Radiant RKR 24, RKR 28, RKR 34, RK 18, RK 25 Instruction Manual

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Page 1

Installation, operating, commissioning and maintenance instructions

0694

RKR 24_28_34 - RAD - ING - MAN.INST - 1104A - DIGITECH 2 - REGNO UNITO - EXTRAHEAT

- CBD

Technical specification RADIANT BRUCIATORI S.p.A. Montelabbate (PU) ITALY ENGLISH

Instruction Manual

for model

RKR 24

RKR 28

RKR 34

Wall mounted instantaneous combi boiler

premix condensing boiler

Page 2

Page 3

CONTENTS

1. General information

1.1 General warnings page 1

1.2 Product conformity 3

2. Technical characteristics

2.1 Technical data 4

2.2 Dimensions 6

2.3 Internal parts of the boiler 8

2.4 Water circuit 9

2.5 Circulation pump head/flow graph 10

2.6 Printed circuit board – Technical characteristics 11

2.7 Control panel 11

3. Installation

3.1 Reference standard 12

3.2 Boiler room – installation requirements 13

3.3 Unpacking 13

3.4 Installation boiler 14

3.5 Water connections 15

3.6 Central heating circuit 16

3.7 Condensate drain 17

3.8 Gas connection 18

3.9 Electrical connections

3.10 Flue connections 21

4. Commissioning the appliance (authorised personnel)

4.1 General warnings 27

4.2 Filling the system 28

4.3 Filling the condensate trap 29

4.4 Starting up the boiler 30

5. Regulating the appliance (authorised personnel)

5.1 Parameters table 31

5.2 Setting the parameters 32

5.3 Gas Data 38

5.4 Converting the boiler to a different gas type 41

6. Annual Service and Maintenance (authorised personnel)

6.1 General warnings 42

6.2 Boiler inspection 42

6.3 Accessing the boiler 43

6.4 Draining the central heating and domestic hot water system 44

6.5 Maintenance operations 45

6.6 Wiring diagrams 54

6.7 Troubleshooting 58

6.8 Diagnostics 59

6.9 Parts list 60

Page 4

GENERAL INFORMATION

1. GENERAL INFORMATION

1.1 General warnings

Professionally qualified personnel in accordance with current laws and standards and in line with the

manufacturer’s instructions must install the appliance.

In GB, the installation must be carried out by a Gas Safe Registered Installer. To check for authorised

qualified engineers please contact

Phone Number 0800 408 5500.

It must be carried out in accordance

with the relevant requirements of the:

- Gas Safety Regulations;

- The appropriate Building Regulations either The Building Regulation, The Building Regulations

(Scotland), Building Regulations (Northern Ireland);

- The Water Fittings Regulations or Water Byelaws in Scotland;

- The current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.

The commissioning of the boiler and any subsequent works carried out on the appliance must be

effected by a suitably trained Gas Safe Registered Technician. The BENCHMARK record for Commissioning and Annual Service at the back of this book should be completed.

The appliance must be used solely for the purpose for which it has been designed and manufactured:

central heating and domestic hot water production. Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through noncompliance with current local and national standards and/or the manufacturer’s instructions.

The installation, operation and maintenance manual form an integral and essential part of the product

and must be kept near the appliance always.

This Manufacturer Installation and Maintenance manual must not be removed on completion of the

installation; must be kept in a safe place and made available for future reference. This Manual must be left along with the Benchmark commissioning booklet with the boiler as Regulation 29 of the HSC Gas safety (installation and use) Regulations 1998.

The warnings contained in this chapter have been written for the appliance user, the installer and the

service engineer.

The “operating instructions” chapter of this manual must be read carefully as it provides information on

the operation and the operating limits of the appliance.

This appliance must be used exclusively in an un-vented central heating system.

• After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children in that these items represent a potential hazard and must be disposed of in a responsible manner.

• Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains electricity supply by switching off at the main switch and/or any other isolating device.

• Do not obstruct the air intake or flue exhaust grills.

• Do not obstruct the air intake or flue exhaust terminals.

• In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt any

repairs. Call for professionally qualified technical assistance only.

• Any repairs to the appliance under the manufacturers warranty must be carried out exclusively by the manufacturer’s authorised technicians. Non-compliance with this requirement may compromise the safety of the appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its correct operation, it must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions.

• When the appliance is no longer required for use, any parts that may constitute potential sources of danger must be rendered harmless.

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GENERAL INFORMATION

• Only original accessories or optional extras (including electrical parts) must be used with the appliance.

• Should there be a smell of gas present in the room where the appliance is installed, DO NOT attempt to activate any

electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to create a current of air and ventilate the room. Shut-off the main gas supply valve (at the meter), or on the cylinder in the case of bottled gas, and call an authorised service centre.

• Do not attempt to interfere with the appliance in any way.

• As dictated by current legislation, this appliance must be installed exclusively by qualified personnel. Before

starting the boiler for the first time, make sure that it is connected to a water supply and central heating system compatible with its performance characteristics.

• Check the technical data reported on the packing and on the data plate located on the inside of the front casing. Also check that the burner is appropriate for the type of gas to burn.

• Make sure that the pipes and fittings used for the gas service are perfectly tight and that there are no gas leaks.

• Prior to initial start-up, the central heating pipes should be flushed to remove any residues that could compromise the operation of the appliance.

• The appliance can be regarded as being electrically safe when it has been connected to an efficient earth system installed in accordance with the requirements of current safety standards. This fundamental safety requirement must be checked and verified. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an ineffective or non-existent earth system.

• The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the appliance data plate (positioned on the inside of the front casing). In particular, make sure that the cable ratings are adequate for the power absorbed.

• Do not use adapters; multiple sockets or extension leads to connect the appliance to the mains power supply.

• The appliance must be connected to the mains power supply through an appropriate electrical isolator in accordance

with the current wiring regulations.

• When using an electrical appliance, a few fundamental rules must be observed:

• Do not touch the appliance with damp or wet parts of the body or when barefoot

• Do not pull on the electric wires

• Do not leave the appliance exposed to atmospheric elements (rain, sun, etc,) unless these conditions have been

expressly provided for.

• Do not allow the appliance to be used by children or anyone unfamiliar with its operation.

• The user must not replace the power supply cable.

• If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified

electrician.

• When the appliance is no longer required for use, switch off the main power supply, to switch all electrical components off (circulating pump, burner etc.)

Page 6

GENERAL INFORMATION

1.2 Product conformity

RADIANT BRUCIATORI S.p.A. declares that all its products are manufactured to a high specification and in compliance with the relevant standards.

All RADIANT boilers are CE certified and possess technical and functional characteristics that comply with the following standards:

UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT ≤ 70 kW EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT ≤ 70 kW UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING

BOILERS WITH NOMINAL HEAT INPUT ≤ 70 kW

Gas fired boilers also comply with the following directives: GAS APPLIANCES DIRECTIVE 2009/142/CE LOW VOLTAGE DIRECTIVE 2006/95 CEE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108 CEE BOILER EFFICIENCY DIRECTIVE 92/42 CEE

The materials used such as copper, brass, stainless steel, etc. form a compact, homogeneous, highly functional unit that is easy to install and simple to operate. In its simplicity, the wall-mounted appliance is equipped with all the appropriate accessories required to make it a fully independent boiler capable of satisfying domestic hot water production and central heating needs. All boilers are fully inspected and are accompanied by a quality certificate, signed by the inspector, and a guarantee certificate. This manual must be kept in a safe place and must

accompany the boiler at all times.

RADIANT BRUCIATORI S.p.A. will not be held responsible for any misinterpretation of this manual resulting from the inaccurate translation of same.

RADIANT BRUCIATORI S.p.A. will not be held responsible for the consequences in the case of nonobservance of the instructions contained in this manual or in the case where actions not specifically described herein are undertaken.

Radiant Bruciatori S.p.A. declare that no substances harmful to health are contained in the appliance or used during appliance manufacture and have not used or intend to use any of the following substances in the manufacture of Radiant heating products.

−

Asbestos

−

Mercury

−

CFC's.

Page 7

TECHNICAL CHARACTERISTCS

2. TECHNICAL CHARACTERISTICS

2.1 Technical data

Models RKR 24 RKR 28 RKR 34

CE Certification n° 0694BN3485 Appliance Type B23p – B33 - C13 - C33 - C43 - C53 - C63 - C83 – C93 Appliance Category II2H3B/P Heat Input max

kW 18 25 34

Heat Input max D.H.W.

kW 23.5 28.5 34

Heat Input min

kW 4 9 10

Heat Output max (50/30°)

19.26 26.68 36.24

Heat Output max

– 80/60°C (Non condensing)

17.69 24.6 33.42

Heat Output min

– 80/60°C (Non condensing)

3.9 8.73 9.73

Full Load Efficiency

(SEDBUK EFFICIENCY)

%,net 98.3 98.4 98.3

Part Load Efficiency

(SEDBUK EFFICIENCY)

%,net 108.1 106.3 107.9

GAS DIRECTIVE 92/42/ECC – Efficiency marking stars 4 Sedbuk band A

Central Heating circuit Central Heating water temperature setting (min-max) °C 30-80 / 25-40 Max. Heating working temperature °C 80 Expansion vessel capacity litres 7 Max. Working pressure (heating) bar 3 Min. Working pressure (heating) bar 0.3

Domestic Hot Water circuit D.H.W. temperature setting (min-max) °C 35-60 Max. Hot water working pressure bar 6 Min. Hot water working pressure bar 0.5 D.H.W. flow rate at ∆T 25K litr/mn 13,3 16 19,2 D.H.W. flow rate at ∆T 30K litr/mn 11,1 13,4 16 D.H.W. flow rate at ∆T 35K litr/mn 9,5 11,5 13,7 D.H.W. flow rate at ∆T 40K litr/mn 8,3 10,1 12 D.H.W. flow rate at ∆T 50K litr/mn 6,7 8,1 9,6

Dimensions (Boiler casing size) Width mm 410 Height mm 730 Depth mm 285 285 310 Weight (net) kg 38 40 42

Hydraulic connections Central Heating Flow connection Ø mm

Central heating Return connection Ø mm

Cold water mains connection Ø mm

D. Hot water connection Ø mm

Gas connection Ø mm

Condensate Drain Ø mm

Flue systems Horizontal-Concentric flue system Ø mm 60/100 Max. Flue length m 6 6 3 Horizontal-Concentric flue system Ø mm 80/125 Max. Flue length m 12 10 8 Twin pipe flue system Ø mm 80/80 Max. Flue length (from terminal to terminal) m 50 Twin pipe flue system Ø mm 60/60 Max. Flue length (from terminal to terminal) m 30 Vertical-Concentric flue system Ø mm 60/100 Max. Flue length m 6 6 3

Vertical-Concentric flue system Ø mm

80/125

Max. Flue length m 12 10 8 Gas Supply

Natural gas G 20 Inlet pressure mbar 20 Gas consumption m3/h 1.91 2.65 3.6 Butane G30 Inlet pressure mbar 30 Gas consumption kg/h 1.42 1.97 2.68 Propane G31 Inlet pressure mbar 37 Gas consumption kg/h 1.4 1.94 2.64

Electrical specifications Power supply V/Hz 230/50 Electrical power consumption W 180 Electrical protection IP X4D

Page 8

TECHNICAL CHARACTERISTCS

Models

RKR 24 RKR 28 RKR 34

Efficiency 100% (full load 80/60°) % 98.3 98.4 98.3 Efficiency 100% (full load 50/30°) % 107 106.7 106.6 Efficiency 30% (partial load) % 101.1 100.1 100.7 Flue efficiency losses with burner on (50/30°C) (Pn /Pr) % 2,51/2,43 2,20/2,10 2,60/2,40 Flue gas temperature (50/30°C) (Pn) °C 50,8 53 51.7 Flue gas temperature (80/60°C) (Pn) °C 71 65 73.3 Flue Mass (50/30°C) (Pn/Pr) Kg/h 29,95/6,65 42,50/15,30 58,95/17,34 Flue Mass (80/60°C) (Pn/Pr) Kg/h 28,32/6,49 39,32/15,08 54,89/17,15 Air excess (Heat output max/min) (Pn/Pr) λ 1,25/1,3 1,24/1,33 1,27/1,36 NOx content mg/kWh 35 40 32 Condensate production l/h 2 2.2 3 Expansion vessel pre-charge pressure bar 1 Fan electrical power consumption W 75 Pump electrical power consumption W 88 93 Fan head Pa 75 75 120

Page 9

TECHNICAL CHARACTERISTCS

CWI

HWO

105

110137163

285

131

S R

CWI

HR HWO

65 280 65

730

1525

730

7049 78 80 102 31

410

285

2.2 Dimensions - RKR 24 – RKR 28

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

Page 10

TECHNICAL CHARACTERISTCS

110137163

310

132

730

CWI

HR HWO

7049 78 80 102 31

310

730

111.5187111.5

48.5 313 48.5

105

RKR 34

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

Page 11

TECHNICAL CHARACTERISTCS

2.3 Internal parts of the boiler

4 5

27 26

2 3

LEGEND

1. PRIMARY CONDENSING HEAT EXCHANGER

2. PREMIX BURNER UNIT (GAS MANIFOLD + BURNER)

3. CONDENSATE DRAIN PIPE

4. IONISATION ELECTRODE

5. IGNITION ELECTRODE

6. FAN

7. VENTURI

8. IGNITION TRANSFORMER

9. ELECTRONIC GAS VALVE

10. 3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT

11. AUTOMATIC AIR VENT VALVE

12. HEATING SAFETY THERMOSTAT

13. HEATING SENSOR

14. PUMP WITH AIR VENT

15. WATER PRESSURE SWITCH

16. FLUE HOOD

17. SAFETY THERMO FUSE

18. EXPANSION VESSEL

19. D.H.W. SENSOR

20. CONDENSATE TRAP

21. WATER PRESSURE GAUGE

22. AUTOMATIC BY-PASS

23. CONDENSATE DRAIN PIPE

24. SYSTEM DRAIN VALVE

25. ROOM SEAL CHAMBER BACK SIDE

26. 3-WAY VALVE

27. ELECTRONIC FLOWSWITCH

28. DHW EXCHANGER

Page 12

TECHNICAL CHARACTERISTCS

2.4 Water circuit

LEGEND

PRIMARY CONDENSING HEAT EXCHANGER

PREMIX BURNER UNIT (GAS MANIFOLD+BURNER)

CONDENSATE DRAIN PIPE

IONISATION ELECTRODE

IGNITION ELECTRODE

FAN

VENTURI

IGNITION TRANSFORMER

ELECTRONIC GAS VALVE

10.

3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT

11.

AUTOMATIC AIR VENT VALVE

12.

HEATING SAFETY THERMOSTAT

13.

HEATING SENSOR

14.

PUMP WITH AIR VENT

15.

WATER PRESSURE GAUGE

16.

FLUE HOOD

17.

SAFETY THERMO FUSE

18.

EXPANSION VESSEL

19.

D.H.W. SENSOR

20.

CONDENSATE TRAP

21.

WATER PRESSURE SWITCH

22.

AUTOMATIC BY-PASS

23.

CONDENSATE DRAIN PIPE

24.

SYSTEM DRAIN VALVE

25.

ROOM SEAL CHAMBER BACK SIDE

26.

FLOW LIMITER

27.

ELECTRONIC FLOWSWITCH

28.

DHW EXCHANGER

29.

3-WAY VALVE

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

28 29

G CWI HFHR HWO

Page 13

TECHNICAL CHARACTERISTCS

2.5 Circulation pump head/flow graph

III

Appliance Loss

Pump head at minimum speed

Pump head at second speed

Pump head at maximum speed

III

Flow l/h

Head (kPa)

RKR 24

III

Flow l/h

III

Pump head at maximum speed Pump head at second speed

II I

Pump head at minimum speed Appliance Loss

Head (kPa)

RKR 28

Pump head at minimum speed

Pump head at second speed

Pump head at maximum speed

III

Appliance Loss

Flow l/h

III

Head (kPa)

RKR 34

Page 14

TECHNICAL CHARACTERISTCS

2.6 DIGITECH 2® printed circuit board – SM30003

Technical characteristics

Adjustments possible by service personnel only

• Standard (30/80°C) / reduced (25-40°C) central h eating temperature

• Water hammer prevention function

• Central Heating timer - (adjustable from 0 to 7,5 minutes)

• Central Heating pump overrun timer

• Domestic Hot Water pump overrun timer

• Minimum Gas pressure setting

• Maximum Heating Load

• Heating output rising time

User settings

• On/Off

• Heating Temperature setting (30-80°C) – (25-40°C)

• D.H.W. temperature setting (35-60°C)

• Summer only mode / Winter only mode / Summer + Winter mode selection

Operation/Functions display

• Lock-Out

• Water deficiency indicator

• Temperature display

 When the boiler is switched off at the switch on the control panel, the word OFF appears on the

display. The D.H.W and central heating frost protection system, nevertheless, remain enabled. If the boiler was previously on, it is switched off and the post-ventilation, pump overrun , circulation pump and three-way valve inactivity protection functions are enabled.

 The remote control, where fitted, remains active and illuminated.

2.7 Control panel

LEGEND

1. ON/OFF BUTTON

HEATING TEMPERATURE CONTROL KNOB

3. D.H.W TEMPERATURE CONTROL KNOB.

4. D.H.W TEMPERATURE BUTTON. KEEP PRESSED FOR 5

SECONDS TO DISPLAY OUTSIDE TEMPERATURE (ONLY IF OPTIONAL OUTDOOR SENSOR IS FITTED)

5. SERVICE BUTTON.

6. SUMMER, WINTER OR SUMMER/WINTER MODE

SELECTION BUTTON.

7. TERMINAL BOARD FOR EXTERNAL WIRING.

8. TEMPERATURE, ERROR CODE AND OPERATING STATUS

DISPLAY

9. TIME CLOCK (optional)

7654321

Page 15

INSTALLATION INSTRUCTIONS

3. INSTALLATION (authorised personnel)

3.1 Reference standard

In GB, the installation must be carried out by a

Gas Safe

Registered Installer. To check for authorised

qualified engineers please contact

Phone Number 0800 408 5500.

It must be carried out in accordance with

the relevant requirements of the:

- Gas Safety Regulations;

- The appropriate Building Regulations either The Building Regulation, The Building Regulations

(Scotland), Building Regulations (Northern Ireland);

- The Water Fittings Regulations or Water Byelaws in Scotland;

- The current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.

In GB, the following Codes of Practice apply:

BS 5440:Part1 – Flues BS 5440:Part2 – Air Supply BS 5446 Installation of hot water supplies for domestic purposes (1

, 2nd and 3rd family gases) BS 5449 Forced circulation hot water systems BS 6700 Installation of cold water supplies for domestic purposes (1

, 2nd and 3rd family gases) BS 6798 Installation of gas-fired hot water boilers BS 6891 Gas Installation BS 7074 Expansion Vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems BS 7671 IEE wiring regulations.

This appliance meets the requirements of:

- UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING

BOILERS WITH NOMINAL HEAT INPUT ≤ 70 kW

- IPX4D rating for electrical appliances.

- EMC DIRECTIVE 89/336 CEE

- LVD DIRECTIVE 73/23 CEE

- BOILER EFFICIENCY DIRECTIVE 92/42 CEE

Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is in the interest of the installer and safety that the law is complied with.

The manufacturers instructions form an integral part of the installation and should be left with the appliance but do not over ride in anyway statutory obligations.

Page 16

INSTALLATION INSTRUCTIONS

3.2 Boiler room – Installation requirements

Please refer to local and national standards in force in the Country of destination of the product. In particular the manufacturer recommends:

The presence of threaded connections on the gas line, require that the room in which the appliance is

installed is ventilated by means of air intakes.

A compartment used to house the appliance must be specifically designed and constructed for the

purpose. An existing compartment or cupboard may be used providing it is suitably modified. Adequate space for servicing must be provided and it must permit safe installation and termination of the flue. (See 3.4.1 ‘Compartment Ventilation’)

3.3 Unpacking

■

The materials (cardboard) used for packing the appliance are fully recyclable.

■ It is recommended that the packing material is only removed prior to installing the boiler. The

manufacturer will not be held responsible for damage caused by incorrect storage of the product.

■ Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that

these items represent a potential hazard.

A. Place the packed

appliance on the floor (see fig.

1) making sure that the "up” arrow is facing down. Remove the staples and open out the four flaps of the box.

B. Rotate the boiler 90° while manually supporting it from underneath

C. Lift the box and remove the protections. Lift the boiler by grasping the rear part and proceed with the installation.

STORAGE & HANDLING

Please note that prior to installation the Radiant boilers should be stored in the horizontal position with no more than three boilers to a stack; Ensure that the boilers are stored in dry conditions and be aware that the carton is a two man lift;

Fig. 1

Page 17

INSTALLATION INSTRUCTIONS

3.4 Installing the boiler

■ The appliance must be installed

exclusively on a flat vertical solid wall capable of supporting its weight.

■ The boiler should be fitted within the

building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (the boiler may be fitted inside a cupboard, (see 3.4.1 “Compartment Ventilation”).

■ If the boiler is sited in an unheated

enclosure then it is recommended to leave the power on to give frost protection (frost protection is active even with On/Off switch in Off position).

■ If the boiler is installed in a room

containing a bath or shower reference must be made to the relevant requirements. The appliance controls or any related switch or control should not be within reach while using the bath or shower.

In GB this is the current I.E.E. Wiring regulations and Building Regulations;

In order to allow access to the interior of the boiler for maintenance purposes, it is important that the necessary clearances indicated in figure 1 are respected. To make the installation easier, the boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall.

To install the boiler, proceed as follows (see fig. 2): a. Use a spirit level (of not less than 25

mm long) to mark a horizontal line on the wall where the boiler is to be fitted.

b. Position the top of the template along

the line drawn with the level, respecting the distances indicated. Then mark the centres of the positions of the two wallplugs or anchors. Finally, mark the positions of the water and gas pipes.

c. Remove the template and install the

domestic hot and cold water pipes, the gas supply pipe and the central heating pipes using the fittings supplied with the boiler.

Fix the boiler to the wall using the wall plugs or bracket and connect the pipes.

Compartment Ventilation

Where the appliance is installed in a compartment, no air vents are required.

BS 5440:Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.

MINIMUM DITANCES IN mm

X Y L HBA B

20060 60 410 1000 300

Fig. 1

Fig. 2

Page 18

INSTALLATION INSTRUCTIONS

3.5 Water connections

In order to safeguard the heat exchanger and circulation

pump, especially in case of boiler replacement, it is recommended that the system is hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators.

Make sure that the domestic water and central heating

pipes are not used to earth the electrical system. The pipes are totally unsuitable for this purpose.

The Isolation Valves provided must be installed

on the heating and D.H.W circuits. This will facilitate all maintenance and service operations where the boiler needs to be drained.

■ To prevent vibration and noise coming from the system, do

not use pipes of reduced diameter, short radius elbows or severe reductions in the cross sections of the water passages.

■ In order to guarantee the reliability of the boiler and prevent

permanent damage in areas with very high water inlet pressure a 2.5 bar pressure reducing valve should be fitted.

■ To facilitate the installation, the boiler is supplied with a

hydraulic connection kit (see fig.2).

Domestic hot water circuit

■ In order to prevent scaling and eventual damage to the D.H.W

heat exchanger, the mains water supply must not have a hardness rating of more than 17.5 °Ck. It is nevert heless advisable to check the properties of the water supply and install the appropriate treatment devices where necessary.

The cold water supply pressure at the inlet to the boiler must be between 0.5 and 6 bar. In areas with higher water inlet pressure a pressure reducing valve must be fitted before the boiler.

The frequency of the heat exchanger coil cleaning depends on the hardness of the mains water supply and the presence of residual solids or impurities, which are often present in the case of a new installation. If the characteristics of the mains water supply are such that require it to be treated, then the appropriate treatment devices must be installed, while in the case of residues, an in-line filter should be sufficient.

All D.H.W. circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.

Guidance G17 to G24 and recommendations R17 to R24 of the Water Regulation Guide.

Central heating circuit

In order to prevent scaling or deposits in the primary heat exchanger, the mains supply water to the heating circuit must be treated according to the requirements of local standards.

This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained.

The outlet connection of the boiler safety valve must be connected to a discharge pipe with a continuous fall from the boiler to outside. It must terminate in a safe position where any water, possibly boiling, can discharge without causing a hazard. The manufacturer will not be held responsible for flooding or damage caused by the operation of the safety valve in the case of system overpressure.

Condensate Drain

The condensate drain flexible pipe supplied with the boiler (conforming to UNI EN 677 standard) must be connected to a proper condensate trap. The condensate discharge into the drainage system is allowed providing a condensate trap (siphon) is installed.

Any condensate discharge pipe work external to the building (or in an unheated part of it) must be insulated to protect against frost. Before switching the boiler On, check the correct condensate discharge.

HFCWIGHWOHR

49 78 70 80 102 31

105

Fig. 2

Fig. 1

Ø 15 mm

Ø 22 mm

CWI

HWO

Ø 22 mm

Ø 15 mm

Page 19

INSTALLATION INSTRUCTIONS

3.6 Central heating circuit

The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance table for guidelines. System volume -The 7 litre expansion vessel incorporated into the boiler is generally suitable for most sealed heating systems however if the system has a larger volume of water it may be necessary to provide extra capacity for expansion.

The boiler is supplied with the following components built in:Pressure relief valve -complying with BS 6759 and set to operate at 3 bars. The outlet connection of the boiler safety valve must terminate to atmosphere in accordance with current regulations. The manufacturer will not be held responsible for flooding caused by the operation of the safety valve in the case of system overpressure..

Pressure gauge -To indicates the system pressure to be maintained. Expansion vessel – Volume 7 litre. Conforming to BS 7074:1 for GB, By-pass -The boiler incorporates a by-pass, however where all radiators are fitted with thermostatic radiator valves it is

recommended an automatic system by-pass is fitted.

Additional expansion vessel (if required)

Double check valve assy

Temperature/pressure relief valve

Boiler

Automatic air vent

Heating return

System drain tap

Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance

Note: If required, an automatic by-pass is preferred

Radiator

valve

Filling point

DHW outlet

Pressure reducing valve (supplied)

Mains water inlet

Static head of system

Make up vessel

Heating by-pass (if required)

Lockshield valve

Filling the central heating system – figs. 2-3

The system design pressure (cold) should be set to 1.5 bar. This pressure is equivalent to a static head of 15.4 metres of water. Provision should be made to replace water lost from the system during servicing etc. as shown in Figs. 2 and 3. The position for connecting an alternative make-up vessel is indicated in Fig. 1. A double check valve assembly must be used. as shown in Fig. 3. Filling of the system must be carried out in a manner approved by the local Water Undertaking (GB: Guidance G24.2 and Recommendation R24.2 of the Water Regulation Guide). Where allowed the system may be filled via a temporary connection as shown in Fig. 2. After filling, always disconnect the flexible hose of the filling loop. All fittings used in the system must be able to withstand pressures up to 3 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained.

Double

check valve

assembly

Test cock

Feed cistern to be

located above highest

point in the system

Overflow

Heating

circuit return

Test cock

Double

check valve

assembly

Stop

valve

Mains water

supply

Mains

water

supply

Stop valve

Filling loop

temporarily

Hose

unions

Heating

circuit return

order to prevent scaling or deposits in the primary heat exchanger, the water in the heating circuit must be treated

according to the requirements of standard.

This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained. Frequent topping-up of the system should be avoided and normally indicates a leak within the heating system.

Fig. 1

Fig. 2

Fig. 3

Page 20

INSTALLATION INSTRUCTIONS

3.7 Condensate drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER. The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run.

CAREFUL ATTENTION IS REQUIRED TO MINIMISE THE RISK OF FREEZING DURING PROLONGED COLD SPELLS.

I. The boiler condensate outlet terminates in a 25 mm flexible plastic pipe for connection to a plastic pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain or suitable soak-away is acceptable.

2. Ensure the discharge of condensate complies with any national or local regulations in force.

BS 6798:2000 & Part H I of the Building Regulations give further guidance.

3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP and take the shortest practicable route to a termination point.

4. Metal pipe work is NOT suitable for use in condensate discharge systems.

5. The pipe should be a minimum of 22 mm diameter and must be supported using suitably spaced clips to prevent sagging.

6. Any pipe fitted externally should not exceed 3 metres. 7 Any condensate discharge pipe work external to the building (or in an unheated part of it e.g. garage) must be insulated to protect against frost. It is also recommended that the pipe diameter is increased to 32mm.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

9. In alI cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped or freezing, as few bends and fittings as possible should be used.

10. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout. Examples are shown of the following methods of termination:- i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) iii) to a drain or gully iv) to a purpose made soak away

450mm min

Holes in the soak-away must

face away from the building

500mm min

External termination to a purpose made soak-away

External termination to a drain or gully

Pipe must terminate above

water level but below surrounding surface

Boiler

Pipe must terminate above

water level but below

surrounding surface

External termination via internal discharge branch e.g. sink waste - downstream

Sink

Termination to an internal soil and vent pipe

Boiler

Page 21

INSTALLATION INSTRUCTIONS

3.8 Gas Connection

The connection to the gas supply must be carried out by professionally qualified Gas Safe Registered

personnel in accordance with relevant standards:

In GB this is BS 6891.

When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The

use of hemp, Teflon tape and similar materials is not allowed.

Before installing the boiler, check the following:

■ The pipe work must have a section appropriate for the flow rates requested and the pipe lengths installed, and

must be fitted with all the safety and control devices provided for by current standards.

■ The gas supply line must be a minimum of a 22 mm diameter pipe with an uninterrupted supply from meter to

boiler and comply with current standards and regulations.

■ Check the internal and external seals of the gas supply system.

■ A gas shut-off valve must be installed upstream of the appliance

■ The gas pipe work must have and bigger or equal section to the one of the boiler.

■ Before starting up the boiler, make sure that the type of gas corresponds to that for which the appliance has

been set-up (see gas type label inside the boiler).

■ The gas supply pressure must be between the values reported on the rating plate (see gas type label inside the

boiler).

■ Prior to installation, it is good practice to ensure that there are no machining residues on the gas supply pipe.

■ Conversion of the appliance from natural gas to LPG or vice versa must be carried out by qualified personnel ;

Page 22

INSTALLATION INSTRUCTIONS

3.9 Electrical connections

General warnings

The connection to the mains power supply must be carried out by professionally qualified personnel,

registered in accordance with current legislation

Always check to make sure that the appliance has an efficient earth system. This requirement is only

satisfied if it has been properly connected to an efficient earth system installed in accordance with the requirements of current safety standards and carried out by professionally qualified personnel.

In GB this is I.E.E. Wiring Regulation.

This basic safety measure must be checked, verified and carried out by professionally qualified personnel. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an inefficient or inexistent earth system;

■ The boiler functions with an alternating current of 230 V and 50 Hz and has maximum power absorption of 180

W. The appliance should be protected by a 3 A fuse. The connection to the mains electricity supply must be via a single-pole switch, with at least 3 millimetres gap between open contacts, mounted upstream of the appliance. Make sure that the positions of the live and neutral wires correspond to the wiring diagram;

■ Ensure the domestic power supply is checked by a qualified electrician to ensure that it can support the

maximum power absorption of the appliance, as indicated on the rating plate. In particular, make sure that the cable sizes are adequate for the power absorbed by the appliance;

■ The power supply cable must not be replaced by the user. if the cable is damaged in any way, switch off the

appliance and have the cable replaced by a suitably qualified electrician;

■ When replacing the power supply cable, only use cables of the same characteristics (HO5 VV-F 3x1) with

maximum external Ø 8 mm;

When using an electrical appliance, a few fundamental rules must be observed:

• Do not touch the appliance with damp or wet parts of the body or when barefoot.

• Do not pull on the electric wires.

• Do not leave the appliance exposed to atmospheric elements (rain, sun, etc,) unless these conditions have

been expressly provided for.

• Do not allow the appliance to be used by children or anyone unfamiliar with its operation;

Page 23

INSTALLATION INSTRUCTIONS

Electrical connection

Connect the power supply to the terminal board inside the control panel as follows:

a. Switch off the power supply at the main switch. b. Remove the front case panel of the boiler. c. Slacken the screws and remove plate A (see fig. 1). d. With the plate removed, connect the wires to the terminal board B as follows:

• Connect the earth wire (normally coloured green/yellow) to the terminal marked with the earth symbol “ “.

• Connect the neutral wire (normally coloured blue) to the terminal marked with the letter “N”.

• Connect the live wire (normally coloured brown) to the terminal marked with the letter “L”.

• Terminals identified by the letters: Ta ⇒ Room thermostat or external timer or control (Voltage 24?)

Se ⇒ Outside temperature sensor (optional)

When the wires have been connected, place plate “A" back to position.

TaL N Ta Se Se

Fig. 1

Page 24

INSTALLATION INSTRUCTIONS

3.10 Flue connections

Flue position

IMPORTANT: THE FLUE SYSTEM SHALL BE INSTALLED IN ACCORDANCE WITH THE RECOMMENDATIONS CONTAINED IN BS 5440:1.

The boiler MUST be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows free passage of air across it at all times. If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway. In certain weather conditions a terminal may emit a plume of steam. Positions where this would cause a nuisance should be avoided. IMPORTANT REQUIREMENT: The correct dimensional relationship between the terminal and any obstruction, openable window or ventilator as shown in Fig 1 It is ESSENTIAL TO ENSURE, in practice, that products of combustion discharging from the terminal cannot re-enter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/air conditioning systems. If this should occur, the appliance MUST BE TURNED OFF IMMEDIATELY and the local gas region consulted. Where the lowest part of the terminal is fitted less than 2m (6.6ft) above a balcony, above ground, or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed guard. Where the terminal is fitted within 850mm (34in) of a plastic or painted gutter, or 450mm (18in) of painted eaves, an aluminium shield of at least 1000 mm (40in) long should be fitted to the underside of the gutter painted surface. The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm (1in) to combustible material.

TERMINAL POSITION

F F

H,I

TOP VIEW REAR FLUE

B.C

TERMINAL ASSEMBLY

PROPERTY BOUNDARY LINE

300 min

FROM A CHIMNEY OR STRUCTURE NEXT TO VERTICAL TERMINAL 500mm

A Directly below an openable window, air vent or any other ventilation opening. 300 mm B Below gutter, drain pipes or soil pipes. 25 mm C Below eaves. 25 mm D Below balcony or carport roof. 25 mm E From vertical drain pipes or soil pipes. 25 mm F From internal or external corners. 25 mm G Above adjacent ground, roof or balcony level. 300 mm H From a surface facing the terminal. 600 mm I Facing the terminals. 1200 mm J From opening (door, window)in the carport into dwelling. 1200 mm K Vertically from a terminal on the same wall 1500 mm L Horizontally from a terminal on the same wall 300 mm M Above an opening, air brick, opening window etc. 300 mm N Horizontally to an opening, air brick, opening window etc. 300 mm

Fig. 1

Page 25

INSTALLATION INSTRUCTIONS

Concentric Flue System- Type K

Horizontal concentric flue kit Ø60/100 mm polypropylene inner pipe.

Adjustable through 360°.Discharges exhaust fumes an d draws air from atmosphere.

Suitable for

condensing boilers

only. Discharges exhaust gases and draws combustion air by means of two concentric ducts. The external Ø100 duct draws the combustion air while the Ø60 plastic inner duct discharges the exhaust fumes. The discharge duct can be terminated directly to the outside or can be connected to a suitable plume management system.

MAXIMUM FLUE LENGTH: RKR 24 - 6 m RKR 28 - 6 m RKR 34 - 3 m

The maximum flue length (linear equivalent) is obtained by totalling the length of linear pipe and the equivalent lengths of each bend fitted.

The linear equivalent is intended as being the total length of the duct from the connection with the combustion chamber of the appliance, excluding the first bend.

The linear equivalent of additional bends is as follows:

Ø 60/100 x 90° bend = 0.8 m. Ø 60/100 x 45° bend = 0.5 m.

N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS FOR DISCHARGING EXHAUST GASES AND DRAWING COMBUSTION AIR.

100

163

132

Page 26

INSTALLATION INSTRUCTIONS

Concentric Flue System - Type AK50

Horizontal concentric flue kit Ø80/125 mm polypropylene inner pipe. Adjustable through 360°. Discharges exhaust fumes and draws air from atmo sphere.

Suitable for

condensing boilers

only. Discharges exhaust gases and draws combustion air by means of two concentric ducts. The external Ø125 duct draws the combustion air while the Ø80 plastic inner duct discharges the exhaust fumes. The discharge duct can be terminated directly to the outside or can be connected to a suitable plume management system.

MAXIMUM FLUE LENGTH: RKR 24 - 12 m RKR 28 - 10 m RKR 34 - 8 m

The maximum flue length (linear equivalent) is obtained by totalling the length of linear pipe and the equivalent lengths of each bend fitted.

The linear equivalent is intended as being the total length of the duct from the connection with the combustion chamber of the appliance, excluding the first bend.

The linear equivalent of additional bends is as follows:

Ø 80/125 x 90° bend = 1.6 m. Ø 80/125 x 45° bend = 0.9 m.

N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS FOR DISCHARGING EXHAUST GASES AND DRAWING COMBUSTION AIR.

132

163

125

Page 27

INSTALLATION INSTRUCTIONS

Twin Flue System- Type H

Horizontal twin pipe flue kit Ø80/80 in polypropylene adjustable through 360°.

The dual pipe system discharges exhaust fumes and draws air from atmosphere in two separate ducts.

Horizontal twin pipe flue kit Ø80/80 – Ø60/60 in polypropylene adjustable through 360°.

The dual pipe system discharges exhaust fumes into a chimney and draws air from atmosphere.

Subtracting

Suitable for

condensing boilers

only. Discharges exhaust gases and draws combustion air through two separate Ø 80 ducts.

MAXIMUM FLUE LENGTH: Ø80/80: 50 m Ø60/60: 30 m

The maximum flue length (linear equivalent) is obtained by totalling the length of linear pipe and the equivalent lengths of each bend fitted.

The linear equivalent is intended as being the total length of the duct (exhaust discharge + air intake) from the connection with the combustion chamber of the appliance, excluding the first bend.

The addition of a bend has the effect of increasing the linear equivalent length of the duct as follows:

Ø80 x 90° bend = 1.5 m. Ø80 x 45° bend = 1.2 m. Ø60 x 90° bend = 1.8 m. Ø60 x 45°bend = 1.5 m.

N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS FOR DISCHARGING EXHAUST GASES AND DRAWING COMBUSTION AIR.

131

122

137

163

106

Page 28

INSTALLATION INSTRUCTIONS

Vertical Flue System - Type CK50

Vertical concentric flue kit Ø80/125 polypropylene inner pipe.

Discharges exhaust fumes and draws air directly from roof level.

Ø125

Ø80

max. 8 m

410

310

730

Ø80

Ø125

163

131

Suitable for

condensing boilers

only. Discharges exhaust gases and draws combustion air at roof level by means of two concentric ducts. The external Ø125 duct draws the combustion air while the Ø80 plastic inner duct discharges the exhaust fumes.

MAXIMUM FLUE LENGTH: RKR 24 - 12 m RKR 28 - 10 m RKR 34 - 8 m

The maximum flue length (linear equivalent) is obtained by totalling the length of linear pipe and the equivalent lengths of each bend fitted.

The linear equivalent is intended as being the total length of the duct from the connection with the combustion chamber of the appliance .

The linear equivalent of additional bends is as follows:

Ø80/ 125 x 90° = 1.6 m. Ø80/125 x 45° = 0.9 m.

N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE SYSTEMS FOR DISCHARGING EXHAUST GASES AND DRAWING COMBUSTION AIR.

Page 29

INSTALLATION INSTRUCTIONS

Vertical Flue System - Type V

Vertical concentric flue kit Ø60/100 polypropylene inner pipe.

Discharges exhaust fumes and draws air directly from roof level.

Suitable for

condensing boilers

only. Discharges exhaust gases and draws combustion air at roof level by means of two concentric ducts. The external Ø100 duct draws the combustion air while the Ø60 plastic inner duct discharges the exhaust fumes.

MAXIMUM FLUE LENGTH: RKR 24 - 6 m RKR 28 - 6 m RKR 34 - 3 m

The maximum flue length (linear equivalent) is obtained by totalling the length of linear pipe and the equivalent lengths of each bend fitted.

The linear equivalent is intended as being the total length of the duct from the connection with the combustion chamber of the appliance, excluding the first bend.

The linear equivalent of additional bends is as follows:

Ø60/100 x 90° = 0.8 m. Ø60/100 x 45° = 0.5 m.

N.B.: USE ONLY RADIANT TYPE-APPROVED FLUE

Ø100

Ø60

131

730

285

410

163

max 6 m

Ø60

Ø100

Page 30

INSTALLATION INSTRUCTIONS

4. COMMISSIONING THE APPLIANCE

4.1 General warnings

The following operations must be carried out by professionally qualified personnel and Gas Safe Registered in accordance with current legislation. Reference should be made to BS 5449:5 “Commissioning”.

The boiler leaves the factory pre-set and tested for burning either natural Gas or LPG. Nevertheless,

when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler and check that the correct C02 value is present as stated in Section 4.5.

Once the system has been filled and the necessary adjustments made, remember to tighten the screws of the gas valve test point and make sure that there are no gas leaks from the test point and from any pipe fittings upstream of the gas valve.

The BENCHMARK commissioning record contained in this book should be completed.

■ Preliminary operations

Switching the boiler on for the first time means checking that the installation, regulation and operation of the appliance are correct :

• If the gas supply system is newly installed, then the air present in the pipes can cause the boiler not to light at the first attempt. A number of attempts may be required in order to light the boiler;

• Check that the data on the data plate corresponds to that of the mains supply networks (gas, electricity, water));

• Check that the power supply voltage to the boiler complies with the data plate (230 V – 50 Hz) and that the live,

neutral and earth wires are connected properly. Also make sure that the earth connection is sound;

• Check the seals on the gas supply pipe from the mains, and make sure that the meter does not register any flow of gas;

• Turn the gas supply on and purge according to in GB BS6891.

• Test for gas soundness.

• Check that the gas supply is correctly sized for the flow rate required by the boiler and that it is fitted with all the

safety and control devices as lay down by current regulations

• Check that the supply of combustion air and exhaust and condensate discharge systems are functioning correctly and in line with current law and national and local standards;

• Check for the presence of permanent aeration/ventilation openings as required by current law for the type of appliances installed.

• Check that the flue duct and its connections to the terminal/chimney comply with the requirements of current law and national and local standards for the type of appliances installed and are to the manufacturers specification.

• Make sure that any central heating isolation valves are open.

• Check that the condensate drain system, including outside the boiler (flue system condensate collection

devices), allows the condensate to flow freely to the collection devices. If the condensate is discharged to the domestic drainage system, install an inspection trap in the condensate system prior to it entering the drainage system to interrupt the continuity between the two systems.

• Check that there are no exhaust fumes discharged into the condensate drain system itself.

• Check that there are no flammable materials or liquids in the immediate vicinity of the boiler;

• Flush out both primary and domestic hot water circuits (see 4.3 “ Flushing the system”).

Page 31

INSTALLATION INSTRUCTIONS

4.2 Filling the system

Use only a WRAS approved filling loop for

connection and filling of the primary system. This should be disconnected when not in use.

Check the properties of the water supply and

install the appropriate treatment devices if the mains water has a hardness rating more than

17.5 °Ck in order to prevent scaling and eventual damage to the D.H.W heat exchanger.

Use only clean tap water to fill the system.

Once the water pipes have been connected, close the gas feed valve and fill the system as follows:

• Check that the circulation pump runs freely;

• Check that the plug of the air vent valve has been

slackened slightly to allow air to escape from the system (see fig.1);

• Open the main domestic water supply valve;

• Open the external filling loop (see fig.3);

• Unscrew the plug on the pump to remove any

trapped air, check that the pump is free then retighten it when water starts to flow out;

• Open the air vents on the radiators and monitor the

air evacuation process. When water starts to flow out of the radiators, close the air vents;

• Use the pressure gauge M (see fig. 2) to check that

the system pressure reaches 1 bar and that the code H2O does NOT appear on the control panel display (see 2.7 “Control Pane”’);

• If, after the above operations, there is a reduction

in the pressure, re-open the external filling loop until the pressure gauge reads 1 bar and that the code H

O disappears on the control panel display;

• On completion, make sure that the external

filling loop is completely closed.

Emptying the central heating system

Whenever it is necessary to empty the system, proceed as follows:

• turn off the main power supply switch;

• wait for the boiler to cool down;

• turn the system drain tap RS (see fig. 2) and use a

container to collect the water that runs out;

Emptying the domestic hot water system

Whenever there is danger of freezing or any other occurrence, the hot water system could be emptied in the following way:

• Shut off the water at the mains;

• Open all hot and cold water taps;

• Empty from the lowest point (where possible).

PUMP PLUG

PUMP

AIR VENT VALVE PLUG

AIR VENT VALVE

CWI

12-00710

OPTIONAL

Fig. 2

Fig. 1

Fig. 3

Page 32

INSTALLATION INSTRUCTIONS

4.3 Filling the condensate trap

The condensation trap must be pre-filled when starting the boiler for the first time in order to prevent flue gases from flowing back through the trap.

The filling operation is carried out as follows (see fig. 1):

• Remove plug T and fill the trap S three

quarters full with water;

• Replace plug T and connect the drainpipe

P into a condensate discharge trap

conforming to current legislation;

Attention! It is recommended to clean the condensate trap, after a few months of boiler operation and periodically to remove any deposits/residuals that may interfere with correct operation.

Fig. 1

Page 33

INSTALLATION INSTRUCTIONS

4.4 Starting up the boiler

Once the system has been filled, proceed as follows:

• Check that the exhaust flue is free of obstructions and correctly connected to the boiler;

• Switch on the power supply to the boiler;

• Open the gas isolation valve;

• Place switch 1 in the ON position (see

2.7 “Control Panel”), after a few seconds the circulating pump will start to run;

• Use button 6 to set the SUMMER, WINTER or SUMMER/WINTER function. The symbols

will light up (fixed light) to indicate that

the boiler is working;

• The automatic ignition system will then light the burner. This operation is repeated for 3 times. It may however be necessary to repeat the operation in order to eliminate all the air from the pipes. To repeat the operation, wait approximately three minutes before reattempting to light the boiler. To reset the boiler Switch off switch 1 (see 2.7 “Control Panel”) and switch it back on again and repeat the lighting procedure;

• With the boiler ignited, if the system still emits noises, the operations must be repeated until all the air has been removed;

• Check the pressure in the system. If the pressure has fallen, re-open the filling tap until the code H2O disappears on the display and the pressure gauge reads 1.5 bar, on completion, close the filling tap.

• Unscrew the aluminium plug and insert an analyser in the exhaust sampling point PF (see fig. 1) to check the CO2 value. Make sure that the value complies with that reported in table 1;

• If the CO2 value does not correspond to the specified value, adjust screw V (see fig. 1) on the venturi clockwise to reduce the CO2 value or anticlockwise to increase it

;

Table n°1

RKR 24

RKR 28 RKR 34

Gas type CO2 % CO2 % CO2 %

Methane - G20 9.1 9.4 9.18 Liquid Butan Gas - G 30 11.1 10.9 10.3 Liquid Propane Gas - G 31 10.1 10.96 10.3

Fig. 1

Page 34

REGULATION INSTRUCTIONS

5. REGULATING THE APPLIANCE

5.1 Parameters table

NOTES:

P04 – This parameter allows adjustment of the time taken to reach the maximum heating load. (Heating curve). P10, P11, P12 – These parameters are automatically adjusted according to the value set in parameter P00. P13 –Range rating of maximum heating load according to the graph “Heating power (Kw) – Fan frequency (Hz)” on Page

39. P15 - If the heating system has more than one zone, an additional interface board (optional extra) can be installed on the circuit board and parameter 15 set at 01. P16 - To install the telephone control, use non-polarised conductors connected to contact TA of the terminal board in

parallel with the remote control if fitted. Set the parameter 16 at 01.

PARAMETER N° TYPE OF OPERATION PARAMETER VALUE FUNCTION

P00 Selects the model of boiler

01(default)

02 03 04

00 = 24Kw 01 = 28Kw

02 = 29Kw 03 = 34 Kw 04 = 50 Kw

P01 Selects the type of boiler

00 01 02

00 = Instantaneous

01 = Boiler with storage tank

02 = B. w/storage tank Comfort (+7°C)

P02 Selects the type of gas

00 01

00 = Natural gas

01 = Lpg

P03

Sets the central heating

temperature

00 01

00 = Standard (30-80°C)

01 = Reduced (25-40°C )

P04 Heating output rising time

01(default)

02 03 04

00 = 0sec

01 = 50 sec 02=100 sec 03=200 sec 04=400 sec

P05

Water hammer prevention

function

00 01

00 = Off 01 = On

P06 D.H.W priority function

00 01

00 = Off 01 = On

P07 Central heating timer 00-90 (default = 36)

Delays the heating restart to prevent

frequent On/Offs, Expressed in steps of 5

sec (factory set at 36 x 5 = 180”)

P08

Central heating pump overrun

timer

00-90 (default = 36)

The overrun timer can be modified.

Expressed in steps of 5 sec (factory set

at 36 x 5 = 180”)

P09 D.H.W pump overrun timer 00-90 (default = 18)

The overrun timer can be modified.

Expressed in steps of 5 sec (factory set

at 18 x 5 = 90”)

P10 Minimum fan speed setting Preset

To set the minimum frequency value (Hz)

for the fan operation

P11 Maximum fan speed setting Preset

To set the maximum frequency value

(Hz) for the fan operation

P12

Minimum fan speed setting

(Central Heating)

Preset

To set the minimum frequency value (Hz)

for the fan operation in heating mode

P13

Maximum fan speed setting

(Central Heating)

Adjustable

To set the maximum frequency value

(Hz) for the fan operation in heating

mode

P14 Ignition sequence setting 33-203

To set the fan frequency value (Hz) at the

ignition

P15

Zone management board

activation

00 01

00 = Off 01 = On

P16 Telephone control activation

00 01

00 = Off 01 = On

P17 Fan frequency value display

00 01

00 = Off 01 = On

Page 35

REGULATION INSTRUCTIONS

5.2 Setting the parameters

To modify the preset values of the parameters reported in the previous table, open the parameter settings menu as follows:

1. Place the On/Off switch in the OFF position.

2. Activate the On/Off switch while keeping buttons ‘+’ and “-“ pressed. Wait for “P 00” to appear on the display.

3. Release buttons ‘+’ and ‘-’.

4. Keep button ‘S’ pressed and use button ‘+’ to select the parameter to modify.

5. Release button ‘S’, then re-press and release it. The display will indicate the value of the parameter to modify.

Adjust the value of the parameter using the procedure described in the following pages.

To enter the parameters menu, follow the previously described procedure (steps 1-5).

OFF

P 00

P 01

Page 36

REGULATION INSTRUCTIONS

PARAMETER P00 – SELECTS THE MODEL OF BOILER

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = 24 Kw 01 = 28 Kw (default) 02 = 29 Kw 03 = 34 Kw 04 = 50 Kw

7. Press and release button ‘S’ to confirm. The parameter number (P00) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER P01 – SELECTS THE TYPE OF BOILER

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = instantaneous boiler 01 = storage boiler 02 = boiler with storage tank Comfort (+7°C)

7. Press and release button ‘S’ to confirm. The parameter number (P01) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P02 – SELECTS THE TYPE OF GAS

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = Natural Gas 01 = LPG

7. Press and release button ‘S’ to confirm. The parameter number (P02) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P03 – SETS THE CENTRAL HEATING

TEMPERATURE

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = standard (30-80°C) 01 = reduced (25-40°C) for under-floor heating.

7. Press and release button ‘S’ to confirm. The parameter number (P03) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

P 00

P 03

P 02

P 01

Page 37

REGULATION INSTRUCTIONS

PARAMETER P04 – HEATING OUTPUT RISING TIME

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = 0 seconds

01 = 50 seconds (default) 02 = 100 seconds 03 = 200 seconds 04 = 400 seconds

7. Press and release button ‘S’ to confirm. The parameter number (P04) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P05 –

WATER HAMMER PREVENTION

FUNCTION

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = off 01 = on (default = 2”)

7. Press and release button ‘S’ to confirm. The parameter number (P05) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P06 – D.H.W PRIORITY FUNCTION

It keeps 3 way valve in D.H.W. production position, for a period equals to D.H.W. pump overrun, so that plate exchanger is kept hot.

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter: 00 = off 01 = on (default =120”);

7. Press and release button ‘S’ to confirm. The parameter number (P06) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

P 06

P 05

P 04

Page 38

REGULATION INSTRUCTIONS

PARAMETER P07 – CENTRAL HEATING TIMER

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter within the prescribed limits: 00 = 0 x 5” = 0” 90 = 90 x 5” = 450” (7,5 min) The default value is 36 = 180” = 3 min

7. Press and release button ‘S’ to confirm. The parameter number (P07) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P08 – CENTRAL HEATING PUMP

OVERRUN TIMER

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter within the prescribed limits: 00 = 0 x 5” = 0” 90 = 90 x 5” = 450” (7,5 min) The default value is 36 = 180” = 3 min

7. Press and release button ‘S’ to confirm. The parameter number (P08) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P09 – D.H.W PUMP OVERRUN TIMER

6. Use buttons ‘+’ and ‘-‘ to modify the value of the parameter within the prescribed limits: 00 = 0 x 5” = 0” 90 = 90 x 5” = 450” (7,5 min) The default value is 18 = 90” = 1.5 min

7. Press and release button ‘S’ to confirm. The parameter number (P09) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

P 07

P 08

P 09

Page 39

REGULATION INSTRUCTIONS

PARAMETER P10 – MINIMUM FAN SPEED SETTING

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between: min = 33 Hz ; max = 133 Hz. The default value is adjusted according to the output set in parameter P00.

7. Press and release button ‘S’ to confirm. The parameter number (P10) will appear on the display .

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER P11 – MAXIMUM FAN SPEED SETTING

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between: min = value of parameter P10; max = 203 Hz. The default value is adjusted according to the output set in parameter P00.

7. Press and release button ‘S’ to confirm. The parameter number (P11) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER P12 – MINIMUM FAN SPEED SETTING (CENTRAL HEATING)

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between: min = 33 Hz ; max = 133 Hz. The default value is adjusted according to the output set in parameter P00.

7. Press and release button ‘S’ to confirm. The parameter number (P12) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P13 – MAXIMUM FAN SPEED SETTING (CENTRAL

HEATING)

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between: min = value of parameter P12 ; max = 203 Hz. The default value is adjusted according to the output set in parameter P00.

7. Press and release button ‘S’ to confirm. The parameter number (P13) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

168

P 13

P 12

168

P 11

P 10

Page 40

REGULATION INSTRUCTIONS

PARAMETER P14 – IGNITION SEQUENCE SETTING

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between: min = 33 Hz; max = 203 Hz. The default value is adjusted according to the output set in parameter P00.

7. Press and release button ‘S’ to confirm. The parameter number (P14) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER P15 – ZONE MANAGEMENT BOARD ACTIVATION

6. If the system is fitted with zone valves, set the parameter at ‘01’. If a remote control is installed, an extra interface board must be installed to control the zone valves. Then set the parameter at ‘01’.

7. Press and release button ‘S’ to confirm. The parameter number (P15) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

PARAMETER

P16 – TELEPHONE CONTROL ACTIVATION

6. If a telephone interface is installed, enable the board by setting parameter P16 at ‘01’.

7. Press and release button ‘S’ to confirm. The parameter number (P16) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

N.B.: The connection of the telephone interface to contact TA of the terminal board must be wired in parallel with the remote control using two non-polarised conductors.

PARAMETER

P17 – FAN FREQUENCY VALUE DISPLAY

6. Use buttons ‘+’ and ‘-’ to modify the value of the parameter between:

- 00 = Off;

- 01 = On. If parameter value 01 is selected, during the boiler operation, the display will show the fan frequency value for 10 min.

7. Press and release button ‘S’ to confirm. The parameter number (P17) will appear on the display.

8. Switch off the appliance and switch it back on again to render the new parameter operative.

P 17

P 16

P 15

P 14

Page 41

REGULATION INSTRUCTIONS

5.3 Gas data

Technical data tables – RKR 24

Gas data table

NATURAL GAS

G20

LIQUID BUTANE GAS

G30

LIQUID PROPANE

GAS G31

Indice di Wobbe inferiore (15°C; 1013 mbar)

MJ/Nm

45.67 80.58 70.69

Pressione nominale di alimentazione

mbar 20 30 37

Consumi (15°C; 1013 mbar)

m3/h 1.90 - -

Consumi (15°C; 1013 mbar

)

kg/h - 1.42 1.4

Heating Power (kW) – Fan frequency (Hz) diagram

G 31

G 30

G20

Values

Gas type CO2 %

Natural gas - G20 9.1 Liquid Butan Gas - G 30 11.1 Liquid Propane Gas - G 31 10.1

Frequency

Gas type Minimum (Hz)

Maximum Central

Heating (Hz)

Maximum D.H.W.(Hz)

Natural gas - G20 38 145 185 Liquid Butan Gas - G 30 43 135 170 Liquid Propane Gas - G 31 50 143 183

Page 42

REGULATION INSTRUCTIONS

Technical data tables - RKR 28

Gas data table

NATURAL GAS

G20

LIQUID BUTANE

GAS G30

LIQUID PROPANE

GAS G31

Indice di Wobbe inferiore (15°C; 1013 mbar)

MJ/Nm

45.67 80.58 70.69

Pressione nominale di alimentazione

mbar 20 30 37

Consumi (15°C; 1013 mbar)

m3/h

2.65 - -

Consumi (15°C; 1013 mbar)

kg/h

- 1.97 1,94

Heating Power (kW) – Fan frequency (Hz) diagram

G20

G30 / G31

Values

Gas type CO2 %

Natural gas - G20 9.4 Liquid Butan Gas - G 30 10.9 Liquid Propane Gas - G 31 10.96

Frequency

Gas type Minimum (Hz) Maximum Central Heating (Hz) Maximum D.H.W. (Hz)

G 20

66 162

185

G 30

60 149

175

G 31

60 149

178

Page 43

REGULATION INSTRUCTIONS

Technical data tables – RKR 34

Heating Power (kW) – Fan frequency (Hz) diagram

G20 G30 / G31

Tab

le no.1

- CO

Values

Gas type CO2 %

Natural gas - G20 9.18 Liquid Butan Gas - G 30 10.3 Liquid Propane Gas - G 31 10.3

Table no.2

- Frequency

Gas type Minimum (Hz) Maximum (Hz)

Natural gas - G20 55 164 Liquid Butan Gas - G 30 52 155 Liquid Propane Gas - G 31 52 155

Table no.3 - Gas data table

NATURAL GAS

G20

LIQUID BUTANE GAS

G30

LIQUID PROPANE GAS

G31

ower Wobbe index (15°C; 1013 mbar)

MJ/Nm

45.67 80.58 70.69

Nominal Supply pressure mbar 20 30 37 Consumption

(15°C; 1013 mbar)

m3/h 3.6 - -

Consumption

(15°C; 1013 mbar)

kg/h - 2.68 2.64

Page 44

REGULATION INSTRUCTIONS

5.4 Converting the boiler to a different gas type

All maintenance operations must be carried out by professionally qualified and Gas Safe Registered

personnel and the BENCHMARK Annual Service Record completed.

Check that the gas supply pipe is suitable for the new fuel type.

Conversion is performed as follows:

• Select the new gas type by changing parameter no.P02 (see ‘Parameters table’ 5.2);

• Unscrew the aluminium plug and insert the analyser in the exhaust sampling point PF (see fig.1 paragraph

4.4) to check the CO value. Make sure that the value complies with that reported in table 1 (paragraph 4.4);

• If the CO2 value does not correspond to the specified value, adjust screw V (see fig. 1 paragraph 4.4) on the venturi clockwise to reduce the CO2 value or anticlockwise to increase it;

Page 45

MAINTENANCE INSTRUCTIONS

6. Annual Service and Maintenance

6.1 General Warnings

All maintenance operations must be carried out by professionally qualified and Gas Safe Registered

personnel and the BENCHMARK Annual Service Record completed.

The frequency of boiler maintenance must comply with current law and, nevertheless, should be

carried out once a year.

In order to guarantee the long life of the appliance and in accordance with the current gas safety

regulations, only use Radiant original spare parts.

Before carrying out any type of maintenance operation, disconnect the appliance from the mains

electricity supply and close the gas valve.

6.2 Boiler inspection

In order to ensure that the boiler operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year. The following operations should be carried out annually

■ Check the condition of the gas seals and replace where necessary.

■ Check the condition of the water seals and replace where necessary.

■ Visually inspect the condition of the combustion chamber and flame.

■ When required, check that the combustion is correctly regulated and if necessary proceed in line with section

“Commissioning the boiler”.

■ Remove and clean any oxidation from the burner.

■ Check that the seal of the room-sealed chamber is undamaged and positioned correctly.

■ Check the primary heat exchanger and clean if necessary.

■ Check the maximum and minimum modulation pressures and the modulation itself.

■ Check the condition and operation of the ignition and gas safety systems. If necessary, remove and clean the

scaling from the ignition and flame detection electrodes, paying particular attention to replace them at the correct distance from the burner.

■ Check the heating safety systems: temperature limit safety thermostat, pressure limit safety device.

■ Check the pre-fill pressure of the expansion vessel (see expansion vessel data plate).

■ For safety reasons, periodically check the integrity and operation of the flue gas exhaust system.

■ Check that the connection to the mains electricity supply complies with that reported in the boiler’s instruction

manual.

■ Check the electrical connections inside the control panel.

■ Check the D.H.W flow rate and temperature.

■ Check that the condensate drain system is working correctly, including any parts of the system outside the boiler

such as condensate collection devices along the length of the flue and/or any acid neutralising devices.

■ Check that the condensate flows freely and that there are no exhaust fumes present within the appliance.

Page 46

MAINTENANCE INSTRUCTIONS

6.3 Accessing the boiler

All maintenance operations require one or more of the boiler casing panels to be removed.

The side panels can only be removed after the front panel has been removed.

Front panel:

 Remove the fixing screws at the lower edge of the

front panel.

 Grasp the lower part of the panel and pull it

outwards (see fig. 1) and then up (see fig. 2).

Left and right side panel:  Remove the fixing screws at the front and lower

edge of the side panel to remove.

 Grasp the bottom of the panel, move it sideways

and then upwards to remove it.

To access the electrical connections of the control panel, proceed as follows:

• Remove the front panel (see fig. 1 and fig. 2).

• Grasp the left and right control panel support

brackets (see fig. 5) and pull them outwards, at the same time rotating the panel downwards.

• Unscrew the four fixing screws (see fig. 6) and

remove the panel back piece.

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Page 47

MAINTENANCE INSTRUCTIONS

6.4 Draining the central heating system

If the need arises to drain the system, this can be done as follows:

• Switch the system to “WINTER” mode and ignite the

boiler.

• Switch off the power supply to the boiler.

• Wait for the boiler to cool down.

• Connect a hosepipe to the system drain point and

locate the other end of the hose in a suitable drainage system.

• Open the system drain valve (see fig. 1).

• Open the air vents on the radiators, starting with the

highest and moving down the system to the lowest.

• When the system has been drained, close the

radiator breather valves and the drain valve.

• If only the boiler needs to be drained, close the

flow/return isolating valves on the heating circuit and open the drain valve located at the bottom of the boiler on the pump manifold (see fig. 1);

■

Draining the domestic hot water system

If there is a danger of freezing, the domestic hot water system should be drained. This can be done as follows:

• Close the mains water supply valve.

• Open all the hot and cold water taps.

• On completion, close all the previously opened taps.

Fig. 1

Page 48

MAINTENANCE INSTRUCTIONS

6.5 Maintenance operations

Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY,

WATER

and GAS supplies to the boiler.

Radiant Bruciatori s.p.a. will not be held responsible for damage to any of the boiler’s components

caused by non-compliance with this instruction.

For all maintenance operations requiring removal of the boiler casing, refer to the procedures described in paragraph 6.3 “Accessing the boiler”.

ignition electrode

ignition transformer

primary heat exchanger

gas valve

3 way diverter valve

safety thermostat

burner unit

electric fan

heating sensor

circulating pump

d.h.w sensor

d.h.w heat exchanger

condensate drain trap

Fig. 1

ionisation electrode

expansion vessel

Page 49

MAINTENANCE INSTRUCTIONS

Cleaning the main exchanger module and combustion unit (see fig. 1)

• Disconnect the electrical connections of the

electric fan.

• Disconnect the joint and remove the pipe linking

the gas valve to the injector unit (venturi).

• Disconnect the joint and remove the gas feed

pipe from the gas valve.

• Un-plug the ignition electrode and flame

detection wires from the ignition control unit.

• Unscrew the ring-nut at the bottom of the room-

sealed chamber and remove the gas valve.

• Unscrew the nuts securing the burner unit

(consisting of a fan, manifold and burner) to the primary heat exchanger.

• Remove the burner unit, paying particular

attention not to remove the ceramic fibre protection from the bottom of the heat exchanger.

• Check that the burner is not affected by deposits,

scaling or excessive oxidation. Check that all the holes in the burner are free;

• Clean the electrodes carefully without altering

their positions with respect to the burner;

• Clean the burner cylinder using a non-metal

brush and without damaging the ceramic fibre;

• Check the integrity of the washer on the cover of

the burner;

• Clean the heat exchanger (see fig. 2) using a

household detergent for stainless steel, distributing the product on the spirals of the exchanger using a brush. Do not wet the ceramic fibre coating. Wait a few minutes then remove the deposits using a non-metal brush. Then remove the residues under running water;

• Remove the pipe clip, remove the condensate

drainpipe and clean under running water.

• Unscrew the joint to the condensate trap, remove the trap and wash under running water.

•

With the cleaning completed, re-assemble the components following the above procedure in reverse order and replacing washers where necessary.

•

Finally, check the soundness to make sure that all gas and exhaust joints are tight.

primary heat exchanger

flue connection chamber

stainless steel pipe coil

ceramic fibre washer

Fig. 2

Fig. 1

premix burner unit

burner

ionisation

electrode

ignition

electrode

primary heat exchanger

Page 50

MAINTENANCE INSTRUCTIONS

Cleaning the D.H.W heat exchanger

(see fig. 1)

• Close the shut-off valve and drain the domestic hot

water circuit and central heating circuit of the boiler;

• Use a 4 mm Allen key to unscrew the two screws

securing the heat exchanger to the multiplex unit;

• Remove the heat exchanger from the left side of the

boiler, note its orientation;

• De-scale the heat exchanger by chemically washing

the plates

• Fit new rubber washer, inserting them in their

housings on the multiplex unit;

• Re-assemble the heat exchanger and components

following the above procedure in reverse order;

• Fill the system with water and check for any leaks

from the joints.

Part replacement

Ignition and/or flame detection electrodes (see fig. 2)

• Un-Plug the electrode wires;

• Slacken the fixing screws;

• Remove the electrodes. When fitting the new ones,

check that the seals are not damaged. Replace if necessary;

• Reconnect the wires and re-assemble the

components following the above procedure in reverse order;

• Switch on the power supply and restart the

appliance;

If the boiler does not restart, check the positions of

the electrodes (especially the ignition electrode). Make sure that original position and distances between the electrodes and the burner are respected to avoid a boiler malfunction).

Fig. 1

d.h.w heat exchanger

fixing screws

Fig. 2

ionisation electrode

ignition electrode

Page 51

MAINTENANCE INSTRUCTIONS

POSITIONING THE IGNITION ELECTRODE AND THE IONISATION ELECTRODE

0.5

3.5

Page 52

MAINTENANCE INSTRUCTIONS

Safety thermostat

(see fig. 1)

• Disconnect the connecting wire;

• Unscrew the fixing screws and remove the

thermostat;

• Replace the thermostat and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies and

restart the appliance.

Heating sensor

(see fig. 1)

• Un-Plug the connecting wire;

• Replace the sensor and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies,

open the shut-off valves and fill the central heating circuit. Then restart the appliance, remembering to discharge any air that may be trapped in the system;

Gas valve

(see fig. 2)

• Disconnect the joints and remove the gas pipe

connecting the gas valve to the venturi.

• Disconnect the gas feed pipe and valve ring-nut at

the bottom of the room-sealed chamber.

• Remove the flanged elbow coupling of the existing

valve and fit it to the new valve; also fit a new cork washer.

• Replace the gas valve and re-assemble the

components following the above procedure in reverse order.

• Replace all the gas seals.

• Fully tighten the gas connections.

• Switch on the electricity, water and gas supplies and

carry out gas soundness test.

gas valve

Fig. 2

heating sensor

safety thermostat

Fig. 1

Page 53

MAINTENANCE INSTRUCTIONS

Electric fan

(see fig. 1)

• Remove and dismantle the entire burner unit (see

6.6.1 “Cleaning the burner unit”).

• Use an 8 mm spanner to unscrew the four nuts

securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer and diaphragm.

• Remove the air intake duct, unscrew the two fixing

screws from the venturi and remove the electric fan, paying particular attention not to damage the cork gasket.

• Replace the electric fan and re-assemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies and

check the soundness of the joint by measuring the CO

levels;

Expansion vessel

(see fig. 2)

• Close the shut-off valves and drain the central

heating circuit of the boiler.

• Use a 19 mm spanner to unscrew the pipe coupling

to the vessel.

• Unscrew the fixing screws and remove the upper

mounting bracket. Remove the expansion vessel from the front of the boiler.

• Replace the expansion vessel and re-assemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies

and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit;

D.H.W heat exchanger

(see fig. 3)

•

Close the shut-off valve and drain the domestic hot water circuit and central heating circuit of the boiler.

• Use a 4 mm Allen key to unscrew the two screws

securing the heat exchanger to the multiplex unit.

• Remove the heat exchanger from the left side of the

boiler, note its orientation.

• Fit new rubber washer, inserting them in their

housings on the multiplex unit.

• Replace the heat exchanger and re-assemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies, fill

the system with water and check for any leaks from the joints.

fixing bracket

expansion vessel

Fig. 2

venturi

electric fan

Fig. 1

d.h.w heat exchanger

fixing screws

Fig. 3

Page 54

MAINTENANCE INSTRUCTIONS

Circulating pump

(motor body) (see fig. 1)

• Close the shut-off valves and drain the central

heating circuit of the boiler;

• Use a 5 mm Allen key to unscrew the four screws

securing the motor body to the impeller body;

• Remove the motor body and check the condition of

the washer. If necessary, replace the washer;

• Replace the circulation pump and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies

and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the boiler.

Diverter valve

(see fig. 2)

Replacing the motor

• Unscrew the fixing screws securing the transparent

cover of the diverter valve and remove the cover;

• Unscrew the two motor fixing screws and

disconnect the wires;

• Replace the motor and re-assemble the

components following the above procedure in reverse order;

• Replace the motor and re-assemble the

components following the above procedure in reverse order;

Replacing the diverter valve body

• Close the shut-off valves and drain the central

heating circuit of the boiler;

• Unscrew the fixing screws securing the transparent

cover of the diverter valve and remove the cover;

• Unscrew the four fixing screws and remove the

diverter valve body and washer;

• Replace the valve body and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies

and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the boiler.

diverter valve body

diverter valve motor

Fig. 1

circulating pump

Fig. 2

Page 55

MAINTENANCE INSTRUCTIONS

Modulation circuit board

(see fig. 1-2)

• Open the control panel (see 6.3 “Accessing the

boiler”);

• Disconnect all the connectors, remove the regulating knobs, unscrew the four fixing screws and remove the modulation circuit board;

• Replace the circuit board and re-assemble the components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies

and regulate the boiler (see 5.3 “Gas data”);

When replacing the modulation circuit

board, it’s necessary to set parameter P00 according to the boiler model (24-28-29-34-

50).

modulation circuit board

Fig. 1

Fig. 2

modulation circuit board

Page 56

MAINTENANCE INSTRUCTIONS

Primary heat exchanger

(see fig. 1)

• Close the shut-off valves and drain the central heating circuit of the boiler;

• Switch off the power and gas supply to the boiler;

• Remove and dismantle the entire burner unit

(see 6.6.1 “Cleaning the condensation module and burner unit”);

• Remove the gas valve;

• Remove the spring and then the condensate

drainpipe;

• Remove the fixing springs and then the delivery and return pipes;

• Remove the support brackets and pull out the heat exchanger;

• Remove the regulation sensor from the old heat exchanger and refit it together with the two condensate drainpipes to the new one;

• Replace the heat exchanger and re-assemble the components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the boiler, making sure that there are no gas leaks;

primary heat exchanger

flue connection chamber

steinless steel pipe coil

ceramic fibre washer

Fig. 1

Page 57

MAINTENANCE INSTRUCTIONS

6.6 Wiring diagrams

Electrical connections

EXHAUST FAN type RG128/1300-3612

PRINTED CIRCUIT BOARD DIGITECH 2 - SM30003

COD. 40-00016

M1 M2

M10

Heating

D.H.W.

IG SR S S

Pacq

EV1

EV2

Tra

TF1

TF2

orange

light-blue

brown

red / black

black

white/black

brown

light-blue

brown

light-blue

black

brown

light-blue

EV2 B

EV1 A

EV1 B

EV2 A

red

light-blue

brown

light-blue

brown

Storage cylinder timer (option)

for storage boilers only

orange

brown

violet

orange

M10

orange

black

M11M11

M11

brown

light-blu e

Key

IG: Main Switch TF: Thermo Fuse 102 °C TS: Safety thermostat SR: Heating sensor SS: DHW sensor EV: Fan ER: lonisation electrode EA: Ignition electrode TRA:Ignition transformer VD: 3-way valve C: Circulating pump MF: Flowswitch micro PACQ : Water pressure switch

Page 58

MAINTENANCE INSTRUCTIONS

Connecting a room thermostat or external timer/control (Option)

Connect the wires to the terminal board inside the instrument panel as follows: (Example with WEEK digital weekly chronostat):

a. switch off the power supply at the main switch. b. remove the front case panel of the boiler. c. slacken the screws and remove plate A (see fig.1). d. remove jumper TA -TA from the terminal board B; e. connect the room thermostat/chronostat wires;

When the wires have been connected, place plate “A" back to position and then the front case panel.

Connecting the outside temperature sensor (Option)

Connect the wires to the terminal board inside the instrument panel as follows:

a. switch off the power supply at the main switch. b. remove the front case panel of the boiler. c. slacken the screws and remove plate A (see fig.1). d. connect the outside temperature sensor on contacts marked as SE-SE on the terminal board B ;

When the wires have been connected, place plate “A" back to position and then the front case panel.

L N Ta Se Se

TELEPHONE CONTROL

CHRONOSTAT REMOTE

Outside temperature sensor

Optional:

Fig. 1

Page 59

MAINTENANCE INSTRUCTIONS

REMOTE "OPEN THERM"

SeSe

TaNL

Outside

temperature

sensor (option)

L N Ta

REMOTE "OPEN THERM"

Telephone control

Connecting a remote controller and the outside temperature sensor (option)

Connect the wires to the terminal board inside the instrument panel as follows:

a. switch off the power supply at the main

switch.

b. remove the front case panel of the

boiler.

c. slacken the screws and remove plate A

(see fig.1).

d. remove jumper TA-TA from the terminal

board B;

e. connect the remote controller wires.

When the wires have been connected, place plate “A" back to position and then the front case panel.

Connecting a remote controller and the telephone control (option)

Connect the wires to the terminal board inside the instrument panel as follows:

a. switch off the power supply at the main

switch.

b. remove the front case panel of the

boiler.

c. slacken the screws and remove plate A

(see fig.1).

d. remove jumper TA-TA from the terminal

board B;

e. connect the remote controller and the

telephone control wires;

f. Active the telephone control through the

parameter no.16 (see 5.1 “Parameters Table”)

When the wires have been connected, place plate “A" back to position and then the front case panel.

Fig. 2

Fig. 1

cod. 40-00017

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MAINTENANCE INSTRUCTIONS

Regulating the Flow temperature in accordance with the outdoor temperature

The outdoor sensor has to be connected directly to circuit board SM30003. The sensor can thus be managed in one of two ways:

• In case of

RADIANTS remote controller + outdoor temperature sensor installation, the climatic compensation

curve is set by the remote itself (see remote control installation and operating manual).

• In case of outdoor temperature sensor only installation, the climatic compensation curve is set using the central

heating control knob. As the knob (see fig. 2) is rotated, the numbers corresponding to the curve shown in

figure 1 are displayed The factors governing the correction is reported in figure 1. The selection of the compensation curve is determined by the maximum delivery temperature Tm and the minimum

outdoor temperature Te.

N.B. The y-axis values of the delivery temperature Tm refer to standard 80-30 °C appliances or 40-25 °C flo or- mounted appliances. The type of appliance can be programmed using parameter 3 (see 5.1 “Parameter programming”).

OUTDOOR SENSOR

DELIVERY TEMPERATURE CORRECTION AS A FUNCTION OF OUTSIDE

TEMPERATURE WITH RESPECT TO THE POSITION OF THE HEATING

TEMPERATURE CONTROL SET BY THE USER

TM-MAX/MIN = delivery temperature range selected

MIN

27 26

45 40

60 55

192425 23 2122 20 1618 17 15 14

MAX40 80

Te = Outdoor temperature Tm = delivery temperature

-121012 11 89 7 56 4 23 1 -6-3-10 -2 -4 -5 -9-7 -8 -10-11

6 5

Te (°C)

-15-13 -14

Fig. 1

Fig. 2

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MAINTENANCE INSTRUCTIONS

6.7 Troubleshooting

ERROR

CODE

PROBLEM

POSSIBLE CAUSE

REMEDY

E01

NO FLAME

WITH NO IGNITION

NO GAS.

IGNITION ELECTRODE BROKEN OR EARTHED.

GAS VALVE MALFUNCTION

MECHANICAL MINIMUM ADJUSTMENT (ON GAS VALVE) SET TOO LOW OR SLOW IGNITION ADJUSTMENT SET TOO LOW.

GAS VALVE INLET PRESSURE TOO HIGH (FOR LPG BOILERS ONLY );

WITH IGNITION

POWER SUPPLY LIVE AND NEUTRAL WIRES INVERTED.

IONISATION ELECTRODE MALFUNCTION.

IONISATION ELECTRODE CABLE DISCONNECTED.

CHECK MAINS SUPPLY.

REPLACE PART.

REPLACE PART

REGULATE MECHANICAL MINIMUM OR SLOW IGNITION.

CHECK THE MAXIMUM PRESSURE SETTING.

CONNECT THE POWER SUPPLY WIRES CORRECTLY.

REPLACE PART.

CONNECT THE IONISATION ELECTRODE WIRE.

E02

SAFETY THERMOSTAT TRIPPED (95°C)

THERMOSTAT MALFUNCTION OR OUT OF CALIBRATION.

THERMOSTAT CABLE DISCONNECTED.

REPLACE PART.

CHECK THE WIRING ;

E03

FLUE SAFETY THERMOSTAT

THERMOSTAT BROKEN;

THERMOSTAT CABLE DISCONNECTED;

THERMOSTAT LOCK OUT. (HIGH FLUE TEMPERATURE)

REPLACE PART;

CHECK THE ELECTRICAL CONNECTION;

RESTART AND CHECK THE THERMOSTAT

H20

NO WATER IN THE SYSTEM

INSUFFICIENT WATER PRESSURE IN THE SYSTEM (STOPS AT 0.3 BAR).

WATER PRESSURE SWITCH CABLE DISCONNECTED.

WATER PRESSURE SWITCH MALFUNCTION.

FILL THE SYSTEM;

CHECK THE WIRING;

REPLACE PART;

E05

HEATING SENSOR

SENSOR MALFUNCTION OR OUT OF CALIBRATION (RESISTANCE VALUE 10 kOhms AT 25 °C).

SENSOR CABLE DISCONNECTED OR WET.

REPLACE PART;

CHECK THE ELECTRICAL CONNECTION;

E06

D.H.W SENSOR

SENSOR MALFUNCTION OR INCORRECT (RESISTANCE VALUE 10 kOhms AT 25 °C).

SENSOR CABLE DISCONNECTED OR WET.

REPLACE PART;

CHECK THE ELECTRICAL CONNECTION ;

E16

FAN

BURNT FAN

REPLACE PART

E22

PARAMETER PROGRAMMING REQUEST

LOSS OF MICROPROCESSOR MEMORY;

REPROGRAM PARAMETERS;

E35

FLAME DETECTION MALFUNCTION

IONISATION ELECTRODE MALFUNCTION

IONISATION ELECTRODE CABLE MALFUNCTION

PRINTED CIRCUIT BOARD MALFUNCTION

CLEAN IT OR REPLACE PART

REPLACE PART

Page 62

MAINTENANCE INSTRUCTIONS

6.8 Diagnostics

■ Error codes:

E01 Ionisation Lock Out E02 Safety Thermostat Tripped E03 Flue Gas Thermostat Tripped H2O Low Water Pressure Alarm E05 Heating Sensor Malfunction E06 D.H.W Sensor Malfunction E16 Electric Fan Malfunction E22 Parameter Programming Request E35 Flame Detection Malfunction

■ Function codes :

Code

Function

Description

Flue test function active

(Chimney-Sweeper)

Pressing the “service” button for 7 seconds activates the Flue test function. Pressing the boiler off button deactivates the function. The Flue test function operates the boiler at the maximum heating pressure for 15 minutes without any modulation. The function is useful for combustion testing.

Frost Protection

Central heating circuit

The function is activated when the heating sensor senses a temperature of 5 °C. The boiler operates at minimum gas pressure with the 3-way diverter valve in the winter position. The function is deactivated when the temperature detected by the sensor reaches 30°C.

Frost Protection

D.H.W. circuit

The function is activated when the sensor senses a temperature of 4°C. The boiler operates at minimum gas pressure. The 3-way diverter valve closes in the summer position and heats the D.H.W. circuit. The function is deactivated when the D.H.W. sensor detects a temperature of 8°C.

31 Incompatible Remote Control

Function active when the remote control connected is not compatible with the printed circuit board .

Page 63

MAINTENANCE INSTRUCTIONS

6.9 Parts List

Main components

CODE

DESCRIPTION

RKR

24 RKR 28

RKR 34

20040LA

PLATE EXCHANGER 16 PLATES

√

20047LA

PLATE EXCHANGER 20 PLATES

√

20076LA

PLATE EXCHANGER 14 PLATES √

30-00041

CONDENSING EXCHANGER 3+1 CBD COMPLETE √

30-00042

CONDENSING EXCHANGER 4+1 CBD COMPLETE

√

30-0004

CONDENSING EXCHANGER 5+1 CBD COMPLETE

√

24045LA

PUMP RSL 15/5 √

√

24046LA

PUMP RSL 15-6-3-KU √

27044LA

CONDENSATE TRAP √ √ √

35031LA

IGNITION ELECTRODE √ √ √

35032LA

IONISTATION ELECTRODE √ √ √

36068LA

VENTURI MINIFOLD √ √ √

36076LA

ELECTRONIC GAS VALVE √ √ √

37032LA

FAN √ √ √

40-00016

PRINTED CIRCUIT BOARD DIGITECH 2 – SM30003 √ √ √

59015LA

WATER PRESSURE SWITCH √ √ √

73507LA D.H.W-HEATING 1/8" WHITE SENSOR √ √ √

73516LA

HTG CLIP SENSOR FOR PIPE 17/18 mm BLUE √ √

√

73517LA

THERMO FUSE 102°C RED √ √ √

86006LA

SAFETY THERMOSTAT 95 °C √ √ √

86014LA

WATER PRESSURE GAUGE √ √ √

88023LA

TRANSFORMER √ √ √

95013LA

EXPANSION VESSEL LT.7 3/8" √ √ √

96032LA

DIVERTER VALVE

√ √ √

25-00131

3 BAR PRESSURE RELIEF VALVE -HTG CIRCUIT √ √ √

Page 64

Page 65

Page 66

eXtraheat Limited Belmayne House Clarkehouse Road Sheffield S10 2LN South Yorkshire

Phone Number 0844 3814115 Fax Number 01142 309147 E Mail:

radiantboilers@extraheat.co.uk radiantcustomersupport@extraheat.co.uk

Website:

www.radiant.eu

THE TECHNICAL DATA AND MEASUREMENTS ARE PROVIDED FOR INFORMATION PURPOSES ONLY AND ARE NOT BINDING. THE COMPANY RESERVES THE RIGHT TO APPLY VARIATIONS WITHOUT PRIOR NOTIFICATION. NEITHER WILL THE COMPANY BE HELD RESPONSIBLE FOR ANY INACCURACIES IN THIS HANDBOOK DERIVING FROM PRINTING OR TRANSLATION ERRORS. E+OEALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED, MEMORISED IN ANY FILING SYSTEMS OR TRANSMITTED IN ANY FORM WHATSOEVER, INCLUDING ELECTRONIC, MECHANICAL, PHOTOCOPIES, RECORDINGS OR ANY OTHER MEANS WITHOUT THE COMPANY’S PRIOR WRITTEN APPROVAL.

Radiant RKR 24, RKR 28, RKR 34, RK 18, RK 25 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual