INSTALLATION AND MAINTENANCE MANUAL

CONDENSING BOILERS B - BK 5 B - 5 BK INSTALLATION AND MAINTENANCE MANUAL BK 5 BK B 5 B

CONFORMITY INSIEME CONDENS r condensing boilers conform to the following directives: Directive 9//EEC on efficiency requirements and Annex E and Pres. Republic Decree n., August 99 (HHHH) EN 77 Standard: Gas-fired central heating boilers; specific requirements for condensing boilers with a nominal heat input not exceeding 70 kw Directive 009//EC - Gas Appliances Low Voltage Directive 00/95/EC Electromagnetic Compatibility Directive 00/08/EC Ecodesign Directive 009/5/CE for energy-related products Energy Labelling Directive 00/0/EU Delegated Regulation (UE) N. 8/0 Delegated Regulation (UE) N. 8/0 Delegated Regulation (UE) N. 8/0 RANGE MODEL CODE INSIEME CONDENS B 0090 INSIEME CONDENS 5 B 009590 INSIEME CONDENS BK 0098 INSIEME CONDENS 5 BK 0097

Dear heating engineer, Congratulations on having chosen a INSIEME CONDENS r 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.

CONTENTS GENERAL Page General Safety Information 5 Precautions 5 Description of the appliance Safety devices Identification 7 Data plate 7 Layout 8 Technical specifications 0 Accessories Water circuit Location of sensors Pumps Functional wiring diagrams 5 Control panel 7 INSTALLER Page Unpacking the product 9 Dimensions and weight 9 Handling 0 Place of installation Installation in older systems and systems requiring modernisation Water in heating circuits Water connections Draining the condensate 7 Electrical connections 8 Fuel connections 0 Flue gas vent and comburent air intake Filling and emptying the system TECHNICAL ASSISTANCE SERVICE Page Preparing for initial start-up 8 Initial start-up 8 Checks during and after initial start-up Temporary shutdown Preparing for extended periods of disuse Maintenance Oil burner - Layout - Removing the burner - Accessing the nozzle, flame guide and electrodes 5 - Setting the electrodes - Oil pump - Adjusting pump pressure - Adjusting the air damper - Removing the burner control box 7 - Burner electrical connections 7 - Functioning program 8 Disassembling and cleaning the boiler 9 Troubleshooting 5 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 00058, Rev. (0/), is made up of 5 pages. CONTENTS

GENERAL SAFETY INFORMATION b 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. br INSIEME CONDENS boilers 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. b The boiler must only be used for the purpose specified by r and for which it is designed. 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. b 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. b Do not clean the boiler or any of its component parts with easily flammable substances (e.g. petrol, alcohol, etc.). b Periodically check that operating pressure in the water circuit is over bar. If water pressure is consistently low, contact r s Technical Assistance Service or a professionally qualified heating engineer. b If the boiler is not going to be used for an extended period of time, proceed as follows to prepare it for shutdown: - Switch the appliance OFF at the control panel. - Turn the mains power switch OFF. - Close the boiler s fuel cock and heating circuit water cock. - Drain the central heating circuit if there is any risk of freezing. b Low temperature (under-floor) heating systems must be fed through a circuit fitted with a mixer valve. b The boiler must be serviced at least once a year. b 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 r Technical Assistance Centre. PRECAUTIONS The operation of any appliance that uses fuel, electrical power and water demands that a number of fundamental safety precautions be respected. a Do not allow children or infirm persons to operate the boiler unsupervised. a 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 your local r Technical Assistance Service or a professionally qualified heating engineer. a Do not touch the boiler when barefoot or wet. anever clean or service the boiler without first disconnecting it from the mains electricity supply by turning the main power switch and the control panel switch OFF. a Do not tamper with or adjust the safety or control devices without prior authorisation and instructions from the boiler s manufacturer. a 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 Do no obstruct or restrict the vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion. a Do not expose the boiler to the elements. It is not designed for use outdoors. a Do not switch the boiler off if outside temperature drops below ZERO (risk of freezing). a Do not store containers of flammable substances in the room where the boiler is installed. a 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

PRODUCT DESCRIPTION INSIEME CONDENS boilers are high efficiency, oil fuelled condensing boilers. B models are designed for heating only. BK models come with a 0 litre vitrified storage cylinder and are designed for combined heating and domestic hot water production. These boilers may be used as type C boilers if fitted with a specific accessory kit to extend the comburent air inlet to draw in air from outside the room where they are installed. The single stage jet burner is fitted with a fuel oil pre-heater to ensure dependable functioning under all conditions. The most important technical features of these boilers are: - The combustion chamber and heat exchange system are specially designed and shaped to achieve the best possible volume to surface area ratio. - The primary heat exchanger features vitrified steel pipes and wave turbulators to recover and transfer a large proportion of the thermal energy carried by the combustion fumes. - The secondary heat exchanger is made from AISI 90L stainless steel and recovers latent heat from the flue gases, boosting efficiency to up to 0. % (50 C 0 C range). - The horizontal vitrified storage cylinder incorporates a vertical primary heat exchanger coil. The exclusively designed heat exchange unit and secondary exchanger are insulated by ultra-efficient high density glass wool. The controls and safety devices of the electromechanical control panel conform to all applicable technical and safety standards. A specific accessory kit is available to control a high temperature central heating circuit. Additional controllers can also be added to manage additional direct/mixed circuits or to integrate the boiler with r solar water heating systems. SAFETY DEVICES INSIEME CONDENS boilers are equipped with the following safety devices: - A safety thermostat that forces the boiler to perform a safety shutdown if temperature exceeds the safety threshold (0 C). - A flue gas thermostat in the bottom of the secondary heat exchanger that signals an error if flue gas temperature exceeds 90 C. - A burner safety system: The oil burner is equipped with an electronic controller that monitors the correct functioning of the selected program. In the event of an error, this controller displays a burner lockout signal on the control panel. b 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. You may attempt to restart the boiler after a short delay (see preparing for initial start-up). a Never start the boiler up even for a short period if the safety devices are not functioning correctly or have been tampered with. b Safety devices must only be replaced by r s Technical Assistance Service using original spare parts. Refer to the spare parts catalogue supplied with the boiler. Always check that the boiler is functioning correctly after any repairs. GENERAL

IDENTIFICATION r INSIEME CONDENS boilers are identified by two plates: - Data plate This lists the appliance s technical specifications and performance data. RIELLO S.p.A. Via Ing.Pilade Riello 7 705 Legnago (VR) - ITALY T0779GE Mod. Cod. N PAESE DI DESTINAZIONE/PAYS DE DESTINATION/BESTIMMUNGSLAND/LAND VON BESTEMMING COUNTRY OF DESTINATION/PAÍS DE DESTINO/PAÍS DE DESTINO: COMBUSTIBILE/COMBUSTIBLE/BRENNSTOFF/BRANDSTOF/FUEL/COMBUSTIBLE/COMBUSTÍVEL: TIPO/TYP/TYP/TYPE/TIPO/TIPO: IP NO X mg/kwh V~Hz W S % Qn(min)= kw kw Pn(min)= kw kw Pmw= bar T = C Qn(max)= Pn(max)= kw kw kw D= l/min kw Pms= bar T = C - 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 7 705 Legnago (VR) - ITALY T0779GE Mod. Cod. N Qn(max) Pn(max) Pms bar kw kw b 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 production (BK models only) RIELLO S.p.A. Via Ing.Pilade Riello 7 705 Legnago (VR) - ITALY T0779GE Qn Pn IP Central heating circuit characteristics Rated heat input Rated useful heat output Index of protection Mod. Cod. N PAESE DI DESTINAZIONE/PAYS DE DESTINATION/BESTIMMUNGSLAND/LAND VON BESTEMMING COUNTRY OF DESTINATION/PAÍS DE DESTINO/PAÍS DE DESTINO: COMBUSTIBILE/COMBUSTIBLE/BRENNSTOFF/BRANDSTOF/FUEL/COMBUSTIBLE/COMBUSTÍVEL: Pmw Pms Maximum operating pressure for DHW system (BK models only) Maximum operating pressure, central heating system TIPO/TYP/TYP/TYPE/TIPO/TIPO: V~Hz IP W Qn(min)= kw kw NO S X mg/kwh % T η D Temperature Efficiency Specific flow rate (BK models only) Pmw= bar T = C Pn(min)= Qn(max)= Pn(max)= kw kw kw kw kw kw D= l/min Pms= bar T = C GENERAL 7

LAYOUT INSIEME CONDENS B - 5 B SIDE VIEW FRONT VIEW 5 5 7 5 7 8 8 9 0 9 7 8 0 8 TOP VIEW - Control panel - Side panel - Automatic vent valve - Automatic vent valve collector 5 - Boiler sensor sockets - Fitting for CH circuit safety valve 7 - Fitting for CH circuit expansion vessel 8 - Flame inspection window 9 - Burner 0 - Condensate drain siphon - Socket for flue gas thermostat - Insulated boiler body - Insulated secondary heat exchanger - Flue gas vent pipe 5 - Cover panel - Front panel 7 - Boiler drain cock 8 - Lifting points 9 - Flue fitting 9 5 8 GENERAL

INSIEME CONDENS BK - 5 BK SIDE VIEW FRONT VIEW 7 5 7 8 9 5 8 5 8 9 7 5 5 9 0 0 0 0 - Control panel - Side panel - Automatic vent valve - Automatic vent valve collector 5 - Boiler sensor sockets - Fitting for CH circuit safety valve 7 - Fitting for CH circuit expansion vessel 8 - Flame inspection window 9 - Burner 0-0 litre insulated storage cylinder - Storage cylinder drain cock - Condensate drain siphon - Socket for flue gas thermostat - Insulated boiler body 5 - Insulated secondary heat exchanger - Flue gas vent pipe 7 - Cover panel 8 - Front panel 9 - Boiler drain cock 0 - Lifting points - Storage cylinder temperature sensor socket - Storage cylinder flange - CH circuit filling cock - Magnesium anode 5 - Non-return valve - Storage cylinder pump 7 - Flue fitting 7 7 TOP VIEW 5 GENERAL 9

TECHNICAL SPECIFICATIONS Description INSIEME CONDENS B BK 5 B 5 BK Type of boiler condensing boiler for central heating condensing boiler for mixed heating condensing boiler for central heating condensing boiler for mixed heating Fuel B-BP-C-C-C Rated heat input at furnace referred to HVC (LCV) 7, (,0), (,5) kw Useful (rated) heat output 5 kw Maximum rated heat output (80-0 C) P 5,0, kw 0% heat output with return at 0 C (P) 7,5 0,0 kw Useful heat output (50-0 ), 5,0 kw Efficiency class in central heating mode B Efficiency class in DHW mode - - Seasonal energy efficiency in central heating mode hs 89 % Efficiency at rated heat input in high Useful Pn h temperature mode (HCV) (0-80 C) 90, 9,0 % Efficiency at 0% rated heat input in low Useful h temperature mode (HCV) 0% of Pn 95,7 95, % Combustion efficiency 97,8 97,7 % Energy efficiency in DHW mode hwh - - % Storage cylinder charging profile - - Heat loss in standby mode Pstby 70 W Annual energy consumption QHE 8 08 GJ Daily electrical energy consumption Qelec - - kwh Annual electrical energy consumption AEC - - kwh Daily fuel consumption Qfuel - - kwh Annual fuel consumption AFC - - GJ Noise level (sound power) LWA 8 9 7 9 db(a) Nox (referred to HCV) mg/kwh Emissions at maximum heat input CO <,5 % CO w.a. < < 5 ppm Δt flue gas 80-0 C < 75 C 50-0 C < 55 C Flue gas mass flow rate (*) 0,008 0,0 Kg/s Flue gas thermostat trip temperature 90 C Water-side pressure drop (Δt 0 C) 0 mbar Maximum working pressure bar Safety thermostat trip temperature 0 C Maximum operating temperature 8 C Minimum return temperature 0 C Boiler water temperature selection range - 8 C Boiler water capacity 8 l Maximum condensation at 00% rated heat output (50-0 C),5,8 l/h Power supply 0 ~ 50 V-Hz Electric degree of protection X0D IP Absorbed power supply (max) 5 8 5 8 W Consumption at full load Elmax 5 W Consumption at part load Elmin,5 W Consumption in standby mode PSB P sb 5 W Oil (*) Values referred to atmospheric pressure at sea level. 0 GENERAL

Description of storage cylinder INSIEME CONDENS BK 5 BK Description of storage cylinder Vitrified Cylinder layout Horizontal Heat exchanger layout Horizontal Maximum energy consumption 5 8 kw DHW water temperature setting range 0-70 C Storage cylinder capacity 0 l Coil water capacity 5,5 l Heat exchanger surface area 0,85 m Domestic hot water production with ΔT 5 C 70 l/h Water draw in 0 minutes with storage cylinder at 8 C 5 l Water draw in 0 minutes with storage cylinder at 0 C 0 l Specific flow rate (EN 5) l/min. Replenishment time (Δt 5 C) 0 min. Maximum operating pressure of storage cylinder bar For a complete list of accessories and details of their compatibility, refer to the Catalogue. ACCESSORIES GENERAL

WATER CIRCUIT INSIEME CONDENS B - 5 B RI 8 7 MI INSIEME CONDENS BK - 5 BK RI 8 7 5 5 9 0 - Boiler body - Secondary heat exchanger - Automatic vent valve - Burner 5 - Boiler drain cock - Drains 7 - Condensate drain siphon 8 - Flue gas vent 9 - Storage cylinder pump 0 - Non-return valve - Storage cylinder drain cock - CH system filling cock - Storage cylinder MI - CH flow RI - CH return UAC - Domestic hot water outlet EAF - Domestic cold water inlet RC - DHW recirculation UAC RC EAF MI GENERAL

LOCATION OF SENSORS INSIEME CONDENS B - 5 B INSIEME CONDENS BK - 5 BK 5 8 8 7 INSIEME CONDENS B - 5 B - Boiler thermostat sensor - Minimum temperature thermostat sensor - Boiler temperature gauge sensor - Safety thermostat sensor 8 - Flue gas thermostat sensor INSIEME CONDENS BK - 5 BK - Boiler thermostat sensor - Minimum temperature thermostat sensor - Boiler temperature gauge sensor - Safety thermostat sensor 5 - Maximum temperature thermostat sensor - Storage cylinder thermostat sensor 7 - Storage cylinder temperature gauge sensor 8 - Flue gas thermostat sensor GENERAL

PUMPS r INSIEME CONDENS boilers come without a pump. A pump must therefore be provided as part of the installation. In order to choose a pump of the right size, bear in mind the boiler s water-side pressure drop, as shown in the figure below. 00 PRESSURE PERDITA DI DROP CARICO (mbar) 550 500 50 00 50 00 50 00 50 00 50 0 5 B - BK B - BK 0 500 000 500 000 500 000 500 000 500 5000 FLOW PORTATA RATE (l/h) (l/h) a Never run the pump dry. GENERAL

FUNCTIONAL WIRING DIAGRAMS INSIEME CONDENS B - 5 B L PE N T T S B FU TM LV LR DAI S NC NC RE C C T N BR C TR CO COA A D B C Brown Yellow-green Blue Black Red White COMG C C C MO 5 7 8 9 0 7 8 5 TF TS L N PE TA TA LPI NPI PE L N PE 0 V~50 Hz Power supply TA PI Electrical connections to be made by the heating engineer DAI - Automatic shut-off device (not supplied; only where required; see also the "Fuel connections" section). The automatic shut-off device (DAI) and the relay (RE) must be suitable for a 0 VAC power supply. RE - Relay (not supplied) K COMG - position function selector TF - Flue gas thermostat (90 C) TS - Safety thermostat (0 C) TM - Minimum temperature thermostat (0 C) TR - Boiler control thermostat ( - 8 C) K - Burner control relay LV - Mains power indicator LR - Burner lockout indicator FU - Mains power fuse. A-T CO - pin connector BR - Burner connector MO - Terminal strip Connections to be made by the heating engineer PI - CH pump TA - Room thermostat GENERAL 5

INSIEME CONDENS BK - 5 BK Brown Yellow-green Blue Black Red White COMG LV LR FU MO TA L N PE 0 V~50 Hz Power supply PI PB Electrical connections to be made by the heating engineer BR COME/I CO COA K CO COA C 90 C 8 C 5 7 8 9 5 7 8 9 9 0 5 7 8 9 5 7 8 0 A D B C D B C C L PE N T T S B 8 7 5 TR L N PE TA TA LPI NPI PE LPB NPB PE C NC TF C DAI NC C C T TS S RE N TM TL TB COMG - position function selector COME/I - Summer/Winter selector TF - Flue gas thermostat (90 C) TS - Safety thermostat (0 C) TM - Minimum temperature thermostat (0 C) TR - Boiler control thermostat ( - 8 C) TL - Maximum temperature thermostat (8-90 C) TB - Storage cylinder thermostat (0-70 C) K - Burner control relay LV - Mains power indicator LR - Burner lockout indicator FU - Mains power fuse. A-T CO - pin connector CO - 9 pin connector BR - Burner connector MO - Terminal strip PB - Storage cylinder pump DAI - Automatic shut-off device (not supplied; only where required; see also the "Fuel connections" section). The automatic shut-off device (DAI) and the relay (RE) must be suitable for a 0 VAC power supply. RE - Relay (not supplied) Connections to be made by the installer PI - CH pump TA - Room thermostat GENERAL

CONTROL PANEL INSIEME CONDENS B - 5 B 0 0 0 80 00 0 0 5 7 - Function selector I Off II On III On IIII Automatic mode (only active with temperature control kit installed) 8 - Boiler temperature gauge Displays the temperature of the central heating water. - Boiler control thermostat Allows you to set the temperature of the central heating water. - Electrical power indicator Lights to show that the system is receiving electrical power. 5 - Burner lockout indicator Lights to show that a burner lockout has occurred. - Manual reset for safety thermostat Allows you to reset the boiler if the safety thermostat trips. Unscrew the protective cover to access the reset button. 7 - Function indicators 8 - Manual reset for flue gas thermostat Allows you to reset the boiler if the flue gas thermostat trips. Unscrew the protective cover at rear of control panel to access the reset button. GENERAL 7

INSIEME CONDENS BK - 5 BK 0 0 0 80 00 0 0 0 80 00 7 0 0 0 0 8 9 5 0 - Function selector I Off II On III On IIII Automatic mode (only active with temperature control kit installed) - Boiler temperature gauge Displays the temperature of the central heating water. - Boiler control thermostat Allows you to set the temperature of the central heating water. - Electrical power indicator Lights to show that the system is receiving electrical power. 5 - Burner lockout indicator Lights to show that a burner lockout has occurred. - Summer (I) / Winter (II) selector 7 - Storage cylinder temperature gauge Displays the temperature of the domestic hot water. 8 - Manual reset for safety thermostat Allows you to reset the boiler if the safety thermostat trips. Unscrew the protective cover to access the reset button. 9 - Storage cylinder thermostat Allows you to set the temperature of the domestic hot water. 0 - Function indicators - Manual reset for flue gas thermostat Allows you to reset the boiler if the flue gas thermostat trips. Unscrew the protective cover at rear of control panel to access the reset button. 8 GENERAL

UNPACKING THE PRODUCT r INSIEME CONDENS boilers come in a robust wooden cage, protected by a PVC sheet. The following items are delivered in a plastic bag inside the boiler: INSIEME CONDENS BK - 5 BK - Installation, operation and maintenance manual - Spare parts catalogue - Warranty certificate - Hydraulic test certificate - Non-return valve INSIEME CONDENS B - 5 B b The instruction manual is an integral part of the boiler. Once located, read it thoroughly and keep it safe. DIMENSIONS AND WEIGHT P INSIEME CONDENS BK - 5 BK P INSIEME CONDENS B - 5 B H H L L Description INSIEME CONDENS B 5 B BK 5 BK L 00 00 00 00 mm P 85 85 05 05 mm H 05 05 50 50 mm Net weight 0 0 00 00 kg INSTALLER 9

HANDLING Once you have removed the packaging, proceed as follows to handle the boiler. - Remove the front panel () by pulling it forwards. - Remove the screws () securing the boiler to the wooden pallet. - Make sure that the equipment used to move the boiler is adequate for the weight involved. - Insert two /" pipes () through the lifting points () inside the boiler and lift the boiler carefully off the pallet. INSIEME CONDENS B - 5 B ROTATE INSIEME CONDENS BK - 5 BK ROTATE b Wear suitable personal protective equipment and use suitable safety devices. a Do not leave packaging material within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation. 0 INSTALLER

PLACE OF INSTALLATION r INSIEME CONDENS boilers must be installed in rooms with suitably dimensioned ventilation grilles in conformity to applicable technical standards. b When installing the boiler, allow sufficient space around it to access all safety and control devices and to permit easy maintenance. a These boilers must be installed indoors. They are not designed for outside use. 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. INSTALLATION IN OLDER SYSTEMS AND SYSTEMS REQUIRING MODERNISATION When installing these 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. b The manufacturer declines all responsibility for damage caused by incorrectly constructed flue systems. b Flue pipes for condensing boilers must be made from special materials, different from those used for standard non-condensing boiler flues. HEATING CIRCUIT WATER 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

WATER IN CENTRAL HEATING SYSTEMS: INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF CENTRAL HEATING SYSTEMS. 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 88 standard and to the following tables: STEEL BOILERS with furnace power < 50 kw Water used for first filling Water with system operating (*) ph -8 7,5-9,5 Hardness fh < 0 < 0 Electrical conductivity μs/cm < 50 Chlorides mg/l < 0 Sulphides mg/l < 0 Nitrides mg/l < 0 Iron mg/l < 0,5 STEEL BOILERS with furnace power > 50 kw Water used for first filling Water with system operating (*) ph -8 7,5-9,5 Hardness fh < 5 < 5 Electrical conductivity μs/cm < 00 Chlorides mg/l < 0 Sulphides mg/l < 0 Nitrides mg/l < 0 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.. 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.. 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.) INSTALLER

. 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).. Corrosion. 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.. 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.. 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

WATER CONNECTIONS r INSIEME CONDENS boilers are designed and made for installation in combined central heating and domestic hot water production systems. The following table lists the specifications of the water fittings. INSIEME CONDENS BK - 5 BK b Install the non-return valve supplied with the boiler in the central heating flow pipe. 70 8 INSIEME CONDENS B - 5 B MI 8 RI Sc MI 08 UAC 0 7 RI Sc RC EAF 95 0 0 70 00 00 Description INSIEME CONDENS B 5 B BK 5 BK MI - CH flow " M " M " M " M Ø RI - CH return " M " M " M " M Ø UAC - Domestic hot water outlet - - /" F /" F Ø EAF - Domestic cold water inlet - - /" F /" F Ø RC - DHW recirculation - - /" F /" F Ø Sc - Condensate drain / Safety valve - b The safety valve must be connected to a suitable collection and drain system. The manufacturer declines all responsibility for damage caused by water escaping from the safety valve. b Circuits filled with anti-freeze must be fitted with water disconnectors. b Low temperature (under-floor) heating systems must be fed through a circuit fitted with a mixer valve. b The choice of system components and the method of their installation are left up to the heating engineer installing the system. Installers must use their expertise to ensure proper installation and functioning in compliance with all applicable legislation. INSTALLER

TYPICAL WATER SYSTEM SCHEMATICS INSIEME CONDENS B - 5 B MI 5 - Isolating valve - Non-return valve - CH circuit pump - CH circuit expansion vessel (also available as accessory) 5 - CH circuit safety valve (also available as accessory) - Drain 7 - Softener filter 8 - Pressure reducer RI MI - CH flow RI - CH return 8 7 EAF INSIEME CONDENS BK - 5 BK UAC MI 0 RI 9 8 7 EAF - Isolating valve - Non-return valve - CH circuit pump - CH circuit expansion vessel (also available as accessory) 5 - CH circuit safety valve (also available as accessory) - Drain 7 - Softener filter 8 - Pressure reducer 9 - DHW safety valve (also available as accessory) 0 - CH circuit expansion vessel (also available as accessory) - DHW recirculation pump 0 MI RI - CH flow - CH return EAF - Domestic cold water inlet UAC - Domestic hot water outlet INSTALLER 5

0 0 80 0 00 0 0 0 TYPICAL WATER SYSTEM SCHEMATIC for INSIEME CONDENS B - 5 B with DEDICATED ACCESSORIES SE 9 RI MI SCo M R MC UAC 0 0 RC SZ PI 0 PB 0 8 SB 7 0 PR 0 5 7 M C PS 8 9 SC 0 0 0 SB 0 0 7 0 5 0 EAF 0 0 Valve group 9 8 - Solar collector - Collector sensor socket - Manual bleed valve (accessory) - Bleed valve 5 - Vent valve - Pressure gauge 7 - Safety valve 8 - Drain 9 - Expansion vessel 0 - Isolating valves - Temperature gauge - Flow regulator - Flow meter - Pressure reducer 5 - Softener filter - Non-return valve 7 - Thermostatic mixer valve 8 - Storage cylinder 9 - r RVS temperature controller (accessory) UAC - Domestic hot water outlet EAF - Domestic cold water inlet MI - CH flow RI - CH return MC - To SC from boiler RC - Return from SC to boiler M - To SC from collector R - Return from SC to collector PB - Solar storage cylinder heating pump PI - Central heating pump PR - DHW recirculation pump PS - Solar circuit pump SE - Outdoor temperature sensor SC - Boiler temperature sensor SZ - Zone temperature sensor SB - Storage cylinder top temperature sensor SB - Storage cylinder bottom temperature sensor SCo - Collector temperature sensor Nota: The above schematic is purely indicative. The r RVS temperature controller (accessory) provides a programmable output "QX" that can be used to control any of the following devices: - Solar circuit pump PS (5890 = Q5 solar circuit pump) Solar controller parameters: 509=yes; 570=sensor; 590=collector sensor B; 59=B - DHW recirculation pump PR (5890 = Q DHW recirculation pump) DHW recirculation parameters: 570=sensor; 590=B9 - Central heating circuit pump PI (5890 = CRP Q0 CH pump). It is NOT possible to have all three functions together. INSTALLER

DRAINING THE CONDENSATE b Always maintain a slope i of over and ensure that the diameter of any hose used is greater than that of the boiler s own condensate drain pipe. i i b The connection to the waste water drain must be made in compliance with national and local legislation and standards. b Condensate from the boiler and from the flue stack should be channelled to the same drain point. b The surface on which the boiler stands must be perfectly horizontal and flat over the entire area of the boiler frame in order to avoid condensate drainage problems. Condensate from boiler Condensate from stack BOILER Flue gas vent pipe b 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. To drain or neutralisation unit if installed drain b It is mandatory to use a condensate trap (see the r catalogue). INSTALLER 7

ELECTRICAL CONNECTIONS r INSIEME CONDENS boilers are fully cabled in the factory. The only connections required for installation are those to the control panel terminal strip. B Proceed as follows to access the control panel terminal strip: A - Remove the front and top panels (A) and (B) - Unscrew the screws (C) and remove the cover (D) D C - Route the power cable (E) through the cable clamp (F) and fix it in place - Access the terminal strip (G). G F E G 8 INSTALLER

- Make the electrical connections as shown in the diagram alongside. L N PE TA TA L N PE 5 7 8 9 0 b Remove the jumper (TA-TA) before connecting a room thermostat. G L N PE TA TA 5 On completion of the electrical connections, replace all removed components in the opposite order. Automatic shut-off device (DAI) (not supplied; only where required; see also the "Fuel connections" section). - Connect up the automatic shut-off device (DAI) as shown in the wiring diagram on page 5. This ensure that fuel only passes when the burner is functioning. TA PI L N PE 0 V~50 Hz Power Alimentazione supply elettrica L Live N Neutral PE Earth/ground TA Room thermostat PI CH pump (accessory kit) G Terminal strip b The following instructions are mandatory: - Use a multi-pole magnetic thermal trip switch and disconnector conforming to EN standards (with a contact gap of at least mm). - Respect the L (Phase) - N (Neutral) polarity. Keep the ground wire about cm longer than the power wires. - Use cables with a cross section of.5 mm or more, complete with end terminals. - Always refer to the electrical wiring diagrams in this manual when performing any electrical work. 5 - Make sure the appliance is connected to an efficient ground. a It is strictly forbidden to use fuel and/or water pipes to ground the appliance. a Do not route the power cable or room thermostat cables near hot surfaces (like heating circuit flow pipes). Use a suitable class of cable if there is any possibility of contact with parts at temperatures above 50 C. 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 9

FUEL CONNECTIONS r INSIEME CONDENS boilers have their fuel connections at the rear. Fuel supply hoses must pass through the gap between the boiler base and the floor before being connected to the fuel pump. H (*) max. m If the oil feed system is in negative pressure, the return line must reach the same height as the suction line. This avoids having to install a bottom valve, which would be essential if the return hose were to reach above the level of the fuel. H b The installer must ensure that negative pressure in the oil feed never exceeds 0. bar (0 cm Hg). If this value is exceeded, the fuel oil will release gas. Make sure that the oil hoses are perfectly oil-tight. b Clean out the oil tank at suitable intervals. b The oil feed line must be suitable for the flow rate demanded by the burner. The oil feed system must also be equipped with all the necessary safety and control devices required by applicable legislation and standards. Refer to the table alongside for oil feed line characteristics. b A filter must be installed in the oil feed line. b Make sure that the oil return line is not kinked or blocked before starting up the boiler. Excessive backpressure can lead to breakage of the pump seal. Priming the pump To prime the oil pump simply start up the burner and check for a flame. If the burner enters lockout before any fuel reaches it, wait at least 0 seconds then press the remote burner reset button on the control panel and repeat the ignition procedure until the flame lights. (*) Automatic shut-off device (only where required). See the wiring diagram on page 5 for details of the electrical connections. H (m) L (m) Øi (8 mm) Øi (0 mm) 0 5 00 0,5 0 00 5 00,5 0 90 5 70 8 0,5 0 H = Head L = Maximum length of suction hose Øi = Internal diameter of hose - Suction port - Return port - By-pass screw - Pressure gauge fitting 5 - Pressure regulator - Vacuum gauge fitting 7 - Valve 8 - Auxiliary pressure measurement fitting 7 5 8 0 INSTALLER

FLUE GAS VENT AND COMBURENT AIR INTAKE The flue and the connection to the stack must be made in compliance with applicable laws and standards. Use of heat resistant, condensate resistant and stress resistant rigid pipe and sealed joints is mandatory. 7 r INSIEME CONDENS boilers can be installed as "sealed" boilers with the addition of the relevant accessory kit. Øi = 80 B BP C C B Upstream fan. Comburent air intake directly from the room where the boiler is installed. Flue gas vent via horizontal or vertical flues, with air ventilation to room. BP As B but with flue gas vent designed to operate at positive pressure. (*) C 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. (*) C Concentric roof vent. Outlets as for C. (*) C Upstream fan. Comburent air intake and flue gas vent without flue terminals. C C C (*) Configurations possible only with dedicated accessories installed (to be ordered separately). INSTALLER

Residual pressure INSIEME CONDENS B - BK 5 B - 5 BK Maximum residual pressure in flue gas vent (*) Pa 5 0 (*) Values referred to atmospheric pressure at sea level. Maximum equivalent length of pipes INSIEME CONDENS B - BK 5 B - 5 BK Category Flue Ø (mm) Maximum length of flue pipe (m) (*) Maximum length of flue pipe (m) (*) open B - BP twin flue pipes C concentric flue pipes C - C 80 0 0 80 0+0 0+0 80/5 0 0 (*) These length must be reduced by metres for every 90 curve and by.5 metres for every 5 curve. INSTALLER

b A check on the quality of combustion must be made on initial start-up. Combustion quality can be affected by parameters other than the length, height and position of the flue pipes. b All flue seals must be made from condensate (acid) resistant materials. r INSIEME CONDENS boilers can also be installed in B open configurations using suitable piping in compliance with applicable laws and standards. r INSIEME CONDENS boilers derive their comburent air from the room in which they are installed. Suitable air vents must therefore be provided in compliance with applicable laws and standards. a Never obstruct or restrict the air vents in the room where the appliance is installed. INSTALLER

FILLING AND EMPTYING THE SYSTEM INSIEME CONDENS B and 5 B boilers need a filling pipe to be connected to the central heating circuit return pipe. Models BK and 5 BK are equipped with a filling cock () for the central heating system and storage cylinder primary circuit. INSIEME CONDENS B and 5 B MI b See Appendix for further information on water treatment for the central heating system.. RI INSIEME CONDENS BK and 5 BK FILLING THE CENTRAL HEATING SYSTEM - Make sure that the boiler drain cock () is closed before you start filling the system. On models BK and 5 BK, make sure that the drain cock () is closed too. 5 Non-return valve OPEN Non-return valve OPEN - Open the non-return valve () on the CH flow pipe. On models BK and 5 BK, open the non-return valve (5) too. See the figure to ascertain the correct position for the dot on the screw. INSIEME CONDENS B and 5 B - Slacken off the cap of the automatic vent valve () to let air out of the system. INSTALLER

On models B and 5 B: - Open the water supply shut-off cocks and slowly fill the central heating system until the pressure gauge reads out a value of.5 bar (cold). INSIEME CONDENS BK and 5 BK On models BK and 5 BK: - Open the filling cock () and slowly fill the central heating system until the pressure gauge installed as part of the installation reads out a value of,5 bar. - Close the water supply shut-off cocks. On models BK and 5 BK, close the filling cock () too. Tighten down the cap on the automatic vent valve (5). INSIEME CONDENS BK and 5 BK - Close the non-return valve () on the CH flow pipe. On models BK and 5 BK, close the non-return valve (5) too. See the figure to ascertain the correct position for the dot on the screw. 5 Non-return valve in CLOSED (non-return) position FILLING THE STORAGE CYLINDER (models BK and 5 BK only) - Make sure that storage cylinder drain cock (fitted during installation) 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. Non-return valve in CLOSED (non-return) position INSTALLER 5

EMPTYING Switch the electricity supply OFF at the system s main switch and at the control panel before starting to empty the boiler or storage cylinder. 0 0 80 0 00 0 0 INSIEME CONDENS BK and 5 BK EMPTYING THE CENTRAL HEATING SYSTEM - Open the non-return valve () on the CH flow pipe. On models BK and 5 BK, open the non-return valve (5) too. See the figure to ascertain the correct position for the dot on the screw. - Close the water supply shut-off cocks. On models BK and 5 BK, make sure that the filling cock () is closed too. 5 Non-return valve OPEN Non-return valve OPEN - Connect a plastic hose to the nipple on the boiler drain cock (). On models BK and 5 BK, connect a plastic hose to the nipple on drain cock () too. Open the cocks. - When the system is completely empty, close the cock (). On models BK and 5 BK, close the cock () too. INSIEME CONDENS B and 5 B INSTALLER

INSIEME CONDENS BK and 5 BK - Close the non-return valve () on the CH flow pipe. On models BK and 5 BK, close the non-return valve (5) too. See the figure to ascertain the correct position for the dot on the screw. EMPTYING THE STORAGE CYLINDER (models B and 5 B only) - Close the shut-off cocks for the domestic hot water circuit. 5 Non-return valve in CLOSED (non-return) position - Connect a hose to the storage cylinder drain cock fitted on installation, and open the cock. - Close the drain cock once the storage cylinder is empty. NOTE: Open a hot water tap to facilitate emptying. Non-return valve in CLOSED (non-return) position INSTALLER 7

PREPARING FOR INITIAL START-UP It is essential to perform the following checks before starting up or testing the functioning of the boiler. - Check that the water supply and fuel shut-off cocks are open. - Check that the water pressure gauge shows a pressure over bar with the system cold. Check also that the water circuit is properly de-aerated. - Check that the expansion vessel (fitted on installation) is properly pre-charged. - Check that the electrical connections have been made correctly. - Check that the flue gas vent and air intake pipes have been correctly installed and connected. - Check that pump turns freely. Unscrew the inspection cap and use a flat blade screwdriver to check that the pump shaft turns smoothly. b Protect all electrical devices under the pump before you unscrew the inspection cap just in case water comes out. INITIAL START-UP Once you have completed all the checks listed above, proceed as follows to start up the boiler for the first time. - Set the room thermostat to the required temperature (~0 C) or, if the system has a timer or temperature controller, make sure that this is switched On and adjusted to the required temperature (~0 C). - Turn the system s mains power switch ON. - Turn the boiler thermostat to about the middle of the section with three lines. On models BK and 5 BK: - Turn the boiler thermostat to about the middle of the section with two lines. 0 0 80 0 00 0 0 0 0 80 0 0 0 0 8 TECHNICAL ASSISTANCE SERVICE

On models BK and 5 BK: - Turn the (I)Summer/(II)Winter selector to (II) Winter. 0 0 0 80 00 0 0 - Turn the function selector to ON (II) and make sure that the green power indicator lights. 0 0 0 80 00 0 0 The burner should ignite and remain in operation until the temperature setpoint is reached. If any ignition or functioning errors occur, the burner performs a LOCK-OUT and the red LED on the control panel comes on to indicate this. 0 0 0 80 00 b If a LOCK-OUT occurs, wait about 0 seconds before resetting the burner. 0 0 To reset the burner, press the button light on the burner. Wait for the burner to complete the entire start-up cycle again, up to the ignition of the flame. IMPORTANT Before it starts pre-ventilation (pre-purging), the oil burner pre-heats the fuel oil for about and half minutes. The first time the burner starts up for the winter, ignition problems can occur if the temperature of the fuel oil is below 8 C. After the burner has started up or times, the temperature of the supply increases and these problems disappear. TECHNICAL ASSISTANCE SERVICE 9

If the problems persist, proceed as follows to make sure that the flue gas thermostat has not tripped. - Wait about 5 minutes, then remove the cover from the flue gas thermostat reset button (8) and push the button. - Wait for the burner to complete the entire start-up cycle again, up to the ignition of the flame. 8 b If the flue gas thermostat trips repeatedly, make sure that the flue gas vent pipe is not blocked and that the flue has been installed correctly. b No warning signal is given if the safety thermostat trips, but the fact that is has tripped can be seen from the boiler temperature gauge (T>0 C). Proceed as follows to reset the safety thermostat: - Wait until boiler temperature falls below 80 C. - Remove the safety thermostat cover. 0 0 80 - Press the manual reset button. 0 00 0 0 - Wait for the burner to complete the entire fuel preheating and start-up cycle again, up to the ignition of the flame. 0 TECHNICAL ASSISTANCE SERVICE

CHECKS DURING AND AFTER INITIAL START-UP Once the boiler has started up, make sure that it shuts down and re-starts properly when: - The boiler thermostat and storage cylinder thermostat settings are changed. 0 0 80 0 00 0 0 0 0 80 0 0 0 0 - The function selector is moved from position (II) to (I) and back. 0 0 0 80 00 0 0 - The room thermostat or timer setting is changed. Make sure that all the pumps in the system are free and rotate in the right direction. Turn the main power switch OFF and make sure that the boiler shuts down completely. Provided all the above conditions are satisfied, start the boiler up again, then analyse the combustion fumes. TECHNICAL ASSISTANCE SERVICE