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MAINTENANCE INSTRUCTIONS

37

6.6 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

safety thermostat

burner unit

electric fan`

heating sensor

circulating pump

condensate drain trap

Fig. 1

ionisation electrode

expansion vessel

3-way valve

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Summary of Contents for Ekoflux RK 34/B

Page 1: ...NG MAN INST 1305 1 DIGITECH 2 CBD AUSTRALIA Technical specification RADIANT BRUCIATORI S p A Montelabbate Instruction Manual for model RK 34 B Ekoflux Premix condensing boiler version for remote storage cylinder connection ...

Page 2: ......

Page 3: ...ce standard 12 3 2 Boiler room installation requirements 12 3 3 Unpacking 13 3 4 Installation boiler 14 3 5 Water connections 15 3 6 Gas connection 16 3 7 Electrical connections 17 3 8 Flue connections 19 4 Commissioning the appliance authorised personnel 4 1 General warnings 21 4 2 Filling the system 22 4 3 Flushing the system 23 4 4 Filling the condensate trap 23 4 5 Starting up the boiler 24 5 ...

Page 4: ...4 6 2 Boiler inspection 34 6 3 Accessing the boiler 35 6 4 Flushing out the primary side 35 6 5 Draining the central heating and domestic hot water system 36 6 6 Maintenance operations 37 6 7 Wiring diagrams 45 6 8 Troubleshooting 52 6 9 Diagnostics 53 6 10 Parts list 54 ...

Page 5: ...een 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 ...

Page 6: ...een 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 dom...

Page 7: ...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 ce...

Page 8: ...ing 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 30 C l min 16 63 Dimensions Boiler casing size Width mm 410 Height mm 730 Depth mm 310 Weight net kg 42 Hydraulic connections Central Heating Flow connection Ø Central heating Return conn...

Page 9: ... G HF 730 132 310 162 140 108 410 RCF RCR 20 HF HR G 105 CWI 80 102 CWI 2 2 Dimensions LEGEND HR HEATING RETURN Ø 3 4 HF HEATING FLOW Ø 3 4 RCR REMOTE D H W CYLINDER RETURN Ø 3 4 RCF REMOTE D H W CYLINDER FLOW Ø 3 4 CWI COLD WATER INLET Ø 1 2 G GAS Ø 3 4 SC CONDENSATE DRAIN Ø 25 ...

Page 10: ...ot water working pressure Max heating working pressure H6 H5 mm mm mm mm Lt h kW lt h mq Lt Storage cylinder capacity H4 H3 H2 H1 H Internal diameter Di Externa diameter De Hot water flow rate Dt 30 Heat Input max Circulation pump Storage cylinder exchange area H6 MODEL U M 150 Dm 30 30 F ANODE 100 H 2 H 2 H A B C BRACKET G 3 4 BRACKET G D E A mm Ø3 4 B mm Ø3 4 C mm Ø3 4 Ø1 2 mm D Ø1 2 mm E B A C ...

Page 11: ...C 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 ROOM SEALED CHAMBER BACK SIDE 20 CONDENSATE TRAP 21 WATER PRESSURE GAUGE 22 AUTOMATIC BY PASS 23 CONDENSATE DRAIN PIPE 24 SYSTEM DRAIN VALVE 25 3 WAY VALVE 26 FILLIN...

Page 12: ...R 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 ROOM SEAL CHAMBER BACK SID 20 CONDENSATE TRAP 21 WATER PRESSURE GAUGE 22 AUTOMATIC BY PASS 23 CONDENSATE DRAIN PIPE 24 SYSTEM DRAIN VALVE 25 3 WAY VALVE 26 FILLING TAP LEGEND HR HEATING RETURN HF HEATING FLOW RCR REMOTE D H W CYLINDER ...

Page 13: ...SENSOR code 31368LA SUPPLIED WITH THE BOILER NOTE THERE IS A STRAINER ON THE HEATING CIRCUIT THE INSTALLATION OF AN ADDITIONAL STRAINER ON THE SECONDARY CIRCUIT IS RECOMMENDED RCF RCR G HF HR SC NON RETURN VALVE 4 bar SAFETY VALVE SHUTTER CONTROL THERMOMETER EXTERNAL SENSOR code 73506LA REMOTO LCD Water circuit installation example ...

Page 14: ...TECHNICAL CHARACTERISTCS 10 2 5 Circulation pump head flow graph III II I Head kPa Flow l h III Pump head at maximum speed Pump head at second speed II I Pump head at minimum speed ...

Page 15: ...ncy 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 ...

Page 16: ...stallation and should be left with the appliance but do not over ride in anyway statutory obligations 3 2 Installation requirements Please refer to local and national standards in force in the Country of destination of the product In particular the manufacturer recommends Installation must be in accordance with the following Manufacturer s installation instructions AS5601 1 gas installations for i...

Page 17: ...resent 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...

Page 18: ...enance 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 whe...

Page 19: ... exchanger the mains water supply must not have a hardness rating of more than 17 5 Ck It is nevertheless 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 ...

Page 20: ...ified personnel in accordance with relevant standards 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 th...

Page 21: ...onnection 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 applianc...

Page 22: ...d 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 Se Outside temp...

Page 23: ...back to the combustion chamber which has been specifically designed to collect and drain the acidic condensate o for the air intake the entire length of the duct slopes upwards towards the boiler to prevent the entry of rainwater dust or foreign bodies into the pipe o in case of a vertical flue pipe installation a condensate trap is fitted at the base of the flue installation and connected into dr...

Page 24: ...an be connected directly to the outside or can be connected to a suitable combined flue system MAXIMUM FLUE LENGTH 8 m The maximum flue length linear equivalent is obtained by summing 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 exclud...

Page 25: ...rth 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 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 suppl...

Page 26: ...n the main domestic water supply valve Open the filling tap R fig 2 Unscrew the plug on the pump to remove any trapped air check that the pump is free then re tighten it when water starts to flow out fig 1 Before switching on the boiler purge air completely from the air vent valve positioned on the top of the condensing exchanger fig 3 Open the air vents on the radiators and monitor the air evacua...

Page 27: ... that the DHW expansion vessel has been fitted in line with the instructions on page 14 of the manual b Open all hot water outlets c Turn on inlet group supply so water enters the boiler leave to fill until water is released from the hot water outlets Turn off all hot water outlets d Connect a hosepipe to the cylinder drain cock and open the drain cock e Allow water to flow through the boiler and ...

Page 28: ...oximately three minutes before re attempting 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 unt...

Page 29: ...ced 25 40 C P04 Heating output rising time 00 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 ove...

Page 30: ...ng 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 previ...

Page 31: ...pear 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 paramet...

Page 32: ...arameter 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...

Page 33: ...meter 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 prescrib...

Page 34: ...pliance 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 ap...

Page 35: ...n 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 in...

Page 36: ...niversal LPG Nominal Supply pressure kPa 1 13 2 75 Consumption MJ h 130 5 130 5 Heating Power kW Fan frequency Hz diagram L P G G30 G31 Natural gas G20 CO2 Values Gas type CO2 Natural gas 9 18 Universal LPG 10 3 Frequency Gas type Minimum Hz Maximum Hz Natural gas 55 164 Universal LPG 52 155 ...

Page 37: ...pply 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 5 to check the CO value Make sure that the value complies with that reported in table 1 paragraph 4 5 If the CO2 value does not correspon...

Page 38: ...ction 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 t...

Page 39: ...eft 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 6 4 Flushing out the primary side Fill the boiler as per the filling instructions Using a drain off cock on the lowest point of the system allow the water to drain from the system and boiler In order to ...

Page 40: ...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...

Page 41: ...ge 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 safety thermostat burner unit electric fan heating sensor circulating pump condensate drain trap Fig ...

Page 42: ...odes 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 cerami...

Page 43: ...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 POSITIONING THE IGNITION ELECTRODE AND TH...

Page 44: ...ral 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 fi...

Page 45: ... the above procedure in reverse order Switch on the electricity water and gas supplies and check the soundness of the joint by measuring the CO2 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 expan...

Page 46: ...ks from the joints and bleed off any air from the circuit Restart the boiler Diverter valve see fig 2 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 t...

Page 47: ...d 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 The preset parameters of the printed circuit board correspond to a 34 kw instantaneous condensing boiler fed by natural gas When replacing the modulation circuit board it s necessary to set parameter P00 according to the boiler model ...

Page 48: ...eturn 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 ...

Page 49: ...light blue brown brown light blue black brown light blue EV2 B EV1 A EV1 B EV2 A red light blue brown light blue brown orange orange brown violet orange M10 M1 orange black black M2 M9 M5 M7 VG M11 brown light blue L N M11 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 w...

Page 50: ...s 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 temperatu...

Page 51: ...oller wires When the wires have been connected place plate A back to position and then the front case panel Connecting the 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 re...

Page 52: ...sary to access the main p c b for electrical connection see 6 3 Accessing the boiler and to activate the parameter P15 see 5 1 Parameters table Outside temperature sensor option Terminal block REMOTE OPEN THERM Zone valve management option remote controller board cod 40 00018 cod 40 00017 Option remote lock out indicator ...

Page 53: ...ol zone valves and telephone control wirings Outside temperature sensor option Terminal block REMOTE OPEN THERM Telephone control Zone valve management option remote controller board cod 40 00018 cod 40 00017 Option remote lock out indicator ...

Page 54: ...s 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 floor mounted appliances The type of appliance can be programmed using parameter 3 see 5 1 Parameter programming 13 ...

Page 55: ...MAINTENANCE INSTRUCTIONS 51 D H W sensor connection M2 FILLING LOOP MAX LENGHT 8 mt HOT WATER SENSOR LEAD REMOTE DHW CYLINDER FLOW REMOTE DHW CYLINDER RETURN PRINTED CIRCUIT BOARD SM30003 ...

Page 56: ...BLE DISCONNECTED i REPLACE PART j CHECK THE WIRING E03 102 C THERMO FUSE TRIPPED k THERMOFUSE BROKEN l THERMOFUSE CABLE DICONNECTED m THERMOFUSE LOCK OUT HIGH FLUE TEMPERATURE k REPLACE PART THEN INTERRUPT AND RECONNECT ELECTRICAL SUPPLY l CHECK THE ELECTRICAL CONNECTION m RESTART AND CHECK THE THERMOSTAT H20 NO WATER IN THE SYSTEM n INSUFFICIENT WATER PRESSURE IN THE SYSTEM STOPS AT 0 3 BAR o WAT...

Page 57: ... 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 13 Frost Protection D H W circuit for storage boilers 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 clo...

Page 58: ...N ELECTRODE 36076LA ELECTRONIC GAS VALVE 36072LA VENTURI 57kW 37032LA FAN 40 00016 PRINTED CIRCUIT BOARD DIGITECH 2 SM30003 59015LA WATER PRESSURE SWITCH 73516LA HTG CLIP SENSOR FOR PIPE 17 18 mm BLUE 73517LA THERMO FUSE 102 C RED 86006LA SAFETY THERMOSTAT 95 C 25 00196 WATER PRESSURE GAUGE 88023LA TRANSFORMER 95013LA EXPANSION VESSEL LT 7 3 8 96031LA DIVERTER VALVE 25 00131 3 BAR PRESSURE RELIEF ...

Page 59: ......

Page 60: ... 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 O...

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