STOKVIS ENERGY SYSTEMS R600 Series Owner's manual

Stokvis R600 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
420010686500 09/2015 ErP

4
Contents
General regulations ..........................................................................................................................6
Application ................................................................................................................... 6
Norms and regulations............................................................................................ 6
Informations for installer and maintenance service..................................... 7
Data plate ..................................................................................................................... 7
Construction ........................................................................................................................................8
Layout of boiler .......................................................................................................... 8
Operating principle................................................................................................... 8
Technical data .....................................................................................................................................9
Product information ErP ....................................................................................... 10
Dimensions ................................................................................................................ 11
Extend of delivery .......................................................................................................................... 12
Standard boiler........................................................................................................ 12
Accessories................................................................................................................ 12
Installation ......................................................................................................................................... 13
Boiler transport........................................................................................................ 13
Removing the casing............................................................................................. 14
Warnings before installation .............................................................................. 15
Boiler installation .................................................................................................... 15
Connecting the boiler ........................................................................................... 16
Air/Flue gas system................................................................................................ 17
Dimensioning single.............................................................................................. 20
Electrical connection.............................................................................................. 21
Wiring diagram - Boiler........................................................................................ 22
Wiring diagram - Accessories............................................................................ 24
Commissioning ................................................................................................................................ 26
Water and hydraulic system............................................................................... 26
Neutralisation systems.......................................................................................... 27
Gas supply ................................................................................................................. 28
Condensate connection ....................................................................................... 28
Flue and air intake connections ........................................................................ 28
Prepare boiler for first startup ........................................................................... 29

5GB
Contents
Combustion analysis.............................................................................................. 30
Check water flow..................................................................................................... 31
Check functionality of safety devices.............................................................. 32
Gas tightness check ............................................................................................... 32
Boiler shut down ..................................................................................................... 32
Commissioning protocol ..................................................................................... 33
Operating instructions ................................................................................................................. 34
Controls ...................................................................................................................... 34
Display / Programming ........................................................................................ 35
Overview of main functions................................................................................ 36
Maintenance ..................................................................................................................................... 37
Checklist ..................................................................................................................... 37
Replacing the electrodes ..................................................................................... 37
Cleaning the condens tray .................................................................................. 38
Cleaning and refilling the syphon .................................................................... 38
Inspection of combustion chamber................................................................. 38
Water physical and chemical check................................................................. 39
Gas and water quality............................................................................................ 39
Safety devices........................................................................................................... 39
Maintenance Protocol........................................................................................... 40
Lockouts .............................................................................................................................................. 41
Sensor Values .................................................................................................................................... 43
Declaration of Conformity ......................................................................................................... 44
Note ....................................................................................................................................................... 44

6
General regulations
Application
Norms and regulations
This documentation contains
important information, which is a
base for safe and reliable installation,
commissioning and operation of the
boiler. All activities described in this
document may only be excecuted by
authorized companies.
Changes to this document may be
effected without prior notice. We ac-
cept no obligation to adapt previously
delivered products to incorporate
such changes.
Only original spare parts may be
used when replacing components on
the boiler, otherwise warranty will be
void.
Application
The boiler may be used for heating
and hot water production purposes
only. The boiler should be connected
to closed systems with a maximum
temperature of 100ºC (high limit
temperature), maximum setpoint
temperature is 90ºC.
Norms and regulations
When installing and operating the
boiler, all applicable norms (europe-
DQDQGORFDOVKRXOGEHIXO¿OOHG
 Local building regulations for in-
VWDOOLQJ FRPEXVWLRQ DLU DQG ÀXH
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/regula-
tions with regard to installing and
operating heating systems.
This boiler is CE approved and
applies to the following European
standards:
 1992 / 42 / EEC%RLOHUHI¿FLHQF\
directive.
 2004 / 108 / EEC EMC directive.
 2014/68/EU PED directive,
art.4-3.
 2006 / 95 / EEC Low voltage di-
rective.
 2009 / 142 / EEC Gas appliance
directive.
 2009/125/CE Energy related
Products.
 811-813/2013 EU regulation
 EN 15502-1 *DV¿UHG KHDWLQJ
boilers. General requirements
and tests.
 EN 15502-2-1*DV¿UHGKHDWLQJ
ERLOHUV  6SHFL¿F VWDQGDUG IRU
type C and devices type B2, B3,
B5 with a nominal heat input not
exceeding 1000 kW.
 EN 656:1999*DV¿UHGFHQWUDO
heating boilers. Type B boilers of
nominal heat input exceeding 70
kW, but not exceeding 300 kW.
 EN 13836:2006*DV¿UHGFHQWUDO
heating boilers. Type B boilers of
nominalheatinputexceeding 300.
kW, but not exceeding 1000 kW.
 EN 15420:2010*DV¿UHGFHQWUDO
heating boilers. Type C boilers of
nominal heat input exceeding 70
kW, but not exceeding 1000 kW.
 EN 15417:2006 *DV¿UHGFHQWUDO
KHDWLQJ ERLOHUV 6SHFL¿F UHTXL-
rements for condensing boilers
with a nominal heat input greater
than 70 kW but not exceeding
1000 kW.
 EN 60335-1 (2002) Household
and similar electrical appliances
6DIHW\3DUW*HQHUDOUHTXL-
rements
 EN 60335-2-102 (2006) Hou-
sehold an similar electrical ap-
SOLDQFHVSDUWLFXODUUHTXLUHPHQWV
for gas, oil and solid-fuel burning
appliances having electrical con-
nections.
 EN 50165 Electrical equipment
of non-electric appliances for
household and similar purposes
- Safety requirements
 EN 55014-1 (2000) Electroma-
gnetic compatibility - Require-
ments for household appliances,
electric tools and similar appara-
WXV3DUW(PLVVLRQ
 EN 55014-2 (1997) Electroma-
gnetic compatibility - Require-
ments for household appliances,
electric tools and similar appara-
WXV3DUW,PPXQLW\3URGXFW
family standard
 EN 61000-3-2 (2000) Electroma-
gnetic compatibility (EMC) - Part
/LPLWV/LPLWVIRUKDUPRQLF
current emissions (equipment in-
put current 16 A per phase)
 EN 61000-3-3 (2001) Electro-
magnetic compatibility (EMC)
 3DUW  /LPLWDWLRQ RI YROWDJH
FKDQJHV YROWDJH ÀXFWXDWLRQV
DQG ÀLFNHU LQ SXEOLF ORZYROWDJH
supply systems, for equipment
with rated current 16 A per pha-
se and not subject to conditional
connection.
Additional national standards
Germany:
 5$/8=',1
Switzerland:
 SVGW
Austria:
 15a V-BG

7GB
The use of the appliance for purposes
RWKHU WKDQ WKRVH VSHFL¿HG LV VWULFWO\
forbidden. The manufacturer cannot
be held responsible for any damage
caused by improper, incorrect and
unreasonable use of the appliance or
by the failure to comply with the in-
structions given in this manual.
,QVWDOODWLRQ PDLQWHQDQFH DQG DOO
other interventions must be carried
out in full conformity with the gover-
ning legal regulations and the instruc-
tions provided by the manufacturer.
,QFRUUHFW LQVWDOODWLRQ FDQ KDUP SHU-
sons, animals and possessions; the
manufacturing company shall not
be held responsible for any damage
caused as a result.
The boiler is delivered with protection
packaging. Once you have removed
all the packaging, make sure the ap-
pliance is intact and that no parts are
PLVVLQJ,IWKLVLVQRWWKHFDVHSOHDVH
contact your supplier.
Keep all packaging material (clips,
plastic bags, polystyrene foam, etc.)
out of reach of children as it may pre-
sent a potential hazard.
Before any maintenance or repair
work is performed on the boiler, make
sure you have disconnected it from
the electricity supply by switching the
external bipolar switch to the “OFF”
position. All repairs should only be
performed using original spare parts.
Information for the User
,QIRUPWKHXVHURQWKHPRGHRIRSH-
ration of the system.
6SHFL¿FDOO\GHOLYHUWRWKHXVHUWKHLQ-
struction manuals, informing him that
they must be stored with the applian-
ce.
$OVRUHPLQGWKHXVHUWR
tPeriodically check the water
pressure system and instruct him
on how to reintegrate and bleed.
tHow to set the temperature and
the adjusters for a correct and
more economical management
of the system.
tTo perform periodic maintenance
system, according to legislation.
tDo not change, in any case, the
settings for supply of air for com-
bustion and gas combustion.
tPay attention to the warnings
contained in the user manual.
General regulations
Informations for installer and maintenance service
Data plate
26-05-2015
S/N 0000000KE000000000000
00
100% min.
ηη
= =
0$; 0,1
Q(Hi)
P
P
&
30/50C
gas
mbar
gas
mbar
gas
mbar
1
2
345
6
7
8
9
10
11
12
13
14
15
16
17
18
/HJHQGă-HOPDJ\DUi]DW
Symbols used on the data plate
Legend :
1 Brand
2Country of origin
3Boiler model -
Serial number
4 Commercial reference
5&HUWL¿FDWLRQQXPEHU
6Destination country -
Gas category
7 Gas setting
 ,QVWDOODWLRQW\SH
9 Electrical data
10 Factory settings
11 Maximum water pressure
12 Boiler type
13 12[FODVV(I¿FLHQF\
14 ,QSXWUDWLQJQRPLQDOKHDWLQJ
15 Power output heating
16 Gases which may be used
17 Ambient operating temp.
 Max. central heating temp.

8
Construction
Layout of boiler
Operating principle
Operating principle
This boiler 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 combu-
VWLRQ¿JXUHVDQGWKHUHZLWKWKHEHVW
HI¿FLHQF\
7KHÀXH JDVHVFUHDWHGE\WKHFRP-
bustion are transported downwards
through the heat exchanger and lea-
ve the boiler at the top into the chim-
ney connection.
The return water from the system
enters the boiler in the lower section,
ZKHUHLVWKHORZHVWÀXHJDVWHPSHUD-
WXUHLQWKHERLOHU,QWKLVVHFWLRQ
condensation takes place.
The water is being transported
upwards through the heat exchanger,
LQRUGHUWROHDYHWKHERLOHUDWWKHÀRZ
connection.
7KHFURVVÀRZZRUNLQJSULQFLSOHZD-
WHU XS ÀXH JDV GRZQ HQVXUHV WKH
PRVWHI¿FLHQWFRPEXVWLRQUHVXOWV
The LMS14 control unit can control
WKHERLOHURSHUDWLRQEDVHGRQ
 boiler control (standalone opera-
tion);
 weather compensated operation
(with optional outdoor sensor);
 ZLWK 9 H[WHUQDO LQÀXHQFH
(temperature or capacity) from a
building management system.
Layout of boiler
The boiler consists of the
following main components:
1
2
3
4
5
6
7

9
10
11
12
13
14
15
16
17

19
20
21
22
23
24
25
Casing
Front panel
Adjustable feet
Control panel (below cover)
Flue gas connection
Air intake connection (under
casing)
Gas connection
Flow water connection
Return water connection
2nd (hot) return water connection
(for split system use), accessory
Filling/draining valve
Electrical input connections
Frame
Burner/1st heat exchanger
assembly
2nd/3rd heat exchanger assembly
Water headers
Condens tray
Whirlwind gas/air mixing system
Fan
Gas valve
Gas pressure switch
Sight glass
,JQLWLRQDQGLRQLVDWLRQHOHFWURGHV
Syphon
5HPRYDEOHÀXHJDVDGDSWHU
1
5 4
2
3
7 6

9
12
10
14
1524 13 1716
23
19

20 - 21
25
11
22

9GB
Technical data
R601 R602 R603 R604 R605 R606 R607
Nominal heat output at 80/60ºC max/min **
Nominal heat output at 75/60ºC max/min **
Nominal heat output at 40/30ºC max/min **
Nominal heat input Hi max/min **
Efficiency at 80/60ºC
Efficiency at 40/30ºC
Annual efficiency (NNG 75/60ºC)
Annual efficiency (NNG 40/30ºC)
Heat loss (Pstby)
Max. condensate flow
Gas consumption G20 max/min (10,9 kWh/m3)
Gas consumption G25 max/min (8,34 kWh/m3)
Gas consumption G31 max/min (12,8 kWh/kg)
Gas pressure G20
Gas pressure G25
Gas pressure G31
Maximum gas pressure
Max temperature flue gas
Flue gas temperature at 80/60°C max/min
Flue gas temperature at 40/30°C max/min
Flue gas quantity max/min
CO2level G20/G25 max/min
CO2level G31 max/min
NOxlevel max/min
CO level max/min
Max. permissible flue resistance max/min
Water volume
Water pressure max/min
Max. water temperature (High limit thermostat)
Maximum temperature setpoint
Nominal water flow at dT=20K
Hydraulic resistance at nominal water flow
Electrical connection
Frequency
Mains connection fuse
IP class
Power consumption boiler max/min (excl. pump)
Power consumption speed controlled pump (opt)
Weight (empty)
Sound Power Level LWA ***
Ionisation current average
pH value condensate
CE certification code
Water connections
Gas connection
Flue gas connection
Air intake connection (for room sealed use)
Condensate connection
kW 142,1/23,9 190,1/40,6 237,2/40,6 285,2/40,6 384,5/79,6 480,6/79,6 545,1/79,6
kW 142,2/23,9 190,3/40,6 237,4/40,6 285,5/40,6 384,9/79,7 481,1/79,7 545,6/79,7
kW 149,2/26,4 201,6/45,6 251,4/45,6 302,3/45,6 403,1/88,4 503,9/88,4 571,5/88,4
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
% 98,0 98,0 98,0 98,0 99,1 99,1 99,1
% 102,9 103,9 103,9 103,9 103,9 103,9 103,9
% 106.8
% 110,4
W 442 442 442 442 474 474 474
l/h 24,8 35,5 44,3 53,2 71 88,7 100,7
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
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
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
mbar 20
mbar 25
mbar 30/50
mbar 50
°C 100
°C 78/61
°C 56/30
m³/h 238/40 318/69 397/69 477/69 636/134 795/134 901/134
% 10,2/9,4
% 11,9/10,0
mg/kWh 35/15
mg/kWh 14/8
Pa 160/10 160/10 200/10 200/10 200/10 250/10 250/10
l 27 31 35 61 68 75 82
bar 8/1
°C 100
ºC 90
m³/h 6,1 8,1 10,2 12,2 16,3 20,4 23,1
kPa 10 18 28 15 27 42 55
V 230/400
Hz 50
A 16
- IP20
W 243/37 281/32 289/34 289/34 697/47 697/47 697/47
W 190/9 190/9 310/12 310/12 470/25 590/25 800/38
kg 295 345 400 465 535 590 650
dB 72 75 76 76 77 77 77
µA 14
- 3.2
- CE-0063BS3840
- R2” R2” R2” DN65PN16
- R3/4” R1” R1” R1” R1.1/2” R1.1/2” R1.1/2”
mm 150 150 200 200 250 250 250
mm 130 150 150 150 200 200 200
mm 40 40 40 40 40 40 40
** min load on gasses G20, G25, G31. For type R602-607 on gasses G25 (LL) the min value is 15% higher.
*** non room sealed.

10
Product information about the directive 2009/125/EG and regulation (EU) 813/2013
R600 Icon Unit 601 602 603 604 605
Condensing boiler - - Yes Yes Yes Yes Yes
Low-temperature boiler - - No No No No No
B1 boiler - - No No No No No
Cogeneration space heater - - No No No No No
Combination heater - - No No No No No
ErP Heating
Rated heat boiler Prated kW 142 190 237 285 384
At rated heat output and high-tempera-
ture regime P4 kW 142.1 190.1 237.2 285.2 384.5
At 30% of rated heat output and lowtem-
perature regime 1) P1 kW 47.8 63.9 79.7 95.9 127.8
Seasonal space heating energy effi-
ciency Ks % 94 94 94 94 94
At rated heat output and high-temperatu-
re regime 2) K4 % 88.3 88.3 88.3 88.3 89.3
At 30% of rated heat output and low
temperature regime 1) K1 % 98.9 98.9 98.9 98.9 98.9
Auxiliary electricity consumption
At full load elmax kW 0.243 0.281 0.289 0.289 0.697
At rated heat output and high-tempera-
ture regime elmin kW 0.037 0.032 0.034 0.034 0.047
At 30% of rated heat output and
lowtemperature regime 1) PSB kW 0.004 0.005 0.004 0.004 0.009
Supplementary heater
Standby heat loss Pstby kW 0.442 0.442 0.442 0.474 0.474
Ignition burner power consumption Pign kW 0.000 0.000 0.000 0.000 0.000
Emissions of nitrogen oxides NOXmg/kWh 35 35 35 35 35
1) by return temperature 30°C
2) by return temperature and feed temperature (60-80°C)
Product information ErP
R600

11 GB
Dimensions
Dimension
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(DN) 130 1150 2150 2150 2200 3200 3200 3
D2 mm(DN) 150 2150 2200 3200 3250 4250 4250 4
W1 R” / DN R2” R2” R2” DN65 PN16
W2 R” / DN R2” R2” R2” DN65 PN16
G R R3/4” R1” R1” R1” R1 1/2”
R601 R602 R603 R604 R605 R606 R607
1
DN 130 = Øint. 131
±0.3
mm;
2
DN 150 = Øint. 151
±0.3
mm;
3
DN 200 = Øint. 201
±0.3
mm;
4
DN 250 = Øint. 251
±0.3
mm
Components
1 Electrical connections
2 Gas supply
3 Water supply
4 Water return (Cold)
5 Air Intake (under casing)
6 Water 2nd return (optional)
7 Boiler water drain valve 1/2”
8 Flue gas Outlet
9 Condensate drain flexible hose 25 mm diameter

12
Extend of delivery
Standard boiler
Accessories
Standard boiler
$ERLOHUGHOLYHU\SDFNDJHFRQWDLQVWKHIROORZLQJFRPSRQHQWV
Accessories
Additional to the boiler, the following
DFFHVVRULHVFDQEHRUGHUHG
tSpeed controlled pump incl. con-
nection kit;
tSafety valve, manometer and de-
aerator (3,4,5 or 6 bar) incl. con-
nection kit;
t2x max. water pressure switch
and 1 external high limit thermo-
stat incl. connection kit;
t*DV¿OWHULQFOFRQQHFWLRQNLW
tMax. gas pressure switch;
tExternal high limit thermostat
incl. connection kit;
tGas valve leakage tester (not
possible for R601);
t2nd Return connection for
Split System use;
tControlled bypass (incl. pump)
incl. connection kit;
tPlate heat exchanger
(dT=10K/15K or dT=20K) incl.
connection kit;
tLow velocity header, suitable for
dT=10K/15K and dT=20K incl.
connection kit;
tDuo header for connecting 2 boi-
lers in cascade (excl. connection
kit);
tExtension module AVS75 for he-
ating zone control or external gas
valve and/or room fan control.
For each boiler a maximum of
3 AVS75 modules (2x heating
zone, 1x ext. gas valve / room fan)
can be integrated in the boiler;
tAdditional RVS63 heating zone
controller, when controlling more
than 2 zones (incl. wall hung box,
all necessary sensors and so-
ckets and connection material for
bus communication).
The above accessories are specially
designed for the R600 boiler and the-
rewith easy to install (plug and play).
By choosing a combination of the kits
mentioned above, you can create
your own complete system solution.
Ask your supplier for more detailed
information.
Component Pcs. Package
Boiler fully assembled and tested 1 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)
2SHUDWLRQDQG,QVWDOODWLRQPDQXDO 1 Map attached to back panel of the boiler

13 GB
Installation
Boiler transport
!

%
Boiler transport
The boiler will be supplied as a
complete unit being fully assembled
and pre-tested. The maximum width
is 670mm for models R601-R603
and 770mm for models R604-R607,
which makes it possible to transport
all models through a normal door in
one piece. The boiler can be tran-
sported 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 di-
smantled parts with their weight and
dimensions.
When the boiler has to be transported
with a crane, it is necessary to remo-
ve the casing before connecting the
boiler to the crane. Always connect
the crane to the frame of the boiler by
using straps.
R601 R602 R603 R604 R605 R606 R607
Component
Burner/1st heat
exchanger assembly
Weight [kg]
Length [mm]
Width [mm]
Height [mm]

735
400
321
100

400
321
112
1035
400
321
135
735

321



321

1035

321



321
2nd/3rd heat exchanger
assembly
Weight [kg]
Length [mm]
Width [mm]
Height [mm]
90
735
400
244
103

400
244
116
1035
400
244
150
735

244
170


244

1035

244
219


244
Condensate receptacle
Weight [kg]
Length [mm]
Width [mm]
Height [mm]
7


225
9
739

225
10


225
11

665
225
12
739
665
225
13

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

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

1304
202
11

1304
202
11

1304
202
12

1304
202
12

1304
202
12

1304
202
12

1304
202
R600
1 Hoisting belt (4x)
2 Wooden retaining beam (2x)
3 Hoisting belt position (4x)

14
Installation
Removing the casing
!
-
.
9
:
.<
2@
!:
":
#:
$:
:
%:
Removing the casing
Remove the casing before transporting
the boiler, in order to avoid damage to
the casing parts during transportation.
5HPRYLQJWKHFDVLQJLVGRQHDVIROORZV

15 GB
Installation
Warnings before installation
Boiler installation
,QVWDOODWLRQ¿UVWLJQLWLRQPDLQWHQDQFHDQGERLOHUUHSDLUPXVWEHSHUIRUPHGE\
TXDOL¿HGSHUVRQVDFFRUGLQJWRWKHQDWLRQDOLQVWDOODWLRQSURYLVLRQVDQGDQ\
requirements of the local authorities and public health agencies.
Before installing the appliance
%HIRUHFRQQHFWLQJWKHERLOHULWLV¿UVW
necessary to perform the following
RSHUDWLRQV
tCarefully wash the system piping
in order to remove any screw
thread or welding residues, or
any dirt which might prevent the
boiler from operating correctly;
tMake sure that the boiler is set
up for operation with the type of
gas available (read the informa-
tion on the packaging label and
on the boiler data plate);
tMake sure that there are no obsta-
FOHVLQVLGHÀXHH[KDXVWDQGWKDW
it does not contain any dischar-
ge from other appliances, unless
WKHÀXH LVPHDQWWR VHUYHPRUH
than one user (in accordance
with current legal requirements);
tWhere there is already a con-
QHFWLRQWRH[LVWLQJÀXHH[KDXVWV
check that these exhausts have
been perfectly cleaned and are
without residues, because any
disconnection could obstruct the
passage of fumes and create po-
tentially dangerous situations;
tMake sure that, where unsuitable
ÀXHH[KDXVWVDUHDWWDFKHGWKH\
have been ducted;
t,Q DUHDV ZLWK SDUWLFXODUO\ KDUG
water, limescale may build up on
the components inside the boiler
DQGUHGXFHLWVRYHUDOOHI¿FLHQF\
t,QFDVHRILQVWDOODWLRQQHDUZDOO
sensitive to heat (for example
wood) make sure to protected it
by suitable insulation;
tObserve the clearance between
the wall on which the boiler is
installed and the hot parts on the
outside of the boiler.
WARNING!
1R LQÀDPPDEOH LWHPV VKRXOG EH
left near the boiler.
Make sure the installation site
and any systems to which the
appliance must be connected
are fully compliant with the
current applicable legislation.
Install the boiler respecting the
minimum distances from any
ÀDPPDEOHPDWHULDOV
If dust and/or aggressive
vapours are present in the room
in which it is to be installed, the
appliance must operate indepen-
dently of the air inside the room.
Boiler installation
The boiler should be positioned in a
IURVWSURRI ERLOHU URRP ,I WKH ERLOHU
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 cle-
arance in the picture. When the boi-
ler is positioned with less free space,
maintenance activities will be more
GLI¿FXOW
Once the boiler is in the correct po-
sition, the wooden blocks (1) should
be removed and the adjustable feet
(2) (with vibration absorption dam-
pers) 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.
1
2
฀
2
฀

16
Connecting the boiler
This chapter will explain how to make
all connections to the boiler with re-
JDUGWR
tHydraulic connections
tCondensate drain connection
tGas connection
tFlue gas connection
tAir intake connection
(under casing)
tElectrical connection
The boiler should always be con-
nected in such a way, that the system
applies to all relevant standards and
regulations (European, national and
ORFDO ,W¶V WKH UHVSRQVLELOLW\ RI WKH
installer to ensure that all standards
and regulations are respected.
Hydraulic connections
The boiler should always be con-
QHFWHGLQVXFKDZD\WKDWZDWHUÀRZ
through the boiler can be ensured at
all times.
&RQQHFW WKH ÀRZ  DQG UHWXUQ 
connection of the system tension free
to the boiler connections.
The (optional) 2nd return kit allows
the boiler to be used in a system with
two return circuits. The common re-
turn becomes the low temperature
return, the 2nd return connection (6)
is the high temperature return.
The (optional) accessory kit with
safety valve, manometer and deae-
UDWRUVKRXOGEHPRXQWHGRQWKHÀRZ
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.
Installation
Connecting the boiler
Condensate connection
$IWHU ¿OOLQJ ZLWK ZDWHU WKH V\SKRQ
(included in delivery) should be in-
stalled to the connection at the
bottom of the condens tray.
Lead the hose under the frame
at the back of the boiler and con-
nect it to the draining system in the
boiler room. The connection to the
draining system should always be
done with an open connection,
LQ RUGHU WR DYRLG D ÀRRGLQJ RI WKH
boiler in case of a blocked drain.
5
4
1
3
6

Gas connection
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.
$ JDV ¿OWHU FDQ EH PRXQWHG GLUHFWO\
on the gas connection of the boiler.

17 GB
Requirements and regulations
Regulations for the construction of
ÀXH JDV V\VWHPV DUH YHU\ GLIIHUHQW
IRUHDFK FRXQWU\ ,WVKRXOGEH HQVX-
red that all national regulations with
UHJDUG WR ÀXH JDV V\VWHPV DUH UH-
spected.
Pay attention to the following recom-
mendations when dimensioning a
ÀXHJDVV\VWHP
2QO\DSSURYHGÀXHJDVPDWHULDOPD\
EH XVHG 7KH ÀXH JDV V\VWHP PXVW
be properly calculated to ensure a
safe functioning of the system.
Flue gas system components should
be removable for maintenance pur-
poses.
You have to take in consideration the
following material requirements.
Materials
Exclusively materials which are heat
UHVLVWDQWDQGUHVLVWDQWWRÀXHJDVHV
and aggressive condensate, and CE
approved may be used.
,QSDUWLFXODUIRUÀXHJDVV\VWHPVHH
the following data.
Installation
Air/Flue gas system
Plastic
PP*
Stainless
steel**
Temperature
class: T120 T250
Pressure
class P1 P1
Corrosion
class: W1 W1
* Use material with “E” reaction top
¿UHFODVVDVPLQLPXP
** Stainless steel is admitted but with
a minimum wall thickness, which
depends on the country regulation.

18
Installation
Air/Flue gas system
Air intake connection
The air intake can be connected in
case of room sealed installation. The
cover (3) must be disassembled in or-
der to connect the air intake piping to
the connector inside the boiler.
The diameter should be calculated
according to the national regulations,
WRJHWKHU ZLWK WKH ÀXH JDV V\VWHP
The total resistance of both systems
should never overcome the maxi-
mum permissible resistance of the
fan inside the boiler (see also chap-
WHU7HFKQLFDOGDWD
Flue gas connection
&RQQHFW WKH ÀXH JDV V\VWHP WR WKH
ÀXHJDVFRQQHFWLRQRIWKHERLOHU
XVHÀXHJDVV\VWHPVZLWKVHDPOHVV
FRQQHFWLRQV RQO\ ,W¶V QRW QHFHVVD-
ry to make a separate condensate
GUDLQIRUWKHÀXHJDVV\VWHPDVWKH
condensate will be drained via the
syphon of the boiler. Please note the
IROORZLQJLVVXHV
t7KHGLDPHWHURIWKHÀXHJDVV\-
stem must be chosen by calcu-
lation according to the national
regulations
t&RQVWUXFWWKHÀXHJDVV\VWHPDV
short as possible (for maximum
length see planner documenta-
tion)
tConstruct horizonal ways with a
minimum angle of 3º.
&RQQHFWLQJWKHÀXH
7KH ÀXH JDV H[KDXVW GXFWLQJ PXVW
not be in contact with or placed near
ÀDPPDEOH PDWHULDOV DQG PXVW QRW
cross building structures or walls
PDGHXVLQJÀDPPDEOHPDWHULDO
This boiler has an integrated high li-
PLW WKHUPRVWDW IXQFWLRQ IRU WKH ÀXH
JDVHV :KHQ WKH ÀXH JDV WHPSHUD-
ture exceeds 100 ºC, the burner is
switched off. With this function, an
additional (external) safety device is
not necessary.
When replacing an old boiler, the
YHQWLODWLRQ DQG ÀXH JDV H[KDXVW
system must always be replaced.
7KH ÀXH JDV H[KDXVW GXFWLQJ
joint should be created using a
male/female coupling and a seal.
Couplings should always be arran-
ged so that they go against the direc-
WLRQRIWKHFRQGHQVDWHÀRZ
1
7
3
2
Legend:
1. Gas Connection
2. Electrical connection
3. Air intake connection
7. Flue gas connection

19 GB
Combustion air
drawn from the
room
B23 ([WHUQDOÀXHJDVH[KDXVW$LUGUDZQIURPWKHURRP
Combustion
air intake from
cascade
C63
Air and exhaust connection to separate tested and supplied air /
exhaust pipes.
%DVHPHQWÀRRULQVWDOODWLRQ
Air and exhaust venting via exterior wall.
Exhaust venting through heat insulated exhaust pipe or moistu-
re-resistant pipe.
Exhaust line (standing air layer) at exterior wall.
The terminals for the supply of combustion air and for the eva-
cuation of combustion products shall not be installed on opposite
walls of the building.
Installation
Air/Flue gas system
R601
R602
R603
R604
R605
R606
R607
kW kW mm % °C g/s Pa
max min max min max min max min max min max min
142.1 23.9 145.0 24.5 150
10.2 9.4  30
70 13 160 10
190.1 40.6 194.0 41.5 150 93 22 160 10
237.2 40.6 242.0 41.5 200 116 22 200 10
 40.6 291.0 41.5 200 140 22 200 10
 79.6   250  43 200 10
 79.6   250 233 43 250 10
545,1 79.6 550,0  250 264 43 250 10

 
Flue gas data
Boiler
type
Nominal heat
output
Nominal heat
input
Flue
gas
connection
CO ഺ
Level
Flue gas
temperature
Flue gas
quantity
Max
permissible
ÀXHUHVLVWDQFH

20
Ø110 Ø130 Ø150 Ø200 Ø250
15 40 55
22 39 55
31 55
21 55
55 55
44 55
34 55
Ø110 Ø130 Ø150 Ø200 Ø250
10 35 50
17 34 50
26 50
16 50
50 50
39 50
29 50
Installation
Flue gas system
Dimensioning single
Dimensioning
:KHQ GLPHQVLRQLQJ D ÀXH JDV
system, it’s necessary to perform
D FDOFXODWLRQ FKHFN RI WKH ÀXH JDV
system in order to verify if the
choosen system is applicable.
The following table shows two
H[DPSOHV RI SRVVLEOH ÀXH JDV
systems, including the maximum
possible length of the system.
These examples only give an
indication of the possible length, but
WKH\FDQQRWEHXVHGIRURI¿FLDOÀXH
JDVOD\RXWFDOFXODWLRQ(DFKÀXHJDV
system must be calculated by an
authorized company.
7KH PD[LPXP QHJDWLYH ÀXH JDV
pressure, which doesn’t affect the
burner modulation ratio, is 30 Pa.
Higher negative pressure will lead
to limitation of the burner modulation
ratio.
7KHPD[LPXPKRUL]RQWDOÀXHJDVZD\
is 20 m. With horizontal ways longer
than 20 m, a faultless burner start in
cold condition can not be guaranteed.
R601
R602
R603
R604
R605
R606
R607
R601
R602
R603
R604
R605
R606
R607
7ZLQSLSHÀXHJDV
system
&DOFXODWLRQEDVH
Total connection length
LQERLOHUURRPP
without bends
Maximum permissible lenght (m)
RIÀXHJDVV\VWHP
Boiler type
Max length reduction tEHQGPHWHUV
tEHQGPHWHUV
Example
&DOFXODWLRQEDVH
7RWDOFRQQHFWLRQOHQJWKLQERLOHUURRPP
[EHQG
Maximum permissible lenght (m)
RIÀXHJDVV\VWHP
Boiler Type

21 GB
Installation
Electrical connection

!!
Electrical connection
The electrical connection must be
made by an authorized installer
in accordance with the applicable
national and local standards and
regulations.
For the power supply it’s necessary
to use a mains isolator switch with
a contact opening of at least 3 mm
within the boiler room. This switch
can be used to switch off the power
supply for maintenance purposes.
All cables should be lead through
the cable glant from the back of the
boiler into the electric panel (11).
Connect all wires to the terminals
according to the wiring diagram of
the boiler (see next pages).
It is mandatory connecting the
boiler to a suitable earth connec-
tion

22
Installation Wiring diagram - Boiler
Main gas valve
Pressure switch
Room fan. (2A max.)
Mod. feedback
0-10V DC
LPB Bus
Enable
Ext. Setpoint
0-10V DC
Outside
temp. sensor
DHW thermostat
or
DHW temp. sensor
Min. gas
pressure switch
Common flow
temp. sensor