STOKVIS ENERGY SYSTEMS R6142 User manual

ECONOFLAME R6000
GAS FIRED
CONDENSING BOILERS
OPTIONS & SYSTEMS
DOCUMENTATION
STOKVIS ENERGY SYSTEMS
96R WALTON ROAD
EAST MOLESEY
SURREY
KT8 0DL
TEL: [phone]
FAX: [phone]
E-MAIL:[email protected]
WEBSITE:www.stokvisboilers.com
03/2008 ART NR. 12 083 431 GB

Contents
2
Gas condensing boiler R6000Models and output ................................................................................................4
Application possibilities.........................................................................................4
Value propositions ................................................................................................4
Technical description Description ...........................................................................................................4
Technical data ......................................................................................................5
Dimensions...........................................................................................................6
Declaration of conformity .....................................................................................7
Extent of delivery .................................................................................................8
Boiler transport .....................................................................................................8
Boiler installation ..................................................................................................8
Norms and regulations Regulations ..........................................................................................................9
Maintenance.......................................................................................................10
Fuel ....................................................................................................................10
Combustion air ...................................................................................................10
Water quality ......................................................................................................10
Noise protection..................................................................................................11
Antifreeze ...........................................................................................................11
Flue gas system Requirements and regulations ............................................................................12
Materials.............................................................................................................12
Flue gas data......................................................................................................12
Dimensioning......................................................................................................13
Neutralisation General...............................................................................................................14
Neutralisation systems........................................................................................14
Hydraulic connection Hydraulic resistance ...........................................................................................15
T-measurement................................................................................................15
p-measurement ................................................................................................15
Hydraulic connection into a system ....................................................................16
Standard.............................................................................................................16
Bypass ...............................................................................................................16
Split System .......................................................................................................17
Controls Basic controls and connections ..........................................................................18
Control by building managemant system ............................................................18
Boiler enable signal ............................................................................................18
Temperature or capacity setpoint........................................................................18
Capacity feedback signal....................................................................................19
OK/Alarm output signal.......................................................................................19
Weather compensated controller BM8................................................................19
Heating zone controller E8..................................................................................20
Cascade manager KKM8....................................................................................21

Contents
3
Accessories System selection ................................................................................................22
Plug & Play kits
Kit A: 2x max. Water pressure switch + 1x external high limit thermostat............23
Kit B: max. gas pressure switch..........................................................................23
Kit C: external high limit thermostat ....................................................................23
Kit D: gas valve leakage tester ...........................................................................23
Kit E: bypass ......................................................................................................23
Kit F: wiring for room fan and external gas valve ................................................23
Kit G: plate heat exchanger + connection kit.......................................................24
Kit H: low loss header + connection kit ...............................................................24
Kit I: BM8............................................................................................................25
Kit K: E8 extended heating zone control .............................................................25
Kit L: pump 3-step ..............................................................................................25
Kit M: speed controlled pump .............................................................................27
Kit N/O/P/Q: safety valve (3-4-5-6 bar) TÜV + manometer + de-aerator .............28
Kit R: gasfilter .....................................................................................................28
Set S: LOGON B ................................................................................................29
Connection possibilities
Low loss header ................................................................................................30
Plate heat exchanger .........................................................................................31
Installation examples 2-A-C: 1 heating zone + low loss header ...........................................................32
2-5-A-C: 1 heating zone and sanitary hot water + low loss header .....................33
4-A-C: 2 heating zones + low loss header ..........................................................34
4-5-A-C: 2 heating zones and sanitary hot water + low loss header ...................35
A-C: Boiler control via 0-10VDC + low loss header ............................................36
2-B-C: 1 heating zone + plate heat exchanger ...................................................37
2-5-B-C: 2 heating zones and sanitary hot water + plate heat exchanger ..........38
4-B-C: 2 heating zones + plate heat exchanger ..................................................39
4-5-B-C: 2 heating zones and sanitary hot water + plate heat exchanger ..........40
B-C: Boiler control via 0-10VDC + plate heat exchanger ....................................41
4-5-A-C-E: 2 heating zones and sanitary hot water
+ cascade via low loss header............................................................................42
Extension 2 heating zones .................................................................................43
Norms ...........................................................................................................................44

Gas condensing boiler R6000
Models and output
Application possibilities
Value propositions
Technical description
4
Models and output
The floor standing gas condensing
boiler R6000is available in 7 types
within an output range from 142 until
539 kW.
Application possibilities
The gas condensing boiler R6000is
applicable for alle central heating sys-
tems built according to EN12828. In
cascade applications (max. 8 boilers
with KKM8 cascade manager) the
R6000can cover installations up to
4300kW.
Preferred applications are central
heating and sanitary hot water
production in multi-family buildings,
municipal and industrial buildings.
Value propositions
• Unique reliability
proven technology with exceptional
high quality
• Highest system flexibility
easy planning and Plug & Play instal-
lation with pre-assembled system kits
• Easy maintenance
boiler design optimised for easy ac-
cess on servicing
• Unequalled lifetime high efficiency
corrosion resistant stainless steel
heat exchanger
• Environmental friendly
lowest emission values
Description
The R6000is a fully modulating boiler.
The control unit of the boiler adapts the
modulation ratio automatically to the
heat demand requested by the system.
This is done by controlling the speed of
the fan. As a result, the Whirlwind mix-
ing system will adapt the gas ratio to
the chosen fan speed, in order to main-
tain the best possible combustion fig-
ures and therewith the best efficiency.
The flue gases created by the combus-
tion are transported downwards
through the boiler and leave at the back
side into the chimney connection.
The 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.
4
1
2
3
5
1 Water cooled premix burner
2 Water cooled stainless steel heat exchanger (3 levels)
3 Speed controlled Whirlwind gas/air mixing system
4 KM628 boiler management unit
5 Space for neutralisation-equipment

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

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

Technical description
Declaration of conformity
7

Technical description
Extent of delivery
Boiler transport
Boiler installation
8
Boiler installation
The boiler should be positioned in a
frost-proof boiler room. If the boiler
room is on the roof, the boiler itself may
never be the highest point of the
installation.
When positioning the boiler, please
note the recommended minimum
clearance in the picture. When the
boiler is positioned with less free space,
maintenance activities will be more
difficult.
The (inter)national and local norms for
the installation of heating systems
should be respected at all times.
Standard boiler
A boiler delivery package contains the following components:
Component Pcs. Package
Boiler fully assembled and tested 1 Mounted on wooden blocks with wooden border,
sealed in PE foil
Adjustable feet 4 Mounted on frame of the boiler
Syphon for condensate connection 1 Cardboard box on top of heatexchanger
(under casing)
Conversion kit for natural gas L and propane incl. instruction 1 Cardboard box on top of heatexchanger
(under casing)
Operation and Installation manual 1 Map attached to back panel of the boiler
Spare parts list 1 Map attached to back panel of the boiler
Wiring diagram 1 Map attached to back panel of the boiler
Integrated additional system controller , incl. all necessary
sensors and sockets (optional)
1 Integrated in electronic switchboard of the boiler.
Sensors and sockets in cardboard box on top of
the heatexchanger (under casing).
Component 6142 6190 6237 6285. 6380. 6475 6539
Burner/1st heat exchanger assembly Weight [kg]
Length [mm]
Width [mm]
Height [mm]
86
735
400
321
100
885
400
321
112
1035
400
321
135
735
680
321
158
885
680
321
181
1035
680
321
198
1185
680
321
2nd/3rd heat exchanger assembly Weight [kg]
Length [mm]
Width [mm]
Height [mm]
90
735
400
244
103
885
400
244
116
1035
400
244
150
735
680
244
170
885
680
244
198
1035
680
244
219
1185
680
244
Condensate receptacle
Weight [kg]
Length [mm]
Width [mm]
Height [mm]
7
589
385
225
9
739
385
225
10
889
385
225
11
589
665
225
12
739
665
225
13
889
665
225
15
1039
665
225
Frame
Weight [kg]
Length [mm]
Width [mm]
Height [mm]
15
990
624
335
16
1140
624
335
17
1350
624
335
17
1100
724
335
18
1320
724
335
19
1470
724
335
21
1620
724
335
Front U-frame with electronic board Weight [kg]
Length [mm]
Width [mm]
Height [mm]
11
628
1304
202
11
628
1304
202
11
628
1304
202
12
728
1304
202
12
728
1304
202
12
728
1304
202
12
728
1304
202
Boiler transport
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.

Norms and regulations
9
Additional national standards
Germany:
−RAL - UZ 61 / DIN 4702-8
Switzerland:
−SVGW
Netherlands:
−NOx staatsblad 344 (1994)
−GASKEUR BASIS
−GASKEUR SV
−GASKEUR HR107
Belgium:
−HR TOP
The R6000boiler is CE approved and
applies to the following European
standards:
− 92 / 42 / EEC
Boiler efficiency directive
− 90 / 396 / EEC
Gas appliance directive
− 73 / 23 / EEC
Low voltage directive
− 89 / 336 / EEC
EMC directive
−EN 656
Gas-fired central heating boilers –
Type B boilers of nominal heat input
exceeding 70 kW but not exceeding
300 kW
−EN 15420
Gas-fired central heating boilers -
Type C boilers of nominal heat input
exceeding 70 kW, but not exceeding
1000 kW
−EN 15417
Gas-fired central heating boilers -
Specific requirements for condensing
boilers with a nominal heat input
greater than 70 kW but not exceeding
1000 kW
−EN 13836
Gas fired central heating boilers -
Type B boilers of nominal heat input
exceeding 300 kW, but not exceeding
1000 kW
−EN 15502-1
Gas-fired central heating boilers -
Part 1: General requirements and
tests
−EN 55014-1
Electromagnetic compatibility - Re-
quirements for household appliances,
electric tools and similar apparatus -
Part 1: Emission
−EN 55014-2
Electromagnetic compatibility - Re-
quirements for household appliances,
electric tools and similar apparatus -
Part 2: Immunity - Product family
standard
−EN 61000-3-2
Electromagnetic compatibility (EMC) -
Part 3-2: Limits - Limits for harmonic
current emissions (equipment input
current 16 A per phase)
−EN 61000-3-3
Electromagnetic compatibility (EMC) -
Part 3-3: Limitation of voltage
changes, voltage fluctuations and
flicker in public low-voltage supply
systems, for equipment with rated
current 16 A per phase and not sub-
ject to conditional connection
−EN 60335-1
Household and similar electrical appli-
ances - Safety - Part 1: General re-
quirements
−EN 50165
Household and similar electrical appli-
ances - Safety - Part 2-102: Particular
requirements for gas, oil and solid-
fuel burning appliances having
electrical connections
Norms and regulations
When installing and operating the
boiler, all applicable norms (european
and local) should be fulfilled:
• Local building regulations for install-
ing combustion air and flue gas sys-
tems;
• Regulation for connecting the boiler to
the electrical appliance;
• Regulations for connecting the boiler
to the local gas network;
• Norms and regulations according to
safety equipment for heating systems;
• Any additional local laws/regulations
with regard to installing and operating
heating systems.
An overview of the most important nati-
onal norms can be found in the chapter
„Norms“.

Norms and regulations
Maintenance
Fuel
Combustion air
Water quality
10
Maintenance
Regular maintenance is necessary to
secure a safe and economical operati-
on of the installation. For the R6000, one
annual maintenance visit is recommen-
ded. During this visit, the proper functi-
oning of the complete heating system
should be checked as well.
Water quality
The lifetime of the complete heating
system is affected by the water quality.
Additional costs for water treatment of
an installation are always lower than
repairing costs for damage created by
poor water quality.
Fuel
The gas condensing boiler R6000 is
applicable for natural gases H, L and
LL, and for LPG. Factory settings are
always done for H-gas. For other types
of natural gas, a correction can be ma-
de on the gas valve. For LPG, it’s ne-
cessary to change the gas injector
(included in delivery) before operating
the boiler.
The R6000 can work with gas pressures
up to 100 mbar. In case of a gas pres-
sure above 100 mbar, a pressure regu-
lator should be fitted in the gas line.
The gas consumption and gas pressu-
res of the different gases can be found
in the chapter „Technical data“.
Combustion air
The gas condensing boiler R6000 can
be used in both non-roomsealed and
roomsealed applications. The com-
bustion air to the boiler shouldn’t con-
tain high concentrations of dust and/or
halogen, as they can damage the heat
exchanger surface. Especially in buil-
dings, where chemicals are used, the
combustion air facility should prevent
these chemicals to enter the boiler.
The different room sealed connection
possibilities the R6000 is approved for,
can be found in the chapter „Flue gas
system“.
The following water quality levels must
be respected at all times for warranty
claiming. Damage to the boiler due to
poor water quality will not be taken un-
der warranty.
The system should be filled with water
with a PH value between 8,0 and 9,5.
The chloride value of the water should
not exceed 50 mg/l. Entry of oxygene
by diffusion should be prevented at all
times. Damage to the heat exchanger
because of oxygene diffusion will not
be taken under warranty.
Boiler output
[kW]
Max. sum of alkaline earths
[mol/m3]
Max. total hardness
[dºH]
50 - 200 2.0 11.2
200 - 600 1.5 8.4
Concentrate
Ca(HCO3)2
Capacity of installation Q (kW)
150 200 250 300 400 500 600
mol/m3dºH Maximum water (re)fill volume Vmax [m3]
0.5 2.8 - - - - - - -
1.0 5.6 - - - - - - -
1.5 8.4 3 4 5 6 8 10 12
2.0 11.2 3 4 5 6 6.3 7.8 9.4
2.5 14.0 1.9 2.5 3.1 3.8 5.0 6.3 7.5
3.0 16.8 1.6 2.1 2.6 3.1 4.2 5.2 6.3
In installations with higher water
volumes, it’s necessary to respect the
maximum filling and additional volumes
with corresponding hardness values as
stated in the german VDI2035
standard. In the table you can find the
nominal values for filling and additional
water for the R600 according to the the
VDI2035.
The table at the left gives an indication
of the relation between the water
quality and the maximum water filling
volume during the lifetime of the boiler.
Consult the original text of the VDI2035
for more detailed information.
Constant entry of oxygene in the
installation should be avoided. The
system water pressure should be
higher than the atmospheric pressure in
all parts of the installation. Underfloor
heating components without oxygen
diffusion barrier should never be used.
When they’re used anyway, a system
separation (f.e. with plate heat
exchanger) is compulsory.

Norms and regulations
Noise protection
Antifreeze
11
Noise protection
The gas condensing boiler R6000 is
equipped with a patented premix bur-
ner. The noise level of this very quiet
premix burner is extremely low in com-
parison to conventional gas burners.
Therefore no further measures have to
be taken for noise protection in the boi-
ler room.
Antifreeze
The R6000 can be used with the an-
tifreeze type Shell Antifreeze Con-
centrate. The concentration of the an-
tifreeze in the system affects the maxi-
mum capacity the boiler can work on.
The relation between antifreeze con-
centration and capacity reduction of the
boiler can be found in the graph.
The R6000 is supplied with adjustable
feet, which also prevent the transmissi-
on of vibration noise from the boiler into
the building.
Noise created by system components
(f.e. pumps) should be taken care of
with external measures, in case of hig-
her noise level requirements.
0
10
20
30
40
50
10 15 20 25 30 35 40 45 50 55
Antifreeze [%]
Capacity reduction [%]

Flue gas system
Requirements and regulations
Materials
Flue gas data
12
Boiler
type
Nominal heat
output
Nominal heat
input
Flue gas
connection
CO2
level
Flue gas
temperature
Flue gas
quantity
Max. permissible flue
resistance
kW kW mm % ºC kg/s Pa
max min max min max min max min max min max min
6142 142.1 23.3 145.0 24.5 150
10.2 9.4 78 30
0.070 0.013 160 10
6190 190.1 39.5 194.0 41.5 150 0.093 0.022 160 10
6237 237.2 39.5 242.0 41.5 200 0.116 0.022 200 10
6285 285.2 39.5 291.0 41.5 200 0.140 0.022 200 10
6380 380.2 76.6 388.0 80.5 250 0.186 0.043 200 10
6475 475.3 76.6 485.0 80.5 250 0.233 0.043 250 10
6539 539.0 76.6 550.0 80.5 250 0.264 0.043 250 10
Requirements and regulations
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. The most
important national norms can be found
in the chapter „Norms“.
Pay attention to the following recom-
mendations when dimensioning a flue
gas system:
Only approved flue gas material may
be used.
The flue gas system must be properly
calculated to ensure a safe functioning
of the system.
Flue gas system components should be
removable for maintenance purposes.
Horizontal flue gas ways must be
mounted under an angle of 3º mini-
mum.
A separate condensate drain for the
chimney is not necessary, as the con-
densate can enter the drain via the
syphon connection of the boiler.
The R6000 is certified for the flue gas
systems B23 (and B23P for France)
and C33, C53 and C63.
Materials
Exclusively materials, which are heat
resistant and resistant to flue gases
and aggressive condensate, may be
used. Recommended materials are
plastic (PPS, category T120) or stain-
less steel. Aluminium (only thick wall!)
can also be used (in Germany only
after consulting the chimney sweeper).
The R6000 has an integrated high limit
thermostat function for the flue gaes.
When the fluegas temperature exceeds
100ºC, the burner is switched off. With
this function, an additional (external)
safety device is not necessary.
Flue gas data

Flue gas system
Dimensioning
13
VERSION 1
Calculation base:
Total connection length in boiler room 1.5 m;
2x 87°-bend
Maximum permissible height (h) of flue gas
system in m
Boiler type Ø 110
[mm]
Ø 130
[mm]
Ø 150
[mm]
Ø 200
[mm]
Ø 250
[mm]
6142 10 35 50
6190 17 34 50
6237 26 50
6285 16 50
6380 50 50
6475 39 50
6539 29 50
VERSION 2
Calculation base:
Total connection length in boiler room 3 m;
4x 87°-bend
Maximum permissible height (h) of flue gas
system in m
Boiler type Ø 110
[mm]
Ø 130
[mm]
Ø 150
[mm]
Ø 200
[mm]
Ø 250
[mm]
6142 5 29 50
6190 11 27 50
6237 19 50
6285 9 50
6380 43 50
6475 31 50
6539 20 50
Dimensioning
When dimensioning a flue gas system,
it’s necessary to perform a calculation
check of the flue gas system in order to
verify if the choosen system is appli-
cable.
The following table shows two
examples of possible flue gas systems,
including the maximum possible height
of the system. These examples only
give an indication of the possible
heights, but they can not be used for
official flue gas layout calculation. Each
flue gas system must be calculated by
an authorized company.
The maximum negative flue gas pres-
sure, which doesn’t affect the burner
modulation ratio, is 30 Pa. Higher nega-
tive pressure will lead to limitation of
the burner modulation ratio.
The maximum horizontal flue gas way
is 20 m. With horizontal ways longer
than 20 m, a faultless burner start in
cold condition can not be guaranteed.

Neutralisation
General
Neutralisation systems
Standard neutralisation system (DN)
Neutralisation system with pump (HN)
14
General
Condensate, created by the R6000,
should be drained into the public drai-
ning system. The condensate PH is
between 3.0 and 3.5. National and/or
local regulations have to be checked, in
order to find out whether the condensa-
te should be neutralised before entering
the public draining system.
Type DN2 DN3
Applicable for [kW] 450 1500
Length [mm] 420 640
Width [mm] 300 400
Height [mm] 240 240
Type HN1.5 HN2.5
Applicable for [kW] 280 540
Length [mm] 410 640
Width [mm] 300 400
Height [mm] 290 240
Power con-
sumption pump
[W] 40 150
Pump head [m] 6 3
Neutralisation systems
The neutralisation systems can be pla-
ced in the bottom section of the boiler.
The delivery of the system contains the
following components:
• Granulate for first filling
• Connection hoses for inlet and outlet
connection
• Boiler connection adapter
For the neutralisation two different sys-
tems are available:
Standard neutralisation system (DN)
The standard neutrlisation system is used, when the public draining connection is
at lower level than the boiler syphon connection.
Neutralisation system with pump (HN)
The neutralisation system with pump is used, when the public draining system is at higher level than the boiler syphon con-
nection and the condensate needs to be transported to a higher level before draining is possible. The built-in pump of the
neutralisation system takes care of the transport of the condensate.
The maximum amount of condensate
for each boiler type can be found in the
chapter „Technical data“.

Hydraulic connection
Hydraulic resistance
∆T-measurement
∆p-measurement
Water flow data
15
Hydraulic resistance
The hydraulic resistance depends on
the flow rate through the boiler and the
boiler type. In the graph the resistance
for a specific flow rate can be found.
The R6000 is able to control a speed
controlled pump via a 0-10VDC signal.
It makes the flow rate modulate in pa-
rallel with the burner load. The mini-
mum flow rate, to which the pump is
allowed to modulate with the burner
load, is 30% of the nominal flow rate
through the boiler.
The flow rate through the boiler can
also be checked by calculation. This
can be done with a T as well as a p
measurement.
1.0
10.0
100.0
1.0 10.0 100.0
[m3/h]
[kPa]
R6285-6539
R6142-6190
∆T-measurement
Check the temperature difference over
the boiler (T flow-return) when the
boiler is running on 100% load. The
nominal T is 20K and must be at least
between 15K and 25K for secure boiler
operation. An indication of the actual
flow rate can be found with the follow-
ing calculation (see table below for
nominal data):
∆p-measurement
Check the pressure difference over the
boiler (p flow-return) when the boiler
pump is running (burner on is not re-
quired). The nominal p for each boiler
type can be found in the table below,
actual p must be within:
0.35*pnom p 1.75*pnom. An indi-
cation of the actual flow rate can be
found with the following calculation (see
table below for nominal data):
Water flow data
6142 6190. 6237. 6285 6380 6475. 6539
Nominal flow rate m3/h 6,1 8,1 10,2 12,2 16,3 20,4 23,1
T at nominal flow rate K 20
p at nominal flow rate kPa 10 18 28 15 27 42 55
qactual = (Tnominal / Tmeasured) * qnominal [m3/h]
qactual = (pmeasured / pnominal) * qnominal [m3/h]

Hydraulic connection
Hydraulic connection into a system
Standard
Bypass - Not applicable
16
Hydraulic connection into a system
The R6000 must be connected in such a
way, that a minimum flow rate of 30%
of the nominal flow rate can be ensured
at all times, independent from the flow
rate in the secundary system. This can
be achieved by using one of the follo-
wing 3 possibilities:
• Standard, with low loss header or
plate heat exchanger
• Bypass, with integrated minimum flow
rate by Bypass pump* N/A
• Split System, with 2 return connecti-
ons for best possible efficiency (warm
and cold return)
* only applicable in single boiler instal-
lations
Standard
This is the most common way to
connect the boiler to the system. By
using a low loss header or plate heat
exchanger a minimum flow rate can be
ensured at all times, independent from
the flow rate in the secundary system.
The boiler pump is available as a
standard 3-step or a speed controlled
version. The speed controlled pump
mudulates the flow rate in the primary
system in parallel with the burner load.
This ensures the lowest possible return
temperature to the boiler for high
efficiency usage.
Details of the available pump kits can
be found in the chapter „Accessories“.
Bypass - not applicable
In single boiler installations, the R6000
can also be used without low loss hea-
der or plate heat exchanger. For this
solution a bypass kit is available as
accessory to the standard boiler. The
bypass is connected between the flow
connection and the second return con-
nection of the boiler.
The performance of the bypass pump is
very low when the system flow rate is
high. As soon as the system flow rate
decreases, the bypass pump perfor-
mance increases to ensure a minimum
flow rate through the boiler.
The bypass pump does not transport
the water from the boiler into the
system. The system pump should
overcome the boiler resistance at
nominal flow rate to transport the
from the boiler into the system and
vice versa.
Details of the available pump kits can
be found in the chapter „Accessories“.
Bypass
Details to the 3 possibilities mentioned
above, can be found in the next secti-
ons.
Standard

Hydraulic connection
Split System
17
Split System
The split system boiler enables the
connection of two returns with different
water temperatures. By evasing the low
loss header the cold return water enters
the condensor of the boiler directly,
without mixing with the high temepra-
ture return water (f.e. from an air heater
circuit). This hydraulic separation in-
creases the efficiency of the system.
The primary boiler pump, controlled by
the boiler managemant unit, ensures a
minimum water flow through the boiler
except for the bottom heat exchanger
(condensor). The system pump of the
low temperature circuit must be dimen-
sioned in such a way, that it can over-
come the boiler resistance.
The nominal flow rate in the (warm)
boiler circuit must be minimum 50%
of the total nominal flow rate through
the boiler.
The following data can be used for the dimensioning of the pumps in a split system.
Min. and max. flow rate Q1-Q2
Q2,min Q
2,max (Q1+Q2)min (Q1+Q2)max
[m3/h] [m3/h] [m3/h] [m3/h]
6142
0
3.0 4.9 8.1
6190 4.0 6.5 10.8
6237 5.1 8.2 13.6
6285 6.1 9.8 16.3
6380 8.1 13.0 21.7
6475 10.2 16.3 27.2
6539 11.5 18.5 30.8
0.10
1.00
10.00
100.00
1.00 10.00 100.00
Q1+Q2 [m3/h]
R1 [kPa]
R6142-R6237 R6380-R6539
0.00
0.01
0.10
1.00
10.00
100.00
0.10 1.00 10.00 100.00
Q2 [m 3/h]
R2 [kPa]
R6142-R6237 R6380-R6539
R1
R2
Q1
Q2 P2
P1
Q1+Q2
Necessary head pump P2: RP2 = R2at Q2 + R1at (Q1+Q2) + RSystem
Necessary head pump P1: R1at (Q1+Q2)

Controls
Basic controls and connections
Control by building managemant system
Boiler enable signal
Temperature or capacity setpoint
18
Basic controls and connections
The standard version of the R6000 is
equipped with a KM628-R600 boiler
management unit. This controller
controls both the burner safety operati-
on and the temperature regulation of
the boiler. The KM628-R600 includes
the following functions:
When additional control of secundary
heating zones or cascade systems are
required, the R6000 can be extended
with different additional controls. Expla-
nation of these controls can be found in
the next sections.
• Electronic high limit thermostat
• Electronic flue gas temperature limiter
• Primary boiler pump control (via re-
lay)
• Primary sanitary hot water pump
control (via relay)
• Interlock input
• Lockout input
• OK/Alarm output signal
• Boiler enable signal
• 0-10VDC temperature or capacity
setpoint (programmable)
• 0-10VDC capacity feedback or 10V
contact for external gas valve
(programmable)
• Temperature control central heating
via PID controller
• Temperature control sanitary hot wa-
ter (hot water priority)
Control by building managemant
system
The R6000 can be connected to a buil-
ding management system. This can be
done by using (one of) the following
connections:
0
20
40
60
80
100
0246810
[V]
[ºC]
0
20
40
60
80
100
0246810
[V]
[%]
Boiler enable signal, terminals 22-23
(230V)
The boiler enable signal is provided
with a jumper from the factory. When
connecting a (volt free!!!) external sig-
nal, the jumper must be removed.
Temperature or capacity setpoint,
terminals 117-118 (0-10VDC)
The R6000 can be controlled via a
temperature or capacity setpoint. The
following graphs show the signal va-
lues for both possibilities.
Temperature setpoint
A signal below 2V will not be recogni-
sed by the boiler controller. In case of
a signal below 2V, the controller will
control the boiler temperature based
on the internal setpoint programmed
at parameter P1.
Capacity setpoint
The burner will be started when a
signal of minimum 3V is recognised.
The burner will be switched off, when
the signal drops below 2.9V.
When controlling the boiler via a ca-
pacity setpoint, it’s highly recommen-
ded to control the primary boiler pump
with the internal pump control of the
KM628 boiler controller. The mini-
mum flow rate through the boiler must
be respected at all times. The nomi-
nal T is 20K and should be at least
within 15K-25K at full load to secure a
safe boiler operation.

Controls
Capacity feedback signal
OK/Alarm output signal
Weather compensated controller BM8
19
0
20
40
60
80
100
120
0246810
[V]
[%]
OK/Alarm output signal, terminals
25-26-27 (volt free)
At terminal 25 (COM), a desired voltage
of maximum 230V, 1A can be connec-
ted. The boiler will transfer the signal,
depending on the boiler situation, either
to terminal 27 (OK) or teminal 26
(Alarm).
Weather compensated controller
BM8
The R6000 can be extended with a BM8
controller for weather compensated
operation. Additional to the weather
compensation, the BM8 also provides
clock programs for central heating and
sanitary hot water operation. The BM8
can not control secundary heating zo-
nes!
1
2
3
5
4
To be controlled
externally
The BM8 can be integrated in the
control panel of the boiler, but can also
be used as a room unit (with integrated
room sensor for room temperature opti-
misation). The maximum length of the
communication cable between boiler
and BM8 is 100m (consult BM8 docu-
mentation for further details).
1 KM628 (integrated in boiler)
2 Outside temperature sensor, to be connected at terminals 105-106
3 BM8, to be connected at terminals 102-103
4 Primary sanitary hot water pump control, to be connected at terminals 19-20-21
5 Sanitary hot water sensor, to be connected at terminals 114-115 (Remove jumper from terminals 113-114!)
Further details about the electrical connections can be found on the wiring diagram.
Capacity feedback signal, terminals
111-112 (0-10VDC)
This signal is available at the mentio-
ned terminals, when the burner is acti-
ve. The following graph shows the va-
lue of the signal.

Controls
Heating zone controller E8
20
Heating zone controller E8
The R6000 can be extended with an E8
controller for extended control of two
heating zones and sanitary hot water
operation. The E8 combines weather
compensated operation with control of
two heating zones and the control of a
secundary hot water circulation pump.
1
2
3
5
4
6a 7a
6b 7b
6c 7c
8
1 KM628 (integrated in boiler)
2 Outside temperature sensor, to be connected at terminals 105-106
3 E8 (integrated in boiler)
4 Primary sanitary hot water pump control, to be connected at terminals 19-20-21
5 Sanitary hot water sensor, to be connected at terminals 114-115 (Remove jumper from terminals 113-114!)
6 Heating zone 1
a Temperature sensor, to be connected at terminals 125-126
b Pump, to be connected at terminals 50-51-53
c Mixing valve, to be connected at terminals 55-56-57
7 Heating zone 2
a Temperature sensor, to be connected at terminals 127-128
b Pump, to be connected at terminals 51-52-53
c Mixing valve, to be connected at terminals 59-60-61
8 Sanitary hot water circulation pump, to be connected at terminals 63-64-65
Further details about the electrical connections can be found on the wiring diagram.
In case of heating systems with more
than two heating zones, an additonal kit
with E8 in a wall hung box is available.
These kits can be used in a modular
way up to a maximum of 15 heating
zones.
For room temperature optimisation of
each heating zone, an additional roo-
munit BM8 can be connected via bus
connection. The values for the specific
heating zone can then be displayed
and changed on the room unit.