Riello Array AR 3000 Installation And Operation Manual
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Riello Array AR 3000 Installation And Operation Manual

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Array AR 3000 - AR 4000
US INSTALLATION AND OPERATION MANUAL

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  • Page 1 Array AR 3000 - AR 4000 US INSTALLATION AND OPERATION MANUAL...
  • Page 2 This appliance ensures maximum comfort for an extended period, with high reliability, MODEL CODE efficiency, quality and safety. Array AR 3000 20115025 This manual provides information that is essential to the in- Array AR 4000 20115026 stallation of the appliance. Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly.

  • Page 3: Table Of Contents

    4.3.1 Riello Screen ....... 25 Prolonged shutdown ......5 4.3.2 Cascade Screen .

  • Page 4: General

    GENERAL GENERAL 1.1 Warnings & cautions Array AR 3000 and AR 4000 MBH Boilers are modulating Installers and operating personnel MUST, at all times, observe all and condensing units. They represent a true industry advance that safety regulations. The following warnings and cautions are gen- meets the needs of today’s energy and environmental concerns.

  • Page 5: Emergency Shutdown

    GENERAL 1.2 Emergency shutdown a. In the event that the side wall horizontally vented gas fueled If overheating occurs or the gas supply fails to shut off, close the equipment is installed in a crawl space or an attic, the hard manual gas shutoff valve (Fig.

  • Page 6: Installation

    2.4 Site preparation Ensure that the site selected for installation of the Array AR 3000 and AR 4000 Boiler includes: − Access to AC Input Power at 230 VAC, Phase-Phase-Neutral, 60 Hz @ 24 FLA −...

  • Page 7: Installation Clearances

    24” 24” Fig. 3 Array AR 3000 and AR 4000 Forklift Handling If a crane is required, the boiler must be lifted through bands. WARNING: When lifting the boiler with crane: use bands, no chains. Bands must comply with federal, state and local rules.

  • Page 8: Boiler Location

    − The boiler should be located close to a floor drain in an area where leakage from the appliance or connections will Fig. 4 Array AR 3000 and AR 4000 Crane Lifting Handling not result in damage to the adjacent area or to lower floors in the structure.

  • Page 9: Supply And Return Piping

    Fig. 7 Array AR 3000 and AR 4000 Connections Excessive water hardness causing a lime buildup in the stainless A minimum water pressure is required for optimum performance. steel coils or tubes is not a fault of the appliance and is not cov- Minimum water pressure required: 7.25 psi (0.5 bar).

  • Page 10: Low Water Cutoff

    INSTALLATION 2.7 Low water cutoff 2.10 Condensate drain and piping The Array Boiler is designed to condense water vapor from the flue A low water cut off (LWCO) is installed on each boiler. products. Each module of the boiler is equipped with a conden- To check the functionality of LWCO go to the 905PB inner display, sate trap (see Fig.

  • Page 11: Gas Supply Specifications

    The maximum condensate flow maximum capacity. rate is 23.8 GPH for Array AR 3000 and 31.7 GPH for Array AR 4000. The drain line must be removable for routine maintenance. 2.11.2 Manual Gas Shutoff Valve...

  • Page 12: External Gas Supply Regulator

    INSTALLATION 2.11.3 External Gas Supply Regulator SWITCHING FROM NATURAL GAS TO LP An external gas pressure regulator is required on the gas inlet pip- − Close the gas shutoff valve ing under most conditions. Regulators must conform to the fol- −...

  • Page 13: Adjusting And Setting Co

    INSTALLATION 2.11.5 Adjusting and setting CO limits 2.12 AC electrical power wiring − Insert a combustion analyzer probe into the test port External AC power connections are made to the unit inside the shown in Fig. 13 electrical box, located on the front of the unit, inside the front −...

  • Page 14: Electrical Power Requirements

    Neutral 2.12.1 Electrical Power Requirements The voltage configuration of Array AR 3000 and AR 4000 is as fol- lows: − 230VAC, Phase-Phase-Neutral, 60 Hz Each unit must be connected to a dedicated electrical circuit.

  • Page 15: Field Control Wiring

    INSTALLATION If an external electrical power source is used, the installed boil- Openings for wires er must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction. In the absence of such requirements, the installation shall conform to National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.

  • Page 16: Venting

    INSTALLATION 2.14 Venting − Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical draft Array boilers must be vented and supplied with combustion and systems operating under positive pressure. ventilation air as described in this section. −...
  • Page 17 INSTALLATION VENTING CONFIGURATIONS: The following figures show the acceptable piping installation for venting and combustion air. EXHAUST EXHAUST BOILER BOILER Fig. 25 All Combustion Air from Adjacent Indoor Spaces through Fig. 27 All Combustion Air From Outdoors - Inlet Air From Ventilat- indoor Combustion Air Openings ed Crawl Space and Outlet Air to Ventilated Attic EXHAUST...
  • Page 18 INSTALLATION EXHAUST EXHAUST BOILER BOILER Fig. 29 All Combustion Air from Outdoors through Single Combus- Fig. 31 Sealed Combustion located on same side with Exhaust tion Air Opening (horizontal) EXHAUST EXHAUST BOILER BOILER Fig. 30 Sealed Combustion located on same side with Exhaust Fig.

  • Page 19: Combustion Air

    INSTALLATION − For a natural draft installation the draft must not exceed - 0.25” W.C. − These factors must be planned into the vent installation. If the maximum allowable equivalent lengths of piping are ex- ceeded, the unit will not operate properly or reliably. −...

  • Page 20: Combustion Air From Outside The Building

    INSTALLATION 2.15.1 Combustion air from outside the building Air supplied from outside the building must be provided through two permanent openings. For each unit these two openings must have a free area of not less than one square inch for each 4000 BTUs input of the equipment or 750 square inches of free area.

  • Page 21: Commissioning

    COMMISSIONING 3 COMMISSIONING Filling the boiler heating system To fill the heating system, proceed as follows: Introduction − Open any automatic air vents in the heating system. − Open the fill valve and proceed to fill the heating system Before starting the boiler, the user must be correctly instructed by and boiler until the pressure gauge (shown on Fig.

  • Page 22: Boiler Startup Procedure

    COMMISSIONING 3.5 Boiler startup procedure − Pushing the Settings button, the Settings screen will show To start the boiler, do the following: − Open the manual gas shut off valve (Fig. 1). − Turn ON the main power switch (Fig. 19). −...

  • Page 23: Minimum Water Flow (Heat Exchanger Protection)

    COMMISSIONING Adjusting the parameters on that screen, the reset curve below The setpoint modulation will occur between 2 and 9 volts. The re- will modify shape and slope to meet the needs of the specific ap- quest for heat will be removed when the voltage drops below 1 plication.

  • Page 24: Boilers' Cascade Installation And Start-Up

    COMMISSIONING 3.6 Boilers’ cascade installation and start-up Appendix L shows an example of Array boilers installed in a cascade of three units. The built-in control system is capable to manage up to 8 boilers as a single, coordinated heating system. The logical scheme is: Demand: 0-10V / OpenTherm / On-Off System sensor D2 is T outside...

  • Page 25: Operation

    6 must be completed before attempting to start the unit. Control panel description Fig. 45 Riello Screen All Array Series Boilers utilize the Touchscreen Control Panel shown in Fig. 45. This Touchscreen panel contains the basic controls for The R logo is the entry point of the Control System.

  • Page 26: Boiler Screen

    OPERATION − Home button: move back to the R screen; − Performance button: move to the Performance screen of the cascade; − Stats button: not active; − Errors button: move to the Errors screen; − Service button: move to Service screen; −...

  • Page 27: Error Screen

    OPERATION 4.3.6 Error Screen how long service was overdue on the system/appliance which can be useful when handling warranty claims. For each boiler, the Error screen shows the list of the last 40 errors A maximum of 15 Service moments can be logged by the 900PB, occurred on its own modules.

  • Page 28: Shutdown

    SHUTDOWN 5 SHUTDOWN 6 ENVIRONMENTAL PROTECTION/DISPOSAL Environmental protection is one of the fundamental company policies of the . We regard quality of performance, economy CAUTION: Risk of system damage through frost. and environmental protection as equal objectives. When there is a frost, the heating system can freeze up if it is not Environmental protection laws and regulations are strictly ad- operational, e.g.

  • Page 29: Appendix

    SHUTDOWN APPENDIX APPENDIX A - WIRING DIAGRAM LOW VOLTAGE TERMINAL STRIP HIGH VOLTAGE TERMINAL STRIP ALARM PUMP DHW / 3-WAY CH MAIN PUMP / Air Damper 3-WAY DHW PUMP CH 101 102 104 105106 107 108 109 110 111 112 113 114 115 J6-13 h J8-2 J3-5...
  • Page 30 SHUTDOWN APPENDIX WIRING DIAGRAM - MASTER - LEFT DOOR J7-2 WATER PRESSURE SWITCH CONDENSATE PRESS. SWITCH SLAVE 4 CONDENSATE PRESS. SWITCH SLAVE 8 FLOWMETER 11 12 J6-5 FLUE SENSOR MIN+MAX GAS J6-12 J7-4 9 10 PRESSURE SWITCH J9-4 J6-10 RETURN T. SENSOR J9-2 J6-3 WATER PRESSURE...
  • Page 31 SHUTDOWN APPENDIX WIRING DIAGRAM - SLAVE 2 / 3 / 4 - LEFT DOOR J12-2 UNIT FLOW TEMP. J12-5 J12-4 SAFETY LIMIT WATER THERMOSTAT J12-1 FLOWMETER J7-8 J7-7 FLUE PRESS. SWITCH + J7-6 CONDENSATE PRESS. SWITCH J7-2 J7-3 FOR SLAVE 2 / 3 J6-5 Only ON Slave 4 FLUE TEMP.
  • Page 32 SHUTDOWN APPENDIX RIGHT DOOR...
  • Page 33 SHUTDOWN APPENDIX WIRING DIAGRAM - SLAVE 5 / 6 / 7 / 8 - RIGHT DOOR...

  • Page 34: Appendix B - Size And Connections

    SHUTDOWN APPENDIX APPENDIX B - SIZE AND CONNECTIONS ARRAY AR 3000, AR 4000 72.74” 14.21” 3.62” 7.75” 7.08” 23.47” 56.78” Dimensions are in inches...

  • Page 35: Appendix C - Connection Diagram

    SHUTDOWN APPENDIX APPENDIX C - CONNECTION DIAGRAM Int. ionization CONNECTION DIAGRAM 905MN CONTROL BOARD 0...10V J9-1 Ignition 0V(GND) J9-3 BURNER J9-2 Open Thermostat interface Spark Return Room Thermostat ON/OFF J9-4 J10-1 J2 1-6 J10-2 J10-5 J10-6 J1-5 MAINS SUPPLY (120VAC, 60Hz) J1-1 COMM.
  • Page 36 SHUTDOWN APPENDIX CONNECTION DIAGRAM 905PB DISPLAY CONNECTION DIAGRAM 905PB DISPLAY 905PB05_3R Connector Function PC interface Connection to MN control/Modbus 905PB05_3R Display: RJ-11 Connector: RS485 / Mod BUS J25-1 J25-2 J25-3 1: GND/VSS J25-4 2: ModBus_B (= Data -) AL-BUS J25-5 3: ModBus_A (= Data +) +24V J25-6...

  • Page 37: Appendix D - Technical Data

    SHUTDOWN APPENDIX APPENDIX D - TECHNICAL DATA Unit AR 3000 AR 4000 Boiler Category ASME Sect.IV Type of Gas Natural Gas, Propane* Max input rate BTU/hr 3,000,000 4,000,000 (kW) (879) (1172) Min input rate BTU/hr 100,000 100,000 (kW) (29) (29) Turndown Rate 30:1...

  • Page 38: Appendix E - Structure

    SHUTDOWN APPENDIX APPENDIX E - STRUCTURE 28 27 26 25...
  • Page 39 SHUTDOWN APPENDIX Item Description Q.ty Item Description Q.ty Outer frame Burner head O-ring Burner flange (outer) Burner gasket Supply pipe Sight glass combustion Purge valve Ingiter Gas pipe Burner tube Gas valve Burner flange (inner) Heat exchanger Gasket burner flange Pump Water shutoff valve Brass connection...

  • Page 40: Appendix F - Maintenance

    SHUTDOWN APPENDIX APPENDIX F - MAINTENANCE GAS LEAKING INSPECTION A qualified and adequately trained technician must perform the Verify all gas piping to ensure that there are no leaks. inspection as specified in these instructions and in the Service Manual (provided separately) before each heating season and at DANGER: To verify the gas leaks use a soap solution or a gas regular intervals.

  • Page 41: Appendix G - Head Available For The System

    SHUTDOWN APPENDIX APPENDIX G - HEAD AVAILABLE FOR THE SYSTEM HEAD AVAILABLE (NO GLYCOL) Array ∆T = 36°F ∆T = 45°F AR 3000 12ft AR 4000 12ft HEAD AVAILABLE (65% GLYCOL) ∆T = 36°F ∆T = 45°F Array AR 3000 9,5ft AR 4000 9,5ft...

  • Page 42: Appendix H - De-Rating For Altitude Installation

    (input BTU/hr ARRAY AR 3000 Altitude (ft)

  • Page 43: Appendix I - Efficiency Curves

    SHUTDOWN APPENDIX APPENDIX I - EFFICIENCY CURVES ARRAY AR 3000, AR 4000 100% 100% input 30% input 20% input Return water temperature (°F)@36 Degree Rise...

  • Page 44: Appendix J - Troubleshooting Table

    SHUTDOWN APPENDIX APPENDIX J - TROUBLESHOOTING TABLE LOCKOUT CODES Error no. Error Description Checks Solutions E2PROM_READ_ERROR Internal software error Replace the power control board IGNIT_ERROR Three unsuccessful ignition a- Check gas supply pres- a- If the gas supply pres- attempts in a row sure;...
  • Page 45 SHUTDOWN APPENDIX Error no. Error Description Checks Solutions MAX_TEMP_ERROR The external overheat pro- a- Check the pump to verify a- Change the pump or tection is enabled or the the flow circulation; restart it; T_Supply sensor measures a b- Check if the valves on b- Open the valves on hy- temperature of over hydraulic circuit are open;...
  • Page 46 SHUTDOWN APPENDIX Error no. Error Description Checks Solutions AIR_DAMPER_LOCKING Air Damper feedback is not received when the relative output is closed for the fourth time. FLUE_PRESSURE_LOCKING Flue pressure switch is closed for the fourth time. BLOCKING ERRORS Error no. Error Description Checks Solutions...
  • Page 47 SHUTDOWN APPENDIX Error no. Error Description Checks Solutions a- If the wiring is damaged, replace it; a- Check the integrity of the b- Verify that the tempera- wire connections; RETURN_OPEN Return sensor open ture sensor has the correct b- Check the return tem- resistance values.
  • Page 48 SHUTDOWN APPENDIX Error no. Error Description Checks Solutions Too many resets in a short RESET_BUTTON_ERROR time period Exchange temperature ex- T_EXCHANGE_BLOCK_ERROR ceeded 90°C T_CHIMNEY_OPEN Chimney sensor open T_EXCHANGE1_OPEN Exchange 1 sensor open T_EXCHANGE2_OPEN Exchange 2 sensor open T_SELECTION1_OPEN Selection 1 sensor open T_SELECTION2_OPEN Selection 2 sensor open T_SELECTION3_OPEN...
  • Page 49 SHUTDOWN APPENDIX Error no. Error Description Checks Solutions Flow is too low, demand needs to be stopped with LOWEXFLOW_PROTECTION fan at ignition speed but no error needed to be stored at this time WARNINGS Error no. Error Description Checks Solutions Cascade System: Leading burner lost communication CC_LOSS_COMMUNICATION...

  • Page 50: Appendix K - Boiler Installation (Example Drawings)

    SHUTDOWN APPENDIX APPENDIX K - BOILER INSTALLATION (EXAMPLE DRAWINGS) ARRAY AR 3000 / AR 4000 Single Unit Installation...
  • Page 51 SHUTDOWN APPENDIX ARRAY AR 3000 / AR 4000 Multiple Units Installation...

  • Page 52: Appendix L - Ladder Diagram

    SHUTDOWN APPENDIX APPENDIX L - LADDER DIAGRAM MAIN POWER...
  • Page 53 SHUTDOWN APPENDIX MASTER SLAVE POWER MASTER SLAVE POWER...
  • Page 54 SHUTDOWN APPENDIX J2 CONNECTIONS...
  • Page 55 SHUTDOWN APPENDIX J3 CONNECTIONS...
  • Page 56 SHUTDOWN APPENDIX J4 CONNECTIONS...
  • Page 57 SHUTDOWN APPENDIX J5 CONNECTIONS...
  • Page 58 SHUTDOWN APPENDIX J6 CONNECTIONS...
  • Page 59 SHUTDOWN APPENDIX J7 CONNECTIONS...
  • Page 60 SHUTDOWN APPENDIX J8-J9 CONNECTIONS...
  • Page 61 SHUTDOWN APPENDIX J10-J11 CONNECTIONS...
  • Page 62 SHUTDOWN APPENDIX J12 CONNECTIONSl...

  • Page 63: Appendix M - Venting Size Data

    SHUTDOWN APPENDIX APPENDIX M - VENTING SIZE DATA ARRAY AR 3000 T supply / return (F°) - 176 / 140 T supply / return (F°) - 176 / 140 Unit Maximum Minimum Maximum Minimum Exhaust gas mass (weight) lb/s 0.79 0.02...

  • Page 64: Appendix N - Exhaust Terminals And Air Inlet Clearances

    SHUTDOWN APPENDIX APPENDIX N - EXHAUST TERMINALS AND AIR INLET CLEARANCES Direct vent (sealed combustion) Fan assisted appliance (Room air for combustion) Forced air inlet Forced air inlet Gravity air inlet Gravity air inlet Exhaust terminal Exhaust terminal X1 1 foot (305 mm) X1 1 foot (305 mm) X2 See Note 1) X2 See Note 1)
  • Page 65 SHUTDOWN APPENDIX Horizontal venting system (sealed combustion): Vertical venting system (sealed combustion): X ≥ 4” (102 mm); X > 12” (305 mm) Y ≥ 12” (305 mm) Y = 12” (305 mm) above maximum snow level or at least 24” which- ever is greater Air intake Vent...

  • Page 66: Appendix O - Sensor Resistance

    SHUTDOWN APPENDIX APPENDIX O - SENSOR RESISTANCE SENSOR RESISTANCE TABLE Vent terminals Temperature °F (°C) Resistance [Ω] Testing tolerance ±10% Vent terminals 32 (0) 27396 41 (5) 22140 50 (10) 17999 59 (15) 14716 68 (20) 12099 77 (25) 10000 86 (30) 8308 95 (35)
  • Page 68 RIELLO S.p.A. 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 www.rielloboilers.com The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specifications, standard equipment and...

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