Flexiheat S Series User manual

STORAGE WATER HEATER
S SERIES
GAS OR OIL-FIRED - FORCED DRAFT
STORAGE WATER HEATER
S SERIES
MODEL Gas-fired S SERIES
UM S 60 S 75 S 90 S 115
RIELLO BURNER MODEL mod. BS 2 BS 2 BS 3 BS 3
RIELLO BURNER TYPE type 912 T1 912 T1 913 T1 913 T1
APPLIANCE EFFECTIVE CAPACITY litres 320 320 317 280
RATED OUTPUT kW 60 75 90 115
EFFECTIVE OUTPUT kW 51 64 76 96
Ø FLUE GAS VENTING PIPE mm 220 220 220 220
MAX WATER PRESSURE bar 8 8 8 8
TIME TAKEN TO HEAT WATER TO 60° C min. 20 15 14 9
CONTINUOUS DRAW AT 60° C (∆T 45°C) l/h 975 1224 1455 1847
CONTINUOUS DRAW AT 45° C (∆T 30°C) l/h 1462 1835 2180 2755
CONTINUOUS DRAW AT 40° C (∆T 25°C) l/h 1754 2203 2615 3305
G20 NATURAL GAS – 20 mbar PRESSURE at valve inlet
INLET GAS PRESSURE mbar 20 20 20 20
BURNER PRESSURE mbar 4 6 3 4,3
GAS CONSUMPTION (15° C and 1013 mbar) m3/h 6,35 7,94 9,53 12,17
G31 PROPANE GAS - PRESSURE 30/37/50 mbar at valve inlet
INLET GAS PRESSURE mbar 30/37/50 30/37/50 30/37/50 30/37/50
BURNER PRESSURE mbar 4,4 6,5 2,6 3,7
GAS CONSUMPTION (15° C and 1013 mbar) Kg/h 4,9 6 7,4 9,1
G30 BUTANE GAS - PRESSURE 30/50 mbar at valve inlet
INLET GAS PRESSURE mbar 30/50 30/50 30/50 30/50
BURNER PRESSURE mbar 6,3 8,7 3,35 4,9
GAS CONSUMPTION (15° C and 1013 mbar) Kg/h 4,81 5,97 7,31 9,01
MODEL Oil-fired S SERIES
IT
STORAGE WATER HEATER
S SERIES
STORAGE WATER HEATERSTORAGE WATER HEATERSTORAGE WATER HEATERSTORAGE WATER HEATERSTORAGE WATER HEATERSTORAGE WATER HEATERSTORAGE WATER HEATER
S SERIESS SERIESS SERIES
S SERIES
S SERIES
S SERIES
S SERIES
S SERIES
S SERIES
S SERIES
STORAGE WATER HEATER
S SERIES
UM S 60 S 75 S 90 S 115
RIELLO BURNER MODEL mod. BGK3 BG6.1D BG6.1D BG7.1D
RIELLO BURNER TYPE type Gas oil Gas oil Gas oil Gas oil
OIL NOZZLE type 1.25/60º 1.35/60º 1.65/60º 2.25/60º
APPLIANCE EFFECTIVE CAPACITY litres 320 320 317 280
RATED OUTPUT kW 63 76 88 114
EFFECTIVE OUTPUT kW 54 64 74 96
Ø FLUE GAS VENTING PIPE mm 220 220 220 220
MAX WATER PRESSURE bar 8 8 8 8
TIME TAKEN TO HEAT WATER TO 60° C min. 20 15 14 9
OIL FLOW RATE Kg/h 5,4 6,4 7,5 9,6
PUMP PRESSURE bar 12 12 12 12
Installation, Operation and Maintenance Manual
'SO' Series Oil Fired Water Heaters
** Please Note: The water heater is no longer available in the gas fired option **

This manual is an integral part of the appliance and must be kept with the
appliance for its entire life. Before installing, adjusting or operating this applian-
ce, carefully read all the instructions contained in this manual.
The installation and maintenance operations must be carried out periodically
by qualified engineers, in full compliance with current gas appliances safety
and installation standards. The improper, negligent or irresponsible use of this
appliance, including the packaging items, can cause serious personal injuries or
damages to properties.
The company undertakes no responsibility for personal injuries or damages to
properties occurred because of non compliance with current standards relating
to appliance installation and assembly and with all requirements established by
law no. 46/90 relating to gas appliances, as well as because of incorrect and
negligent operation and maintenance of the water system and water heater and
non compliance with the instructions contained in this manual.
DESCRIPTION OF THE APPLIANCE
This storage water heater has been defined as a “Gas-fired water heater with
forced draft burner”, and has been designed for personal hygiene hot water pro-
duction in industrial applications.
Any other type of usage must regarded as improper and therefore dangerous.
The appliance consists of a water storage tank, electrically welded and enamel
coated to protect it from water induced corrosion. The tank is housed in a painted
metal casing containing the thermally insulating material. The water is heated by
a forced draft, gas/oil-fired burner mounted in the bottom section of the applian-
ce which, in turn, is connected to the combustion camber.
From the combustion chamber the flue gas venting pipes, which go across the
entire length of the tank, are branched off. The burner is operated by the control
thermostat located at the side of the appliance.
The appliance must be connected to a flue gas venting pipe. This appliance is
classified in the “II2H3+” category, and can therefore be supplied by G20 or G30
gas. Being a “B23” type appliance, it an be connected to a flue gas venting pipe.
IMPORTANT:
THIS APPLIANCE IS NOT SUITABLE FOR OUTDOOR INSTALLATION
General Information
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Fig. 1
DIMENSIONAL DATA
S 60 S 75 S 90 S 115
COLD WATER INLET 1” ½ 1” ½ 1” ½ 1” ½
HOT WATER OUTLET 1” ½ 1” ½ 1” ½ 1” ½
DRAIN ¾ ¾ ¾ ¾
ANODE ROD FITTING ¾ ¾ ¾ ¾
NO. OF ANODE RODS 2 2 2 2
PRESSURE VALVE
FITTING 1” 1” 1” 1”
MAX. OPERATING
PRESSURE (bar) 8 8 8 8
WEIGHT WITH TANK
EMPTY (Kg) 261 261 289 289

INSTALLATION:
- Check that the appliance is suitable for the type of gas supplied.
-
CONNECTION MUST BE PROVIDED.
- A clearance of at least 1000mm must be available in front of the appliance to
WATER CONNECTION
Connection to the water system must be carried out by using pipes with the
same Ø as that shown in the table. Connect to the water inlet pipe, marked on
the appliance with a blue ring, the water safety unit (not supplied), which must
comply with standard EN89 paragraph 5.5, and must consist of:
- a shutoff valve,
- a check valve,
- a check valve monitoring device,
- a safety valve,
- a draining device.
If the mains pressure exceeds 6 bar, a pressure relief valve must be installed as
far away from the appliance as possible. A shutoff valve must also be installed
on the mains inlet pipe to enable any maintenance operations on the appliance
to be carried out.
The pipes must then be flushed with water to remove any debris, which could
damage the system.
Connect the appliance pipes to the water system pipes (the water inlets and
outlets on the appliance are identified by blue and red rings respectively).
During the appliance normal operation, especially during the heating stage, the
safety valve will drip a little to release pressure from the system, if required. It
is therefore recommended to connect this valve to an open drain and to install
downstream of the safety valve an expansion vessel for food use with a capacity
no lower than 4% of the total capacity of the appliance.
DRAIN
During installation, fit a drain valve. To drain the water heater, proceed a follows.
- Close the shutoff valve located upstream of the appliance.
- Open the water taps downstream of the water heater.
- Open the drain valve.
- Full drainage of the appliance is carried out by siphoning.
- Connect a hose to the drain valve.
RECIRCULATION
For water recirculation, connect the circuit to allow recirculation to the fitting (fig.1)
FILLING UP
The appliance must work with the tank full and at the operating pressure; before
operating the appliance, the tank must therefore be filled up by following the
instructions below:
- after connecting the appliance to the water system, open the cold water supply
valve and a hot water tap (for the bath, bidet, sink etc).
Wait until a continuous flow of water comes out of the tap.
When this happens, the water heater is full and the water tap can be closed,
whilst the water supply valve must be left open.
ELECTRICAL CONNECTION
Connect the appliance to a 200V, single phase, earthed mains power supply.
In the proximity of the appliance, fit a two-pole main switch to stop appliance
operation if necessary. Connect the appliance power cable, making sure CEI
electrical standards are complied with.
IMPORTANT: When connecting the power cable to the mains power supply,
observe the correct polarity (live-neutral). In case of inverted polarities or
live-live power supply, the appliance cannot work.
THE MANUFACTURER CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGES
CAUSED BY THE ELECTRICAL SYSTEM BEING UNEARTHED.
ROOM VENTILATION
FLUE GAS VENTING
Installer Section
Installation Instructions
ease burner installation, adjustment and inspection operations. A clearance
of 1300mm must also be provided above the appliance to clean the flue gas
venting pipes, and of 500mm at the back and at the side of the appliance to
allow access to the internal cleaning holes.
These appliances have been designed to be floor mounted. A DRAINING
The appliance must be installed in compliance with all local relevant
applicable standards esta-blished by standards, which must be referred
to for issues which are not contemplated in this manual. This model of
water heater has been designed to be fixed mounted to the floor. If the
floor is made of wood or of a synthetic material, the water heater must
be positioned on a fire retardant base. If the appliance is to be installed in
an enclosed room without windows, adequate, fresh ventilation must be
provided. An inadequate ventilation can cause fire, explosion or
suffocation. Refer to national or local legislation.
The openings must be made in such a way as to avoid obstructions both from
inside and outside of the wall. Grilles, wired mesh etc. may be used to protect the
openings, without reducing the free net section mentioned above. These openings
must be positioned as close as possible to the ground and they must not interfere
with the flue gas vents .
Warning: this appliance can only be used inside permanently ventilated
rooms,more specifically, the room must be ventilated with the quantity of air
required by all appliances installed in the room.The air must enter through
permanent openings made on the outside walls of the room to be ventilated.
These openings must have a net free section of at least 6cm² for each kW
installed on the appliance, with a minimum of 100cm²
This appliance is a B23 type appliance and is therefore fitted with a flue gas vent,
which must be directly connected to a chimney or a flue of established efficiency,
with a pipe section at least 50cm long. Only if these devices are not available the
appliance may be directly connected outdoors to vent the combustion products,
as long as the requirements established are complied with. It is also advisable
to read the text of this standard also for the purpose of viewing possible
solutions for making a venting pipe, which are shown in details. The flue gas
venting pipe must have the diameter shown in the table and must be resistant
to acid corrosion caused by condensation. For the oil-fired version, this
pipe must be made of stainless steel. For all versions, the
maximum length of the venting pipe must not exceed 8 metres.
Electrical anode protection
Certain areas of the country have particularly soft water and
therefore poor conductivity of the water with less than 200
micro-siemens per centimetre, such as Cornwall, Scotland and
Devon for example. In these areas of soft water, the magnesium
sacrificial anodes may not suffice in providing adequate protection
against corrosion of the water heater. In these geographical areas,
or other areas with particularly soft water, we insist that you use our
electrical anode protection system, as it is more effective at
providing protection in these circumstances. It is also to be noted
that a constant and uninterrupted power supply is required to these
anodes to ensure the full protection of the water heater.
Our oil-fired storage water heaters are all fitted with removable
magnesium sacrificial anodes as standard which ensuring excellent
protection against corrosion of the water heater. Clearance is
required above the water heater for maintenance and replacement
of the magnesium sacrificial anodes. Should you have insufficient
clearance above the water heater that will prevent anode
replacement using the standard magnesium anodes, then electrical
anode protection may be fitted, instead of the magnesium anodes
Sacrificial anode protection

BURNER INSTALLATION
The S series water heaters can be fitted with burners made by other manufactu-
rers, as long as the following conditions are met:
- the burner to be used is CE certified.
- the burner to be used is capable of generating a pressure of at least 25 Pa in
the combustion chamber.
- the air pressure switch is set to switch the burner off before the CO value in
combustion products reaches 2000ppm.
- the flame length of the burner used is less than 500mm.
- read the installation manual supplied with the selected burner.
BURNER CONNECTION
To connect the forced draft burner, please refer to the user manual supplied
with the burner. Before installing and connecting the burner, carefully read the
instructions contained in that manual. The rated load (kWs burnt) must always be
adjusted because the load of different types of forced draft burners available on
the market may change according to applications. The correct load for burners
is not normally factory set. The rated load and the correct air/gas ratio must be
set by following the burner installation instructions. The pressure values to be set
with Riello burners are shown in the table on the front page.
GAS CONVERSION
If the appliance will be used with another gas category (LPG or natural gas) dif-
ferent to the standard gas category the burner has been set for in the factory, the
burner must be reset to the category of gas to be used. The conversion to another
type of gas must be carried out only by qualified engineers.
WARNING
If the appliance is to be used with LPG, a “first stage” pressure reducer must be
fitted near the tank in order to reduce the pressure to 1.5 bar. A “second stage”
pressure reducer must also be fitted near the appliance to reduce the gas supply
pressure to a value of 29 mbar (G30 pure butane gas) or to 37 mbar (G31 pure
propane gas).
SWITCHING ON THE WATER HEATER
Before switching on the appliance, please make sure that:
- the appliance has been preset for the available gas
- all current standards and regulations relating to installation of such
appliance have been complied with, specially as far as correctly connec-
ting the combustion product venting pipe and the gas supply line
- the electrical power supply is connected, with the correct polarity (live
and neutral) as well as an earthing socket compliant with current legisla-
tion
- the gas shutoff valves on the meter and near the water heater are open
- the water heater is full of water
KEY
A
B
C
D
E
F
G
H
“I / O” SWITCH
SAFETY THERMOSTAT
LIMIT THERMOSTAT
CONTROL THERMOSTAT
7-POLE MALE CONNECTOR
EARTHING
FAULT INDICATOR LIGHT
OPERATION HOUR COUNTER
S SERIES WIRING DIAGRAM
E
F
C D
G
B
H
A
BLUE
BROWN
BLUE
BROWN
YELLOW/GREEN
WHITE
BROWN
GREEN
YELLOW
BLUE
BLUE BROWN YELLOW/GREEN BLUE BROWN JAUNE/VERT BLACK BLUE
BLACK
CABLE
CÂBLE CÂBLE
The S series water heaters have been tested with Riello burners (gas- fired) and
Riello burners (oil-fired).

CONTROL THERMOSTAT, AVAILABLE RANGE 40-80°C
This controls the operations of the water heater by switching the burner on and off,
according to the desired water temperature. This thermostat is a capillary thermo-
stat, with fluid expansion probe, single pole, and with switching contacts.
LIMIT THERMOSTAT
When this limit thermostat clicks in, the water heater won’t be shut down and
the control thermostat will reset the water temperature as soon as the limit ther-
mostat is disabled.
SAFETY THERMOSTAT
This stops burner operation if the water heater gets overheated because of a
faulty control thermostat or limit thermostat. Water heater operation must then
be restored manually, after identifying and removing the cause of the safety
shutdown.
AIR PRESSURE SWITCH (ONLY FOR THE GAS-FIRED VERSION)
The air pressure switch ensures that the correct quantity or air is drawn during the
combustion and preventilation stages. The air pressure switch click-in value must
be adjusted at the time of water heater installation and commissioning, in order
to switch off the burner before the fumes CO value reaches 2000ppm. The values
shown in the table are given for information only and refer to laboratory tests.
AIR PRESSURE SWITCH ACTIVATION IN MBAR
Model G20 natural gas G31 propane gas G30 butane gas
S 60 3,5 3,3 3,5
S 75 5,2 5,5 5,2
S 90 4,2 4,2 3,7
S 115 5,6 5,1 5,1
GAS PRESSURE SWITCH (ONLY FOR THE GAS-FIRED VERSION)
The gas pressure switch ensures that the pressure of the gas supplied to the
appliance at the valve inlet does not go below the preset value.
The gas pressure switch click-in value must be adjusted at the time of water
heater installation and commissioning, in order to switch off the burner before the
fumes CO value reaches 2000ppm. The values shown in the table are given for
information only and refer to laboratory tests.
GAS PRESSURE SWITCH ACTIVATION IN MBAR
Model G20 natural gas G31 propane gas G30 butane gas
S 60 6 6 6
S 75 6 6 6
S 90 7 7 7
S 115 7 6 6
BURNER HEAD NOTCH ADJUSTMENT
The burner head is adjusted according to the burner output at the water heater
commissioning stage by following the table below. For more information, see the
selected burner instruction booklet.
BURNER HEAD NOTCH ADJUSTMENT
Model G20
natural gas
G31
propane gas
G30
butane gas OIL
S 60 2 2 2 2
S 75 3 3 3 3
S 90 2,5 1,5 1,5 3
S 115 3 3 3 3
RIELLO BURNER-AIR VALVE NOTCH ADJUSTMENT
The air valve must be adjusted at the water heater commissioning stage according
to the table below. These values are supplied for information only as they have
been detected in laboratory conditions. For more information, see the selected
burner instruction booklet to ensure that the CO2 value for natural gas does not
exceed 10% and, for LPG, does not exceed 12%. For the oil-fired version, the CO2
value must not exceed 12.5%.
TIPS ON USING THE WATER HEATER
Check that the hot water taps are tightly closed as any leak, as well as wasting
water and gas, can cause an abnormal and dangerous increase in water tempera-
ture in the boiler.
MAINTENANCE
Long lasting safety and efficiency may be ensured only by correctly carrying out
maintenance operations on the appliance and on the systems it is connected to.
- Carry out maintenance operations at least once a year.
- First of all, check and clean the internal heat exchange tubes.
- Check and clean the flue and flue gas venting pipes.
- Remove and clean any scaling built up in the safety water valve.
- If the appliance remains switched off in rooms subject to frost, it must be
drained and the gas valve must be closed.
- If the appliance is not going to be used for long periods of time, it is always
advisable to switch off the appliance and to close the gas supply valve.
- When cleaning the appliance, only use non abrasive cleaners.
DO NOT USE FLAMMABLE PRODUCTS.
ANODE ROD REPLACEMENT
Regularly check the anode rods, preferably when the enamelled tank is ins-
pected. The anode rods must be replaced if they are used up for more than 60%.
DESCALING
The quantity of scale contained in local water supply depends on the frequency
of use of the water heater and on the water temperature set on the thermostat. It
is advisable to set the water temperature to 60° C in order to reduce scale build-
up. The front section of the water heater casing is fitted with access covers used
for tank inspection and descaling. Drain the water heater before opening the
internal flanges. Descaling must be carried out with appropriate products. Check
with the supplier of such products. Every time the flanges are opened, the seals
must be replaced to avoid any leaks.

GAS/OIL-FIRED S SERIES WATER HEATER
SPARE PARTS
Item Description Qty
01 Top cover 1
02 Tank top ring 1
03 Turbolator with 9 fins at 23° 1
04 Fibreglass insulation 1
05 Sheet metal outer casing 1
06 Steel tank 1
07 Hot water outlet hole covering ring (red) 1
08 Recirculation hole covering ring (black) 1
09 Cold water inlet hole covering ring (blue) 1
10 Drain hole covering ring (black) 1
11 Ceramic trap 1
12 Combustion chamber side cover 1
13 Bottom cover disc with mounting brackets 1
14 Burner flange 1
15 Flame control cover disc, ø110 1
16 Instrument panel guard 1
17 Instrument panel 1
18 Thermostat, 84° 1
19 Safety reset thermostat 1
20 Temperature control thermostat 1
21 Thermostat knob 1
22 Switch 1
23 Burner connector pin 1
24 Probe wire guard 1
25 Water temperature probe 1
26 Probe sheathing 1
27 Safety thermostat probes 1
28 Probe sheathing 1
29 Inspection flange 1
30 Inspection flange gasket 1
31 Magnesium anode rod 3
32 Ceramic trap plug 1