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RBI FLEXCORE CK7000, Installation And Operation Instructions Manual


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Cast Iron Condensing Boilers – Installation Manual

FlexCore Stainless Steel Condensing Boilers – Installation Manual

FlexCore Parts List

Model Size with Quantities Below

Ref # Name of Part

Part No.

850

1000 1500 2000 2500 3000 3500 4000 4500 5000 6000 7000 8000 9000

15 LH Front Panel Bracket

74-0017-001

1

1

1

1

1

1

1

1

16 RH Front Panel Bracket

74-0017-002

1

1

1

1

1

1

1

1

17 RH Front Lower Access Panel

75-0029-006

1

1

1

1

1

1

17A

75-0029-007

1

1

1

1

1

1

1

1

17B RH Rear Lower Access Panel

75-0029-008

1

1

1

1

1

17C RH Center Lower Access Panel

75-0029-009

1

1

1

17D RH Rear Lower Access Panel

75-0029-010

1

1

1

18 RH Electrical Jacket Panel

03-4521-002

1

1

1

1

1

1

1

1

1

1

1

1

1

1

19 RH Upper Access Jacket Panel

75-0028-004

1

1

1

1

1

1

1

1

1

1

1

19A

75-0028-005

1

1

1

1

1

2

2

2

19B

75-0028-006

1

1

1

20 LH Electrical Jacket Panel

03-4521-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

21 Releif Valve Jacket Panel

03-4520-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

22 LH Upper Access Jacket Panel

75-0028-001

1

1

1

1

1

1

1

1

1

1

1

22A

75-0028-002

1

1

1

1

1

2

2

2

22B

75-0028-003

1

1

1

23 LH Front Lower Access Jacket Panel

75-0029-001

1

1

1

1

1

1

23A

75-0029-002

1

1

1

1

1

1

1

1

23B LH Rear Lower Access Jacket Panel

75-0029-003

1

1

1

1

1

23C LH Center Lower Access Jacket Panel

75-0029-004

1

1

1

23D LH Rear Lower Access Jacket Panel

75-0029-005

1

1

1

24 Top Jacket Panel

75-0027-001

1

1

1

1

1

1

24A

75-0027-002

1

1

1

1

1

2

2

2

24B

75-0027-003

1

1

1

1

1

75-0027-004

1

1

1

NS Latch

20-0046

2

2

2

2

2

2

2

2

2

2

2

2

2

2

25 Air Box Panel

74-0015-001

1

1

1

1

1

1

25A Front Air Box Panel

74-0015-002

1

1

1

1

1

1

1

1

25B Rear Air Box Panel

74-0015-003

1

1

1

1

1

25C Center Air Box Panel

74-0015-004

1

1

1

25D Rear Air Box Panel

74-0015-005

1

1

1

33 Air Box Splice Panel

74-0022-001

1

1

1

1

1

2

2

2

41 Rear Jacket Panel

75-0049-001

1

1

1

1

1

1

41A

75-0049-002

1

1

1

1

1

41B

75-0049-003

1

1

1

NS Drain Valve

11-0461

1

1

1

1

1

1

2

2

2

2

2

3

3

3

NS Condensate Trap

75-0025-001

1

1

1

1

1

1

75-0025-002

1

1

1

1

1

75-0025-003

1

1

1

NS Filter Box Cover

74-0019-001

1

1

1

1

1

1

74-0019-002

1

1

1

1

1

74-0019-003

1

1

1

42 Filter Box Assembly

75-0018-001

1

1

75-0018-002

1

75-0018-003

1

1

1

42A

75-0018-004

1

1

75-0018-005

1

1

1

42B

75-0018-006

1

1

1

43 Combustion Air Filter

09-0494-001

1

1

1

1

1

1

43A

09-0494-002

1

1

1

1

1

43B

09-0494-003

1

1

1

NS Grommet 1"

06-0070

1

1

Grommet 1 1/2"

06-0072

1

1

1

Grommet 2"

06-0073

1

1

1

1

2

1

2

2

3

3

3

45 LWCO Board

14-0258

1

1

1

1

1

1

1

1

1

1

1

1

1

1

LWCO Probe

14-0275

1

1

1

1

1

1

1

1

1

1

1

1

1

1

45A LWCO, RB-122-E

14-0259

1

1

1

1

1

2

2

2

46 Display Board (Touchscreen)

40-0091-002

1

1

1

1

1

1

1

1

1

1

1

1

1

1

NS Display Cable 35"

40-0115-001

1

1

1

1

1

1

Display Cable 41"

40-0115-002

1

1

1

1

1

1

1

1

Cable, Sata 7 Pin

48-0705-005

1

1

1

1

1

1

1

1

47 Top Front Jacket Panel

75-0032-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

FlexCore Overlay

82-0520-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Center Front Jacket Panel for Touchscreen Enclosure

75-0033-002

1

1

1

1

1

1

1

1

1

1

1

1

1

1

HeatNet/RBI Overlay for Touchscreen Enclosure

82-0751-002

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Bottom Front Jacket Panel

75-0035-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

48 Single Fuel Switch Panel Assembly

75-0015-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

NS Switch Panel Overlay

82-0752-001

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Switch, Red

48-0013

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Switch, Green

48-0016

2

2

2

2

2

2

2

2

2

2

2

2

2

2

49 Molded Flue Outlet

09-0601-001

1

1

1

1

1

1

49A Molded Front Flue Outlet

09-0601-002

1

1

1

1

1

1

1

1

49B Molded Rear Flue Outlet

09-0601-003

1

1

1

1

1

49C Molded Center Flue Outlet

09-0601-004

1

1

1

Summary of Contents for FLEXCORE CK7000

Page 1: ...ge The boiler can only be operated with a dust freeairsupply Followtheinstructionmanualprocedurestoductairtotheboilerairintake Iftheboilerhasbeencontaminatedbyoperation with contaminated air follow th...

Page 2: ...OF 160 PSI 1103 kPa WATER INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER WATER HEATER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES CONTENTS Before Your Start pa...

Page 3: ...flooring but never on carpeting 4 Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or during routine maintenance 5 DO NOT place this boiler hea...

Page 4: ...be within 12 in 300 mm of but not less than 3 in 80 mm from the bottom of the enclosure Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each o...

Page 5: ...propriate thimbles and fire stops must be used where required Improper installation of common positive pressure vent systems can result in excessive levels of carbon monoxide which can cause severe pe...

Page 6: ...ry IV 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Standard Tee 1 25 20 ft 25 ft 25 ft 30 ft 35 ft 35 ft 40 ft 40 ft 40 ft 50 ft 50 ft 55 ft 55 ft 55 ft Boot Tee 0 65 10 ft 15 ft 15 ft 15 f...

Page 7: ...all metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F 204 C Structural penetrations must be made using approved fire stops The top of a vertical v...

Page 8: ...UARD Security Chimneys Secure Seal Schebler Chimney Systems e Vent VAN PACKER CS Z Flex Z Vent Jeremias GOV ICC VIC Exhaust Termination Hood Exhaust 90 deg Exhaust Tee Exhaust 45 deg Exhaust Straight...

Page 9: ...L6 S2D 09 00002 002 09 0112 2000 2500 9801MAD SS8FFNSAU SSD8FFNSAUK SWKL8 S2D 09 00002 001 09 0113 3000 3500 91001MAD SS10FFNSAU SSD10FFNSAUK SWKL10 S2D 09 0310 004 09 0115 4000 4500 5000 91201MAD SS1...

Page 10: ...ric dampers may be omitted When required by applicable codes install a thermal spill switch on each barometric damper 1 Connect each boiler riser to the common vent with a Y connection or Boot T only...

Page 11: ...er to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation 0 1 2 3 4 5 6 7 8 9 0 5 10 15 20 Horizontal Distance...

Page 12: ...nsing Boilers Installation Manual Figure 4 Vertical Air Intake and Venting for Direct Vent System Figure 5 Combination Direct Vent Systems 10 FT 3 1 m 4 FT 1 2 m 5 FT 1 5 m 1 5 FT 0 5 m 5 1 2 FT 1 7 m...

Page 13: ...ction must also be followed Figure 6 Side Wall Venting VERTICAL VENT Recommended POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products vertically to t...

Page 14: ...e 8 The chimney system must provide a negative pressure of 0 02 to 0 10 in 0 51 to 2 5 mm WC at the boiler flue collar with the unit running When using a listed metal chimney system the chimney system...

Page 15: ...s les portes entre l espace o les appareils toujours raccord s du syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s a...

Page 16: ...of 2 ft 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each side of center line extended above...

Page 17: ...00 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening C Clearance to permanently closed window D Vertical c...

Page 18: ...ch deck or balcony is fully open on a minimum of two sides beneath the floor NOTES 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the curren...

Page 19: ...PE DISCHARGE PER ASME SECTION IV SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR AND ALLOW COMPLETE DRAINAGE OF RELIEF VALVE AND PIPING LOW WATER CUTOFF CONDENSATE DRAIN ASSEMBLY AIR VENT AI...

Page 20: ...670 9 89 4 8000 154 3 771 5 102 9 9000 174 3 871 5 116 2 Min Max flow correspond to a 20 F 100 F t at full input for applications requiring operation above and or below these parameters please consult...

Page 21: ...ppm chloride concentration and no greater than 300 ppm hardness Suspended solids such as Magnetite Iron Oxides must be flushed from the system prior to commissioning the boiler s The PH level must be...

Page 22: ...WATER MAKE UP Water Meter WM WM For Heat net Operation A Sensor Is Required And Installed At A Minimum Of 12 From Primary Loop Tee Riom 0205_a Tangential Type Air Separator Aquastat Heat Net Sensor Pr...

Page 23: ...water born bacteria Figure 14 Typical Single Boiler with Indirect Storage Tank Piping RIOM 0206_A HEAT NET SENSOR EXPANSION TANK THERMOMETER BACKFLOW PREVENTION DEVICE GATE VALVE PUMP TEMPERATURE PRES...

Page 24: ...M 0207_A HEAT NET SENSOR EXPANSION TANK THERMOMETER ATURE URE VALVE PRESURE RELIEF VALVE VACUUM RELIEF VALVE NOTES 1 WHEN USING INTERMITTENT PUMP AND PUMP DELAY LOCATE HEAT NET SENSOR WITH WELL IN LOW...

Page 25: ...roperly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 8 shoul...

Page 26: ...to full load of the gas supply line and all the appliances running Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body...

Page 27: ...EGULATOR PILOT SHUT OFF VALVE TYP REAR MODULE FRONT MODULE GAS MANIFOLD MAIN GAS VALVE RIOM 0210_C MODULATING GAS VALVE TYP SUPPLIED BY OTHERS PIPING GAS SUPPLY CK7000 TO 9000 REAR MODULE FRONT MODULE...

Page 28: ...g Close the make up water valve and check and clean the strainers and make up water pressure reducing valve Open the make up water valve and adjust the system pressure if necessary The system should b...

Page 29: ...ay will say Standby Figure 18 13 Slide the HeatNet controls low fire switch on the HeatNet control board to the low fire position 14 The boiler will begin the start sequence 15 When the main display r...

Page 30: ...es and observe the combustion reading The Calibration Min Max represents the mapped signal sent to the blower and doesn t reflect the modulation as indicated on the Master Member Screens a Place the S...

Page 31: ...that it can be changed Adjust the maximum value using the arrow keys to achieve the required combustion CO2 O2 Table 11 and pressure delta p Table 12 c The high fire trim adjustment is located on the...

Page 32: ...0 45 0 45 0 45 0 45 0 40 0 45 0 45 0 45 0 45 Firing Rate 4500 Delta P W C 5000 Delta P W C 6000 Delta P W C 7000 Delta P W C 8000 Delta P W C 9000 Delta P W C Front Module Rear Module Front Module Re...

Page 33: ...st limit in the Limit String to Ignition Control Have We received the BLOWER signal CALL FOR HEAT PRE_PURGE Interlocks OK Are we below the Temp Band YES fire the boiler NO Send 120 VAC BLOWER signal L...

Page 34: ...h a dc voltmeter Figure 20 Pilot Assembly CHECKING ADJUSTMENT OPERATION Spark Gap The gap has to be measured and adjusted with the igniter removed from the boiler Observe the trial for ignition to con...

Page 35: ...Water Cutoff Ensure that the low water cutoff device s function properly Test in accordance with the manufacturer s instructions included with the device s DIAGNOSTICS The FlexCore has a display that...

Page 36: ...this manual for reference 1 Check the operating controls for proper operation 2 The probe on a probe low water cut off must be removed cleaned and inspected at least once a year Ensure that the low wa...

Page 37: ...UBING POSITIVE PRESSURE TAP NEGATIVE PRESSURE TAP PILOT VALVE ASSEMBLY ASCO AIR SHUT OFF VALVE UV SCANNER AIR PUMP AIR BOX DIFFERENTIAL PRESSURE PILOT GAS PILOT AIR NOTES 1 TYPICAL PER EACH INDIVIDUAL...

Page 38: ...OVE 1 2 3 4 5 6 7 8 Low Fire Hold Fires the boiler at the minimum rate while in Calibrate This functions exactly as the T1 input Calibrate Allows adjustment of the Minimum Fire Maximum Fire and Pilot...

Page 39: ...E VIEW C SEE VIEW D RIOM 0217_D 46 SEE VIEW F 49 17 22 19 49G 49H 1 1A 2 2A 3 3A 5 5 9 8 10 11 7 6 1 4 23A SEE VIEW A 49F SEE VIEW E 48 47 45 15 16 18 44A 50 51 41A 42A 24 21 25B 33 25A 24A 21 20 43A...

Page 40: ...VIEW D RIOM 0217_D SEE VIEW F 22A 23A 48 47 46 45 15 16 19A 18 17A 44A SEE VIEW A 25A 25C 25D 21 22A 21 22B 23D 24A 24B 23C 17C 19A 17D 19B 41B 42B 43B 49D 49C 49A 33 49H 49G 49E 44C 44D 44F 2B 5 1B...

Page 41: ...66A 67A 68A 69 65A 68B CK0850 TO 1000 ONLY 58C 58A 58B 59 58 53 52 54 56 61 54 63 54 65 60A 60C 60B 60 VIEW A RIOM 0217_D 64 60D 62 57 55 67 68 69 66 VIEW B 73 73 45 72 RIOM 0217_D 72 72 45 72 45A 45...

Page 42: ...42 FlexCore Stainless Steel Condensing Boilers Installation Manual 80 82A 82A 81 80A 79A 78 77A RIOM 0217_D VIEW C 76A 77A 79A 80A 81 78 82A 82 81 79 77 78 76 VIEW D RIOM 0217_D 84 83 86 85...

Page 43: ...ainless Steel Condensing Boilers Installation Manual VIEW E RIOM 0217_D OR 92A 97A 95A 96 93 98 94A 87 88 95 98 97 93 92A 96 94 87 88 90 89 OR 93 94 96 97 98 91 95 92 96A 88 87 VIEW F RIOM 0217_D 71 1...

Page 44: ...74 0015 005 1 1 1 33 Air Box Splice Panel 74 0022 001 1 1 1 1 1 2 2 2 41 Rear Jacket Panel 75 0049 001 1 1 1 1 1 1 41A 75 0049 002 1 1 1 1 1 41B 75 0049 003 1 1 1 NS DrainValve 11 0461 1 1 1 1 1 1 2...

Page 45: ...mall Combustion Chamber 01 0061 002 1 1 1 1 1 SS Ring Large Combustion Chamber 01 0062 002 1 1 1 1 2 1 2 2 3 3 3 56 Combustion Chamber Small 05 0401 001 1 1 1 1 1 Combustion Chamber Large 05 0401 002...

Page 46: ...lve 11 0376 002 1 1 1 1 1 1 2 2 2 2 2 3 3 3 86 Mini Fan 12 0021 002 1 1 1 1 1 1 2 2 2 2 2 3 3 3 87 Air Pressure Switch 0 25 WC 14 0067 1 1 1 1 1 1 2 2 2 2 2 3 3 3 88 Air Pressure Switch 2 5 WC 14 0068...

Page 47: ...10 2 Disable any external call for heat and toggle the remote local switch to REMOTE follow section Operating Instructions Steps 11 14 3 Ignition and pilot adjustment Toggle the LOW FIRE switch to cy...

Page 48: ...LOW WATER CUT OFF HIGH LIMITS COMMISSIONING THE BOILER UNIT CYCLED MINIMUM OF 15 TIMES THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROP ER FLOW BEFORE YOU LEAVE THE JOB SITE YOU MU...

Page 49: ...ll exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INS...

Page 50: ...ioning the boiler s In addition pH levels must be in the 6 5 10 range Failure to follow these guidelines will void the warranty This Limited Warranty does not Apply a If the product has been subjected...

Page 51: ...51 FlexCore Stainless Steel Condensing Boilers Installation Manual...

Page 52: ...www rbiwaterheaters com 7555 Tranmere Drive Mississauga Ontario L5S 1L4 Canada Phone 905 670 5888...

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