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5

GENERAL

1.2 

Safety Instructions

Observe these instructions for your safety.

The burner and control must be correctly installed and adjusted to 

ensure safe and economical operation of the gas boiler.

Read this installation and maintenance manual carefully and note 

the details on the boiler nameplate before placing the boiler in 

operation.

Risk of fatal injury from explosion of flammable gases

If you smell gas there is a danger of explosion.

•  Never work on gas lines unless you are licensed contractor / gas 

fitter.

•  Make sure that a licensed contractor / gas fitter installs the boiler, 

connects gas and vent, places the boiler in operation, connects 

the electrical power, and maintains and repairs the boiler.

•  No open flame! No smoking! Do not use lighters.

•  Prevent spark formation. Do not operate electrical switches, 

including telephones, plugs or door bells.

•  Close main gas valve.

•  Open doors and windows.

•  Warn other occupants of the building, but do not use door bells.

•  Call gas company from outside the building.

•  If gas can be heard escaping, leave the building immediately, 

prevent  other  people  from  entering,  notify  police  and  fire 

departments from outside the building

Risk to life from electrical shock.

•  Disconnect the power supply to the boiler heating system 

before conducting any work on it, e.g. turn off the heating 

system emergency switch outside the boiler room.

•  It is not sufficient just to turn off the control.

•  Do not carry out electrical work unless you are qualified for this 

type of work.

•  Before servicing, disconnect electrical power and lock out to 

prevent accidental reconnection.

•  Observe and follow the local, state and federal installation 

regulations.

Risk of fatal injury from flue gas poisoning

Insufficient ventilation or combustion air availability may cause 

dangerous flue gas leaks and accumulation.

•  Make sure that inlets and outlets are not reduced in size, 

restricted, or blocked.

•  If faults are not corrected immediately, the boiler must not be 

operated until all faults have been corrected.

•  Inform the system operator and/or owner of the fault and the 

danger in writing.

When working on the flue gas venting equipment or vent damper, 

leakage of flue gases may endanger the lives of people.

•  Carefully observe proper operation of the vent damper. Do not 

start up the boiler unless the vent damper is operating properly.

•  Use only genuine OEM parts when replacing parts.

•  When replacing the vent damper, install the new one in the 

specified position.

Risk to life by poisoning by leakage of flue gases

•  If the blocked vent switch trips frequently, the fault must be 

corrected and proper operation of the blocked vent switch test 

must be conducted.

Risk to life by poisoning by leakage of flue gases

•  Make  sure  that  the  boiler  is  not  equipped  with  a  thermally 

controlled flue gas vent damper after the open draft hood.

Risk of fatal injury from neglecting your own safety in case of 

emergency, such as with a fire

•  Never put yourself at risk. Your own safety must always take 

priority.

Fire danger due to flammable materials or liquids

•  Make sure that there are no flammable materials or liquids in 

the immediate vicinity of the boiler.

•  Maintain a minimum distance of 15 inches from the boiler.

Installation and maintenance

•  Observe all current standards and guidelines applicable to 

the installation and operation of the boiler heating system as 

applicable in your state or local jurisdiction.

•  Clean and service the boiler system once a year. Check that the 

complete heating system operates correctly.

•  Immediately correct all faults to prevent system damage.

•  Only use original 

R

 spare parts. Losses caused by the use of 

parts not supplied 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 

latest edition of the National Fuel Gas Code, ANSI Z223.1./NFPA 54. In 

Canada, installation must be in accordance with the requirements 

of CAN/CSA B149.1, Natural Gas and Propane Installation Code.

Where required by local, state and federal regulations, the system 

must comply with the American Society of Mechanical Engineers 

Safety Code for Controls and Safety Devices for Automatically Fired 

Boilers (ASME CSD-1).

The hot water distribution system must comply with all applicable 

codes and regulations. When replacing an existing boiler, it 

is important to check the condition of the entire hot water 

distribution system to ensure safe operation.

Valves external to the boiler must be fitted with T-handles and 

condensate piping must be installed in accordance with the State 

Plumbing Code.

NOTICE:

•  This boiler must be installed by a licensed contractor/ gas fitter. 

Failure to do so shall void the product warranty.

•  The boiler is intended only for the use for which it was specifically 

designed and built. 

R

 is hereby excluded from any liability 

for damages caused to persons, animals or property resulting 

from installation errors, improper adjustment, maintenance or 

use.

•  In order to ensure safety and correct operation, the installation 

shall always take place in full compliance with the applicable 

codes and following the instructions provided by the 

manufacturer, and must always be carried out by a licensed 

contractor / gas fitter only. 

•  The equipment must be installed in an appropriate place and 

in combination with appropriate systems as specified by code.

•  The unit may be exposed to temperatures between 5 deg F 

(-15°C) and 158 deg F (70°C) in its original packaging. 

•  After removing the packaging check the integrity and 

completeness of delivery and in case of non-compliance, 

contact your dealer.

•  If there is a water leak, disconnect the boiler from the main 

power supply, close the water supply and immediately call 

technical assistance or installer/local contractor.

•  Periodically check that the condensate drain is free from 

obstruction.

•  Periodically check the system pressure. System pressure should 

be checked when the system is in standby mode and no call for 

heat is present.

•  Maintenance is mandatory and shall be carried out at least 

once a year.

•  This manual shall be read carefully, in order to install and 

operate the boiler appropriately, and safely.

•  Boiler installations, settings and service should only be 

performed by an experienced licensed contractor / gas fitter. 

End Users should only make adjustments with the assistance of 

a licensed contractor / gas fitter.

•  Any maintenance, operation or service before disconnecting 

the boiler from the main power supply is forbidden.

•  Do not remove or modify safety equipment.

•  Do not pull or twist the electrical wires, from the boiler, even if 

the device is disconnected from the main power supply.

•  Do not obstruct or reduce the ventilation openings.

•  Do not install the unit outdoors.

•  Do  not  leave  any  combustibles  or  containers  of  flammable 

substances in the room where the boiler is installed.

•  Keep packaging material out of reach of children as it can 

be potentially dangerous. Dispose of packaging material as 

required by law.

•  The opening of metal casing of the device and removing of the 

cover are prohibited to the end user. Any service on the boiler 

must be carried out by authorized personnel.

•  It is prohibited to dispose the product as domestic waste. The 

separate disposal of the appliance avoids possible negative 

consequences for the environment and human health deriving 

from inappropriate disposal. Its materials should be recycled to 

achieve significant savings in energy and resources.

Содержание Array AR 3000

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 69: ...69...

Страница 70: ...70...

Страница 71: ...71...

Страница 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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