RBI FLEXCORE CK7000 Installation And Operation Instructions Manual

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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related

instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these

instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction.

the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-

free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation

with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified

service technician, and to follow all guidelines in the User' s Information Manual.

Boiler Manual

Installation and Operation

Instructions

Stainless Steel Condensing Boilers

Models CK850, CK1000, CK1500,

CK2000, CK2500, CK3000, CK3500,

CK4000, CK4500, CK5000, CK6000,

CK7000, CK8000 & CK9000

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Summary of Contents for RBI FLEXCORE CK7000

Page 1 FCR-IOM-10R 82-0651 Boiler Manual Installation and Operation Instructions Stainless Steel Condensing Boilers Models CK850, CK1000, CK1500, CK2000, CK2500, CK3000, CK3500, CK4000, CK4500, CK5000, CK6000, CK7000, CK8000 & CK9000 Also read and follow: HeatNet Control Manual This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Page 2: Table Of Contents
DESIGNED AND TESTED ACCORDING TO A.S.M.E. MUST FOLLOW the additional instructions contained in BOILER AND PRESSURE VESSEL CODE, SECTION IV RBI's instruction sheet, MACODE-3. Please refer to the FOR A MAXIMUM ALLOWABLE WORKING PRESSURE back of this manual for required regulations. (Models OF 160 PSI, 1103 kPa WATER.
Page 3: Ratings & Capacities
4. Locate the boiler in an area that will prevent water damage to adjacent construction should a leak Direct all questions to your RBI distributor or contact the occur or during routine maintenance. RBI Customer Service Department at: 260 North Elm Street, Westfield, MA 01085.
Page 4 FlexCore Stainless Steel Condensing Boilers – Installation Manual Buildings will require the installation of a fresh air duct When ducts are used, they must have the same cross- or other means of providing make-up air if the intake sectional area as the free area of the opening to which air option isn't used.
Page 5: Venting Guidelines
FlexCore Stainless Steel Condensing Boilers – Installation Manual All joints in metal intake air systems must be For Category II and IV appliances the vent secured using corrosion resistant fasteners shall not terminate: and sealed using a suitable Silicone caulk. If 1) over public walkways;...
Page 6 *Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings. The RBI Flexcore is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems.
Page 7 FlexCore Stainless Steel Condensing Boilers – Installation Manual Avoid terminal locations likely to be affected by winds, The top of a vertical vent system must extend at least ft, 1.8 m above the roof surface that it passes snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue through, 4 ft, 1.3 m above the intake air cap, see Figure gases.
Page 8 FlexCore Stainless Steel Condensing Boilers – Installation Manual Table X - Approved Stainless Steel Vent Manufacturers (CAT II/IV) Make Model DuraVent FasNSeal Vent M&G DuraVent DuraSeal Vent Heatfab Saf-T Vent Metal-Fab CORR/GUARD Security Chimneys Secure Seal Schebler Chimney Systems e Vent VAN-PACKER Z-Flex Z-Vent...
Page 9 9000 *Factory Installed The RBI Flexcore is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers. Use only listed manufacturers (Table X), terminations (Table Y), and...
Page 10 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 1 - Multiple Boiler Common Venting "B" FLUE VENT "C" ALL CONNECTIONS DOUBLE ACTING TO BE "T-WYE" BAROMETRIC DAMPER "D" THERMAL SPILL SWITCH "F" BOILER #2 BOILER #4 BOILER #3 BOILER #1 (IF REQUIRED) (IF REQUIRED) (IF REQUIRED)
Page 11 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System 10 ft (3.1 m) WARNING: When running horizontal WARNING: When running horizontal combustion combustion air and venting for single or air and venting for single or multiple units, multiple units, exhaust and combustion air 2000 &...
Page 12 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m 5 FT 1.5 m Figure 5 - Combination Direct Vent Systems 3 FT.
Page 13 FlexCore Stainless Steel Condensing Boilers – Installation Manual SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION SECTION In this configuration the boiler blower is used to push the must be followed! The vent guidelines under the flue products horizontally to the outdoors, see Figure 6.
Page 14 FlexCore Stainless Steel Condensing Boilers – Installation Manual VERTICAL VENT (Optional) Vent Connections Locate the boiler as close to the chimney system as NEGATIVE PRESSURE - CATEGORY II possible. Use the shortest, straightest vent connector The FlexCore is listed as a Category II appliance when possible for the installation.
Page 15: Common Vent Systems
FlexCore Stainless Steel Condensing Boilers – Installation Manual EXISTING COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où...
Page 16 FlexCore Stainless Steel Condensing Boilers – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
Page 17 FlexCore Stainless Steel Condensing Boilers – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) supply inlet horizontally...
Page 18 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure A - Other Than Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air supply 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) inlet horizontally...
Page 19: General Piping Requirements
FlexCore Stainless Steel Condensing Boilers – Installation Manual GENERAL PIPING REQUIREMENTS Freeze Protection Installations in areas where the danger of freezing exists are not recommended unless proper freeze protection is Improper piping of this boiler will void the provided. The following precautions MUST be observed: manufacturer’s warranty and can cause boiler 1.
Page 20: Heating System Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual Flow Sensor qw = 500*Q*(p/pw)*Cp*ΔT The factory mounted SIKA flow sensor, as shown in Where Figure 9, is wired to prevent the boiler from firing unless qw = Total heat transfer rate, BTU/h Q = flow rate, gpm there's adequate water flow, Table 6, through the unit.
Page 21 FlexCore Stainless Steel Condensing Boilers – Installation Manual Water Treatment Reverse Return Piping (RECOMMENDED) This boiler was designed to operate in a closed loop Systems using multiple boilers can also be installed heating system. System fill water must not contain more using a reverse return system, Figure 11.
Page 22 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local manufactures representative for assistance.) AIR SEPARATOR ALTERNATE LOCATION SYSTEM...
Page 23: Domestic Water Supply Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual DOMESTIC WATER SUPPLY PIPING The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce flow. Proper controls must be used to prevent water supplied for domestic use from Expansion Tank exceeding 130°F, 54°C or a scald injury will...
Page 24 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping COLD WATER MAKE-UP FLOW FLOW WATER E-UP FLOW FLOW COLD WATER BRONZE MAKE-UP/FILL PUMP FLOW FLOW COLD WATER CIRCULATOR MAKE-UP NOTES: RETURN 1.
Page 25: Condensate Piping
If for any reason the boiler is not for Maximum gas volume of pipe (ft /hr) the type of gas available at the installation site, call your 1" RBI representative to resolve the problem. " 1050 400 350 "...
Page 26: Electrical Wiring
FlexCore Stainless Steel Condensing Boilers – Installation Manual ELECTRICAL WIRING A minimum of (3 in WC) and maximum of (14 in WC) must be maintained to the inlet of the boiler gas train not to exceed a maximum Electrical Power Connections of (1 in WC) drop when firing from minimum input to full load of the gas supply line and all Label all wires prior to disconnection when...
Page 27 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 17 - Gas Supply Piping Con't. FROM GAS SUPPLY PILOT PILOT REGULATOR SHUT OFF AND SOLENOID VALVE MAIN GAS VALVE (TYP) VALVE (TYP) LOW GAS PRESSURE SWITCH (TYP) GROUND UNION HIGH GAS PRESSURE SWITCH TEST PORT LOCATED DOWNSTREAM OF (TYP)
Page 28: Boiler Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual BOILER OPERATION The system should be checked and bled after three days of operation. Before proceeding read and fully understand OPERATING INSTRUCTIONS the instructions contained in this manual. Do not attempt to operate this boiler if it has not FOR YOUR SAFETY READ BEFORE OPERATING.
Page 29 FlexCore Stainless Steel Condensing Boilers – Installation Manual Operating Instructions 16. Adjust the pilot pressure per the CHECKING, 1. STOP! Read the safety information above. If, at any ADJUSTMENT & OPERATION on page 29. time, the appliance will not operate properly, follow the instructions "TO TURN OFF GAS TO APPLIANCE"...
Page 30 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 18 - Control Panel Components PRESSURE TAPS (CK0850 TO 2000) 50 VA TRANSFORMER POWER SUPPLY (CK0850 TO 6000) BLOWER PROVE (CK1500 TO 2000) CONNECTIONS 12V - 5A POWER SUPPLY 250 VA TRANSFORMER BLOCKED FLUE OPTION (CK7000 TO 9000)
Page 31: Sequence Of Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual b. Press the ‘Adjust’ button under the Minimum (%) d. When the adjustment is satisfactory press the setting. The percentage value will turn green. Adjust check key to save the setting. Follow the same the minimum value (%), using the arrow keys, to procedure for the middle and rear modules on achieve the required combustion - C02/02, (Table...
Page 32 FlexCore Stainless Steel Condensing Boilers – Installation Manual Table 11 - Combustion Settings FlexCore-Series Whirlwind Bekaert Burner w/Gas Orifice Slide Trim** Inlet High High Temp. Fire Fire Fire Fire -40°F -30°F -20°F -10°F 0°F 10°F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F...
Page 33 FlexCore Stainless Steel Condensing Boilers – Installation Manual FireTube Series "HeatNet Control" Troubleshooting (Firing the FireTube Boiler) Variable Frequency FireTube Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) DISPLAY: INPUTS: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4.
Page 34: Checking & Adjustment
FlexCore Stainless Steel Condensing Boilers – Installation Manual CHECKING, ADJUSTMENT & OPERATION To adjust the pilot the following steps must be taken: 1. Remove the pilot gas pressure regulator cap. Spark Gap The gap has to be measured and adjusted with the 2.
Page 35: Diagnostics
FlexCore Stainless Steel Condensing Boilers – Installation Manual DIAGNOSTICS Ignition Safety To test the ignition safety shutoff device, close the The FlexCore has a display that indicates the sequence manual shutoff valve 1 (Figure 17) in the gas supply line. of operation, Figure 18.
Page 36: Maintenance
FlexCore Stainless Steel Condensing Boilers – Installation Manual MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. Disconnect electrical power and close the 1. Check the operating controls for proper operation. manual gas shut off valve before performing maintenance or severe personal injury may 2.
Page 37 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 21 - Pressure Switches RIOM-0218_C GREEN GREY ORANGE...
Page 38 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 23 - Relays, Interlocks and Boiler Status The Highest priority SYSTEM FLOW PROVE --------- Low Water Cutoff------------------- Variable Frequency Drive -------- Gas Pressure (High & Low) ----- Spare for user or Factory ------ Operator------------------------------ Water Flow Switch----------------- Factory ------------------------------...
Page 39 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 24 - Single Unit Replacement Parts SEE VIEW C SEE VIEW A SEE VIEW F SEE VIEW B SEE VIEW D RIOM-0217_D SEE VIEW E RIOM-0217_D SEE VIEW A SEE VIEW F SEE VIEW B SEE VIEW C SEE VIEW D...
Page 40 FlexCore Stainless Steel Condensing Boilers – Installation Manual SEE VIEW A SEE VIEW F SEE VIEW B SEE VIEW C SEE VIEW D SEE VIEW E RIOM-0217_D RIOM-0217_D...
Page 41 FlexCore Stainless Steel Condensing Boilers – Installation Manual CK0850 TO 1000 ONLY VIEW A RIOM-0217_D VIEW B RIOM-0217_D...
Page 42 FlexCore Stainless Steel Condensing Boilers – Installation Manual VIEW C RIOM-0217_D VIEW D RIOM-0217_D...
Page 43 FlexCore Stainless Steel Condensing Boilers – Installation Manual VIEW E RIOM-0217_D VIEW F RIOM-0217_D...
Page 44 48-0705-005 47 Top Front Jacket Panel 75-0032-001 FlexCore Overlay 82-0520-001 Center Front Jacket Panel for Touchscreen Enclosure 75-0033-002 HeatNet/RBI Overlay for Touchscreen Enclosure 82-0751-002 Bottom Front Jacket Panel 75-0035-001 48 Single Fuel Switch Panel Assembly 75-0015-001 NS Switch Panel Overlay...
Page 45 FlexCore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part No. 1000 1500 2000 2500 3000 3500 4000 4500 5000 6000 7000 8000 9000 49D Molded Rear Flue Outlet 09-0601-005 49E Flue Outlet Expansion Joint 09-0675-001 49F LH Flue Outlet Expansion Joint Clamp 74-0031-001...
Page 46 FlexCore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part No. 1000 1500 2000 2500 3000 3500 4000 4500 5000 6000 7000 8000 9000 68A Blower to Air Box Adapter 74-0030-001 68B Blower to Upper Cover Adapter 74-0029-001 69 Air &...
Page 47: Start-Up
FlexCore Stainless Steel Condensing Boilers – Installation Manual START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STA T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL...
Page 48 FlexCore Stainless Steel Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS INLET PRESSURE (WC) INCHES WC I NCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC...
Page 49 FlexCore Stainless Steel Condensing Boilers – Installation Manual MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure installation must be performed by a licensed used in whole or in part for residential purposes, including plumber or gas fitter.
Page 50 FlexCore Stainless Steel Condensing Boilers – Installation Manual FlexCore Series Water Boiler Limited Warranty One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the FlexCore Series modulating water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation or eighteen (18) months from the date of shipment from the factory whichever comes first.
Page 51 FlexCore Stainless Steel Condensing Boilers – Installation Manual...
Page 52 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada  Phone: (833) 265-5371 Phone: (905) 670-5888 www.rbiwaterheaters.com...

This manual is also suitable for:

Flexcore ck1000 Flexcore ck1500 Flexcore ck2000 Flexcore ck2500 Flexcore ck3000 Flexcore ck3500 ... Show all