RESIDENCE COLONNA CONDENS INSTALLATION AND MAINTENANCE MANUAL

Transcription

1 FLOOR STANDING CONDENSING BOILERS RESIDENCE COLONNA CONDENS KV/ ISC INSTALLATION AND MAINTENANCE MANUAL

2 CONFORMITY r RESIDENCE COLONNA CONDENS boilers conform to the following directives: Gas Appliances Directive 2009/142/CE Boiler Efficiency Directive 92/42/EEC (HHHH) Electromagnetic Compatibility Directive 2004/108/CE Low Voltage Directive 2006/95/CE BS EN 677 Gas-fired central heating boilers; specific requirements for condensing boilers with a nominal heat input not exceeding 70 kw RESIDENCE COLONNA CONDENS boilers therefore bear the CE mark RANGE RATED This boiler is RANGE RATED. That means it is fitted with a device that adjusts its heat output to suit the requirements of the heating system and therefore the thermal energy needs of the building. See the Settings section for information on system calibration. RANGE MODEL CODE RESIDENCE COLONNA CONDENS KV/ ISC

3 Dear heating engineer, Congratulations on having chosen a r RESIDENCE COLONNA CONDENS boiler. You have selected a modern, quality product that is designed to give dependable, efficient and safe service and to provide comfort in the home for many years to come. This manual provides information that is essential to the installation of the appliance. Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly. Once again, please accept our thanks and our congratulations on your choice of product. Riello S.p.A. GENERAL 3

4 CONTENTS GENERAL General safety information page 5 Precautions 5 Product description 6 Safety devices 6 Identification 7 Layout 8 Technical specifications 9 Accessories 11 Water circuit 12 Location of sensors 13 Pump 13 Wiring diagram 14 Control panel 15 INSTALLER Unpacking the product page 16 Dimensions and weight 16 Handling 17 Place of installation 18 Installation in older systems and systems requiring modernisation 19 Water in central heating systems " 19 Water connections 22 Electrical connections 24 Outdoor temperature sensor 26 Fuel connections 27 Flue gas outlet and comburent air intake 27 Filling and draining the system 31 TECHNICAL ASSISTANCE SERVICE Preparing for initial start-up page 33 Initial start-up 33 Shutdown 37 Warning LEDs and errors 38 Automatic temperature control 39 Settings 41 Conversion from one gas type to another 44 Maintenance 45 Troubleshooting 47 Useful information 50 The following symbols are used in this manual: b = Identifies actions that require caution and adequate preparation. a = Identifies actions that you MUST NOT do. This manual, Code Rev. 4 (05/14) is made up of 52 pages. 4

5 GENERAL SAFETY INFORMATION As soon as you open the packaging, check immediately that the contents are all present and undamaged. Contact the r reseller from whom you purchased the product if you notice any problems. b b This system must be installed by a legally qualified heating engineer. On completion of the installation, the installer must issue the owner with a declaration of conformity confirming that the installation has been completed to the highest standards in compliance with the instructions provided by r in this instruction manual, and that it conforms to all applicable laws and standards. This RESIDENCE COLONNA CONDENS boiler must be used only for the proper purpose for which it is designed and made. The manufacturer declines all responsibility, contractual or other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use. If you notice any water leaking from the boiler, disconnect it immediately from the mains electricity supply, shut off the water supply, and notify your local r Technical Assistance Centre or a qualified heating engineer immediately. Periodically, and when the system is cold, check that operating pressure in the heating circuit is between 1 and 1.2 bar. If water pressure is consistently low, contact r s Technical Assistance Service or a professionally qualified heating engineer. b b If the boiler is not going to be used for an extended period of time, proceed as follows to prepare it for shutdown: - Turn the mains power switch OFF. - Close the boiler s fuel cock and water cock. - Drain the central heating circuit if there is any risk of freezing. The boiler must be serviced at least once a year. If the boiler is destined to heat low temperature (under-floor) heating systems, it must be fitted with an accessory mixer valve kit. This instruction manual is an integral part of the boiler. It must be kept safe and must ALWAYS accompany the boiler, even if it is sold to another owner or transferred to another user or to another installation. If you damage or lose this manual, order a replacement immediately from your local Technical Assistance Centre. PRECAUTIONS Observe the following precautions to ensure safe operation of the boiler. aa Do not allow children or infirm persons to operate the boiler unsupervised. aa Do not operate any electrical devices or equipment, including switches or domestic appliances, etc., if you can smell fuel or fumes. If you detect any suspicious smells: - Ventilate the room by opening all doors and windows. - Close the fuel shut-off cock. - Report the fault immediately to r s Technical Assistance Service or to a professionally qualified heating engineer. aa Do not touch the boiler when barefoot or wet. aa Never clean or service the boiler without first disconnecting it from the mains electricity supply by turning the mains switch OFF. a Do not tamper with or adjust the safety or control devices without prior authorisation and instructions from the boiler s manufacturer. aa Never pull, disconnect, or twist the electrical cables coming from the boiler even if it is disconnected from the mains electricity supply at the time. a a Do no obstruct or restrict the vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion. aa Do not expose the boiler to the elements. It is not designed for use outdoors. aa Do not switch the boiler off if outside temperature drops below ZERO (risk of freezing). aa Do not store containers of flammable substances in the room where the boiler is installed. aa Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation. GENERAL 5

6 PRODUCT DESCRIPTION RESIDENCE COLONNA CONDENS boilers are high efficiency, low temperature boilers for the production of hot water for central heating and domestic hot water systems. They incorporate a 130 litre storage cylinder. RESIDENCE COLONNA CONDENS boilers incorporate a low water content, low pressure drop, compact, monobloc, aluminium heat exchanger, and a premixed microflame burner controlled by an electronic control panel, all enclosed within a robust free-standing casing. They feature sealed combustion chambers and, depending on what flue accessories are fitted, can be classed as B23P, B53P, C13, C23, C33, C43, C53, C63 or C83 appliances. The fan extracts flue gases and aspirates comburent air from outdoors, and is continuously controlled by the electronic control card. The characteristics of the heat exchanger and burner ensure an excellent level of performance. The combustion chamber and the heat exchange area are designed to keep temperature low over the burner surface, thus minimising emissions, maximising combustion efficiency and improving ignition reliability. RESIDENCE COLONNA CONDENS boilers come complete with safety valves, vent and bleed valve, expansion vessels, drain cocks, system fill cock and pumps for the central heating circuit, storage cylinder. More than one high or low temperature zone can be heated, with the addition of the relevant multi-zone accessories. See the r catalogue for details. The main technical characteristics of RESIDENCE COLONNA CONDENS boilers are: electronic burner ignition and ionisation flame control continuous electronic flame modulation for domestic hot water and central heating water microprocessor control card for input and output control and alarm management pneumatic control of air-gas ratio 3-way valve with electric actuator water pressure switch digital display for temperature and error codes buttons for OFF-reset, alarm reset, and comfort functions domestic hot water and central heating water temperature controls system filling cock central heating circuit pressure gauge 6 litre domestic hot water circuit expansion vessel 12 litre central heating circuit expansion vessel DC fan controlled by Hall effect speed sensor high head pump fitted as standard automatic bypass for central heating circuit NTC sensors for control of central heating flow and return and domestic hot water temperatures central heating flow temperature range adjustable between 20 and 80 C 130 litre single coil storage cylinder provision for installing a recirculation pump for the domestic hot water circuit inside the boiler casing. SAFETY DEVICES RESIDENCE COLONNA CONDENS boilers are equipped with the following main safety devices: autodiagnostics with display of error codes microprocessor control and display of NTC sensor continuity 3-way valve anti-block function, activated automatically after 24 hours from last movement pump anti-block function, activated automatically for 30 seconds, 24 hours after last pump cycle pressure transducer to prevent ignition in case of low water pressure (with error display) flue gas temperature sensor to shut down the burner if flue gas temperature exceeds the safety threshold condensate drain siphon with float system to prevent the escape of fumes condensate level sensor to shut down the burner if the condensate level in the heat exchanger exceeds the safety threshold first level of frost protection (for indoor systems) functional even with the boiler in standby, activated when water temperature drops below 7 C Maximum temperature thermostat to detect overheating and ensure the safety of the entire system (with error display requiring reset by OFF-RESET button). 3 bar central heating circuit safety valve. 8 bar domestic hot water circuit safety valve. 6 bar solar circuit safety valve. The intervention of a safety device indicates a potentially dangerous malfunction in the system, and means that you must contact r s Technical Assistance Service immediately. aa Never start the boiler up even for a short period if the safety devices are not functioning correctly or have been tampered with. Safety devices must only be replaced by r s Technical Assistance Service using original spare parts. Always check that the boiler is functioning correctly after any repairs. 6 GENERAL

7 IDENTIFICATION r RESIDENCE COLONNA CONDENS boilers are identified by two plates: - Data plate This lists the appliance s technical specifications and performance data. Combustibile: Brennstoff: Combustible: Brandstof: Categoria: Categorie: Kategorie: RIELLO S.p.A. Via Ing.Pilade Riello Legnago (VR) - ITALY / T067745GE Caldaia a condensazione - Chaudière à condensation Brennwertkessel - Condenserende verwarmingsketel NOx: European Directive 92/42/EEC: η = Cod. N IP P.nom.G20= mbar 230 V ~ 50Hz W Qn(min)= Pn(min)= kw kw kw kw D = l/min Qn(max= kw kw Pmw= bar T = C Pn(max)= kw kw Pms= bar T = C - Gas plate This is applied near the data plate and specifies the type of gas used by the boiler, and the country in which the boiler is destined for use. CALDAIA REGOLATA PER: CHAUDIERE REGLEE POUR: VERWARMINGSKETEL INGESTELD OP: KESSEL GEREGELT FÜR: T067745GE - Serial number plate This is located on the base of the boiler and specifies the serial number, model, furnace power, and maximum operating pressure. RIELLO S.p.A. Via Ing.Pilade Riello Legnago (VR) - ITALY T067745I0 Mod. Cod. N Pms bar Qn(max) kw If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper installation and servicing may be rendered difficult. Data plate Domestic hot water section Central heating section Qn Rated heat input Pn Rated useful heat output IP Index of protection P.min Minimum pressure Pmw Maximum operating pressure, DHW system Pms Maximum operating pressure, CH system T Temperature η Efficiency VERWARMINGSKETEL INGESTELD OP: KESSEL GEREGELT FÜR: CALDAIA REGOLATA PER: CHAUDIERE REGLEE POUR: T067745GE RIELLO S.p.A. Via Ing.Pilade Riello Legnago (VR) - ITALY Cod. N IP P.nom.G20= mbar 230 V ~ 50Hz W D = T067745GE l/min Combustibile: Brennstoff: Caldaia a condensazione - Chaudière à condensation Brennwertkessel - Condenserende verwarmingsketel Pmw= bar T = C Pms= bar T = C Qn(min)= Pn(min)= Qn(max= Pn(max)= Combustible: Brandstof: Categoria: Categorie: Kategorie: NOx: kw kw kw kw European Directive 92/42/EEC: η = / kw kw kw kw D Specific flow rate NO x NO x class GENERAL 7

8 C LAYOUT Cover panel 2 Top front panel 3 Automatic vent valve 4 Bleed manifold 5 Water pressure switch 6 Drain cock for delivery group 7 Delivery group 8 Bottom front panel 9 CH/storage cylinder pump 10 Deviator valve and by-pass 11 Storage cylinder temperature sensor socket 12 CH circuit fill cock 13 Storage cylinder drain cock 14 DHW circuit safety valve (8 bar) 15 DHW circuit expansion vessel (6 litres) 16 Bypass pipe 17 Drain collector pipe 18 Electrical cable guides 19 CH circuit safety valve (3 bar) 20 Combustion group 21 Vent/air intake fitting (concentric 60/100) 22 Control panel 23 Gas diaphragm 24 Gas valve DHW capillary temperature gauge fitting 26 Magnesium anode 27 Storage cylinder flange 28 LH side panel 29 CH circuit expansion vessel (12 litres) 30 Comburent air intake pipe (twin pipe) 31 Flue gas analysis socket 32 RH side panel 33 Boiler drain cock GENERAL

9 TECHNICAL SPECIFICATIONS Description RESIDENCE COLONNA CONDENS KV/ ISC Class of boiler II2H3P Type of boiler B23P-B53P-C13-C13x-C23-C33-C33x-C43- C43x-C53-C53x-C63-C63x-C83-C83x Rated heat input, CH 30 kw Rated heat output, CH (80 C/60 C) 29,1 kw Rated heat output, CH (50 C/30 C) 31,62 kw Reduced heat input, CH 6 kw Reduced heat output, CH (80 C/60 C) 5,9 kw Reduced heat output, CH (50 C/30 C) 6,46 kw Rated heat input, DHW 30 kw Reduced heat input, DHW 6 kw Useful efficiency, Pn max - Pn min (80 C/60 C) 97 % Useful efficiency at 30% (return temp. 30 C) 109,3 % Combustion efficiency 97 % Useful efficiency, Pn max - Pn min (50 C/30 C) 105,4 % Useful efficiency at 30% Pn (return temp. 47 C) 103,1 % Losses from stack and casing with burner off 58 W Maximum operating pressure 3 bar Minimum pressure for normal functioning 0,25 0,45 bar Maximum temperature 90 C CH water temperature setting range 20:45/45:80 C Pump: max. head available to system 300 mbar at flow rate of 1000 l/h Power supply voltage V - Hz Consumption 129 W Index of protection Installation type B X4D IP Installation type C X5D IP Volume of expansion vessel (CH) 12 l Precharge of expansion vessel (CH) 1,5 bar Rated gas pressure, methane (G20) 20 mbar Rated gas pressure, LPG (G31) 37 mbar Air flow rate (G20) 37,484 Nm3/h Flue gas flow rate (G20) 40,492 Nm3/h Flue gas mass flow rate (max-min) (G20) 0,014-0,003 kg/s Residual head, concentric pipes, 0.85 m Ø Pa NOx class 5 Emission values at maximum and minimum flow rate with G20 gas (*) CO below 190 ppm Maximum CO2 9 % NOx below 30 ppm Flue gas Δt 82 C CO below 25 ppm Minimum CO2 9,5 % NOx below 23 ppm Flue gas Δt 58 C (*) Calculated with one 90 curve, 24 x 1 metre extensions and a 1 metre horizontal collector. GENERAL 9

10 Description RESIDENCE COLONNA CONDENS KV/ ISC Type of storage cylinder Vitrified Cylinder layout Vertical Heat exchanger layout Vertical Maximum power absorbed by heat exchanger 28 kw DHW temperature setting range C Storage cylinder capacity 130 l Heat exchanger surface area 5,5 l Coil water capacity 0,91 m 2 DHW production T 25 C 15 l/min T 35 C 10 l/min Water draw in 10 minutes with storage cylinder at 48 C (**) 176 l 60 C (**) 229 l Specific flow rate (EN625) 25,1 l/min Maximum operating pressure of storage cylinder 8 bar Volume of expansion vessel (DHW) 6 l Precharge of expansion vessel (DHW) 2,5 bar (**) Specified data must not be used to certify the system. Certificates must state the values listed in the System Service Booklet as measured on initial start-up. Description RESIDENCE COLONNA CONDENS KV/ ISC Function parameters for G20 Lower Woe index (at 15 C mbar) 45,67 MJ/m 3 s Rated supply pressure 20 mbar Minimum supply pressure 10 mbar Gas diaphragm 6,7 mm Maximum gas flow rate, DHW/CH 3,17 Sm 3 /h Minimum gas flow rate, DHW/CH 0,63 Sm 3 /h Maximum fan speed, DHW/CH 6000 rpm Minimum fan speed 1600 rpm Burner ignition slow fan speed 3400 rpm Function parameters for G31 Lower Woe index (at 15 C mbar) 70,69 MJ/m 3 s Rated supply pressure 37 mbar Minimum supply pressure 35 mbar Gas diaphragm 4,7 mm Maximum gas flow rate, DHW/CH 2,33 Sm 3 /h Minimum gas flow rate, DHW/CH 0,47 Sm 3 /h Maximum fan speed, DHW/CH 6000 rpm Minimum fan speed 1600 rpm Burner ignition slow fan speed 3400 rpm 10 GENERAL

11 ACCESSORIES Description Code DHW recirculation kit KV/ Residence Condens remote control Outdoor sensor Zone valve control kit for Residence Condens Condensate drain pump Safety thermostat kit BAG 2 AP BAG 2 MIX BASIC BAG 2 MIX CLIMA BAG 2 2 MIX BASIC Recessed wall box GENERAL 11

12 WATER CIRCUIT GAS CH flow CH return 24 DHW outlet Cold water inlet 1 Primary heat exchanger 2 CH flow temperature sensor 3 Safety thermostat 4 Fan 5 Gas valve 6 CH return temperature sensor 7 Condensate drain siphon 8 Gas diaphragm 9 Sealed chamber 10 Drain 11 Bleed manifold 12 Automatic vent valve 13 CH circuit expansion vessel (12 litres) 14 CH/storage cylinder pump 15 Boiler drain cock 16 Delivery group 17 Water pressure switch 18 Drain cock for delivery group 19 System safety valve (3 bar) 20 Non-return valve 21 Non-return valve and by-pass 22 Automatic bypass 23 Deviator valve litre storage cylinder 25 DHW circuit expansion vessel (6 litres) 26 DHW circuit safety valve (8 bar) 27 CH circuit fill cock 28 Magnesium anode 29 Storage cylinder flange 30 Storage cylinder drain cock 31 Bypass pipe 32 DHW recirculation 12 GENERAL

13 C C LOCATION OF SENSORS CONDENSATE SENSOR (located inside sealed chamber) NTC FLUE GAS TEMPERATURE SENSOR SAFETY THERMOSTAT (located on CH circuit flow pipe inside sealed chamber) STORAGE CYLINDER TEMPERATURE GAUGE SENSOR NTC STORAGE CYLINDER TEMPERATURE SENSOR NTC CH FLOW TEMPERATURE SENSOR (located on CH circuit flow pipe inside sealed chamber) NTC CH RETURN TEMPERATURE SENSOR (located on CH circuit return pipe inside sealed chamber) CENTRAL HEATING TEMPERATURE GAUGE SENSOR PUMP The residual head of the burner pump can be derived from the three speed curves in the graph shown alongside. On initial start-up and at least every year, check that all the pumps in the system rotate freely. Sludge and lime scale can build up and cause seizure, especially after long periods of disuse. Protect all electrical devices under the pump before you unscrew the inspection cap just in case water comes out. aa Never run the pump dry. PRESSURE DROP (mbar) I III 190 II FLOW RATE (l/h) GENERAL 13

14 WIRING DIAGRAM brown CH blue N black DHW TA black OPE OPE pink 5 yellow/green brown blue orange yellow/green white white brown blue M5 M3 N L F blue brown VG CI VD SC N L TAC ER EA brown blue blue brown blue brown red black Power supply 230 VAC VHv CN1 CN3 FA2 FA1 CN5 CN2 2 3 pink F1 F2 X4 blue M3a X red bianco TLS TLA VLv TBT APC P2 CONTROL CARD P3 JP4 P1 X16 X PA orange orange SM black black white white black black blue blue grey red red AD M4a PO brown brown SF SB M4 SR CR SE APC Condensate pump alarm CR Remote control CN1-CN5 Mains voltage connections EA Ignition electrode ER Flame detection electrode F Fuse 3.15A F (fast) F1-F2 Fuse 3.15A T (timed) JP4 Boiler configuration selection jumper (in position 3) M3 M5 Connection terminals OPE Gas valve operator Cl Central heating/storage cylinder pump PA Water pressure switch P1 DHW temperature setting potentiometer P2 CH temperature setting potentiometer P3 Function selector R9 Maximum fan speed trimmer R10 Minimum fan speed trimmer R14 Burner ignition slow fan trimmer R19 Maximum CH fan speed trimmer R35 Temperature control curve selection trimmer SC Condensate sensor SE Outdoor temperature sensor SM Primary circuit flow temperature sensor SR Primary circuit return temperature sensor SW1 Chimney sweep TAC Ignition transformer TR2 Main transformer TBT Low temperature thermostat TLA Water overtemperature threshold thermostat TLS Heat exchanger threshold thermostat VHv Fan power supply 230V VLv Fan control signal VG Gas valve X2 X16 Low voltage connections VD 3-way valve servomotor SB Storage cylinder temperature sensor SF Flue gas temperature sensor PO DHW timer-programmer (accessory) 14 GENERAL

15 CONTROL PANEL THE MAIN CONTROL PANEL bar C 1 Boiler pressure gauge Displays the pressure in the central heating circuit. 2. Storage cylinder temperature selector Allows you to set the temperature of the domestic hot water. 3 Green LED When lit, shows that a flame is being detected. 4 Two figure digital display Displays information on boiler status. 5 Red LED When lit, shows that an error (alarm) condition has been detected. 6 Function selector 0 Off / Reset { Winter mode } Summer mode 7 / Central heating temperature selector Allows you to set the temperature of the central heating water. 8 Storage cylinder temperature gauge Displays domestic hot water temperature. GENERAL 15

16 UNPACKING THE PRODUCT The boiler is delivered in a single package on a wooden pallet, covered by a PVC sheet and inside a wooden crate. The following items are delivered in a plastic bag (A) inside the boiler: User Manual, and Installation and Maintenance Manual for the boiler Hydraulic test certificate Outdoor temperature sensor LPG conversion kit (diaphragm, label). The instruction manuals are integral parts of the boiler. Once located, read them thoroughly and keep them safe. A DIMENSIONS AND WEIGHT RESIDENCE COLONNA CONDENS boilers are designed and made for installation in combined central heating and domestic hot water production systems. Description L 600 mm P 610 mm H 1540 mm Net weight 130 Kg Gross weight (with packaging) 150 Kg H L P 16 INSTALLER

17 HANDLING Once you have removed the packaging, proceed as follows to handle and move the boiler. Unscrew the 4 screws (A) shown in the figure and remove the boiler from the pallet. A A Remove the front panel (1) to facilitate handling and movement of the boiler. Grip the boiler at points (B) and tilt it backwards, then grip it at points (B) and (C) to lift it. An optional handling bracket kit is available to provide a better grip at points (B). Do not lift the boiler by its casing but only by rigid parts such as its base and top frame. 1 LIFT OPEN TILT B B Do not lift the boiler by its casing but only by rigid parts such as its base and top frame. aa Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation. C C INSTALLER 17

18 PLACE OF INSTALLATION RESIDENCE COLONNA CONDENS boilers can be installed in any indoor location provided the flue gases are adequately removed and comburent air drawn in from outdoors. Provided the boiler is properly installed, the boiler room itself does not need any ventilation as such, since the combustion circuit of RESIDENCE COLONNA CONDENS boilers is sealed with respect to the environment. If instead comburent air is drawn from inside the boiler room itself, the room must have adequately dimensioned ventilation conforming to the relevant technical standards. IMPORTANT Before installing the boiler, thoroughly flush out all the pipes to remove any dirt and deposits that could compromise the correct functioning of the boiler. Open expansion chambers must be fitted with an overflow siphon connected to a drain point. Before lighting the burner for the first time, make sure that the boiler is configured for use with the type of gas supplied. The type of gas is specified on the packaging label and on the gas identification plate on the boiler itself. When installing the boiler, allow sufficient space around it to access all safety and control devices and to permit easy maintenance. b b Make sure that the boiler s index of electrical protection is adequate for the characteristics of the room where it is to be installed. If the specific weight of the gas supply to the burner is greater than the specific weight of air, all electrical parts must be installed at least 500 mm above floor level. aa RESIDENCE COLONNA CONDENS boilers must be installed indoors. They are not designed for outdoor use and are not fitted with automatic frost protection devices. 154 cm 50 cm 60 cm 50 cm 61 cm 100 cm 20 cm 18 INSTALLER

19 INSTALLATION IN OLDER SYSTEMS AND SYSTEMS REQUIRING MODERNISATION When installing RESIDENCE COLONNA CONDENS boilers in old systems or systems requiring modernisation, always perform the following checks: - Make sure that the flue is able to withstand the temperature of the combustion gases and that it has been designed and made in compliance with applicable standards. The flue must also be as straight as possible, sealed, insulated and not blocked or choked. - Make sure that the flue is fitted with a condensation drainage union. - Make sure that the electrical system has been installed by a qualified electrician in compliance with applicable standards. - Make sure that flow rate, head and direction of flow of the pumps are suitable and correct. - Make sure that the fuel feed line and any storage tank are made and installed in compliance with applicable standards. - Make sure that expansion vessels are big enough to contain the additional volume generated by thermal expansion. - Make sure that the central heating circuit has been flushed out to remove all sludge and lime scale, and that it has been bled and seal tested. - Make sure that a suitable water treatment system is installed. (See the Water in central heating systems section.) Refer to the r catalogue for details of specific products. The manufacturer declines all responsibility for damage caused by incorrectly constructed flue systems. Flue pipes for condensing boilers must be made from special materials, different from those used for standard non-condensing boiler flues. Use only products that do not corrode aluminium to flush out the system. WATER IN CENTRAL HEATING SYSTEMS INTRODUCTION Water used in central heating systems MUST be suitably treated to ensure the correct functioning of those systems and to guarantee an extended working life for boilers and all other system components. This applies not only to existing systems but to newly installed systems too. Sludge, limescale and other contaminants in water can cause irreversible damage to boilers even in relatively short times, and despite the use of top quality materials in their manufacture. Contact RIELLO s Technical Assistance Service for further information on water additives and their use. b Always conform to the standards and legislation applicable in the country of installation. INSTALLER 19

20 WATER IN CENTRAL HEATING SYSTEMS: INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF CENTRAL HEATING SYSTEMS 1. Chemical and physical characteristics of water The chemical and physical characteristics of water used in central heating systems must conform to the requirements of EN standard and to the following tables: ALUMINIUM BOILERS with furnace power < 150 kw Water used for first filling Water with system operating (*) ph Hardness fh < 10 < 10 Electrical conductivity μs/cm < 200 Chlorides mg/l < 25 Sulphides mg/l < 25 Nitrides mg/l < 25 Iron mg/l < 0,5 ALUMINIUM BOILERS with furnace power > 150 kw Water used for first filling Water with system operating (*) ph Hardness fh < 5 < 5 Electrical conductivity μs/cm < 150 Chlorides mg/l < 15 Sulphides mg/l < 15 Nitrides mg/l < 15 Iron mg/l <0,5 (*) values for water in system after 8 weeks of functioning General note on water used to top up systems: - If softened water is used to top up a system, 8 weeks of functioning after topping up, verify that the water in the system respects the above limits, in particular for electrical conductivity. - This check is not necessary if demineralised water is used to top up the system. 2. Central heating systems b Do not use automatic filling devices to add water to central heating systems. Use a manual device instead and record top-ups in the system service book. b If a system comprises a number of boilers, when that system is first put into service, make sure that all the boilers function simultaneously or on a short interval rotation basis in order to evenly distribute initial limescale deposits. b When you finish installing a system, always flush it out to remove installation residues. b Water used to fill a system for the first time and water used to top it up must always be filtered (using synthetic or metal mesh filters with a filtration rating of no less than 50 microns) to prevent sludge from forming and triggering deposit corrosion. b Before re-filling an existing system, clean and flush it out thoroughly. Only fill the boiler after the central heating circuit has been thoroughly flushed out. 2.1 New central heating systems Initial filling of the system must be performed slowly. In theory, once filled and bled of all air, a heating circuit should not need topping up. Systems should also be operated at maximum working temperature the first time they are started up, in order to facilitate de-aeration. (Gas is not released from the water at low temperatures.) 20 INSTALLER

21 2.2 Reconditioning old central heating systems If a boiler has to be replaced, do not refill the entire central heating circuit if the quality of water in it conforms to requirements. If the quality of water fails to conform to requirements, either recondition the old water or separate the water circuits (water in the boiler circuit must conform to requirements). 3. Corrosion 3.1 Deposit corrosion Deposit corrosion is an electro-chemical phenomenon caused by the presence of foreign bodies (sand, rust, etc.) in the water mass. These solid substances generally form deposits (sludge) in the bottom of the boiler, in the tube heads and in the joins of tube bundles. These parts of the boiler can therefore be affected by micro-corrosion caused by the electrochemical potential difference created between the metal parts in contact with impurities and other metal parts around them. 3.2 Stray current corrosion Stray current corrosion is caused by the different electrical potentials of the water in the boiler and the metal body of the boiler or piping. Stray current corrosion is easily identified by the regular tiny conical holes it leaves. b All metallic parts should be grounded by an efficient earth cable for this reason. 4. Eliminating air and gas from central heating systems. If oxygen enters a circuit continuously or even intermittently (e.g. in under-floor heating systems whose pipes are not protected by impermeable synthetic sheaths, in circuits with open expansion vessels, or in circuits that require frequent top-ups) always separate the boiler s water circuit from the central heating circuit. Mistakes to avoid and precautions. From what has been said above we can see that it is essential to avoid two main factors that could lead to corrosion. These are contact between system water and air and the continuous addition of fresh water to the circuit. To eliminate contact between system water and the air (thus avoiding oxygenation of the system water), we need to: - ensure that the expansion vessel is a closed vessel, and of the correct size and pre-charge pressure (the pressure to be checked periodically); - ensure that the system is always kept at a pressure higher than atmospheric pressure at all points (including the pump suction side) and under all operating conditions (precisely because the seals, gaskets and joins in a water circuit are designed to resist pressure from within, but not to resist a vacuum within); - ensure that no part of the system is made from materials that are permeable to gases (e.g. plastic pipes with no oxygen barrier destined for under-floor heating systems). b Finally, never forget that boiler failures caused by encrustation and corrosion are not covered under the terms of the warranty. INSTALLER 21

22 WATER CONNECTIONS Before installing the boiler, thoroughly flush out all the pipes of the central heating circuit. Connect the boiler to the water supply with a shut-off cock upstream. Connect the condensate drain pipe to a domestic water drain in accordance with national and local legislation and standards. The water fittings have the following specifications: Gas MI RI ACS AFS VSS S Gas supply 3/4" M CH flow 1" M CH return 1" M DHW outlet 3/4" M DHW inlet 3/4" M DHW circuit safety valve Drain The condensate drain pipe must be watertight. b b Connect a pipe to the boiler condensate collector (S) and route it to a domestic water drain in compliance with the relevant standards. The manufacturer declines all responsibility for damage caused by water escaping from the condensate drain pipe. The boiler s safety valves must also be connected to a suitable collection and drain system. The manufacturer declines all responsibility for damage caused by water escaping from the safety valves. Circuits filled with anti-freeze must be fitted with water disconnectors. The choice of system components and the method of their installation are left up to the installer. Installers must use their expertise to ensure proper installation and functioning in compliance with all applicable legislation MI RI GAS ACS VSS AFS 34 S 22 INSTALLER

23 Condensate collection Locate the corrugated condensate drain pipe (S) at the rear of the burner and connect it to a domestic water drain in accordance with national and local legislation and standards. Always maintain a slope i of over 3 and ensure that the diameter of any hose used is greater than that of the boiler s own condensate drain pipe. The connection to the waste water drain must be made in compliance with national and local legislation and standards. S Condensate from the boiler and from the flue should be channelled to the same drain point. The base of the boiler must be perfectly horizontal and flat over the entire area of the boiler frame in order to avoid condensate drainage problems. Any condensate neutralisation units deemed necessary may be connected downstream from the siphon. Evaluate the neutralisation unit after one year of operation to estimate the duration of the neutralisation charge. The total duration of the charge can be estimated from the level after one year. i i 3 Flue BOILER Condensate from burner Condensate from stack To drain or neutralisation unit if installed Drain INSTALLER 23

24 C ELECTRICAL CONNECTIONS All the boiler s internal electrical connections have been pre-wired and tested in the factory. Only the following connections are needed for installation. Connect the boiler to the mains power supply (single phase 230V-50Hz) using the cable (1) from the rear of the appliance. Connect up the room thermostat (TA) and the outdoor temperature sensor (SE). 1 OUTDOOR TEMPERATURE SENSOR (SE) AND ROOM THERMOSTAT (TA) Remove the front panels by pulling them forwards. Remove the two screws (A) and tilt the control panel (B) downwards. B A 24 INSTALLER

25 Open the cover (D) to access the internal terminals and make the connections as shown in the diagram below. M4 CR PO D SE TBT/ACP M3a SB TA nero M5 M3 F Legend CR Remote control SE Outdoor temperature sensor SB Storage cylinder temperature sensor TA Room thermostat F Fuse 3.15A F (fast) PO Programmateur horaire (accessorie) TBT Low temperature thermostat APC Condensate pump alarm M3 M5 Connection terminals M4a On completion of all connections, replace all components in the opposite order. The following instructions are mandatory: 1 Use a multi-pole magnetic thermal trip switch and disconnector conforming to IEC-EN standards (with a contact gap of at least 3 mm). 2 Respect the L (Phase) - N (Neutral) polarity. 3 Use cables with a cross section of 1.5 mm 2 or more, complete with end terminals. 4 Always refer to the electrical wiring diagrams in this manual when performing any electrical work. 5 Ensure that an efficient ground connection is provided. aa It is strictly forbidden to use fuel and/or water pipes to ground the appliance. The manufacturer declines all responsibility for damage caused by failing to ground the appliance adequately or by failure to respect the wiring diagrams provided in this manual. INSTALLER 25

26 OUTDOOR TEMPERATURE SENSOR Correct positioning of the outside temperature sensor is essential to proper indoor temperature control. The sensor must be installed outside the building to be heated, about 2/3 of the way up a NORTH or NORTH-WEST facing wall, well clear of any flues, doors, windows and out of direct sunlight. Fixing the outdoor temperature sensor to the wall Unscrew the protective cover from the sensor, turning it anti-clockwise, to access the sensor terminals. Mark the position of the hole, and drill a 5x25 hole for the expansion plug. Fix the sensor casing to the wall using the expansion plug provided. Insert a two core cable (with cross section between 0.5 and 1 mm2, not supplied) to connect the sensor to the boiler. Connect the two wires of the cable to the sensor terminals. Polarity is irrelevant. Connect the cable from the outdoor temperature sensor to the boiler as instructed in the "ELECTRICAL CONNECTIONS" section. Screw the protective cover back on the outdoor temperature sensor. Position the sensor on a smooth area of wall. Prepare a smooth contact area for the sensor casing if the wall is made from exposed brick or other rough material. Avoid joins in the cable between the outside sensor and the control panel. If different cable lengths have to be joined, make sure that the joins are sealed and adequately protected. If cable ducts are used to route the sensor connection cable, keep these well clear of any power cables (230Vac). Correspondence table Measured temperature ( C) Resistance of outdoor temperature sensor (Ω). T ( C) R (Ω) T ( C) R (Ω) T ( C) R (Ω) INSTALLER

27 FUEL CONNECTIONS The boiler must be connected to the methane gas supply in compliance with the relevant standards. Perform the following checks before making the connection. Check that the boiler is compatible with the type of gas supplied. Check that the gas supply pipes have been thoroughly cleaned. Check that the gas supply pipe is equal to or greater in diameter than the boiler s own gas inlet fitting (3/4 ) and that its pressure drop is less than or equal to the difference between the supply point and the boiler. GAS Fit a suitably sized filter in the gas supply pipe if the gas supply contains any solid particles. The gas feed line must be suitable for the flow rate demanded by the burner. The gas feed system must also be equipped with all the necessary safety and control devices required by applicable legislation and standards. On completion of the installation, check that all joints are sealed in compliance with the relevant installation standards. FLUE GAS OUTLET AND COMBURENT AIR INTAKE RESIDENCE COLONNA CONDENS boilers are type C sealed boilers, and must therefore have a sealed flue gas vent pipe and comburent air intake pipe, both of which must terminate outdoors. The boiler cannot function without these pipes and connections. These pipes form an integral part of the boiler even if they are supplied in a separate kit. Coaxial and twin pipe terminals are available INSTALLER 27

28 C13 C53 B23P B53P C83 C63 C33 C43 C23 C13 C13 B23P Upstream fan. Comburent air intake directly from the room where the boiler is installed. Flue gas vent via horizontal or vertical flues designed to operate at positive pressure, with air ventilation to room. C53 B53P Upstream fan. Comburent air intake directly from the room where the boiler is installed. Flue gas vent via horizontal or vertical flues designed to operate at positive pressure, with air ventilation to room. C13 Concentric wall vent. Twin flue pipes can also be used, but the wall through-pipes must be concentric or located close enough to be subjected to similar wind conditions. If twin intake and vent pipe terminals are used, they must be positioned within a square of 50 cm. C23 Concentric vent to shared flue (air intake and flue gas vent via same concentric pipe). C33 Concentric roof vent. Outlets as for C13. The levels of the intake and vent apertures must be less than 50 cm apart. C43 Vent and air intake via shared twin pipes, subjected to similar wind conditions. Separate wall or roof vent and air intake, in areas of different pressure but never on opposite walls. C63 Upstream fan. Comburent air intake and flue gas vent without flue terminals. If terminals are installed, they must conform to the requirements of EN C83 Upstream fan. Comburent air intake through wall and flue gas vent to roof. In Italy, refer to DPR 412 and UNI CIG 7129 standard. SEALED INSTALLATION (TYPE C) Coaxial flues (Ø 60/100) Coaxial flues can be oriented in whatever direction is most convenient for the room, provided the maximum lengths specified alongside are respected. Ensure that the flue gas vent pipe has a 1% slope towards the boiler. Use of flue pipes longer than the maximum specified alongside leads to a loss of heat output from the boiler (see table alongside). The boiler automatically adapts its ventilation system to suit the type of installation and the length of the flue. Never obstruct or partly choke the comburent air intake pipe. Use only flues specifically designed for use with condensing boilers. Follow the instructions provided in the flue pipe kit to install the flues. Maximum straight length Pressure drop (m) of coaxial flue Ø 60/100 (m) 45 bend 90 bend Maximum straight length is the maximum length of the flue without bends, terminals or joints. Values referred to atmospheric pressure at sea level. 28 INSTALLER

29 Coaxial flues (Ø 80/125) An adapter kit must be used in order to install this size of flue. Coaxial flues can be oriented in whatever direction is most convenient for the room, provided the maximum lengths specified alongside are respected. Use only flues specifically designed for use with condensing boilers. Follow the instructions provided in the flue pipe kit to install the flues. Maximum straight length of Pressure drop (m) coaxial flue Ø 80/125 (m) 45 bend 90 bend Maximum straight length is the maximum length of the flue without bends, terminals or joints. Values referred to atmospheric pressure at sea level. Twin flues (Ø 80) Twin flues can be oriented in whatever direction is most convenient for the room. Ensure that the flue gas vent pipe has a 1% slope towards the boiler. b b Use of flues longer than the maximum specified alongside leads to a loss of heat output from the boiler (see table alongside). The boiler automatically adapts its ventilation system to suit the type of installation and the length of the flue. Never obstruct or partly choke the comburent air intake pipe. Use only flues specifically designed for use with condensing boilers. Follow the instructions provided in the flue pipe kit to install the flues. Maximum straight length of Pressure drop (m) twin flues Ø 80 (m) 45 bend 90 bend Maximum straight length is the maximum length of the flue without bends, terminals or joints. Values referred to atmospheric pressure at sea level. Unscrew the screws and remove the cover from the air intake (A), and connect the comburent air pipe to it. Connect the vent pipe to the flue gas outlet (B). If the flue pipes used differ in length from those shown in the table, make sure that the total length does not exceed 80 metres and that the maximum length of each individual pipe section does not exceed 40 metres. B A INSTALLER 29

30 FORCED/OPEN INSTALLATION (TYPE B23P/ B53P) Boiler gas vent flue (Ø 80) The vent flue can be oriented in whatever direction is most convenient for the room. In this configuration, a Ø mm adapter must be fitted in order to connect the boiler to a Ø 80 mm vent pipe. In this type of installation, comburent air is drawn from inside the boiler room, which must therefore have adequate ventilation. Uninsulated flue pipes are potentially dangerous and can cause burns. Ensure that the flue gas vent pipe has a 1% slope towards the boiler. The boiler automatically adapts its ventilation system to suit the type of installation and the length of the flue. Maximum length of flue gas Pressure drop (m) vent pipe (Ø 80) (m) 45 bend 90 bend INSTALLER

31 FILLING AND DRAINING THE SYSTEM RESIDENCE COLONNA CONDENS boilers incorporate a CH system fill cock. Make sure that the system filling cock (3) is closed before you start to fill or drain the system. FILLING THE STORAGE CYLINDER Make sure that the storage cylinder drain cock (4) is closed. Open a DHW user tap. Open the DHW circuit shut-off cocks and slowly fill the storage cylinder until clean, air-free water flows out from the taps in a uniform manner FILLING THE CENTRAL HEATING SYSTEM Make sure that the delivery group drain cock (5) and boiler drain cock (6) are closed. Slacken off the cap of the automatic vent valves (1) and (2) to let air out of the system. Open the CH system fill cock (3) and slowly fill the system until the pressure gauge (7) reads out a value between 1 and 1.2 bar. Close the CH system fill cock (3). Bleed the central heating circuit thoroughly to ensure that no air remains in it (see page 45). 3 4 The drain points on the solar circuit safety valves must also be connected to a suitable collection and drain system. b b The manufacturer declines all responsibility for damage caused by water escaping from the safety valves bar 7 INSTALLER 31

32 DRAINING Switch the electricity supply OFF at the control panel and at the system s main switch before starting to drain the boiler or storage cylinder. ON OFF DRAINING THE CENTRAL HEATING SYSTEM Make sure that the CH system fill cock (3) is closed. Close the shut-off cocks for the central heating and domestic hot water circuits. Connect a hose to the hose union on the drain cock (6) and open the cock. Close the drain cock (5) once the circuit is empty. 5 DRAINING THE STORAGE CYLINDER Close the shut-off cocks for the central heating and domestic hot water circuits. Make sure that the CH system fill cock (3) is closed. Connect a hose to the storage cylinder drain cock (4) and open the cock. Close the drain cock (4) once the circuit is empty. 6 NOTE! Open a hot water tap to facilitate draining of the storage cylinder INSTALLER

33 PREPARING FOR INITIAL START-UP Initial start-up must be performed by an authorised and qualified heating engineer from a r Technical Assistance Centre. Remove the front panel from the boiler and perform the following checks before switching the boiler on or testing any of its functions. Check that the type of gas supply is correct for the boiler. Check that the fuel and water shut-off cocks to the boiler are open. Check that the central heating water pressure gauge shows a pressure between 1 and 1.2 bar with the system cold. Check that the gas supply pressure is correct for the boiler. Proceed as follows to check the gas supply pressure: Unscrew the pressure measurement point screw upstream from the gas valve about two turns, and connect a pressure gauge to the measurement point Turn the boiler s mains power switch ON Adjust a room thermostat to generate a heat request When the burner is operating at full power, check that the gas supply pressure lies between the minimum and rated pressure values given in the Technical Specifications table Eliminate the heat request Disconnect the pressure gauge and tighten the pressure measurement screw upstream from the gas valve. Pressure measurement point upstream from valve INITIAL START-UP Once you have completed all the checks listed above, proceed as follows to start up the boiler for the first time. Turn the mains power switch ON. ON OFF Turn the boiler function selector to Summer "}" or Winter "{", depending on which functioning mode you require. TECHNICAL ASSISTANCE SERVICE 33

34 Every time electrical power is switched on, the boiler performs an automatic venting cycle that lasts about 12 minutes. Throughout this cycle the two digits of the display flash alternately. At the end of the automatic venting cycle, check the pressure on the gauge (7) again. If necessary, turn the boiler off at the mains power switch and at the control panel and refill the CH circuit as instructed on page 31. Once the CH circuit reaches the right pressure, switch the boiler back on again to start the automatic venting cycle. Repeat these steps until the pressure in the CH circuit stabilises between 1 and 1.2 bar. To interrupt the automatic venting cycle unscrew the four screws (A), remove the front trim (B) and press the combustion analysis button (CO) bar 7 A CO B A A A 34 TECHNICAL ASSISTANCE SERVICE