STOKVIS ENERGY SYSTEMS ECONOPAK R2000 Owner's manual

ECONOPAK R2000
ATMOSPHERIC GAS FIRED
HOT WATER 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
20IP18B 220802

20IP18B
II
Edition B, 09-01-2002
© 2002 Stokvis.
All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior permission in writing of Stokvis.
We aim to achieve continuous improvement in our products. Therefore, specifications are
subject to change without prior notice.
Due to changes the product can deviate from the information specified in this document.
Therefore Stokvis rejectsany responsibilityfor the differences between the
product delivered and the information mentioned in this document.

20IP18B III
R2000 WATER HEATER TECHNICAL DATA
Type R2017 R2022 R2028 R2034 R2041 R2048 R2056 R2066 R2077 R2090 R2105 R2122
Nominal heat output kW 57,7 74,6 95,8 116,7 139,1 162,7 190,7 222,1 261,1 309,0 361,0 425,0
Nominal heat input (nett. CV) kW 65,5 84,8 107,7 131,6 158,6 185,5 217,4 253,3 296,2 348,0 403,9 470,7
Gas consumption
natural gas H (10,9 kWh/m ) m /h 6,0 7,9 9,9 12,2 14,7 17,2 20,2 23,5 27,5 32,3 37,4 43,6
3
propane m /h 2,3 2,9 3,8 4,7 5,6 6,6 7,7 8,9 10,5 12,3 14,3 16,6
3
3
Gas inlet pressure (min.) mbar 17 17 17 17 17 17 17 17 17 17 17 17
(max.) mbar 25 25 25 25 25 25 25 25 25 25 25 25
propane (max.) mbar 50 50 50 50 50 50 50 50 50 50 50 50
Water volume dm 5,6 5,9 6,2 6,5 6,9 7,3 7,7 8,3 8,9 9,6 10,5 11,4
Max. working pressure bar 11 11 11 11 11 11 11 11 11 11 11 11
3
Flue connection D mm 200 225 250 250 300 300 350 350 400 400 450 450
Gas connection G ¾" ¾" 1" 1" 1" 1" 1½" 1½" 1½" 1½" 1½" 1½"
Water connections
cold water feed + hot water flow W 2" 2" 2" 2" 2" 2" 2" 2" 2" 2" 2" 2"
recirculation 1½” 1½” 1½” 1½” 1½” 1½” 1½” 1½” 1½” 1½” 1½” 1½”
Pressure relief valve connection ½" ½" ½" ¾" ¾" ¾" 1" 1" 1" 1" 1¼" 1¼"
relief connection ½" ½" ½" ¾" ¾" ¾" 1¼" 1¼" 1¼" 1¼" 1½" 1½"
standard setting bar 5 5 5 5 5 5 5 5 5 5 5 5
Electrical supply water heater 1N~ V 230 230 230 230 230 230 230 230 230 230 230 230
pump 3N~ V 400 400 400 400 400 400 400 400 400 400 400 400
Frequency Hz 50 50 50 50 50 50 50 50 50 50 50 50
Fuse A 666666666666
Max. electrical consumption
water heater kW 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04
pump kW 0,25 0,25 0,25 0,37 0,37 0,37 0,37 0,37 0,37 0,75 0,75 0,75
Dimensions B mm 704 783 879 974 1085 1196 1323 1482 1657 1863 2101 2371
H mm 1612 1612 1612 1612 1612 1612 1612 1612 1632 1632 1652 1652
Kmm323232323232323252527272
L mm 820 898 994 1090 1200 1312 1438 1598 1772 1978 2216 2486
Weight, empty, ± 5 % kg 225 240 255 270 290 310 335 360 395 430 470 520
Table 1 Technical Data
- Heat output measured with : 60 - 80 °C
- Gas consumption at : 1013 mbar, 15 EC, dry
- Gas specification : I2H
- Appliance category : B11
- Protection degree : IP20
Changes in specifications and dimensions
The manufacturer reserves the right to change the above mentioned dimensions without prior notice.
Because of manufacturing tolerances, the above mentioned dimensions can vary slightly.

20IP18B
IV
Fig. 1 Dimensions
Dimensions
The R2000 unit is also available
as a left-handed model.
Top and side clearances are 600 mm MINIMUM.

20IP18B V
Fig. 2 Dimensions 300 litre tank
Fig. 3 Dimensions 500 litre tank
R2000 ECONOPAK PLUS with BT300 litre tank
R2000 ECONOPAK PLUS with BT500 litre tank

20IP18B
VI

20IP18B VII
INDEX
R2000 Water Heater Technical data .............III
Dimensions ............................... IV
Index .................................... VII
1 INTRODUCTION ............................ 1
1.1 General ................................... 1
1.2 Supplier ................................... 1
1.3 This manual ................................ 1
1.4 Service.................................... 2
1.5 Reservation ................................ 2
2 DESCRIPTION ............................. 3
2.1 General information .......................... 3
2.2 Main components ............................ 4
2.3 Principleofregulation ........................ 8
2.3.1 EMControloption ........................... 8
2.4 Water heater protection ...................... 11
3 SAFETY.................................. 12
4 DELIVERYANDTRANSPORT ................ 15
4.1 Delivery .................................. 15
4.2 Unitprotectivepackaging..................... 15
4.3 Transport ................................. 15
5 INSTALLATION............................ 17
5.1 Boilerroom................................ 17
5.1.1 Siting .................................... 17
5.1.2 Boilerroomventilation ....................... 17
5.2 Unit connections ........................... 18
5.2.1 Gas supply ................................ 18
5.2.2 Electrical supply ............................ 18
5.2.3 Hydraulic connections ....................... 19
5.2.3.1Watersystem.............................. 20
5.2.3.1Pumpinformation........................... 20
5.2.4 Flues .................................... 22
5.3 General recommendations .................... 23
5.4 Watertemperature.......................... 24
5.5 Demand for hot water for sanitary use ........... 24
5.6 Waterquality .............................. 25
5.7 Formulatocalculatehotwaterrequirements...... 27
5.8 Asmallselectionofapplications ............... 29
5.8.1 Singletemperaturesystem ................... 29
5.8.2 Dualtemperaturesystem..................... 29
5.8.3 Industrial application ........................ 30
5.8.4 High peak demand use ...................... 30
6 COMMISSIONING.......................... 31

20IP18B
VIII
6.1 General .................................. 31
6.2 Pre-lighting checks and dry run ................ 34
6.2.1 Check1 .................................. 34
6.2.2 Check2 .................................. 34
6.2.3 Check3 .................................. 35
6.3 Liveruncheck ............................. 36
6.4 Instructionstouser.......................... 38
7 OPERATION AND FAULT INDICATION ......... 40
7.1 Function.................................. 41
7.2 Regulation ................................ 41
7.3 Control panel .............................. 41
7.4 Faultindications............................ 41
7.5 Start-up .................................. 41
7.6 Shut-down ................................ 41
7.7 Warnings ................................. 41
7.8 Faultfindingtable........................... 42
8 MAINTENANCE............................ 44
8.1 Safety.................................... 44
8.2 General information ......................... 44
8.3 Inspection ................................ 44
8.4 Cleaning .................................. 45
8.5 Servicing ................................. 46
8.6 Component replacement ..................... 50
8.6 Service................................... 54
9 LISTOFSERVICEABLEPARTS .............. 55
SUPPLEMENT ............................ 56

20IP18B 1
1 INTRODUCTION
1.1 General Through their unique construction, these water heaters are
renowned for their:
1.2 Supplier StokvisEnergySystems
1.3 This manual This documentation has been to aid the following target
- high thermal efficiency
- environmental friendliness
- light weight and small dimensions
- durability
- low noise production
- large regulating range
- available with many different options.
Continual research and development means that Stokvis
remains at the forefront of boiler and water heater technology.
96R Walton Road
East Molesey
Surrey
KT8 0DL
Tel.: [phone]
Fax:[phone]
For advice or more information with regard to our products
contact Stokvis.
groups:
- the consulting engineer
- the heating installer
- the service engineer
- the user
Because these target groups require mostly similar information
and also specific information, our technical documentation has
been integrated to provide these target groups with the neces-
sary general and specific information to install, service and
operate this product.
The supplier (see 1.2) will be able to provide any further or
supplemental information.

20IP18B
2
1.4 Service Operating instructions for the user can be found on the unit.
1.5 Reservation For commissioning and assistance in maintenance matters,
The following aspects will be explained:
- general description
- technical specifications
- necessary services for system design and unit installation
- example systems
- maintenance instructions.
See also chapter 7.
please contact your supplier’s service department. For more
details see section 1.2.
It is the law that the installation be carried out by a competent
person. The water heater should be installed in accordance
with the British Standards and Codes of Practice referred to in
this manual, the Gas Safety (installation & use) Regulations
1994, Building Regulations, Model Water Bye-laws and any
Requirements of the Local Gas Supplier, Local Authority, Water
and Fire Authorities and I.E.E. Regulations.
Health & Safety at Work Act, 1974
Under Section 6 of the above Act, it is the duty of manufactur-
ers and suppliers of products for use at work to ensure, so far
as it is reasonable practicable, that such products are safe and
without risk to health when properly used and to make available
to users of such products adequate information about their safe
and proper operation.
Andrews water heaters should only be used in the manner and
purpose for wich they were intended, and in accordance with
the recommendations detailed in this manual. Our heaters have
been designed, produced and inspected with safety in mind,
but there are certain basic precautions, wich should be taken by
the user and, in particular attention is drawn to the safety pre-
cautions in this manual and to the operating instructions on the
heater.
It is imperative, therefore, that all persons who make use of our
heaters have all the information and instructions they require to
ensure that they are fully aware of any hazard, and that they
know both the purpose and correct manner of use of our heat-
ers.
The manufacturer can alter its products without any pre-
ceding notification and is therefore not obliged to adapt
earlier delivered products.

20IP18B 3
2 DESCRIPTION
2.1 General information The R2000 series water heaters are atmospheric open flued,
and Sweden under Product Identification Number
low thermal capacity gas-fired water heaters.
These high efficiency water heaters are designed to provide hot
water to various industrial and commercial applications where
there can be varying demands and fluctuating loads.
Several models are available with heat inputs from 65,5 kW to
470,7 kW and recovery rates from 1219 litres per hour to 8577
litres per hour, based upon a temperature rise of 44 K or 976
litres per hour to 6862 litres per hour, based upon a tempera-
ture rise of 56 K.
The R2000 series of water heaters are available in 12 types:
R2017, R2022, R2028, R2034, R2041, R2048, R2056, R2066,
R2077, R2090, R2105, R2122.
The last three digits of the type number indicate the number of
burner bars present in the burner assembly. The load at nett
calorific value is approx. 3,5 kW per burner.
All water heater types are fitted with a 9-tube heat exchanger of
the 2 pass type.
The use of extruded copper fin pipes in the heat exchanger
leads to higher efficiency.
Thermal radiation losses are minimized by the optimal con-
struction of the combustion chamber in which high-grade insu-
lation is integrated.
The advanced construction of the R2000 enables swift assem-
bly and dismantle, which simplifies maintenance and inspec-
tion.
All water heaters have full sequence automatic control with
overheat cut off, water flow switch, modulating turn down on
gas and combustion air (for improved efficiency at varying heat
loads) and fault indicators.
The R2000 has an electronic protection and ignition sys-
tem, indicated by E.
The electronic PID version controlled by a simple to operate
regulator is indicated in the M version.
Appliance category B11.
The R2000 series is CE approved for the following countries:
Great Britain, Belgium, Denmark, France, Ireland, Italy, Spain
0063AQ6600.

20IP18B
4
Fig. 4 View of the R2000 series
2.2 Main components
1. Flue outlet socket 13. Burner bars
2. Draught diverter 14. Quick clamp (securing burner trolley
3. Air supply opening at both sides)
4. Connection box 15. Main gas valve
5. Servomotor (air damper/gas input) 16. Gas train cover
6. Pressure test point 17. Filling and drain valve
7. Gas modulating valve 18. Pressure relief valve
8. Air damper 19. Water flow switch
9. Main burner gas governor 20. Instrumentation panel
10. Gas connection 21. Inspection panel (electrical wiring &
11. Electrodes controls)
12. Sight glass 22. Cable glands

20IP18B 5
Fig. 5 Draught diverter
Fig. 6 Combustion chamber
Draught diverter
The R2000 is fitted with a draught diverter. It is possible to
connect the flue outlet connection on the top cover with a
standard flue pipe.
The inside of the draught diverter is made of aluminium.
The galvanized plate mantle is easily removed without the use
of any special tools by means of a click system.
Combustion chamber
The chassis consists of two side frames with steel supports.
Dura blanket type thermal insulation is sandwiched between the
vermiculite refractory blocks and front, rear and side panels of
the combustion chamber housing. These vermiculite refractory
blocks are mounted so as to allow freedom of expansion. The
refractory blocks backed with the Dura blanket insulate form the
combustion chamber.

20IP18B
6
Fig. 7 Heat exchanger
Fig.8 Pump and bypass with water connections
Heat exchanger
The heat exchanger (type 2-pass) is mounted on the chassis.
To ensure proper heat transfer of the combustion gases, the
copper fin tubes are arranged side by side and expanded
laterally into a mounting plate. The baffles on the copper fin
tubes optimize the efficiency of the heat exchanger. The stain-
less steel supply and return pipes together with the water mani-
folds form the heat exchanger.
Primary pump
The primary circulating pump is sized to prevent the depositing
of limescale in the water heater under the following conditions.
Water hardness in ppm Maximum temperature in °C
0 - 80 90
80 - 250 85
250 - 350 80
350 - 500 60
Table 2 Maximum temperature

20IP18B 7
Fig. 9 Burner
Fig. 10 Combustion air damper
Burner
The burner is mounted under the combustion chamber in the
chassis. The burner bars, mounted in the burner trolley are
manufactured from stainless steel. Each burner bar is supplied
by its own injector nozzle mounted on the gas manifold.
Combustion air damper
A combustion air damper is situated underneath the burners.
Gas train
The principal components of the gas train are a main governor
and two main gas valves or combined main governor and main
gas valve. The quantity of gas is adjusted in proportion of the
quantity of air being supplied by the air damper opening. The
pilot flame has a separate pilot line with pilot governor and gas
valve.

20IP18B
8
2.3 Principle of regulation Electronic Modulating version
This type of boiler control regulation (indicated by the EM
control option) uses a built-in PID regulator to maintain a con-
stant flow temperature to within a minimum temperature devia-
tion of +1 to -1 K.
This system allows the user to fine-tune the reaction of the
boiler to the heating system or application process.
An added bonus with this “EM” control system is that it allows a
Building Management system to influence the flow temperature
using a 0 - 10 VDC control signal.
Boiler temperature controller RWF40
A Process value (actual temperature)
B Set point (temperature)
C Burner enable (not applicable)
D Mod. indicator (decrease fire rate)
E Mod. indicator (increase fire rate)
F Two-stage firing (not applicable)
G Limit comparator
H Manual operation
The keys K-L-M-N are used for displaying
values and changing parameters in the
temperature controllers configuration.
K Down key (reduce value)
L Up key (increase value)
M Programme key
N Exit key
Assignment of levels
All levels can be accessed from the basic
display via the button, as shown in
PGM
the diagram. The upper actual value dis-
play (red) indicates the actual value and
the parameter values for the various levels.
The setpoint and the parameters are
indicated in the lower setpoint display
(green).
1. After using *PGM+to step through all
the parameters of a level, an automatic
return occurs after the last parameter has
been confirmed.

20IP18B 9
Fig. 9 Parallel displacement of the heating curve
2.3.1 EM Control option Electronic Modulating version with outside temperature
compensation and night-time temperature reduction
This system (indicated by the EW control option) uses the
above mentioned PID regulator to regulate the boiler. The “EW”
control system maintains the advantages of the “EM” type boiler
and adds to it the possibility of automatically changing the flow
temperature according to the outside temperature and the
required heating curve. The unit’s built-in week-clock also
means that a night-time and weekend temperature reduction is
possible with a “EW” control system.
Weather-dependent setpoint shift
The RWF40 can be configured in such a way that, if a Ni1000
outside sensor (e.g. QAC22) is connected, a weather-depen-
dent setpoint shift is implemented.
The minimum and maximum setpoint values can be set by the
lower setpoint limit *SPL+and the upper setpoint limit *SPH+.
Parameter *P+can be used to apply a parallel displacement to
the heating curve.
*Each RWF40 must have its own separate outside
sensor connected (no parallel connection)!
Heating curve slope
Slope *H+of the heating curve can be used to adjust the set-
point in response to the outside temperature, as shown in the
diagram. The common origin of the heating curves is set at
(20 °C / 20 °C). The effective range of the weather-adjusted
setpoint is restricted by the setpoint limits *
**
*SPH+
++
+and *
**
*SPL+.
setpoint is restricted by the setpoint limits *
**
*SPH+
++
+and *
**
*SPL+.

20IP18B
10
Fig. 10 Heating curve slope
*
**
*HYS1+
++
+is the switch-on point for the burner, and *
**
*HYS3+
++
+is the
switch-off point. As already described, they act with the set shift
relative to the weather-controlled
Process data
Parameter Display Value range Factory setting
Setpoint 1 SP1 SPL-SPH 0
1
Setpoint 2 (option) SP2 SPL-SPH 0
1
Digital setpoint shift (option) dSP SPL-SPH 0
1
Outside temperature (option) tA *C111 Inputs+-
1
Predefinition of external setpoint SP.E SPL-SPH -
1
Parameter level
Parameter Display Value range Factory setting
Limit value of limit comparator AL -1999...+9999 digit 0
1
Switching differential for limit comparator HYSt 0...999,9 digit 1
1
Proportional band Pb.1 0,1...999,9 digit 10
1
Derivative time dt 0...9999 s 80
Integral action time rt 0...9999 s 350
Contact spacing db 0,0...999,9 digit 1
1
Actuator running time tt 10...3000 s 15 s
Switch-on threshold burner/stage II H Y S 1 0,0...-199,9 digit -5
1
Switch-off level stage II H Y S 2 0,0... HYS3 digit 3
1
Upper switch-off threshold H Y S 3 0,0...999,9 digit 5
1
Response threshold q0,0...999,9 0
Heating curve slope H0,0...4,0 2
Parallel displacement P-90...+90 0
1

20IP18B 11
2.4 Water heater protection
Configuration level
Parameter Display Factory setting
Analog input 1, 2 and 3; setpoint changeover / shift C111 9930
Limit comparator; controller type; setpoint 1; locking C112 5010
Unit address; decimal place / unit signal for out-of-range C113 0
Measurement range start analog input 1 SCL 0
1
Measurement range analog input 1 SCH 100
1
Measurement range analog input 2 SCL2 0
1
Measurement range analog input 2 SCH2 100
1
Lower setpoint limit SPL 30
1
Upper setpoint limit SPH 95
1
Actual value correction, analog input 1 OFF1 0
1
Actual value correction, analog input 2 OFF2 0
1
Actual value correction, analog input 3 OFF3 0
1
Filter time constant for digital filter, analog input 1 dF1 1
These parameters are affected by the setting for the decimal place.
1
The R2000 is protected by the following systems:minimum
water flow switch
The water flow switch is installed in the flow manifold and
monitors continuously the minimum water flow. If the water flow
falls below a preset level, the burner is shut down and go to
lock-out. The water flow switch is factory set and should not be
adjusted.
high limit thermostat
In the event of failure of the control thermostat, a preset high
limit thermostat will shut down the burner and go to lockout.
pressure relief valve
The maximum operating pressure of the R2000 boiler is 11 bar.
The standard safety valve supplied is set to 3 bar. If a different
pressure setting is required this should be specified and will be
set at the factory.
gas burner control
The burner control unit provide control and supervision of the
atmospheric burner. The sequence controller is coupled to the
spindle of the control circuit and to the flame supervision unit
displaying the status, the symbol appearing above the reading
mark indicates the firing sequence or lock-out condition. The
pilot flame is supervised by ionisation current detection.

20IP18B
12
3SAFETY
Instruction of extreme importance in order to guarantee proper
Not following the operation procedures can cause serious
Electric shock hazard.
Useful information.
Installation requirements
Please read these requirements before commencing installa-
tion.
The product has to be installed by a recognized installer fully
according to the current national and local demands, norms
and standards.
The installation procedure should only be used for heating
systems with a maximum water temperature of 95 °C.
We emphasize that you should always give priority to the above
mentioned standards and regulations and that the installation
regulations should be considered as an addition to these stan-
dards and regulations.
Explanation of the icons used in this manual
functioning of the water heater.
damage to the water heater, personal injuries or environmental
pollution.