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Radiant RK 25 Instruction Manual

Radiant premix condensing system boiler
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See also: User Manual
Instruction Manual
for model
RK 25
Premix condensing system boiler
SEDBUK BAND A
.
Installation, operating, commissioning and maintenance instructions
CE
0694
TA05A140.A0307
Technical specification RADIANT BRUCIATORI S.p.A. Montelabbate (PU) ITALY
ENGLISH

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Summary of Contents for Radiant RK 25

  • Page 1 Instruction Manual for model RK 25 Premix condensing system boiler SEDBUK BAND A Installation, operating, commissioning and maintenance instructions 0694 TA05A140.A0307 Technical specification RADIANT BRUCIATORI S.p.A. Montelabbate (PU) ITALY ENGLISH...

  • Page 3: Table Of Contents

    CONTENTS 1. General information 1.1 General warnings pag. 1.2 Product conformity 2. Technical characteristics 2.1 Technical data 2.2 Dimensions 2.3 Internal parts of the boiler 2.4 Water circuit 2.5 Circulation pump head/flow graph 2.6 Printed circuit board – Technical characteristics 2.7 Control panel 3.
  • Page 4 CONTENTS 6. Maintenance (authorised personnel) 6.1 General warnings pag. 6.2 Boiler inspection 6.3 Accessing the boiler 6.4 Flushing out the primary side 6.5 Draining the central heating and domestic hot water system 6.6 Maintenance operations 6.7 Wiring diagrams 6.8 Troubleshooting 6.9 Diagnostics 6.10 Parts list...

  • Page 5: General Information

    • In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt any repairs. Call for professionally qualified technical assistance only. Radiant Helpline UK 0870 770 0414 • Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorised service centre using original spare parts.
  • Page 6 • If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified electrician. • When the appliance is no longer required for use, switch off the main power supply, to switch all electrical components off (circulating pump, burner etc.) • Radiant Helpline UK 0870 770 0414 TA05A140.A0307...

  • Page 7: Product Conformity

    GENERAL INFORMATION 1.2 Product conformity RADIANT BRUCIATORI S.p.A. declares that all its products are manufactured to a high specification and in compliance with the relevant standards. All RADIANT boilers are CE certified and possess technical and functional characteristics that comply with the following standards: UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT ≤...

  • Page 8: Technical Characteristics

    TECHNICAL CHARACTERISTCS 2. TECHNICAL CHARACTERISTICS 2.1 Technical data Models RK 25 CE Certification n° 0694BN3485 Appliance Type C13, C33, C43, C53, C63, C83 Appliance Category II2H3+ Heat Input max Heat Input min Heat Output max (50/30°) 26.67 Efficiency 100% (full load 50/30°) 106.7...

  • Page 9: Dimensions

    TECHNICAL CHARACTERISTCS 2.2 Dimensions 48.5 48.5 111.5 111.5 LEGEND HEATING RETURN Ø3/4” HEATING FLOW Ø3/4” Ø1/2” CONDENSATE DRAIN Ø25 TA05A140.A0307...

  • Page 10: Internal Parts Of The Boiler

    TECHNICAL CHARACTERISTCS 2.3 Internal parts of the boiler LEGEND PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD + BURNER) CONDENSATE DRAIN PIPE IONISATION ELECTRODE IGNITION ELECTRODE VENTURI IGNITION TRANSFORMER ELECTRONIC GAS VALVE 10. 3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT 11.

  • Page 11: Water Circuit

    TECHNICAL CHARACTERISTCS 2.4 Water circuit LEGEND PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD+BURNER) PRIMARY CONDENSING HEAT EXCHANGER CONDENSATE DRAIN PIPE IONISATION ELECTRODE IGNITION ELECTRODE VENTURI IGNITION TRANSFORMER ELECTRONIC GAS VALVE 3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT AUTOMATIC AIR VENT VALVE HEATING SAFETY THERMOSTAT HEATING SENSOR...

  • Page 12: Circulation Pump Head/Flow Graph

    TECHNICAL CHARACTERISTCS 2.5 Circulation pump head/flow graph 1200 1400 1600 1000 Flow l/h Available head at maximum speed Available head at second speed Available head at minimum speed Appliance Loss TA05A140.A0307...

  • Page 13: Printed Circuit Board - Technical Characteristics

    TECHNICAL CHARACTERISTCS ® 2.6 DIGITECH printed circuit board – SM 20019 Technical characteristics Adjustments possible by service personnel only • Standard (30/80°C) / reduced (25-40°C) central heating temperature • Water hammer prevention function • Central Heating timer - (adjustable from 0 to 7,5 minutes) •...

  • Page 14: Installation (Authorised Personnel)

    INSTALLATION INSTRUCTIONS 3. INSTALLATION (authorised personnel) 3.1 Reference standard In GB, the installation must be carried out by a CORGI Registered Installer. To check for authorised qualified engineers please contact CORGI 01256-372400. It must be carried out in accordance with the relevant requirements of the: Gas Safety Regulations;...

  • Page 15: Boiler Room - Installation Requirements

    C. Lift the box and remove the protections. Lift the boiler by grasping the rear part and proceed with the installation. STORAGE & HANDLING Please note that prior to installation the Radiant boilers should stored horizontal position with no more than three boilers to a stack;...

  • Page 16: Installation Boiler

    M INIM UM DISTANCES IN mm ■ If the boiler is sited in an unheated M odel enclosure then it is recommended to RK 25 1000 leave the power on to give frost protection (frost protection is active Fig. 1 even with On/Off switch in Off position).

  • Page 17: Water Connections

    INSTALLATION INSTRUCTIONS 3.5 Water connections order safeguard heat exchanger circulation pump, especially in case of boiler replacement, it is recommended that the system is hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators. Make sure that the domestic water and central heating pipes are not used to earth the electrical system.

  • Page 18: Central Heating Circuit

    INSTALLATION INSTRUCTIONS 3.6 Central heating circuit The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc.

  • Page 19: Condensate Drain

    INSTALLATION INSTRUCTIONS 3.7 Condensate drain Termination to an internal soil and vent pipe Boiler FAILURE INSTALL CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...

  • Page 20: Gas Connection

    INSTALLATION INSTRUCTIONS 3.8 Gas Connection The connection to the gas supply must be carried out by professionally qualified personnel in accordance with relevant standards: In GB this is BS 6891. When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The use of hemp, Teflon tape and similar materials is not allowed.

  • Page 21: Electrical Connections

    The connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation and authorised by Radiant Bruciatori s.p.a. Always check to make sure that the appliance has an efficient earth system. This requirement is only satisfied if it has been properly connected to an efficient earth system installed in accordance with the requirements of current safety standards and carried out by professionally qualified personnel.
  • Page 22 INSTALLATION INSTRUCTIONS 3.9.2 Remote control connection Connect the power supply to the terminal board inside the control panel as follows: a. Switch off the power supply at the main switch. b. Remove the front case panel of the boiler. c. Slacken the screws and remove plate A (see fig. 1). d.

  • Page 23: Flue Connections

    INSTALLATION INSTRUCTIONS 3.10 Flue connections In order to ensure that the appliance functions correctly and efficiently, the flue connection between the boiler and the flue terminal must be made using original components specifically designed for condensing boilers. Traditional flue components cannot be used for conveying exhaust fumes from condensing boilers, nor vice versa.
  • Page 24 INSTALLATION INSTRUCTIONS 3.10.1 Flue position IMPORTANT: FLUE SYSTEM SHALL INSTALLED ACCORDANCE WITH RECOMMENDATIONS CONTAINED IN BS 5440:1. The boiler MUST be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows free passage of air across it at all times. If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway.
  • Page 25 The linear equivalent of additional bends is as follows: Ø 60/100 x 90° bend = 0.8 m. Ø 60/100 x 45° bend = 0.5 m. N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS DISCHARGING EXHAUST GASES DRAWING COMBUSTION AIR.
  • Page 26 Ø80 x 90° bend = 1.5 m. Ø80 x 45° bend = 1.2 m. Ø60 x 90° bend = 1.8 m. Ø60 x 45°bend = 1.5 m. N.B.: ONLY RADIANT TYPE- APPROVED FLUE SYSTEMS DISCHARGING EXHAUST GASES DRAWING COMBUSTION AIR.
  • Page 27 The linear equivalent of additional bends is as follows: Ø60/100 x 90° = 0.8 m. Ø60/100 x 45° = 0.5 m. N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS DISCHARGING EXHAUST GASES DRAWING COMBUSTION AIR.

  • Page 28: Commissioning The Appliance (Authorised Personnel)

    INSTALLATION INSTRUCTIONS 4. COMMISSIONING THE APPLIANCE 4.1 General warnings The following operations must be carried out by professionally qualified personnel, registered in accordance with current legislation. Reference should be made to BS 5449:5 “Commissioning”. The boiler leaves the factory pre-set and tested for burning either natural Gas or LPG. Nevertheless, when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler.

  • Page 29: Filling The System

    INSTALLATION INSTRUCTIONS 4.2 Filling the system Use only a WRAS approved filling loop for AIR VENT VALVE connection and filling of the primary system. This should be disconnected when not in AIR VENT VALVE PLUG use. PUMP Check the properties of the water supply PUMP PLUG install appropriate...

  • Page 30: Flushing The System

    All systems must be thoroughly drained and flushed out using additives – corrosion inhibitors and flushing agents/descalers that comply to BS7593 requirements. For informations or advices please contact Radiant Helpline UK To flush out the primary side of this unit.

  • Page 31: Starting Up The Boiler

    INSTALLATION INSTRUCTIONS 4.5 Starting up the boiler Once the system has been filled, proceed as follows: Table n°1 • Check that the exhaust flue is free of Gas type obstructions and correctly connected to the boiler; Methane - G20 • Switch on the power supply to the boiler; Liquid Butan Gas - G 30 10.9 •...

  • Page 32: Regulating The Appliance (Authorised Personnel)

    REGULATION INSTRUCTIONS 5. REGULATING THE APPLIANCE 5.1 Parameters table PARAMETER PARAMETER N° TYPE OF OPERATION FUNCTION VALUE Instantaneous Selects the type of boiler Boiler with storage tank B. w/storage tank Comfort (+7°C) Natural gas Selects the type of gas Sets the central heating Standard (30-80°C) temperature Reduced (25-40°C )

  • Page 33: Setting The Parameters

    REGULATION INSTRUCTIONS 5.2 Setting the parameters To modify the preset values of the parameters reported in the previous table, open the parameter settings menu as follows: 1. Place the On/Off switch in the OFF position. 2. Activate the On/Off switch while keeping buttons ‘+’...
  • Page 34 REGULATION INSTRUCTIONS To enter the parameters menu, follow the previously described procedure (steps 1-5). 1 – T ARAMETER YPE OF BOILER 6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = Instantaneous boiler 01 = Storage boiler; 02 = Storage boiler ‘comfort’...
  • Page 35 REGULATION INSTRUCTIONS 4 – C ARAMETER ENTRAL HEATING PUMP 6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = standard (3” overrun) 01 = permanent (always running) 7. Press and release button ‘S’ to confirm. The parameter number (4) will appear on the display.
  • Page 36 REGULATION INSTRUCTIONS 7 – C ARAMETER ENTRAL HEATING PUMP OVERRUN TIMER 6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter within the prescribed limits 00 = 0 x 5” = 0” 90 = 90 x 5” = 450” (7.5 min) The default value is 36 = 180”...
  • Page 37 REGULATION INSTRUCTIONS 13 – D.H.W ARAMETER PRIORITY Not applicable 14 – T ARAMETER YPE OF BURNER 6. Use buttons ‘+’ o ‘-’ to modify the value of the parameter: 00 = boiler with atmospheric burner; 01 = boiler with premix burner 25 kW; 02 = boiler with premix burner 29-34 kW ;...
  • Page 38 REGULATION INSTRUCTIONS 17 – M ARAMETER INIMUM PEED ETTING Not applicable 18 – M ARAMETER AXIMUM PEED ETTING Not applicable 19 – M ARAMETER INIMUM PEED ETTING ENTRAL EATING 6. Use buttons ‘+’ o ‘-’ to modify the value of the parameter between: min = 33 ;...
  • Page 39 REGULATION INSTRUCTIONS 21 – I ARAMETER GNITION EQUENCE ETTING 6. Use buttons ‘+’ o ‘-’ to modify the value of the parameter between: min = value of parameter 17; max = value of parameter 18. The default value is: - 90 Hz for Natural Gas; - 110 Hz for L.P.G.;...

  • Page 40: Gas Data

    REGULATION INSTRUCTIONS 5.3 Gas data 5.3.1 Technical data tables Table no.1 - CO Values Gas type Natural gas - G20 Liquid Butan Gas - G 30 10.9 Liquid Propane Gas - G 31 10.96 Table no.2 - Frequency Gas type Minimum (Hz) Maximum (Hz) Natural gas - G20...

  • Page 41: Maintenance (Authorised Personnel)

    All maintenance operations must be carried out by professionally qualified personnel, authorised by Radiant Bruciatori Spa. The RADIANT HELPLINE UK 0870 770 0414 The frequency of boiler maintenance must comply with current law and, nevertheless, should be carried out once a year.

  • Page 42: Accessing The Boiler

    INSTALLATION INSTRUCTIONS 6.3 Accessing the boiler All maintenance operations require one or more of the boiler casing panels to be removed. The side panels can only be removed after the front panel has been removed. Front panel: Remove the fixing screws at the lower edge of the front panel.

  • Page 43: Draining The Central Heating And Domestic Hot Water System

    INSTALLATION INSTRUCTIONS 6.5 Draining the central heating system If the need arises to drain the system, this can be done as follows: • Switch the system to “WINTER” mode and ignite the boiler. • Switch off the power supply to the boiler. •...

  • Page 44: Maintenance Operations

    Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY, WATER and GAS supplies to the boiler. Radiant Bruciatori s.p.a. will not be held responsible for damage to any of the boiler’s components caused by non-compliance with this instruction.
  • Page 45 INSTALLATION INSTRUCTIONS 6.6.1 Cleaning the main exchanger module and combustion unit primary heat exchanger (see fig. 1) • Disconnect the electrical connections of the electric fan. • Disconnect the joint and remove the pipe premix burner unit linking the gas valve to the injector unit (venturi).
  • Page 46 INSTALLATION INSTRUCTIONS Part replacement 6.6.2 Ignition and/or flame detection electrodes (see fig. 1) • Un-Plug the electrode wires; • Slacken the fixing screws; • Remove the electrodes. When fitting the new ones, check that the seals are not damaged. Replace if necessary;...
  • Page 47 INSTALLATION INSTRUCTIONS (see fig. 2) 6.6.5 Gas valve • Disconnect the joints and remove the gas pipe connecting the gas valve to the venturi. • Disconnect the gas feed pipe and valve ring-nut at the bottom of the room-sealed chamber. •...
  • Page 48 INSTALLATION INSTRUCTIONS (see fig. 1) 6.6.7 Expansion vessel • Close the shut-off valves and drain the central heating circuit of the boiler. fixing bracket • Use a 19 mm spanner to unscrew the pipe coupling to the vessel. • Unscrew the fixing screws and remove the upper mounting bracket.
  • Page 49 INSTALLATION INSTRUCTIONS (see fig. 1-2) 6.6.9 Modulation circuit board • Open the control panel (see 6.3 “Accessing the boiler”); electric fan circuit board • Disconnect all the connectors, remove the regulating knobs, unscrew the four fixing screws and modulation circuit board remove the modulation circuit board;...
  • Page 50 INSTALLATION INSTRUCTIONS (see fig. 1) 6.6.11 Primary heat exchanger • Close the shut-off valves and drain the central heating circuit of the boiler; primary heat flue connection exchanger • Switch off the power and gas supply to the boiler; chamber •...

  • Page 51: Wiring Diagrams

    INSTALLATION INSTRUCTIONS 6.6 Wiring diagrams 6.7.1 Electrical connections PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 76702LA PRINTED CIRCUIT BOARD DIGITECH - SM20019 COD. 76677LA EXHAUST FAN type RG128/1300-3612 Legend Main Switch Air Pressure switch Safety thermostat fusibile 2A brown Thermo Fuse 102°C Heating sensor light-blue...
  • Page 52 INSTALLATION INSTRUCTIONS 6.7.2 Connecting the room thermostat (Option) Connect the wires to the terminal board inside the instrument panel as follows: (Example with WEEK digital weekly chronostat): a. switch off the power supply at the main switch. b. remove the front case panel of the boiler. c.
  • Page 53 INSTALLATION INSTRUCTIONS 6.7.4 Connecting the remote controller the outside temperature sensor (option) Connect the wires to the terminal board inside the instrument panel as follows: a. switch off the power supply at the main Outside temperature switch. sensor (option) b. remove the front case panel of the boiler.
  • Page 54 INSTALLATION INSTRUCTIONS 6.7.6 Remote control and zone valves wiring For the installation of a zone valve p.c.b, it is necessary to access the main p.c.b for electrical connection (see 6.3 “Accessing the boiler” ) and to activate the parameter no. 16 (see 5.1 “Parameters table”). TA05A140.A0307...
  • Page 55 INSTALLATION INSTRUCTIONS 6.7.7 Remote control, zone valves and telephone control wirings TA05A140.A0307...
  • Page 56 INSTALLATION INSTRUCTIONS 6.7.8 Regulating the Flow temperature in accordance with the outdoor temperature The outdoor sensor has to be connected directly to circuit board SM 20019. The sensor can thus be managed in one of two ways: • In case of remote controller + outdoor temperature sensor installation, the climatic compensation curve is set by the remote itself (see remote control installation and operating manual).

  • Page 57: Troubleshooting

    INSTALLATION INSTRUCTIONS 6.8 Troubleshooting ERROR PROBLEM POSSIBLE CAUSE REMEDY CODE WITH NO IGNITION NO GAS. CHECK MAINS SUPPLY. IGNITION ELECTRODE BROKEN OR EARTHED. REPLACE PART. GAS VALVE MALFUNCTION REPLACE PART MECHANICAL MINIMUM ADJUSTMENT (ON GAS REGULATE MECHANICAL VALVE) SET TOO LOW OR SLOW IGNITION MINIMUM OR SLOW IGNITION.

  • Page 58: Diagnostics

    INSTALLATION INSTRUCTIONS 6.9 Diagnostics ■ Error codes: Ionisation Lock Out Safety Thermostat Tripped Flue Gas Thermostat Tripped Low Water Pressure Alarm Heating Sensor Malfunction D.H.W Sensor Malfunction (not applicable) D.H.W Storage Cylinder Sensor Malfunction (not applicable) Air Pressure Switch Tripped (not applicable) Electric Fan Malfunction Parameter Programming Request Flame Detection Malfunction...

  • Page 59: Parts List

    INSTALLATION INSTRUCTIONS 6.10 Parts List 6.10.1 Main components CODE DESCRIPTION RK 25 20069LA PRIMARY EXCHANGER ISOTHERM. 4+1 3+2 25KW 24052LA PUMP UPS 15-50 CIAO 3V. 27044LA CONDENSATE TRAP 99200229 36067LA ELECTRONIC GAS VALVE VK4115V1006B 36068LA VENTURI 45900444002B 37018LA FAN 88667.11130 RG128/1300-3612/4...
  • Page 60 RADIANT BRUCIATORI s.p.a. Via Pantanelli, 164/166 - 61025 Loc. Montelabbate (PU) Tel. +39 0721 9079.1 • fax. +39 0721 9079279 e-mail: tecnico@radiant • Internet: http://www.radiant.it RADIANT HELPLINE UK Technical Helpline - 0870 770 0414 Spares - 0870 770 0424 Email - info@portsdean.co.uk...

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