Stokvis R600 Boiler Gas-Fired Floor Standing Condensing

Stokvis R600 Boiler Gas-Fired Floor Standing Condensing Installation, Operation & Maintenance Manual STOKVIS ENERGY SYSTEMS 96R Walton Road East Molesey Surrey KT8 0DL Tel: 020 8783 3050 / 0870 7707747 Fax: 020 8783 3051 / 0870 7707767 E-Mail: info@stokvisboilers.com Website: www.stokvisboilers.com 420010686500 09/2015 ErP

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 4

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 5 GB

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 accept 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- Local building regulations for in- 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. 6 This boiler is CE approved and applies to the following European standards: 1992 / 42 / EEC directive. 2004 / 108 / EEC EMC directive. 2014/68/EU PED directive, art.4-3. 2006 / 95 / EEC Low voltage directive. 2009 / 142 / EEC Gas appliance directive. 2009/125/CE Energy related Products. 811-813/2013 EU regulation EN 15502-1 boilers. General requirements and tests. EN 15502-2-1 type C and devices type B2, B3, B5 with a nominal heat input not exceeding 1000 kw. EN 656:1999 heating boilers. Type B boilers of nominal heat input exceeding 70 kw, but not exceeding 300 kw. EN 13836:2006 heating boilers. Type B boilers of nominal heat input exceeding 300. kw, but not exceeding 1000 kw. EN 15420:2010 heating boilers. Type C boilers of nominal heat input exceeding 70 kw, but not exceeding 1000 kw. EN 15417:2006 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 rements EN 60335-2-102 (2006) Household an similar electrical ap- for gas, oil and solid-fuel burning appliances having electrical connections. EN 50165 Electrical equipment of non-electric appliances for household and similar purposes - Safety requirements EN 55014-1 (2000) Electromagnetic compatibility - Requirements for household appliances, electric tools and similar appara- EN 55014-2 (1997) Electromagnetic compatibility - Requirements for household appliances, electric tools and similar appara- family standard EN 61000-3-2 (2000) Electromagnetic compatibility (EMC) - Part current emissions (equipment input current 16 A per phase) EN 61000-3-3 (2001) Electromagnetic compatibility (EMC) supply systems, for equipment with rated current 16 A per phase and not subject to conditional connection. Additional national standards Germany: Switzerland: SVGW Austria: 15a V-BG

General regulations Informations for installer and maintenance service Data plate The use of the appliance for purposes 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 instructions given in this manual. other interventions must be carried out in full conformity with the governing legal regulations and the instructions provided by the manufacturer. 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 appliance is intact and that no parts are contact your supplier. How to set the temperature and the adjusters for a correct and more economical management of the system. To perform periodic maintenance system, according to legislation. Do not change, in any case, the settings for supply of air for combustion and gas combustion. Pay attention to the warnings contained in the user manual. S/N Symbols used on the data plate 3 1 0000000KE000000000000 6 4 5 10 26-05-2015 2 00 Keep all packaging material (clips, plastic bags, polystyrene foam, etc.) out of reach of children as it may present 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 ration of the system. struction manuals, informing him that they must be stored with the appliance. Periodically check the water pressure system and instruct him on how to reintegrate and bleed. Legend : gas mbar gas mbar gas mbar 1 Brand 9 11 2 Country of origin 3 8 Boiler model - Serial number 12 13 η = η = 100% min. 4 Commercial reference 5 6 Destination country - Gas category 7 Gas setting 16 7 Q(Hi) P P 30/50C 14 15 9 Electrical data 10 Factory settings 17 18 11 Maximum water pressure 12 Boiler type 13 14 15 Power output heating 16 Gases which may be used 17 Ambient operating temp. Max. central heating temp. 7 GB

Construction Layout of boiler Operating principle 1 5 4 2 7 6 Layout of boiler The boiler consists of the following main components: 3 14 22 23 9 12 20-21 19 10 25 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 Syphon 24 15 16 13 17 11 8 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- bustion are transported downwards through the heat exchanger and leave the boiler at the top into the chimney connection. The return water from the system enters the boiler in the lower section, - condensation takes place. The water is being transported upwards through the heat exchanger, connection. - The LMS14 control unit can control boiler control (standalone operation); weather compensated operation (with optional outdoor sensor); (temperature or capacity) from a building management system.

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/m 3 ) Gas consumption G25 max/min (8,34 kwh/m 3 ) 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 CO 2 level G20/G25 max/min CO 2 level G31 max/min NO x level 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. 9 GB

Product information ErP R600 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 P rated kw 142 190 237 285 384 At rated heat output and high-temperature regime At 30% of rated heat output and lowtemperature regime 1) Seasonal space heating energy efficiency At rated heat output and high-temperature regime 2) At 30% of rated heat output and low temperature regime 1) P4 kw 142.1 190.1 237.2 285.2 384.5 P1 kw 47.8 63.9 79.7 95.9 127.8 s % 94 94 94 94 94 4 % 88.3 88.3 88.3 88.3 89.3 1 % 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-temperature regime At 30% of rated heat output and lowtemperature regime 1) elmin kw 0.037 0.032 0.034 0.034 0.047 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 NO X mg/kwh 35 35 35 35 35 1) by return temperature 30 C 2) by return temperature and feed temperature (60-80 C) 10

Dimensions 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 Dimension R601 R602 R603 R604 R605 R606 R607 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 1 150 2 150 2 150 2 200 3 200 3 200 3 D2 mm(dn) 150 2 150 2 200 3 200 3 250 4 250 4 250 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 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 11 GB

Extend of delivery Standard boiler Accessories Standard boiler 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) 1 Map attached to back panel of the boiler Accessories Additional to the boiler, the following Speed controlled pump incl. connection kit; Safety valve, manometer and deaerator (3,4,5 or 6 bar) incl. connection kit; 2x max. water pressure switch and 1 external high limit thermostat incl. connection kit; Max. gas pressure switch; External high limit thermostat incl. connection kit; Gas valve leakage tester (not possible for R601); 2nd Return connection for Split System use; Controlled bypass (incl. pump) incl. connection kit; Plate heat exchanger (dt=10k/15k or dt=20k) incl. connection kit; Low velocity header, suitable for dt=10k/15k and dt=20k incl. connection kit; Duo header for connecting 2 boilers in cascade (excl. connection kit); Extension module AVS75 for heating 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; Additional RVS63 heating zone controller, when controlling more than 2 zones (incl. wall hung box, all necessary sensors and sockets and connection material for bus communication). The above accessories are specially designed for the R600 boiler and therewith easy to install (plug and play). By choosing a combination of the kits mentioned above, you can create your own complete system solution. Ask your supplier for more detailed information. 12

Installation Boiler transport Boiler transport The R600 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 transported with a pallet truck, entering either from the front or from the side. Whenever necessary, the boiler can be dismantled into smaller parts for easier transport inside the building. The table below shows the main dismantled parts with their weight and dimensions. When the boiler has to be transported with a crane, it is necessary to remove the casing before connecting the boiler to the crane. Always connect the crane to the frame of the boiler by using straps. 1 Hoisting belt (4x) 2 Wooden retaining beam (2x) 3 Hoisting belt position (4x) Component R601 R602 R603 R604 R605 R606 R607 Burner/1st heat exchanger assembly 2nd/3rd heat exchanger assembly Condensate receptacle Frame Weight [kg] Length [mm] Width [mm] Height [mm] Weight [kg] Length [mm] Width [mm] Height [mm] Weight [kg] Length [mm] Width [mm] Height [mm] Weight [kg] Length [mm] Width [mm] Height [mm] 735 400 321 90 735 400 244 7 225 15 990 624 335 100 400 321 103 400 244 9 739 225 16 1140 624 335 112 1035 400 321 116 1035 400 244 10 225 17 1350 624 335 135 735 321 150 735 244 11 665 225 17 1100 724 335 321 170 244 12 739 665 225 1320 724 335 1035 321 1035 244 13 665 225 19 1470 724 335 321 219 244 15 1039 665 225 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 13 GB

Installation Removing the casing Removing the casing Remove the casing before transporting the boiler, in order to avoid damage to the casing parts during transportation. 14

Installation Warnings before installation Boiler installation requirements of the local authorities and public health agencies. Before installing the appliance necessary to perform the following 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; Make sure that the boiler is set up for operation with the type of gas available (read the information on the packaging label and on the boiler data plate); Make sure that there are no obsta- it does not contain any discharge from other appliances, unless than one user (in accordance with current legal requirements); Where there is already a con- check that these exhausts have been perfectly cleaned and are without residues, because any disconnection could obstruct the passage of fumes and create potentially dangerous situations; Make sure that, where unsuitable have been ducted; water, limescale may build up on the components inside the boiler sensitive to heat (for example wood) make sure to protected it by suitable insulation; Observe the clearance between the wall on which the boiler is installed and the hot parts on the outside of the boiler. WARNING! 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 If dust and/or aggressive vapours are present in the room in which it is to be installed, the appliance must operate independently of the air inside the room. Boiler installation 1 The boiler should be positioned in a 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 Once the boiler is in the correct position, the wooden blocks (1) should be removed and the adjustable feet (2) (with vibration absorption dampers) should be adjusted to the right height. Water and gas connections should be done after mounting the feet, as they affect the exact height of all connections. 2 2 15 GB

Installation Connecting the boiler Connecting the boiler This chapter will explain how to make all connections to the boiler with re- Hydraulic connections Condensate drain connection Gas connection Flue gas connection Air intake connection (under casing) Electrical connection The boiler should always be connected in such a way, that the system applies to all relevant standards and regulations (European, national and installer to ensure that all standards and regulations are respected. Hydraulic connections The boiler should always be con- through the boiler can be ensured at all times. 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 return 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- connection (4) of the boiler, before connecting to the system. The (optional) pump kit should be mounted directly to the return connection (5) of the boiler, before connecting to the system. Condensate connection (included in delivery) should be installed to the connection at the bottom of the condens tray. Lead the hose under the frame at the back of the boiler and connect it to the draining system in the boiler room. The connection to the draining system should always be done with an open connection, boiler in case of a blocked drain. 1 4 5 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. on the gas connection of the boiler. 3 6 16

Installation Air/Flue gas system Requirements and regulations Regulations for the construction of red that all national regulations with spected. Pay attention to the following recommendations when dimensioning a be properly calculated to ensure a safe functioning of the system. Flue gas system components should be removable for maintenance purposes. You have to take in consideration the following material requirements. Materials Exclusively materials which are heat and aggressive condensate, and CE approved may be used. the following data. Temperature class: Pressure class Corrosion class: Plastic PP* T120 P1 W1 Stainless steel** T250 P1 W1 * Use material with E reaction top ** Stainless steel is admitted but with a minimum wall thickness, which depends on the country regulation. 17 GB

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 order to connect the air intake piping to the connector inside the boiler. The diameter should be calculated according to the national regulations, The total resistance of both systems should never overcome the maximum permissible resistance of the fan inside the boiler (see also chap- Flue gas connection ry to make a separate condensate condensate will be drained via the syphon of the boiler. Please note the stem must be chosen by calculation according to the national regulations short as possible (for maximum length see planner documentation) Construct horizonal ways with a minimum angle of 3º. not be in contact with or placed near cross building structures or walls This boiler has an integrated high li- 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 system must always be replaced. joint should be created using a male/female coupling and a seal. Couplings should always be arranged so that they go against the direc- 7 3 1 Legend: 1. Gas Connection 2. Electrical connection 3. Air intake connection 7. Flue gas connection 2 18

Installation Air/Flue gas system Flue gas data Boiler type R601 R602 R603 R604 R605 R606 R607 Nominal heat output Nominal heat input 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 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 10.2 9.4 30 43 200 10 79.6 250 233 43 250 10 545,1 79.6 550,0 250 264 43 250 10 Flue gas connection CO Level Flue gas temperature Flue gas quantity Max permissible Combustion air drawn from the room B23 Combustion air intake from cascade C63 Air and exhaust connection to separate tested and supplied air / exhaust pipes. Air and exhaust venting via exterior wall. Exhaust venting through heat insulated exhaust pipe or moisture-resistant pipe. Exhaust line (standing air layer) at exterior wall. The terminals for the supply of combustion air and for the evacuation of combustion products shall not be installed on opposite walls of the building. 19 GB

Installation Flue gas system Dimensioning single system Total connection length without bends Max length reduction Maximum permissible lenght (m) Boiler type R601 R602 R603 R604 R605 R606 R607 R601 R602 R603 R604 R605 R606 R607 Ø110 Ø130 Ø150 Ø200 Ø250 15 40 55 22 39 55 31 55 21 55 55 55 44 55 34 55 Example Maximum permissible lenght (m) Boiler Type Ø110 Ø130 Ø150 Ø200 Ø250 10 35 50 17 34 50 26 50 16 50 50 50 39 50 29 50 Dimensioning system, it s necessary to perform system in order to verify if the choosen system is applicable. The following table shows two systems, including the maximum possible length of the system. These examples only give an indication of the possible length, but system must be calculated by an authorized company. pressure, which doesn t affect the burner modulation ratio, is 30 Pa. Higher negative pressure will lead to limitation of the burner modulation ratio. is 20 m. With horizontal ways longer than 20 m, a faultless burner start in cold condition can not be guaranteed. 20

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 connection 21 GB

22 Main gas valve Pressure switch Room fan. (2A max.) Wiring diagram - Boiler Installation 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

Installation Wiring diagram - Boiler Lockout Input DHW Pump 230V ~ (1Amax.) Boiler pump / Bypass pump 23 GB

1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 4 5 6 7 8 9 24 -N6 QX23 PEN QX22 PEN QX21 Alarm Heating circuit 2 Heating circuit 1 NPE L -N5 QX23 PEN QX22 PEN QX21 NPE L -N4 QX23 PEN QX22 PEN QX21 NPE L Wiring diagram - Accessories Installation MH2 MBX22M BX21 1 ON MH2 MBX22M BX21 1 ON MH2 MBX22M BX21 1 ON X50 1 2 2 X30 X50 1 2 2 X30 X50 1 2 2 X30 -STB1 T 1 2 -STB2 T 1 2 -Q2 L N PE M 1~ -Y1 N PE. -B1 M B QAD36 -Q6 L N PE M 1~ -Y5 N PE. -B12 M B QAD36 Flow temp. sensor Mixing valve control 0.5A max. Heating circuit pump 2A max. Flow temp. sensor Mixing valve control 0.5A max. Heating circuit pump 2A max.

Installation Wiring diagram - Accessories * Remove jumper when connecting device STL Boiler temp. Max. water pressure switch Max. water pressure switch Max. water pressure switch Gas valve Leakage test 25 GB

Commissioning Water and hydraulic system 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 example of commissioning protocol). This chapter explains the commissioning of the boiler with the standard boiler controller. When an additional system controller is installed, please refer to its manual for commissioning the controller. Boiler output Max. sum of alkaline earths Max. total hardness [kw] [mol/m³] [ dh] [ f] 50-200 2.0 11.2 20 200-600 1.5 15 Concentrate Ca(HCO ) mol/m³ dh f Capacity of installation Q (kw) 150 200 250 300 400 500 600 ³] 0.5 - - - - - - - 1.0 5.6 10 - - - - - - - 1.5 15 3 4 5 6 10 12 2.0 11.2 20 3 4 5 6 6.3 9.4 2.5 14.0 25 1.9 2.5 3.1 5.0 6.3 7.5 3.0 1.6 2.1 2.6 3.1 4.2 5.2 6.3 Water quality ter with a ph value between 7 and 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. lumes, it s necessary to respect the lumes with corresponding hardness values as indicated in the table. The table on the left gives an indication of the relation between the water volume during the lifetime of the boiler. Water pressure Open the valves to the system. Check the water pressure in the sy- low (see table below), increase the pressure up to at least the minimum required water pressure in the table. Filling can eventually be done via the the return connection (1) of the boiler. Hydraulic system Check if the boiler is hydraulically connected to the system in such at all times during burner opera- ner stop and lockout of the boiler. 1 Maximum operating pressure [bar] Flow temperature [ C] 2 > 1.5 90 > 1,0 26

Commissioning Neutralisation systems General Condensate, created by the boiler should be drained into the public draining system. The condensate ph is between 3.0 and 3.5. National and/or local regulations have to be checked, densate should be neutralised before entering the public draining system. The maximum amount of condensate for each boiler type can be found in the chapter Technical data. Neutralisation systems The neutralisation systems can be placed in the bottom section of the boiler. The delivery of the system contains Connection hoses for inlet and outlet connection; Boiler connection adapter. For the neutralisation are avaiable Standard neutralisation system (DN) The standard neutrlisation system is used when the public draining connection is at lower level than the boiler syphon connection. Type Applicable for Length Width Height DN2 DN3 kw 450 1500 mm 420 640 mm 300 400 mm 240 240 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 connection 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. Type Applicable for Length Width Height Power consumption pump Pump head HN1.5 HN 2.5 kw 540 mm 410 640 mm 300 400 mm 290 240 W 40 150 m 6 3 27 GB

Commissioning Gas supply Condensate connection Flue and air intake connections Gas supply Check the gas supply connection to the boiler for tightness. leakage before starting the boiler! Remove any air between the gas valve and the gas line. This can be done at the test point (1) at the gas pressure switch. Don t forget to close the test point afterwards! Check the gas type and values with the local gas company, in order to know for which gas type the boiler should be commissioned. Consult the conversion kit instruction if the boiler is to be installed with natural gas L or LPG. Condensate connection Remove the syphon (2) from the condensate connection. Fill it with water and place it back in the original position. Make sure the discharging through the condensate connection! Flue and air intake connections systems are made according to the national and local regulations. the regulations, are not allowed to be commissioned. Make sure that all connections are free. connections may not be reduced. 28

Commissioning Legend: A B C D E F G H L M On/off switch Return (ESC) Room temperature control Manual mode Chimney sweeper mode Reset button Operation mode heating Zone(s) Display Operation mode DHW Initial procedures To guarantee safety and the correct operation of the appliance, the boiler must be prepared for operation by a the skills which are required by law. Electricity supply Check that the voltage and frequency of the electricity supply correspond to the data shown on the boiler data plate; Make sure that the earthing Filling the hydraulic circuit Open cold water inlet tap; Gradually open the valve under the boiler; Open each air release tap starting with the lowest point and close it only when clear water, free of air, is visible; Close the valve under the boiler when at least 1,5 bar registers on the pressure gauge. Gas supply Make sure that the main gas supply uses the same type of gas as indicated on the boiler data plate; Open all doors and windows; Make sure there are no sparks or Make sure that the system does not leak fuel. Open the gas supply; Enable the power supply to the boiler; Switch on the boiler with the on/ off switch (A); Make sure the boiler is in standby mode ; make sure the pump runs in the right direction; Release all air from the pump motor. this is the best starting point to do a proper combustion analysis. This can goes into controller Stop mode. the actual boiler load (%) appears in the display; Choose set up OK button), now the boiler load can be changed by rotating the 50% setting with the OK button. After checking the combustion value (see next page), the controller Stop mode can be stopped by pushing 29 GB

Commissioning Combustion analysis Combustion check at full load Start the boiler in controller stop mode and go to 50% load. Now the boiler operates at 50% load. Allow the boiler to stabilize the combustion for 3 minutes. Then increase the boiler load step by step up to 100%. Check the gas pressure on the inlet of the gas valve while increasing the never go below the minimum required value see technical data. Set the minimum gas pressure switch (1) at 75% of the required gas pressure. Check the combustion settings via the test point in the chimney con- on the outlet of the gas valve (2). Combustion settings max. load for natural gas G20 / G25 R601-R607 CO max % 10.2 ± 0.2 Combustion settings for LPG G31 Convert boiler before operation (see coversion kit instruction) R601-R607 CO max % 11.9 ± 0.2 - Combustion check at minimum load Switch the boiler to minimum load (0%). Check the combustion settings the same way as described for full with the allen key adjustment screw on either side of the gas valve (4). Combustion check at 50% load An additional reference check of combustion values at 50% load is recommended in order to check if the gas valve is set in such way, that the modulating behaviour is normal. The CO 2 value should be in between the settings of full load and minumum load. CO value should be equal to full load and minimum load values. Make sure that the boiler is set to automatic operation and controller stop mode is disabled Combustion settings min. load for natural gas G20 / G25 R601-R607 CO min % 9.4 ± 0.2 Combustion settings for LPG G31 Convert boiler before operation (see coversion kit instruction) R601-R607 CO min % 10.0 ± 0.2 30

Commissioning be checked with two different methods shown below. Check the temperature difference the boiler is running on 100% load. at least between 15K and 25K for secure boiler operation. An indication of the following calculation (see table qactualnominalmeasured) * qnominal [m 3 /h] Check the pressure difference over boiler pump is running (burner on each boiler type can be found in the can be found with the following calculation (see table below for nominal qactualmeasurednominal) * qnominal [m 3 /h] Nominal flow rate T at nominal flow rate p at nominal flow rate R601 R602 R603 R604 R605 R606 R607 [m³/h] 6.1 8.1 10.2 12.2 16.3 20.4 23.1 [ C] 20 20 [kpa] 10 18 28 15 27 42 55 31 GB

Commissioning Check functionality of safety devices Gas tightness check Boiler shut down 1 2 3 Check functionality of safety devices All safety devices have to be checked on good functioning. Safety devices temperature sensor, water return rature sensor and ionisation electrode. These devices can be checked as described below. Flow temperature sensor (1) Disconnect the plug from the sensor while the boiler is switched on. This should result in a lockout no. 20. The lockout should disappear as soon as the plug is placed back in position, the boiler will restart. Ionisation electrode (4) Remove electrical connection from the ionisation electrode while the boiler is running, the boiler will go try to restart. With the electrical connection removed, the restart will result in lockout no. 133. When the connection is already mounted, the restart will be successful. Measuring the ionisation current can be done by mounting a multi-meter (set electrode and its electrical connection. The ionisation current and above. Return temperature sensor (2) Disconnect the plug from the sensor while the boiler is switched on. This should result in a lockout no. 40. The lockout should disappear as soon as the plug is placed back in position, the boiler will restart. Flue gas temperature sensor (3) Disconnect the plug from the sensor while the boiler is switched on. This The lockout should disappear as soon as the plug is placed back in position, the boiler will restart. Minimum gas pressure switch (5) Close the gas cock when the boiler is in standby position ( ). Open the test point on the gas line (4) while measuring the gas pressure on the test point of the gas pressure switch (5). The boiler will go in lockout no. 2 when the switch off setting is achieved. Close both test points and open the gas cock. Gas tightness check Check the gas tightness of all sealed connections with an approved soap or electronic gas analyzer, for Test points; Bolt connections; Gaskets of mixing system, etc. Boiler shut down When the boiler will not be used for longer periods, shut it down accor- Switch the boiler in standby mode ; Switch off the boiler with the on/off switch (7); Disable power supply to the boiler by deactivating the mains isolator switch in the boiler room; Close the gas supply to the boiler. 32

Commissioning Commissioning protocol - - 33 GB

Operating instructions Controls Legend: A B C D E F G H L M On/off switch Return (ESC) Room temperature control Manual mode Chimney sweeper mode Reset button Operation mode heating zone(s) Display Operation mode DHW Operation mode DHW (M) For switching on the DHW operation (indication in display below DHW symbol). Operation mode heating zone(s) (I) by time program; comfort mode; in reduced mode; tection activated. Display (L) Info mode (G) Display possibility of following info wi- temperatures, operation mode Heating / DHW, error code. Room temperature control (C) for changing room comfort temperature for changing settings when programming. Return (ESC) (B) These buttons are used for programming in combination with the wheel. By pressing the ESC button it s possible to go back one level, changed values are not taken over by the controller. By pressing the OK button it s possible to arrive in the next level or con- Manual mode (E) This button is used for switching the mode all pumps will run and the mixing valves are no longer controlled, the burner setpoint is 60 C (indicated by spanner symbol). On/off switch (A) electrical components are no powered. Frost protection is not secured. nected electrical components are powered and stanby for operation. Deaeration mode (E) By pressing the manual mode button longer than 3 seconds, the automatic hydraulic deaeration is activated. During deaeration the system is put in standby mode. The pumps are switched on and off for several times. After deaeration, the boiler automatically returns to normal operation. Chimney sweeper mode (F) Used for combustion analysis. By pressing the button once again, or automatically after 15 minutes, the chimney sweeper mode will be deactivated (indicated by spanner symbol). Reset button (H) By shortly pressing the reset button a burner lockout can be cancelled. 34

Operating instructions Display / Programming DHW mode selection Heating operation mode selection (Controller Stop mode when pressing > 3 sec.) Display Info button Quit menu Reset Confirm Manual mode (Deaeration mode when pressing > 3 sec.) Select (turn left/right) Chimney sweeper mode Heating to comfort setpoint Info level activated Heating to reduced setpoint programming activated Heating for frost protection setpoint heating temporarily switched off Process running please wait ECO function active Burner operating (only oil / gas boiler) Error messages Info level activated Programming activated Heating temporarily switched off ECO function active Holiday function active Reference to heating circuit Maintenance / special operation Parameter number PRESS OK (1x) END USER DEFAULT MODE (BUTTON) COMMISSIONING PRESS OK (1x) PRESS INFO (4sec) EXPERT choose menu confirm with OK button choose parameter confirm with OK button change value + - with wheel confirm with OK button return to main menu with ESC button choose menu confirm with OK button choose parameter confirm with OK button change value + - with wheel confirm with OK button return to main menu with ESC button 35 GB

Operating instructions Overview of main functions = cancel, return to main menu Button Action Procedure Display / Function Set room temperature Zone 1 and zone 2 Actuate wheel left/right Turn wheel Confirm with OK button or wait 5 sec. or press Comfort setpoint with blinking temperature Blinking temperature in 0,5 C steps from 10 to 30 C Comfort setpoint saved Comfort setpoint cancelled - after 3 sec. main menu appears Set room temperature for zone 1 or zone 2 Zone 2 independent from zone 1 Actuate wheel left/right Confirm with OK button Actuate wheel left/right Confirm with OK button or wait 5 sec. or press Choose heating zone Heating zone is chosen Blinking temperature in 0,5 C steps from 10 to 30 C Comfort setpoint saved Comfort setpoint cancelled - after 3 sec. main menu appears 36 Switch on /off DHW operation Change heating operation mode Press button DHW mode on / off (see indication below DHW symbol) - On: DHW mode by time program - Off: no DHW operation - Safety functions activated Factory setting Press button 1x Press button 1x again Press button 1x again Controller Stop mode Press button > 3 sec. Press button > 3 sec. again Info display Operation by manual setpoint Change factory setting boiler temperature Press button 1x Press button 1x again Press button 1x again.. Press button 1x Press button 1x Press button Press button Turn wheel -/+ Press button Press button Press button Deaeration Press button > 3 sec. Press button > 3 sec. again Activate chimney sweeper mode Temporary reduction of reduced temperature on QAA75 Press button (< 3 sec.) Press button again (< 3 sec.) Press button Press button again RESET Reset button Press button (< 3 sec.) Press button again > 3 sec. Automatic mode on, with: - Heating by time program - Temperature setpoint by heating program - Safety functions activated - Summer/Winter automatic switching activated - ECO -functions activated (see indication below operation symbol) Continuous COMFORT heating on, with: - Heating without time programm by comfort setpoint - Safety functions activated Continuous REDUCED heating on, with: - Heating without time programm by reduced setpoint - Safety functions activated - Summer/Winter automatic switching activated - ECO -functions activated Safety mode on, with: - Heating off - Temperature by frost protection - Safety functions activated 304: Controller Stop mode after 3 sec. main menu appears INFO Segment displayed - Status Boiler - room temperature - room temperature minimum - Status DHW - room temperature maximum - Status zone 1 - outside temperature - Status zone 2 - outside temperature minimum - outside temperature maximum - Time / Date - DHW temperature 1 - Error indication - Boiler temperature - Maintenance indication - Flow temperature (Info display depends on configuration) Back to main menu; INFO Segment disappears Manual mode on (spanner symbol appears) - Haeting by fixed setpoint (factory setting = 60 C) 301: Manual mode blinking temperature set value Status boiler Manual mode off (spanner symbol disappears) 312: Deaeration on Deaeration off Chimney sweeper mode on Chimney sweeper mode off Heating by reduced setpoint Heating by comfort setpoint Boiler manually blocked, no release Boiler released, Alarm symbol disappears

Maintenance Checklist Replacing the electrodes Maintenance of the boiler should be carried out by authorized personnel only. and safe operation of the boiler, it should be inspected at least once per year. A maintenance protocol should be example of maintenance protocol). Checklist The following activities must be carried out, see following paragraphs for an extensive description of the main Replace the ignition and ionisation electrodes; Clean the condens tray; clean if necessary (DON T use water!); Check the water pressure of the system; Check the water quality of the system water as well as supply water; gh the boiler; Check/correct the combustion values at full and mimimum load with a combustion analyzer; Check the gas pressure to the boiler; Check the tightness of all sealed connections and test points; Check the functionality of all safety devices; Fill out a maintenance protocol. Replacing the electrodes The electrodes are positioned on the top side of the boiler. Replace the ignition electrode (1) and ionisation electrode (2) as shown on the picture. 37 GB

Maintenance Cleaning the condens tray Inspection of combustion chamber Cleaning the condens tray gas temperature sensor (1); Remove the condens tray (2); Clean the tray; Mount the condens tray; temperature sensor. Remove the syphon (4) from the condensate connection (3); Mount the syphon back in the original position. Inspection of combustion chamber The sight glass (5) is positioned on the left hand side of the boiler. ber by viewing through the sight glass. 38

Maintenance Water physical and chemical check Gas and water quality Safety devices Check physical and chemical water After some weeks of operation, check the main phisicals and chemicals ph Hardness: Electrical Conductivity Chlorides: Sulphides Nitrides Iron < 10 fh <150 µs/cm <50 mg/l <50 mg/l <50 mg/l <0.5 mg/l water treatment system must be used. Water pressure and quality Check if the water pressure and quality meet the requirements. water and hydraulic system for more detailed information. the boiler is within the limits. Consult mation. Combustion analysis Check the combustion at full load and minumum load, correct the settings if necessary. An additional reference check at 50% load is recommended. combustion analysis for more detailed information. Gas pressure Check the dynamic pressure of the gas supply to the boiler, when the of a boiler cascade, all boilers should be running at full load. See technical data for required values. Gas tightness check Check the tightness of all sealed connections with an approved soap or Test points; Bolt connections; Gaskets of mixing system, etc. Safety devices Check the functionality and the settings of all safety devices connected. Check functionality of safety devices for more detailed information. 39 GB

Maintenance Maintenance Protocol - - 40

Lockouts ( ) indication of possible cause "ERROR CODE" DESCRIPTION OF ERROR CAUSE 10 Outside sensor fault 20 Boiler temperature 1 sensor fault 26 Common flow temperature sensor fault 28 Flue gas temperature sensor fault 40 Return temperature 1 sensor fault 50 DHW temperature sensor/thermostat 1 fault 52 DHW temperature sensor/thermostat 2 fault 78 Water pressure sensor fault Outside sensor fault (B9) (room model, plant frost protection, sensor value not plausible) Short-circuit boiler flow sensor (B2) Open-circuit boiler flow sensor (B2) Common flow temperature sensor fault (B10) (sensor missing, double configured, configured on slave, ) Open-circuit flue gas sensor Short-circuit flue gas sensor Short-circuit boiler return sensor (B7) Open-circuit boiler return sensor (B7) DHW temperature sensor/thermostat 1 fault (B3) DHW temperature sensor/thermostat 2 fault (B31) Water pressure sensor fault (short- or opencircuit) 81 LPB short-circuit or no bus power supply LPB short-circuit or no bus power supply 82 LPB address collision LPB address collision 83 BSB-Wire short-circuit or no communication BSB-Wire short-circuit or no communication 84 BSB-Wire address collision BSB-Wire address collision 85 BSB radio communication fault BSB radio communication fault 91 Data loss in EEPROM Data loss EEPROM 100 Two clock time masters Two clock time masters 105 Maintenance message Maintenance message 110 SLT lock-out SLT-temperature exceeded open TL/SLT causes lockout Boiler return temperature is higher than/ equal to (boiler temperature + Sd_RL_groesser_VL - 2K) Delta-T too high Boiler temperature rises faster than allowed in TempGradMax 111 Temp limiter safety shut-down Temp limiter safety shut-down 119 Water pressure switch has cut out Thermostat burner door 128 Loss of flame in operation Repetition error counter exceeded Loss of flame in operation 130 Flue gas temperature max. limit exceeded 132 Gas pressure switch safety shut-down Interlock, input interrupted Gas pressure switch is open 41 GB

Lockouts 133 Safety time for establishment of flame exceeded Repetition error counter exceeded Safety time for establishment of flame exceeded 151 BMU fault internal False polarity of the 230V power supply 152 Parameterization error Reprogram PCB 153 Unit manually locked Reset button pressed too long 160 Fan speed threshold not reached Fan speed threshold not reached 162 APS does not close Air pressure switch does not close 164 Flow/pressure switch HC fault Flow/pressure switch HC fault 166 Air pressure switch does not open Air pressure switch does not open 183 Unit in parameterization mode Unit in parameterization mode (parameter stick) 322 Water pressure 3 too high Water pressure on input H3 too high 323 Water pressure 3 too low Water pressure on input H3 too low 324 Same sensor Input BX Same sensor Input BX 330 Sensor input BX1 no function Sensor input BX1 no function 331 Sensor input BX2 no function Sensor input BX2 no function 332 Sensor input BX3 no function Flue gas sensor not programmed correctly 353 Cascade flow sensor B10 missing Cascade flow sensor B10 missing 384 Extraneous light Short circuit ionization electrode 385 Mains undervoltage Mains undervoltage 386 Fan speed tolerance Fan speed tolerance exceeded 388 DHW sensor no function Configuration error sensor input B3/B38 426 Check flue gas damper Malfunction of flue gas damper 427 Config flue gas damper Parameterization flue gas damper 432 Function ground missing Missing earth connection 42