Flexiheat HDCS Series User manual

INSTRUCTIONS
INSTALLATION AND OPERATING
HDCS - Floor Mounted Electric Combination Boiler
HDCSM - Wall Mounted Electric Combination Boiler

This manual forms an essential part of the product and it must be
given to the user. Read the warnings and recommendations in the
manual carefully, as they contain important information on the safety,
use and maintenance of the installation.
These boilers are to be installed by qualified personnel only, following
the manufacturer’s instructions.
The manufacturer will hold no liability in case of damage to people,
animals or property caused by incorrect installation of these boilers

1
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15
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22
22
INDEX Page.
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..........................................................................................................................................19
1 LIST OF COMPONENTS ............................................................................................................................................2
3.1 WHO THIS BOOKLET IS FOR....................................................................................................................................................................4
3.2 RECOMMENDATIONS............................................................................................................................................................................4
3IMPORTANT INFORMATION.............................................................................................................................................................4
2 CONTROL COMPONENTS
3.3 APPLICABLE LEGISLATION.......................................................................................................................................................................4
3.4 WARNINGS.....................................................................................................................................................................................4
4 INSTALLATION INSTRUCTIONS
4.1 HYDRAULIC INSTALLATION ..................................................................................................................................................................6
4.2 ELECTRICAL INSTALLATION .....................................................................................................................................................................6
5 FIRST START-UP
5.1 FILLING THE INSTALLATION ............................................................................................................................................................7
5.2 CHECKING THE CIRCULATING PUMP FUNCTIONING ...................................................................................7
5.3 BLEED THE AIR FROM THE INSTALLATION.............................................................................................................................7
6 INSTALLATION DELIVERY
7 OPERATION.............................................................................................................................................................................7
7.1 POWER SETTING SELECTION................................................................................................................................................................7
7.2 TEMPERATURE SELECTION...........................................................................................................................................................7
8 FUNCTIONING WITH TIMER (OPTIONAL)
6.1 OBSERVATIONS...................................................................................................................................................................................7
9 SWITCHING OFF THE BOILER
10 BOILER MAINTENANCE ....................................................................................................................................8
10.1 SAFETY DEVICE MAINTENANCE................................................................................................................8
19 GENERAL WARRANTY CONDITIONS....................................................................................................................................................23
18.3 LOW PRESSURE LOCKING.................................................................................................................................................22
18.2 BOILER TEMPERATURE SECURITY LOCK...................................................................................................
18.1 ACCUMULATOR TEMPERATURE SECURITY LOCK.............................................................................................
18 SECURITY LOCKS
17 ANOMALIES
10.2 RECOMMENDATIONS..........................................................................................................................................................................8
11 DIAGRAMS AND MEASUREMENTS .....................................................................................................................................................................9
12 CIRCULATING PUMP FLOW CURVES
13 TECHNICAL CHARACTERISTICS....................................................................................................................................................11
14 ELECTRICAL DIAGRAM
14.1 CONTROL DIAGRAM......................................................................................................................................................................12
14.2 POWER DIAGRAM......................................................................................................................................................................14
14.3 POWER CABLE DIMENSIONS............................................................................................................
14.4 CHANGING THE VOLTAGE .......................................................................................................................................................................15
14.5 CHANGING THE BOILER POWER..........................................................................................................................................15
15 ELECTRICAL CHARACTERISTICS................................................................................................................................................16
16 SPARE PARTS LIST
16.1 MODEL HDCS..............................................................................................................................................................................19
16.2 MODEL HDCSM..........................................................................................................................................................................20
16.3 MAIN CONTROL BOARD..................................................................................................................................................................21

HDCS / HDCSM
2
HDCS
HDCSM
1
2
3
4
5
6
7
8
9
10
11
12
1
1
236 7
8
4
11
9
12
514 10
1LIST OF COMPONENTS
7. Automatic trap
6. Pressure switch 12. Heating pump
4. Modular maneuver 11. Expansion Vessel
13. Drain point
8. Heating tank.
9. Heating elements
10. Heating safety valve
3. Safety thermal 80 ºC
14. DHW safety valve
5. DHW heater elements
2. DHW Stainless Steel Tank
1. Dielectric nipple

3
1
2
3
4
5
6
897
2CONTROL COMPONENTS
4. Safety thermostat “E”:
6. Boiler control thermostat:
8. General heating switch“i”:
Indicates the DHW temperature
5. Scheduler (Optional) “q”:
7. Power selectors:
1. DHW thermometer.:
2. DHW general switch. “i”:
3. DHW control thermostat.:
Indicates the temperature and pressure of the
9. Thermo hydrometer:
Turns the heating side of the boiler on or off
heating circuit
Ensures that the boiler temperature does
not exceed 110 ºC.
It is an optional element, which can be weekly
or daily and allows you to select the on and
off period for the heating
Select the power stages for the heating,
selecting half power with each stage. Activate
both switches get the maximum power output
Allows you to select the desired heating
water temperature
It is used to select thedesired temperature
for the DHW Tank
Turns the Domsetic Hot Water On or Off

HDCS / HDCSM
4
3IMPORTANT INFORMATION
3.1 Who this booklet is for
This instruction booklet is for use by the boiler user and installer.
3.2 Recommendations
The installation must be made by a qualified technician.
The installation must be made in accordance with applicable law.
Failure to comply with these operating and control procedure instructions may give rise to personal
injury and risk of environmental pollution.
It is recommended to have a qualified technician carry out yearly maintenance of the boiler.
In case of anomaly, please contact the installer.
Before carrying out boiler maintenance, it is essential to cut off the electricity supply.
Users must not access internal boiler components or control components.
3.3 Applicable legislation
It is essential to observe the laws in force regarding electric boiler installation.
with applicable legislation..
The availability of certain models and their accessories may vary according to the market.
Flexiheat UK shall hold no liability for any damages caused by incorrect installation or incorrectuse
of the appliance or accessories.
of its products without prior notice.
3.4 Warnings
This manual forms an integral part of the appliance it refers to and must be given to the user.
Boiler installation and maintenance must be carried out by qualified technicians, in accordance
Flexiheat UK reserves the right to modify the technical characteristics and components

5
500
400200
500
500
DCS DCSM
495±15 mm
4INSTALLATION INSTRUCTIONS
Wall mounting system (for HDCSM)
Clearance measurements

HDCS / HDCSM
6
HDCS HDCSM
4.1 Hydraulic installation
Choose a location complying with the conditions required by applicable law.
.
If the boiler is located on a lower level than any of the heating water pipes, it is recommended to
fit shut-off valves to the flow and return pipes, to avoid having to drain the installation when
maintenance work is carried out on the boiler.
Before connecting the boiler hydraulically, thoroughly clean the pipes.
Remember to provide for a fill valve connected to the flow or return heating circuit.
4.2 Electrical installation
Ensure the voltage in the home is the same as that indicated for the boiler. Make the
electrical connections in accordance with the electrical diagrams shown in this manual.
The boiler must be installed by a qualified technician, observing the applicable legislation. It must
be connected to a heating circuit or domestic hot water network in accordance with its features
and power.
Feed gland
Feed gland
Thermostat Cable
Glandgland
Thermostat cable
We recommend installing a main switch on the power lines enabling all supply phases to the
boiler to be cut off. A neutral phase is required to connect the boiler in 3phase 380v .

7
5FIRST START-UP
5.1 Filling the installation
Unscrew the circulating pump cap so that the rotation shaft is visible. Connect the boiler main
switch and check if the pump shaft is turning. Screw the cap back on.
If the shaft is not turning, switch off the boiler main switch and use a suitable screwdriver to turn
the pump shaft in both directions to unblock it. Turn on the main switch again and check the shaft
is turning. Screw the cap back on.
5.3 Bleed the air from the installation
Connect the boiler main switch and drain the air from the installation and the boiler using the
air vent valves provided in the installation and on the boiler.
6INSTALLATION DELIVERY
The installer will explain how the boiler functions to the user, making all necessary observations
such as how to fill, bleed and drain the boiler.
6.1 Observations
If the boiler does not start up when you have checked that the power is reaching it, the
installation is filled with water at the correct pressure, the circulating pump is turning and the
boiler has not been cut out by the safety circuit breaker, turn off the main switch and contact the
installer.
7OPERATION
7.1 Power setting selection
The total power to the boiler may be reduced by half, using the half-power switches on the
control panel. When both switches are connected, the boiler will function at maximum power.
7.2 Temperature selection
Use a filling valve to fill the installation slowly until the pressure shown on the thermo hydrometer is
between 1 to 1.5 bar.
5.2 Checking the circulating pump functioning
This is done using the control thermostat command on the control panel. Turn it clockwise for a
higher temperature, or anticlockwise for a lower temperature. Models HDCD and HDCSM allows
the possiblity of selecting the heating temperature and the domestic hot water tank temperature.
When the selected temperature is reached, the thermostat automatically maintains a constant
temperature

HDCS / HDCSM
8
8FUNCTIONING WITH TIMER (OPTIONAL)
The boiler may optionally be supplied with a timer, which can be fitted to the main control panel.
Both the boiler and the timer are equipped with a quick fixing system using the 12-way connector
(X12) shown on the electrical diagram. The procedure for this is described in the installation and
operating instructions enclosed with the timer.
9SWITCHING OFF THE BOILER
To totally switch off the boiler, turn the main switch to “O”.
To regulate the room temperature you will need to install a room thermostat. This thermostat
switches off the boiler when the selected temperature is reached, and starts it up again when the
temperature drops.
The boiler is pre-wired for connection of a room thermostat. To do this, remove the bridge from
the connector block and connect the room thermostat.
10 BOILER MAINTENANCE
10.1 Safety device maintenance
Check the thermostats and safety devices are working correctly.
Check the heating circuit pressure relief valves, and the domestic hot water circuit if applicable.
10.2 Recommendations
Boiler maintenance is recommended at least once a year.
Maintenance must be carried out by qualified technicians.
-It is recommendable to exhaustively check the boiler once a year.
-The installation pressure should be kept at 1 - 1.5 bar.
To keep the boiler in perfect working order, a yearly overhaul must be performed by a
qualified technican

9
HDCS
200
160
475
110220270590600
75
835
IC
EAS IAS
RC
510
65
HDCSM
4
95
395
600
50
7
00
11
0
22
0
IC EAS IASRC
V
S
6
0
7
0
90
IC
35
RC
VS
IAS
EAS
14
0
4
5
17
5
11 DIAGRAMS AND MEASUREMENTS
IC: Heating OutputHDCSM1"H, HDCS 3/4" M.
RC: Heating Return,3/4"M.
VS: Pressure relief valve,1/2"H.
EAS: Domestic Cold Water Inlet,1/2"M.
IAS: Domestic Hot Water Outlet ,1/2"M.

HDCS / HDCSM
10
I
II
III
Min.
Min.
12 CIRCULATING PUMP FLOW CURVES
The graphs below can be used to obtain the hydromotive pressure available in the installation at the
boiler output, taking the boiler pressure drop and pump functioning curves into account. These
graphs show three curves, corresponding to the three speeds of the circulating pumps and the boiler
pressure drop. 1- Constant speed I, II, III (traditional mode):
The pump operates at a constant, pre-set speed.
2- Variable differential pressure (Δp-v):
The setpoint value of the differential pressure H increases in a straight line between ½H
and H within the permitted flow margin. The differential pressure generated by the pump
is adjusted to the appropriate setpoint value of differential pressure.

11
HDCS HDCSM
45/90 10/15 180 210 45/90 10/15 180 210
V
230 V~
230 V 3~
400 V 3N~ 400 V 3N~ 230 V~
230 V 3~
400 V 3N~ 400 V 3N~
- 1 1 1 2 1 1 1 2
kW 1 x 6 1 x 6
- 1 1
Ohm 8 8
bar 3 3
ºC 90 90
ºC 110 110
3/4" M 3/4" M
mm 835 700
Kg 57 53
13 TECHNICAL CHARACTERISTICS
kW 4.5-9 10.5-15 18 21 4.5-9 10.5-15 18 21
MODEL
kW 6x1.5 6x2.5 6x3 6x1.75 6x1.5 6x2.5 6x3 6x1.75
Ohm 35.2 21.1 17.6 30.2 35.2 21.1 17.6 30.2
mca 0.02 0.08 0.1 0.2 0.3 0.4 0.03 0.1 0.13 0.25 0.35 0.47
Litres 80 50
Litres 8 7,5
HDCS: Pump Curve HDCSM: Pump Curve
bar 0.6 0.6
mm 600 600
3/4" M 1" M
mm 590 395
Power
Main Supply Voltage
Number of heating elements
Number of resistors (heating)
Water charge loss
Heating element for DHW
Number of resistors (DHW)
Ohmic value heating element of DHW
DHW Tank volume
Ohmic value of the heating element
Expansion vessel volume
Operating pressure (max)
Minimum operating pressure (heating)
Heating Temperature (max)
Safety Temperature
Connection of heating
Flow
Return
Height
Width
Depth
Weight (Dry)

HDCS / HDCSM
12
HDCS-HDCSM 45/90, HDCS-HDCSM 10/15
0 1 L1 L2 L3 OO O O
BC TA
TC1
IAC S
P1/ 2
TS1
C
2
C1C2P1/2
I1/2
P
C
2
TC
C
1
TS
C
2
P
A
CS
C3
PC
F
7
2
3
9
8
1
5
6
4
I1/ 2
IC
C
2
9 10 11 125 6 7 81 2 3 4
X12
I
I P:
14 ELECTRICAL DIAGRAM
14.1 Control diagram
BC: Heating pump.
TA: Room thermostat.
F: Fuse.
X12: 12-way connector for timer (Optional).
C1,C2: Heating contactors.
Pressure switch.
TS: Heating safety thermostat.
TC: Heating control thermostat.
C
3: DHW contactors
TS1:DHW Safety thermal
TC1:DHW Regulation Thermostat
I
C:GeneralHeating Switch
ACS:DHW switch
1/2:Medium Power Switch
P
C:Power Light
PACS:DHW Light
P
1/2:Light of1/2power.

13
HDCS-HDCSM 180, HDCS-HDCSM 210
0 1 L1 L2 L3 OO O O
BC TA
TC1
IACS
P1/ 2
TS1
C
2
C1C2P1/2
I1/2
P
C
2
TC
C
1
TS
C
2
P
A
CS
C3
PC
F
7
2
3
9
8
1
5
6
4
I1/ 2
IC
C
2
9 10 11 125 6 7 81 2 3 4
X12
I
I P:
BC: Heating Pump.
TA: Ambient Thermostat.
F: Fuse
X12: C12 way connector for programmer(Optional).
I
C:General Heating Switch.
1/2:Medium Power switch
TS: Thermal security heating
Pressure switch
ACS:DHW switch
PACS:DHW Pilot Light
TC1:DHW Regulation thermostat
TS1:DHW safety thermostat
TC: Heating control thermostat
C1,C2: Heating contactors
C
3: DHW Contactors
P
C:Power Light
P
1/2:Light of 1/2 Power

HDCS / HDCSM
14
HDCS-HDCSM 45/90, HDCS-HDCSM 10/15
O
1 L1L2L3
R1
R3
R5
R2
R4
R6
B
C
A
C1C2
P1P2
R
R
R
R
R
R
C3
HDCS-HDCSM 180, HDCS-HDCSM 210
NL1L2L3
R1
R3
R5
R2
R4
R6
C1C2
P1P2
R
R
R
R
R
R
C3
C
1,C2:
14.2 Power diagram
C1,C2:Heating contactors.
P1,P2:Heating element units.
A, B, C: Bridges for heating power selection.
Heating contactors.
P1,P2:Heating element units.
A.C.S.: DHW Resistance group
A.C.S.: DHWResistance Group
HEATING
DHW
HEATING
DHW

15
4 32
6 40
10 63
16 80
O 1 L1 L2 L3
N L1L2 L3
400 V 3N~
O 1 L1 L2L3
L2L1L3
230 V 3~
O1 L1 L2 L3
N L
230 V~
(kW)
45/90 10/15
A
14.3 Power cable dimensions
The size of the power cables should correspond to the type and calibre of the fuse, which should be
chosen according to the boiler’s nominal current. The installation must comply with applicable
legislation in all cases.
The permissible current for the electric cabling depends on the room temperature, the diameter,
length and insulation of the conductors, the type of conduit and the conduit fitting and
environment. The table below shows the approximate values for a room temperature of 30 ºC and a
maximum length of 5 metres. The installation must comply with applicable legislation in all cases.
14.4 Changing the voltage
If the main supply voltage is different from the voltage the boiler is designed for, the boiler must be
adapted to the new voltage. To do this, before connecting the boiler to the main supply, change
the position of the terminal strip bridges as shown in the figures below
To remove a bridge, loosen the screws holding it in place and then pull it out of its housing. Repeat the
above procedure in reverse order to replace it.
the corresponding figure. Remember to make an earth connection.
When the bridges are correctly positioned, connect the electrical supply to the boiler as shown in
14.5 Changing the boiler power
HDCS-HDCSM 45/90 and HDC-HDCSM 10/15 boilers allow the maximum boiler heating power
to be altered to suit your requirements. To do this, simply remove some of the heat exchanger
element bridges as shown in the table below.
Bridges
Total power according to models
9 15 Leave in place
7.5 12.5Remove
6 10 RemoveA&B
4.5 - RemoveA, B & C
Models - HDCS-HDCSM 45/90 &HDCS-HDCSM 10/15).
Nominal Section (mm2) Rated current of the circuit breaker (A)
1.5 16
2.5 25

HDCS / HDCSM
16
HDCS/HDCSM 45/90
O 1 L1 L2 L3
N L
C
B
A
O 1 L1 L2 L3
N L
C
B
O 1 L1 L2 L3
N L
C
O 1 L1 L2 L3
N L
O 1 L1 L2 L3
NL1 L2 L3
C
B
A
O 1 L1 L2 L3
NL1 L2 L3
C
B
O 1 L1 L2 L3
NL1 L2 L3
C
O 1 L1 L2 L3
NL1 L2 L3
Single Phase 230 V~, 9 kW
Terminal L3 L (A) 19,5 19,5 39,1
Terminal 0 N (A) 19,5 19,5 39,1
Power kW 4,5 4,5 9
Single Phase 230 V~, 7,5 kW
Single Phase 230 V~, 6 kW
Single Phase 230 V~, 4,5 kW
Three Phase 400 V 3N~, 9 kW
Three Phase 400 V 3N~, 7,5 kW
Three Phase 400 V 3N~, 6 kW
Three Phase 400 V 3N~, 4,5 kW
Terminal L3 L (A) 19,5 13 32,5
Terminal 0 N (A) 19,5 13 32,5
Power kW 4,5 3 7,5
Terminal L3 L (A) 13 13 26
Terminal 0 N (A) 13 13 26
Power kW 3 3 6
Terminal L3 L (A) 13 6,5 19,5
Terminal 0 N (A) 13 6,5 19,5
Power kW 3 1,5 4,5
Heating Circuit Stage 1 Stage 2 Total Terminal Strip Power Selection
Terminal L1 L1 (A) 6,5 6,5 13
Terminal L2 L2 (A) 6,5 6,5 13
Termnal L3 L3 (A) 6,5 6,5 13
Terminal 0 N (A) 0 0 0
Power kW 4,5 4,5 9
Terminal L1 L1 (A) 6,5 6,5 13
Terminal L2 L2 (A) 6,5 6,5 13
Terminal L3 L3 (A) 6,5 0 6,5
Terminal 0 N (A) 0 6,5 6,5
Power kW 4,5 3 7,5
Terminal L1 L1 (A) 0 6,5 6,5
Terminal L2 L2 (A) 6,5 6,5 13
Terminal L3 L3 (A) 6,5 0 6,5
Terminal 0 N (A) 6,5 6,5 6,5
Power kW 3 3 6
Terminal L1 L1 (A) 0 6,5 6,5
Terminal L2 L2 (A) 6,5 0 6,5
Terminal L3 L3 (A) 6,5 0 6,5
Termnal 0 N (A) 6,5 6,5 0
Power kW 3 1,5 4,5
15.ELECTRICAL CHARACTERISTICS

17
O 1 L1 L2 L3
N L
C
B
A
O 1 L1 L2 L3
N L
C
B
O 1 L1 L2 L3
N L
C
O 1 L1 L2 L3
NL1 L2 L3
C
B
A
O 1 L1 L2 L3
NL1 L2 L3
C
B
O 1 L1 L2 L3
NL1 L2 L3
C
Terminal 0 N (A) 32,6 32,6 65,2
Terminal L3 L (A) 32,6 21,7 54,3
Terminal L3 L (A) 32,6 32,6 65,2
Terminal 0 N (A) 32,6 21,7 54,3
Terminal L3 L (A) 21,7 21,7 43,4
Terminal 0 N (A) 21,7 21,7 43,4
Terminal L1 L1 (A) 10,85 10,85 21,7
Terminal L2 L2 (A) 10,85 10,85 21,7
Terminal L3 L3 (A) 10,85 10,85 21,7
Terminal 0 N (A) 0 0 0
TerminalL1 L1 (A) 10,85 10,85 21,7
Terminal L2 L2 (A) 10,85 10,85 21,7
Terminal L3 L3 (A) 10,85 0 10,85
Terminal 0 N (A) 0 10,85 10,85
Terminal L1 L1 (A) 0 10,85 10,85
Terminal L2 L2 (A) 10,85 10,85 21,7
Terminal L3 L3 (A) 10,85 0 10,85
Terminal 0 N (A) 10,85 10,85 10,85
Power kW 5 5 10
Power kW 7,5 5 12,5
Power kW 7,5 7,5 15
Power kW 5 5 10
Power kW 7,5 5 12,5
Power kW 7,5 7,5 15
Single Phase 230 V~, 15 kW
Single Phase 230 V~, 10 kW
Three Phase 400 V 3N~, 15 kW
Three Phase 400 V 3N~, 10 kW
Heating Circuit Stage 1 Stage 2 Total Terminal Strip Power Selection
Single Phase 230 V~, 12.5 kW
Three Phase 400 V 3N~, 12.5 kW
HDCS/HDCSM 10/15

18
HDCS/HDCSM 1860
O 1 L1 L2 L3
NL1 L2 L3
O 1 L1 L2 L3
NL1 L2 L3
O 1 L1 L2 L3
N L
O 1 L1 L2 L3
NL1 L2 L3
Three Phase 400 V 3N~, 6 kW
Single Phase 230 V~, 6 kW
For models HDCS/HDCSM
Three Phase 400 V 3N~, 18 kW
Three Phase 400 V 3N~, 21 kW
Terminal L1 L1 (A) 13 13 26
TerminalL2 L2 (A) 13 13 26
Terminal L3 L3 (A) 13 13 26
Terminal 0 N (A) 0 0 0
Terminal L1 L1 (A) 15,2 15,2 30,4
Terminal L2 L2 (A) 15,2 15,2 30,4
Terminal L3 L3 (A) 15,2 15,2 30,4
Terminal 0 N (A) 0 0 0
Power kW 10,5 10,5 21
Power kW 9 9 18
Heating Circuit Stage 1 Stage 2 Total Terminal Strip
Heating Circuit Stage 1 Stage 2 Total Terminal Strip
Terminal L3 L3 (A) 26
Terminal 0 N (A) 26
Power kW 6
Terminal L1 L1 (A) 8,6
Terminal L2 L2 (A) 8,6
Terminal L3 L3 (A) 8,6
Terminal 0 N (A) 0
Power kW 6
HDCS/HDCSM 2160
HDCS / HDCSM
D.H.W. Terminal Strip
Consumption of the Domestic Hot Water Tank