Flexiheat R1K 50 RAIN Quick start guide

R1K 50 RAIN - RAD - ING - Manuale - 2103.1_SKM1.3_25-8_firm.L224G
Installation, Use
and Maintenance Manual
for model
0476
R1K 50 RAIN
Premix condensing system boiler
only heating, suitable for outdoor installation

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R1K 50 RAIN_EN
SUMMARY
SUMMARY
INTRODUCTION 4
1. INSTALLER SECTION 7
1.1. INSTALLATION 8
1.1.1. GENERAL INSTALL ATION WARNINGS 8
1.1.2. BOILER LOCATION ENVIRONMENTAL REQUIREMENTS 8
1.1.3. REFERENCE LEGISLATION 9
1.1.4. BOILER OVERALL DIMENSIONS 10
1.1.5. JIG 10
1.1.6. FASTENING JIG 10
1.1.7. CIRCULATOR PREVALENCE/FLOW DIAGRAM 11
1.1.8. BOILER INSTALLATION 12
1.1.9. HYDRAULIC CONNECTION 14
1.1.10. CHARACTERISTICS OF THE WATER OF THE SYSTEM 15
1.1.11. SYSTEM FILLING 17
1.1.12. CONDENSATE DRAIN 18
1.1.13. ANTI-FREEZE PROTECTION 20
1.1.14. GAS CONNECTION 21
1.1.15. ELECTRICAL CONNECTION 21
1.1.16. POWER SUPPLY 22
1.1.17. OPTIONAL ELECTRICAL CONNECTIONS 23
1.1.18. FUME EXHAUST FITTINGS 26
1.1.19. INSTALLATION MODES 27
1.1.20. TYPES OF FUME EXHAUST SYSTEMS 29
2. SUPPORT CENTER SECTION 33
2.1. FIRST START-UP 34
2.1.1. PRELIMINARY OPERATIONS FOR FIRST START-UP 34
2.1.2. BOILER COMMISSIONING 35
2.1.3. CO2 VALUE CHECK AND CALIBRATION 36
2.1.4. ACCESSING AND PROGRAMMING THE PARAMETERS 37
2.1.5. DIGITECH CS PARAMETERS TABLE 39
2.1.6. ELECTRIC FAN FREQUENCY/HEAT CAPACITY DIAGRAM 48
2.2. MAINTENANCE 49
2.2.7. GENERAL MAINTENANCE WARNINGS 49
2.2.8. TECHNICAL DATA 50
2.2.8. TECHNICAL ASSEMBLY 52
2.2.9. HYDRAULIC BOARD 53
2.2.10. WIRING DIAGRAM 54

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SUMMARY
2.2.11. ACCESSING THE BOILER 55
2.2.12. ACCESSING THE ELECTRONIC BOARD 56
2.2.13. SYSTEM EMPTYING 57
2.2.14. FAULT SIGNALLING CODES 58
2.2.15. ACTIVE FUNCTIONS SIGNALLING CODES 62
2.2.16. GAS CONVERSION 63
3. USER SECTION 65
3.1. USE 66
3.1.1. GENERAL USE WARNINGS 66
3.1.2. CONTROL PANEL 67
3.1.3. DISPLAY ICONS 68
3.1.4. INFO MENU DISPLAY DATA 69
3.1.5. START-UP 70
3.1.6. OPERATING MODE 70
3.1.7. INFORMATIONAL NOTE ON ANTI-FREEZE FUNCTION 71
3.1.8. FAULT SIGNALLING CODES 72
3.1.9. ACTIVE FUNCTIONS SIGNALLING CODES 74
3.1.10. COVER CLEANING 75
3.1.11. DISPOSAL 75

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1.
INTRODUCTION
WARNING
Before starting any operation it is mandatory to
read this instruction manual, in relation to the
activities to be carried out as described in each
relevant section. Proper operation and optimal
performance of the boiler are ensured by strict
compliance with all the instructions given in this
manual.
The installation, use and maintenance manual is
an integral and essential part of the product and
must be delivered to the user.
MANUAL USERS
The manual users are all those who install, use
and maintain the boiler.
The boiler must be used and accessed only by
qualified operators that fully read and understood
the use and maintenance manual, paying particular
attention to the warnings.
READING AND SYMBOLS OF THE MANUAL
To ease the understanding of this manual,
recurrent symbols where used, in particular:
› On the outer margin of the page is placed a
thumb index indicating the type of user to which
the instructions in that section address.
› The titles are differentiated by thickness and
size in accordance with their hierarchy.
› The images contain important parts described
in the text, marked with numbers or letters.
› (See chap “chapter name”): this entry indicates
another section in the Manual that you should
refer to.
› Device: this term is used referring to the boiler.
DANGER
It identifies an information related to a
general danger that if not complied with, may cause
serious personal damage or even death.
ATTENTION
It identifies an information that if not
complied with may cause small or medium level
lesions to the person or serious deterioration to the
boiler.
WARNING
It identifies a precaution information that
must be observed in order to avoid damaging the
machine or parts of it.
MANUAL STORAGE
The manual must be carefully stored and replaced
in case of deterioration and/or low legibility.
If you misplace the use and maintenance manual,
you can request it from the Technical Support
Centre giving the serial number and model of the
boiler indicated on the plate placed on the right
side of its casing.
INTRODUCTION

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1 .
MANUFACTURER WARRANTY AND
RESPONSIBILITY
The technical and functional features of the device
are ensured by its use in compliance:
1. with the use and maintenance instructions
contained in the manuals accompanying the
product, the content of which the customer
certifies that he is aware;
2. with the conditions and purposes to which
assets of the same type are intended.
For more information on the warranty validity,
its duration, the obligations and the exemptions,
please consult the First start-up certificate
attached to this manual.
The manufacturer reserves:
› the right to modify the tools and relative
technical documentation without any obligation
to third parties; neither will the company be
held responsible for any inaccuracies in this
handbook deriving from printing or translation
errors;
› the material and intellectual ownership of
this manual and forbids its distribution and
duplication, even partial, without prior written
authorization.
PRODUCT CONFORMITY
› Eco-design Directive 2009/125 CE,
› Energy labeling Directive 2010/30/CE,
› Regulation EU 811/2013,
› Regulation EU 813/2013,
› Regulation EU 2016/426,
› Electromagnetic compatibility Directive
2014/30/CE,
› Performance Directive 92/42/CE,
› Low voltage Directive 2014/35/CE.
The materials used such as copper, brass,
stainless steel create a homogeneous, compact
and functional assembly, easy to install and
manage. In its simplicity, the boiler is equipped
with all accessories necessary to render it a
veritable independent heating unit. All boilers
are tested and delivered with a quality certificate
signed by the tester.
INTRODUCTION
Flexiheat declares that these gas boilers comply
with the European Directives and with the
requirements provided in the European
standards below:

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.
1. INSTALLER SECTION1. INSTALLER SECTION

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1Avvertenzegeneraliperl'installazione_Localecaldaia_cond_altapotenza_EN
1. INSTALLATION
INSTALLER
1.1. INSTALLATION
1.1.1. GENERAL INSTALLATION
WARNINGS
ATTENTION
This machine may be used only for the
purpose for which it has been designed: heat water
to a temperature below boiling point at atmospheric
pressure. Any other use is considered wrong and
dangerous. The manufacturer is excluded from
any contractual or out of contract responsibility for
damage caused to people, animals or property due
to errors during installation.
ATTENTION
This boiler should be installed 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.
ATTENTION
After having removed the packing, make
sure the equipment is intact. In case of doubt, do not
use the equipment and contact the supplier.
BEFORE INSTALLING THE BOILER, THE
INSTALLER MUST MAKE SURE THAT THE
FOLLOWING CONDITIONS ARE MET:
› The device is connected to a heating plant and a
water supply network appropriate for its power
and performance.
› The location must be properly vented through
an air vent.
› The air vent must be placed at floor level to
prevent it from being obstructed, protected by
a grid that does not hamper the useful section
of passage.
› The device is suitable for use with the type of
gas available by checking the boiler data plate
(placed on the inner side of the front casing.
› Make sure that the tubes and couplings are
perfectly sealed, without any gas leaks.
› Make sure that the grounding system works
properly.
› Make sure that the electrical systems is
suitable for the maximum power absorbed by
the equipment, value indicated on the data plate.
1.1.2. BOILER LOCATION
ENVIRONMENTAL
REQUIREMENTS
The boiler has a thermal power over 35 kW and,
therefore, it must be installed only into a heating
unit.
The device's installation location should be vented
due to the presence of threaded joints on the gas
adduction line. The location should be therefore
provided with vents as to ensure air exchange,
with output grid in the natural accumulation area
of eventual gas losses.
WARNING
DO NOT install the boiler in a technical
compartment near a swimming pool or a laundry, to
avoid that the combustion air is exposed to chlorine,
ammonia or alkaline agents that may worsen the
corrosion phenomenon of the heat exchanger. Failure
to observe this caution will void the warranty of the
heat exchanger.

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1. INSTALLATION
INSTALLER
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’).
WARNING
The manufacturer will not be held
responsible for damages caused by incorrect
installation not in conformity with the over mentioned
instructions and not protected adequately from the
freeze.
1.1.3. REFERENCE LEGISLATION
The installation must be realized according to
the requirements of current legislation and in
compliance with local technical regulations,
according to the indications of the good technique.

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2. INSTALLATION
INSTALLER
1.1.4. BOILER OVERALL DIMENSIONS
1.1.5. JIG
1.1.6. FASTENING JIG
240
160
600
910
480
RGsc A
95 83 55 145 102
82
131
273
115
99
49
561
564
R- HEATING RETURN Ø 1” 1/4
G- GAS Ø 3/4
A- HEATING FLOW Ø 1” 1/4
SC- CONDENSATE DRAIN Ø 25 mm

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1Diagrammaportata-prevalenzacircolatore_R1K50_YONOSPARAINTRS25-8_EN
1. INSTALLATION
INSTALLER
1.1.7. CIRCULATOR PREVALENCE/FLOW DIAGRAM
Appliance Loss
Wilo-Yonos PARA INT RS 25/8
PREVALENCE (m)
FLOW RATE (m3/h)

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1Installazionegeneratore_R1K50RAIN_EN
2. INSTALLATION
INSTALLER
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
cause the incorrect discharge of condensate by
means of the discharge duct with consequent
condensate stagnation inside the condensate
module.
WARNING
The boiler must be installed only on a
vertical solid wall, able to sustain its weight.
H
A
X Y
B
A - 200 mm
B - 500 mm
X - 200 mm
Y - 200 mm
H - 1,000 mm fig.1

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1Installazionegeneratore_R1K50RAIN_EN
2. INSTALLATION
INSTALLER
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.
To facilitate the assembly, the boiler is equipped with a template and a frame that allow to prepare in
advance the connections to the pipes with the possibility to install the boiler only when masonry works
are completed. For assembly follow the instructions below:
1. With the help of a spirit level, fix the mounting template to the wall where you intend to install the
boiler, mark the points to insert the ø10 dowel screws and points for the heating flow and heating
return system’s connections.
2. Make the holes and fix the frame to wall (Figure 1).
3. Hook the boiler using the slots on the frame (Figure 2).
4. unscrew the fixing screws of the lower bracket (fig. 3) ensuring the free sliding of the bracket towards
the boiler;
5. adjust the inclination of the boiler (fig. 4) by sliding the lower bracket ensuring an inclination of the
boiler, against the vertical, of about 1–1.5°.
1-1.5°
fig.2
fig.1
fig.3
fig.4
LOWER BRACKET
LOWER BRACKET

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1 Allacciamento idraulico_combinata_EN
1. INSTALLATION
INSTALLER
1.1.9. HYDRAULIC CONNECTION
DANGER
Make sure that the tubes of the water and
heating plant are not used as grounding system for
the electrical plant. There are not suitable for such
use.
WARNING
To prevent voiding the warranty and to
ensure the proper operation of the boiler, please
wash the plant (if possible when hot) with suitable
pickling or descaling solutions in order to remove the
impurities coming from tubes and radiators.
WARNING
If the boiler is installed in a hydrostatic
position lower than those of the user devices
(radiators, fan coils, etc.), mount the shut-off valves
on the domestic water heating circuit to ease the
performance of the maintenance operations if it is
necessary only to empty the boiler.
WARNING
When connecting the equipment to
water supply, avoid excessive bending and recovery
operations from any off axis positioning that may
damage the tubes causing leaks, malfunction or
early wear.
WARNING
In order to avoid any vibrations and noises,
do not use tubes with small diameters or elbows with
small radius and significant cut-off of the passage
sections.
WARNING
Connect the boiler safety drains to a
discharge funnel. The manufacturer is not responsible
for any floods due to safety valve opening in case of
plant overpressure.
DOMESTIC CIRCUIT
In order to prevent limestone build-up and
damages to the domestic water heat exchanger,
the hardness of the domestic supply water
should not exceed 15 °f. However, please check
the characteristics of the water used and install
suitable treating devices.
The heat exchanger coil cleaning frequency
depends on the hardness of the supply water and on
the presence of solid residues or impurities inside
the water that are often present in case of recently
installed plants. Based on the characteristics of
the infeed water, you should install suitable water
treating devices, for residues presence please
install a line filter.
The pressure of the cold infeed water should be
between 0.5 and 6 bar. In case of greater pressure
values, please install a pressure reducer upstream
from the boiler.
HEATING CIRCUIT
In order to avoid any scale or deposits on the
primary exchanger, the hardness of the heating
circuit infeed water should not exceed 25 °f.
However, please check the characteristics of the
water used and install suitable treating devices.
This treatment is mandatory if frequent episodes
of return water or partial or total emptying of the
plant occur.
WARNING
In case the boiler is installed as part of
a low temperature circuit, please install a safety
thermostat on the heating flow, which can stop
the boiler activity in case of high heating flow
temperature. The company assumes no liability for
damage caused to persons or for failure to comply
with these instructions.

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1Riempimentodell'impianto_MIAH4_R1K100_v.2_EN
1. INSTALLATION
INSTALLER
1.1.10. CHARACTERISTICS OF THE
WATER OF THE SYSTEM
For a correct operation of the system, it is
necessary to make sure that:
1. The system does not present losses or that the
most obvious are at least eliminated;
2. If an automatic filling system is present, a litre
meter must be installed in order to precisely know
the extent of any losses;
3. The filling in of the system and the top ups are
performed with softened water in order to reduce
the total hardness. The water must also be treated
in order to maintain the pH within the provided
threshold so as to avoid corrosion phenomena.
4. Either on new systems or on replacements, the
system must be fitted with efficient systems which
ensure the elimination of the air and impurities:
Y filters, micro impurity separators and micro
bubbles of air separators;
5. Avoid draining the water of the system during the
routine maintenance even if it is about apparently
insignificant quantities: for example, in order to
clean the filters, provide the system with adequate
shut-off valves;
6. Always perform an analysis of the water of
the system before opening the communication
between the new generator and the system, in
order to establish if the parameters present in the
water indicate the need to fully drain the system,
to use the water already present in the system or
to chemically wash the system using utility water
adding a detergent when it is suspected that the
system might be dirty or particularly clogged and
at the next loading with new treated water.
Water treatment
In order to preserve the integrity of the water-
fume exchanger and to guarantee optimal thermal
exchanges, it is necessary that the water of the
primary circuit, circulating inside the exchanger
of the condensate boiler, has the characteristics
defined and constant in time. To obtain this, it
is fundamental to perform a series of system
preparation and maintenance operations such as:
• washing the system;
• check the characteristics of the water of the
system;
The type of treatment to be performed will be
chosen based on the characteristics of the water
to treat, of the type of system and on the requested
purity limits
Oxygen
A certain amount of oxygen always enters the
system, both during the filling phase and during
the use in case of reintegration or presence of
hydraulic components without oxygen barriers.
The reaction between the oxygen and the stainless
steel creates corrosion and forms sludge. While
the water fume exchanger is made of stainless
steel, and therefore it is not subject to corrosion,
the sludge created in the carbon steel system
is deposited in the warm points, including the
exchanger. This has the effect to reduce the heat
capacity and thermally insulate the active parts of
the exchanger, which might cause damages.
The precautions to limit the phenomena are:
- Mechanical systems: a deaerator combined with
a sludge remover, correctly installed, reduce the
quantity of oxygen circulating inside the system.
- Chemical systems: the additives allow the oxygen
to dissolve in water.

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1. INSTALLATION
INSTALLER
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.
The filling and make-up water of the system, if
it does not fall under the values indicated below,
should be softened. Moreover, additives can be
added in order to maintain the limestone into
the solution. The hardness must be periodically
checked and registered.
Acidity 7 < pH < 8.5
Conductivity < 400 μs/cm (at 25°C)
Chlorides < 125 mg/l
Iron < 0.5 mg/l
Copper < 0.1 mg/l
If the above indicated limits are exceeded, a water
must be chemically treated.
The type of treatment to be performed will be
chosen based on the characteristics of the water
to treat, of the type of system and on the requested
purity limits.

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1Riempimentodell'impianto_MIAH4_R1K100_v.2_EN
1. INSTALLATION
INSTALLER
1.1.11. SYSTEM FILLING
WARNING
For system filling use only clean tap
water. In order to prevent limestone build-up and
damages to the domestic water heat exchanger,
the hardness of the domestic supply water
should not exceed 15° Fr. However, please check
the characteristics of the water used and install
suitable treating devices.
WARNING
If the system is filled by adding ethylene
glycol-type chemical agents you have to install on
the loading system a hydraulic trip unit in order
to separate the heating circuit from the domestic
circuit.
Before powering up the boiler, fill the system as
follows:
1. slightly loosen the cap of the jolly valve placed
on the top of the condensing block to release
the air form the top of the system (1-fig.1);
2. check that the jolly valves vent the air present
in the system are not blocked;
3. connect a rubber pipe to the draining tap placed
on top of the condensing heat exchanger (2-
fig.1);
4. open the general domestic water input tap and
load the system by exhaling all the air;
5. use pressure gauge present in the system to
make sure that the system pressure reaches
the design value;
6. after performing this operation, make sure
that the loading tap is properly closed.
7. Open the air relief valves of the radiators and
check the air removal process. When the
water starts to leak close the radiators air
relief valves.
8. If after performing these operations you
observe a decrease of the water pressure
inside the system, open once again the loading
tap until the pressure gauge reaches the
design pressure.
2
1
fig. 1

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1. INSTALLATION
INSTALLER
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”
(fig. 1);
› Connect the adequately prepared flexible
condensate drain tube to a disposal system
(it is necessary to neutralise the condensate
if the material out of which the canal system
where the condensate arrives is composed
presents a corrosion risk; please see
paragraph ‘CONDENSATE NEUTRALISER’).
The condensate can be drained directly in
the sewerage system by inserting an easily
serviceable siphon.
WARNING
After the first months of operation of the
device, it is recommended to clean the condensate
collection siphon from any deposits deriving
from the first transit of the condensate inside the
technical components of the boiler. Such deposits
might cause a malfunction of the siphon.
CONDENSATE DRAIN
The boiler produces a significant quantity of
condensate during operation. This condensate has
an acid pH of 3-5. Observe the national standard in
force and the local regulations for the disposal of
the condensate produced by the boiler.
The designer, according to the power of the system
and the intended use of the building, is bound to
evaluate the acceptance of systems in order to
neutralise the acid condensate.
The system must be performed so as to avoid the
freezing of the condensate. Before putting into
operation the device, check the correct evacuation
of the condensate.
WARNING
Before connecting the condensate
collection siphon to the drain tube, check that the
slope of the boiler is ensured according to the
indications from chapter ‘INSTALLATION OF THE
BOILER’.
WARNING
Correctly connect the condensate
collection siphon of the boiler to a draining system
by adding the slope to the drain of the condensate
of the fume exhaust duct. Where possible, it is
recommended to perform such connection by
means of a collection glass in order to check
the correct discharge of the condensate avoiding
stagnations that might cause dangerous returns of
the condensate to the boiler.
In order to connect the condensate draining to
the draining system, use only corrosion-resistant
materials with an adequate diameter.
T
P
fig. 1

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1 Scarico condensa_R1K_100_EN
1. INSTALLATION
INSTALLER
CONDENSATE NEUTRALISER
Assemble the condensate neutralisation box, fitted
with granulate and active carbons for a treated
power up to 350 kW (see fig.2). The device allows
neutralising the condensate which is collected
inside the boiler and/or in the fume discharge
systems made of stainless steel, plastic, glass or
ceramic.
The acid condensate, inserted into the
neutralisation box, follows a mandatory path for
two phases; the first one, filtration of nitrates and
sulphates by means of active carbons contained
in the first tube line, in the second one, the pH is
increased.
The acidity of the condensate can be checked
by using litmus paper in order to determine the
pH. Then, the neutralised condensate can be
transported into the sewage system.
MAINTENANCE
The pH parameters must be comprised between
< 7 and 8.5 >.
Every six months, it is necessary to establish the
PH of the treated condensate inside the neutraliser.
Immerse a litmus paper (or a suitable digital
tool) in the condensate near the tapped draining
connection for about 2 seconds and thus lay it on a
white paper. After about 30 seconds, it is possible
to compare with the coloured scale. The neutral
point is on the value 6.8-7; at a lower value, the
condensate is acid, at a higher value, it is base].
If necessary, replace the active carbon and the
reagent granulate.
cod.: 82153LA
fig. 2
CONDENSATE
COLLECTION HOLE
SULPHATE
ACTIVE CARBONS
SEAT TUBE
CARBONS
OUTPUT CONNECTION
NEUTRALISED CONDENSATE

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1 Protezione antigelo_firm.L224A_EN
1. INSTALLATION
INSTALLER
1.1.13. ANTI-FREEZE PROTECTION
The boiler is protected against freezing thanks to
the electronic board preparation with functions
that start the burner and heat the concerned parts
when their temperature goes below the minimum
pre-set values, protecting the boiler up to an
external temperature of -10 °C.
The device starts when the hot water temperature
goes below 8 °C, automatically starting the burner
until the heating flow water temperature reaches
the 30°C and, in presence of a return sensor, until
the heating return water temperature reaches the
20°C.
The system starts even if on the display appears
“OFF”, as long as the boiler is connected to the
power (230 V) and gas supply.
For long periods of standby, please empty the
boiler and the plant.
If the temperature goes below -10° centigrades,
please fill the plant with anti-freeze liquid
(CLEANPASS FLUIDO AG cod. 98716LA) and insert
and electrical resistances kit (cod. 82259LP).
DILUTION PERCENTAGE OF CLEANPASS
FLUIDO AG
ANTIFREEZE -
ETHYLENE GLYCOL
TEMPERATURE
FREEZING POINT
(%) VOLUME (°C)
20 -7.5
30 -13
35 -18
40 - 22.5
45 -28
50 -33.5
55 -42
60 -50
RECOMMENDED MINIMUM PERCENTAGE OF
GLYCOL : 20 %