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Array AR 800 US INSTALLATION AND OPERATION MANUAL...
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MODEL ASSEMBLY NUMBER efficiency, performance, quality and safety. Array AR 800 20164509 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.
GENERAL GENERAL 1.1 Warnings & Cautions Array AR 800 MBH Boilers are fully modulating, high- Installers and operating personnel MUST, at all times, observe efficiency condensing units. They represent a true industry advance all safety regulations. The following warnings and cautions that meets the needs of today’s energy and environmental...
GENERAL 1.2 Safety Instructions 1.3 General Warning Observe these instructions for your safety. The installation must conform to the requirements of the authority The burner and control must be correctly installed and adjusted to having jurisdiction or, in the absence of such requirements, to the ensure safe and economical operation of the gas boiler.
PRODUCT DESCRIPTION 2 PRODUCT DESCRIPTION 2.3 Proper Use ► The Array boilers are designed for large residential, commercial 2.1 Introduction and industrial applications. ► The Array boilers are delivered in compliance with CSD-1 • The gas-fired condensing Array boilers are designed to be used Commercial applications.
PRODUCT DESCRIPTION 2.6 Prolonged Shutdown or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. After prolonged shutdown, the startup procedures and the safety device test procedures of this manual shall be performed to verify 4.
PRODUCT DESCRIPTION 2.7 Size and Connections ARRAY AR 800 29.4” 12” 7.6” 17” Ø6” Ø6” Ø2.5” 5.7” 4.1” 10” Ø2.5” 11.9” 7.2” Dimensions are in inches (*) Mounting feet may be removed during installation to reduce the overall height by 2”. Feet must be re-installed once boiler is in its...
PRODUCT DESCRIPTION 2.8 Technical Data Unit AR 800 Boiler Category ASME Sect.IV Type of Gas Natural Gas, Propane* BTU/hr 800,000 Max input rate (kW) (234) BTU/hr 40,000 Min input rate (kW) (12) Turndown Rate 20:1 Gas Connection (NPT) Ø Inch 1.5”...
4.4 Site Preparation Ensure that the site selected for installation of the Array AR 800 Boiler includes: − Access to AC Input Powerat 120VAC, single phase, 60Hz −...
All gas piping, water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels, or inhibit service or maintenance of the unit. 52,4” 24” 24” Array AR 800 Clearances Fig. 3...
FRONT 31.1” 7.6” Fig. 5 Array AR 800 Crane Lifting Handling Fig. 4 Array AR 800 Forklift Handling If a crane is required, the boiler must be lifted through bands. WARNING: When lifting the boiler with crane: use bands or straps, no chains.
ø 0.41’’ 2.56’’ ø 0.41’’ Fig. 8 Array AR 800 Anchoring bolt detail 4.5 Boiler Location − This boiler is suitable only for indoor installations. − To operate properly and safely, this boiler requires a continuous supply of air for combustion. Install this boiler in a clean, dry location with adequate air supply.
− When using oxygen permeable PEX, the system must be Fig. 9 Array AR 800 Connections separated from the boiler by a heat exchanger. − A correctly sized and working expansion vessel must be installed.
INSTALLATION 4.11 Condensate Drain and Piping inlet block” will appear on the screen. At this point press the Reset button. The error will turn off. The Array Boiler is designed to condense water vapor from the Module level: flue products. Each heat exchanger of the boiler is equipped A Low Water Cut Off (LWCO) sensor is installed on top of the supply with a condensate trap (see Fig.
If a floor drain is not available, a condensate pump can be used to remove the condensate to an alternate drain. The maximum condensate flow rate is 6.3 GPH for Array AR 800. The drain line must be removable for routine maintenance.
INSTALLATION 4.12.4 Gas Type Conversion supply piping. − Installation of a union fitting at the appliance gas line connection is required for ease of service. The heating unit is factory preset for operating with natural gas. This set-up can be changed using the conversion kits supplied by 4.12.1 Gas Supply Specifications the manufacturer, on demand.
INSTALLATION − Use the PB inner display to enter the appliance configuration menu and change the parameter #98 from ‘’80‘’ to ‘’81‘’. Follow this path: menu-> setting -> appliance -> configuration -> password -> boiler -> managing -> 98 appliance setting (from ‘’80‘’ to ‘’81‘’) -> configuration confirmed (‘’yes’’).
INSTALLATION 4.13 AC Electrical Power Wiring Press “LOW POWER”: the fan will run at the minimum speed. To adjust the O value at the minimum input, turn the screw “B” External AC power is connected to the unit inside the electrical (rotate clockwise to decrease O ) shown in Fig.
4.13.1 Electrical Power Requirements The voltage configuration of Array AR 800 is: − 120VAC/1PH/60Hz Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS Fig.
Do not attempt to install the boilers using any other means. Suitable, UL approved, positive pressure, watertight vent materials MUST be used for safety and UL certification. Array AR 800 boiler can use the following material for venting: Maximum Flue Approved Fig.
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INSTALLATION − The boiler must not support the weight of any ductwork. 6" Air Intake 6" Flue Gas − Do not mix components from different systems. The vent system could fail, causing leakage of flue products into the Connection living space. Use only approved materials. −...
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INSTALLATION VENTING CONFIGURATIONS: The following figures show the acceptable piping installation for venting and combustion air. EXHAUST EXHAUST BOILER BOILER Fig. 29 All Combustion Air from Adjacent Indoor Spaces through Fig. 31 All Combustion Air From Outdoors - Inlet Air From Ventilated Indoor Combustion Air Openings Crawl Space and Outlet Air to Ventilated Attic EXHAUST...
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INSTALLATION EXHAUST EXHAUST BOILER BOILER Fig. 33 All Combustion Air from Outdoors through Single Fig. 35 Sealed Combustion Located on Same Side with Exhaust Combustion Air Opening (horizontal) EXHAUST EXHAUST BOILER BOILER Fig. 34 Sealed Combustion Located on Same Side with Exhaust Fig.
INSTALLATION Ventilation air must be provided in either case. Material Standard ANSI/ASTM D1527 PVC Schedule 40 ANSI/ASTM D1785 or D2665 CPVC Schedule 40 ANSI/ASTM F441 Polypropylene ULC S636 Single wall galvanised steel 26 gauge In cold climates it is essential to provide a motorized air inlet damper to control the supply of combustion air and prevent EXHAUST BOILER...
COMMISSIONING 4.16.3 Ducted Combustion Air 5.4 Warnings Concerning the Gas Supply For ducted combustion air installations, the air ductwork must be When starting up the unit for the first time the following must be attached directly to the air inlet connection on the sheet metal checked: enclosure.
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COMMISSIONING − Date and Time can be adjusted through the screen below: Ver X.X.XX Ver X.X.XX Fig. 38 Touchscreen Control Panel Stand-by screen Fig. 41 Date & Time screen By touching the logo, the Cascade screen will appear: − After the Date&Time setting, CH modes can be selected accessing the CH MODE settings screen below: Settings Ver X.X.XX...
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COMMISSIONING mode requires an outdoor sensor, in addition to the room accessing the list of parameters through the Service display thermostat. The system functions similar to CH mode − 0, except the Tempererature Setpoint is automatically and move parameter #124 from 1 (default value) to 0. calculated based on the Reset curve.
COMMISSIONING 5.5.1 Minimum Water Flow (Heat Exchanger Protection) DHW store setpoint is manually set on the CH/DHW Setpoints screen (through the Settings screen). This unit is self-protected against low water flow. A flow meter continuously monitors the water flow to each module. If the water flow decreases below the minimum stated, the burner automatically shuts off.
COMMISSIONING 5.6 Multiple Boiler 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 of managing up to 8 boilers as a single, coordinated heating system. The logical schematic is: Demand: 0-10V / OpenTherm / On-Off System sensor D2 is T outside...
Ver X.X.XX 6.2 Control Panel Description Fig. 56 Riello Screen All Array Series Boilers utilize the Touchscreen Control Panel shown in Fig. 55. This Touchscreen panel contains the basic controls for The R logo is the entry point of the Control System. By touching monitoring the boiler.
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; −...
OPERATION 6.3.6 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.
OPERATION 6.4 Display board replacement − Press the ▼ key, select "(98) Appliance Settings" and press the ● key System configurations must be performed only by the Technical Assistance Service or by personnel authorized by Appliance Configuration “ ” (97) IO Configuration “...
OPERATION 6.5 Control board replacement − With the ▲ / ▼ keys change the value following what is in the following table and press the ● key: Par. 98 System configurations must be performed only by the Technical Model Managing Dependent Assistance Service or by personnel authorized by When replacing the main board, an initial screen with the logo...
SHUTDOWN SHUTDOWN 8 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 adhered operational, e.g.
APPENDIX SHUTDOWN APPENDIX APPENDIX C - MAINTENANCE Gas Leak Inspection A qualified and adequately trained technician must perform the Inspect all gas piping and gas valve especially pressure inlet to inspection as specified in these instructions before each heating confirm there are no leaks. season and at regular intervals.
APPENDIX SHUTDOWN APPENDIX APPENDIX D - HEAD AVAILABLE FOR THE SYSTEM HEAD AVAILABLE (NO GLYCOL) ∆T = 36°F ∆T = 45°F Array AR 800 16,0 ft 20,0 ft HEAD AVAILABLE (50% MAXIMUM GLYCOL) ∆T = 36°F ∆T = 45°F Array AR 800 14,4 ft 18,0 ft...
(input BTU/hr) NOTE: The following chart compensates for the affects of altitude on the energy content of the gas supply. No additional de-rate required. ARRAY AR 800 Altitude (ft) From 0% to 25%...
APPENDIX SHUTDOWN APPENDIX APPENDIX F - TROUBLESHOOTING TABLE LOCKOUT CODES Error no. Error Description Checks Solutions E2PROM_READ_ERROR Internal software error Control board replacement IGNIT_ERROR Three unsuccessful ignition attempts in a- Check gas supply pressure; a- If the gas supply pressure is a row b- Check ignition spark;...
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APPENDIX SHUTDOWN APPENDIX Error no. Error Description Checks Solutions FLUE_SWITCH_NOT_CLOSING The blocked flue sensor is not closed within 10 minutes TSUPPLY_DIFF_ERROR The 2 supply sensors deviate too much for more than 60 seconds TFLUE_DIFF_ERROR The 2 flue sensors deviate too much for more than 60 seconds FILLING_TOO_MUCH Too many automated filling attempts in a...
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APPENDIX SHUTDOWN APPENDIX Error no. Error Description Checks Solutions REFLO2_TOO_LOW Internal software error Control board replacement Flame is detected in a state in which no FALSE_FLAME Control board replacement flame is allowed to be seen LOW_WATER_PRESSURE_ERROR Low water pressure error LOW_WATER_PRESSURE_SENSOR Low water pressure BLOCKED_DRAIN Blocked drain switch is active...
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In order to detect which of the combined failures is stopping the boiler, please go through the following procedures: 1. For Array AR 800: “LWCO/Air inlet block” error message on TS Boiler screen. This message shows on touchscreen as a result of two possible errors: −...
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APPENDIX SHUTDOWN APPENDIX − Disconnect the multimeter and reconnect the wires, as shown in the picture below. − 1 (NC) 3 (COM) 2 (NO) Fig. 69 Wired pressure switch − Test the pressure switch on the other side of the boiler (module 4 or 8);...
MAX equiv. ft AR 800 Data for Venting size T supply / return (F°) - 176 / 140 T supply / return (F°) - 104 / 86 ARRAY AR 800 Maximum Input Minimum Input Maximum Input Minimum Input Exhaust gas mass (weight) 0.22 lb/s...
APPENDIX SHUTDOWN APPENDIX APPENDIX I - 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)
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APPENDIX 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” whichever is greater Air intake Vent...
APPENDIX SHUTDOWN APPENDIX APPENDIX K - LIST OF PARAMETERS (WITH RANGES AND DEFAULT VALUES) Menu item Sub item / Parameter Range Default Value Units User level Boiler Parameters (1) CH Mode 30...90 (86...194) 2: Installer (3) CH Setpoint 30…90 70 (158) °C (°F) 1: User (185) Calc.
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APPENDIX SHUTDOWN APPENDIX Menu item Sub item / Parameter Range Default Value Units User level (52) DHW Instant PID I 0…1255 3: Factory (53) DHW Instant PID D 0…1255 3: Factory (60) Flow Rate Start 0.1…20 l/min 3: Factory (61) Flow Rate Lo Temp Pwr 0.1…20 l/min 3: Factory...
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APPENDIX SHUTDOWN APPENDIX Menu item Sub item / Parameter Range Default Value Units User level 0) Disabled 1) General Pump 2) CH Pump 3) DHW Pump 4) System Pump 5) Cascade Pump 6) Alarm Relay 7) Filling Valve Managing: 2 (125) Prog.
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APPENDIX SHUTDOWN APPENDIX Menu item Sub item / Parameter Range Default Value Units User level 0) Disabled 1) General Pump 2) CH Pump 3) DHW Pump 4) System Pump 5) Cascade Pump 6) Alarm Relay 7) Filling Valve Managing: 2 (187) Prog.
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APPENDIX SHUTDOWN APPENDIX Menu item Sub item / Parameter Range Default Value Units User level (80) Max Setp Offset Up 0...40 (0...72) 20 (36) °C (°F) 2: Installer (81) Start Mod Delay Fact 0…60 Min. 2: Installer (82) Next Module Start Rate 10…100 2: Installer (83) Next Module Stop Rate...
APPENDIX SHUTDOWN APPENDIX APPENDIX L - FLOWCHARTS SINGLE MODULE Module in Stop pump Stand-by Demand for Post pump module ready Start pump Supply Temp Start fan lower than Setpoint Module Blocking CH flow Start burner (*) error is above min_flow? BURN Burn: Based on delta of Supply sensor and Setpoint PID output is determined...
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APPENDIX SHUTDOWN APPENDIX BURNER IGNITION SEQUENCE Start burner Pre-Purge 0 Pre-Purge 1 Fan on ignition speed Fan on ignition Blocking error speed within time? Pre ignition on Ignite: ignition on, Gas Valve open Flame Proving, Checking flame Flame Current Ignition Tries Above Minimal less than 3? Current?
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APPENDIX SHUTDOWN APPENDIX MODULE CASCADE (STAND-ALONE BOILER) Boiler in Stop boiler Locking error stand-by pump Boiler error Locking Present? error? Blocking error Post pump Boiler Heat ready Demand? Calculate Start boiler boiler pump setpoint Boiler Temperature Clear demand Remove all higher than active modules setpoint...
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APPENDIX SHUTDOWN APPENDIX MODULE CASCADE (STAND-ALONE BOILER): ADD/REMOVE MODULE Add module function Delay period for starting new module is 0? Open Air damper Air damper open? Are we allowed to add another dependent? Add dependent to the cascade demand Reload delay time Update demand flags...
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APPENDIX SHUTDOWN APPENDIX BOILER CASCADE Stop system System in pump Locking error stand-by Boiler error Locking Present? error? Blocking error System Post pump Heat completed Demand? Start system Calculate system pump setpoint System Temperature Clear demand Remove all higher than active boilers setpoint Clear demand?
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APPENDIX SHUTDOWN APPENDIX BOILER CASCADE: ADD/REMOVE BOILER Add Boiler function Delay period Are we allowed for starting new to add another boiler is 0? dependent? Add dependent from the Reload delay time cascade demand Update demand flags Remove Boiler function Delay period for Are we allowed to removing boiler...
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APPENDIX SHUTDOWN APPENDIX ERROR CHECKING CYCLE Stand-by Boiler Min/Max Gas pressure Locking error switches are closed? Boiler Blocked Blocking Flue pressure error switch is closed Boiler Water Blocking pressure switch is error closed? Module High limit Locking error sensor is closed? Supply/return/ Blocking Flue sensor are...
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RIELLO S.p.A. 37045 Legnago (VR) Tel. 0442630111 - Fax 044222378 RIELLO NORTH AMERICA 35 Pond Park Road Hingham, Massachusetts U.S.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. Appearance, dimensions, technical specifications, standard equipment and...
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