Riello 20044966 Installation And Maintenance Manual Download Page 4

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CONTENTS

This manual, Code 20045110 - Rev. 5 (07/14) is made
up of 56 pages.

The following symbols are used in this manual:

= Identifies actions that require caution and

adequate preparation.

= Identifies actions that you MUST NOT do.

GENERAL

General safety information

page 5

Precautions

“ 5

Product description

“

Safety devices

“

Safety devices

“

Layout

“ 8

Technical specifications

“

Accessories

“ 10

Water circuit

“ 11

Location of sensors

“ 12

Pumps

“ 12

Wiring diagram

“ 14

Control panel

“ 15

INSTALLER

Unpacking the product

page 17

Dimensions and weight

“ 17

Handling

“ 18

Place of installation

“ 19

Installation in older systems
and systems requiring modernisation

“ 20

Water in central heating systems

" 20

Water connections

“ 23

Electrical connections

“ 25

Outdoor temperature sensor

“ 27

Fuel connections

“ 28

Flue gas outlet and comburent air intake

“ 28

Filling and draining the system

“ 32

TECHNICAL ASSISTANCE SERVICE

Preparing for initial start-up

page 35

Initial start-up

“ 35

Shutdown

“ 39

Warning LEDs and errors

“ 40

Automatic temperature control

“ 41

Settings

“ 43

Conversion from one gas type to another

“ 46

Maintenance

“ 47

Troubleshooting

“ 50

CONTENTS

Summary of Contents for 20044966

Page 1: ...KV 200 20 ISC Solar KV 200 30 ISC Solar RESIDENCE COLONNA CONDENS INSTALLATION AND MAINTENANCE MANUAL FLOOR STANDING CONDENSING BOILERS ...

Page 2: ...densing boilers with a nominal heat input not exceeding 70 kW RESIDENCE COLONNA CONDENS boilers therefore bear the CE mark 0694 MODEL CODE RESIDENCE COLONNA CONDENS KV 200 20 ISC Solar 20044966 RESIDENCE COLONNA CONDENS KV 200 30 ISC Solar 20044968 RANGE 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...

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: ... Control panel 15 INSTALLER Unpacking the product page 17 Dimensions and weight 17 Handling 18 Place of installation 19 Installation in older systems and systems requiring modernisation 20 Water in central heating systems 20 Water connections 23 Electrical connections 25 Outdoor temperature sensor 27 Fuel connections 28 Flue gas outlet and comburent air intake 28 Filling and draining the system 32...

Page 5: ... it from the mains electricity supply by turn ing the mains switch OFF a 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 consistently low contact r s Technical Assistan...

Page 6: ...d comfort func tions domestic hot water and central heating water tempera ture controls system filling cock central heating circuit pressure gauge 8 litre domestic hot water circuit expansion vessel 12 litre central heating circuit expansion vessel 18 litre solar circuit expansion vessel DC fan controlled by Hall effect speed sensor high head pump fitted as standard automatic bypass for central he...

Page 7: ...s 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 kW kW kW kW kW kW kW kW RIELLO S p A Via Ing Pilade Riello 7 37045 Legnago VR ITALY Categoria Categorie Kategorie Combustible Brennstoff Combustibile Brandstof KESSEL GEREGELT FÜR CALDAIA REGOLATA PER CHAUDIERE REGLEE POUR VERWARMINGSKETEL INGESTELD OP T067745GE T067745GE Caldaia a condensazione Chaudière à condens...

Page 8: ...ylinder temperature sensor socket bottom 17 200 litre storage cylinder 18 Storage cylinder drain cock 19 DHW circuit expansion vessel 8 litres 20 DHW circuit safety valve 8 bar 21 CH circuit drain cock 22 Drain collector pipe 23 Solar circuit safety valve 6 bar 24 Electrical cable guides 25 CH circuit safety valve 3 bar 26 Manual bleed valve 27 Vent air intake fitting concentric 60 100 28 CH circu...

Page 9: ...urn temp 47 C 102 6 103 1 Losses from stack and casing with burner off 54 58 W Maximum operating pressure 3 bar Minimum pressure for normal functioning 0 25 0 45 bar Maximum temperature 90 C CH water temperature setting range 20 45 40 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 123 129 W Index of protection Installation type...

Page 10: ...e cylinder 8 bar Volume of expansion vessel DHW 8 l Precharge of expansion vessel DHW 3 5 bar Description RESIDENCE COLONNA CONDENS KV 200 20 ISC Solar KV 200 30 ISC Solar 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 Gas diaphragm 4 6 6 7 mm Maximum gas flow rate 2 12 3 17 Sm3 h Minimum gas flow rate 0 37 0 63...

Page 11: ... expansion vessel 12 litres 14 CH storage cylinder pump 15 CH circuit drain cock 16 Deviator group 17 Deviator valve 18 Water pressure switch 19 Deviator group drain cock 20 Deviator group safety valve 3 bar 21 Automatic bypass 22 Non return valve 23 Solar circuit expansion vessel 18 litres 24 Solar circuit pressure gauge 25 Solar circuit pump 26 Flow regulator 27 Solar circuit filling and drain c...

Page 12: ... NTC FLUE GAS TEMPERATURE SENSOR CONDENSATE SENSOR located inside sealed chamber NTC STORAGE CYLINDER TEMPERATURE SENSOR bottom NTC STORAGE CYLINDER TEMPERATURE SENSOR top STORAGE CYLINDER TEMPERATURE GAUGE SENSOR r RESIDENCE COLONNA CONDENS boilers come with the pumps for the central heating and a solar heating circuits already installed and connected up electrically and to the water circuit The ...

Page 13: ... I II III 50 100 150 200 250 300 350 400 450 500 600 550 RESIDUAL HEAD mbar FLOW RATE l h SOLAR HEATING SYSTEM bOn 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 espe cially after long periods of disuse bProtect all electrical devices under the pump before you unscrew the inspection cap just in case...

Page 14: ...15A F fast F1 F2 Fuse 3 15A T timed JP4 Boiler configuration selection jumper in position 3 M3 M5 Connection terminals OPE Gas valve operator Cl Central heating storage cylinder pump PA Water pressure switch P1 DHW temperature setting potentiometer P2 CH temperature setting potentiometer P3 Function selector R9 Maximum fan speed trimmer R10 Minimum fan speed trimmer R14 Burner ignition slow fan tr...

Page 15: ...thermostatic mixer valve has to be adjusted to change this value see page 37 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 temperat...

Page 16: ...ed by the sen sor over the last few hours is also shown If temperature sensor F2 is not installed the dis play reads out the message Not connected Storage cylinder top temperature sensor The display reads out the temperature currently measured by storage cylinder top temperature sensor F3 The trend in temperatures measured by the sen sor over the last few hours is also shown If temperature sensor ...

Page 17: ...ctor 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 A RESIDENCE COLONNA CONDENS boilers are designed and made for installation in combined central heating and domestic hot water production systems and incorporate provision for connection to a solar heating system 1900 610 600 DI...

Page 18: ...t points B and C to lift it An optional handling 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 Wear suitable personal protective equipment and use suitable safety devices a aDo not dispose of packaging material into the envi ronment or leave it within the reach of children since it c...

Page 19: ...mbers must be fitted with an over flow 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 contr...

Page 20: ...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 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 spe...

Page 21: ...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 22: ...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 23: ...rtight b b Connect a pipe to the boiler 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 dam age caused by water escaping from the conden sate drain pipe b b The boiler s safety valves must also be connected to a suitable collection and drain system The manufacturer declines all responsibil...

Page 24: ...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 25: ... the mains power supply single phase 230V 50Hz using the cable 1 from the rear of the appliance Connect up the room thermostat TA outdoor tempera ture sensor SE and solar collector temperature sensor SColl OUTDOOR TEMPERATURE SENSOR SE AND ROOM THERMOSTAT TA Remove the front panels by pulling them forwards Remove the two screws A and tilt the control panel B downwards B A 0 bar 4 1 3 2 C 0 120 20 ...

Page 26: ...d connect the sensor to the terminals M b b The following instructions are mandatory 1 Use a multi pole magnetic thermal trip switch and disconnector conforming to IEC EN standards with a contact gap of at least 3 mm 2 Respect the L Phase N Neutral polarity 3 Use cables with a cross section of 1 5 mm2 or more complete with end terminals 4 Always refer to the electrical wiring diagrams in this manu...

Page 27: ...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 28: ...pply 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 installa tion stan...

Page 29: ...ntilation to room B53P Upstream fan Comburent air intake directly from the room where the boiler is installed Flue gas vent via horizontal or vertical flues designed to operate at positive pressure with air ventilation to room C13 Concentric wall vent Twin flue pipes can also be used but the wall through pipes must be con centric or located close enough to be subjected to similar wind conditions C...

Page 30: ... 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 table make sure that the total lengt...

Page 31: ...nstallation 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 system to suit the type of installation and the length of the flue Maximum length of flue gas...

Page 32: ...fill cock 4 is closed Slacken off the cap of the automatic vent valve 1 to let air out of the system Slacken off the cap of the manual bleed valve 5 Close the valve again as soon as water starts to come out Open the CH system fill cock 2 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 2 Tighten down the cap on the manual v...

Page 33: ...tes to check that no air remains in the circuit Adjust circuit pressure again if necessary Set the non return valve 7 to automatic functioning See the figure to ascertain the correct position for the dot on the screw Close the previously opened manual bleed valves on the system bleed manifold Set a flow rate proportional to the number of solar col lectors installed on adjuster screw 10 2 l min per...

Page 34: ...er tap to facilitate draining of the storage cylinder DRAINING THE SOLAR HEATING CIRCUIT Open the non return valve 9 to facilitate draining See the figure to ascertain the correct position for the dot on the screw Open the manual bleed valves on the system bleed manifold Connect a hose between the container you are using to collect the water glycol mix and the drain cock B on the valve group 11 Op...

Page 35: ...at to generate a heat request When the burner is operating at full power check that the gas supply pressure lies between the minimum and rated pressure values given in the Technical Specifications table Eliminate the heat request Disconnect the pressure gauge and tighten the pres sure measurement screw upstream from the gas valve Once you have completed all the checks listed above proceed as follo...

Page 36: ...d the sys tem automatically adjusts the temperature of the central heating flow to bring room temperature rapidly to a level determined on the basis of outdoor air temperature To adjust room temperature manually with respect to the automatic setting calculated by the control card turn the heating temperature selector clockwise to increase temperature or anti clockwise to reduce it The available ad...

Page 37: ... do so unscrew the fixing screw from the top of the knob and pull off the knob Fit the knob again so that the keyway in the knob s body engages with the key in the valve cap Reference conditions Hot water temperature 68 C Cold water temperature 13 C Hot and cold water inlet pressure 3 bar Knob position Min 1 2 3 4 5 6 7 Max Temperature C 27 32 38 44 49 53 58 63 67 p bar 1 5 p m c a 10 20 50 0 5 1 ...

Page 38: ... If a timer or room thermostat is installed these must be switched on and adjusted to a temperature higher than current room temperature before the boiler can start up The boiler will remain in stand by mode until the burner ignites following a request for heat The green LED 3 on the left of the control panel lights to show that a flame is being detected The boiler will carry on functioning until ...

Page 39: ... is active or combustion analysis CO in being performed If you are going away for a short period of time like a weekend or a short holiday etc turn the function selector to 0 OFF RESET The digital display reads out the message shown along side Because electrical power and the gas supply to the boiler both remain on the boiler is protected by the following systems Frost protection Central heating T...

Page 40: ... functioning turn the function selector to 0 OFF RESET then return it to its previous position Summer or Winter If the boiler does not restart after a number of resets call your local Technical Assistance Centre ON OFF 3 5 0 bar 4 1 3 2 CODE DESCRIPTION OF ERROR STATUS AL10 Ignition attempts finished no flame condensate detected Lockout AL20 Temperature threshold error Lockout AL21 Low temperature...

Page 41: ...nect it immedi ately to the relevant terminals in the boiler see page 25 The boiler will now be able to function with AUTOMATIC TEMPERATURE CONTROL SELECTING THE TEMPERATURE COMPENSATION CURVE A number of central heating temperature compensa tion curves are available to maintain a theoretical room temperature of 20 C for outdoor temperatures between 20 C and 20 C The choice of curve depends on the...

Page 42: ...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 43: ... table 1 MAX 1a Maximum fan speed MAXIMUM FAN SPEED METHANE G20 PROPANE G31 20 ISC Solar 6 1 6 1 x 1000 rpm 30 ISC Solar 6 0 6 0 x 1000 rpm 2 MIN 2a Minimum fan speed MINIMUM FAN SPEED METHANE G20 PROPANE G31 20 ISC Solar 1 3 1 3 x 1000 rpm 30 ISC Solar 1 6 1 6 x 1000 rpm 3 HTG 3a Maximum CH fan speed MAXIMUM CH FAN SPEED METHANE G20 PROPANE G31 20 ISC Solar 6 1 6 1 x 1000 rpm 30 ISC Solar 6 0 6 0...

Page 44: ...t input CH mode kW 1300 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1700 2100 2500 2900 3300 3700 4100 4500 4900 5300 5700 6100 Heating curve Qnheating 20 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 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 45: ...ckwise until minimum speed 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 correct Max CH setting see table Turn the function selector to exit chimney sweep mode Remove the combustion analysis probe and replace the cap Fit the front trim B and secure with the four screws A The com...

Page 46: ...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 Apply the n...

Page 47: ...int 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 Reconditioning of compo...

Page 48: ...s 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 Unscrew the four...

Page 49: ... Turn the parameter selector 4 to enter the password pressing key 2 to confirm each digit Turn the parameter selector 4 to set a parameter value of 7 Press the confirm key 2 again to confirm b b When you change the system selection parameter all other parameter settings return to their factory default values including the password Installer access is also blocked Repeat the above steps to set para...

Page 50: ...combustion fumes Check That all joints are tight That the flues are not obstructed That combustion is efficient There is a smell of combustion fumes Boiler does not start up Check electrical connections fuse No electrical power green LED off Ignition is slow and the burner pulses Check setting Check position and condition Incorrect gas pressure at burner Problem with the ignition electrode Boiler ...

Page 51: ...k temperature setting Check electrical wiring Check positioning of sensors 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 pump Check pump electrical connections Problem with CH circuit expansion ...

Page 52: ...r Solar controller needs reprogramming Flow rate too high Fit a pressure reducer Check and clean Make sure that the T between the collector and the storage cylinder is not too high or too low Set a T of 8 10 C Fit a flow reducer Check functioning of DHW circuit pump Check positioning of sensors Check boiler operating temperature Check temperature setting of thermostatic mixer valve Reduce the spee...

Page 53: ... in the storage cylinder Solar controller has reached maximum temperature and stopped the pump The pump will start working again as soon as the temperature drops in the collectors Check the safety devices and electrical connections Check the controller and the temperature sensor or reduce the temperature differential setting There is natural circulation to the collectors The storage cylinder loses...

Page 54: ...TECHNICAL ASSISTANCE SERVICE 54 ...

Page 55: ......

Page 56: ...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 20045110 ...

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