Riello 20044965 Installation And Maintenance Manual Download Page 4

Page: 4 / 52

GENERAL

General safety information

page 5

Precautions

“ 5

Product description

“

Safety devices

“

Identification

“ 7

Layout

“ 8

Technical specifications

“

Accessories

“ 11

Water circuit

“

Location of sensors

“

Pump

“ 13

Wiring diagram

“

Control panel

“

INSTALLER

Unpacking the product

page 16

Dimensions and weight

“

Handling

“ 17

Place of installation

“

Installation in older systems and
systems requiring modernisation

“

Water in central heating systems

Water connections

“

Electrical connections

“

Outdoor temperature sensor

“

Fuel connections

“

Flue gas outlet and comburent air intake

“

Filling and draining the system

“

TECHNICAL ASSISTANCE SERVICE

Preparing for initial start-up

page 33

Initial start-up

“

Shutdown

“ 37

Warning LEDs and errors

“

Automatic temperature control

“

Settings

“ 41

Conversion from one gas type to another

“

Maintenance

“ 45

Troubleshooting

“ 47

Useful information

“

CONTENTS

This manual, Code 20045107 - Rev. 4 (05/14) is made
up of 52 pages.

The following symbols are used in this manual:

= Identifies actions that require caution and

adequate preparation.

= Identifies actions that you MUST NOT do.

Summary of Contents for 20044965

Page 1: ...KV 130 30 ISC RESIDENCE COLONNA CONDENS INSTALLATION AND MAINTENANCE MANUAL FLOOR STANDING CONDENSING BOILERS ...

Page 2: ...95 CE BS EN 677 Gas fired central heating boilers specific requirements for condensing boilers with a nominal heat input not exceeding 70 kW RESIDENCE COLONNA CONDENS boilers therefore bear the CE mark 0694 RANGE CONFORMITY RANGE RATED This boiler is RANGE RATED That means it is fitted with a device that adjusts its heat output to suit the requirements of the heating system and therefore the therm...

Page 3: ...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 ...

Page 4: ...onnections 22 Electrical connections 24 Outdoor temperature sensor 26 Fuel connections 27 Flue gas outlet and comburent air intake 27 Filling and draining the system 31 TECHNICAL ASSISTANCE SERVICE Preparing for initial start up page 33 Initial start up 33 Shutdown 37 Warning LEDs and errors 38 Automatic temperature control 39 Settings 41 Conversion from one gas type to another 44 Maintenance 45 T...

Page 5: ... it from the mains electricity supply by turning the mains switch OFF aDo not tamper with or adjust the safety or control devices without prior authorisation and instructions from the boiler s manufacturer b b Periodically and when the system is cold check that operating pressure in the heating circuit is between 1 and 1 2 bar If water pressure is con sistently low contact r s Technical Assistance...

Page 6: ...the condensate level in the heat exchanger exceeds the safety threshold first level of frost protection for indoor systems func tional even with the boiler in standby activated when water temperature drops below 7 C Maximum temperature thermostat to detect overheating The main technical characteristics of RESIDENCE COLONNA CONDENS boilers are electronic burner ignition and ionisation flame control...

Page 7: ...rie Kategorie Combustible Brennstoff Combustibile Brandstof KESSEL GEREGELT FÜR CALDAIA REGOLATA PER CHAUDIERE REGLEE POUR VERWARMINGSKETEL INGESTELD OP T067745GE T067745GE Caldaia a condensazione Chaudière à condensation Brennwertkessel Condenserende verwarmingsketel European Directive 92 42 EEC η N 230 V 50Hz W Pms bar T C Pmw bar T C D l min Qn min Pn min NOx IP P nom G20 mbar Qn max Pn max Cod...

Page 8: ...rature sensor socket 12 CH circuit fill cock 13 Storage cylinder drain cock 14 DHW circuit safety valve 8 bar 15 DHW circuit expansion vessel 6 litres 16 Bypass pipe 17 Drain collector pipe 18 Electrical cable guides 19 CH circuit safety valve 3 bar 20 Combustion group 21 Vent air intake fitting concentric 60 100 22 Control panel 23 Gas diaphragm 24 Gas valve 25 DHW capillary temperature gauge fit...

Page 9: ...ure for normal functioning 0 25 0 45 bar Maximum temperature 90 C CH water temperature setting range 20 45 45 80 C Pump max head available to system 300 mbar at flow rate of 1000 l h Power supply voltage 230 50 V Hz Consumption 129 W Index of protection Installation type B X4D IP Installation type C X5D IP Volume of expansion vessel CH 12 l Precharge of expansion vessel CH 1 5 bar Rated gas pressu...

Page 10: ... operating pressure of storage cylinder 8 bar Volume of expansion vessel DHW 6 l Precharge of expansion vessel DHW 2 5 bar Description RESIDENCE COLONNA CONDENS KV 130 30 ISC Function parameters for G20 Lower Wobbe index at 15 C 1013 mbar 45 67 MJ m3s Rated supply pressure 20 mbar Minimum supply pressure 10 mbar Gas diaphragm 6 7 mm Maximum gas flow rate DHW CH 3 17 Sm3 h Minimum gas flow rate DHW...

Page 11: ... Condens remote control 20001248 Outdoor sensor 4047726 Zone valve control kit for Residence Condens 20000785 Condensate drain pump 4047462 Safety thermostat kit 20005268 BAG2 AP 20001191 BAG2 MIX BASIC 20000901 BAG2 MIX CLIMA 20000902 BAG2 2 MIX BASIC 20007472 Recessed wall box 20007305 ...

Page 12: ... Bleed manifold 12 Automatic vent valve 13 CH circuit expansion vessel 12 litres 14 CH storage cylinder pump 15 Boiler drain cock 16 Delivery group 17 Water pressure switch 18 Drain cock for delivery group 19 System safety valve 3 bar 20 Non return valve 21 Non return valve and by pass 22 Automatic bypass 23 Deviator valve 24 130 litre storage cylinder 25 DHW circuit expansion vessel 6 litres 26 D...

Page 13: ...sealed chamber NTC STORAGE CYLINDER TEMPERATURE SENSOR STORAGE CYLINDER TEMPERATURE GAUGE SENSOR The residual head of the burner pump can be derived from the three speed curves in the graph shown along side b b On initial start up and at least every year check that all the pumps in the system rotate freely Sludge and lime scale can build up and cause seizure especially after long periods of disuse...

Page 14: ...r configuration selection jumper in position 3 M3 M5 Connection terminals OPE Gas valve operator Cl Central heating storage cylinder pump PA Water pressure switch P1 DHW temperature setting potentiometer P2 CH temperature setting potentiometer P3 Function selector R9 Maximum fan speed trimmer R10 Minimum fan speed trimmer R14 Burner ignition slow fan trimmer R19 Maximum CH fan speed trimmer R35 Te...

Page 15: ... 3 Green LED When lit shows that a flame is being detected 4 Two figure digital display Displays information on boiler status 5 Red LED When lit shows that an error alarm condition has been detected 6 Function selector 0 Off Reset Winter mode Summer mode 7 Central heating temperature selector Allows you to set the temperature of the central heating water 8 Storage cylinder temperature gauge Displa...

Page 16: ...e boiler Hydraulic test certificate Outdoor temperature sensor LPG conversion kit diaphragm label b b The instruction manuals are integral parts of the boiler Once located read them thoroughly and keep them safe Description L 600 mm P 610 mm H 1540 mm Net weight 130 Kg Gross weight with packaging 150 Kg A RESIDENCE COLONNA CONDENS boilers are designed and made for installation in combined central ...

Page 17: ...o lift it An optional han dling bracket kit is available to provide a better grip at points B b b Do not lift the boiler by its casing but only by rigid parts such as its base and top frame b b Do not lift the boiler by its casing but only by rigid parts such as its base and top frame a a Do not dispose of packaging material into the envi ronment or leave it within the reach of children since it c...

Page 18: ...ith an overflow siphon connected to a drain point Before lighting the burner for the first time make sure that the boiler is configured for use with the type of gas supplied The type of gas is specified on the packaging label and on the gas identification plate on the boiler itself b b When installing the boiler allow sufficient space around it to access all safety and control devices and to permi...

Page 19: ...ke 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 spe cific products b b The manufacturer declines all responsibility for damage caused by incorrectly constructed flue systems b b Flue pipes for condensing boilers must be made from special materials different from those used for standard non condensi...

Page 20: ...phides mg l 15 Nitrides mg l 15 Iron mg l 0 5 2 Central heating systems b Do not use automatic filling devices to add water to central heating systems Use a manual device instead and record top ups in the system service book b If a system comprises a number of boilers when that system is first put into service make sure that all the boilers function simultaneously or on a short interval rotation b...

Page 21: ...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 s...

Page 22: ...ler condensate collector S and route it to a domestic water drain in compli ance with the relevant standards b b The manufacturer declines all responsibility for damage caused by water escaping from the con densate drain pipe b b The boiler s safety valves must also be connected to a suitable collection and drain system The manufacturer declines all responsibility for damage caused by water escapi...

Page 23: ...nd standards b b Condensate from the boiler and from the flue should be channelled to the same drain point b b The base of the boiler must be perfectly horizontal and flat over the entire area of the boiler frame in order to avoid condensate drainage problems b b Any condensate neutralisation units deemed nec essary may be connected downstream from the siphon Evaluate the neutralisation unit after...

Page 24: ...tion Connect the boiler to the mains power supply single phase 230V 50Hz using the cable 1 from the rear of the appliance Connect up the room thermostat TA and the outdoor temperature sensor SE OUTDOOR TEMPERATURE SENSOR SE AND ROOM THERMOSTAT TA Remove the front panels by pulling them forwards Remove the two screws A and tilt the control panel B downwards C 0 120 20 100 40 80 60 B A 1 ...

Page 25: ...er to the electrical wiring diagrams in this manual when performing any electrical work 5 Ensure that an efficient ground connection is provided a a It is strictly forbidden to use fuel and or water pipes to ground the appliance The manufacturer declines all responsibility for damage caused by failing to ground the appliance adequately or by failure to respect the wiring diagrams provided in this ...

Page 26: ...e to the sensor termi nals Polarity is irrelevant Connect the cable from the outdoor temperature sen sor to the boiler as instructed in the ELECTRICAL CONNECTIONS section Screw the protective cover back on the outdoor tem perature sensor b b Position the sensor on a smooth area of wall Prepare a smooth contact area for the sensor casing if the wall is made from exposed brick or other rough materia...

Page 27: ...supply pipe if the gas supply contains any solid particles b b The gas feed line must be suitable for the flow rate demanded by the burner The gas feed system must also be equipped with all the necessary safety and control devices required by applicable legisla tion and standards b b On completion of the installation check that all joints are sealed in compliance with the relevant installation sta...

Page 28: ... via horizontal or vertical flues designed to operate at positive pressure with air ventilation to room C13 Concentric wall vent Twin flue pipes can also be used but the wall through pipes must be concen tric or located close enough to be subjected to similar wind conditions If twin intake and vent pipe terminals are used they must be positioned within a square of 50 cm C23 Concentric vent to shar...

Page 29: ...ke the combu rent air intake pipe b b Use only flues specifically designed for use with condensing boilers Follow the instructions pro vided in the flue pipe kit to install the flues Unscrew the screws and remove the cover from the air intake A and connect the comburent air pipe to it Connect the vent pipe to the flue gas outlet B If the flue pipes used differ in length from those shown in the tab...

Page 30: ... In this type of installation comburent air is drawn from inside the boiler room which must therefore have adequate ventilation b b Uninsulated flue pipes are potentially dangerous and can cause burns b b Ensure that the flue gas vent pipe has a 1 slope towards the boiler b b The boiler automatically adapts its ventilation sys tem to suit the type of installation and the length of the flue Maximum...

Page 31: ...SYSTEM Make sure that the delivery group drain cock 5 and boiler drain cock 6 are closed Slacken off the cap of the automatic vent valves 1 and 2 to let air out of the system Open the CH system fill cock 3 and slowly fill the system until the pressure gauge 7 reads out a value between 1 and 1 2 bar Close the CH system fill cock 3 b b Bleed the central heating circuit thoroughly to ensure that no a...

Page 32: ...tic hot water circuits Connect a hose to the hose union on the drain cock 6 and open the cock Close the drain cock 5 once the circuit is empty DRAINING THE STORAGE CYLINDER Close the shut off cocks for the central heating and domestic hot water circuits Make sure that the CH system fill cock 3 is closed Connect a hose to the storage cylinder drain cock 4 and open the cock Close the drain cock 4 on...

Page 33: ... boiler Check that the fuel and water shut off cocks to the boiler are open Check that the central heating water pressure gauge shows a pressure between 1 and 1 2 bar with the system cold Check that the gas supply pressure is correct for the boiler Proceed as follows to check the gas supply pressure Unscrew the pressure measurement point screw upstream from the gas valve about two turns and con ne...

Page 34: ...f neces sary turn the boiler off at the mains power switch and at the control panel and refill the CH circuit as instructed on page 31 Once the CH circuit reaches the right pressure switch the boiler back on again to start the auto matic venting cycle Repeat these steps until the pressure in the CH circuit stabilises between 1 and 1 2 bar b b To interrupt the automatic venting cycle unscrew the fo...

Page 35: ...ed on the basis of outdoor air temperature To adjust room temperature manually with respect to the automatic setting calculated by the control card turn the heating temperature selector clockwise to increase temperature or anti clockwise to reduce it The available adjustment range is between 5 and 5 comfort levels as shown on the digital display when the knob is turned see the AUTOMATIC TEMPERATUR...

Page 36: ... the display The red LED 5 indicates a burner lock out See the WARNING LEDS AND ERRORS section for details on the various error codes and how to reset the boiler RESET FUNCTION To reset the boiler turn the function selector to 0 then return it to its previous position and check that the red LED goes out Provided correct functioning conditions have been restored the boiler restarts automatically As...

Page 37: ...ature read by the DHW temperature sensor falls below 4 C Under these conditions a heat request is generated igniting the burner at minimum power and keeping it on until the temperature of the central heating flow water reaches 55 C b b The message AF flashes on the display for as long as the frost protection function remains active Pump anti block function The pump is switched on for 30 seconds ev...

Page 38: ...S AL10 Ignition attempts finished no flame condensate detected Lockout AL20 Temperature threshold error Lockout AL21 Low temperature thermostat condensate pump safety error Lockout AL29 Flue gas sensor overtemperature error Lockout AL60 Storage cylinder temperature sensor error Signalling AL71 CH flow temperature sensor error open short circuit Shutdown AL73 CH return temperature sensor error open...

Page 39: ...nect it immedi ately to the relevant terminals in the boiler see page 23 The boiler will now be able to function with AUTOMATIC TEMPERATURE CONTROL SELECTING THE TEMPERATURE COMPENSATION CURVE A number of central heating temperature compensation curves are available to maintain a theoretical room tem perature of 20 C for outdoor temperatures between 20 C and 20 C The choice of curve depends on the...

Page 40: ...nerated by the room thermostat contacts closing and terminated by the contacts opening The boiler calculates the necessary CH flow temperature automatically though the user can adjust the boiler settings The CENTRAL HEATING temperature selector however does not give the user control over the CENTRAL HEATING SET POINT as such but only permits variation within a range between 5 and 5 C Changing this...

Page 41: ...Adjust the trimmers in the sequence given below to achieve the values specified in the table 1 MAX 1a Maximum fan speed MAXIMUM FAN SPEED METHANE G20 PROPANE G31 30 ISC 6 0 6 0 x 1000 rpm 2 MIN 2a Minimum fan speed MINIMUM FAN SPEED METHANE G20 PROPANE G31 30 ISC 1 6 1 6 x 1000 rpm 3 HTG 3a Maximum CH fan speed MAXIMUM CH FAN SPEED METHANE G20 PROPANE G31 30 ISC 6 0 6 0 x 1000 rpm 4 IGN 4a Burner ...

Page 42: ...t input CH mode kW COnoair curve Qnheating 30 kW Heating curve Qnheating 30 kW Fan speed in CH mode rpm 1300 1700 2100 2500 2900 3300 3700 4100 4500 4900 5300 5700 6100 Rated heat input CH mode kW 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 COnoair p p m G20 30 ISC When supplied the boiler is configured with the settings shown in the table below These settings can be cha...

Page 43: ... content If the value is not as speci fied in the table adjust the gas valve maximum screw accordingly Turn the HTG trimmer anticlockwise until the fan speed for minimum DHW power is reached see table Check the CO2 content If the value is not as speci fied in the table adjust the gas valve minimum screw accordingly Return the HTG trimmer to the fan speed for maximum CH power see table Turn the fun...

Page 44: ...le the boiler Switch the electricity supply to the boiler back on and open the gas cock Adjust the boiler as instructed in the SETTINGS section taking care to use the values for LPG Labels Remove the G20 label from the outside of the boiler casing Apply the G31 label to the inside of the casing covering the old G20 label b b Gas conversions must only be carried out by quali fied personnel b b Appl...

Page 45: ...parts Do not use paint thinners to clean the casing or any painted or plastic parts of the boiler Use only soapy water to clean the boiler casing Extraordinary maintenance Extraordinary maintenance involves actions designed to restore the functioning of the boiler to its design specifica tions and legal requirements after a failure or malfunction These actions can be Part replacements Repairs Reco...

Page 46: ...mbustion analysis Autodiagnosis of primary heat exchanger cleaning The boiler incorporates an autodiagnosis system that uses the number of hours of operation under certain con ditions to notify the user that the primary heat exchanger needs cleaning error code 91 Clean the heat exchanger using the relevant accessory kit then proceed as follows to reset the hour counter Switch off electrical power ...

Page 47: ...stion settings Poor combustion Gas valve blocked Check presence of 230Vac at terminals of gas valve Check wiring and connections Burner does not start on signal from control panel Boiler does not start up No electrical power green LED off Check electrical connections fuse Ignition is slow and the burner pulses Check setting Check position and condition of electrodes Burner gas pressure incorrectly...

Page 48: ...Check CH circuit pressure Verify the temperature setting Check positioning of sensors Check correct functioning of sensors and electrical cables Air in the circuit Pump malfunctioning Boiler reaches set temperature but radiators are still cold Bleed the circuit Unseize the pump Change the pump Check pump electrical connections Pump malfunctioning Pump does not start Unseize the pump Change the pum...

Page 49: ...or sludge in storage cylinder Flow rate too high Fit a pressure reducer Check and clean Fit a flow reducer Check functioning of DHW circuit pump Check positioning of sensors Check boiler operating temperature Boiler incorrectly adjusted Check correct functioning Check the temperature setting SOLUTION FAULT CAUSE ...

Page 50: ...r Address Tel Technical Assistance Service Mr Address Tel Fuel oil supplier Mr Address Tel Installer Mr Address Tel Date Work done Date Quantity supplied Date Quantity supplied Date Quantity supplied Date Quantity supplied USEFUL INFORMATION ...

Page 51: ...TECHNICAL ASSISTANCE SERVICE 51 ...

Page 52: ...Tel 0442630111 Fax 0442630371 www riello it As part of the company s ongoing commitment to perfecting its range of products the appearance dimensions technical data equipment and accessories may be subject to variation Cod 20045107 ...

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