
EN 60335-1 (2002)
Household and similar electrical appli-
ances - Safety - Part 1: General re-
quirements
EN 60335-2-102 (2006)
Household an similar electrical
appliances: Particular requirements
for gas, oil and solid-fuel burning ap-
pliances having electrical connections

Construction
Layout of boiler
Operating principle
4
Layout of boiler
The R6000 boiler consists of the follow-
ing main components:
1 Casing
2 Front panel
3 Adjustable feet
4 Control panel (below cover)
5 Flue gas connection
6 Air intake connection
(under casing)
7 Gas connection
8 Flow water connection
9 Return water connection
10 2nd (hot) return water connection
(for split system use)
11 Filling/draining valve
12 Electrical input connections
13 Frame
14 Burner/1st heat exchanger
assembly
15 2nd/3rd heat exchanger assembly
16 Water headers
17 Condensate receptacle
18 Whirlwind gas/air mixing system
19 Fan
20 Gas valve
21 Gas pressure switch
22 Inspection opening
23 Ignition and ionisation electrodes
24 Syphon
25 Removable flue gas adapter
Operating principle
The R6000 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 mix-
ing system will adapt the gas ratio to
the chosen fan speed, in order to main-
tain the best possible combustion fig-
ures and therewith the best efficiency.
The flue gases created by the combus-
tion are transported downwards
through the boiler and leave at the back
side into the chimney connection.
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.
The return water from the system en-
ters the boiler in the lower section,
where is the lowest flue gas tempera-
ture in the boiler. In this section con-
densation takes place. The water is
being transported upwards through the
boiler, in order to leave the boiler at the
top (burner) section. The cross flow
working principle (water up, flue gas
down) ensures the most efficient com-
bustion results.
1 5 4 2 7 6
3 8 12 9 10
14 22 23 18, 19, 20, 21 25
13 24 15 16 17 11

Technical data
5
R6142 R6190 R6237 R6285 R6380 R6475 R6539
Nominal heat output at 80/60ºC max/min* kW 142.1/23.3 190.1/39.5 237.2/39.5 285.2/39.5 380.2/76.6 475.3/76.6 539.0/76.6
Nominal heat output at 75/60ºC max/min* kW 142.2/23.5 190.3/39.5 237.4/39.5 285.5/39.5 380.6/76.6 475.8/76.6 539.6/76.6
Nominal heat output at 40/30ºC max/min* kW 150.7/26.7 201.6/45.2 251.4/45.1 302.3/45.2 403.1/87.7 503.9/87.7 571.5/87.7
Nominal heat input Hi max/min* kW 145.0/24.5 194.0/41.5 242.0/41.5 291.0/41.5 388.0/80.5 485.0/80.5 550.0/80.5
Efficiency at 80/60ºC % 98.0
Efficiency at 40/30ºC % 103.9
Annual efficiency (NNG 75/60ºC) % 106.8
Annual efficiency (NNG 40/30ºC) % 110.4
Standstill losses (Twater = 70ºC) % 0.21 0.18 0.17 0.16 0.15 0.14 0.13
Max. condensate flow l/h 11 15 19 22 30 37 42
Gas consumption H-gas max/min (10,9 kWh/m3)m3/h 13.3/2.3 17.8/3.8 22.2/3.8 26.7/3.8 35.6/7.4 44.5/7.4 50.5/7.4
Gas consumption L-gas max/min (8,34 kWh/m3)m3/h 17.4/2.9 23.2/5.0 29.0/5.0 34.9/5.0 46.5/9.7 58.2/9.7 66.0/9.7
Gas consumption LL-gas max/min (8,34 kWh/m3)m3/h 17.4/2.9 23.2/5.8 29.0/5.8 34.9/5.8 46.5/11.2 58.2/11.2 66.0/11.2
Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 11.3/1.9 15.2/3.2 18.9/3.2 22.7/3.2 30.3/6.3 37.9/6.3 43.0/6.3
Gas pressure H-gas mbar 20
Gas pressure L/LL-gas mbar 25
Gas pressure LPG mbar 30/50
Maximum gas pressure mbar 100
Flue gas temperature at 80/60ºC max/min ºC 78/61
Flue gas temperature at 40/30ºC max/min ºC 56/30
Flue gas quantity max/min* m3/h 238/40 318/69 397/69 477/69 636/134 795/134 901/134
CO2level natural gas H/E/L/LL max/min % 10.2/9.4
CO2level liguid gas P max/min % 11.9/10.0
NOx level max/min mg/kWh 35/15
CO level max/min mg/kWh 14/8
Max. permissible flue resistance max/min Pa 160/10 160/10 200/10 200/10 200/10 250/10 250/10
Water volume l 27 31 35 61 68 75 82
Water pressure max/min bar 8/1
Max. water temperature (High limit thermostat) ºC 100
Maximum temperature setpoint ºC 90
Nominal water flow at dT=20K m3/h 6.1 8.1 10.2 12.2 16.3 20.4 23.1
Hydraulic resistance at nominal water flow kPa 10 18 28 15 27 42 55
Electrical connection V 230/400
Frequency Hz 50
Mains connection fuse A 16
IP class - IP20
Power consumption boiler max/min (excl. pump) W 158/43 200/35 230/35 260/35 470/61 650/61 770/61
Power consumption 3-step pump (optional) W 170/90 190/120 380/210 380/210 530/300 720/380 1150/600
Power consumption speed controlled pump (opt) W 180/10 180/10 435/25 435/25 450/25 800/35 800/35
Power consumption bypass pump (optional) W 55/35 85/65 170/90 170/90 190/120 460/225 470/280
Weight (empty) kg 295 345 400 465 535 590 650
Noise level at 1 meter distance dB(A) 59
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063BS3840
Water connections - R2" DN65 PN16
Gas connection - R3/4" R1" R1" R1" R1.1/2" R1.1/2" R1.1/2"
Flue gas connection mm 150 150 200 200 250 250 250
Air intake connection (for room sealed use) mm 130 150 150 150 200 200 200
Condensate connection mm 40 40 40 40 40 40 40
* min load on gasses H/L/LPG. For type R6237-R6539 on gasses LL-Gas min value is 15% higher.

Technical data
6
Dimension R6142 R6190 R6237 R6285 R6380 R6475 R6539
L mm 1105 1260 1470 1220 1435 1585 1735
L2 mm 127.5 127.5 137.5 137.5 187.5 187.5 187.5
H mm 1480 1480 1500 1500 1500 1500 1500
H2 mm 1120 1130 1130 1150 1245 1245 1245
B mm 670 670 670 770 770 770 770
B2 mm 225 235 235 235 215 215 215
B3 mm 260 260 260 310 310 310 310
B4 mm 260 260 260 490 490 490 490
B5 mm 130 130 130 245 245 245 245
D1 mm (Diam.) 130 150 150 150 200 200 200
D2 mm (Diam.) 150 150 200 200 250 250 250
W1 R" / DN R2" R2" R2" DN65 PN16
W2 R" / DN R2" R2" R2" DN65 PN16
G R R 3/4" R 1" R 1" R 1" R 1 1/2"
1 Electrical connections
2 Gas supply
3 Water supply
4 Water return (Cold)
5 Air Intake (under casing)
6 Water 2nd return (Hot)
7 Boiler water drain valve 1/2"
8 Flue gas Outlet
9 Condensate drain
flexible hose 25mm diam.

Extent of delivery
Standard boiler
Accessories
7
Standard boiler
A boiler delivery package contains the
following components:
The above accessories are specially
designed for the R6000boiler and there-
with easy to install (plug and play). By
choosing a combination of the kits men-
tioned above, you can create your own
complete system solution. Ask your
supplier for more detailed information.
Extension module AVS75 for heating
zone control or external gas valve
and/or room fan control.
For each boiler a maximum of 3
AVS75 modules (2x heating zone, 1x
ext. gas valve / room fan) can be inte-
grated in the boiler;
Additional RVS63 heating zone con-
troller, when controlling more than 2
zones (incl. wall hung box, all neces-
sary sensors and sockets and con-
nection material for bus communica-
tion).
Component Pcs. Package
Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border,
sealed in PE foil
Adjustable feet 4 Mounted on frame of the boiler
Syphon for condensate connection 1 Cardboard box on top of heatexchanger
(under casing)
Conversion kit for natural gas L and propane incl. instruction 1 Cardboard box on top of heatexchanger
(under casing)
Operation and Installation manual 1 Map attached to back panel of the boiler
Spare parts list 1 Map attached to back panel of the boiler
Wiring diagram 1 Map attached to back panel of the boiler
Accessories
Additional to the boiler, the following
accessories can be ordered:
Standard 3-step pump incl. connec-
tion kit;
Speed controlled pump incl. connec-
tion kit;
Safety valve, manometer and de-
aerator (3,4,5 or 6 bar) incl. connec-
tion kit;
2x max. water pressure switch and 1
external high limit thermostat incl.
connection kit;
Gas filter incl. connection kit;
Max. gas pressure switch;
External high limit thermostat incl.
connection kit;
Gas valve leakage tester (not possi-
ble for R6142);
Controlled bypass (incl. pump) incl.
connection kit;
Plate heat exchanger (dT=10K/15K or
dT=20K) incl. connection kit;
Low velocity header, suitable for
dT=10K/15K and dT=20K incl. con-
nection kit;
Duo header for connecting 2 boilers
in cascade (excl. connection kit);

Installation
Boiler transport
8
Boiler transport
The R6000 boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The maximum width is
670mm for models R6142-R6237 and
770mm for models R6285-R6539, which
makes it possible to transport all mo-
dels through a normal door in one pie-
ce. The boiler can be transported with a
pallet truck, entering either from the
front or from the side.
Whenever necessary, the boiler can be
dismantled into smaller parts for easier
transport inside the building. The table
below shows the main dismantled parts
with their weight and dimensions.
When the boiler has to be transported
with a crane, it is necessary to remove
the casing before connecting the boiler
to the crane. Always connect the crane
to the frame of the boiler by using
straps.
Component R6142 R6190 R6237 R6285 R6380 R6475 R6539
Burner/1st heat exchanger assembly Weight [kg]
Length [mm]
Width [mm]
Height [mm]
86
735
400
321
100
885
400
321
112
1035
400
321
135
735
680
321
158
885
680
321
181
1035
680
321
198
1185
680
321
2nd/3rd heat exchanger assembly Weight [kg]
Length [mm]
Width [mm]
Height [mm]
90
735
400
244
103
885
400
244
116
1035
400
244
150
735
680
244
170
885
680
244
198
1035
680
244
219
1185
680
244
Condensate receptacle
Weight [kg] Length [mm]
Width [mm]
Height [mm]
7
589
385
225
9
739
385
225
10
889
385
225
11
589
665
225
12
739
665
225
13
889
665
225
15
1039
665
225
Frame
Weight [kg] Length [mm]
Width [mm]
Height [mm]
15
990
624
335
16
1140
624
335
17
1350
624
335
17
1100
724
335
18
1320
724
335
19
1470
724
335
21
1620
724
335
Front U-frame with electronic board Weight [kg]
Length [mm]
Width [mm]
Height [mm]
11
628
1304
202
11
628
1304
202
11
628
1304
202
12
728
1304
202
12
728
1304
202
12
728
1304
202
12
728
1304
202
1 Hoisting belt (4x)
2 Wooden retaining beam (2x)
3 Hoisting belt position (4x)
1
2
3

Installation
Removing the casing
9
Boiler transport
Remove the casing before transporting
the boiler, in order to avoid damage to
the casing parts during transportation.
Removing the casing is done as fol-
lows:
1.
2.
3.
4.
5.
6.

Installation
Boiler installation
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 instal-
lation.
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.
Once the boiler is in the correct positi-
on, the wooden blocks (1) should be
removed and the adjustable feet (2)
(with vibration absorption dampers)
should be adjusted to the right height.
Water and gas connections should be
done after mounting the feet, as they
affect the exact height of all connecti-
ons.
10
1 2 2

Installation
Connecting the boiler
11
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
(under casing)
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 en-
sure that all standards and regulations
are respected.
Hydraulic connections
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 (4) and return (5) con-
nection of the system tension free to
the boiler connections. If the boiler is
used in a system with two return cir-
cuits, the common return becomes the
low temperature return, the 2nd return
connection (6) is the high temperature
return (remove cap/flange before con-
necting).
The (optional) accessory kit with safety
valve, manometer and deaerator
should be mounted on the flow connec-
tion (4) of the boiler, before connecting
to the system.
The (optional) pump kit should be
mounted directly to the return connecti-
on (5) of the boiler, before connecting
to the system.
Condensate connection (8)
After filling with water, the syphon
(included in delivery) should be in-
stalled to the connection at the bottom
of the condensate receptacle. Lead the
hose under the frame at the back of the
boiler and connect it to the draining
system in the boiler room. The connec-
tion to the draining system should al-
ways be done with an open connection,
in order to avoid a flooding of the boiler
in case of a blocked drain.
8
1 3
4 5 6

Installation
Connecting the boiler
12
Gas connection (1)
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 (1) of
the boiler. A gas cock should be moun-
ted directly behind the boiler.
A gas filter can be mounted directly on
the gas connection of the boiler.
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
fluegas 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 fluegas systems
The diameter of the flue gas system
must be chosen by calculation ac-
cording to the national regulations
Construct the flue gas system as
short as possible (for maximum
length see planner documentation)
Construct horizonal ways with a mini-
mum angle of 3º
Air intake connection (3)
The air intake can be connected in
case of room sealed installation. The
cover (3) must be disassembled in order
to connect the air intake piping to the
connector inside the boiler. The diame-
ter should be calculated according to
the national regulations, together with
the flue gas system. The total resistan-
ce of both systems should never over-
come the maximum permissible resis-
tance of the fan inside the boiler (see
also chapter: Technical data).
Electrical connection
The electrical connection must be
madde 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 con-
tact 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 gland(2) from the back of the
boiler boiler into the electro panel
(11).
Connect all wires to the terminals
according to the wiring diagram of the
boiler (enclosed in map attached to
back panel of the boiler).
1 7 3
2
11

Commissioning
Water and hydraulic system
13
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 [dºH]
50 - 200 2.0 11.2
200 - 600 1.5 8.4
Concentrate
Ca(HCO3)2Capacity of installation Q (kW)
150 200 250 300 400 500 600
mol/m3dºH 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
> 1.0 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 be done via the fill and drain
valve (2) on the return connection (1) of
the boiler.
1
2
Hydraulic system
Check if the boiler is hydraulically con-
nected to the system in such way, that
water flow can be secured at all times
during burner operation. The water flow
is supervised by the water flow switch
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 commissio-
ning of the boiler with the standard boi-
ler controller. When an additional sys-
tem controller is installed, please refer
to its manual for commissioning the
controller.
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 R6000 according to the the VDI2035.
The table at the left gives an indication
of the relation between the water quali-
ty and the maximum water filling volu-
me during the lifetime of the boiler.
Consult the original text of the VDI2035
for more detailed information.

Commissioning
Gas supply
Condensate connection
Flue and air intake connections
14
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 con-
densate connection. Fill it with water
and place it back in the original positi-
on. Make sure the syphon is filled
before starting the boiler, in
order to prevent flue gases dischar-
ging 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. Installati-
ons which don’t comply with the regula-
tions, are not allowed to be commissio-
ned.
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
15
1
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 (1);
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.

Commissioning
Combustion analysis
16
Combustion settings
for natural gas G20 / G25
R6142-R6539
CO2, max % 10.2 ± 0.2
COmax ppm < 30
Combustion settings
for LPG G31
Convert boiler before operation
(see coversion kit instruction)
R6142-R6539
CO2, max % 11.9 ± 0.2
COmax ppm < 30
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. Set the minimum
gas pressure switch (1) at 75% of the
required gas pressure.
Check the combustion settings via the
test point in the chimney connection(3).
If necessary, correct the settings with
the flat adjustment screw on the outlet
of the gas valve (2).
Combustion settings
for natural gas G20 / G25
R6142-R6539
CO2, min % 9.4 ± 0.2
COmin ppm < 30
Combustion settings
for LPG G31
Convert boiler before operation
(see coversion kit instruction)
R6142-R6539
CO2, min % 10.0 ± 0.2
COmin ppm < 30
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
allen key adjustment screw on either
side of the gas valve (4).
Combustion check at 50% load
An additional reference check of com-
bustion values at 50% load is recom-
mended in order to check if the gas
valve is set in such way, that the modu-
lating behaviour is normal. The CO2
value 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.
2
4
R6142
R6237-R6539
1
2
4
3

Commissioning
Check water flow
17
qactual = (∆Tnominal / ∆Tmeasured) * qnominal [m3/h]
Water flow data
R6142R6190 R6237 R6285 R6380 R6475 R6539
Nominal flow rate [m3/h] 6.1 8.1 10.2 12.2 16.3 20.4 23.1
∆T at nominal flow rate [ºC] 20
∆p at nominal flow rate [kPa] 10 18 28 15 27 42 55
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 15K and 25K for secure boiler
operation. An indication of the actual
flow rate can be found with the follo-
wing 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 requi-
red). 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
indication of the actual flow rate can be
found with the following calculation (see
table below for nominal data):

Commissioning
Check functionality of safety devices
Gas tightness check
Boiler shut down
18
5
4
6
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.
.
Minimum gas pressure switch (5)
Close the gas cock when the boiler is in
standby position (K). Open the test
point on the gas line (4) while measur-
ing the gas pressure on the test point
of the gas pressure switch (5).
The boiler will go in lockout no. 2 when
the switch off setting is achieved. Close
both test points and open the gas cock.
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 tem-
perature sensor, fluegas temperature
sensor, water flow switch minumum
gas pressure switch and ionisation
electrode. These devices can be
checked as described below.
Ionisation electrode (6)
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 elec-
trode and its electrical connection. The
ionisation current should always be
above 1.2 µA, in normal conditions it
will be 6 µA and above.
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 (7)
Disable power supply to the boiler by
deactivating the mains isolator switch
in the boiler room
Close the gas supply to the boiler.
7
1 2 3

Commissioning
Commissioning protocol
19
Commissioning Protocol R6000
Project
Boiler type Project
Serial number Address
Year City
Nominal load (Hi) [kW] Date
Nominal output (Hi) [kW] Engineer
System
Water pressure [bar] Installati-
on: Roof top 
Water pH E\RWKHUV [-] Ground floor 
Water hardness E\RWKHUV [dºH] Basement 
Water chloride E\RWKHUV [mg/l] Other: ......................... 
Water ∆T full load [ºC] Hydrau-
lics: 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RSWLRQDO[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
20
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 bur-
ner setpoint is 60°C (indicated by span-
ner symbol).
On/off switch (A)
Position 0:
Boiler and connected electrical compo-
nents are notpowered. Frost protection
is not secured.
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 pres-
sing the button once again, or automati-
cally after 15 minutes, the chimney swee-
per mode will be deactivated (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