Flexiheat R1KG 180 Service manual

R1KG 180_240 - RAD - ING - Manuale - 2306.1_SKM1.4_firm.L224G
Installation, Use
and Maintenance Manual
for model
0476
R1KG
Floor standing premix condensing boiler
Heating only
R1KG 180 - R1KG 240

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R1KG 180_240 - RAD - ING - Manuale - 2306.1_SKM1.4_firm.L224G
R1KG 180_240_EN
SUMMARY
SUMMARY
INTRODUCTION 4
1. INSTALLER SECTION 7
1.1. INSTALLATION 8
1.1.1. GENERAL INSTALLATION WARNINGS 8
1.1.2. BOILER LOCATION ENVIRONMENTAL REQUIREMENTS 8
1.1.3. REFERENCE LEGISLATION 9
1.1.4. UNPACKING 10
1.1.5. OVERALL DIMENSIONS 11
1.1.6. MECHANICAL SYSTEM DIAGRAM 12
1.1.7. PUMP HEAD / FLOW DIAGRAM 14
1.1.8. BOILER INSTALL ATION 16
1.1.9. HYDRAULIC CONNECTION 17
1.1.10. CHARACTERISTICS OF THE WATER OF THE SYSTEM 18
1.1.11. SYSTEM WATER SPECIFICATIONS 20
1.1.12. CONDENSATE DRAIN 21
1.1.13. FROST PROTECTION 23
1.1.14. GAS CONNECTION 24
1.1.15. ELECTRICAL CONNECTION 24
1.1.16. POWER SUPPLY 25
1.1.17. OPTIONAL ELECTRICAL CONNECTIONS 26
1.1.18. FLUE SYSTEMS 28
1.1.19. INSTALLATION MODES 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. PARAMETERS TABLE 39
2.1.6. HEAT INPUT / FAN FREQUENCY DIAGRAM* 48
2.2. MAINTENANCE 49
2.2.7. GENERAL MAINTENANCE WARNINGS 49
2.2.8. TECHNICAL DATA 50
2.2.9. TECHNICAL ASSEMBLY 52
2.2.10. HYDRAULIC BOARD 53
2.2.11. CONTROL PANEL NO.1 - ELECTRONIC PCB ELECTRICAL CONNECTIONS 54
2.2.12. ACCESSING THE BOILER 55

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SUMMARY
2.2.13. ACCESSING THE ELECTRONIC P.C.B. 56
2.2.16. SYSTEM EMPTYING 57
2.2.14. FAULT / ERROR CODES 58
2.2.15. FUNCTIONS CODES 63
2.2.16. GAS CONVERSION 64
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 69
3.1.5. START-UP 70
3.1.6. INFORMATIONAL NOTE ON ANTI-FREEZE FUNCTION 70
3.1.7. FAULT / ERROR CODES 71
3.1.8. FUNCTIONS CODES 73
3.1.9. MAINTENANCE 74
3.1.10. EXTERNAL CASING CLEANING 74
3.1.11. DISPOSAL INFORMATION 74

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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 Service Centre giving
the serial number and model of the boiler indicated
on the data 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
devices 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 labelling 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 its gas boilers comply
with the European Directives and with the
requirements provided in the European
standards below:

The installation operations described in this section, must
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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1. INSTALLATION
INSTALLER
1.1. INSTALLATION
1.1.1. GENERAL INSTALLATION
WARNINGS
ATTENTION
This boiler 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 extra-contractual responsibility for
damages caused to people, animals or property due
to errors during installation.
ATTENTION
This boiler must 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 device is intact. In case of doubt, do not use
the device 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 system
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 passage
section.
› 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 pipes and joints are perfectly
sealed, without any gas leaks.
› Make sure that the grounding system works
properly.
› Make sure that the electrical system is suitable
for the maximum power absorbed by the device,
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 installation location should be vented
due to the presence of threaded joints on the
gas supply line. The location should be therefore
provided with vents as to ensure air exchange,
with output grid in the natural accumulation area
of potential 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 appliance
installation location goes below -10 centigrades,
please fill the plant with anti-freeze liquid and insert
and a frost prtotection 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 above
mentioned instructions and not duly protected from
freeze.
1.1.3. REFERENCE LEGISLATION
The installation must be done 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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1. INSTALLATION
INSTALLER
1.1.4. UNPACKING
WARNING
Please unpack the boiler just before
installing it. The Company is not responsible for
the damages caused to the device due to incorrect
storage.
WARNING
The packing elements (cardboard box,
wooden crate, nails, fasteners, plastic bags, expanded
polystyrene, etc.) must be kept out of the reach of
children as they may be dangerous. Therefore they
should be dismantled suitably differentiating them in
accordance with the standards in force.
To unpack the boiler, proceed as follows:
› cut the fixing strip (see A-fig.1);
› remove the cardboard box lifting it upwards
(see B-fig.1);
› push the boiler on one side and remove the
pallet underneath (see C-fig.1).
AB C
fig. 1

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1. INSTALLATION
1.1.5. OVERALL DIMENSIONS
AI HEATING FLOW Ø 2”1/2
RI HEATING RETURN Ø 2”1/2
G GAS Ø 1”1/2
S FLUE OUTLET Ø 160 mm
SC CONDENSATE DRAIN CONNECTION Ø 29 mm
710
1880
680170
850
530
130
S Ø 160
410 100
670 790
250
1830
G1” 1/2
G
90
1970
AI
AI
RI
RI
177
SC

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1. INSTALLATION
INSTALLER
1.1.6. MECHANICAL SYSTEM DIAGRAM
HEATING ONLY INSTALLATION
The boiler can manage a heating system at a fixed point delivery temperature or in climatic compensation
with an external probe, managing the modulation according to the actually requested thermal load.
DESCRIPTION
1 OUTDOOR SENSOR
2 CONTROL PANEL NO.1
AI HEATING FLOW
RI HEATING RETURN
CI SYSTEM LOADING
GGAS
SC CONDENSATE DRAIN CONNECTION
RI
CI
G
AI
SC
1
2

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1. INSTALLATION
INSTALLER
HEATING + DHW AND SOLAR MANAGEMENT
DESCRIPTION
1SEQUENCE CONTROL
AND SYSTEM
MANAGEMENT
CONTROL BOX
(MASTER)
2 SOLAR PCB (SLAVE)
3ROOM THERMOSTAT
4 ROOM TEMPERATURE
CONTROL
(ALTERNATIVE TO
ROOM THERMOSTAT)
5CONTROL PANEL NO.1
6MANIFOLD SENSOR
7 MIXED CIRCUIT SENSOR
8 STORAGE TANK
SENSOR
9OUTDOOR SENSOR
10 MIXED CIRCUIT
CIRCULATING PUMP
11 STORAGE TANK
LOADING PUMP
12 RE-CIRCULATION LOOP
PUMP
13 MIXED CIRCUIT MIXING
VALVE
14 SOLAR CIRCUIT PUMP
15 SBS SOLAR PANEL
SENSOR
16 SBI SOLAR TANK
SENSOR
17 DHW STORAGE TANK
18 SOLAR PANEL
19 SEPARATOR /
EXCHANGER SENSOR
20 EXPANSION VESSEL
18
18
17
15
14
16
811
1
9
7
13
7
32 4
10 10
3 4
12
19
COLD WATER FLOW
DHW FLOW
DHW RE-CIRCULATION
M
DHW SYSTEM LOADING
FLUE SYSTEM
NORTH FACING WALL
HEATING SYSTEM LOADING
. . . . . .
GAS
5
13
20 20
20
FROM WATER METER
MIXED CIRCUIT
NO.1 FLOW
MIXED CIRCUIT
NO.1 RETURN
MIXED CIRCUIT
NO.2 FLOW
MIXED CIRCUIT
NO.2 RETURN

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1. INSTALLATION
INSTALLER
1.1.7. PUMP HEAD / FLOW DIAGRAM
Load losses of only one active unit
GPA 25/11H
A
HEAD (m)
FLOW RATE (m3/h)
Fig. 1
By pressing the selection button (see ‘A’ fig. 1), the
type of operation corresponding to the reference
curve shown in the diagram can be activated,
depending on the displayed LED combination.
Note: If the LED ‘P’ is ON, it indicates that the
PWM cable is connected to the boiler board and
that pump operation is only managed according to
the ΔT set in the boiler board reference parameter.

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1. INSTALLATION
INSTALLER
Failure code Failure description
Overvoltage protection When the input voltage is above 278 ± 10V for 2s, the overvoltage
protection is activated, the indicator flashes once and the pump stops
working. When the voltage is back to 270 ± 5V, the pump goes back to
normal operation.
Undervoltage protection (V) When the voltage is 140 ± 5V for 2s, the undervoltage protection is
activated, the indicator flashes twice and the pump stops working.
When the voltage is restored to 150 ± 5V, the pump returns to normal
operation.
Overcurrent protection (A) When the current is too high, the overcurrent protection is activated,
the indicator flashes 3 times and the pump stops working. After 8s the
pump restarts. If the fault has not been rectified, the warning light
flashes 3 times and the pump stops running. This cycle is repeated
until the fault is rectified.
Phase failure protection When the motor is out of phase, the phase-failure protection is
activated, the warning light flashes 4 times and the pump stops
running. After 8s the pump restarts. If the phase failure is repeated 5
times, the pump stops running. The pump must be re-powered.
Locked rotor protection When the pump speed, within 3s after start-up, is less than 500RPM,
the blocking protection is activated, the warning light flashes 5 times
and the pump stops running. After 8s the pump restarts. If the rotor
blocking failure is repeated 5 times, the pump stops running. The
pump must be re-powered.
Water shortage protection When there is a lack of water inside the pump, the water shortage
protection is activated, the warning light flashes 6 times and the pump
stops working. After 8 seconds, the pump restarts. If the fault has not
been rectified after 5 cycles, the pump will stop running. The pump
must be re-powered.

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1. 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
Make sure, using a spirit level, that the
boiler is properly inclined being levelled (see fig.2) so
as to allow the condensate to drain.
WARNING
Incorrect inclination of the boiler
would cause the condensate to flow incorrectly
through the drainage pipe, resulting in condensate
stagnating inside the condensing module.
H
A
X Y
B
A - 200 mm
B - 800 mm
X - 60 mm
Y - 60 mm
H - 500 mm
fig.1
fig.2

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1 Allacciamento idraulico_combinata_EN
1. INSTALLATION
INSTALLER
1.1.9. HYDRAULIC CONNECTION
DANGER
Make sure that the water and heating pipes
are not used as grounding system for the electrical
plant. They are not suitable for such use.
WARNING
To prevent voiding the warranty and
ensure proper operation of the boiler, please wash the
system (if possible when hot) with suitable pickling or
descaling solutions in order to remove the impurities
coming from pipes and radiators.
WARNING
If the boiler is installed in a hydrostatic
position lower than those of the connected devices
(radiators, fan coils, etc.), install the shut-off valves
on the D.H.W. and heating circuits to ease the
performance of the maintenance operations, if it is
necessary only to empty the boiler.
WARNING
When connecting the boiler to water
supply, avoid excessive bending and recovery
operations from any off axis positioning that may
damage the pipes causing leaks, malfunction or
early wear.
WARNING
In order to avoid any vibrations and noises,
do not use pipes 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 manufactureris not responsible
for any floods due to safety valve opening in case of
plant overpressure.
D.H.W. CIRCUIT
In order to prevent limestone build-up and damages
to the D.H.W. 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 inlet water, the installation of suitable water
treating devices is recommended, for residues
presence please install a line filter.
The pressure of the cold inlet water should be
between 0.5 and 6 bar. In case of higher 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 inlet 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
damages caused to persons or property for failure to
comply with these instructions.

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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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1. INSTALLATION
INSTALLER
1.1.11. SYSTEM WATER
SPECIFICATIONS
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. check that the system air vent valves are not
blocked;
2. unscrew the manual air vent valve (1-fig.1)
located at the top of each of the condensing
exchangers;
3. slightly loosen the plugs of the two air vent
valves at the top of the manifold to allow air
to vent from the highest point of the system
(2-fig.2);
4. open the water mains tap and fill the system
by venting all the air;
5. check through the pressure gauge in the
system that the system pressure reaches the
design value;
6. after performing this operation, make sure
that the filling tap is properly closed.
7. Open the radiators air vent valves and check
the air venting process. WHEN THE WATER
COMES OUT, CLOSE THE RADIATOR AIR
VENT VALVES AND THOSE AT THE TOP OF
THE CONDENSING EXCHANGER (1-FIG.1).
8. If the water pressure in the system drops after
the above-mentioned operations, open the
filling tap again until the pressure in the gauge
reaches the design pressure.
1
22
fig. 1
fig. 2