Flexiheat SF 14 EVOLUTION NOx Service manual

SF14EVOLUTIONNOx-RAD-ING-Manuale-2009.1_HDIMS13_firm.05_R9
Installation, Use
and Maintenance Manual
for model
0476
SF 14 EVOLUTION NOx
Room sealed chamber water heater

2
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION 4
1. INSTALLER SECTION 7
1.1. INSTALLATION 8
1.1.1. GENERAL INSTALLATION WARNINGS 8
1.1.2. WATER HEATER LOCATION ENVIRONMENTAL REQUIREMENTS 8
1.1.3. REFERENCE LEGISLATION 9
1.1.4. UNPACKING 10
1.1.5. OVERALL DIMENSIONS 11
1.1.6. HYDRAULIC CONNECTIONS 11
1.1.7. POSITIONING AND MINIMAL TECHNICAL SPACES 12
1.1.8. HYDRAULIC CONNECTION 13
1.1.9. FROST PROTECTION KIT 14
1.1.10. GAS CONNECTION 15
1.1.11. ELECTRICAL CONNECTION 15
1.1.12. OPTIONAL ELECTRICAL CONNECTIONS 16
1.1.13. FLUE SYSTEMS 17
1.1.14. TYPES OF INSTALLATION 18
1.1.15. TYPES OF FLUE SYSTEMS 20
2. SUPPORT CENTER SECTION 25
2.1. COMMISSIONING 26
2.1.1. COMMISSIONING PRELIMINARY OPERATIONS 26
2.1.2. WATER HEATER IGNITION 27
2.1.2. GAS PRESSURE CHECK AND CALIBRATION 28
2.1.3. TOTAL GAS VALVE CALIBRATION 29
2.1.4. CO2 VALUE CHECK AND CALIBRATION 30
2.1.5. ACCESSING AND PROGRAMMING THE PARAMETERS 31
2.1.6. HDIMS13 PARAMETERS TABLE 34
2.1.7. HEAT INPUT/ GAS PRESSURE DIAGRAM 37
2.2. MAINTENANCE 38
2.2.7. GENERAL MAINTENANCE WARNINGS 38
2.2.8. TECHNICAL DATA 39
2.2.9. TECHNICAL ASSEMBLY 41
2.2.10. HYDRAULIC DIAGRAM 42
2.2.11. WIRING DIAGRAM 43
2.2.9. ACCESSING THE WATER HEATER 44
2.2.10. ACCESSING THE ELECTRONIC P.C.B. 45
2.2.11. EMPTYING THE DOMESTIC SYSTEM 46

3
TABLE OF CONTENTS
2.2.12. ERROR CODES 47
2.2.13. FUNCTION CODES 51
2.2.14. DELAY CODES 51
2.2.15. INFO MENU DISPLAY DATA 52
2.2.16. POSITIONING OF THE ELECTRODE 53
2.2.17. GAS CONVERSION 54
3. USER SECTION 55
3.1. USE 56
3.1.1. GENERAL USE WARNINGS 56
3.1.2. CONTROL PANEL 57
3.1.3. DISPLAY ICONS 58
3.1.4. START-UP 59
3.1.5. DOMESTIC HOT WATER TEMPERATURE ADJUSTMENT 59
3.1.6. OUTPUT ADJUSTMENT 59
3.1.7. OFF MODE 59
3.1.8. FROST PROTECTION FUNCTION INFORMATION 59
3.1.9. ERROR CODES 60
3.1.10. FUNCTION CODES 61
3.1.11. MAINTENANCE 62
3.1.12. EXTERNAL CASING CLEANING 62
3.1.13. DISPOSAL 62

4
2.
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 water heater 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 water heater.
The water heater 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 water
heater.
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
water heater.
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
water heater indicated on the plate placed on the
right side of its casing.
INTRODUCTION

5
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;
The technical and functional features of the device are ensured by its use in compliance:
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.
INTRODUCTION
›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.
In its simplicity, the water heater is equipped with all accessories necessary to render it
a veritable independent heating unit. All water heaters are tested and delivered with a
quality certificate signed by the tester.
The materials used such as copper, brass, stainless steel create ahomogeneous,
compact and functional assembly, easy to install and manage.
PRODUCT CONFORMITY
MANUFACTURER WARRANTY AND RESPONSIBILITY
The manufacturer reserves:
2.

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

8
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 water heater 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 WATER HEATER,
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 water heater 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. WATER HEATER LOCATION
ENVIRONMENTAL
REQUIREMENTS
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
If the temperature in the water heater
installation location goes below 4°C please insert
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

9
1. INSTALLATION
INSTALLER
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.

10
1. INSTALLATION
INSTALLER
1.1.4. UNPACKING
WARNING
Please unpack the water heater 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 water heater, proceed as follows:
› Place the packed water heater on the floor (fig.
1-A) and remove the fasteners opening the four
flaps of the box outwards.
› Turn the water heater at 90° holding it with your
hand (fig. 1-B).
› Lift the box (fig. 1-C) and remove the guards (fig.
1-D).
C
B
D
A
fig. 1

11
1. INSTALLATION
INSTALLER
1.1.5. OVERALL DIMENSIONS
1.1.6. HYDRAULIC CONNECTIONS
110
203
642
410
245
83
64
2
41
0
245
110 95 95 110
108
CGF
127
C- D.H.W. OUTLET Ø 1/2
G- GAS Ø 3/4
F- COLD WATER INLET Ø 1/2

12
1. INSTALLATION
INSTALLER
1.1.7. POSITIONING AND MINIMAL
TECHNICAL SPACES
The water heater must be installed only on a
vertical solid wall, able to sustain its weight.
In order to allow the access inside the water heater
for maintenance operations, you have to respect
the minimum technical spaces indicated in figure
1.
To facilitate the installation, the water heater is
provided with a jig that allows setting in advance the
connections to the tubes offering you the possibility
of connecting the water heater to completed
masonry works.
For machine positioning, proceed as follows (see fig. 2):
1. Trace a line using a spirit level (min. length 25 cm) on the installation wall.
2. place the top of the jig along the traced line respecting the distances of the water connections; then
mark the two points to insert the two knobs or the fasteners, then trace the points for the fume
exhaust fittings;
3. remove the jig and drill the wall;
4. hang the device using the knobs or the bracket and perform the connections.
3
142
70 80 10249 3178
Ø80
Ø125
Ø100
35826 26
54 54
821
681
699
302
785
H
B
A
Y
X
A - 200 mm
B - 300 mm
X - 60 mm
Y - 60 mm
H - 1000 mm
fig.1
fig.2

13
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 water heater,
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 water heater 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 water heater.
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 water heater safety drains
to a discharge funnel. The manufacturer is not
responsible for any floods due to safety valve opening
in case of plant overpressure.
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 water heater.
Please note
Because the minimum power of the SF14 Water heater is 10 kW, at low water
flows (i.e., 5 Litres/ minute or less) the temperature may exceed the set
temperature programmed on the unit. This is to avoid continuous shutdowns, it
initially heats the water up to 60°C, within the heat exchanger ( as a by-product this
is good for anti-legionella purposes, as although this is a little volume of
water within the heat exchanger , if the unit hasn’t been used for some time –
it’s good to heat it up to this level ), then a downward output adjustment is
performed by the burner, to adjust to the required power to achieve your desired
temperature.
This can be avoided / overcome by installing a mixing valve on the hot water
outlet – which can limit the hot water temperature to 43C to prevent any scalding
issues.
A TMV (Thermostatic mixing valve) are also good for applications, whereby you
might want lower hot water temperatures than the unit can produce which is 35°C
on the control panel. For example, we supply these units to the equine sector, for
warm washing down of horses etc – in the summer months, they may only
require a temperature °of 30C – by using one of the above valves fitted to the hot
water outlet – you can reduce the temperature down to 30C , as most of these TMV
mixing valves can control the water temperature between 30°C to 50°C.

14
1. INSTALLATION
INSTALLER
1.1.9. FROST PROTECTION KIT
Thanks to the optional electrical heating elements
(code 50-00106), it is possible to protect the water
heater up to an outside temperature of 0°C.
The kit of electrical heating elements is a frost
protection that is triggered when the water
probe detect a temperature of 4°C to heat up the
exchanger pipes to a temperature of 8°C.
ATTENTION
The system operates even if the water
heater is in OFF mode, as long as it is electrically
powered.
Whenever there is a risk of freezing and no optional
kit of electrical heating elements is fitted on the
water heater, the water circuit will have to be
drained (see chapter ‘DRAINING THE DOMESTIC
HOT WATER SYSTEM’).

15
1. INSTALLATION
INSTALLER
1.1.10. 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.
1.1.11. 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.
WARNING
Make sure that the phase and neutral
cables connection is performed in compliance with
the wiring diagram (see chapter WIRING DIAGRAM).
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.

16
1. INSTALLATION
INSTALLER
1.1.12. OPTIONAL ELECTRICAL
CONNECTIONS
DISABLING THE D.H.W. MODE BY CONTACT
It is possible to enable/disable the request to
turn on the burner in DHW mode, when there is
a connection (for example of a storage tank time
clock, a temperature thermostat or a solar control
box) on the ‘CS’, D.H.W. contact (see chapter
‘ELECTRICAL DIAGRAM’).
Example 1: With ‘CS’ D.H.W. contact open, upon
D.H.W. request, the flow-switch activates and the
water heater starts.
Example 2: With ‘CS’ D.H.W. contact closed, upon
D.H.W. request, the flow-switch activates but the
water heater doesn’t start.

17
1. INSTALLATION
INSTALLER
1.1.13. FLUE SYSTEMS
WARNING
In order to ensure proper operation and
efficiency of the device you have to connect the
choosen flue system to the flue exhaust duct using
appropriate flue systems for traditional water
heaters.
.
WARNING
You cannot use plastic material
(polypropelene) flue fittings for the flue exhaust of
non-condensing units.
› For all horizontal sections of discharge ducts
and air suction, with regard to the air path, you
should provide an uphill slope (towards the
boiler) of a minimum of 2% (see fig. 1) so as to
avoid water, dust or foreign object ingress inside
the duct.
› In order to discharge fumes through a fume
exhaust duct, carefully follow the technical
standards in force.
› Suction and discharge systems, tailored to
individual installations, must be protected with
accessories that prevent the ingress of foreign
objects and atmospheric agents.
› Make sure that the discharge tube does not
rotrude inside the fumes exhaust duct, stop
efore it reaches the inner surface of the latter.
he discharge duct must be perpendicular with
he opposite internal wall of the chimney or of
he fumes exhaust duct (fig. 2).
2%
>
2%
>
fig. 1
fig. 2

18
1. INSTALLATION
INSTALLER
1.1.14. TYPES OF INSTALLATION
For this type of boiler are available the following
fumes discharge configurations: B22, C12 and C32
(see Fig. 1).
› B22- Indoor suction and outdoor discharge.
› C12- Concentric wall discharge. The tubes can
be split but the outputs must be concentric or
close enough to each other to undertake similar
wind conditions (within 50 cm).
› C32- Roof concentric discharge.
DISCHARGE OF COMBUSTION PRODUCTS FOR
B-TYPE DEVICES.
The gas devices, provided with connection for
fumes exhaust tube, must be directly connected
to efficient chimneys or fume exhaust ducts:
only if these are missing you can discharge the
combustion products directly through the wall.
The connection to the chimney or to the fume
exhaust ducts must respect the following
requirements:
· Be sealed and realised in materials suitable
to resist normal mechanical stress, heat,
the action of combustion products and any
condensate forming;
· have no more than three changes in direction,
including the chimney and/or fume exhaust
duct inlet connection, made with internal
angles greater than 90°. The changes in
direction must be made only by using curved
curved elements;
· have the axis of the inlet end perpendicular to
the internal wall opposite to the chimney or
fume exhaust duct;
· have, along its entire length, a section equal
to or greater then that of the connection of the
device discharge tube;
· have no shut-off devices (shutters).
· for direct external discharge there must be no
more than two changes in direction.
LOCATIONS VENTING FOR B-TYPE DEVICES
The locations in which are installed gas devices
must be vented so as to ensure the amount of air
necessary for a regular combustion and for location
ventilation. The natural air intake must take place
directly through:
B22
C12 C12
C32 C32
Max 50 cm
fig. 1

19
1. INSTALLATION
INSTALLER
· permanent openings on the external walls of
the location (windows);
· single or collective, ramified ventilation ducts.
The openings on the external walls of the location
must respect the following requirements:
· have a net overall free passage section of
at least 6 cm2for every kW of heat capacity
installed with a minimum of 100 cm2;
· they must be realized so as to make sure that
the opening inlets are not obstructed (neither
indoors nor outdoors);
· they must be protected with grids, metal
meshes, etc. so as to keep the useful section
mentioned above.
· they must be placed at a height next to the
floor level such as to allow proper operation of
the combustion products discharge systems;
if such position can not be obtained, please
increase by at least 50% the section of the
vents.

20
1. INSTALLATION
INSTALLER
1.1.15. TYPES OF FLUE SYSTEMS
KIT A - HORIZONTAL CONCENTRIC FLUE KIT
Ø60/100 mm.
It allows the flue exhaust and the air intake from external
wall.
Suitable only for traditional water heaters.
It allows the combustion gas exhaust and the combustion
air intake through concentric pipes, the external one for
air intake, the internal one for flue exhaust.
PLEASE SEE THE MAXIMUM EXHAUST LENGTH IN THE
TABLE OF “TECHNICAL DATA” CHAPTER.
The maximum exhaust length (or linear length) can be
calculated summing the length of the linear pipe and the
equivalent length of each flue bend additional to the first
one.
For the further addition of a bend, the linear length must
be updated according to the indications below:
concentric flue bend Ø60/100 at 90°= 1 m
concentric flue bend Ø60/100 at 45°= 0.6 m
See the next paragraph table to select the
correct flue insert to be installed, among
those supplied with the water heater (Ø
40-42-44 mm), according to the maximum
exhaust length.
Warning! A fixed Ø 40mm flue insert is
factory fitted on the flue inspection flange
(Fig.1)

21
1. INSTALLATION
INSTALLER
Maximum discharge length -
Ø60/100 mm
m4
from 0,5 to 1 m - Ø60/100 mm diaf. pos. USE FLUE INSERT Ø42 mm in the
flue inspection flange (Do NOT install
an adjustable flue diaphragm)
from 1 to 2 m - Ø60/100 mm diaf. pos. USE FLUE INSERT Ø44 mm in the
flue inspection flange (Do NOT install
an adjustable flue diaphragm)
FLUE INSERTS FOR THE CONCENTRIC FLUE KIT Ø60/100 mm
from 3 to 4 m - Ø60/100 mm diaf. pos. No flue insert
from 2 to 3 m - Ø60/100 mm diaf. pos. No flue insert