CONDENSING BOILERS 45 B - 55 B INSTALLATION AND MAINTENANCE MANUAL GENERAL
CONFORMITY INSIEME CONDENS r condensing boilers conform to the following directives: Efficiency Directive 9/4/EEC (HHHH) EN 677 Standard: Gas-fired central heating boilers; specific requirements for condensing boilers with a nominal heat input not exceeding 70 kw Directive 009/4/EC - Gas Appliances Low Voltage Directive 006/95EEC Electromagnetic Compatibility Directive 004/08EEC 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 RANGE MODEL CODE INSIEME CONDENS 45 B 00457 INSIEME CONDENS 55 B 00458
Dear heating engineer, Congratulations on having chosen a r INSIEME 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.
CONTENTS GENERAL Page General Safety Information 5 Precautions 5 Description of the appliance 6 Safety devices 6 Identification 7 Data plate 7 Layout 8 Technical specifications 9 Accessories 0 Water circuit 0 Location of sensors Pumps Functional wiring diagrams Control panel INSTALLER Page Unpacking the product 4 Dimensions and weight 4 Handling 5 Place of installation 6 Installation in older systems and systems requiring modernisation 6 Water in heating circuits 6 Water connections 9 Draining the condensate Electrical connections Fuel connections 5 Flue gas vent and comburent air intake 6 Filling and emptying the system 9 TECHNICAL ASSISTANCE SERVICE Page Preparing for initial start-up Initial start-up Checks during and after initial start-up 4 Temporary shutdown 5 Preparing for extended periods of disuse 5 Maintenance 6 Oil burner - Layout 7 - Removing the burner 7 - Accessing the nozzle, flame guide and electrodes 8 - Setting the electrodes 8 - Oil pump 9 - Adjusting pump pressure 9 - Adjusting the air damper 9 - Removing the burner control box 40 - Burner electrical connections 40 - Functioning program 4 Disassembling and cleaning the boiler 4 Troubleshooting 45 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 00446, Rev. 7 (09/5), is made up of 48 pages. 4 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. b r 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 RIELLO Technical Assistance Service or a professionally qualified heating engineer. a Do not touch the boiler when barefoot or wet. a Never 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 for heating only. They can also be used for combined heating and domestic hot water production if connected to an external storage cylinder. 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 904L stainless steel and recovers latent heat from the flue gases, boosting efficiency to up to 0. % (50 C 0 C range). 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. 6 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 7045 Legnago (VR) - ITALY T06779GE 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 7045 Legnago (VR) - ITALY T06779GE 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 Qn Central heating circuit characteristics Rated heat input RIELLO S.p.A. Via Ing.Pilade Riello 7 7045 Legnago (VR) - ITALY T06779GE Pn IP Pms T η Rated useful heat output Index of protection Maximum operating pressure, central heating system Temperature Efficiency 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: V~Hz IP W NO S X mg/kwh % Qn(min)= kw kw Pn(min)= kw kw Pmw= bar T = C Qn(max)= Pn(max)= kw kw kw kw D= l/min Pms= bar T = C GENERAL 7
LAYOUT INSIEME CONDENS 45 B - 55 B SIDE VIEW FRONT VIEW 4 5 0 4 5 5 6 6 0 7 7 8 9 8 4 6 TOP VIEW - Control panel - Side panel - Automatic vent valve 4 - Automatic vent valve collector 5 - Boiler sensor sockets 6 - Insulated boiler body 7 - Flame inspection window 8 - Burner 9 - Condensate drain siphon 0 - Insulated secondary heat exchanger - Flue gas vent pipe - Cover panel - Front panel 4 - Boiler drain cock 5 - Lifting points 6 - Socket for flue gas thermostat 7 - Flue fitting 7 6 0 5 4 8 GENERAL
TECHNICAL SPECIFICATIONS Description Type of boiler Fuel (*) Values referred to atmospheric pressure at sea level. INSIEME CONDENS 45 B 55 B condensing boiler for central heating B-BP-C-C-C6 Rated heat input at furnace referred to HVC (LCV) 47,7 (45) 58,4 (55) kw Useful (rated) heat output 4 5 kw Maximum rated heat output (80-60 C) P4 4, 5, kw 0% heat output with return at 0 C (P),0 5,9 kw Efficiency class in central heating mode Seasonal energy efficiency in central heating mode hs 90 % Efficiency at rated heat input in high Useful Pn h4 temperature mode (HCV) (60-80 C) 90,8 9,0 % Efficiency at 0% rated heat input in low Useful 0% h temperature mode (HCV) of Pn 95,6 95, % Combustion efficiency 97,8 % Heat loss in standby mode Pstby 80 70 W Annual energy consumption QHE 8 69 GJ Noise level (sound power) LWA 68 70 db(a) Nox (referred to HCV) < 08 mg/kwh CO <,5 % Emissions at minimm heat input CO w.a. < 5 ppm Δt flue gas 80-60 C <75 C Δt flue gas 50-0 C <50 C Flue gas mass flow rate (*) 0,07 0,00 Kg/s Flue gas thermostat trip temperature 90 C Water-side pressure drop (Δt 0 C) 60 5 mbar Maximum working pressure bar Safety thermostat trip temperature 0 C Maximum operating temperature 8 C Minimum return temperature 40 C Boiler water temperature selection range -8 C Boiler water capacity 4 4 l Maximum condensation at 00% rated heat output (50-0 C),9,5 l/h Power supply 0-50 V-Hz Electric degree of protection X0D IP Consumption at full load Elmax 60 W Consumption at part load Elmin 4 48 W Consumption in standby mode PSB P sb 5 5 W Oil A GENERAL 9
ACCESSORIES For a complete list of accessories and details of their compatibility, refer to the Catalogue. WATER CIRCUIT INSIEME CONDENS 45 B - 55 B RI 8 7 4 6 5 MI - Boiler body - Secondary heat exchanger - Automatic vent valve 4 - Burner 5 - Boiler drain cock 6 - Drains 7 - Condensate drain siphon 8 - Flue gas vent MI - CH flow RI - CH return 0 GENERAL
LOCATION OF SENSORS FRONT VIEW TOP VIEW 5 4 - Boiler thermostat sensor - Minimum temperature thermostat sensor - Boiler temperature gauge sensor 4 - Safety thermostat sensor 5 - Flue gas thermostat sensor 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. PRESSURE PERDITA DI DROP CARICO (mbar) 600 550 500 450 400 50 00 50 00 50 00 50 0 55 B 45 B 0 500 000 500 000 500 000 500 4000 4500 5000 FLOW PORTATA RATE (l/h) (l/h) a Never run the pump dry. GENERAL
FUNCTIONAL WIRING DIAGRAMS INSIEME CONDENS 45 B - 55 B L PE N T T S B4 FU LV LR DAI S NC NC RE C C T TR N BR C CO COA 9 0 4 5 6 7 8 COMG - 4 position function selector TF - Flue gas thermostat (90 C) TS - Safety thermostat (0 C) TM - Minimum temperature thermostat (40 C) TR - Boiler control thermostat (-8 C) K - Burner control relay LV - Mains power indicator LR - Burner lockout indicator FU - Mains power fuse 6. A-T CO - pin connector BR - Burner connector MO - Terminal strip TM A 4 D B C Brown Yellow-green Blue Black Red White COMG C C C 7 8 5 6 4 TF TS MO 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 Connections to be made by the heating engineer PI - CH pump TA - Room thermostat GENERAL
CONTROL PANEL INSIEME CONDENS 45 B - 55 B 0 40 60 80 00 0 0 6 4 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. 4 - 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. 6 - 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
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: - Installation, operation and maintenance manual - Spare parts catalogue - Warranty certificate - Hydraulic test certificate - Non-return valve b The instruction manual is an integral part of the boiler. Once located, read it thoroughly and keep it safe. DIMENSIONS AND WEIGHT Description INSIEME CONDENS 45 B 55 B L 600 600 mm P 0 0 mm H 05 05 mm Net weight 5 60 kg P H L 4 INSTALLER
HANDLING Once you have removed the packaging, proceed as follows to handle the boiler. - Remove the top panel () by pulling it upwards. - 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. - Lift the boiler carefully off the pallet using the eyebolts () on the boiler body. REMOVE 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. INSTALLER 5
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. 6 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 4868 standard and to the following tables: STEEL BOILERS with furnace power < 50 kw Water used for first filling Water with system operating (*) ph 6-8 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 6-8 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 7
. 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. 4. Eliminating air and gas from central heating systems If oxygen enters a circuit continuously or even intermittently (e.g. in under-floor heating systems whose pipes are not protected by impermeable synthetic sheaths, in circuits with open expansion vessels, or in circuits that require frequent top-ups) always separate the boiler s water circuit from the central heating circuit. Mistakes to avoid and precautions From what has been said above we can see that it is essential to avoid two main factors that could lead to corrosion. These are contact between system water and air and the continuous addition of fresh water to the circuit. To eliminate contact between system water and the air (thus avoiding oxygenation of the system water), we need to: - ensure that the expansion vessel is a closed vessel, and of the correct size and pre-charge pressure (the pressure to be checked periodically); - ensure that the system is always kept at a pressure higher than atmospheric pressure at all points (including the pump suction side) and under all operating conditions (precisely because the seals, gaskets and joins in a water circuit are designed to resist pressure from within, but not to resist a vacuum within); - ensure that no part of the system is made from materials that are permeable to gases (e.g. plastic pipes with no oxygen barrier destined for under-floor heating systems). b Finally, never forget that boiler failures caused by encrustation and corrosion are not covered under the terms of the warranty. 8 INSTALLER
WATER CONNECTIONS r INSIEME CONDENS boilers are designed and made for installation in central heating systems. They can also be used in combined central heating and domestic hot water production systems if connected to an external storage cylinder. The following table lists the specifications of the water fittings. INSIEME CONDENS 45 B INSIEME CONDENS 55 B 48 48 MI MI RI RI 67 49 67 Sc 49 Sc 0 4 b Install the non-return valve supplied with the boiler in the central heating flow pipe. Description INSIEME CONDENS 45 B 55 B MI - CH flow " M " M Ø RI - CH return " M " M 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 9
TYPICAL WATER SYSTEM SCHEMATICS MI EAF 8 7 6 5 4 RI - Isolating valve - Non-return valve - CH circuit pump 4 - CH circuit expansion vessel 5 - CH circuit safety valve 6 - Drain 7 - Softener filter 8 - Pressure reducer MI - CH flow RI - CH return 6 UAC 6 5 MI 9 0 6 RI EAF 8 7 4 6 - Isolating valve - Non-return valve - CH circuit pump 4 - CH circuit expansion vessel 5 - CH circuit safety valve 6 - Drain 7 - Softener filter 8 - Pressure reducer 9 - DHW recirculation pump 0 - Automatic vent valve - DHW circuit safety valve - DHW circuit expansion vessel - r 700 Storage cylinder MI - CH flow RI - CH return EAF - Domestic cold water inlet UAC - Domestic hot water outlet 0 INSTALLER
40 60 80 0 00 0 0 4 0 TYPICAL WATER SYSTEM SCHEMATIC for INSIEME CONDENS 45 B - 55 B with DEDICATED ACCESSORIES SE 9 4 RI MI SCo M R MC UAC 0 0 RC SZ PI 0 6 6 PB 0 8 SB 7 0 PR 6 0 6 5 7 6 M C PS 8 9 SC 0 0 0 SB 0 0 7 0 5 4 0 EAF 0 0 Valve group 9 8 - Solar collector - Collector sensor socket - Manual bleed valve (accessory) 4 - Bleed valve 5 - Vent valve 6 - Pressure gauge 7 - Safety valve 8 - Drain 9 - Expansion vessel 0 - Isolating valves - Temperature gauge - Flow regulator - Flow meter 4 - Pressure reducer 5 - Softener filter 6 - Non-return valve 7 - Thermostatic mixer valve 8 - Storage cylinder 9 - r RVS 4 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 4 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 B6; 59=B - DHW recirculation pump PR (5890 = Q4 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. Flue gas vent pipe BOILER 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 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
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: - Remove the front and top panels (A) and (B) A - Unscrew the screws (C) and remove the cover (D) C D - Route the power cable (E) through the cable clamp (F) and fix it in place - Access the terminal strip (G). G F E G INSTALLER
- Make the electrical connections as shown in the diagram alongside. L N PE TA TA L N PE 4 5 6 7 8 9 0 b Remove the jumper (TA-TA) before connecting a room thermostat. G L N PE TA TA 4 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). TA L N PE 0 V~50 Hz Power Alimentazione supply elettrica PI - Connect up the automatic shut-off device (DAI) as shown in the wiring diagram on page. This ensure that fuel only passes when the burner is functioning. L N PE TA PI G Live Neutral Earth/ground Room thermostat CH pump 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. 4 - 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. 4 INSTALLER
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. 4 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 0.4 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 back-pressure 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 for details of the electrical connections. H (m) Øi (8 mm) L (m) Øi (0 mm) 0 5 00 0,5 0 00 5 00,5 0 90 5 70 8 0,5 6 0 H = Head L = Maximum length of suction hose Øi = Internal diameter of hose - Suction port - Return port - By-pass screw 4 - Pressure gauge fitting 5 - Pressure regulator 6 - Vacuum gauge fitting 7 - Valve 8 - Auxiliary pressure measurement fitting 7 6 5 8 4 INSTALLER 5
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. A B r INSIEME CONDENS boilers can be installed as "sealed" boilers with the addition of the relevant accessory kit. Øi = 80 Description INSIEME CONDENS 45 B 55 B A 60 74 mm B 70 mm B BP C6 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. (*) C6 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). 6 INSTALLER
Residual pressure INSIEME CONDENS 45 B 55 B Maximum residual pressure in flue gas vent (*) Pa 40 70 (*) Values referred to atmospheric pressure at sea level. Maximum equivalent length of pipes INSIEME CONDENS 45 B 55 B Category Flue Ø (mm) Maximum length of flue pipe (m) (*) Maximum length of flue pipe (m) (*) open B - BP twin flue pipes C6 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 45 curve. INSTALLER 7
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. 8 INSTALLER
FILLING AND EMPTYING THE SYSTEM INSIEME CONDENS 45 B and 55 B boilers need a filling pipe to be connected to the central heating circuit return pipe. MI b See Appendix for further information on water treatment for the central heating system.. RI FILLING THE CENTRAL HEATING SYSTEM - Make sure that the boiler s drain cock () is closed before starting to fill the system - Open the non-return valve () on the CH flow pipe. See the figure to ascertain the correct position for the dot on the screw. - Slacken off the cap of the automatic vent valve () to let air out of the system Non-return valve OPEN - 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) - Close the water supply shut-off cocks. Tighten down the cap on the automatic vent valve () - Close the non-return valve () on the CH flow pipe. See the figure to ascertain the correct position for the dot on the screw. Non-return valve in CLOSED (non-return) position INSTALLER 9
EMPTYING THE CENTRAL HEATING SYSTEM Switch the electricity supply OFF at the system s main switch and at the control panel before starting to empty the boiler. 60 40 80 0 00 0 0 - Open the non-return valve () on the CH flow pipe. See the figure to ascertain the correct position for the dot on the screw. - Close the water supply shut-off cocks - Connect a plastic hose to the hose union on the boiler s drain cock () and open the cock Non-return valve OPEN - Close the drain cock () once the circuit is empty - Close the non-return valve () on the CH flow pipe. See the figure to ascertain the correct position for the dot on the screw. Non-return valve in CLOSED (non-return) position 0 INSTALLER
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. 0 40 60 80 00 0 0 TECHNICAL ASSISTANCE SERVICE
- Turn the function selector to ON (II) and make sure that the green power indicator lights. 40 0 60 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. 40 0 60 80 00 0 0 b If a LOCK-OUT occurs, wait about 0 seconds before resetting the burner. 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 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
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. 40 60 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. 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 setting is changed 0 40 60 80 00 0 0 - The function selector is moved from position (II) to (I) and back. 40 60 80 0 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. 4 TECHNICAL ASSISTANCE SERVICE
TEMPORARY SHUTDOWN If you are going away for a short period of time like a weekend or a short holiday, etc., and outdoor temperatures are going to remain above ZERO, proceed as follows: 0 40 60 80 00 - Turn the function selector to OFF (I) and make sure that the green power indicator goes out. 0 0 - Turn the system s mains power switch OFF. b Do NOT perform this procedure if outdoor temperatures might fall below ZERO (risk of freezing). Now proceed as follows: - Turn the boiler thermostat to about the middle of the section with one line. - Turn the room thermostat to about 0 C or select the frost protection function. 60 40 80 0 00 0 0 PREPARING FOR EXTENDED PERIODS OF DISUSE If the boiler is not going to be used for an extended period of time, proceed as follows to prepare it for shut-down: - Turn the function selector to OFF (I) and make sure that the green power indicator goes out 60 40 80 0 00 0 0 - Turn the system s mains power switch OFF - Close the boiler s fuel cock and water supply cock. b Drain the central heating circuit if there is any risk of freezing. TECHNICAL ASSISTANCE SERVICE 5
MAINTENANCE Regular maintenance is a legal requirement. In Italy it is required by Presidential Decree 4 of the 6th August 99. It is also essential for the safety, efficiency and durability of the boiler. Proper maintenance keeps consumption and emissions down, and ensures that the boiler continues to operate reliably over time. Perform the following operations before beginning any maintenance: - Switch the electricity supply OFF at the system s main switch and turn the control panel function selector to OFF (I) 60 40 80 0 00 0 0 - Close the fuel shut-off cocks. Once all the necessary maintenance has been completed, restore all original settings (see the values in the tables below). Description INSIEME CONDENS 45 B 55 B Air damper position (*),6,5 line 0,85, GPH Nozzle 60 H 45 H Danfoss Danfoss mark Pump pressure,5 bar Combustion head setting Fissa Fissa line Fuel flow rate,8 (±4%) 4,5 (±4%) kg/h (*) Standard setting, to be adjusted as necessary on installation, to achieve a CO value of.5%. b Perform combustion analysis to verify the correct functioning the boiler. 6 TECHNICAL ASSISTANCE SERVICE
OIL BURNER LAYOUT 4 5 6 0 9 8 7 - Photoresistor - Flange with seal - Air intake 4 - Blast tube 5 - Recirculation pipe 6 - Oil pump pressure adjuster screw 7 - Pressure gauge fitting 8 - Oil pump 9 - Air damper adjuster screw 0 - Motor - Reset button with lockout indicator - Burner control box REMOVING THE BURNER Proceed as follows to remove the burner: - Close the fuel shut-off cocks. - Disconnect the connector (). - Unscrew the fixing nut () and remove the burner. Reverse the above steps to reassemble. b If the burner needs to be taken completely out of the boiler, disconnect the hoses () first. Use a suitable rag to soak up the fuel that inevitably comes out. TECHNICAL ASSISTANCE SERVICE 7
ACCESSING THE NOZZLE, FLAME GUIDE AND ELECTRODES Proceed as follows to access the nozzle, flame guide and electrodes: - Unscrew and remove the fixing nut from the flange and remove the burner. - Loosen the screws () and pull out the blast tube assembly () - Loosen the screw (4) and remove the flame guide holder (6) from the nozzle holder (7). - Completely unscrew the fixing screw and pull out the fibre optic cable (4) from the flame guide holder (6). 8 6 - Disconnect the cables (5) from the electrodes. - Replace the nozzle (8), taking care to screw it in and tighten it correctly as shown in the figure. 5 7 4 Reverse the above steps to reassemble. a It is strictly forbidden to use nozzles of different make, type and specifications to the original. POSITIONING THE ELECTRODES Correct electrode positioning is essential for efficient ignition and combustion. Proceed as follows to set electrode position. - Engage the flame guide holder () with the nozzle holder () and secure it with the screw (). - Loosen the screw (5) to set the electrodes (4) in the right position. 4 5 4,5-0,5 mm ± 0, mm a It is forbidden to change the positions and dimensions given. 5,5 ± 0, mm 8 TECHNICAL ASSISTANCE SERVICE
OIL PUMP - Suction port - Return port - By-pass screw 4 - Pressure gauge fitting 5 - Pressure regulator 6 - Vacuum gauge fitting 7 - Valve 8 - Auxiliary pressure measurement fitting 8 7 6 5 4 ADJUSTING PUMP PRESSURE Turn the adjuster screw () to achieve the pressure setting specified in the table on page 6. 4 5 0 6 ADJUSTING THE AIR DAMPER The air damper can be adjusted without removing the burner cover: - Use an Allen key to turn the adjuster screw () to achieve the required setting on the graduated scale (). b See the table on page 6. TECHNICAL ASSISTANCE SERVICE 9
REMOVING THE BURNER CONTROL BOX The burner cover has to be removed first in order to remove the control box. Proceed as follows. - Loosen the screw (), open the cover () and remove all the components inside. - Remove the coil (). - Unscrew and remove the two screws (4) to remove the control box. 4 4 BURNER ELECTRICAL CONNECTIONS Burner lockout indicator (on boiler control panel) L N T T S B4 7 pin male connector 7 pin female connector Ignition electrodes Burner ground CONTROL BOX 55SE/LD Photoresistor Fuel shut-off valve Motor Black White Blue Condenser 40 TECHNICAL ASSISTANCE SERVICE
FUNCTIONING PROGRAM Power supply Thermostat Motor Ignition transformer Valve Flame detected Lockout indicator A ~ s A normal functioning cycle Lockout because of ignition failure ~ s ~ 5s b If the flame does not ignite within the safety time (5 seconds), the burner controller enters lockout and the red light button () lights. Press the light button () to reset the burner controller. TECHNICAL ASSISTANCE SERVICE 4
DISASSEMBLING AND CLEANING THE BOILER Clean the boiler and remove any carbon deposits from the surfaces of the heat exchanger at least once a year. This not only extends the boiler s working life, but also keeps it efficient in terms of heat output and consumption. 60 40 80 0 00 0 0 Before performing any cleaning operation: - Switch the electricity supply OFF at the system s main switch and turn the control panel function selector to OFF (I) - Close the fuel shut-off cocks. External cleaning Clean the boiler s casing panels and control panel with a soft cloth damped in soapy water. To remove stubborn marks, use a cloth damped in a 50% mix of water and denatured alcohol or a suitable cleaning product. Wipe the boiler dry after cleaning it. a Do not use abrasive products, petrol or triethylene. Internal cleaning b To ensure that the boiler remains efficient, change the burner nozzle and check the smoke scale reading at every annual maintenance. Also check combustion conditions at regular intervals during normal functioning. Proceed as follows to access the internal parts of the boiler: 9 8 - Remove the front and top panels () and () - Remove the burner (see page 7) 4 Cleaning the boiler body - Release the clips () and remove the cover (4) from the flue gas box - Remove the turbulators (5) and check them for wear. Replace as necessary. - Clean the flue gas path with a flue brush or other suitable tool and remove any soot through the hole in the combustion chamber. Take care not to damage the flame guard (6). 7 5 b Do not use chemical solvents or detergents to clean the heat exchanger. 4 TECHNICAL ASSISTANCE SERVICE
Proceed as follows on completion of cleaning. - Refit the turbulators (5) in the flue gas pipes, making sure that they are correctly seated 6 - Check the condition of the flame guard (6) and seal (7). Replace as necessary. On completion of cleaning, follow the above steps in the reverse order to refit all removed parts. If necessary, adjust the closure of the flue gas box by loosening the nut (8) that holds the alignment bracket (9). Make sure that the cover sits firmly on the body, then tighten the nut (8). Cleaning the secondary heat exchanger Remove the flue then proceed as follows. - Unscrew the screws (0) and remove the top cover (). - Remove the turbulators () and check them for wear. Replace as necessary. - Use a flue brush or other suitable tool to clean inside the flue gas pipes. - Remove the condensate drain hose () and the siphon (4). - Remove the flue gas temperature sensor (5). - Unscrew the nuts (6) and remove the bottom cover (7). - Clean out any soot. 0 9 Proceed as follows on completion of cleaning. - Refit the turbulators () in the flue gas pipes, making sure that they are correctly seated. - Check the condition of the seals (8) and (9). Replace as necessary. On completion of cleaning, follow the above steps in the reverse order to refit all removed parts. 8 6 5 7 b Chemical solvents or detergents may be used to clean the after-exchanger provided they are suitable for use with stainless steel. 4 TECHNICAL ASSISTANCE SERVICE 4