STOKVIS ENERGY SYSTEMS ECONOFLAME R6000 User manual

ECONOFLAME R6000
GAS FIRED CONDENSING BOILERS
(KM628 CONTROLLER)
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
03/2008 DOC0260 0410AC

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 Main menu (operating mode) .................... 20
Parameter menu........................................ 20
(information/programming mode) ..............
Changing parameter values....................... 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 .................................................................. 26
Declaration of Conformity .................................................................. 27

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 Econoflame 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 Econoflame R6000 boiler may be
used for heating and hot water pro-
duction 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 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
Austria:
− ÖVGW
Netherlands:
− NOx staatsblad 344 (1994)
− GASKEUR BASIS
− GASKEUR SV
− GASKEUR HR107
Belgium:
− HR TOP
The Econoflame R6000 boiler is
CE approved and applies to the
following European standards:
− 92 / 42 / EEC
Boiler efficiency directive
− 90 / 396 / EEC
Gas appliance directive
− 73 / 23 / EEC
Low voltage directive
− 89 / 336 / 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
Electromagnetic compatibility - Re-
quirements for household appliances,
electric tools and similar apparatus -
Part 1: Emission
− EN 55014-2
Electromagnetic compatibility - Re-
quirements for household appliances,
electric tools and similar apparatus -
Part 2: Immunity - Product family
standard
− EN 61000-3-2
Electromagnetic compatibility (EMC) -
Part 3-2: Limits - Limits for harmonic
current emissions (equipment input
current 16 A per phase)
− EN 61000-3-3
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
Household and similar electrical appli-
ances - Safety - Part 1: General re-
quirements
− EN 50165
Household and similar electrical appli-
ances - Safety - Part 2-102: Particular
requirements for gas, oil and solid-
fuel burning appliances having
electrical connections

Construction
Layout of boiler
Operating principle
4
Layout of boiler
The Econoflame R6000 boiler
consists of the following main
components:
1 Casing
2 Front panel
3 Adjustable feet
4 Control panel (below cover)
5 Flue gas connection
6 Air intake connection
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 Water flow switch
22 Gas pressure switch
23 Inspection opening
24 Ignition and ionisation electrodes
25 Syphon
26 Removable flue gas adapter
Operating principle
The Econoflame 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
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 boiler and
leave at the back side into the chimney
connection.
The KM628 control unit can control the
boiler operation based on:
• fixed temperature (stand alone opera-
tion);
• weather compensated operation (with
optional controller);
• 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 12 6
3 8 9 10
21 14 23 24 18, 19, 20, 22 26
13 25 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 10
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 R6190-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
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:
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;
• Electronic kit for possibility to connect
room fan and/or external gas valve;
• 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;
The above accessories are specially
designed for the R6000 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.
• Duo header for connecting 2 boilers
in cascade (excl. connection kit);
• Weather compensated controller, also
suitable as room unit (incl. all necas-
sary sensors and sockets).;
• Additional heating zone controller,
when controlling more than 2 zones
(incl. wall hung box, all necessary
sensors and sockets and connection
material for bus communication).
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
Integrated additional system controller , incl. all necessary
sensors and sockets (optional) 1 Integrated in electronic switchboard of the boiler. Sensors and sockets in cardboard box on top of
the heatexchanger (under casing).

Installation
Boiler transport
8
Boiler transport
The Econoflame 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-R66539, which makes it
possible to transport all models through
a normal door in one piece. 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
follows:
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
installation.
When positioning the boiler, please
note the recommended minimum
clearance in the picture. When the
boiler is positioned with less free space,
maintenance activities will be more
difficult.
Once the boiler is in the correct
position, 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
connections.
10
1 2 2

Installation
Connecting the boiler
11
1 2 3
4 5 6
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
regulations (European, national and
local). It’s the responsibility of the
installer to ensure 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)
connection of the system tension free
to the boiler connections. If the boiler is
used in a system with two return
circuits, the common return becomes
the low temperature return, the 2nd
return connection (6) is the high
temperature return (remove cap/flange
before connecting).
The (optional) accessory kit with safety
valve, manometer and deaerator
should be mounted on the flow
connection (4) of the boiler, before
connecting to the system.
The (optional) pump kit should be
mounted directly to the return
connection (5) of the boiler, before
connecting to the system.
Condensate connection (7)
After filling with water, the syphon
(included in delivery) should be
installed 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 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.
7

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
mounted 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
connections 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 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).
When the boiler is installed in a non
room sealed situation, a vertical air
intake with an air entry above boiler
level should be connected to the boiler.
Electrical connection
The electrical connection must be
made by an authorized installer in ac-
cordance 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.
Insert all cables through the cable
glands at the back of the boiler (10)
and guide them through the cable
tray (11) into the electrical panel at
the front of the boiler (12).
Connect all wires to the terminals
according to the wiring diagram of the
boiler (enclosed in map attached to
back panel of the boiler).
12
11
10
1 2 7 3

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 oxygene
by diffusion should be prevented at all
times. Damage to the heat exchanger
because of oxygene 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
temperature
[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 pres-
sure 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
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 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
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 R6000according 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.

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
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.
2
1

Commissioning
Prepare boiler for first startup
15
Prepare boiler for first startup
• Open gas connection;
• Switch on mains isolator switch for
power supply to the boiler;
• Switch on boiler with on/off switch (1)
• Make sure the boiler remains in
standby operation K(2)
use rotational switch (3);
• Check the pump operation: make
sure that the direction of the rotation
is correct;
• Remove any air from the pump by
removing the end cap of the pump
motor housing.
It’s recommended to keep the boiler at
50% load for a while after the first
startup, as this is the easiest base for
starting the combustion analysis. This
can be assured as follows:
• Open the lid of the boiler controller;
• Use rotational switch (3) for going to
parameter P9 in the menu;
• Change P9 (5) into 50% (push pro-
gramming button (4), change value
with rotational switch (3), push pro-
gramming button (4) to confirm);
• Close the lid of the boiler controller.
1
2
3
3
4
5

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 at service mode for full
load operation (W2). When you have
reduced P9 to 50% (see previous chap-
ter), the boiler will operate at 50% load.
Allow the boiler to stabilise the combu-
stion for 3 minutes. Then increase P9
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 be-
low the minumum required value Î
see technical data. Set the minimum
gas pressure switch (1) at 50% 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 service mode for
minimum load operation (W1). 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
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 parameter P9 is set back to
100 and switch the boiler to automatic
operation (F) after the combustion test
is finished.
2
4
R6142
R6190 - R6539
1
2
4
3

Commissioning
Check water flow
17
qactual = (∆Tnominal / ∆Tmeasured) * qnominal [m3/h]
qactual = √(∆pmeasured / ∆pnominal) * qnominal [m3/h]
Water flow data
R6142 R6190 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
following 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
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
7
3 1 2
5
4
6
Water flow temperature sensor (1)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 12.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Flue gas temperature sensor (2)
Disconnect the plug from the sensor
while the boiler is switched on. This
should result in a lockout no. 13.
The lockout should disappear as soon
as the plug is placed back in position,
the boiler will restart.
Water flow switch (3)
Close (slowly!) the valve in the flow
connection to the system while the
boiler is running on minimum load.
When the valve is almost closed and
the water flow is insufficient, the water
flow switch will switch off and the
boiler will go in lockout 40. Open the
valve. A manual reset is necessary.
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.5. The boiler will try to restart. With
the electrical connection removed, the
restart will result in lockout no. 4. 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.
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.

Commissioning
Commissioning protocol
19
Commissioning Protocol Econoflame R6000
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 [dºH] Basement 
Water chloride [mg/l] Other: ......................... 
Water ∆T full load [ºC] 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]
Parameter settings
P1 Setpoint temperature heating [ºC] P12 Boiler hysteresis [ºC]
P2 Setpoint temperature DHW [ºC] P17 Fan speed min. load [%]
P11 Maximum boiler setpoint [ºC] P19 Fan speed 100% load [%]
Remarks
Hydraulics:

Operating instructions
Main menu (operating mode)
Parameter menu (information/programming mode)
20
The boiler controller has two menus: the main menu (operating mode) when the lid is closed, and the parameter menu
(information/programming mode) when the lid is open. Both menus and possibilities are explained in the next paragraphs.
Main menu (operating mode) Îlid closed
With the lid closed and by using the rotational switch (1) clockwise or anticlockwise
the boilers’ operating mode (2) can be set. The available modes are:
KStandby mode (only frost protection)
FAutomatic operation mode (heating and DHW)
FSummer mode (only DHW, no heating)
W1 Service mode minimum load
W2 Service mode full load (limited by P9)
Besides the operating mode, the display also shows the actual water flow
temperature (3) and, in case of a lockout, a warning triangle (4) combined with a
lockout code (5). The explanation of the lockout codes can be found in chapter
“Lockouts”.
Parameter menu (information/programming mode) Îlid open
With the lid open and by using the rotational switch (1) clockwise or anticlockwise
it’s possible to read/change certain values/parameters from the boiler controller.
An arrow at the bottom of the display (2) indicates which parameter has been
selected. The available values/parameters are:
P1 Actual / setpoint water flow temperature [ºC]
P2 Actual / setpoint DHW temperature [ºC]
P3 Actual temperature/capacity setpoint for boiler [ºC]*
P4 --
P5 Actual outside temperature [ºC] (if sensor is connected)
P6 Actual fluegas temperature [ºC]
P7 --
P8 Actual low velocity header temperature [ºC] (if sensor is connected)
P9 Actual / Limit boiler output [%]
P10 Password for advanced settings
• Press the reset/programming button
to select (the LED lights up)
• Turn the rotational switch until the
desired DHW setpoint value has been
reached
• Press the reset/programming button
to confirm (the LED goes out)
• Close the lid.
Output indications
Power to main gas valve
Power to ignition transformer
Fan control signal
ZPower to primary boiler pump
FPower to DHW pump/diverter valve
Behind the lid you find an optical I/O
connection (6), a reset/programming
button (7) and an alarm/programming
LED (8). Besides the parameter values/
settings, the display also shows
additional information with regard to
input and output indications to and from
the boiler:
Input indications
HFlame ionisation detected
SW Water flow switch active
DW --
RT Boiler enabled**
Bus Bus communication active
Changing parameter values
For changing any parameters, in the
example parameter P2 (DHW setpoint),
the following procedure should be
carried through:
• Open the lid (the arrow at the bottom
of the display indicates parameter P1)
• Turn the rotational switch clockwise
until the arrow indicates parameter P2
The new value is now activated. All
parameters can be changed by
following the same procedure as
described above.
**The boiler enable signal is equipped with a jumper in the standard delivery and therefore the boiler will normally be enabled. If a building
management system is connected to provide the enable signal to the boiler (jumper should be removed), check the building management
system if the boiler remains disabled.
* P3 shows the actual temperature setpoint of the boiler, either coming from P1/P2 or from an additional (weather compensated) controller or
building management system (2-10V). When the boiler capacity is controlled via a cascade manager or building management system (2-10V),
P3 shows the actual capacity setpoint of the boiler.
2 5 3 4 1
2 1
6 7 8