Riello Array AR 3000 Installation And Operation Manual Download Page 66

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SHUTDOWN

APPENDIX

YES

Boiler error

Present?

System

Heat

Demand?

System

Temperature

higher than

setpoint Clear

demand?

System Temp

higher than

setpoint remove

fast?

System Temp

higher than

setpoint

remove

System Temp

lower than

Setpoint add

fast

System Temp

lower than

Setpoint add

First boiler

active?

Post pump

ready

Locking

error?

System in

stand-by

Locking error

Blocking

error

Clear demand Remove all

active boilers

Turn on ﬁrst boiler

immediately

Remove

Boiler fast

Remove

Boiler

Add boiler

fast

Power

Balancing

Add boiler

Start system

pump

Calculate

system

setpoint

Stop system

pump

YES

See the ﬂow of Add

boiler of how a boiler

is added

BOILER CASCADE

Summary of Contents for Array AR 3000

Page 1: ...cod Doc 0079789 rev 5 09 2018 Array AR 3000 AR 4000 US INSTALLATION AND OPERATION MANUAL...

Page 2: ...or consequential damages occurring in connection with the furnishing performance or use of this material ENGLISH RANGE MODEL ASSEMBLY NUMBER Array AR 3000 20144522 Array AR 4000 20144042 9WARNING If...

Page 3: ...the Building 27 4 16 3 Ducted Combustion Air 27 5 COMMISSIONING 27 5 1 Introduction 27 5 2 Filling the Condensate System 27 5 3 Filling the Boiler Heating System 27 5 4 Warnings Concerning the Gas Sup...

Page 4: ...tallers and operating personnel MUST at all times observe all safety regulations The following warnings and cautions are general and must be given the same attention as specific precautions included i...

Page 5: ...lied by R are excluded from the R warranty 1 3 General Warning The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the late...

Page 6: ...1 PVC female 1 Cardboard box on pallet Component Qty Packaging method 7 Relief Valves Drain Adapter 2 5 NPT female 1 Cardboard box on pallet 8 Flue Adapter 10 8 1 Cardboard box on pallet 9 Mounting A...

Page 7: ...arbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 7...

Page 8: ...RIPTION 78 91 2 75 81 67 72 74 6 2 15 5 2 36 2 4 4 10 8 10 1 57 4 5 7 07 7 08 7 75 7 08 35 39 23 47 56 78 2 7 Size and Connections Array AR 3000 AR 4000 Boilers feet may be removed for reducing overal...

Page 9: ...m3 h 39 52 Water flow at max power T 45 F 25 C GPM 136 182 m3 h 31 41 Vent Air Intake Connections Inch 8 or 10 10 8 or 10 10 mm 200 or 250 250 200 or 250 250 Vent Materials CPVC PP Stainless Steel AL2...

Page 10: ...10 PRODUCT DESCRIPTION 2 9 Assembly Components 1 5 4 3 6 2 12 18 7 8 14 9 16 10 17 13 11 24 23 15 21 22 20 19 30 29 26 25 31 29 27 33 32...

Page 11: ...n 22 Vertical supply manifold 23 Condensate drain 24 Relief valve drain Item Description 25 Burner head O ring 26 Burner flange outer 27 Burner gasket 28 Sight glass combustion 29 Igniter 30 Burner tu...

Page 12: ...DESCRIPTION 2 10 Efficiency Curves Array AR 3000 AR 4000 80 88 90 92 94 96 98 100 70 80 90 100 110 120 130 140 150 160 170 Thermal Efficiency Return water temperature F 36 Degree Rise 100 input 30 inp...

Page 13: ...U hr energy input for the AR 3000 OR 4 000 000 BTU hr energy input for the AR 4000 The boilers should be mounted on a concrete service housekeeping pad 4 in height The boiler should be located close t...

Page 14: ...lift from the SIDE ONLY see Fig 3 FOR MASSACHUSSETTS ONLY For Massachusetts installations the unit must be installed by a plumber or gasfitter licensed within the Commonwealth of Massachusetts In addi...

Page 15: ...28 0 75 0 28 0 75 Fig 8 Array AR 3000 and AR 4000 Anchoring bolt detail 4 5 Boiler Location This boiler is suitable only for indoor installations To operate properly and safely this boiler requires a...

Page 16: ...ated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle A minimum water pressure is required...

Page 17: ...ed to a nearby floor drain In multiple unit installations the discharge lines must not be manifolded together Each must be individually run to a suitable discharge location Relief valves should be man...

Page 18: ...ch NPT gas inlet connection on the top of the unit as shown in Fig 9 9WARNING Never use matches candles flames or other sources of ignition to check for gas leaks 9CAUTION Many of the soaps used for g...

Page 19: ...codes and requirements of the authority having jurisdiction If the information in these instructions is not followed exactly or the installation adjustment modification operation or maintenance is ca...

Page 20: ...POWER the fan will run at the minimum speed Screw B Screw A Fig 16 O2 Adjustment To adjust the O2 value at the minimum input turn the screw B rotate clockwise to decrease O2 shown in Fig 16 Verify tha...

Page 21: ...n in Fig 21 does not remove power from the left door terminal blocks NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers inhibi...

Page 22: ...s air damper alarm must be powered through a relay not included in the boiler to be provided and wired by the installer 101 102 104105 106107 108109 110 111 112 113 114 115 103 ALARM MAIN CH PUMP Air...

Page 23: ...raps must be filled with water or combustion gases will enter the room with a risk of an excessive level of carbon monoxide Vent connectors serving appliances vented by natural draft shall not be conn...

Page 24: ...Outdoors through Ventilated Attic EXHAUST BOILER Fig 29 AllCombustionAirFromOutdoors InletAirFromVentilated Crawl Space and Outlet Air to Ventilated Attic EXHAUST BOILER AIR DUCT AIR DUCT Fig 30 All...

Page 25: ...s through Single Combustion Air Opening BOILER EXHAUST Fig 32 Sealed Combustion Located on Same Side with Exhaust vertical EXHAUST BOILER Fig 33 Sealed Combustion Located on Same Side with Exhaust hor...

Page 26: ...endix H Venting Size Data 4 16 Combustion Air Air supply is a direct requirement of ANSI 223 1 NFPA 54 CSA B149 1 and local codes These codes should be consulted before a permanent design is determine...

Page 27: ...ill void any warranty 9CAUTION All of the installation procedures in Installation page 13 must be completed before attempting to start the unit 5 2 Filling the Condensate System The condensate system...

Page 28: ...Units It mustmatchthenumberofmodulesoftheboiler 6forAR3000 and 8 for AR 4000 By default the number of expected modules is 8 Follow the path below on the Service display Menu Settings Boiler Settings M...

Page 29: ...ist Fan Speed Maximum Fan Speed Minimum 1 5 1 0 2 0 9 Voltage OFF ON ON OFF Hysterese O F F O N M o d u l a t i n g Fig 42 10VDC Control mode The CH setpoint Min and CH setpoint Max parameters can be...

Page 30: ...scade installation scheme After the electrical wiring of the Managing controllers of each boiler of the cascade through the Cascade link connections on the Low voltage terminal strips the following st...

Page 31: ...panel contains the basic controls for monitoring the boiler All other controls indicators and displays necessary to operate adjust and troubleshoot the boiler are available on the 905PB inner display...

Page 32: ...e temperature water flowrate fan speed flame rod ionization current burner and pump status any error status or service required Use the side buttons to perform the actions listed below Home button mov...

Page 33: ...ll it will overwrite the oldest log entry Each time the Service Reminder is being reset a new service moment is counted and the Service Overdue counter will be stored in the log history There are two...

Page 34: ...an Emergency Only in emergencies switch OFF the heating system via the boiler room breaker or the heating system emergency stop switch In dangerous situations immediately close the main fuel shut off...

Page 35: ...h J6 6 b SLAVE 2 TOUCH SCREEN 485 101 102 104105 106107 108109 110 111 112 113 114 115 103 ALARM MAIN CH PUMP Air Damper DHW 3 WAY CH DHW Pump CH Pump N L3 L2 L1 N L3 L2 L1 OUT IN N L3 L2 L1 A1 A2 A1...

Page 36: ...1 b 213 GAS VALVE J5 1 bl J5 2 w J2 4 gr FAN 216 J4 2 bl J4 3 w J2 1 gr 5 4 2 1 J4 1 br J4 4 h J4 5 grey J4 6 bl 211 PWM PRESSURE SWITCH SWITCH SWITCH CONDENSATE PRES SWITCH FAN J12 3 J11 1 LWCO J12...

Page 37: ...12 2 b 202 212 SAFETY LIMIT WATER THERMOSTAT UNIT FLOW TEMP 213 GAS VALVE J5 1 bl J5 2 w J2 4 gr J1 1 w J1 5 bl J1 4 gr FAN 216 J4 2 bl J4 3 w J2 1 gr 5 4 2 1 J4 1 br J4 4 h J4 5 grey J4 6 bl 211 PWM...

Page 38: ...PUMP 8 PUMP 7 PUMP 6 COM COM O N O N A2 A1 R6 COM COM NO NO A2 A1 R7 A2 A1 R8 NO NO COM COM PUMP 5 COM COM O N O N A2 A1 R5 J3 4 DEP 5 J3 9 DEP 5 M5 LEFT DOOR ON OFF POWER BUTTON M6 M7 M8 PRE WIRED Bl...

Page 39: ...39 SHUTDOWN 39 APPENDIX WIRING DIAGRAM DEPENDENT 5 6 7 8 RIGHT DOOR...

Page 40: ...0 5 J10 6 J11 2 J11 4 J11 1 J11 3 J8 1 J8 2 SWL J1 1 J1 5 J1 4 J1 2 PROG OUTPUT 4 CONFIG 1 2 CH Pump 3 DHW Pump PROG OUTPUT 1 2 CH Pump PROG OUTPUT 5 1 General Pump L N L L N N J3 4 J3 9 J3 3 J3 8 J3...

Page 41: ...24V To 905MN 1 2 3 4 5 6 J25 Wire Colors j25 1 Grey j25 2 Black j25 3 Green j25 4 Yellow j25 5 Red j25 6 Blue CONNECTION DIAGRAM 905PB DISPLAY CONNECTION DIAGRAM 905TS Touchscreen AND 905PB DISPLAY Mo...

Page 42: ...ck wiring and connections Annually Verify startup Annually Verify the flame stability and signal strength Annually Check relief valve Annually Inspect the burner gasket Annually or every 2000 hours Wh...

Page 43: ...5ft AR 4000 7ft 16 5ft Array Model Boiler Quantity Combined Max GPM Common Pipe Size Inch Max Equivalent Length of Pipe ft AR 3000 1 150 4 150 2 300 6 300 3 450 6 150 4 600 8 330 AR 4000 1 200 6 180...

Page 44: ...ray AR 4000 Altitude ft From 0 to 25 From 25 to 50 From 50 to 75 From 75 to 100 0 2 000 4 000 000 4 000 000 4 000 000 4 000 000 3 000 3 671 586 3 607 867 3 544 141 3 480 422 4 000 3 549 798 3 488 189...

Page 45: ...Safety relay Replace the power control board 4 BLOCKING_TOO_LONG Control had a blocking error for more than 20 hours This error is caused when any of the Blocking errors have occurred and wasn t corre...

Page 46: ...e flame failures during one demand cycle a Check the integrity of the wire connections of the spark and the earth on heat exchanger b check ionization signal while running a If wires are damaged repla...

Page 47: ...osed a Check all hydraulic valves and pumps are open and functioning correctly b Check supply sensor c Check the value of the reading of this sensor in the info screen a Change the pump or restart it...

Page 48: ...t resistance values If values are incorrect sensor must be replaced 122 DHW_OPEN DHW sensor open a Check the integrity of the wire connections b Check the DHW temperature sensor a If the wiring is dam...

Page 49: ...ressure switch is closed a Check flue for obstructions Clear if found b Check flue pressure to ensure flue has been installed and sized properly c Flue pressure switch default to 2 2 wc a Remove any o...

Page 50: ...Mode to activate on that particular boiler c Remaining cascade will continue to operate as normal d Check the value of the reading of this sensor on the info screen 204 T_CASCADE_WRONG T_Cascade sens...

Page 51: ...ED FOR FLOW RATES LESS THAN 4 0 FT SEC COMMON PIPE LENGTH BETWEEN THE CLOSE TEES MUST BE 3 TO 5 TIMES ITS DIAMETER NOTES 1 THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING CONCEPT ONLY 2 INSTALLATIO...

Page 52: ...l A NOTES 1 THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING CONCEPT ONLY 2 INSTALLATIONS MUST COMPLY WITH ALL LOCAL CODES 3 INSTALL A MINIMUM OF 12 DIAMETERS OF STRAIGHT PIPE UPSTREAM OF ALL CIRCUL...

Page 53: ...boilers to a single exhaust system No more than eight 8 boilers should be cascade vented together The boiler vent installation must be in compliance with ANSI Z223 1 NFPA 54 and all local state and fe...

Page 54: ...m above grade or snow line YB Exhaust terminal must be at least 3 feet 915 mm above forced air inlet within 10 feet 3050 mm horizontally USA 6 feet 915 mm above forced air inlet Canada It is not recom...

Page 55: ...Vent Vent Y Multiple air and vent vertical termination X 12 305 mm Y 12 305 mm Y X Y X X Vertical venting system sealed combustion X 12 305 mm Y 12 305 mm above maximum snow level or at least 24 which...

Page 56: ...2582 158 70 2221 167 75 1918 176 80 1663 185 85 1446 194 90 1262 203 95 1105 212 100 970 221 105 855 230 110 755 239 115 669 248 120 594 257 125 529 Resistance table for Heat exchanger supply temperat...

Page 57: ...ly Temp 30 90 40 C 2 Installer 22 Baseline Outdoor Temp 0 30 20 C 2 Installer 23 Design Supply Min Limit 4 82 30 C 2 Installer 24 Design Supply Max Limit 27 90 80 C 2 Installer 25 Warm Weather Shutdow...

Page 58: ...an Speed Ignition 0 12750 See Appliance settings RPM 2 Installer 116 Prog Input 1 0 Disabled 1 Water pressure sensor 2 CH flow switch 3 Flue pressure switch See Appliance settings 2 Installer 117 Prog...

Page 59: ...m Pump 5 Cascade Pump 6 Alarm Relay 7 Filling Valve 8 LPG Tank 9 External Igniter 10 Air Damper 14 Alarm Burner CC 15 Status Burner CC 16 Zone pump 17 Mixing valve open 18 Mixing valve closed 19 Anti...

Page 60: ...2 Installer 139 Dair active Yes No No 2 Installer 140 Minimal Flow 0 0 100 17 l min 2 Installer 107 Anti legionella Day Sun Sat Sun Day 2 Installer 108 Anti legionella Hour 0 23 0 Hour 2 Installer 18...

Page 61: ...r 159 Delay Per Stop Next Blr 0 1275 1275 Sec 2 Installer 160 Delay Quick Start Next 0 1275 400 Sec 2 Installer 161 Delay Quick Stop Next 0 1275 240 Sec 2 Installer 162 Hyst Down Start Boiler 0 40 5 C...

Page 62: ...Temp lower than Setpoint Module CH ow is above min_ ow Demand Still active Post Pump timer nished or no longer priority Is the supply Temp Above the module setpoint Hyst Up Is the supply Temp Above th...

Page 63: ...Purge 0 Pre Purge 1 Fan on ignition speed Blocking error Pre ignition on Ignite ignition on Gas Valve open Flame Proving Checking ame Locking error Burn Fan on ignition speed within time Flame Current...

Page 64: ...Air damper open First module active Post pump ready Locking error Boiler in stand by Locking error Blocking error Clear demand Remove all active modules Turn First module on immediately Remove module...

Page 65: ...BOILER ADD REMOVE MODULE Add module function Delay period for starting new module is 0 Air damper open Are we allowed to add another dependent YES YES YES Add dependent to the cascade demand Open Air...

Page 66: ...oint add fast System Temp lower than Setpoint add First boiler active Post pump ready Locking error System in stand by Locking error Blocking error Clear demand Remove all active boilers Turn on rst b...

Page 67: ...or starting new boiler is 0 Are we allowed to add another dependent Are we allowed to remove another dependent YES YES YES YES Remove dependent from the cascade demand Remove dependent from the cascad...

Page 68: ...r is closed Supply return Flue sensor are OK Module LWCO detects water Flue condensate pressure sitch closed State burn Flue gas Temp above the max_ ue_gas_temp YES YES YES YES YES YES YES Stand by Lo...

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Page 72: ...A 02043 2165 Meadowpine Blvd Mississauga Ontario Canada L5N 6H6 Tel 905 542 0303 www riello com North America www rielloboilers com The manufacturer strives to continuously improve all products Appea...

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