Riello ALU PRO power Series User guide

INSTRUCTIONS FOR THE INSTALLER AND
FOR THE TECHNICAL ASSISTANCE CENTRE
ALUMINIUM
CONDENSING
BOILERS
ALU PRO
power

GENERAL
2
ALU PRO Power condensing boilers comply with:
• Gas Appliance Directive 2009/142/EC
• Efficiency Directive 92/42/EEC and Attachment E of the Pres. Decree 26 August 1993 no. 412 (****)
• Electromagnetic Compatibility Directive 2014/30/EU
• Ecodesign Directive for energy-related products 2009/125/EC
• Energy Consumption Labelling Directive 2010/30/EU
• Low Voltage Directive 2014/35/EU
• Condensing boilers Standard EN 677.
• Delegated regulation (EU) N. 813/2013
CONFORMITY
MODEL CODE
ALU 115 PRO power 20021781
ALU 150 PRO power 20020843
ALU 225 PRO power 20020844
ALU 300 PRO power 20020845
ALU 349 PRO power 20029287
ALU 375 PRO power 20020846
ALU 450 PRO power 20020847
ALU 525 PRO power 20020848
ALU 600 PRO power 20020849
RANGE

GENERAL 3
Dear Installer,
congratulations on having chosen a r boiler, a quality product that is designed to give
dependable, efficient and safe service and to provide comfort in the home for many years to come.
This manual provides information that is essential for the proper 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.
Please accept our thanks again on your choice of product
Riello S.p.A.

4INDEX
This booklet Cod. 20125662 Rev. 20 (09/16) is com-
posed of 72 pages.
In some parts of the booklet, some symbols are used:
b = for actions that require particular caution and
adequate preparation
a = for actions that absolutely SHOULD NOT be
carried out
CONTENTS
GENERAL
Conformity 2
Range 2
Index 4
General Safety Information 5
Basic safety rules 5
Description of the appliance 6
Safety devices 6
Identification 7
Data plate 7
Structure 8
Technical data 11
Accessories 11
Water circuit 12
Pumps 12
Positioning the temperature sensors 13
Wiring diagram 14
Control panel 16
Operation 19
INSTALLER
Product delivery 24
Opening 24
Dimensions and weights 25
Handling 25
Place of installation 28
Installation in older systems and systems requiring
modernisation 28
Water in central heating systems 29
Water connections 32
Draining the condensate 37
Condensate neutraliser 38
Gas connection 40
System anti-freeze protection 41
Flue gas exhaust and comburent air intake 41
Electrical wiring 42
Connecting the outdoor temperature sensor 45
System filling and emptying 46
Preparing for initial start-up 46
TECHNICAL ASSISTANCE CENTRE
Initial commissioning 47
Checks during and after initial start-up 49
Temporary shut-down 50
Preparing for extended periods of disuse 50
Setting the combustion parameters 51
Conversion from one type of gas to another 55
Setting the functional parameters 57
Information display 59
Fault codes 60
Parameters menu 62
Maintenance 65
Cleaning the condensate drain and siphon 65
Removing the burner 66
Positioning electrodes 67
Troubleshooting 68ß

GENERAL 5
Remember that the use of products that use fuel, electrical power and water demands that a number of fundamental
safety precautions be respected, like:
aDo not allow children or persons (including children)
with reduced physical, sensorial or mental abilities
or with insufficient experience and knowledge to use
the system without proper supervision or instruction
from the person responsible for its safe use.
aIt is forbidden to use electrical devices or equip-
ment, such as switches, domestic appliances, etc. if
there is a smell of gas or unburned products. In this
case:
- air the room, opening doors and windows;
- close the fuel shut-off cock;
- promptly contact the rTechnical Assistance
Centre or other professionally qualified personnel.
aDo not touch the boiler while barefoot or when wet.
aNever clean or service the boiler without first dis-
connecting it from the mains electricity supply by
turning the main power switch to "off" and the main
switch of the boiler to “OFF”.
aDo not modify the safety or adjustment devices with-
out the receiving the manufacturer’s authorisation
and precise instructions.
aDo not plug the condensate drain outlet.
aNever pull, disconnect, or twist the electrical cables
coming from the boiler even if it is disconnected
from the mains electricity supply.
aDo not obstruct or restrict the air vents in the room
where the boiler is installed.
The ventilation openings are vital for correct com-
bustion.
aDo not expose the boiler to the elements.
It has been designed to work outdoors only when
used with the special accessory kit.
aNever leave inflammable substances and contain-
ers in the room where the boiler is installed.
aDo not dispose of packaging material into the envi-
ronment, or leave it within the reach of children,
since it can become a potential hazard. It must be
disposed in accordance with the present law.
BASIC SAFETY RULES
GENERAL SAFETY INFORMATION
bAfter removing the packaging make sure that
everything is there and undamaged, if not contact
the rAgency that sold you the appliance.
b The installation of the ALU PRO power boiler must
be carried out by a qualified company that will
issue the owner with the installation declaration of
conformity on completion of the work, in compliance
with the applicable National and Local Standards
and the instructions supplied by r in the instruc-
tion booklet supplied with the appliance.
b The ALU PRO power boiler must be used for the
purpose intended by rfor which it was express-
ly made. No contractual or extra-contractual liability
is accepted by rfor damage caused to people,
animals, or objects due to errors in installation,
adjustment, or maintenance or by improper use.
bIn the event of a water leak, disconnect the boiler
from the mains electricity supply, shut off the water
supply and promptly notify the rTechnical
Assistance Centre or else professionally qualified
personnel.
b Periodically check that operating pressure in the
water circuit is greater than 1.5 bar and less than
the maximum limit provided for the appliance.
Otherwise, contact the rTechnical Assistance
Centre or professionally qualified personnel.
b If the boiler is not going to be used for an extended
period of time, proceed as follows to prepare it for
shut-down:
- set the appliance's main switch to “OFF”
- turn off the system general switch
- close the fuel and water taps of the heating system
- drain the heating and domestic hot water circuits to
prevent freezing
b The boiler must be serviced at least once a year.
b This manual is an integral part of the appliance
and must therefore be kept with care and must
ALWAYS accompany the boiler even when passed
on to another owner or user or transferred to another
installation. In case of loss or damage, please con-
tact the local rTechnical Assistance Centre in
your Area for a new copy.

GENERAL
6
The aluminium ALU PRO POWER boilers are modular
condensing heat generators for heating systems and
when used with storage cylinders, for producing domes-
tic hot water.
The generator is based on a cascade of independent 75
kW thermal modules, managed in sequence by cascade
control.
The modules are connected to each other using a deliv-
ery collector, a return line collector and a flue gas collec-
tor with a single condensate drain.
The number of modules ranges from 1 to 8 for outputs
ranging from 75 to 600 kW. This logic allows you to
ensure a high degree of continuous service and a high
degree of modulation (up to 40:1 for the 600 kW model).
The aluminium elements with a low water content
have large exchange surface for maximising the heat
exchange, energy efficiency, thermal equilibrium obtain-
ing high condensation yields.
The stainless steel with continual total premix burner
provides stable and quiet combustion
with low pollutant emissions (NOx class).
Mixing takes place using a venturi tube upstream of the
fan.
The adjustment of the sequence is carried out with a
DESCRIPTION OF THE APPLIANCE
The ALU PRO power condensing boiler has the following safety devices:
Safety thermostat with manual reset, intervenes when the
boiler water temperature exceeds 99°.
Water pressure switch intervenes when the water circuit
pressure is less than 0.5 bar.
Water circuit diagnosis checks the temperature differ-
ence between delivery and return (∆T).
Flue gases safety, a probe intervenes when an increase
in the temperature of the flue gases indicates the gases
themselves are not being vented correctly.
Gas pressure switch intervenes if the gas supply pres-
sure is less than 10 mbar.
b The intervention of the safety devices indicates a
boiler malfunction, which is potentially dangerous,
therefore immediately contact the rTechnical
Assistance Centre. In any event, you may attempt
to restart the boiler after a short wait (see chapter
on initial start-up.
aNever start the boiler up, even for a short period, if
the safety devices are not functioning correctly or
have been tampered with.
b Replacement of safety devices must be performed
by the rTechnical Assistance Service, using
only original components. Refer to the spare parts
catalogue supplied with the boiler. After making the
repair, check that the boiler is working properly.
climate logic, with an outdoor temperature sensor, and it
allows you to regulate the outlet temperature according
to the outside temperature.
The ALU PRO POWER boiler, in its turn, can be man-
aged in cascade logic in a system composed of up to 8
boilers, using a second level master (see RVS) thereby
creating boilers up to 4.8 MW.
The sequence control on-board the boiler is set up to
manage a pump (primary or system depending on the
parametrisation) with modulating logic controlled with a
0-10V DC signal.
The sequence control can in any event be controlled with
a TA, OT+ input or a 0-10V DC signal.
It is also possible to display the error codes on the dis-
play and the connections for diagnostics with a PC.
The boilers are supplied to operate with G20 methane
gas. However, they can operate with G25 or G31 gas
using the conversion kit supplied (for Belgium this type
of conversion is prohibited).
SAFETY DEVICES

GENERAL 7
IDENTIFICATION
The products are identified by:
- Data plate
It indicates the technical
and performance data.
- Serial Number plate
Displays the serial
number, model and
output.
Paese di destinazione:
Tipo di apparecchio
Caldaia categoria
:
:
B23P
II2H3P
Pressioni di alimentazione gas:
Regolazione effettuata dal costruttore:
G20 - 20 mbar
ATTENZIONE
Leggere attentamente il libretto istruzioni
prima di installare e mettere in servizio
l'apparecchio.
Questo apparecchio può essere installato e
funzionare solo in locali permanentemente
ventilati, in conformità alle normative vigenti.
(Laterale DX)
068786_1_E4
G20 20 mbar
G31 37 mbar
- Gas label
applied at the rear of the
boiler and specifies the type
of gas used by the boiler,
and the country in which the
boiler is destined for use.
DATA PLATE
Heating operation
Qn Nominal heat delivery
Pn Nominal operating output
IP Electrical protection rating
P.nom Nominal pressure
Pms Maximum pressure, heating
TTemperature
ηEfficiency
NOxClass of NOx
European Directive
92/42/EEC:
η
N°
230 V ~ 50Hz W
Pms= bar T = °C
Qn(min)=
Pn(min)=
NOx:
/
IP P.nom.G20= mbar
Qn(max=
Pn(max)=
Cod.
kW
kW
kW
kW
kW
kW
kW
kW
RIELLO S.p.A.
Via Ing.Pilade Riello 7
37045 Legnago (VR) - ITALY
Categoria:
Categorie:
Kategorie:
Combustible:
Brennstoff:
Combustibile:
Brandstof:
KESSEL GEREGELT FÜR:
CALDAIA REGOLATA PER: CHAUDIERE REGLEE POUR:
VERWARMINGSKETEL INGESTELDOP:
T067746GE
T067746GE
Caldaia a condensazione - Chaudière à condensation
Brennwertkessel - Condenserende verwarmingsketel
- G20 label
European Directive
92/42/EEC:
η
N°
230 V ~ 50Hz W
Pms= bar T = °C
Qn(min)=
Pn(min)=
NOx:
/
IP P.nom.G20= mbar
Qn(max=
Pn(max)=
Cod.
kW
kW
kW
kW
kW
kW
kW
kW
RIELLO S.p.A.
Via Ing.Pilade Riello 7
37045 Legnago (VR) - ITALY
Categoria:
Categorie:
Kategorie:
Combustible:
Brennstoff:
Combustibile:
Brandstof:
KESSEL GEREGELT FÜR:
CALDAIA REGOLATA PER: CHAUDIERE REGLEE POUR:
VERWARMINGSKETEL INGESTELDOP:
T067746GE
T067746GE
Caldaia a condensazione - Chaudière à condensation
Brennwertkessel - Condenserende verwarmingsketel
Cod. N°
Qn(max)
PmsbarkW
RIELLO S.p.A.
Via Ing.Pilade Riello 7
Mod.
37045 Legnago (VR) - ITALY
T067746I0

GENERAL
8
1
2
3
14
15
4510
13
9
8
11
7
6
12
STRUCTURE
1 - Control panel
2 - Control panel
3 - Front panel
4 - Base
5 - Condensate drain
6 - Flue gas thermostat
7 - Module insulation
8 - Flue gas box
9 - Return temperature sensor fitting
10 - Water pressure switch
11 - Drain tap
12 - Return line collector
13 - Burner
14 - Gas collector
15 - Delivery collector
16 - Cover panel
17 - Burner check valve
18 - Ignition electrode
19 - Flame inspection window
20- Side panel
21 -
Thermal module safety thermostat
22 - Flue gas probe
23 - Flue gas box
24 - Flue gas analysis outlet
25 - Flue gas exhaust
26 - Boiler aluminium body
27 - Flow sensor
28 - Sensor socket + Safety thermostat
29 - Detection electrode
30 - Thermal module flow sensor
31 - Flame control boards
32 - Board support
33 - Fan motor
34 - Gas valve
35 - Transfer gas pressure switch
36 - Venturi tube
37 - Ignition transformer
38 - Thermal module cover
FRONT view LEFT SIDE view

GENERAL 9
14 33 3534
25
37 3638
1
32 31 30
25
26
28
29
22
23 24 5
27
16
17
18
19
21
10
20
RIGHT SIDE view
TOP view

GENERAL
10
NON
MODIFICARE
Modulo 1
OFF ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Modulo 2
Modulo 3
Modulo 4
Modulo 5
Modulo 6
Modulo 7
Modulo 8
Modulo
8
Modulo
7
Modulo
6
Modulo
...
IMPOSTAZIONE
MODULO
DIP-Switch
DIP
Switch
Modulo
1
Diagram of SETTINGS FOR THE THERMAL MODULES
DIP-Switch
DIP
Switch
Module 1
Module Module Module Module Module
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Module 2
Module 3
Module 4
Module 5
Module 6
Module 7
Module 8
DO NOT
CHANGE MODE SETTING
OFF ON

GENERAL 11
TECHNICAL DATA
ACCESSORIES
ALU PRO power UM 115 150 225 300 349 375 450 525 600
Type of appliance condensing boiler for central heating
B23, B23P
Fuel
IT-CH: G20=20mbar G31=37mbar
FR: G20/G25 - 20/25 mbar G31=37mbar
BE: G20/G25 - 20/25 mbar
Appliance category IT-CH: II2H3P - FR: II2Esi3P - BE: I2E(R)
Maximum rated heat input (GCV) G20 kW 127,8 166,6 250,0 333,3 387,7 416,6 499,9 583,3 666,6
Maximum rated heat input NCV G20 kW 115 150 225 300 349 375 450 525 600
Reduced heat input GCV (NCV) G20 kW 16,7 (15)
Rated heat output (80-60°C) P4 G20 kW 112,3 146,7 220,2 294,3 342,8 368,7 443,0 517,4 591,9
30% heat output with return at 30°C (P1) G20 kW 33,7 44,0 66,1 88,3 102,8 110.6 132,9 155,2 177,6
Reduced heat output (80-60°C) G20 kW 14.7
Constant pressure drop with the burner off %< 1
Losses from stack % 0.7 0.7 0.6 0.5 0.4 0.4 0.4 0.4 0.4
Efficiency at rated heat input and in High temper-
ature mode (GCV) η 4 - (80-60°C) % 87.9 88 88.1 88,3 88.4 88,5 88.6 88,7 88,8
Efficiency at 30% rated heat input and in Low
temperature mode (GCV) η1
% 97,4
Max gas consumption G20 m3/h 12.1 15.8 23.7 31.6 36.7 39.5 47,4 55.3 63.2
Max. flue gas temperature (80°- 60°) °C 65 - 70
Min. flue gas temperature (80°- 60°) °C 60 - 65
Mass flue gas flow rate (80°- 60°) min-max kg/h 30-164 30-164 38-224 63-285 67-336 67-336 73-392 73-457 73-523
Residual head Pa ~ 100
Noise levels (*) at Pn min/Pn max dB(A) 44-62 44-62,5 44-63 44-64 44-64,5 44-65 44-66 44-67 44-68
CO2 max-min G20 %9 - 9
CO S.A. max-min mg/kWh 42 - 4
NOx (referring to GCV) mg/kWh < 63
Max-min heating pressure bar 6 - 0,5
Max heating temperature °C 85
Boiler minimum operating output l/h 1,300 1,300 1950 2600 3250 3250 3900 4550 5200
Water content in the heating circuit l 30 30 40 55 65 65 78 88 100
Pressure drop water side (∆T 20)
mbar 30 50 60 70 80 80 90 100 150
Elmax electric power consumption W 300 300 440 580 720 720 860 1000 1140
Electric power consumption at partial load - Elmin W 90 90 132 174 216 216 258 300 342
Electric power consumption in
Psb Standby mode
W 20
Voltage supply Volt/Hz 230/50
Electrical protection level as standard
IP 20
with kit for outdoors IP X5D
Boiler net weight Kg 240 240 310 395 470 470 565 640 735
(*) Noise levels measured as continuous A-weighted sound pressure, at 1 metre from the appliance.
For the specific related accessories see the Riello catalogue and the product datasheet.

GENERAL
12
GAS
MI
RI
1
2
5
8
Sc
6
3
9 9 9 9
4
7
1 Gas inlet collector
2 Burner assembly
3 Combustion chamber
4 Heat exchange element
5 Flue gas box
6 Flue gas outlet fitting
7 Boiler filling/draining tap
8 Condensate discharge syphon
9 Automatic venting valve
SF System flow
SR System return
Gas Fuel supply
Sc Discharge
WATER CIRCUIT
b At first start-up, and at least once a year, the ro-
tation of the circulator shaft should be checked,
especially after long periods of not being operat-
ed, since deposits and/or residues could impede it
from rotating freely.
b Before loosening or removing the circulator cap,
protect the electric devices located underneath
from any water that might come out.
a Never operate the pumps without water.
Select a pump that is compatible with the water resistor of the boiler and the system.
The illustration below shows the resistor characteristics.
PUMPS
Perdite di carico (mbar)
Portata (m3/h)
0
350
300
250
200
150
100
50
0
510 15 20 25 30 35 40
115-150 225 300 450 600 525
349-375
Pressure drop (mbar)
Output (m3/h)
GAS

GENERAL 13
POSITIONING THE TEMPERATURE SENSORS
6
1
7
3
2
5
4
SENSORS INSERTED IN THEIR SOCKETS IN THE BOILER
1 - Return temperature sensor
2 - Thermal module safety thermostat
3 - Thermal module flow sensor
4 - Safety thermostat
5 - Flow sensor
6 - Flue gas probe
7 - Flue gas thermostat
RIGHT SIDE
view
LEFT SIDE
view

GENERAL
14
WIRING DIAGRAM
S.E.
X4-7-ST2
S. Ritorno
X4-3-ST2
OUTPUT 0-10V -X11-4-J5
Pres. ACQ. X7-2-CN2
S.E.
X4-8-ST2
S.Mand
X4-1-ST2
L1-P. Colet.
X2-2-x1
L1-P. ACS
X2-4-x1N-P. ACS X2-3-x1
L1-V.I.GAS
X2-6-x1
INPUT 0-10V +X11-3-J5
N-P. Colet.
X2-1-x1
N
X1-2-J3
T.Fumi X6-4-ST1
P.GASX6-2-ST1 P.GASX6-1-ST1
TA X7-6-CN2
RESETX7-4-CN2
T. Fumi X6-3-ST1
S.Fumi X5-2-ST3
OUTPUT 0-10V + X11-5-J5
S.Fumi X5-1-ST3
INPUT 0-10V -X11-1-J5
RS 485 -X10-2-J19
L
X1-3-J3
PE
X1-1-J3
N-V.I.GAS
X2-5-x1
NO-Con.Alarme
X3-2-J4 C-Con.Alarme X3-1-J4
S. Ritorno
X4-4-ST2
S.ACS
X4-6-ST2
S.Mand
X4-2-ST2
S.ACS
X4-5-ST2
Pres. ACQX7-1-CN2
RESETX7-3-CN2
TA X7-5-CN2
RS 485 +X10-1-J19
OT X8-2-J20 OT X8-1-J20
DISP
X12-1/12-X2
SCH
SCH-SEQ-01
N pompa L1 pompa N Ventil
X1-4-J2 L1 Veltil X1-3-J2 N 230V X1-2-J2 L1 230V X1-1-J2
ER
ER-FA2
L1 VG
X2-5-CN14N VG X2-4-CN14N acc-AT X2-3-CN14
PE acc-AT
X2-1-CN14
L1 acc AT
X2-2-CN14
PE
PE-J7
TA X3-1-ST2 TA X3-2-ST2 PA X3-3-ST2 PA X3-4-ST2
pX3-5-ST2 pX3-6-ST2
OT X3-7-ST2 OT X3-8-ST2
SM X4-1-ST1 SM X4-2-ST1
RS485 X4-3-ST1 RS485 X4-4-ST1
massa X5-1-CN1
Hall X5-2-CN1
PWMX5-3-CN1
+24V X5-4-CN1
SCH2
X1-1/12-x2 T1
T2 T3
T4
T5
T6 T7 T8 T9 T10
SCH1
FU
0
1
IG
Pacqua Pgas
a
b
c
d
e
c
d
e
a
b
TS
MO1
SESB
SM
AL
TA
0-10 out
0-10
in
SR SF
H1
H2
PCol
COLLEGAMENTI A CURA DELL’INSTALLATORE
PB ViG
TF
M
DCV
VE1VE8
RIV
ER1
VG1
Tm-TA1
EA1
SM1
TS1
PWM
PWM
N pompa L1 pompa N Ventil
X1-4-J2 L1 Veltil X1-3-J2 N 230V X1-2-J2 L1 230V X1-1-J2
ER
ER-FA2
L1 VG
X2-5-CN14N VG X2-4-CN14N acc-AT X2-3-CN14
PE acc-AT
X2-1-CN14
L1 acc AT
X2-2-CN14
PE
PE-J7
TA X3-1-ST2 TA X3-2-ST2 PA X3-3-ST2 PA X3-4-ST2
pX3-5-ST2 pX3-6-ST2
OT X3-7-ST2 OT X3-8-ST2
SM X4-1-ST1 SM X4-2-ST1
RS485 X4-3-ST1 RS485 X4-4-ST1
massa X5-1-CN1
Hall X5-2-CN1
PWMX5-3-CN1
+24V X5-4-CN1
SCH9
M
DCV
RIV
ER8
VG8
Tm-TA8
EA8
SM8
TS8
PWM
PWM
Da 1 a 8 Moduli
RS 485
Alimentazione
Dei
Moduli
Alimentazione
230V 50Hz
LNPE
FL
SCH Main board
SCH1 Display and control board
SCH2..9 Combustion unit control board
Pacqua Water pressure switch
TF Flue gas thermostat 75°C (+0/-10)
Pgas Gas pressure switch
TS Safety thermostat 110°C (+0/-6)
IG Main switch
H1 Electrical power indicator
H2 Lock-out signal
FU Fuse 6.3 AT
SM Flow sensor
SR Return sensor
SF Flue gas probe
CONNECTIONS TO BE PROVIDED BY THE INSTALLER
Power supply
230V 50Hz
Pacqua
0-10 out
DISP
0-10
in
Pgas

GENERAL 15
S.E.
X4-7-ST2
S. Ritorno
X4-3-ST2
OUTPUT 0-10V -X11-4-J5
Pres. ACQ. X7-2-CN2
S.E.
X4-8-ST2
S.Mand
X4-1-ST2
L1-P. Colet.
X2-2-x1
L1-P. ACS
X2-4-x1N-P. ACS X2-3-x1
L1-V.I.GAS
X2-6-x1
INPUT 0-10V +X11-3-J5
N-P. Colet.
X2-1-x1
N
X1-2-J3
T.Fumi X6-4-ST1
P.GASX6-2-ST1 P.GASX6-1-ST1
TA X7-6-CN2
RESETX7-4-CN2
T. Fumi X6-3-ST1
S.Fumi X5-2-ST3
OUTPUT 0-10V + X11-5-J5
S.Fumi X5-1-ST3
INPUT 0-10V -X11-1-J5
RS 485 -X10-2-J19
L
X1-3-J3
PE
X1-1-J3
N-V.I.GAS
X2-5-x1
NO-Con.Alarme
X3-2-J4 C-Con.Alarme X3-1-J4
S. Ritorno
X4-4-ST2
S.ACS
X4-6-ST2
S.Mand
X4-2-ST2
S.ACS
X4-5-ST2
Pres. ACQX7-1-CN2
RESETX7-3-CN2
TA X7-5-CN2
RS 485 +X10-1-J19
OT X8-2-J20 OT X8-1-J20
DISP
X12-1/12-X2
SCH
SCH-SEQ-01
N pompa L1 pompa N Ventil
X1-4-J2 L1 Veltil X1-3-J2 N 230V X1-2-J2 L1 230V X1-1-J2
ER
ER-FA2
L1 VG
X2-5-CN14N VG X2-4-CN14N acc-AT X2-3-CN14
PE acc-AT
X2-1-CN14
L1 acc AT
X2-2-CN14
PE
PE-J7
TA X3-1-ST2 TA X3-2-ST2 PA X3-3-ST2 PA X3-4-ST2
pX3-5-ST2 pX3-6-ST2
OT X3-7-ST2 OT X3-8-ST2
SM X4-1-ST1 SM X4-2-ST1
RS485 X4-3-ST1 RS485 X4-4-ST1
massa X5-1-CN1
Hall X5-2-CN1
PWMX5-3-CN1
+24V X5-4-CN1
SCH2
X1-1/12-x2 T1
T2 T3
T4
T5
T6 T7 T8 T9 T10
SCH1
FU
0
1
IG
Pacqua Pgas
a
b
c
d
e
c
d
e
a
b
TS
MO1
SESB
SM
AL
TA
0-10 out
0-10
in
SR SF
H1
H2
PCol
COLLEGAMENTI A CURA DELL’INSTALLATORE
PB ViG
TF
M
DCV
VE
1V
E8
RIV
ER1
VG1
Tm-TA1
EA1
SM1
TS1
PWM
PWM
N pompa L1 pompa N Ventil
X1-4-J2 L1 Veltil X1-3-J2 N 230V X1-2-J2 L1 230V X1-1-J2
ER
ER-FA2
L1 VG
X2-5-CN14N VG X2-4-CN14N acc-AT X2-3-CN14
PE acc-AT
X2-1-CN14
L1 acc AT
X2-2-CN14
PE
PE-J7
TA X3-1-ST2 TA X3-2-ST2 PA X3-3-ST2 PA X3-4-ST2
pX3-5-ST2 pX3-6-ST2
OT X3-7-ST2 OT X3-8-ST2
SM X4-1-ST1 SM X4-2-ST1
RS485 X4-3-ST1 RS485 X4-4-ST1
massa X5-1-CN1
Hall X5-2-CN1
PWMX5-3-CN1
+24V X5-4-CN1
SCH9
M
DCV
RIV
ER8
VG8
Tm-TA8
EA8
SM8
TS8
PWM
PWM
Da 1 a 8 Moduli
RS 485
Alimentazione
Dei
Moduli
Alimentazione
230V 50Hz
LNPE
FL
SM1..8 Flow sensor heating element
TS1..8 Safety thermostat heating element
ER1..8 Flame detection electrode
EA1..8 Ignition electrode
Tm-TA1..8 Ignition transformer
VG1..8 Combustion unit gas valve
VE1..8 Variable speed fan
MO1 Electrical supply terminal board
Connections to be provided by the installer:
PCol Circulator collector (accessory)
PB Circulator storage cylinder (accessory)
ViG Gas shut-off valve (accessory)
SB Storage cylinder probe (accessory)
SE Outdoor temperature sensor (supplied)
TA Room thermostat (low voltage 24V)
0-10 out Output 0-10 Volt (for system pump)
0-10 in Input 0-10 Volt
AL Alarm connection with clean contact
FL Flow switch (accessory)
From 1 to 8 Modules
Power supply
of the modules

GENERAL
16
CONTROL PANEL
BASIC INFORMATION / INTERFACE COMMANDS
21
53 4 7
89101112131516 14
6
CONTROL PANEL IN CLOSED POSITION
1 - Electrical power indicator (green)
Lights to show that the system is receiving electri-
cal power .
2 - Burner lockout indicator (red)
Lights to show that a burner lockout has occurred.
3 - DHW production on/off button
When active the symbol vappears on the display
4 - Main switch
5 - Button regulating heating temperature or room
temperature setpoint
6 - Display
7 - Button for selecting operating mode.
A line appears under the symbols:
sAutomatic: the boiler functions according to
the set program
oContinuous: continuous mode
lReduced: reduced mode
bStand-by
8 - Information button
9-10 - Button for changing parameter value
11 - Fuse (accessed by slightly turning the control
panel)
12-13 - Buttons for electing parameters
14 - Button for regulating DHW temperature
15 - Reset button
Restores normal functioning after a safety shut-
down
16 - Safety thermostat with manual reset (accessed by
slightly turning the control panel)
CONTROL PANEL IN OPEN POSITION

GENERAL 17
A F
B DEG C
A -Large numeric display.
Displaying current value, non-volatile errors
B -Display symbols:
vDHW temperature or DHW mode active
rCH or room temperature setpoint, or CH mode active
cOutdoor temperature
oNominal mode
lReduced mode
fFlame present
nError
C -Small numeric display
Displays time, parameters or error codes,
displaying combustion module
D -Heating circuit operating modes:
sAutomatic: the boiler functions according to the set program
oContinuous: the boiler operates at daytime (comfort) setpoint
lReduced: the boiler operates at night-time (reduced) setpoint
bStand-by
E -DHW mode: ON or OFF
F -Current time bar
G -Indicating 0-10 V device operating
SECONDARY INFORMATION / DISPLAY VIEW
Auto Standby

GENERAL
18
MAIN SCREEN
E1 G1
A1 FC1 D1B1
F1 H1
I1
A1 -Operating mode.
Pressing the "
Mode " button, the bar appears under the corresponding mode
symbol.
B1 -DHW mode.
The button "w" (above the display) switches the mode on or off.
C1 -Nominal operating mode
D1 -Time of day
E1 -Current boiler temperature
F1 -Flame presence
G1 -Current time indication
H1 -Current mode heating
I1 -Current mode DHW.
Auto Standby

GENERAL 19
- The domestic hot water priority function that gives
domestic hot water priority over heating hot water.
- The anti-freeze function:
The boiler's anti-freeze function. If the boiler's temper-
ature is less than H511 the burner comes on at maxi-
mum power until the boiler temperature reaches H512.
The anti-freeze system, active only with the outdoor
temperature sensor connected. If the outside temper-
ature drops below -5°C the pumps are switched on.
If the outdoor temperature is between -5° and 1.5°C,
the pumps are switched on for 10 minutes at intervals
of 6 hours; If outside temperature is above 1.5°C the
pumps are switched off.
- The over-temperature dispersal function: if for any rea-
son the limit temperature C515 is reached, the boiler
switches off and the accumulated heat is dispersed
activating the system pump, if the last request was
heating, or the domestic hot water pump if the last
request was domestic hot water.
- The cascade control function: using the regulator
(accessory) it is possible to connect the boiler in cas-
cade up to a maximum of 16.
- The ignition/shut-off control function: to prevent repeat-
ed ignitions and shut-downs, the boiler stays off for a
minimum period of time. The boiler will only start up
again if the difference between the setpoint and the
actual boiler temperature exceeds a predetermined
value.
Functional notes
The control panel of the ALU PRO power boiler oversees:
OPERATION
HEAT REQUEST (WITH THREE SYSTEMS)
The ALU PRO POWER adjustment system has three
different types.
1 - with OT+ signal
2 - with external 0-10V control
3 - with room thermostat.
Once the heat request is finished, the system carries
out the post-circulation, namely the heating circulator is
started for the time set in parameter H543.
1 - Heat request with OT+ signal
The OT+ input is enabled only using the RVS communi-
cation kit available as an accessory ordered separately.
2 - Temperature request with 0-10V control
The 0-10Vdc input is translated into a temperature set-
point.
- 0Vdc - 1Vdc = no request;
- 1Vdc = request present with temperature setpoint at
the minimum permitted value;
- 10Vdc = request present with temperature setpoint at
the maximum permitted value.
The 0-10V regulators are: output 0-10V RVS63.
The management of the 0-10V device is set using the
selection of parameter C750, which can have the follow-
ing values:
- 0 = no 0-10V device is connected to the system;
- 1 = the 0-10V device is connected to the system; the
minimum stand-by signal is 0.5V. If the input read by
the main board is less than this threshold, the request
through TA is enabled; for higher values the TA input is
disabled;
- 2 = the 0-10V device is connected to the system;
the minimum stand-by signal is 0.5V. The TA input is
always disabled.
If both an opentherm device and a 0-10V device (param-
eter C750 in cases 1 or 2) are detected connected to the
system at the same time, any requests coming from the
latter will not be handled.
The display regarding the presence and the operating
status of the 0-10V input device is as follows:
- If C750 = 0: no signal is activated;
- if C750 = 1 or 2, and the input signal is greater than
0.5Vdc: the symbol in the top left of the ’LCD comes
on in a fixed manner;
- if C750 = 1 or 2, and the input signal is less than
0.5Vdc: the symbol in the top left of the ’LCD comes
on flashing;
3 - Enabling request with TA function
the heating request with a room thermostat is managed
only in the case where no device is connected to the
opentherm bus nor to the 0-10V input of the system
(
C750 = 0 or else C750 = 1 with 0-10V input less than
the threshold of 0.5V). In the above-mentioned cases, the
closure of the thermostat generates a request with a set
point set from the interface keypad, if there is no outdoor
probe, or with a set point calculated on the basis of the
climatic curves, if there is an outdoor temperature sensor.

GENERAL
20
NIGHT-TIME REDUCTION
the night-time reduction function is active when all the
following conditions exist contemporaneously:
- parameter C806 = 1 (function enable);
- there is an outdoor temperature sensor and it is work-
ing;
- no device is connected to the OpenTherm input;
- no device is connected to the 0-10Vdc input.
In this case, also outside the time band programming
the closure of the Ambient Thermostat input generates a
heat request. The set point is the one calculated from the
weather compensation curves, reduced by a value given
by the parameter H507.
WEATHER COMPENSATION
The weather compensation is activated if there is an
outdoor temperature probe; The delivery temperature set
point is calculated using the weather compensation curve
that is established in the following way:
The slop of the compensation curve is set using the
parameter H532, so as to adjust the delivery temperature
of the water in accordance with the outdoor temperature,
When the compensation curve is active the parameter
T_SET (H505) is added to the value calculated by the
weather curve, so as to be able to shift the curve verti-
cally.
Outdoor temperature Setpoint temperature
TE >= 0 TV = TRw + s(TRw - 8/9 TE) + Korr
TE < 0 TV = TRw + s(TRw - 0.7 TE) + Korr
TV = delivery setpoint temperature
TRw = ambient temperature setpoint
TE = outdoor temperature
s = weather curve slope
Korr = (20 – TRw) * (20 - TE) * s/120
The outdoor temperature used for the weather com-
pensation is that currently measured every 10 minutes
and averaged over a period of 10 hours. Based on the
temperature parameter for the passage from summer/
winter and winter/summer, the change of season occurs
automatically.
In this way the delivery setpoint temperature to be main-
tained is established.
SEQUENCE CONTROL STRATEGIES
The sequence control commands the flame control send-
ing a target output signal and operating with two different
strategies that can be selected using the parameter
C604:
Strategy A = Simultaneous Ignition/Switching off of all
modules (C604=0)
Strategy B = independent Simultaneous Ignition/
Switching off (C604=1).
The control for managing the output at the flame controls
can be adjusted regarding frequency updating with the
parameter C607 (establishes every how many seconds
the command for varying the request output is sent) and
how much with parameter C608 (establishes the max-
imum output variation that can be adjusted with each
update).
Strategy A
The burners, in this sequence management mode, oper-
ate at the same time like a single burner and the same
command signal is passed to all of them simultaneously.
They switch on and modulate together to seek to main-
tain the collector temperature at the same value that has
been set.
The switching off and switching on of the burners take
place according to the logic presented in the diagram
below operating on the base of an offset value on the
delivery setpoint which is set at parameter H606.
T_SET
T_SPEG = T_SET + D_SPEG
T_ACC = T_SET + D_ACC
Tempo
Temperatura mandata
sequenziatore °C
Time
Delivery temperature
sequencer °C
Each module, therefore, takes care of its own safety
working on the module probe in the following way:
if the water temperature exceeds the maximum value set
in parameter C517, the effective output of the module is
reduced with respect to the value requested by the boil-
er. If there is no temperature reduction and this exceeds
by a value equal to DELTA OFF the limit set above, the
flame control switches off the burner. The burner is then
restarted when the water temperature of the module has
dropped by a value equal to DELTA ON below the value
expressed in parameter C517.
Strategy B
In this control strategy the burners are ignited one after
the other.
In the event of a heat request, the first module (leader
module) comes on and the second module comes on
when the output percentage requested by the regulator
of the leader module reaches the value of the parame-