Riello TAU 55 UNIT Installation And Maintenance Manual
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Riello TAU 55 UNIT Installation And Maintenance Manual

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CONDENSING
BOILERS
TAU 55 - 75 - 110
UNIT
INSTALLATION AND
MAINTENANCE MANUAL

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Summary of Contents for Riello TAU 55 UNIT

  • Page 1 CONDENSING BOILERS TAU 55 - 75 - 110 UNIT INSTALLATION AND MAINTENANCE MANUAL...
  • Page 2 70 kW • Delegated Regulation (EU) N. 811/2013 • Delegated Regulation (EU) N. 813/2013. RANGE MODEL FUEL CODE TAU 55 UNIT Methane - LPG 20011771 TAU 75 UNIT Methane - LPG 20011772 TAU 110 UNIT...
  • Page 3 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. GENERAL...

  • Page 4: Table Of Contents

    CONTENTS GENERAL General Safety Information Precautions Product description Safety devices Identification Data plate Layout Technical specifications Water circuit Wiring diagram Positioning the temperature sensors Pumps Control panel Programming levels Information levels INSTALLER TECHNICAL ASSISTANCE SERVICE Unpacking the product Opening Initial start-up Dimensions and weight Checks during and after initial start-up Handling...

  • Page 5: General Safety Information

    GENERAL SAFETY INFORMATION As soon as you open the packaging, check imme- Periodically check that operating pressure in the diately that the contents are all present and undam- central heating circuit is over 1 bar but below the aged. Contact the r reseller from whom you pur- maximum limit specified for the boiler.

  • Page 6: Product Description

    B23P Tipo di apparecchio Caldaia categoria 2H3P Pressioni di alimentazione gas: - Serial number plate 20 mbar RIELLO S.p.A. Via Ing.Pilade Riello 7 37 mbar 37045 Legnago (VR) - ITALY This specifies the Mod. Cod. N° Regolazione effettuata dal costruttore:...

  • Page 7: Data Plate

    Brandstof: Brennstoff: Kategorie: Drivstoff: Kategori: Rated useful heat output RIELLO S.p.A. Via Ing.Pilade Riello 737045 Legnago (VR) - ITALY Index of protection T067697GE P.min Minimum pressure Caldaia a condensazione - Chaudière à condensation Brennwertkessel - Condenserende verwarmingsketel - Kondenskjel Maximum operating pressure, G25 BE P.min.G20=...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS MODELS TAU 55 UNIT TAU 75 UNIT TAU 110 UNIT condensing boiler for central heating Device type IT-CH: G20=20mbar G31=37mbar FR: G20/G25 - 20/25 mbar G31=37mbar Fuel BE: G20/G25 - 20/25 mbar NO: G20=20mbar IT-CH: II2H3P IT-CH: II2H3P...

  • Page 9: Water Circuit

    MODELS TAU 55 UNIT TAU 75 UNIT TAU 110 UNIT Maximum condensation at 100% rated heat output (40-30°C) 12,0 14,4 Power supply V-Hz 230-50 Electric degree of protection Consumption at full load Elmax Consumption at part load Elmin Consumption in standby mode PSB P sb (*) Values referred to atmospheric pressure at sea level..

  • Page 10: Wiring Diagram

    WIRING DIAGRAM BOILER CONTROL PANEL Pboiler Pgas Fan-PWM SCH2 SCH1 X40-5 OCI420 X50-5 M1 M2 M3 AGU2.5 Treg X30-14 X30-1/14 AGU2.3 FILTRO 6.3A 230 Vac Room thermostat (low voltage, 24V) Fuse 6.3 A-T Fan-PWM Main switch Mains filter Treg Connection for temperature controller (accessory) Flue gas thermostat, 75°C (+0/-10) Pboiler Pressure switch (combustion chamber)
  • Page 11 Connection schematic for added accessories SCH4 CLIP-IN communication card MB-LPB DB-LPB SCH3 SCH5 NTC/10K NTC 10K SCH3 RVS control card (**) SCH4 Room unit control card SCH5 Mixed zone interface card (clip-in) Additional mixed zone pump Mixer valve for additional zone CH flow temperature sensor for additional mixed zone (**) Refer to the instructions provided with your card for details on how to connect it to the RVS unit.

  • Page 12: Positioning The Temperature Sensors

    This TAU UNIT boiler comes without a pump. A pump must therefore be provided as part of the installation. In order to choose a pump of the right size, bear in mind the boiler’s water-side pressure drop, as shown in the figure below Water-side pressure drop TAU 55 UNIT TAU 75 UNIT TAU 110 UNIT...

  • Page 13: Control Panel

    CONTROL PANEL CONTROL PANEL AND SYMBOLS 11 12 13 - Burner lockout indicator - DHW mode selector (for use with remote storage cylinder: accessory) - Central heating or room temperature setting key - DHW temperature setting key (for use with remote storage cylinder: accessory) - Reset key.
  • Page 14 DISPLAY - Water pressure reading (not used) - Large numeric display. Displays current value - Chimney sweep or Service Required symbol - Display symbols: v DHW temperature or DHW mode active r CH or room temperature setpoint, or CH mode active c Outdoor temperature o Daytime CH mode l Night-time CH mode...
  • Page 15 MAIN SCREEN A1 - Functioning mode. Press the mode key to activate the various modes, as shown by the line under the corresponding symbol B1 - DHW mode. Press the key to activate and deactivate DHW mode C1 - Daytime CH mode D1 - Time of day E1 - Current boiler temperature - Water pressure (not used)

  • Page 16: Programming Levels

    Notes on functioning The control panel on the TAU UNIT boiler controls the following functions: - The DHW priority function. This ensures that the boiler - Overtemperature dispersal function. If the temperature can still serve the central heating circuit even when threshold thermostat trips (86°C) the boiler shuts down domestic hot water is drawn off.
  • Page 17 INSTALLER LEVEL Parameters in this level must only be changed by personnel from r's Technical Assistance Service. This level contains, among others, parameters for selecting the slope of the central heating 1 curve and setting the DHW reduced temperature setpoint (if an optional remote storage cylinder is connected). See the “Complete list of parameters”...

  • Page 18: Information Levels

    Explanation Press one of these keys until you reach the parameter you require. The example here shows the parameter Oxxx. Press these keys to change the current value. To memorise the new value, you need to move on to another parameter. Press one of these keys to exit the manufacturer programming level.
  • Page 19 Functioning phases (table 1) Nr. displayed Characteristic Standby Ignition prevented Fan start Pre-ventilation Wait time Pre-ignition time Safety time, constant Safety time, variable Central heating mode Domestic hot water mode Simultaneous CH and DHW mode Post-ventilation with last control used Post-ventilation at pre-ventilation level Home run (*) Burner lockout (error code displayed)
  • Page 20 EXTENDED INFORMATION LEVEL 2: process values Press the key. Press and hold both keys for at least 3 seconds. Press the key. Press one of the keys until you reach the parameter you require. Process values Characteristic Reserved Ionisation current Fan speed Fan control current (PWM) Relative boiler heat output...

  • Page 21: Unpacking The Product

    UNPACKING THE PRODUCT The boiler is delivered on a wooden pallet, suitably packed and protected by a wooden crate. Check immediately that there is no damage and that the boiler is exactly as ordered. The product specifications are shown on the outside of the packing: model, power, equipment, fuel type.

  • Page 22: Dimensions And Weight

    DIMENSIONS AND WEIGHT TAU 55 TAU 75 TAU 110 UNIT UNIT UNIT 1550 1550 1800 Weight HANDLING Proceed as shown to move and handle the boiler in the boiler room: - Pull the front panel towards you then lift it up to remove it. - Unscrew the screws (1) securing the boiler to the pallet (2).

  • Page 23: Place Of Installation

    PLACE OF INSTALLATION Because this TAU UNIT, boiler generates over 35 kW of When installing the boiler, allow sufficient space heat output, it MUST be installed in a dedicated boiler around it to access all safety and control devices room in compliance with applicable technical standards. and to permit easy maintenance.

  • Page 24: Water In Heating Circuits

    Contact RIELLO’s Technical Assistance Service for fur- ther information on water additives and their use. WATER IN CENTRAL HEATING SYSTEMS: INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF CENTRAL HEATING SYSTEMS 1.
  • Page 25 2. Central heating systems 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. 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 basis in order to evenly distribute initial limescale deposits.
  • Page 26 These are contact between system water and air and the continuous addition of fresh water to the circuit. To eliminate contact between system water and the air (thus avoiding oxygenation of the system water), we need to: - ensure that the expansion vessel is a closed vessel, and of the correct size and pre-charge pressure (the pressure to be checked periodically);...

  • Page 27: Water Connections

    WATER CONNECTIONS TAU UNIT boilers are designed and made for installation in combined central heating and domestic hot water produc- tion systems. The water fittings have the following specifications: TAU 55 - 75 UNIT TAU 55 TAU 75 UNIT UNIT 1168 1275 1550...
  • Page 28 TAU 110 UNIT TAU 110 UNIT 1 - Central heating flow Ø 2” M 2 – High temperature return Ø 1 1/2” M 3 – Low temperature return Ø 2” M 4 - Condensate drain siphon 5 - Flue gas exhaust Ø...
  • Page 29 Typical water system schematics TAU UNIT: basic configuration TAU UNIT Storage cylinder (if present) TAU UNIT: configuration with temperature control kit installed TAU UNIT Storage cylinder (if present) 1 - Isolating valve 9 - Pressure reducer 2 - Non-return valve 10 - Mixer valve 3 - Pump 4 - Expansion vessel...

  • Page 30: Draining The Condensate

    DRAINING THE CONDENSATE Always maintain a slope “i” of over 3° and ensure that the diameter of any hose used is greater than that of the boiler’s own condensate drain pipe. i≥3° The connection to the waste water drain must be made in compliance with national and local legislation and standards.

  • Page 31: Condensate Neutralisation Unit

    CONDENSATE NEUTRALISATION UNIT NEUTRALISATION UNIT TYPE N2 N2 neutralisation units are designed for systems with boiler condensate drain pits located at a lower level than the boiler condensate drain fitting. These neutralisation units do not require any electrical connections. Type Q.ty of Dimensions Ø...
  • Page 32 The inlet fitting (A) of the HN2 neutralisation unit (the lower fitting) must be connected to the boiler conden- sate drain fitting using the flexible hose (C) supplied. This condensate drain hose is specially made to prevent combustion fumes escaping into the atmosphere. 1,5 m The outlet fitting (B) of the neutralisation unit (the top fitting) must be connected to the boiler room’s waste...

  • Page 33: Gas Connection

    GAS CONNECTION TAU 55 - 75 UNIT TAU 110 UNIT TAU 55 UNIT TAU 75 UNIT TAU 110 UNIT 1402 1505 1639 141,5 141,5 Gas fitting Ø 1/2” M Ø 1/2” M Ø 3/4” M r TAU UNIT boilers must be connected to the meth-...

  • Page 34: Ch Frost Protection

    CH FROST PROTECTION TAU UNIT condensing boilers are equipped with an No special anti-frost additives are therefore needed, electronic frost protection system. This system starts up unless the system is to be completely shut down for the boiler if temperature drops below a certain threshold. an extended period of time.

  • Page 35: Electrical Connections

    ELECTRICAL CONNECTIONS TAU UNIT condensing boilers are fully wired in the factory. Only the following electrical connections remain to be made: - mains electricity supply; - room thermostat; - outdoor temperature sensor; - storage cylinder pump (if relevant). Proceed as follows to make these connections: - Remove the front and top panels from the boiler.

  • Page 36: Sensor Connections

    SENSOR CONNECTIONS Proceed as follows to access the control panel terminal strip: - Unscrew the screws (5) and turn out the front panel hous- ing the control panel. - Route the connection cables through the cable grommets in the rear of the control panel and the slots inside the front of the panel.

  • Page 37: Outdoor Sensor Connections

    OUTDOOR SENSOR CONNECTIONS Correct positioning of the outside temperature sensor is essential to proper indoor climate control. The sensor must be installed outside the building to be heated, about 2/3 of the way up a NORTH or NORTH-WEST fac- ing wall, well clear of any flues, doors, windows and out of direct sunlight. Fixing the outside sensor to the wall - Unscrew (anti-clockwise) the cover from the sensor casing to access the sensor terminals and fixing holes.

  • Page 38: Filling And Draining The System

    FILLING AND DRAINING THE SYSTEM TAU UNIT boilers require a filling pipe connected to the central heating circuit return pipe. All the necessary circuit shut-off and drain cocks must be provided. FILLING THE SYSTEM Make sure that the boiler’s central heating drain cock (1) is closed before you start filling the system.

  • Page 39: Initial Start-Up

    INITIAL START-UP - Switch the electricity supply ON at the system's main switch and at the control panel. - The boiler switches on and the display shows the soft- ware version of the main control board. - The display shows the system status and the tempera- ture measured by the boiler temperature sensor.
  • Page 40 If a remote storage cylinder (accessory) is present, connect the storage cylinder temperature sensor to the control panel and set the manufacturer level parameter “558b2”=0 (see the “Manufacturer level” section). - Press the key. Press the keys to adjust the setpoint. Press any of the keys to exit R T M V The new setting is stored in memory.

  • Page 41: Checks During And After Initial Start-Up

    CHECKS DURING AND AFTER INITIAL START-UP Once the boiler has started up, make sure that it shuts down and re-starts properly when: - The central heating temperature setpoint is changed (see page 49) - The control panel is switched OFF - The room thermostat or timer setting is changed Make sure that all the pumps in the system are free and rotate in the right direction.

  • Page 42: Temporary Shutdown

    TEMPORARY SHUTDOWN If you are going to be away for a short period of time like a weekend or a short holiday, etc. proceed as follows. - Press and hold the key until the bar (1) appears under "Stand-by" mode". Provided power to the boiler remains switched on, as shown by the green LED, and the fuel supply remains open, the boiler remains protected by the frost protec-...

  • Page 43: Calibrating Combustion Parameters

    CALIBRATING COMBUSTION PARAMETERS Boilers are calibrated in the factory for G20/G25 20/25 mbar. If actual combustion parameter values differ from those given in the tables below, contact r's Technical Assistance Service. Proceed as follows to set combustion parameters. - Press and hold the keys for between 3 and 6 seconds to enter chimney sweep mode.
  • Page 44 - Press the key. The fan switches to minimum speed. - Set the CO level by turning the adjuster screw (4) on the gas valve. Turn anti-clockwise to reduce CO clockwise to increase CO - Make sure that the parameters listed in the table below are set as shown.

  • Page 45: Setting Functioning Parameters

    SETTING FUNCTIONING PARAMETERS If an outdoor temperature sensor is connected, the controller uses the heating curve to generate the CH flow tempera- ture setpoint, thus enabling the boiler to maintain a constant room temperature even without the use of a room unit. The steeper the slope of the heating curve, the higher the flow temperature setpoint at low outdoor temperatures (see Manufacturer parameter 532).
  • Page 46 Compound outdoor temperature is calculated from effective outdoor temperature and attenuated outdoor temperature. It is calculated at 10 minute intervals on the basis of effective outdoor temperature and directly determines Summer/ Winter mode switching (par. 516). Attenuated outdoor temperature °C Te - Outdoor temperature Tea - Attenuated outdoor temperature...
  • Page 47 SETTING CENTRAL HEATING PARAMETERS - Press the key: - With an outdoor temperature sensor connected, set the room temperature setpoint. This setting shifts the heating curves (see the second figure on page 47) - With no outdoor temperature sensor connected, set a fixed boiler temperature setpoint.

  • Page 48: Error Codes

    ERROR CODES TEMPORARY ERROR DISPLAY - If a temporary error occurs, the display alternates between displaying the time display and the error code. - Press the key to display the error code on the main display. - Press and hold the keys simultaneously for 3 seconds.
  • Page 49 PERMANENT ERROR DISPLAY - If a permanent error occurs, the error code flashes on the main display. The controller performs a safety shut- down. Example: E154. - Press the key to display the error code on the main display. - Press and hold the keys simultaneously for 3 seconds.
  • Page 50 ERROR TABLE Error Diagnostic code via Description of error Type of fault System action Procedure info No input code No input code No input code No input code Message Outdoor temperature Short circuit in outdoor Check/replace outdoor Message sensor error temperature sensor temperature sensor Outdoor temperature...
  • Page 51 Error Diagnostic code via Description of error Type of fault System action Procedure info DHW 1 temperature DHW temperature sensor Check/replace Message sensor error (B3) faulty temperature sensor Short circuit and fault in DHW 1 temperature Check/replace DHW temperature sensor Message sensor error temperature sensor...
  • Page 52 Error Diagnostic code via Description of error Type of fault System action Procedure info Data overflow caused Burner lockout Contact Technical EEPROM data loss by power failure during (permanent). Lockout Assistance Service functioning reset required Burner lockout Contact Technical EEPROM data loss Hardware fault (permanent).
  • Page 53 Error Diagnostic code via Description of error Type of fault System action Procedure info Threshold thermostat Threshold thermostat Temperature too high: Safety shutdown tripped tripped check system TaAbschal (flue gas Check flue gas vent; temperature threshold Burner lockout Flue gas thermostat check temperature for boiler shutdown) (permanent).
  • Page 54 Error Diagnostic code via Description of error Type of fault System action Procedure info Check the air pressure Comburent air system Air pressure switch switch; check the air Safety shutdown error tripped intake pipe; check the The air pressure switch has been closed Check the air pressure incorrectly (toggles...
  • Page 55 Error Diagnostic code via Description of error Type of fault System action Procedure info The pressure switch input has been Check for blockages in configured as a switch Gas feed pressure the air/gas feed lines; that prevents start-up Safety shutdown switch (GPS) tripped check the pressure (FaEinstellFlags2) and...
  • Page 56 Error Diagnostic code via Description of error Type of fault System action Procedure info The boiler return OEM parameter not temperature is above editable via QAA. Generic error or equal to the boiler Safety shutdown Generic error. Check temperature + Sd_RL_ the system.
  • Page 57 Error Diagnostic code via Description of error Type of fault System action Procedure info Water schematic with CH Generic error circuit 2 and room unit Message Check HMI programming unavailable The acceptable speed range for starting the Burner lockout Fan speed threshold not Contact Technical ignition sequence was (permanent).
  • Page 58 Error Diagnostic code via Description of error Type of fault System action Procedure info OEM parameter not Drift test has exceeded editable via QAA. Software error programmed limit W1 Message Contact Technical (655) Assistance Service OEM parameter not Drift test has exceeded editable via QAA.

  • Page 59: Complete List Of Parameters

    COMPLETE LIST OF PARAMETERS LIST OF END USER LEVEL PARAMETERS Characteristic Range Default setting Time of day 0…23.59 h/min - - - Setpoints 5 (*) Parameter not used if a room unit is connected Room temperature reduced setpoint 10…30 °C Boiler temperature reduced setpoint 30...Boiler temperature setpoint CH circuit 1 program...
  • Page 60 LIST OF INSTALLER LEVEL PARAMETERS Characteristic Range Default setting DHW reduced setpoint 20…DHW setpoint °C DHW program 0=according to DHW program ACS 1=24h/24h PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING THG= Automatic Summer/Winter switching temperature...
  • Page 61 LIST OF MANUFACTURER LEVEL PARAMETERS Characteristic Range Default setting Minimum room temperature setpoint 10…30 °C Parameter only active if an outside temperature sensor is connected. Maximum room temperature setpoint 10…30 °C Parameter only active if an outside temperature sensor is connected. PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING PARAMETER FIXED IN THIS MODEL...
  • Page 62 Characteristic Range Default setting Parameter with 8 bits (= b7b6b5b4b3b2b1b0) b0= PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING. b1=Type of building 0/1=Light/heavy duty b2=Connection of storage cylinder temperature sensor b2=1-------> Termostato bollitore (*) b2=0-------> Sonda b3= PARAMETER FIXED IN THIS MODEL DO NOT CHANGE SETTING.
  • Page 63 Characteristic Range Default setting Limit to number of hours of functioning after last service 0…9998 Limit to number of burner ignitions after last service 0…9995 Limit to number of months after last service 0…255 months Maximum service fan speed 0…9950 Maintenance alarm options 0…255 Maintenance alarm repeat period after initial display...

  • Page 64: Conversion From One Gas Type To Another

    45. The following pressures are required from the gas Calibrated diaphragm diameter (Ø) supply: TAU 55 UNIT TAU 75 UNIT - G20 gas = 20 mbar - LPG (G31) gas = 37 mbar TECHNICAL ASSISTANCE SERVICE...
  • Page 65 Converting the TAU 110 UNIT to G31 gas (using the accessory kit, code 20026803, to be ordered separately) Assembling the new gas valve: - Screw the four studs (1) into the valve body. - Fit the seal (2) and valve mounting flange (3), and fix them in place with the nuts (4).
  • Page 66 For all models Adjusting the gas pressure switch To ensure correct boiler functioning, adjust the pressure switch for minimum gas pressure to a value of at least 5 to 10 mbar below that of the gas supply. Proceed as follows: - Remove the screws (C) securing the pressure switch cover - Turn the knob (D) to the required value...

  • Page 67: Maintenance

    MAINTENANCE On completion of maintenance, the original settings Regular maintenance is a legal requirement. It is also es- must be restored and combustion fumes analysed sential for the safety, efficiency and durability of the boiler. to verify correct functioning. Proper maintenance keeps consumption and emissions down, and ensures that the boiler continues to operate reliably over time.

  • Page 68: Positioning The Electrodes

    POSITIONING THE ELECTRODES Correct positioning of the ignition electrode and flame de- It is essential to respect the dimensions in the figure. tection sensor is essential for efficient ignition and combus- tion. With the burner removed, verify the state of wear and the po- sitioning of the ignition electrode and flame detection sensor according to the figure below.

  • Page 69: Troubleshooting

    TROUBLESHOOTING CAUSE SOLUTION FAULT Flame not detected The burner performs pre-ven- - Call Technical Assistance tilation and ignition correctly but shuts down after about 5 No gas supply attempts - Make sure gas shut-off cock is open The burner shuts down during Flue blocked - Check flue pre-ventilation...
  • Page 70 FAULT CAUSE SOLUTION - Check that all joints are tight and Leaks from the supply circuit There is a smell of gas that the pressure measurement points are closed - Check that the burner body is clean Fumes escaping into the air There is a smell of fumes - Check that the flue pipes are clean - Check the condition of the boiler seals...
  • Page 71 TECHNICAL ASSISTANCE SERVICE...
  • Page 72 RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.riello.com The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specifi cations, standard equipment and accessories are therefore liable to modifi cation without notice.

This manual is also suitable for:

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