Riello INSIEME EVO 25, Installation And Maintenance Manual

Page 1: ...cod 20113821 rev 2 07 2016 INSIEME EVO 25 EN INSTALLATION AND MAINTENANCE MANUAL ...

Page 2: ...O 25 boilers conform to the following directives Directive 92 42 EEC on efficiency requirements Electromagnetic Compatibility Directive 2014 30 EU Low Voltage Directive 2014 35 EU Ecodesign Directive 2009 125 CE for energy related products Energy Labelling Directive 2010 30 EU Delegated Regulation EU N 811 2013 Delegated Regulation EU N 813 2013 9 9This product must only be used for the purpose fo...

Page 3: ...r connections 15 2 7 Boiler water circuit 15 2 8 Typical water system schematics 16 2 9 Fuel connections 17 2 10 Hoses should also be fixed to the floor and suitably protected whenever possible 18 2 10 1 Technical specifications of stack 18 2 10 2 Connection to the stack 18 2 11 System filling and emptying 19 2 11 1 Water quality requirements 19 2 11 2 Filling 19 2 11 3 Emptying 20 2 12 Wiring dia...

Page 4: ...fully and must ALWAYS accompany the boiler even if it is sold to another Owner or User or transferred to another plant If it is damaged or lost request another copy from your local Technical Assistance Service R 1 2 Precautions The operation of any appliance that uses fuel electrical power and water demands that a number of fundamental safety precautions be respected 0 0Do not allow children or in...

Page 5: ...acturer s Technical Assistance Service immediately 9 9Safety devices must only be replaced by the manufacturer s Technical Assistance Service using original spare parts Refer to the spare parts catalogue supplied with the boiler 0 0Do not use the boiler if any of its safety devices are faulty Always check that the boiler is functioning correctly after repairs have been made 1 5 Identification The ...

Page 6: ...sor sockets 5 Capillary pressure gauge fitting 6 CH circuit expansion vessel 7 Burner 8 Drain cock 9 Central heating system pump 10 Water fitting for storage cylinder if installed 11 Flame inspection window 12 Boiler body 13 Fuel oil filter 14 Serial number plate 15 Flue gas exhaust fitting 16 Flue gas box cover 17 Lifting bracket 18 Automatic bleed valve ...

Page 7: ...al 5 Air damper adjuster screw 6 Air intake 7 Oil pump pressure adjuster screw 8 Pressure gauge fitting 9 Photoresistor 10 Combustion head 11 Motor OIL PUMP 7 6 5 4 3 2 1 8 1 Suction port 2 Return 3 By pass screw 4 Pressure gauge fitting 5 Pressure adjuster screw 6 Vacuum gauge fitting 7 Valve 8 Auxiliary pressure measurement fitting ...

Page 8: ...mbustion efficiency referred to LCV 96 Annual energy consumption QHE 82 6 GJ Noise level sound power LWA 60 dB A Emissions at maximum heat input NOx referred to HCV 170 mg kWh CO2 12 5 CO w a 20 ppm Flue gas T At Pn 60 80 C 110 C Smoke scale 0 5 Flue gas mass flow rate 10 0 g s Maximum working pressure 3 bar Safety thermostat trip temperature 100 C Maximum operating temperature 55 82 C Minimum ret...

Page 9: ...tricity consumption according to regulations 641 2009 622 2012 PUMP CURVES 0 1 2 3 4 5 Q m h 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 Q m h 6 7 m H 0 10 20 30 40 50 60 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 p 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 1 0 Q l s 10 20 30 40 50 W P1 Residual head Flow rate The curves refer to a water density of 983 ...

Page 10: ...RMATION 1 9 Location of sensors INSIEME EVO 25 Tm 1 TS TR 2 TS Safety thermostat sensor Tm Minimum temperature thermostat sensor TR Boiler thermostat sensor 1 Boiler temperature gauge 2 Boiler temperature gauge socket ...

Page 11: ...ressure in the central heating circuit 4 Boiler thermostat Allows you to set the temperature of the central heating water setting range 55 82 C 55 82 5 Electrical power indicator green Lights to show that the boiler is receiving electrical power 6 Burner lockout indicator red Lights to show that the burner locked out 7 Manual reset for safety thermostat Allows you to reset the boiler if the safety...

Page 12: ...talogue Hydraulic test certificate Energy label 2 1 1 Positioning of labels A A Packing label 9 9The instruction manual is an integral part of the boiler Once located read it thoroughly and keep it safe 9 9Keep the documentation envelope in a safe place Any replacement documents must be ordered from Riello S p A who reserve the right to charge for the cost of the replacement 2 2 Overall dimensions...

Page 13: ...s A fixing the packing to the pallet A remove the cardboard packing and non scratch cloth 0 0Do not dispose of packaging material into the environment or leave it within the reach of children since it can become a potential hazard Dispose of packaging material in compliance with applicable legislation With the packing removed remove the front panel 1 1 Locate the bag containing the documentation r...

Page 14: ... respected in order to allow proper maintenance of the boiler 1 m 1m 1 m 0 5 m 0 5 m 2 5 Installation in older systems and systems requiring modernisation When installing these boilers in older systems or systems requiring modernisation always perform the following checks Make sure that the flue is able to withstand the temperature of the combustion gases and that it has been designed and made in ...

Page 15: ...VO 25 A 790 mm B 450 mm C 37 mm D 75 mm E 298 mm F 350 mm G 540 mm MI CH flow 3 4 M Ø RI CH return 3 4 M Ø 9 9To avoid damaging the appliance while the burner is functioning there must be a minimum water flow rate of about 25 maximum flow rate with ΔT 10 C Use a suitable pump if necessary Water return temperature in continuous service must be 37 C 2 7 Boiler water circuit 2 4 3 5 7 1 Central heati...

Page 16: ...and the method of their installation are left up to the heating engineer installing the system Installers must use their expertise to ensure proper installation and functioning in conformity to all applicable legislation 9 9If needed water supplies and recovery circuits must be conditioned by suitable treatment systems Refer to the values listed in the table on page 19 9 9The boiler can be connect...

Page 17: ...nd control devices required by applicable legislation and standards Refer to the table alongside for oil feed line characteristics 9 9A filter must be installed in the oil feed line 9 9Make sure that the oil return line is not kinked or blocked before starting up the boiler Excessive back pressure can cause the pump seal to fail Priming the pump To prime the oil pump simply start up the burner and...

Page 18: ...ttom 9 9The diameter of the stack must never be smaller than that of the flue pipe from the boiler 9 9InconfigurationB23 thestackmustguaranteetheminimum draught specified by applicable technical standards assuming zero pressure at the boiler s flue gas exhaust 2 10 2 Connection to the stack The boiler must be connected to the stack using rigid flue pipes that are resistant to heat condensate and m...

Page 19: ...onia ions none Silicon ions less than 30 ppm If the hardness of the water exceeds the value specified in the table it is mandatory to install a water softening system 9 9Excessive water softening leading to a total hardness 15 F can cause corrosion in metal parts pipes and boiler components Keep the electrical conductivity of the water under 200 µS cm 0 0Do not top up the central heating circuit o...

Page 20: ...he boiler Turn the mains power switch OFF and turn the control panel function selector to 0 Close the water supply shut off cocks To empty the boiler connect a rubber hose Øint 12mm to the hose union on the boiler s drain cock 1 then open the cock 1 2 ...

Page 21: ...ns power indicator LR Burner lockout indicator TS Safety thermostat 100 C 0 6 TR Boiler control thermostat 55 82 C Tm Minimum temperature thermostat 50 C FU Mains power fuse 6 3 A T CO1 CO2 Multi connectors MO1 Terminal strip PI Central heating system pump DAI Automatic shut off device not supplied only where required The automatic shut off device DAI and the relay RE must be suitable for a 230 VA...

Page 22: ...as follows to access the control panel terminals Remove the front and top panels A and B from the boiler casing A B loosen the two two screws C securing the instrument panel to the casing of the control panel C open the door D and rotate the instrument panel E outwards E D to facilitate electrical connections remove the two screws F and remove the terminal holder G from the casing H F G H route ca...

Page 23: ...netothermic switch line disconnecting switch in compliance with CEI EN standards contact opening of at least 3 mm Respect the connection L line N neutral Keep the earth conductor 2 cm longer than the power supply conductors Use cables with a section greater than or equal to 1 5 mm2 complete with cable terminal caps Refer to the wiring diagrams in this manual for all electric operations Connect the...

Page 24: ...lows to start up the boiler for the first time turn the boiler s mains power switch ON 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 open the control panel access door Turn the boiler thermostat to about the middle of the section with three lines 20 100 4 40 ...

Page 25: ... 80 3 2 1 0 0 120 9 9Eliminate the cause of the overheating before restarting the boiler 3 3 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 boiler thermostat setting is changed The function selector is moved from position I to 0 and back 20 100 4 40 60 80 3 2 1 0 0 120 20 100 4 40 60 80 3 2 1 0 0 120 The room the...

Page 26: ...50 LED 1 green LEDs 2 3 4 yellow all lit Medium high load 50 75 LED 1 green LEDs 2 3 4 5 yellow all lit High load 75 100 Alarm display If the pump detects one or more alarm conditions LED 1 changes from green to red When an alarm is active the LEDs indicate the type of alarm as shown in the following table If more than one alarm is active at the same time the LEDs only show the alarm condition wit...

Page 27: ...pt the red LED flash for one second to indicate that the button lock function has been activated deactivated Setting mode To modify settings press the button 1 for between 2 and 10 seconds Users can only select new settings provided the button lock function is disabled Available settings are displayed in a pre defined sequence that is repeated everytime the button is brieflypressed and released If...

Page 28: ...ion verification time time following startup of main power supply t2l Check for extraneous light or false flame signal during t2 the burner controller waits for time t2 then enters lockout the motor does not start t2p Maximum fuel oil pre heating time the burner controller waits for time t2p then enters lockout t3 Pre purging time the fan motor runs then the fuel oil valve opens t3l Check for extr...

Page 29: ...t up after pre heating FM Fan motor ID Ignition electrode V Fuel oil valve F Flame detector LED Colour of button LED Lockout caused by extraneous light during pre purging F LED HT FM ID P V M K PH Lockout Red Flashing green Flashing orange POWER ON Flashing green red t1 t2 t3l ts Cycle times t0 t1 1 t2 3 5 t2l 25 t2p max 600 t3 15 t3l 25 t3i 2 ts 5 t4i 10 t4l 1 t5i 3 0 4 0 8 tr 3 repeats tpp 10 Ti...

Page 30: ...OM fault ORANGE GREEN alternate flashing Slow 0 5 0 5 Fault diagnosis lockouts Description of lockout Lockout time Presence of extraneous light during standby After 25 seconds Pre heating not finished After 600 seconds Detection of extraneous light during pre purging or pre heating After 25 seconds Detection of extraneous light during pre heating After 25 seconds Flame not detected by end of safet...

Page 31: ... Mode POST PURGING The post purging function keeps the fan running for a set time after the burner shuts down provided there is no new heat request When the contacts of the heat request thermostat open the burner controller shuts down the flame and shuts off the oil supply Post purging does not occur after a lockout if a heat request is cancelled during pre purging Post purging occurs if a heat re...

Page 32: ...n test sequence ProgrammingallowedinOPERATINGmodeandinSTANDBY Press button for 5 sec t 10 sec RED led Blinking 2 times 0 2s ON 0 2s OFF Release the button The burner shuts down and restarts The burner shuts down then restarts automatically Each shutdown test resets zeroes the ignition cycle count No LEDs flash when you exit the shutdown test menu POST PURGING Post purging time can be set to a maxi...

Page 33: ... can be extended for another 10 seconds by pressing the reset button again while the lockout type is being displayed Always wait 1 second between every press and release of the button to ensure correct interpretation of the command SHUTDOWN TEST If the reset button is pressed and held down for a time between 5 and 10 seconds during normal functioning the burner shuts down the fuel oil valve closes...

Page 34: ...cated by the LED flashing see paragraph Fault diagnosis lockouts on page 30 If an error is detected before a heat request is made or during pre heating the burner does not start up and the error is signalled If an error is detected during pre purging the burner remains in purge mode and the error is signalled If no error is detected during normal functioning the burner continues to function normal...

Page 35: ...itched off the boiler shuts down for a controlled shutdown and restart Pre heating de activation sequence Colour of button LED Only de activate the pre heating if no lockout or errors are present Deactivate the pre heating by means of the reset or remote reset button Switch on the burner and simultaneously hold down the reset or remote reset button for 3 seconds RED Release the reset or remote res...

Page 36: ...ed as follows Adjust the boiler thermostat to its minimum setting 20 100 4 40 60 80 3 2 1 0 0 120 Turn the room thermostat to about 10 C or select the frost protection function 3 5 Preparing for extended periods of disuse If the boiler is not going to be used for an extended period of time proceed as follows to prepare it for shut down Open the control panel access door Turn the control panel powe...

Page 37: ...re beginning any maintenance or cleaning Turn the mains power switch OFF and turn the control panel function selector OFF 0 close all external fuel shut off cocks 3 7 Annual cleaning 3 7 1 Cleaning and maintaining the burner Proceed as follows to access the internal parts of the boiler Remove the front panel 1 1 REMOVING THE BURNER Proceed as follows to remove the burner Close the fuel shut off co...

Page 38: ... the new nozzle is exactly the same type and size as the old one Clean the contact and sealing surfaces Screw the new nozzle into place by hand first then tighten fully Re fit the electrode holder 2 reversing the instructions for removal 0 0Donotusenozzlesofdifferentmake typeandspecifications to the original SETTING THE ELECTRODES Correct electrode positioning is essential for efficient ignition a...

Page 39: ...the suction cover 4 Clean the fan and the inside of the suction cover using a suitable brush and compressed air 4 2 1 3 Reverse the above steps to reassemble Take care to replace all burner parts in their original positions 3 7 2 Cleaning the boiler Proceed as follows to access the internal parts of the boiler Remove the front panel 1 1 Remove the burner remove the panel 2 unscrew the nuts 3 and r...

Page 40: ...ved components in the opposite order 9 9Fit a new fibreglass seal when fitting the cover on the flue gas box 3 7 3 External cleaning Clean the boiler s casing panels and control panel with a soft cloth damped in soapy water To remove marks from the boiler casing use a cloth damped in a 50 mix of water and denatured alcohol or a suitable cleaning product Wipe the boiler dry after cleaning it 0 0Do ...

Page 41: ...he boiler does not reach its temperature setpoint Boiler dirty Clean Burner capacity insufficient Check and adjust the burner Problem with boiler control thermostat Check correct functioning Check the temperature setting The generator triggers a thermal safety block Problem with boiler control thermostat Check correct functioning Check the temperature setting Check the electrical wiring Check the ...

Page 42: ...eading extraneous light Eliminate cause of light or false flame signal The burner performs pre purging and ignition correctly but locks out after about 5 seconds RED Flame detector dirty Clean the flame detector The flame detector is faulty Change as necessary The flame detaches or fails Check fuel oil pressure and flow rate Check the air flow Change the nozzle Check solenoid valve coil The burner...

Page 43: ...43 ...

Page 44: ...Tel 0442630111 Fax 044222378 www riello it The manufacturer strives to continuously improve all products Appearance dimensions technical specifications standard equipment and accessories are therefore liable to modification without notice ...