Flexiheat R1K 75 RAIN Installation And Maintenance Manual
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Flexiheat R1K 75 RAIN Installation And Maintenance Manual

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Installation
and Maintenance Manual
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R1K 75 RAIN
Premix condensing system boiler
only heating, suitable for outdoor installation

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  • Page 1 Installation and Maintenance Manual for model R1K 75 RAIN Premix condensing system boiler only heating, suitable for outdoor installation...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION 1. INSTALLER SECTION 1.1. INSTALLATION 1.1.1. GENERAL INSTALLATION WARNINGS 1.1.2. BOILER LOCATION ENVIRONMENTAL REQUIREMENTS 1.1.3. REFERENCE LEGISLATION 1.1.4. BOILER OVERALL DIMENSIONS 1.1.5. JIG 1.1.6. CIRCULATOR PREVALENCE/FLOW DIAGRAM 1.1.7. CHECK LIST 1.1.8. BOILER INSTALLATION 1.1.9.
  • Page 3 TABLE OF CONTENTS 2.2.13. ACCESSING THE BOILER 2.2.14. ACCESSING THE MASTER ELECTRONIC BOARD 2.2.15. ACCESSING THE SLAVE ELECTRONIC BOARD 2.2.16. SYSTEM EMPTYING 2.2.17. FAULT SIGNALLING CODES 2.2.18. ACTIVE FUNCTIONS SIGNALLING CODES 2.2.4. GAS CONVERSION...

  • Page 4: Introduction

    INTRODUCTION INTRODUCTION WARNING DANGER It identifies an information related to a Before starting any operation it is mandatory to general danger that if not complied with, may cause read this instruction manual, in relation to the serious personal damage or even death. activities to be carried out as described in each relevant section.
  • Page 5 INTRODUCTION MANUFACTURER WARRANTY AND RESPONSIBILITY The technical and functional features of the device are ensured by its use in compliance: with the use and maintenance instructions contained in the manuals accompanying the product, the content of which the customer certifies that he is aware; with the conditions and purposes to which assets of the same type are intended.

  • Page 6: Installer Section

    1. INSTALLER SECTION 1. INSTALLER SECTION The installation operations described in this section should be performed only by qualified personnel, having the appropriate technical training in the field for the installation and maintenance of components of civil and industrial domestic hot water production and heating plants.

  • Page 7: Installation

    WARNING domestic hot water production and heating plants. Use only original Flexiheat optional or kit accessories (including electrical). ATTENTION After having removed the packing, make 1.1.2.

  • Page 8: Reference Legislation

    2. INSTALLATION to observe this caution will void the warranty of the heat exchanger. WARNING If the temperature in the boiler installation location goes below -10 centigrades, please fill the plant with anti-freeze liquid and insert and electrical resistances kit (see chapter ‘ANTI-FREEZE PROTECTION’).

  • Page 9: Boiler Overall Dimensions

    3. INSTALLATION 1.1.4. BOILER OVERALL DIMENSIONS 1.1.5. JIG HEATING RETURN Ø 1” 1/2 Ø 3/4 HEATING FLOW Ø 1” 1/2 SC- CONDENSATE DRAIN Ø 25 mm...

  • Page 10: Circulator Prevalence/Flow Diagram

    1. INSTALLATION 1.1.6. CIRCULATOR PREVALENCE/FLOW DIAGRAM Wilo-Yonos PARA RS 15/7.5 p/kPa PWM1 4770/ 5 PWM1 4270/ 15 PWM1 3780/ 25 PWM1 3280/ 35 PWM1 2780/ 45 PWM1 2280/ 55 PWM1 1780/ 65 PWM1 1290/ 75 Q/m³/ h Q/l/s Q/Igpm max. Q/m³/ h Load losses of the master unit 25 kW Load losses of the slave unit 50 kW...

  • Page 11: Check List

    1. INSTALLATION 1.1.7. CHECK LIST R1K 75 RAIN Check List Air Vent Loosen “Refer to Pg 18 for more details” Use position 2 to adjust minimum Co2 % Natural Gas 9 - 8.8% LPG 9.95 - 9.85% Gas Valve Note: Turn screw clock wise to increase % “Refer to Pg 32 for more details”...

  • Page 12: Boiler Installation

    2. INSTALLATION 1.1.8. BOILER INSTALLATION MINIMAL TECHNICAL SPACES In order to allow the access inside the boiler for maintenance operations, you have to respect the minimum technical spaces indicated in figure 1. WARNING The incorrect slopes of the device can A - 200 mm cause the incorrect discharge of condensate by means of the discharge duct with consequent...
  • Page 13 2. INSTALLATION WALL INSTALLATION BY MEANS OF A FIXING FRAME WARNING In order to avoid condensate stagnations inside the condensate module, check that the boiler is slightly inclined towards the rear part (1-1.5°) in order to evacuate the condensate. WARNING The device must be installed only on a vertical solid wall, able to sustain its weight.

  • Page 14: Hydraulic Connection

    1. INSTALLATION 1.1.9. HYDRAULIC CONNECTION DOMESTIC CIRCUIT DANGER In order to prevent limestone build-up and damages Make sure that the tubes of the water and to the domestic water heat exchanger, the hardness heating plant are not used as grounding system for of the domestic supply water should not exceed 15 the electrical plant.

  • Page 15: Characteristics Of The Water Of The System

    1. INSTALLATION 1.1.10. CHARACTERISTICS OF THE Water treatment WATER OF THE SYSTEM In order to preserve the integrity of the water- For a correct operation of the system, it is fume exchanger and to guarantee optimal thermal necessary to make sure that: exchanges, it is necessary that the water of the primary circuit, circulating inside the exchanger of 1.
  • Page 16 1. INSTALLATION Hardness The filling and make-up water hardness brings a certain amount of limestone into the system. It attacks the warm parts of the exchanger, thus creating load losses and thermal insulation losses on the active parts. This phenomena can cause damages.

  • Page 17: System Filling

    1. INSTALLATION 1.1.11. SYSTEM FILLING If after performing these operations you observe a decrease of the water pressure WARNING inside the system, open once again the loading For system filling use only clean tap tap until the pressure gauge reaches the water.

  • Page 18: Condensate Drain

    2. INSTALLATION 1.1.12. CONDENSATE DRAIN FILLING THE CONDENSATE DRAIN SIPHON Before starting the boiler you have to fill the condensate collection siphon in order to avoid fuel reflux through the siphon. Fill the condensate collection siphon as follows: › Unscrew the screw “P” (fig. 1), extract the siphon and fill it with water up to the highest point “T”...
  • Page 19 2. INSTALLATION CONDENSATE NEUTRALISER - OPTIONAL EXTRA cod.: 82153LA Assemble the condensate neutralisation box, fitted C O N D E N S A T E with granulate and active carbons for a treated COLLECTION HOLE power up to 350 kW (see fig.2). The device allows SULPHATE neutralising the condensate which is collected inside the boiler and/or in the fume discharge...

  • Page 20: Anti-Freeze Protection

    1. INSTALLATION 1.1.13. ANTI-FREEZE PROTECTION DILUTION PERCENTAGE CLEANPASS The boiler is protected against freezing thanks to FLUIDO AG the electronic board preparation with functions that start the burner and heat the concerned parts ANTIFREEZE - TEMPERATURE when their temperature goes below the minimum ETHYLENE GLYCOL FREEZING POINT pre-set values, protecting the boiler up to an...

  • Page 21: Gas Connection

    1. INSTALLATION 1.1.14. GAS CONNECTION 1.1.15. ELECTRICAL CONNECTION DANGER DANGER In order to connect the gas connector of The equipment is electrically safe only the boiler to the supply pipe use a stop seal of an if it is properly connected to an efficient grounding appropriate size and material.

  • Page 22: Power Supply

    2. INSTALLATION 1.1.16. POWER SUPPLY blue To connect the boiler’s power supply, operate on the “SPM” male plug (see fig. 1), located under the yellow/green boiler template, following the below instructions: brown DANGER › Cut off the voltage from the main switch.

  • Page 23: Optional Electrical Connections

    3. INSTALLATION 1.1.17. OPTIONAL ELECTRICAL CONNECTIONS To wire the optionals below: • (SE) EXTERNAL TEMPERATURE PROBE CODE 73518LA • (TA) ENVIRONMENT THERMOSTAT • (CR) REMOTE CONTROL OPEN THERM CODE 40- 00017 operate on the “SPM” male plug (see fig. 1), located under the boiler template, following the below instructions: DANGER...
  • Page 24 4. INSTALLATION To wire the optionals below: DANGER Cut off the voltage from the main switch. • (TP) DOMESTIC HOT WATER PRE-HEATING DEACTIVATION TIMER › remove the boiler's front casing (refer to chapter ACCESSING THE BOILER). • (CT) TELEPHONE DIALER ›...

  • Page 25: Fume Exhaust Fittings

    1. INSTALLATION 1.1.18. FUME EXHAUST FITTINGS WARNING › Suction and discharge systems, tailored to In order to ensure proper operation and individual installations, must be protected with efficiency of the device you have to connect the boiler accessories that prevent the ingress of foreign fume exhaust fitting to the fume exhaust duct using objects and atmospheric agents.
  • Page 26 1. INSTALLATION...
  • Page 27 1. INSTALLATION VERTICAL FLUE PIPE Ø 100 - STAINLESS STEEL FOR OUTDOOR INSTALLATION For a vertical flue exhaust and air intake from the boiler installation site It allows to exhaust the combustion gases by means of a pipe and to intake the air directly from the hole located onto the room sealed chamber top.

  • Page 28: Support Centre Section

    All operations described below relative to first start-up, maintenance and replacement should be performed only by qualified personnel and authorized by FLEXIHEAT UK. Gas leakage and operation of the appliance must be tested by the installer before leaving. When satisfied with the operation, please instruct the consumer on the correct method of operation.

  • Page 29: First Start-Up

    2. FIRST START-UP 2.1. FIRST START-UP 2.1.1. PRELIMINARY OPERATIONS › make sure that there are no flammable liquids FOR FIRST START-UP or materials near the device; The first start-up operations consist in checking › open the boiler gas tap and make sure that there the correct installation, adjustment and operation are no gas leaks upstream from the device (the of the device.

  • Page 30: Boiler Commissioning

    2. FIRST START-UP 2.1.2. BOILER COMMISSIONING WARNING Make sure that the system is correctly filled. Proceed with boiler commissioning as follows: › check that the gas tap is closed; › power the boiler; › make sure the circulator is not blocked; ›...

  • Page 31: Co2 Value Check And Calibration

    2. FIRST START-UP 2.1.3. CO2 VALUE CHECK AND › Then press the key ‘ ’ of the heating CALIBRATION make sure that the CO value did not change to minimum, if changed repeat the calibration WARNING described in the previous paragraph. The CO value should be checked with the casing assembled, while the gas valve should be...

  • Page 32: Accessing And Programming The Parameters

    2. FIRST START-UP 2.1.4. ACCESSING AND PROGRAMMING THE PARAMETERS All the values of the parameters can be changed from the master control panel ‘1’ (see figure), except for the parameters with which it is possible to set the power of a single unit (P00, P10, P11, P12, P13 and P14);...
  • Page 33 2. FIRST START-UP Hold at the same time the keys ‘ ’ and ‘ ’ until on the display appears the symbol ‘ ’with the message ‘P00’, and release the keys ‘ ’ and ‘ ’. Use the keys ‘ ’...
  • Page 34 2. FIRST START-UP Press the key ‘ ’ to confirm the action and wait for the display to stop blinking, indication of the fact that the adjustment was implemented. To exit the parameters menu, hold at the same time the keys ‘ ’...

  • Page 35: Digitech Cs Parameters Table (Miah406)

    2. FIRST START-UP 2.1.5. DIGITECH CS PARAMETERS TABLE (MIAH406) PARAMETER DESCRIPTION RANGE FUNCTION BOILER MODEL SELECTION 0 - 3 0 = R1K 18_24-R2K 24-R2KA 24 (IN (CHANGE THE PARAMETER VALUE ON BOTH CONTROL PANELS, ALL VERSIONS) MASTER AND SLAVE, PLEASE SEE CHAPTER "PARAMETER ACCESS AND PROGRAMMING").
  • Page 36 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION HEATING RUN-UP 0 - 5 0 = (DISABLED) THROUGH THIS PARAMETER YOU CAN SET THE TIME, DURING START-UP PHASE, NECESSARY FOR THE BOILER TO REACH THE 1 = 50 SECONDS MAXIMUM SET POWER (IN HEATING). (SET BY DEFAULT) 2 = 100 SECONDS 3 = 200 SECONDS...
  • Page 37 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION FAN MINIMUM SPEED ADJUSTMENT 38 - VALUE THE VALUE IS EXPRESSED IN THROUGH THIS PARAMETER YOU CAN SET THE FAN MINIMUM SET FOR HERTZ SPEED THAT CORRESPONDS TO THE MINIMUM POWER OF THE PARAMETER (1HZ = 30 RPM) BURNER.
  • Page 38 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION STARTING STEP ADJUSTMENT VALUE THE VALUE IS EXPRESSED IN THROUGH THIS PARAMETER YOU CAN SET THE FAN SPEED SET FOR HERTZ DURING START-UP PARAMETER (1HZ = 30 RPM) THE VALUE IS PRE-SET BASED ON THE SET POWER (SEE P10 - 255 PARAMETER P00) AND ON THE GAS TYPE (SEE PARAMETER P02).
  • Page 39 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION CLIMATE COMPENSATION CURVE 0 - 30 (SET BY DEFAULT AT 15) THE (ONLY WITH EXTERNAL PROBE CONNECTED) NUMBERING OF THE VALUE YOU CAN CONNECT AN EXTERNAL TEMPERATURE PROBE (SEE CORRESPONDS TO ‘KD’ CURVES CHAPTER ‘ELECTRICAL CONNECTIONS’) THAT AUTOMATICALLY ON THE CHART (SEE CHART CHANGES THE DELIVERY TEMPERATURE BASED ON THE...
  • Page 40 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION ENABLING BUS INDUSTRIAL PILOTING 0 -10V 0 - 2 0 = DISABLED THROUGH THIS PARAMETER YOU CAN ENABLE OR DISABLE THE (SET BY DEFAULT) BUS INDUSTRIAL INPUT 0-10 V TO SET THROUGH EXTERNAL BUS THE BURNER POWER OR THE DELIVERY TEMPERATURE.
  • Page 41 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION ACTIVATION PERCENTAGE OF THE SECONDARY UNIT 60 - 100 THE VALUE IS EXPRESSED IN PERCENTAGE (PRE-SET BY DEFAULT TO 85%) DEACTIVATION PERCENTAGE OF THE SECONDARY UNIT 5 - 40 THE VALUE IS EXPRESSED IN PERCENTAGE (PRE-SET BY DEFAULT TO 10 %) ENABLING THE MASTER BOARD WITH CRAD AREA MANAGEMENT...
  • Page 42 2. FIRST START-UP PARAMETER DESCRIPTION RANGE FUNCTION MODBUS COMMUNICATION BAUD RATE 0 - 5 0 = 9600 BY MEANS OF THIS PARAMETER, IT IS POSSIBLE TO SELECT THE MODBUS COMMUNICATION BAUD RATE SUPPORTED BY THE SAME 1 = 1200 INTERFACE. 2 = 2400 3 = 4800 4 = 9600...

  • Page 43: Electric Fan Frequency/Heat Capacity Diagram Of The Slave Unit (50 Kw)

    2. FIRST START-UP 2.1.6. ELECTRIC FAN FREQUENCY/HEAT CAPACITY DIAGRAM OF THE SLAVE UNIT (50 kW) Natural Gas (Black) Universal LPG (Orange) FREQUENCY (Hz) MINIMUM FREQUENCY DURING MAXIMUM FREQUENCY DURING GAS TYPE HEATING HEATING Natural Gas (Black) Universal LPG (Orange)

  • Page 44: Electric Fan Frequency/Heat Capacity Diagram Of The Master Unit (25 Kw)

    2. FIRST START-UP 2.1.2. ELECTRIC FAN FREQUENCY/HEAT CAPACITY DIAGRAM OF THE MASTER UNIT (25 kW) Natural Gas (Black) Universal LPG (Orange) FREQUENCY (Hz) GAS TYPE MINIMUM HEATING FREQUENCY MAXIMUM HEATING FREQUENCY Natural Gas (Black) Universal LPG (Orange)

  • Page 45: Maintenance

    › check the pre-load pressure of the expansion vessel; on an annual basis. The operations described below, are essential to the validity of the standard Flexiheat UK warranty and must be performed by › make sure that the permanent ventilation outlets...

  • Page 46: Technical Data

    2. MAINTENANCE 2.2.8. TECHNICAL DATA Model R1K 75 Rain MJ/h Maximum nominal heat capacity in heating circuit MJ/h Minimum nominal heat capacity in heating circuit Useful thermal power - 60/80°C 72,83 Minimum useful thermal power - 60/80°C 3,50 Useful thermal power - 30/50°C 79,35 Performance at 100% Pn - 60/80°C...
  • Page 47 2. MAINTENANCE Electrical specifications Voltage-frequency V/Hz 240 / 50 Max Absorbed Power Insulation rate Gas supply Nominal supply pressure - Natural Gas 1,13 Heating Max. fan speed - Natural Gas 247 (50kW) - (25kW) Heating Min. fan speed - Natural Gas 53 (50kW) - 50 (25kW) Fuel consumption - Natural Gas MJ/h...

  • Page 48: Technical Assembly

    2. MAINTENANCE 2.2.9. TECHNICAL ASSEMBLY FUMES SAFETY THERMOFUSE SLAVE UNIT HEAT EXCHANGER BURNER UNIT DETECTION ELECTRODE RETURN PROBE ELECTRIC FAN CIRCULATOR GAS VALVE AUTOMATIC AIR RELIEF VALVE 10. MANUAL AIR RELIEF VALVE 11. HEATING PROBE 12. SAFETY THERMOSTAT 13. LIGHT UP ELECTRODE 14.

  • Page 49: Hydraulic Board

    2. MAINTENANCE 2.2.10. HYDRAULIC BOARD 18. MASTER HEAT EXCHANGER R. HEATING RETURN 19. MANUAL AIR RELIEF VALVE G. GAS INLET SC. CONDENSATE DRAIN A. HEATING FORWARD FUMES SAFETY THERMOFUSE SLAVE HEAT EXCHANGER BURNER UNIT ELECTRIC FAN RETURN PROBE CIRCULATOR GAS VALVE SYSTEM DRAINING TAP AUTOMATIC AIR RELIEF VALVE 10.
  • Page 50 2. MAINTENANCE...

  • Page 51: Slave Board Electrical Connections

    2. MAINTENANCE 2.2.12. SLAVE BOARD ELECTRICAL CONNECTIONS GND +24V TXOUT RXIN ER: DETECTION ELECTRODE TS: SAFETY THERMOSTAT CE: BLUE EA: START-UP ELECTRODE SM: MODBUS BOARD MA: BROWN PM: MODULATING CIRCULATOR SR: HEATING PROBE PA: AIR PRESSURE SWITCH AR: ORANGE VG: GAS VALVE EV: ELECTRIC FAN L: LINE GI: YELLOW...

  • Page 52: Master Board Electrical Connections

    2. MAINTENANCE 2.2.11. MASTER BOARD ELECTRICAL CONNECTIONS GND +24V TXOUT RXIN Pacq ER: DETECTION ELECTRODE TS: SAFETY THERMOSTAT MP: TERMINAL BLOCK FOR EXTERNAL CONSENT EA: START-UP ELECTRODE PACQ:WATER PRESSURE SWITCH SE: EXTERNAL PROBE PM: MODULATING CIRCULATOR SR: HEATING PROBE TA: ENVIRONMENT THERMOSTAT VG: GAS VALVE EV: ELECTRIC FAN L: LINE...

  • Page 53: Accessing The Boiler

    2. MAINTENANCE 2.2.13. ACCESSING THE BOILER For the majority of the control and maintenance operations you have to remove one or more panels of the casing. To intervene on the front of the boiler proceed as follows: › open the Locks (1-Fig. 1) with a triangle wrench; ›...

  • Page 54: Accessing The Master Electronic Board

    2. MAINTENANCE 2.2.14. ACCESSING THE MASTER ELECTRONIC BOARD In order to intervene on the electrical connections of the master electronic board, please proceed as follows: DANGER Cut off the voltage from the main switch. › Grab at the same time the support brackets of the control panel (fig.

  • Page 55: Accessing The Slave Electronic Board

    2. MAINTENANCE 2.2.15. ACCESSING THE SLAVE ELECTRONIC BOARD In order to intervene on the electrical connections of the slave electronic board, please proceed as follows: DANGER Cut off the voltage from the main switch. › Grab at the same time the support brackets of the control panel (fig.

  • Page 56: System Emptying

    2. MAINTENANCE 2.2.16. SYSTEM EMPTYING It is not recommended to empty the heating system as the changes of water generate the increase of limestone deposits inside the exchangers. In case it is necessary to protect against freezing the heating circuit by adding anti-freeze liquid to the system water, these products must be approved by the company.

  • Page 57: Fault Signalling Codes

    2. MAINTENANCE 2.2.17. FAULT SIGNALLING CODES The fault signalling codes are displayed only on the display of the master control panel. Except for the faults common for both units (as for example: E04, E78, E06, E99), the fault signalling code will be displayed with the prefix ‘01’...
  • Page 58 2. MAINTENANCE CODE FAULT POSSIBLE CAUSE SOLUTION RESET FLAME BLOCK NO FLAME LIGHT UP MANUAL RESET (HOLD THE RESET ‘ GAS MISSING; CHECK THE ADDUCTION NETWORK; ’ KEY FROM THE MASTER CONTROL MASS OR BROKEN START-UP REPLACE IT; PANEL). ELECTRODE; GAS VALVE BROKEN;...
  • Page 59 2. MAINTENANCE CODE FAULT POSSIBLE CAUSE SOLUTION RESET FUMES SAFETY THERMOFUSE BROKEN; REPLACE IT; MANUAL RESET THERMOFUSE (102°C) (HOLD THE RESET ‘ THERMOFUSE CABLE CHECK THE WIRING. ’ KEY FROM THE DISCONNECTED. MASTER CONTROL PANEL). WATER MISSING IN THE INSUFFICIENT WATER LOAD THE SYSTEM;...
  • Page 60 2. MAINTENANCE CODE FAULT POSSIBLE CAUSE SOLUTION RESET RETURN PROBE BROKEN OR INCORRECTLY REPLACE IT; AUTOMATIC. CALIBRATED PROBE (RESISTANCE VALUE 10 KOHM AT 25 °C NTC); DISCONNECTED OR WET CHECK THE WIRING. PROBE CONNECTOR. ELECTRIC FAN ELECTRIC FAN BOARD REPLACE IT; AUTOMATIC.
  • Page 61 2. MAINTENANCE CODE FAULT POSSIBLE CAUSE SOLUTION RESET RESIDUAL FLAME FAULTY DETECTION CLEAN IT OR REPLACE IT; MANUAL RESET ELECTRODE; (HOLD THE RESET ‘ ’ KEY FROM THE FAULTY DETECTION REPLACE IT; MASTER CONTROL ELECTRODE CABLE; PANEL). FAULTY MODULATION REPLACE IT. BOARD.

  • Page 62: Active Functions Signalling Codes

    2. MAINTENANCE 2.2.18. ACTIVE FUNCTIONS SIGNALLING CODES CODE FUNCTION DESCRIPTION CHIMNEY SWEEP ACTIVE YOU CAN ACTIVATE IT BY HOLDING FOR 7 SECONDS THE RESET ‘ ’ KEY AND YOU CAN DEACTIVATE IT BY TURNING OFF THE BOILER. THIS FUNCTION BRINGS THE BOILER TO ITS MINIMUM AND MAXIMUM HEATING POWER FOR 15 MINUTES DEACTIVATING THE MODULATION FUNCTION.

  • Page 63: Gas Conversion

    2. MAINTENANCE 2.2.4. GAS CONVERSION ATTENTION Make sure that the gas adduction tube is suitable for the new type of fuel with which the boiler is supplied. › loosen the two screws ‘1’ (fig.1) from the fastening bush, and remove the air suction tube; ›...

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