Flexiheat R2K 50 User manual

R2K 50 - RAD - ING - Manuale - 2107.1_SKM1.3_firm.L224G
Installation, Use
and Maintenance Manual
for model
0476
R2K 50
Condensing boiler with integrated heat
exchanger for domestic hot water
production

2
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. BOILER OVERALL DIMENSIONS 10
1.1.5. JIG 10
1.1.6. CIRCULATOR PREVALENCE/FLOW DIAGRAM 11
1.1.7. GENERATOR INSTALLATION 12
1.1.8. HYDRAULIC CONNECTION 15
1.1.9. SYSTEM FILLING 16
1.1.10. FILLING THE CONDENSATE COLLECTION SIPHON 17
1.1.11. ANTI-FREEZE PROTECTION 18
1.1.12. GAS CONNECTION 19
1.1.13. ELECTRICAL CONNECTION 19
1.1.14. POWER SUPPLY 20
1.1.15. OPTIONAL ELECTRICAL CONNECTIONS 21
1.1.16. FUME EXHAUST FITTINGS 24
1.1.17. TYPES OF FUME EXHAUST SYSTEMS 25
2. SUPPORT CENTRE SECTION 29
2.1. FIRST START-UP 30
2.1.1. PRELIMINARY OPERATIONS FOR FIRST START-UP 30
2.1.2. BOILER COMMISSIONING 31
2.1.3. CO2 VALUE CHECK AND CALIBRATION 32
2.1.4. ACCESSING AND PROGRAMMING THE PARAMETERS 33
2.1.5. DIGITECH CS PARAMETERS TABLE 35
2.1.6. ELECTRIC FAN FREQUENCY/HEAT CAPACITY DIAGRAM 44
2.2. MAINTENANCE 45
2.2.7. GENERAL MAINTENANCE WARNINGS 45
2.2.8. TECHNICAL DATA 46
2.2.9. TECHNICAL ASSEMBLY 49
2.2.8. INTERNAL PIPING SCHEMATIC 50
2.2.9. WIRING DIAGRAM 51
2.2.13. ACCESSING THE BOILER 52
2.2.10. ACCESSING THE ELECTRONIC BOARD 53
2.2.11. SYSTEM EMPTYING 54

3
SUMMARY
2.2.12. FAULT SIGNALLING CODES 55
2.2.13. ACTIVE FUNCTIONS SIGNALLING CODES 59
2.2.14. GAS CONVERSION 60
3. USER SECTION 61
3.1. USE 62
3.1.1. GENERAL USE WARNINGS 62
3.1.2. CONTROL PANEL 63
3.1.3. DISPLAY ICONS 64
3.1.4. INFO MENU DISPLAY DATA 65
3.1.5. START-UP 66
3.1.6. OPERATING MODE 66
3.1.7. INFORMATIONAL NOTE ON ANTI-FREEZE FUNCTION 67
3.1.8. FAULT SIGNALLING CODES 68
3.1.9. ACTIVE FUNCTIONS SIGNALLING CODES 70
3.1.10. FAST H2O FUNCTION 70
3.1.11. MAINTENANCE 71
3.1.12. EXTERNAL CASING CLEANING 71
3.1.13. DISPOSAL 71

4
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

5
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
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, 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

8
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.

9
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.

10
1. INSTALLATION
INSTALLER
1.1.4. BOILER OVERALL DIMENSIONS
1.1.5. JIG
302
157
136
150
642
306
485
410
64
2
485
410
70 84 57 102 70
42
107
244
RG
sc
A
27
CF
164
R- HEATING RETURN Ø 1” 1/4
C - HOT Ø 1/2
G- GAS Ø 3/4
F- COLD Ø 1/2
A- HEATING FLOW Ø 1” 1/4
SC- CONDENSATE DRAIN Ø 25 mm

11
1. INSTALLATION
INSTALLER
1.1.6. CIRCULATOR PREVALENCE/FLOW DIAGRAM
Appliance Loss
Wilo-Yonos PARA INT RS 25/8
PREVALENCE (m)
FLOW RATE (m3/h)

12
1. INSTALLATION
INSTALLER
1.1.7. GENERATOR 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.
WARNING
The boilers have the electrical
protection degree IPX5D. The outdoor installation
in partially protected environments (platform roof,
balcony - see fig. 2) is allowed in compliance with
the related standards. The Company is not held
liable for installations in environments with a
temperature under –10°C or non-compliant with
the above indications.
H
A
X Y
B
A
A
A - 200 mm
B - 300 mm
X - 60 mm
Y - 60 mm
H - 1,000 mm fig.1
fig. 2
1,200 mm minimum
SECTION A-A
balcony/ platform roof

13
1. INSTALLATION
INSTALLER
WALL MOUNTING BY MEANS OF FIXING BRACKET
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.
In order to fix the thermal generator on the wall, proceed as follows:
1. fix on the wall (fig. 1), using the fisher, the upper bracket;
2. hook the eyelets of the boiler into the adequate hooks (fig. 2);
3. unscrew the fixing screws of the lower bracket (fig. 3) ensuring the free sliding of the bracket (fig. 4)
towards the boiler;
4. adjust the inclination of the boiler (fig. 5) 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
fig. 5
LOWER
BRACKET
LOWER
BRACKET

14
1. INSTALLATION
INSTALLER
INSTALLATION ON SELF-SUPPORTING FRAME
WARNING
During the installation of the heat generator, pay maximum attention to the installation of the
self-supporting frame. The frame must rest on a perfectly flat surface and, when supported against
the wall, the latter must be perfectly angled. 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. The correct installation of the frame allows obtaining, acting on the lower
bracket, a counterslope of the device against the perpendicular.
In order to mount the frame and therefore the generator, proceed as follows:
1. check the angle of the wall with the floor;
2. assemble the side profiles 3 and 4 on the pillars 1 and 2 (fig. 1);
3. assemble the side pillars 1 and 2 on the horizontal crossbeam 5;
4. assemble the central crossbeam 8 and the lower one 7;
5. complete the assembly, position the frame binding it to the wall 9 (if provided) and on the floor 10;
6. mount the upper bracket 6 and hook the eyelets of the boiler into the adequate hooks 11;
7. make sure that the frame is angled, adjust the inclination of the boiler by means of the lower bracket
(see "Wall mounting by means of fixing bracket") ensuring an inclination of the boiler, against the
vertical, of about 1–1.5°;
8. complete the installation by assembling the hydraulic components.
4
6
3
7
5
1
2
8
10
10
10
10
9
9
11
11
fig.1

15
1. INSTALLATION
INSTALLER
1.1.8. 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 manufactureris 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.

16
1. INSTALLATION
INSTALLER
1.1.9. SYSTEM FILLING
WARNING
For system filling use only clean tap water.
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 circulator jolly
valve (1-fig. 1) to release the air from the
system;
2. slightly loosen the cap of the jolly valve placed
on the top of the condensing block (fig. 3) to
release the air form the top of the system;
3. open the feeding tap “R” (fig. 2);
4. release all the air;
5. use pressure gauge “M” (fig. 2) to make sure
that the system pressure reaches 1.2 bar (fig.
4);
6. after performing this operation, make sure
that the loading tap “R” (fig. 2) is properly
closed.
1
M
R
fig. 1
fig. 2
fig. 3

17
1. INSTALLATION
INSTALLER
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 “R” until the pressure gauge indicates the
value of 1.2 bar (fig. 4)
1.1.10. FILLING THE CONDENSATE
COLLECTION SIPHON
Before starting the boiler you have to fill the
condensate collection siphon in order to avoid flue
reflux through the siphon.
Fill the condensate collection siphon as follows
(see fig. 5):
› With a glass pour the water in the heat
exchanger’s flue exhaust duct outlet (see fig. 5),
up to fill the condensate trap to the highest point
“T” (fig. 5);
› Connect the dedicated flexible condensate
draining tube to a waste disposal system.
The condensate can be drained directly in
the sewerage system by inserting an easily
serviceable siphon.
T
fig. 4
fig. 5

18
1. INSTALLATION
INSTALLER
1.1.11. 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 -
PROPYLENE 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 %

19
1. INSTALLATION
INSTALLER
1.1.12. GAS CONNECTION
DANGER
In order to connect the gas connector of
the boiler to the supply pipe use a stop seal of an
appropriate size and material. The use of hemp,
teflon tape or similar materials is strictly forbidden.
BEFORE PERFORMING THE GAS CONNECTION,
MAKE SURE THAT:
› the gas adduction line complies with the
standards and regulations in force;
› the tubing's section suits the requested capacity
and its length;
› the tubing is equipped with all safety and control
devices required by the standards in force;
› the internal and external seals of the gas infeed
plant are checked;
› 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. If
they do not match you must take the necessary
measures to adapt the boiler to another type of
gas (see chapter GAS TRANSFORMATION);
› the gas supply pressure falls within the values
indicated on the data plate.
1.1.13. ELECTRICAL CONNECTION
DANGER
The equipment is electrically safe only
if it is properly connected to an efficient grounding
system, performed in compliance with the safety
standards in force. You should check this essential
safety requirement. If in doubt, request an accurate
check of the electrical system performed by qualified
staff, as the manufacturer is not responsible for any
damages caused by lack of grounding system.
› Make sure that the electrical systems is
suitable for the maximum power absorbed by
the equipment, value indicated on the data plate.
› make sure that the cables section is appropriate
for the maximum power absorbed by the
equipment and that it is however not lower than
1 mm2.
› The equipment works with alternating current
of 230 V and 50 Hz. The electrical connection
must be performed using an all-pole switch with
an opening of at least 3 millimetres between
contacts placed upstream from the device.
WARNING
Make sure that the phase and neutral
cables connection is performed in compliance with
the wiring diagram (see chapter POWER SUPPLY).
WARNING
It is strictly forbidden the use of adaptors,
multiple plugs and/or extensions for the general
power supply of the equipment from the electrical
network.

20
1. INSTALLATION
INSTALLER
1.1.14. POWER SUPPLY
To power the boiler connect the electrical cables
to the terminal inside the control panel as follows:
DANGER
Cut off the voltage from the main switch.
› remove the boiler's front casing (refer to chapter
ACCESSING THE BOILER).
› loosen the two screws and remove the plate “A”
(see fig. 1).
› after removing the plate, connect the electrical
cables to terminal “B” (see fig. 1):
· the yellow/green cable to the terminal marked
with grounding symbol “ ”.
· the blue cable to the terminal marked with
“N”.
· the brown cable to the terminal marked with
“L”.
After performing these operations, remount plate
“A” and the front casing.
LNSeSe
A
TaTa
B
BLUE
YELLOW/GREEN
BROWN
fig. 1