Page 1
RESIDENCE COLONNA CONDENS KV 130 - 28 EN INSTALLATION AND MAINTENANCE MANUAL...
Page 2
CONFORMITY RESIDENCE COLONNA CONDENS r boilers conform to the following directives: • Directive 92/42/EEC on efficiency requirements • Gas Appliances Directive 2009/142/CE • Low Voltage Directive 2006/95/CE • Electromagnetic Compatibility Directive 2004/108/CE • Ecodesign Directive 2009/125/CE for energy-related products • Energy Labelling Directive 2010/30/EU • Delegated Regulation (UE) N. 811/2013 • Delegated Regulation (UE) N. 813/2013 • Delegated Regulation (UE) N. 814/2013 RANGE MODEL CODE RESIDENCE COLONNA CONDENS KV/130 28 20105844...
Page 3
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...
CONTENTS GENERAL General safety information page Precautions “ Product description “ Safety devices “ Identification “ Layout “ Technical specifications “ Accessories “ Water circuit “ Location of sensors “ Pump “ Wiring diagram “ Control panel “ INSTALLER Unpacking the product page 18 Dimensions and weight “ Handling “ Place of installation “ Installation in older systems and systems requiring modernisation “...
GENERAL SAFETY INFORMATION As soon as you open the packaging, check imme- Periodically, and when the system is cold, check diately that the contents are all present and unda- that operating pressure in the heating circuit is between 1 and 1.2 bar. If water pressure is con- maged. Contact the r reseller from whom you purchased the product if you notice any problems. sistently low, contact r’s Technical Assistance Service or a professionally qualified heating engi- This system must be installed by a legally qualified...
PRODUCT DESCRIPTION RESIDENCE COLONNA CONDENS boilers are high The combustion chamber and the heat exchange area efficiency, low temperature boilers for the production are designed to keep temperature low over the bur- of hot water for central heating and domestic hot water ner surface, thus minimising emissions, maximising systems. They incorporate a 130 litre storage cylinder.
TECHNICAL SPECIFICATIONS RESIDENCE COLONNA CONDENS Description KV/130 28 ISCN condensing boiler for mixed heating Device type B23P-B53P-C13-C23-C33-C43-C53- C63-C83 Fuel G20/G31 Device category II 2H3P Rated heat input at furnace referred to HVC (LCV) 22,2 (20) Minimum rated heat input at furnace referred to HVC (LCV) 6,7 (6) Useful (rated) heat output Maximum useful heat output (80-60°C) P4 19,6 Maximum useful heat output (50-30°) 21,0 30% heat output with return at 30°C (P1) Reduced heat output at (80-60°) Reduced heat output at (50-30°) Efficiency class in central heating mode Efficiency class in DHW mode Seasonal energy efficiency in central heating mode Efficiency at rated heat input in high Useful Pn 88,2 temperature mode (HCV) (60-80°C) Efficiency at 30% rated heat input in low Useful 96,9...
category B Electric degree of protection category C Absorbed power supply (max) Consumption at full load Elmax Consumption at part load Elmin Consumption in standby mode PSB P sb RESIDENCE COLONNA CONDENS Description KV/130 28 Type of storage cylinder Vitrified Storage cylinder layout Vertical Heat exchanger layout Vertical Maximum power absorbed by heat exchanger DHW temperature setting range 35 ÷ 60 °C Storage cylinder capacity Coil water capacity Coil heat exchange surface area 0,91 ∆T 25°C 13,6 l/min DHW production ∆T 35°C l/min Specific flow rate (EN625) 23,3 l/min Maximum operating pressure of storage cylinder Volume of expansion vessel (DHW) Precharge of expansion vessel (DHW)
PUMP TECHNICAL SPECIFICATIONS DESCRIPTION ERP ready 2015 Electrical consumption EEI Part 3 (*) ≤ 0,20 P L,Avg (**) ≤ 24 Minimum pressure at pump suction inlet (*) Energy efficiency index according to ERP 2015 (Commission regulations 641/2009 and 622/2012) (**) Average annual electricity consumption according to ERP 2015 (Commission regulations 641/2009 and 622/2012) PUMP CURVE [kPa] 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4 Q [m³/h] Flow rate 1,0 Q [l/s] 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 3,2 3,4...
Page 14
ADJUSTING THE PUMP % power Display Meaning LED 1 flashing green Stand-by The boiler's pump is ErP 2015 Ready, and suitable for (only with PWM control) use in central heating only/domestic hot water applica- LED 1 green and LED 2 Low load 0-25 tions. The pump can be controlled by an external PWM yellow, both lit signal and has 4 different pressure curves for central LED 1 green and LEDs Low-medium 25-50...
Page 15
Display Meaning Function Action LED 1 red and LED 5 yellow, The pump rotor is blocked. The pump automatically Wait or check that the pump both lit attempts to start every 1.5 rotor is free to rotate. seconds. LED 1 red and LED 4 yellow, Indication only. The pump Check the voltage of the Supply voltage too low. both lit continues to function. power supply LED 1 red and LED 3 yellow, Electronic controller error The pump has stopped Check the voltage of the both lit because supply voltage is...
CONTROL PANEL THE MAIN CONTROL PANEL °C 1 Boiler pressure gauge Displays the pressure in the central heating circuit. Storage cylinder temperature selector Allows you to set the temperature of the domestic hot water. 3 Green LED When lit, shows that a flame is being detected. 4 Two figure digital display Displays information on boiler status. 5 Red LED When lit, shows that an error (alarm) condition has been detected. 6 Function selector Off / Reset Winter mode Summer mode Central heating temperature selector Allows you to set the temperature of the central heating water.
UNPACKING THE PRODUCT CONFORMITÀ The boiler is delivered in a single package on a wooden pallet, covered by a PVC sheet and inside a wooden crate. The following items are delivered in a plastic bag (A) inside the boiler: - U ser Manual, and Installation and Maintenance Manual for the boiler - H ydraulic test certificate - O utdoor temperature sensor - L PG conversion kit (diaphragm, label). The instruction manuals are integral parts of the boiler. Once located, read them thoroughly and keep them safe.
HANDLING Once you have removed the packaging, proceed as fol- lows to handle and move the boiler. - Unscrew the 4 screws (A) shown in the figure and remo- ve the boiler from the pallet. - Remove the front panel (1) to facilitate handling and movement of the boiler. TILT - Grip the boiler at points (B) and tilt it backwards, then grip it at points (B) and (C) to lift it. An optional handling bracket kit is available to provide a better OPEN grip at points (B).
PLACE OF INSTALLATION RESIDENCE COLONNA CONDENS boilers can be When installing the boiler, allow sufficient space installed in any indoor location provided the flue gases around it to access all safety and control devices are adequately removed and comburent air drawn in from and to permit easy maintenance. outdoors. Provided the boiler is properly installed, the boiler room itself does not need any ventilation as such, Make sure that the boiler’s index of electrical pro- since the combustion circuit of RESIDENCE COLONNA...
INSTALLATION IN OLDER SYSTEMS AND SYSTEMS REQUIRING MODERNISATION When installing RESIDENCE COLONNA CONDENS boilers in old systems or systems requiring modernisation, always perform the following checks: - M ake sure that the flue is able to withstand the tem- - M ake sure that the boiler’s condensate drain system perature of flue gases from a condensing boiler, and (siphon) is properly connected to a domestic water that it has been designed and made in compliance drain.
WATER CONNECTIONS Before installing the boiler, thoroughly flush out all the pipes of the central heating circuit. Connect the boiler to the water supply with a shut-off cock upstream. Connect the condensate drain pipe to a clean domestic water drain in compliance with the relevant standards. The water fittings have the following specifications: Gas Gas supply 3/4" M CH flow 1" M CH return 1" M ACS DHW outlet 3/4" M DHW recirculation 3/4" M AFS DHW inlet 3/4" M Drain The condensate drain pipe must be watertight.
Page 23
Condensate collection Locate the corrugated condensate drain pipe (S) at the rear of the burner and connect it to a domestic water drain in compliance with the relevant standards. Always maintain a slope “i” of over 3° and ensu- re that the diameter of any hose used is greater than that of the boiler’s own condensate drain pipe.
ELECTRICAL CONNECTIONS All the boiler’s internal electrical connections have been pre-wired and tested in the factory. Only the following connections are needed for installation. - Connect the boiler to the mains power supply (single phase 230V-50Hz) using the cable (1) from the rear of the appliance. - Connect up the room thermostat (TA) and the outdoor temperature sensor (SE). OUTDOOR TEMPERATURE SENSOR (SE) AND ROOM THERMOSTAT (TA) - Remove the front panels by pulling them forwards.
Page 25
- Open the cover (D) to access the internal terminals and make the connections as shown in the diagram below. Legend Remote control black Outdoor temperature sensor Room thermostat Fuse 3.15A F (fast) M3-M5 Room timer-thermostat connection terminals On completion of all connections, replace all components in the opposite order. The following instructions are mandatory: 1 Use a multi-pole magnetic thermal trip switch and disconnector conforming to IEC-EN standards (with a contact gap of at least 3 mm). 2 Respect the L (Phase) - N (Neutral) polarity. 3 Use cables with a cross section of 1.5 mm or more, complete with end terminals. 4 Always refer to the electrical wiring diagrams in this manual when performing any electrical work. 5 Ensure that an efficient ground connection is provided. It is strictly forbidden to use fuel and/or water pipes to ground the appliance. The manufacturer declines all responsibility for damage caused by failing to ground the appliance adequately or by failure to respect the wiring diagrams provided in this manual.
OUTDOOR TEMPERATURE SENSOR Correct positioning of the outside temperature sensor is essential to proper indoor temperature control. The sensor must be installed outside the building to be heated, about 2/3 of the way up a NORTH or NORTH-WEST facing wall, well clear of any flues, doors, windows and out of direct sunlight. Fixing the outdoor temperature sensor to the wall - Unscrew the protective cover from the sensor, turning it anti-clockwise, to access the sensor terminals. - Mark the position of the hole, and drill a 5x25 hole for the expansion plug. - Fix the sensor casing to the wall using the expansion plug provided. - Insert a two core cable (with cross section between 0.5 and 1 mm2, not supplied) to connect the sensor to the boiler. - Connect the two wires of the cable to the sensor termi- nals. Polarity is irrelevant. - Connect the cable from the outdoor temperature sen- sor to the boiler as instructed in the "ELECTRICAL CONNECTIONS" section.
FUEL CONNECTIONS The boiler must be connected to the methane gas supply in compliance with the relevant standards. Perform the following checks before making the connec- tion. - Check that the boiler is compatible with the type of gas supplied. - Check that the gas supply pipes have been thoroughly cleaned. - Check that the gas supply pipe is equal to or greater in diameter than the boiler’s own gas inlet fitting (3/4”) and that its pressure drop is less than or equal to the difference between the supply point and the boiler. Fit a suitably sized filter in the gas supply pipe if the gas supply contains any solid particles. The gas feed line must be suitable for the flow rate demanded by the burner. The gas feed system must also be equipped with all the necessary safety...
Page 28
B53P Upstream fan. Comburent air intake directly from the room where the boiler is installed. Flue gas vent via horizontal or vertical flues designed to operate at positive pressure, with air ventilation to room. C13 Concentric wall vent. Twin flue pipes can also be used, but the wall through-pipes must be con- centric or located close enough to be subjected to similar wind conditions.
Page 29
Coaxial flues (Ø 80/125) An adapter kit must be used in order to install this size of Pressure drop (m) Maximum straight length of flue. Coaxial flues can be oriented in whatever direction coaxial flue Ø 80/125 (m) 45° bend 90° bend is most convenient for the room, provided the maximum 0,85 lengths specified alongside are respected. Use only flues specifically designed for use with condensing boilers. Follow the instructions pro- Maximum straight length is the maximum length of vided in the flue pipe kit to install the flues. the flue without bends, terminals or joints.
Page 30
“FORCED/OPEN INSTALLATION” (TYPE B23P/ B53P) Boiler gas vent flue (Ø 80) The vent flue can be oriented in whatever direction is most convenient for the room. In this configuration, a Ø Pressure drop (m) Maximum length of flue gas 60-80 mm adapter must be fitted in order to connect the vent pipe (Ø 80) (m) 45° bend 90° bend boiler to a Ø 80 mm vent pipe.
FILLING AND DRAINING THE SYSTEM RESIDENCE COLONNA CONDENS boilers incorporate a CH system fill cock (3). FILLING THE STORAGE CYLINDER - Make sure that the CH system fill cock (3) is closed. - Make sure that the storage cylinder drain cock (4) is closed. - Open the DHW user taps. - Open the DHW circuit shut-off cocks and slowly fill the storage cylinder until clean, air-free water flows out from the taps in a uniform manner. FILLING THE CENTRAL HEATING SYSTEM - Make sure that the delivery group drain cock (5) and boiler drain cock (6) are closed.
Page 32
DRAINING Switch the electricity supply OFF at the system’s main switch and at the control panel before starting to drain the boiler or storage cylinder. DRAINING THE CENTRAL HEATING SYSTEM - Close the shut-off cocks for the central heating and domestic hot water circuits. - Make sure that the CH system fill cock (3) is closed. - Connect a hose to the hose union on the drain cock (6) and open the cock.
PREPARING FOR INITIAL START-UP GARANZIA Initial start-up must be performed by an authorised and qualified heating engineer from a r Technical Assistance Centre. Remove the front panel from the boiler and perform the following checks before switching the boiler on or testing any of its functions. - Check that the fuel and water shut-off cocks to the boiler are open. - Check that the type and pressure of the gas supply are as specified for the boiler. - Check that the central heating water pressure gauge shows a pressure between 1 and 1.2 bar with the system cold. Check also that the central heating circuit has been properly bled. INITIAL START-UP Once you have completed all the checks listed above, proceed as follows to start up the boiler for the first time.
Page 34
SUMMER ( ): With the function selector set to Summer, the boiler functions only in domestic hot water mode. The temperature gauge (1) shows the temperature of the hot water inside the storage cylinder. °C To ensure correct functioning, set the room tempe- rature thermostat to its minimum setting. WINTER ( ): With the function selector set to Winter, the boiler functions in central heating and domestic hot water modes. The display shows the temperature of the central heating flow. - Set the room thermostat to the required temperature (~ 20°C) or, if the system has a timer or timer-thermostat, make sure that this is switched “On” and adjusted to the required temperature (~ 20°C). SETTING CENTRAL HEATING WATER TEMPERATURE USING THE OUTDOOR TEMPERATURE SENSOR Since an outdoor temperature sensor is installed, the system automatically adjusts the temperature of the cen- tral heating flow to bring room temperature rapidly to a level determined on the basis of outdoor air temperature.
Page 35
STARTING UP THE BOILER If a timer or room thermostat is installed, these must be switched on and adjusted to a temperature higher than current room temperature before the boiler can start up. The boiler will remain in stand-by mode until the burner ignites following a request for heat. The green LED (3) on the left of the control panel lights to show that a flame is being detected.
SHUTDOWN If you are going away for a short period of time like a weekend or a short holiday, etc., turn the function selector to “ ” OFF/RESET. The digital display reads out the message shown alongsi- Because electrical power and the gas supply to the boiler both remain on, the boiler is protected by the following systems: - Frost protection: Central heating This function is activated if the temperature read by the central heating flow temperature sensor falls below 6°C. Under these conditions a heat request is generated, igniting the burner at minimum power and keeping it on until the temperature of the central heating flow water reaches 35°C.
WARNING LEDS AND ERRORS THE MAIN CONTROL PANEL Green LED (3) Off = boiler in stand-by, burner out On = burning lit, boiler functioning normally. Red LED (5) Safety shutdown: an error code flashes on the display. Burner lockout: the red LED lights and an error code flashes on the display. No error code is shown in OFF/RESET mode ( ). To visualise any system errors, turn the function selector to "...
Dealing with error AL41 Check the pressure on the control panel pressure gauge. If it is below 0.5 bar, proceed as follows. - Turn the function selector to “ ” - Remove the top front panel from the boiler by pulling it forwards. - Slowly refill the system, opening the fill cock (3) until the pressure gauge reads between 1 and 1.2 bar. - Fit the top panel back on the boiler. - Return the function selector to its previous position (Summer " ", or Winter " "). If the system loses pressure frequently, call Technical Assistance. AUTOMATIC TEMPERATURE CONTROL Automatic temperature control only works with the outdo- or temperature sensor connected. As soon as you install the outdoor temperature sensor, connect it immediately...
Page 39
Example: if the calculated value is 1.3, it lies between the 1 and 1.5 curves. Choose the nearest curve, in this case 1.5. Adjust the trimmer under the DHW temperature setting knob to select KT. The following KT values can be set: standard system: 1,0 - 1,5 - 2,0 - 2,5 - 3,0 under-floor system 0,2 - 0,4 - 0,6 - 0,8. TEMPERATURE CONTROL CURVE Outdoor temperature (°C) T80 maximum set point temperature for standard systems (pos.1 jumper not fitted) T45 maximum set point temperature for under-floor systems (pos.1 jumper not fitted) TYPE OF HEAT REQUEST Boiler connected to a room thermostat, parameter 51 set to 0 – manufacturer’s default setting. Requests for heat are generated by the room thermostat contacts closing, and terminated by the contacts opening. The boiler calculates the necessary CH flow temperature automatically, though the user can adjust the boiler settings. The CENTRAL HEATING temperature selector, however, does not give the user control over the CENTRAL HEATING SET POINT as such, but only permits variation within a range between +5 and -5°C. Changing this value does not directly change the temperature of the CH flow. Instead, it changes the reference temperature (0=20°C) and modifies the calcu- lation that determines flow temperature automatically.
Page 40
Boiler connected to a timer, parameter 51 set to 1 (parameter only editable using the remote control) With the contacts closed, heat requests are generated by the flow temperature sensor on the basis of outdoor tempera- ture, to achieve a nominal room temperature at DAY level (20°C). When the contacts open, the boiler does not switch off but reduces the heating curve (by performing a parallel shift) to NIGHT level (16°C). This activates night mode heating. The boiler calculates the necessary CH flow temperature automatically, though the user can adjust the boiler settings. The CENTRAL HEATING temperature selector, however, does not give the user control over the CENTRAL HEATING SET POINT as such, but only permits variation within a range between +5 and -5°C. Changing this value does not directly change the temperature of the CH flow. Instead, it changes the reference temperature (0 = 20°C for DAY level, 16°C for NIGHT level), and modifies the calculation that determines flow temperature automatically. PARALLEL SHIFT NIGHT-TIME REDUCTION DAY heating curve NIGHT heating curve Outdoor temperature (°C) TECHNICAL ASSISTANCE SERVICE...
SETTINGS All settings have already been made in the factory. If the boiler needs new settings after repairs have been made, the gas valve changed, or after a conversion from methane to LPG, proceed as follows. The settings for minimum fan speed, maximum CH fan speed, maximum DHW fan speed, and ignition slow fan speed must be made in the sequence given and must only be made by qualified personnel. - Switch on mains power to the boiler. - Turn the function selector to OFF/RESET (the display shows “- -”) - Unscrew the four screws (A) and remove the front trim (B). - Adjust the trimmers in the sequence given below to achieve the values specified in the table. 1 MAX 2 MIN 3 HTG (Max CH) 4 IGN (burner ignition slow fan speed) (set to 3.7 = 3700 rpm).
- Check the CO content. If the value is not as speci- MAXIMUM FAN SPEED, DHW fied in the table, adjust the gas valve minimum screw METHANE (G20) PROPANE (G31) accordingly. 28 ISCN 6100 6100 g/min - Return the HTG trimmer to the fan speed for maximum MAXIMUM FAN SPEED, CH CH power (see table).
MAINTENANCE To maintain maximum functionality and efficiency, and to comply with the relevant legislation, have the boiler inspected at regular intervals. When performing maintenance, always follow the precautions listed in the “GENERAL SAFETY INFORMATION” and "PRECAUTIONS" sections. Always switch the boiler off if any work or servicing has to be done on other equipment installed near the flue pipes and/or flues and associated accessories. On completion of work, have the efficiency of the flues checked by qualified personnel.
Page 44
Checking combustion parameters Proceed as follows to perform combustion analysis. - Unscrew the four screws (A) and remove the front trim (B). - Remove the screw (C) and the combustion analysis cap (40) and insert the combustion analysis probe into the air box. - Check that the values for CO correspond to the values specified in the table. If the value displayed differs from that specified, adjust the boiler as instructed in the “Adjusting the gas valve” section. - Repeat combustion analysis. Then: - Remove the combustion analysis probes and fit the cap back over the hole with the screw. - Fit the front trim (B) and secure with the four screws (A). When inserting the combustion analysis probe, take care to push it all the way in. IMPORTANT The safety function that shuts down the boiler if central heating water reaches 85°C remains active even during combustion analysis.
TROUBLESHOOTING CAUSE SOLUTION FAULT Check that all joints are tight and There is a smell of gas. Leaks from the supply circuit. that the pressure measurement points are closed. There is a smell of Check: There is a smell of combustion combustion fumes. - That all joints are tight. fumes. - That the flues are not obstructed. - That combustion is efficient. Combustion is uneven. Incorrect gas pressure at burner.
Page 46
CAUSE SOLUTION FAULT The boiler does not reach its Burner dirty. Clean the combustion chamber. temperature set point. Insufficient air/fuel flow to burner. Check and adjust the burner. Check correct functioning. Boiler settings. Check temperature setting. Check correct functioning. Boiler settings. Burner locks out. Check temperature setting. Check electrical wiring. Check positioning of sensors. Check the vent and bleed valves. No water supply. Check CH circuit pressure. Boiler reaches set Air in the circuit. Bleed the circuit. temperature but radiators are still cold. Unseize the pump.
Page 47
CAUSE SOLUTION FAULT Reduced supply of domestic Supply pressure is too high. Fit a pressure reducer. hot water. Lime scale and/or sludge in Check and clean. storage cylinder. Flow rate too high. Fit a flow reducer. Check functioning of DHW circuit pump. Check positioning of sensors. Check boiler operating temperature. Check correct functioning. Boiler settings. Check the temperature setting. TECHNICAL ASSISTANCE SERVICE...
Page 52
RIELLO S.p.A. 37045 Legnago (VR) Tel. 0442630111 - Fax 044222378 - www.riello.it As part of the company’s ongoing commitment to perfecting its range of products, the appearance, dimensions, technical data, equipment and accessories may be subject to variation.
Need help?
Do you have a question about the KV 130 - 28 and is the answer not in the manual?
Questions and answers