cod rev. 0 09/15 RESIDENCE COLONNA CONDENS KV EN INSTALLATION AND MAINTENANCE MANUAL

Transcription

1 cod rev. 0 09/15 RESIDENCE COLONNA CONDENS KV EN INSTALLATION AND MAINTENANCE MANUAL

2 CONFORMITY RESIDENCE COLONNA CONDENS r boilers conform to the following directives: Directive 92/42/EEC on efficiency requirements Gas Appliances Directive 2009/142/CE Low Voltage Directive 2006/95/CE Electromagnetic Compatibility Directive 2004/108/CE Ecodesign Directive 2009/125/CE for energy-related products Energy Labelling Directive 2010/30/EU Delegated Regulation (UE) N. 811/2013 Delegated Regulation (UE) N. 813/2013 Delegated Regulation (UE) N. 814/2013 RANGE MODEL CODE RESIDENCE COLONNA CONDENS KV/

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 10 Water circuit 11 Location of sensors 12 Pump 13 Wiring diagram 16 Control panel 17 INSTALLER Unpacking the product page 18 Dimensions and weight 18 Handling 19 Place of installation 20 Installation in older systems and systems requiring modernisation 21 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 36 Warning LEDs and errors 37 Automatic temperature control 38 Settings 41 Conversion from one gas type to another 42 Maintenance 43 Troubleshooting 45 Useful information 48 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. 0 (09/15) is made up of 52 pages. 4 CONTENTS

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. SAFETY DEVICES RESIDENCE COLONNA CONDENS boilers are equipped with the following main safety devices: Ionisation flame control device for shutting off gas supply in case of flame failure. Water pressure switch to prevent ignition in case of low water pressure (with error display). Maximum temperature thermostat to detect overheating and ensure the safety of the entire system (with error display requiring reset by OFF-RESET button). Flue gas temperature sensor to shut down the burner if flue gas temperature exceeds the safety threshold. Flue gas venting safety system incorporated in the pneumatic functioning system of the gas valve. Overtemperature diagnosis with double sensor on central heating flow and return (temperature threshold 85 C). 3 bar central heating circuit safety valve. 8 bar domestic hot water circuit safety valve. Circulation diagnosis by comparison of readings of central heating flow and return temperature sensors. 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 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 Device type Fuel Device category RESIDENCE COLONNA CONDENS KV/ ISCN condensing boiler for mixed heating B23P-B53P-C13-C23-C33-C43-C53- C63-C83 G20/G31 II 2H3P Rated heat input at furnace referred to HVC (LCV) 22,2 (20) kw Minimum rated heat input at furnace referred to HVC (LCV) 6,7 (6) kw Useful (rated) heat output 20 kw Maximum useful heat output (80-60 C) P4 19,6 kw Maximum useful heat output (50-30 ) 21,0 kw 30% heat output with return at 30 C (P1) 6,5 kw Reduced heat output at (80-60 ) 5,9 kw Reduced heat output at (50-30 ) 6,4 kw Efficiency class in central heating mode B Efficiency class in DHW mode A Seasonal energy efficiency in central heating mode hs 91 % Efficiency at rated heat input in high temperature mode (HCV) h4 Useful Pn (60-80 C) 88,2 % Efficiency at 30% rated heat input in low temperature mode (HCV) h1 Useful 30% of Pn 96,9 % Energy efficiency in DHW mode hwh 75 % Storage cylinder charging profile L Heat loss in standby mode Pstby 196 W Combustion efficiency 95,6 % Annual energy consumption QHE 62 GJ Daily electrical energy consumption Qelec 0,209 kwh Annual electrical energy consumption AEC 46 kwh Daily fuel consumption Qfuel 15,9 kwh Annual fuel consumption AFC 12 GJ Noise (sound power) LWA 51 db(a) Nox (referred to HCV) 38 mg/kwh Emissions at maximum heat input CO2 9 % CO w.a. < 170 ppm T flue gas 55 C Nox (referred to HCV) 22 mg/kwh Emissions at minimum heat input CO2 9 % CO 35 ppm T flue gas 37 C Residual head, concentric pipes, 0.85 m 100 Pa Air flow rate (G20) 24,98 Nm3/h Flue gas flow rate (G20) 26,99 Nm3/h Flue gas mass flow rate 0,009 Kg/s Maximum operating pressure 3 bar Safety thermostat trip temperature 110 C Maximum operating temperature 90 C Boiler water temperature selection range C Boiler water capacity 5 l Volume of CH circuit expansion vessel 12 l Precharge of CH circuit expansion vessel 1,5 bar Power supply 230 ~ 50 V-Hz GENERAL 9

10 Electric degree of protection category B X4D IP category C X5D IP Absorbed power supply (max) 118 W Consumption at full load Elmax 65 W Consumption at part load Elmin 19 W Consumption in standby mode PSB P sb 4 W Description RESIDENCE COLONNA CONDENS KV/ Type of storage cylinder Vitrified Storage cylinder layout Vertical Heat exchanger layout Vertical Maximum power absorbed by heat exchanger 28 kw DHW temperature setting range C Storage cylinder capacity 137 l Coil water capacity 5,5 l Coil heat exchange surface area 0,91 m 2 DHW production T 25 C 13,6 l/min T 35 C 8,8 l/min Specific flow rate (EN625) 23,3 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/ ISCN 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 2,96-2,12 Sm 3 /h Minimum gas flow rate, DHW/CH 0,63-0,63 Sm 3 /h Maximum fan speed, DHW/CH giri/min Minimum fan speed 1700 giri/min Burner ignition slow fan speed 3700 giri/min 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 2,17-1,55 Sm 3 /h Minimum gas flow rate, DHW/CH 0,47-0,47 Sm 3 /h Maximum fan speed, DHW/CH giri/min Minimum fan speed 1700 giri/min Burner ignition slow fan speed 3700 giri/min ACCESSORIES For a complete list of accessories and details of their compatibility, refer to the Catalogue. 10 GENERAL

11 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 Flangia bollitore 30 Storage cylinder flange 31 Bypass pipe DHW recirculation GENERAL 11

12 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 12 GENERAL

13 PUMP TECHNICAL SPECIFICATIONS DESCRIPTION ERP ready 2015 Electrical consumption 53 W EEI Part 3 (*) 0,20 P L,Avg (**) 24 W Minimum pressure at pump suction inlet 0,5 bar (*) Energy efficiency index according to ERP 2015 (Commission regulations 641/2009 and 622/2012) (**) Average annual electricity consumption according to ERP 2015 (Commission regulations 641/2009 and 622/2012) PUMP CURVE p [kpa] H [m] Residual head Flow rate 0 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4 Q [m³/h] P1 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 Q [l/s] [W] ,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4 Q [m³/h] Curves are referred to a water density of Kg/m 3, a temperature of +20 C, and a kinematic viscosity of mm 2 /s (0.474 cst). GENERAL 13

14 ADJUSTING THE PUMP Display Meaning % power LED 1 flashing green Stand-by 0 The boiler's pump is ErP 2015 Ready, and suitable for use in central heating only/domestic hot water applications. (only with PWM control) The pump can be controlled by an external PWM LED 1 green and LED 2 Low load 0-25 yellow, both lit signal and has 4 different pressure curves for central LED 1 green and LEDs Low-medium heating applications. 2, 3 yellow, all lit load When controlled by a PWM signal, pump speed varies according to the frequency of the incoming PWM signal, modulating head/flow rate on the basis of the selected curve. In the absence of a PWM signal, the pump runs at full speed and delivers the head/flow rate determined by the selected curve. Each curve is characterised by a maximum head expressed in metres. LED 1 green, LEDs 2, Medium-high , 4 yellow, all lit load LED 1 green, LEDs 2, High load , 4, 5 yellow, all lit PUMP LOAD CURVE User interface The user interface features one button (1), one red/green LED (2) and four yellow LEDs. BUTTON (1) LED (2) 50 % 75 % 100 % 25 % Functioning mode A) Performance display When the pump is functioning, LED 1 is green. The four yellow LEDs indicate the instantaneous power draw as shown in the table above. In functioning mode, all active LEDs are lit (not flashing) to differentiate this condition from setting mode. If the pump is stopped by the external control signal, LED 1 flashes green. Via this interface, users can access:: Functioning (performance display) mode. Pump performance is displayed during functioning as a % of current draw with respect to rated load. Alarm conditions can be seen from the colour of LED (2). Setting mode. Setting mode is accessed by pressing the button (1), and is used to select the pump curve. B) Alarm display If the pump detects one or more alarm conditions, LED 1 changes from green to red. When an alarm is active, the LEDs indicate the type of alarm as shown in the following table. If more than one alarm is active at the same time, the LEDs only show the alarm condition with the highest priority. Alarm priority follows the order of the table. When no alarm is active, the user interface automatically displays pump performance. 14 GENERAL

15 Display Meaning Function Action LED 1 red and LED 5 yellow, both lit The pump rotor is blocked. The pump automatically attempts to start every 1.5 seconds. Wait or check that the pump rotor is free to rotate. LED 1 red and LED 4 yellow, both lit LED 1 red and LED 3 yellow, both lit Supply voltage too low. Electronic controller error Indication only. The pump continues to function. The pump has stopped because supply voltage is too low or because an error has occurred in the internal electronic controller Check the voltage of the power supply Check the voltage of the power supply or replace the pump Setting mode A) Setting display To switch from performance display to setting display, press button (1). The LEDs shows the current setting. See the following table for the meaning of the LED display. Setting display mode shows the type of pump control or the currently selected pump curve. Settings cannot be changed in performance display mode. After 2 seconds, the display returns to performance display mode. If LED 1 is red, it indicates that an alarm is active or that the the pump is being controlled by an external (PWM) signal. LEDs 2 and 3 show the type of internal control while LEDs 4 and 5 show the currently selected curve (1, 2, 3 or 4). All these LEDs are yellow in colour.. LEDs except the red LED flash for one second to indicate that the button lock function has been activated/ deactivated.. C) Setting mode To access setting mode, press and hold the button (1) for between 2 and 10 seconds. The button lock must be deactivated in order to change settings. Available settings are displayed in a pre-defined sequence that is repeated every time the button is briefly pressed and released. If the button is not pressed for over 10 seconds, the pump exits setting mode and returns to performance display mode. The last settings made are saved in memory. See the table above for the meanings of the LED sequences. LED 1 LED 2 LED 3 LED 4 LED 5 PERFORMANCE SETTING MENU > 10 s. PWM A Red ON Curve 1 (4m) s. SELECTED SETTING > 2 s. X Curve 2 (5m) - ON - Curve 3 (6m) - ON ON Curve 4 (7m) - - ON 10 s. B) Button lock function The button lock function serves to prevent improper use or accidental changes to pump settings. When the button lock is active, pressing the button has no effect. This prevents users from accidentally accessing setting mode while allowing them to use setting display mode. Press and hold the button for more than 10 seconds, to activate / deactivate the button lock. When the button is held down for 10 seconds, all the GENERAL 15

16 WIRING DIAGRAM OPE OPE brown CH blue N black DHW TA black pink 5 yellow/green brown blue orange yellow/green brown blue M5 M3 Power supply 230 VAC N L F blue brown VHv VG CI VD SC ER N L TAC EA brown blue blue brown blue brown red black CN CN3 FA2 FA1 CN5 CN2 2 3 pink F1 F2 X4 blue M3a X red bianco TLS TLA VLv TBT APC P2 CONTROL CARD X2 JP4 P3 X16 P purple PO SB SM black black orange orange white white black black blue blue grey white white red red white brown SF SR M4 PA SE CR 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 Room timer-thermostat connection terminals M3a-M4 Outdoor temperature sensor/condensate pump/low temperature thermostat/ remote control 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) 16 GENERAL

17 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 17

18 UNPACKING CONFORMITÀ 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 18 INSTALLER

19 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 19

20 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 20 INSTALLER

21 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 flue gases from a condensing boiler, 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. Finally, the flue must be fitted with adequate condensate collection and drainage systems. Make sure that the electrical system has been installed by a qualified electrician in compliance with applicable standards. Make sure that the gas feed line and any LPG 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 flow rate and useful head of the pump are suitable for the characteristics of the central heating system (see page 12). Make sure that the circuit has been flushed out to remove all sludge and lime scale, and has been bled and seal tested. Make sure that the boiler s condensate drain system (siphon) is properly connected to a domestic water drain. Make sure that a suitable water treatment system is installed if the quality of the supply/recirculation water so demands. (Refer to the reference values listed in the table alongside.) REFERENCE VALUES PH 6-8 Electrical conductivity below 200 mv/cm (25 C) Chlorine ions below 50 ppm Sulphuric acid ions below 50 ppm Total iron below 0,3 ppm Alkalinity M below 50 ppm Total hardness below 35 F Sulphur ions below Ammonia ions none Silicon ions below 30 ppm b Flue pipes for condensing boilers must be made from special materials, different from those used for stan- The manufacturer declines all responsibility for damage caused by incorrectly constructed flue systems. b dard non-condensing boiler flues. Use only products that do not corrode aluminium to flush out the system. 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 clean domestic water drain in compliance with the relevant standards. The water fittings have the following specifications: Gas MI RI ACS RC AFS S Gas supply 3/4" M CH flow 1" M CH return 1" M DHW outlet 3/4" M DHW recirculation 3/4" M DHW inlet 3/4" M 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 RC AFS 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 compliance with the relevant 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. Condensate from the boiler and from the flue should be channelled to the same drain point. S 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. D M4 CR SE TA black M5 M3 F Legend CR Remote control SE Outdoor temperature sensor TA Room thermostat F Fuse 3.15A F (fast) M3-M5 Room timer-thermostat connection terminals 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. 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. C23 Concentric vent to shared flue (air intake and flue gas vent via same concentric pipe). C33 Concentric roof vent. Outlets as for C13. C43 Vent and air intake via shared twin pipes, subjected to similar wind conditions. C53 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. 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. Horizontal Maximum straight length of coaxial flue Ø 60/100 (m) Vertical Pressure drop (m) 45 bend 90 bend 7,80 0,5 0,85 Maximum straight length of coaxial flue Ø 60/100 (m) Pressure drop (m) 45 bend 90 bend 7,80 0,5 0,85 Maximum straight length is the maximum length of the flue without bends, terminals or joints. 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 25 0,5 0,85 Maximum straight length is the maximum length of the flue without bends, terminals or joints. 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 ,5 0,8 Maximum straight length is the maximum length of the flue without bends, terminals or joints. 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 70 0,5 0,85 30 INSTALLER

31 FILLING AND DRAINING THE SYSTEM RESIDENCE COLONNA CONDENS boilers incorporate a CH system fill cock (3). 1 FILLING THE STORAGE CYLINDER Make sure that the CH system fill cock (3) is closed. Make sure that the storage cylinder drain cock (4) is closed. Open the DHW user taps. 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). Every time electrical power is switched on, the boiler performs an automatic venting cycle that lasts about 12 minutes. Follow closely the instructions given in the Initial start-up section to fill and vent the system. 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 system s main switch and at the control panel before starting to drain the boiler or storage cylinder. ON OFF DRAINING THE CENTRAL HEATING SYSTEM 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 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 GARANZIA 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 fuel and water shut-off cocks to the boiler are open. Check that the type and pressure of the gas supply are as specified for the boiler. Check that the central heating water pressure gauge shows a pressure between 1 and 1.2 bar with the system cold. Check also that the central heating circuit has been properly bled. 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. Turn the boiler function selector to Summer "}" or Winter "{", depending on which functioning mode you require. ON OFF bar 4 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 28. 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). 7 A CO B A A A TECHNICAL ASSISTANCE SERVICE 33

34 SUMMER (}): With the function selector set to Summer, the boiler functions only in domestic hot water mode. The temperature gauge (1) shows the temperature of the hot water inside the storage cylinder. To ensure correct functioning, set the room temperature thermostat to its minimum setting C 1 WINTER ({): With the function selector set to Winter, the boiler functions in central heating and domestic hot water modes. The display shows the temperature of the central heating flow. Set the room thermostat to the required temperature (~ 20 C) or, if the system has a timer or timer-thermostat, make sure that this is switched On and adjusted to the required temperature (~ 20 C). SETTING CENTRAL HEATING WATER TEMPERATURE USING THE OUTDOOR TEMPERATURE SENSOR Since an outdoor temperature sensor is installed, the system automatically adjusts the temperature of the central heating flow to bring room temperature rapidly to a level determined on the basis of outdoor air temperature. To adjust room temperature manually with respect to the automatic setting calculated by the control card, turn the heating temperature selector "/": clockwise to increase temperature or anti-clockwise to reduce it. The available adjustment range is between -5 and +5 comfort levels as shown on the digital display when the knob is turned (see the AUTOMATIC TEMPERATURE CONTROL section) C SETTING DOMESTIC HOT WATER TEMPERATURE To adjust the temperature of the domestic hot water (bath, shower, washbasins, etc.), turn the knob with the. symbol. The digital display reads out the new temperature setting as you turn the knob. The adjustment range for DHW temperature is between 35 and 60 C. The display always reads out the setting as you adjust water temperature, both for central heating water and domestic hot water. Once you have set the desired temperature, the setting is memorised after 4 seconds and the display once again reads out the actual temperature of the CH flow or DHW as detected by the temperature sensor bar 34 TECHNICAL ASSISTANCE SERVICE

35 STARTING UP THE BOILER If a timer or room thermostat is installed, these must be switched on and adjusted to a temperature higher than current room temperature before the boiler can start up. The boiler will remain in stand-by mode until the burner ignites following a request for heat. The green LED (3) on the left of the control panel lights to show that a flame is being detected. The boiler will carry on functioning until the set temperatures are reached, when it will return to stand-by mode while continuing to display the central heating flow temperature bar 3 If any ignition or functioning errors occur, the boiler performs a SAFETY SHUTDOWN. The green LED on the control panel goes out and an error code flashes on the display. The red LED (5) indicates a burner lock-out. See the WARNING LEDS AND ERRORS section for details on the various error codes and how to reset the boiler bar 4 RESET FUNCTION To reset the boiler, turn the function selector to 0, then return it to its previous position and check that the red LED goes out. Provided correct functioning conditions have been restored, the boiler restarts automatically. As soon as the burner ignites the green LED lights and the digital display will read out current operating temperature. Turning the function selector to 0 without returning it to { or }, will not reset the boiler If the boiler does not restart after a number of resets, call your local Technical Assistance Centre. Under normal conditions, when the function selector is turned to 0, the digital display reads out - - unless the frost protection function (AF) is active, or combustion analysis (CO) in being performed. 0 bar 4 TECHNICAL ASSISTANCE SERVICE 35