STOKVIS ENERGY SYSTEMS R3600 Instruction manual

Stokvis R3400/R3600 Boiler
Gas-Fired
Floor Standing
Condensing
Installation, Operation & Maintenance
Manual
STOKVIS ENERGY SYSTEMS
96R Walton Road
East Molesey
Surrey
KT8 0DL
Tel: [phone]
Fax: [phone]
E-Mail: [email protected]
Website: www.stokvisboilers.com
420010567700 12/2013

Contents
2
Contents .................................................................. ...................................................... 2
Safety General regulation ............................................................................................ 3
Application ........................................................................................................3
Norms and regulations .............................. ...................................................... 3
Construction Layout of boiler ................................................................................................. 4
Operating principle ........................................................................................... 4
Technical data ......................................................................................................................... 5
Extent of delivery Standard boiler ............................................................................................... 13
Accessories .................................................................................................... 13
Installation Transport ........................................................................................................ 14
Removing the casing ...................................................................................... 16
Boiler installation ............................................................................................ 17
Connecting the boiler ..................................................................................... 18
Commissioning Water and hydraulic system ........................................................................... 20
Gas supply ..................................................................................................... 21
Condensate connection .................................................................................. 21
Flue and air intake connections ...................................................................... 21
Prepare boiler for first startup ......................................................................... 22
Combustion analysis ...................................................................................... 23
Air pressure switch ......................................................................................... 24
Check water flow ........................................................................................... 25
Check functionality of safety devices ............................................................. 26
Gas tightness check ....................................................................................... 26
Boiler shut down ............................................................................................. 26
Commissioning protocol ................................................................................. 27
Operating instructions Main menu (operating mode) ........................................................................ 28
Parameter menu(information/programming mode) ........................................ 28
Changing parameter values ........................................................................... 28
Maintenance Checklist .........................................................................................................29
Replacing the electrodes ................................................................................ 20
Cleaning the condensate receptacle .............................................................. 30
Cleaning and refilling the syphon ................................................................... 30
Water pressure and quality ............................................................................ 30
Water flow rate ............................................................................................... 30
Combustion analysis ...................................................................................... 30
Gas pressure .................................................................................................. 30
Gas tightness check ....................................................................................... 30
Safety devices ................................................................................................ 30
Maintenance protocol .....................................................................................
31
Lockouts ....................................................................................................................... 32
Sensor values ....................................................................................................................... 34
Declaration of Conformity ....................................................................................................................... 35

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 R3400/R3600 boil-
er. All activities described in this docu-
ment may only be excecuted by author-
ized 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 R3400/R3600 boiler may be used
for heating and hot water production
purposes only. The boiler should be
connected to closed systems with a
maximum temperature of 100ºC (high
limit temperature), maximum setpoint
temperature is 90ºC.
Norms and regulations
When installing and operating the
R3400/R3600 boiler, all applicable
norms (european and local) should be
fulfilled:
Local building regulations for in-
stalling combustion air and flue gas
systems;
Regulation for connecting the boiler to
the electrical appliance;
Regulations for connecting the boiler
to the local gas network;
Norms and regulations according to
safety equipment for heating systems;
Any additional local laws/regulations
with regard to installing and operating
heating systems.
The R3400/R3600 boiler is CE ap-
proved 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 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 chang-
es, 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 electri-
cal connections

Construction
Layout of boiler
Operating principle
4
Layout of boiler
The R3400/R3600 boiler consists of the
following main components:
1 Return water connection
2 Flue gas connection
3 Water flow switch
4 Safety valve
5 Flow water connection
6 Filling/draining valve
7 Top plate
8 Plenum
9 Burner
10 1st Heat exchanger
11 Gas filter
12 2nd Heat exchanger
13 Gastrain
14 Frame
15 180° Bend
16 Compensator
17 Flue gas connection
18 Condensate receptacle
19 Flue gas receptacle
20 Combustion chamber
21 Entry electrical connections
22 Syphon
23 Main gas valve
24 Fan
25 Electrical box
26 Control panel
27 Casing
28 Air inlet damper
29 Butterfly valve
30 Main mixing channel
31 Pilot gas valve
32 Pilot mixing channel
33 Boiler pump
34 3rd Heat exchanger (only R3600)
A Air
B Gas
C Flue gasses
D Condensate
Operating principle
The R3400/R3600 is a fully modulating
boiler. The control unit of the boiler
adapts the modulation ratio automati-
cally 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 KM628 control unit can control the
boiler operation based on:
fixed temperature (stand alone
operation);
weather compensated operation (with
optional controller);
with 0-10V external influence
(temperature or capacity) from a buil-
ding management system.
the boiler and leave at the back side
into the chimney connection.
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.
34

Technical data
Technical data R3401 - R3405
5
R3401 R3402 R3403 R3404 R3405
Nominal heat output at 80-60ºC max/min kW 656/164 733/183 857/213 971/242 1084/270
Nominal heat output at 75-60ºC max/min kW 657/164 734/183 858/213 972/242 1085/270
Nominal heat output at 40/30ºC max/min kW 663/181 741/202 867/236 981/268 1095/298
Nominal heat input Hi max/min* kW 702/176 784/196 917/229 1038/260 1159/290
Efficiency at 80/60ºC % 93.5
Efficiency at 40/30ºC % 94.5
Annual efficiency (NNG 75/60ºC) % 100.0
Annual efficiency (NNG 40/30ºC) % -
Standstill losses (Twater = 70ºC) % 0.2
Max. condensate flow l/h -
Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 64.5/16.2 71.9/18.0 84.1/21.0 95.2/23.8 106.3/26.6
Gas consumption L-gas max/min (8,34 kWh/m3) m3/h 84.3/21.1 94.0/23.5 109.9/27.4 124.4/31.2 139.0/34.8
Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 54.9/13.8 61.2/15.3 71.6/17.9 81.1/20.3 90.5/22.6
Gas pressure H-gas mbar 20 35
Gas pressure L/LL-gas mbar 25 35
Gas pressure LPG mbar 30/50
Maximum gas pressure mbar 100
Flue gas temperature at 80/60ºC max/min ºC 165/70
Flue gas temperature at 40/30ºC max/min ºC 135/60
Flue gas quantity max/min* m3/h 1423/356 1580/395 1848/462 2091/523 2334/584
CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3
CO2 level main burner liguid gas P max/min % 11.0/11.0
CO2 level pilot burner natural gas H/E/L/LL max/min % 10.0/10.2
CO2 level pilot burner liguid gas P max/min % 11.0/11.2
NOx level max/min mg/kWh 61.4/22.0
CO level max/min mg/kWh 9.8/3.3
Max. permissible flue resistance max/min Pa 150
Water volume l 50 53 70 75 80
Water pressure max/min bar 6/1
Max. water temperature (High limit thermostat) ºC 100
Maximum temperature setpoint ºC 90
Nominal water flow at dT=20K m3/h 28.5 31.6 37.0 41.8 46.8
Hydraulic resistance at nominal water flow kPa 46 53 36 43 50
Electrical connection V 400
Frequency Hz 50
Mains connection fuse A 16 20
IP class - IP20
Power consumption boiler (excl. pump) W 900 900 1270 1270 1270
Power consumption 3-step pump (optional) W
Weight (empty) kg 675 740 840 950 1070
Noise level at 1 meter distance dB(A) 64
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063AR3514
Water connections - DN65 PN16 DN80 PN16
Gas connection - R 2” DN65 PN16
Flue gas connection mm 300 350 400
Air intake connection (for room sealed use) mm 250 300 355
Condensate connection mm 40
980 1010 1020 1450 1500

Technical data
Technical data R3406
6
R3406
Nominal heat output at 80-60ºC max/min kW 1196/298
Nominal heat output at 75-60ºC max/min kW 1197/298
Nominal heat output at 40/30ºC max/min kW 1209/329
Nominal heat input Hi max/min* kW 1279/320
Efficiency at 80/60ºC % 93.5
Efficiency at 40/30ºC % 94.5
Annual efficiency (NNG 75/60ºC) % 100.0
Annual efficiency (NNG 40/30ºC) % -
Standstill losses (Twater = 70ºC) % 0.2
Max. condensate flow l/h -
Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 117.3/29.3
Gas consumption L-gas max/min (8.34 kWh/m3) m3/h 153.4/38.4
Gas consumption LPG. max/min (12.8 kWh/kg) kg/h 99.9/25.0
Gas pressure H-gas mbar 35
Gas pressure L/LL-gas mbar 35
Gas pressure LPG mbar 30/50
Maximum gas pressure mbar 100
Flue gas temperature at 80/60ºC max/min ºC 165/70
Flue gas temperature at 40/30ºC max/min ºC 135/60
Flue gas quantity max/min* m3/h 2578/645
CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3
CO2 level main burner liguid gas P max/min % 11.0/11.0
CO2 level pilot burner natural gas H/E/L/LL max/min % 10.0/10.2
CO2 level pilot burner liguid gas P max/min % 11.0/11.2
NOx level max/min mg/kWh 61.4/22.0
CO level max/min mg/kWh 9.8/3.3
Max. permissible flue resistance max/min Pa 150
Water volume l 85
Water pressure max/min bar 6/1
Max. water temperature (High limit thermostat) ºC 100
Maximum temperature setpoint ºC 90
Nominal water flow at dT=20K m3/h 51.6
Hydraulic resistance at nominal water flow kPa 58
Electrical connection V 400
Frequency Hz 50
Mains connection fuse A 20
IP class - IP20
Power consumption boiler (excl. pump) W 1270
Power consumption 3-step pump (optional) W 1500
Weight (empty) kg 1200
Noise level at 1 meter distance dB(A) 64
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063AR3514
Water connections - DN80 PN16
Gas connection - DN65 PN16
Flue gas connection mm 400
Air intake connection (for room sealed use) mm 355
Condensate connection mm 40

Technical data
Dimensions R3401 - R3406
7
Dimensions R3401 R3402 R3403 R3404 R3405 R3406
L mm 2265 2265 2653 2653 2658 2658
L1 mm 595 595 610 615 615 770
L2 mm 700 700 1166 1166 1166 1166
L3 mm 108 108 88 88 88 88
H mm 1355 1355 1355 1355 1355 1355
H1 mm 1125 1125 1570 1420 1155 1377
B mm 1330 1330 1130 1130 1330 1330
B1 mm 1160 1210 1003 1053 1203 1253
B2 mm 665 665 565 565 665 665
B3 mm 170 120 127 77 127 77
B4 mm 1146 1146 946 946 1146 1146
B5 mm 115 65 115 65 115 65
D mm 300 350 350 400 400 400
W DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16
G R R 2" R 2" R 2" R 2" DN65 PN16 DN65 PN16

8

Technical data
Technical data R3600 - R3605 Standard
9
R3600 R3601 R3602 R3603 R3604 R3605
Nominal heat output at 80-60ºC max/min kW 572/142 639/182 747/212 846/241 945/269 1043/297
Nominal heat output at 75-60ºC max/min kW 576/144 643/184 753/215 852/243 952/272 1050/300
Nominal heat output at 40/30ºC max/min kW 602/159 672/203 786/237 890/268 994/300 1097/331
Nominal heat input Hi max/min* kW 585/146 653/187 764/218 865/247 966/276 1066/305
Efficiency at 80/60ºC % 97.8
Efficiency at 40/30ºC % 102.9
Annual efficiency (NNG 75/60ºC) % 105,1
Annual efficiency (NNG 40/30ºC) % 109,8
Standstill losses (Twater = 70ºC) % 0,3
Max. condensate flow l/h -
Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 53.7/13.4 59.9/17.1 70.1/20.0 79.4/22.7 88.6/25.3 97.8/27.9
Gas consumption L-gas max/min (8,34 kWh/m3) m3/h 70.3/17.6 78.3/22.4 91.6/26.2 103.7/29.6 115.8/33.1 127.8/36.5
Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 45.7/11.4 51.0/14.6 59.7/17.1 67.6/19.3 75.5/21.6 83.3/23.8
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 85/65
Flue gas temperature at 40/30ºC max/min ºC 59/36
Flue gas quantity max/min* m3/h 969/242 1076/307 1258/359 1424/407 1590/454 1756/502
CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3 10.0/9.3
CO2 level main burner liguid gas P max/min % 11.0/11.0 11.0/11.0
CO2 level pilot burner natural gas H/E/L/LL max/min % - 10.0/10.2
CO2 level pilot burner liguid gas P max/min % - 11.0/11.2
NOx level max/min mg/kWh 32.3/18.8 11.5/19.5
CO level max/min mg/kWh 8.2/10.9 27.3/6.5
Max. permissible flue resistance max/min Pa 100 150
Water volume l 69 73 97 104 110 117
Water pressure max/min bar 6/1
Max. water temperature (High limit thermostat) ºC 100
Maximum temperature setpoint ºC 90
Nominal water flow at dT=20K m3/h 24,7 27,6 32,2 36,5 40,8 45,0
Hydraulic resistance at nominal water flow kPa 48 56 38 45 53 60
Electrical connection V 400
Frequency Hz 50
Mains connection fuse A 10 16 20
IP class - IP20
Power consumption boiler (excl. pump) W 420 900 1270
Power consumption speed controlled pump (optional) W
Weight (empty) kg 810 890 1040 1150 1280 1410
Noise level at 1 meter distance dB(A) 64
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063AR3514
Water connections - DN65 PN16 DN80 PN16
Gas connection - R 2” DN65 PN16
Flue gas connection mm 300 350 400
Air intake connection (for room sealed use) mm 250 300 355
Condensate connection mm 40
471 616 561 661 867 956
Power consumption 3-step pump (optional) W 940 980 1020 1400 1450 1500

Technical data
Dimensions R3600 - R3605 Standard
10
Dimensions R3601 R3602 R3603 R3604 R3605
L mm 2265 2653 2653 2658 2658
L1 mm 595 610 610 615 615
L2 mm 590 1166 1166 1166 1166
L3 mm 198 88 88 88 88
H mm 1405 1405 1405 1405 1405
H1 mm 1175 1450 1450 1205 1427
B mm 1330 1130 1130 1330 1330
B1 mm 1210 1003 1053 1203 1253
B2 mm 665 565 565 665 665
B3 mm 120 127 77 127 77
B4 mm 1146 946 946 1146 1146
B5 mm 65 115 65 115 65
D mm 300 350 350 400 400
W1 DN DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16
G R R 2" R 2" R 2" DN65 PN16 DN65 PN16
R3600
1958
595
700
108
1355
970
1230
1110
615
120
1046
100
300
DN65 PN16
R 2"
D1 mm 250 250 300 300 355 355
W2 DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16

11
R3600 R3601 R3602 R3603 R3604 R3605
Nominal heat output at 80-60ºC max/min kW 572/142 639/182 747/212 846/241 945/269 1043/297
Nominal heat output at 75-60ºC max/min kW 576/144 643/184 753/215 852/243 952/272 1050/300
Nominal heat output at 40/30ºC max/min kW 602/159 672/203 786/237 890/268 994/300 1097/331
Nominal heat input Hi max/min* kW 585/146 653/187 764/218 865/247 966/276 1066/305
Efficiency at 80/60ºC % 97.8
Efficiency at 40/30ºC % 102.9
Annual efficiency (NNG 75/60ºC) % 105,1
Annual efficiency (NNG 40/30ºC) % 109,8
Standstill losses (Twater = 70ºC) % 0,3
Max. condensate flow l/h -
Gas consumption H-gas max/min (10,9 kWh/m3) m3/h 53.7/13.4 59.9/17.1 70.1/20.0 79.4/22.7 88.6/25.3 97.8/27.9
Gas consumption L-gas max/min (8,34 kWh/m3) m3/h 70.3/17.6 78.3/22.4 91.6/26.2 103.7/29.6 115.8/33.1 127.8/36.5
Gas consumption LPG. max/min (12,8 kWh/kg) kg/h 45.7/11.4 51.0/14.6 59.7/17.1 67.6/19.3 75.5/21.6 83.3/23.8
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 85/65
Flue gas temperature at 40/30ºC max/min ºC 59/36
Flue gas quantity max/min* m3/h 969/242 1076/307 1258/359 1424/407 1590/454 1756/502
CO2 level main burner natural gas H/E/L/LL max/min % 10.0/9.3 10.0/9.3
CO2 level main burner liguid gas P max/min % 11.0/11.0 11.0/11.0
CO2 level pilot burner natural gas H/E/L/LL max/min % - 10.0/10.2
CO2 level pilot burner liguid gas P max/min % - 11.0/11.2
NOx level max/min mg/kWh 32.3/18.8 11.5/19.5
CO level max/min mg/kWh 8.2/10.9 27.3/6.5
Max. permissible flue resistance max/min Pa 100 150
Water volume l 73 73 97 104 110 117
Water pressure max/min bar 6/1
Max. water temperature (High limit thermostat) ºC 100
Maximum temperature setpoint ºC 90
Nominal water flow at dT=20K m3/h 24,7 27,6 32,2 36,5 40,8 45,0
Hydraulic resistance at nominal water flow kPa 48 56 38 45 53 60
Electrical connection V 400
Frequency Hz 50
Mains connection fuse A 10 16 20
IP class - IP20
Power consumption boiler (excl. pump) W 730 900 1270
Weight (empty) kg 810 890 1040 1150 1280 1410
Noise level at 1 meter distance dB(A) 64
Ionisation current minimum µA 6
PH value condensate - 3.2
CE certification code - CE-0063AR3514
Water connections - DN65 PN16 DN80 PN16
Gas connection - R 2” DN65 PN16
Flue gas connection mm 300 350 400
Air intake connection (for room sealed use) mm 250 300 355
Condensate connection mm 40

12
Dimensions R3600 R3601 R3602 R3603 R3604 R3605
L mm 1958 2070 2443 2443 2443 2443
L2 mm 700 590 1166 1166 1166 1166
L3 mm 108 198 88 88 88 88
H mm 1355 1405 1405 1405 1405 1405
B mm 1230 1330 1130 1130 1330 1330
B1 mm 1110 1210 1003 1053 1203 1253
B2 mm 615 665 565 565 665 665
B3 mm 120 120 127 77 127 77
B4 mm 1046 1146 946 946 1146 1146
B5 mm 100 65 115 65 115 65
D mm 300 300 350 350 400 400
D1 mm 250 250 300 300 355 355
W1 DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16
W2 DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16
W3 DN DN65 PN16 DN65 PN16 DN80 PN16 DN80 PN16 DN80 PN16 DN80 PN16
G R R 2" R 2" R 2" R 2" DN65 PN16 DN65 PN16

Extent of delivery
Standard boiler
Accessories
13
Standard boiler
A boiler delivery package contains the
following components:
Accessories
On request it is possible to get various
options and/or accessories. Ask your
supplier for the possibilities.
Component Pcs. Package
R3400/R3600 Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border,
sealed in PE foil
Adjustable feet 4 Cardboard box on top of boiler
(on R3407-R3410 already fitted to boiler)
Syphon for condensate connection 1 Cardboard box on top of heatexchanger
(under casing)
Operation and Installation manual 1 Map attached to back panel of the boiler
Wiring diagram 1 Map attached to back panel of the boiler

14
Installation
Transport
Boiler transport
The R3400/R3600 boiler will be
supplied as a complete unit being fully
assembled and pre-tested. The boiler
can be transported with a pallet truck
(at least 1m wide), picking the boiler up
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 R3400/R3600 boiler has to
be transported with a crane, it is neces-
sary to remove the casing before con-
necting the boiler to the crane. Always
connect the crane to the frame of the
boiler by using straps.
1
3
2
Component R3401
R3600
R3402
R3601
R3403
R3602
R3404
R3603
R3405
R3604
R3406
R3605
Burner m [kg]
L [mm]
W [mm]
H [mm]
135
1010
1150
420
135
1010
1150
420
140
1010
1310
500
210
1420
1010
500
215
1420
1110
500
220
1420
1210
500
225
1420
1310
500
1st Heat exchanger m [kg]
L [mm]
W [mm]
H [mm]
120
1010
1150
160
120
1030
1150
150
135
1010
1310
160
180
1420
1010
160
185
1420
1110
160
190
1420
1210
160
195
1420
1310
160
2nd Heat exchanger m [kg]
L [mm]
W [mm]
H [mm]
135
1010
1150
160
135
1030
1050
150
150
1010
1310
160
200
1420
1010
160
200
1420
1110
160
210
1420
1210
160
210
1420
1310
160
Frame
H for R3600 in ( )
m [kg]
L [mm]
W [mm]
H [mm]
50
1325
1165
460
50
1325
1165
360
60
1630
1266
500 (370)
70
2004
1066
500 (370)
70
2004
1066
500 (370)
70
2004
1266
500 (370)
70
2004
1266
500 (370)
Condensate receptacle m [kg]
L [mm]
W [mm]
H [mm]
< 25
1320
990
400
< 25
1320
990
275
< 25
1450
1070
400
< 35
1950
770
400
< 35
1950
870
400
< 35
1950
970
400
< 35
1950
1070
400
3rd Heat exchanger
(only R3600 series)
m [kg]
L [mm]
W [mm]
H [mm]
-
-
-
-
135
1030
1050
150
150
1010
1310
160
200
1420
1010
160
200
1420
1110
160
210
1420
1210
160
210
1420
1310
160
1 Hoisting belt (4x)
2 Wooden retaining beam (2x)
3 Hoisting belt position (4x)

15
Component R3407 R3408 R3409 R3410
Burner m [kg]
L [mm]
B [mm]
H [mm]
230
1510
1400
600
385
2050
1250
600
390
2050
1350
620
395
2050
1450
620
1st Heat exchanger m [kg]
L [mm]
B [mm]
H [mm]
200
1510
1425
150
325
2050
1250
150
330
2050
1350
150
335
2050
1450
150
2nd Heat exchanger m [kg]
L [mm]
B [mm]
H [mm]
220
1510
1425
150
365
2050
1250
150
370
2050
1350
150
375
2050
1450
150
Frame m [kg]
L [mm]
B [mm]
H [mm]
80
2010
1466
510
120
2525
1266
515
120
2525
1466
515
120
2525
1466
515
Condensate m [kg]
L [mm]
B [mm]
H [mm]
< 40
2075
1175
350
< 55
2600
975
350
< 55
2600
1075
350
< 55
2600
1175
350

Installation
Removing the casing
16
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.
3.
5. 4. 2.
5.
4.

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 posi-
tion, 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
effect the exact height of all connecti-
ons.
17
800
1000
The R3407- R3410 are not supplied on
wooden blocks, but on wheels. After
positioning the boiler, the adjustable
feet have to be set to the correct height.
The wheels have to be removed. The
connections to the boiler have to be
made after the feet have been ad-
justed, as the adjustment will effect the
exact height of all connections.

Installation
Connecting the boiler
18
Connecting the boiler
This chapter will explain how to make
all connections to the boiler with regard
to:
Hydraulic connections (1, 3)
Condensate drain connection (7)
Gas connection (6)
Flue gas connection (5)
Air intake connection (only when
using roomsealed, order seperately)
(2)
Electrical connection (4)
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 (3) and return (1) con-
nection of the system tension free to
the boiler connections. If the boiler is
used in a system with two return cir-
cuits (only R3600 series), the common
return becomes the low temperature
return, the 2nd return connection is the
high temperature return (remove cap/
flange before connecting).
Condensate connection (7)
After filling with water, the syphon
(included in delivery) should be in-
stalled to the connection at the bottom
of the condensate receptacle. The con-
nection to the draining system should
always be done with an open connec-
tion, in order to avoid a flooding of the
boiler in case of a blocked drain.
4 5 6
7
1 2 3

Installation
Connecting the boiler
19
Gas connection (6)
The gas connection must be made by
an authorized installer in accordance
with the applicable national and local
standards and regulations.
Connect the gas line from the system
tension free to the gas connection (6) of
the boiler. A gas cock should be
mounted directly behind the boiler.
A gas filter can be mounted directly on
the gas connection of the boiler.
Flue gas connection (5)
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 (5) 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 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)
When using the boiler roomsealed. The
air intake can be connected if the boiler
was ordered as roomsealed. The dia-
meter should be calculated according
to the national regulations, together
with the flue gas system. The total re-
sistance of both systems should never
overcome the maximum permissible
resistance of the fan inside the boiler
(see also chapter: Technical data).
.
Electrical connection (4)
The electrical connection must be ma-
de 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.
Cables can be inserted through the
cable trays and glands at the back of
the electrical panel at the front of the
boiler.
Connect all wires to the terminals ac-
cording to the wiring diagram of the
boiler (enclosed in map attached to
back panel of the boiler).
4
4
6
2
5
WARNING
When designing a flue, the inclusion of
a draught stabiliser should be
considered as any excessive draught
will limit the operation of the burner and
could lead to lockouts on ionisation and
air pressure.

Commissioning
Water and hydraulic system
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]
600 - 2000 1.5 8.4
Minimum operating
pressure
[bar]
Flow tem-
perature
[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.
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 R3400/R3600 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.
Concentrate
Ca(HCO3)2
Capacity of installation Q (kW)
600 800 1000 1200 1400 1600 1800
mol/
m3
dºH Maximum water (re)fill volume Vmax [m3]
0.5 2.8 - - - 75.1 87.6 100.2 122.7
1.0 5.6 - - - 37.6 43.8 50.1 56.3
1.5 8.4 12.0 16.7 20.9 25.0 29.2 33.4 37.6
2.0 11.2 9.4 12.5 15.7 18.8 21.9 25.0 28.2
2.5 14.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
3.0 16.
8
6.3 8.3 10.4 12.5 14.6 16.7 18.8
2000
125.2
62.6
41.7
31.3
25.0
20.9
20
1
2