RIELLO Condexa Pro 90kW Wall Hung Boiler Installation Guide

RIELLO Condexa Pro 90kW Wall Hung Boiler Installation Guide

1 GENERAL

1.1 Website downloads

1. go to the following link and download “CommercialBoilers” form https://www.riello.com/north-america/service/technical-support/commissioning

1.2 Key Symbols

PAY ATTENTION TO THESE TERMS
⚠  DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.
⚠  WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial
property damage if ignored.
⚠  CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or
property damage if ignored.
⚠  NOTICE: Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

2 INITIAL CHECKS

⚠ DANGER: Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.

2.1 Incoming Power and Device Conections

1. Check and ensure correct incoming power (Power as stated on boiler label) Single phase : L-N, N-G.
   WARNING: Risk of electrical shock. Use caution when testing the power sources. Failure to do so may result in severe personal injury or death.

2. Ensure all relevant system connections are tied into low voltage terminal strip and high voltage terminal strip of the boiler.
   NOTE: All line voltage outputs are 120V and require a relay to power external devices.

2.2 Incoming Gas Supply

1. Check for recommended supply gas pressure, upstream of the boiler:
   – For natural gas: 4.0″ we. minimum, 14″ we. maximum.
   – For propane gas: 8.0″ we. minimum, 14″ we. maximum.
   ⚠ WARNING: Ensure the gas supply line has been pressure tested and is free from leaks. Failure to do so may result in substantial property damage, severe personal injury or death.
   ⚠ DANGER: Flammable gas explodes. Beware if you smell gas: there may be an explosion hazard!

2. Ensure all gas connections have been pressure tested. Soap test connections downstream of gas valve while module is running.
   ⚠ NOTE: Check minimum and dynamic pressure when all modules are at high fire.

2.3 Dip Switch Settings

1. Set Sl dip switches on boiler controllers (Fig. 1)
   a. Sl dip switches to be set in off position on all boilers.

2. Set Address Dip Switch on end of control. (Fig 2)
   a. If using single boiler without system sensor: leave all dip switches in the off position.
   b. If using single boiler with system sensor connected: turn . the number 1 dipswitch on.
   c. If using multiple boilers: system sensor is required and turn on corresponding dipswitch for boiler position.
   d. If using multiple boilers with primary and secondary sensors: turn on corresponding dipswitch for boiler position and see section 5.2 of QSG for wiring connections and boiler addressing information.

3 FILLING THE BOILER WITH WATER

CAUTION: Before commissioning ensure all hydronic water connections are tight and free from leaks.

3.1 Filling Module

To Fill the heating system, proceed as follows:

1. Open any automatic air vents in the heating system
2. Open the fill valve and proceed to fill the heating system and boiler. The heating system water pressure must be higher than 7.SPSI.
3. Check that there is no water leaking from the fittings.
4. Check the pressure during the purging process. If the pressure has dropped, reopen the fill valve to bring the pressure back to the desired value.

4 COMMISSIONING MODULE

⚠ DANGER: Ensure all venting has been fastened and secured in-accordance with the venting manufactures instructions, the Riello Array SE Installation & Operation Manual and the local authority having jurisdiction. Failure to do so may result in severe injury or death.
⚠ WARNING: Before commissioning ensure the Riello Array SE Installation and Operation Manual has been read in its entirety.
Failure to do so may result in substantial property damage, severe injury or death.
⚠ WARNING: Before commissioning ensure all gas connections have been pressure tested; failure to do so may result in substantial property damage, severe injury or death.

4.1 Combustion Tuning

1. Make sure to disable the boiler from operation by opening the Enable circuit either from the automation system or by removing the wires from the terminal strip located on the boiler.
2. Press Menu on the boiler screen and select SYSTEM TEST.
3. Move cursor to change Test State. You can select: LOW POWER, IGNITION POWER OR HIGH POWER.

Once boiler has lit and flame has been established, select HIGH POWER in the SYSTEM TEST menu. Let boiler operate for a couple of minutes to allow combustion to stabilize. Insert probe from combustion analyzer into the exhaust port on the flue pipe connector on top of the boiler.

Once O2 level has been achieved, change TEST STATE to LOW POWER and allow boiler combustion to stabilize. Adjust low fire setting screw on gas valve to achieve recommended O2 level of 4.5-5.5%.

For both versions of boiler:
Adjustment screw 2 is for HIGH POWER
Adjustment screw 3 is for LOW POWER

4.2 Testing Safeties

All boiler safeties are tested via the SYSTEM TEST menu on the display.

1. Select MAX THERMOSTAT to test high limit.
2. Select LWCO to test the low water cut-off.

5 SETTING UP CONTROLS

5.1 Control Mode

1. Configure CH Mode for the boiler system by accessing the Boiler parameters menu on the display.

5.2 Boiler Wiring Connections

1. Cascade Link:
   a. Connect from BUS 1 (7 & 8) on Boiler 1 to BUS 2 (17 & 18)on each dependent boiler.

2. Primary Loop Sensor:
   a. Connect the Supply Sensor (11 & 12) on Boiler 1.

3. Secondary Loop Sensor: (Optional)
   a. Connect the Supply Sensor (11 & 12) on Boiler 2.

If not using a system sensor (only 1 boiler installed), Parameter 73 will automatically be set to “Stand Alone” and cannot be changed.
If using 1 system sensor, set Parameter 73 in boiler 1 to “Stand Alone”.
If using both primary and secondary sensors, set Parameter 73 in boiler 1 to “Managing”.

5.3 Boiler & Module Rotation

1. On service display go to:
   Module Cascade Settings > Set Module Rotation – Parameter 84

2. Module Cascade Settings> Parameter 147 – Number of Units. Change this setting to match number of boilers connected together.

5.4 Boiler Control

Observe the boiler running in normal system conditions. If you notice the boiler overshooting setpoint and/or over cycling, the
following parameter changes can be made:
Module Cascade settings: (On Managing Boiler)
Parameter 79 (Max offset down): 10 deg f
Parameter 80 (Max offset up): 10 deg f
Parameter 87 (PID I): 250
Parameter 150 (PID slewrate up) : 5
Parameter 151 (PID slewrate down): 5
Boiler Casacade settings: (On Managing Boiler of first cascade)
Parameter 169 (Max offset down): 15 deg f
Parameter 170 (Max offset up): 15 deg f
Parameter 177 (PID I): 500
Parameter 178 (PID slewrate up) : 5
Parameter 179 (PID slewrate down): 5

6. ERROR

6.1 Multimeter Checks

WARNING: Risk of electrical shock. Use caution when testing the power sources. Failure to do so may result in severe personal injury or death
AL Link
24VDC (with Sl Switch On and open circuit). Voltage is variable while in normal operation depending on data stream.
Pressure Switches
(ie: Gas Pressure, Water Pressure, Flue Pressure, etc) 3.3VDC while circuit is open.
Safety Switch
(High Limit) 24VDC while open Flow Meter
SVDC at all times

6.2 Types Of Errors

1. Locking: Error Codes <100. These are hard lockouts. Manual reset is required to clear these errors. Reset button will be available on the Touchscreen, PB display or the individual controller.
2. Blocking: Error Codes 100<200. These errors are self-resettable errors. No reset button will be available to clear these errors. A blocking error that does not reset itself after a period of time will cause a hard lockout condition to occur. Burner/ boiler will not operate until blocking error is corrected.
3. Warning: Error Codes >200. These are informational errors only. Boiler will still be functional.

6.3 Common Errors

7 NOTES

37045 Legnago (VR)
Tel. 0442630111 – Fax 044222378
RIELLO NORTH AMERICA
35 Pound Park Road
Hingham. Massachusetts
U.S.A. 02043
2165 Meadowpine Blvd
Mississauga. Ontario
Canada L5N 6H6
Tel. 905-542-0303
www.riello.com
www.rielloboilers.com
The manufacturer strives to continuously improve all products. Appearance, dimensions. technical specifications.
standard equipment and accessories are therefore subject to change without notice.

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