Riello Condexa PRO NA 75 P User manual

cod. 20144490 rev. 0 06/2018
9
WARNING: If the information in this manual is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable
vapors and liquids or other combustible materials in
the vicinity of this or any other appliance. To do so
may result in an explosion or fire.
What to do if you smell gas:
- Do not try to light any appliance;
- Do not touch any electrical switch; do not use any
phone in your building;
- Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions;
- If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
This manual should be maintained in legible
condition and kept adjacent to the boiler or in a safe
place for future reference.
Condexa PRO North America
US INSTALLATION OPERATION AND SERVICE MANUAL

2
RANGE
MODEL CODE
Condexa PRO NA 75 P 20142594
Condexa PRO NA 117 P 20142595
ACCESSORIES
For a complete list of accessories and details of their compatibility,
refer to the Catalogue.
CONFORMITY
thermal modules Condexa PRO NA comply with:
ENGLISH
Dear heating engineer,
congratulations on having chosen a thermal module R, a qual-
ity product that is designed to give dependable, efcient and safe
service and to provide comfort in the home for many years to
come.
This manual provides information that is essential to the in-
stallation 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 and our congratulations on your choice
of product.
Riello S.p.A.
INTENDED USE
This boiler must only be used for the purpose specied by the
manufacturer and for which it is designed.
The manufacturer declines all responsibility, contractual or other,
for damage to property or injury to persons or animals caused by
improper installation, adjustment, maintenance or use.
Installation of the boiler must comply with all applicable codes
and regulations imposed by the national, Federal or local author-
ities and bodies. If no specic requirements are dened, in the
USA, the latest edition of the National Fuel Gas Code ANSI Z223.1/
NFPA 54 must be complied with. In Canada, installation must be in
accordance with the requirements of CAN/CSA B149.1, Natural Gas
and Propane Installation Code.
Where required by local regulations, the system must comply with
the American Society of Mechanical Engineers Safety Code for Con-
trols and Safety Devices for Automatically Fired Boilers (ASME CSD-
1).

3
CONTENTS
1 GENERAL INFORMATION ............................5
1.1 General Safety Information ......................5
1.2 Precautions ..................................5
1.3 Description of the appliance .....................7
1.4 Safety devices ................................8
1.5 Identication .................................8
1.6 System layout.................................9
1.7 Technical specications .........................11
1.8 Pumps ..................................... 12
1.9 Water circuit................................. 12
1.10 Positioning the temperature sensors .............. 12
1.11 Control panel ................................ 13
1.12 Regulations and Guidelines ..................... 14
1.12.1 Compliance with standards and regulations ........ 14
1.12.2 Operating limits of the boiler .................... 14
1.12.3 Additional regulations for installations in the
Commonwealth of Massachusetts ................ 14
1.13 Venting and air piping system ................... 15
1.13.1 General venting and combustion air piping system ... 15
1.13.2 Connecting ue gas systems .................... 16
1.13.3 Installation of the exhaust and air intake system......17
1.13.4 Vent and combustion air pipe length [For single boiler
installations] ................................ 19
1.13.5 Approved examples of horizontal and vertical venting
installation .................................20
1.13.6 Multiple boiler ............................... 23
1.13.7 De-rating for altitude installation.................24
1.13.8 Multiple boiler cascade system...................25
1.13.9 Vent and combustion air pipe length for cascade system25
2 INSTALLATION .....................................26
2.1 Unpacking the product ........................26
2.1.1 Positioning of labels...........................26
2.2 Overall dimensions and weights .................26
2.3 Installation premises .......................... 27
2.3.1 Installation clearances ......................... 27
2.4 Installation in older systems and systems requiring
modernisation ............................... 27
2.5 Moving and removing the packing ................ 27
2.6 Thermal module assembly ......................28
2.7 Water connections ............................29
2.8 Typical water system schematics .................30
2.9 Gas connections .............................33
2.10 Combustion gas exhaust .......................33
2.10.1 Preparation for the condensate drain..............35
2.10.2 Water Chemistry Guidelines .....................35
2.11 System lling and emptying.....................36
2.11.1 Filling......................................36
2.11.2 Emptying ................................... 37
2.12 Wiring diagram ..............................38
2.13 Electrical connections .........................40
2.14 Electronic control .............................43
2.14.1 Menu structure ..............................44
2.14.2 Parameters' list ..............................50
3 CONFIGURATION OF THE MAIN BLOCK DIAGRAMS ..58
3.1 Conguration of the primary system ..............58
3.2 Conguration of the secondary system.............59
3.3 Block diagram 1 ..............................60
3.3.1 Electrical power connections Block diagram 1........60
3.3.2 Sensor connections Block diagram 1............... 61
3.3.3 Bus connections Block diagram 1 ................. 61
3.4 System parameters Block diagram 1 ............... 61
3.5 Block diagram 2 ..............................62
3.5.1 Electrical power connections Block diagram 2 .......62
3.5.2 Sensor connections Block diagram 2 ..............63
3.5.3 Bus connections Block diagram 2 .................63
3.6 System parameters Block diagram 2 ...............63
4 COMMISSIONING AND MAINTENANCE...............64
4.1 Initial startup ................................64
4.1.1 Switching the appliance on and off . . . . . . . . . . . . . . . 64
4.1.2 Date and time setting .........................64
4.1.3 Password access..............................65
4.1.4 Setting the heating parameters ..................65
4.1.5 Setting the domestic hot water parameters .........68
4.1.6 Scheduled programme.........................69
4.1.7 Thermal module information .................... 72
4.2 Checks during and after initial start-up ............ 73
4.3 Error List.................................... 74
4.3.1 Permanent Errors............................. 75
4.3.2 Temporary Errors .............................75
4.3.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4 Transformation from one gas type to another .......76
4.5 Adjustments.................................79
4.6 Temporary or short-term shut-down..............80
4.7 Preparing for extended periods of disuse...........80
4.8 Maintenance ................................ 81
4.8.1 "Service reminder" function..................... 81
4.9 Cleaning and removing internal components........82
4.10 Troubleshooting ..............................85

4
This manual, Code 20144490 - Rev. 0 (06/2018)
comprises 104 pages.
The following symbols are used in this manual:
9 CAUTION! = Identies actions that require caution and ad-
equate preparation.
0 STOP! = Identies actions that you MUST NOT do.
This manual, Code
- Rev.
comprises
pages.
5 SYSTEM MANAGEMENT ............................86
5.1 Communication between the thermal modules ......86
5.1.1 Setting the dip-switch .........................86
6 SETTING PARAMETERS OF THE CASCADE SYSTEMS87
6.1 Electronic control .............................87
6.1.1 Parameters specic to cascade systems . . . . . . . . . . . . 88
6.1.2 Setting the main parameters .................... 91
6.1.3 Par.73 – Managing, Stand-alone, Dependent mode. .. 91
6.1.4 Par.147 – No. thermal modules ................... 91
6.1.5 Par.7 – heating setpoint hysteresis . . . . . . . . . . . . . . . . 91
6.1.6 Par.97 – denition of the system with circulator / system
with two-way valve ........................... 91
6.1.7 General operation ............................ 91
6.2 Operation with the primary sensor................ 91
6.3 Operation with the secondary sensor.............. 91
6.4 Parameter 148: operating mode of the cascade ......92
6.4.1 Par 148 = 0 ..................................92
6.4.2 Par 148 = 1 ..................................92
6.4.3 Par 148 = 2 ..................................93
7 SYSTEM MANAGER ................................94
7.1 Commissioning ..............................94
7.2 Temporary or short-term shut-down..............95
7.3 Preparing for extended periods of disuse...........95
7.4 Cleaning....................................95
7.5 Maintenance ................................95
7.6 Useful information ............................96
8 MODBUS CONNECTION.............................97
9 COMMISSIONING LOG FOR THE APPLIANCE........101
10 RECYCLING AND DISPOSAL .......................103

5
GENERAL INFORMATION
1 GENERAL INFORMATION
1.1 General Safety Information
9 Check that the product is complete, undamaged and as or-
dered as soon as you receive it. Report any discrepancies or
damage to the Rdealer who sold it.
9 The boiler must be installed by a qualied heating engineer.
UPON COMPLETION OF THE INSTALLATION THE INSTALLER MUST
INSTRUCT THE OWNER AND OPERATOR ON THE FUNCTIONALITY
AND THE PROPER OPERATION OF THE BOILER AND THE HEATING
SYSTEM.
THIS MANUAL SHOULD BE HANDED TO THE OWNER AND
OPERATOR OF THE APPLIANCE.
INSTALLER MUST REVIEW ALL SAFETY INSTRUCTIONS WITH THE
OWNER AND OPERATOR.
The installation instructions included in this Manual
are intended solely for use by a trained and certied
installer, service company or the gas supply company. If
the information in this manual is not followed, a re or
explosion may result causing property damage, personal
injury, or death.
−Have installation and service performed by a trained and
certied installer or service company, or the gas supply
company.
−Rrecommends signing a service and maintenance con-
tract with a trained and certied installer or service com-
pany that covers annual servicing and condition-based
maintenance. Proper maintenance is a fundamental re-
quirement for safe and efcient operation and long service
life.
−The boiler must be serviced annually including the main
burner, ignition system, the entire venting system, and
the combustion air supply. All parts that show any signs of
damage or corrosion must be replaced.
−The owner and operator is responsible for the operational
safety and regulatory compliance of the heating system.
−Improper installation, adjustment, alteration, service, or
maintenance can cause property damage, personal injury,
or death. Refer to this manual and consult a trained and
certied installer or service company, or the gas supply
company before installation, service or maintenance.
9 This product must only be used for the purpose for which it
is designed and made, as specied by R. Rdeclines all
responsibility, contractual or other, for damage to property or
injury to persons or animals caused by improper installation,
adjustment, maintenance or use.
9 If you notice any water leaks, disconnect the boiler from the
mains electricity supply and shut off the water supply.
9 Periodically check that pressure in the central heating circuit,
when cold, is approximately 20 psi and below the maximum
limit specied for the boiler.
9 If the boiler is not going to be used for an extended period of
time, perform the operations described later in this manual.
9 This instruction manual is an integral part of the boiler. It must
be kept safe and must ALWAYS accompany the boiler, even if it
is sold to another owner or transferred to another user or to
another installation. If you damage or lose this manual, order
a replacement immediately from your local RTechnical As-
sistance Centre.
9 The equipment, before being connected to the hydraulic sys-
tem and to the gas supply and being electrically powered can
be exposed to temperatures ranging between 39°F and 104°F.
Once it is able to activate the antifreeze functions, it can be
exposed to temperatures within -4°F and 104°F.
9 Regularly check that the condensate drain is free from ob-
struction.
9 We recommend cleaning inside the exchanger once a year,
extracting jet and burner and removing any installation debris
by suction. This operation will be done by personnel from the
Technical Assistance Service only.
1.2 Precautions
The operation of any appliance that uses fuel, electrical power
and water demands that a number of fundamental safety pre-
cautions be respected:
0 Do not allow children or inrm persons to operate the system
unsupervised.
0 It is forbidden to use electrical devices or equipment, such as
switches, appliances, etc. if there is a smell of gas or un-burnt
products. If so:
−Ventilate the room, opening doors and windows
−Close the fuel shut-off cock
−Report the fault immediately to the R's Technical Assis-
tance Service or a professionally qualied heating engineer.
0 Do not touch the boiler while barefoot or wet.
0 Any technical or cleaning activity is forbidden before discon-
necting the appliance from the main power supply by switch-
ing the system's master switch and the appliance's main
switch to the "OFF" position.
0 Do not tamper with or adjust the safety or control devices
without prior authorisation and instructions from the man-
ufacturer.

6
GENERAL INFORMATION
0 Do not plug or block the condensate drain outlet.
0 Never pull, disconnect, or twist the electrical cables coming
from the appliance even if it is disconnected from the mains
electricity supply.
0 Do not obstruct or restrict the vents in the room where the
boiler is installed. Adequate ventilation is essential for correct
combustion.
0 Do not expose the appliance to weather elements (without
using the dedicated accessory). It has been designed for in-
door use.
0 Do not switch off the appliance if the outdoor temperature
may drop to below 32°F (frost hazard).
0 Do not leave ammable containers and substances in the
room where the device is installed.
0 Do not dispose of packaging material into the environment, or
leave it within the reach of children, since it can become a po-
tential hazard. Dispose of packaging material in compliance
with applicable legislation.
0 Do not activate the thermal module without water.
0 Individuals without specic qualications and skills are not
allowed not remove the thermal module's casing.
If you hear gas leaking
−Leave the building immediately.
−Prevent others from entering the building.
−Notify the police and re department from outside the
building.
−From outside the building, call the gas supply company
and a trained and certied installer or service company.
If you smell gas
−Turn off the gas shut-off valve.
−Open windows and doors
−Do not touch any electrical switch, telephone, and do not
use outlets.
−Extinguish all open ames.
−Do not smoke!
−Do not use lighters!
−Warn all occupants of the building that they need to leave
the building.
−Do not ring doorbells!
−Notify the police and re department from outside the
building.
−From outside the building, call the gas supply company
and a trained and certied installer or service company.
If you smell ue gas
−Switch off the appliance.
−Open windows and doors.
−Inform a trained and certied heating contractor.
9 DANGER: Risk of fatal injury from failing to consider your own
safety!
−Never risk your own life. Your own safety must always take
the highest priority.
9 NOTICE: Risk of appliance damage from improper operation
of the boiler!
−Only use the boiler for its intended purpose.
−Only operate the boiler if it has been installed and main-
tained per the instructions provided in the Installation
Manual.
−Do not attempt to operate an appliance if any part of it is
not in working order or is damaged.
−Use only original spare parts! The use of parts not supplied
by the manufacturer may cause damage to the boiler, other
property and personal injury. Also, boiler damage caused
by the use of unauthorized parts is not covered by the war-
ranty.
9 DANGER: Risk of re when soldering and brazing!
−Take appropriate protective measures when soldering and
brazing around combustible and ammable material.
9 NOTICE!
−The installation must comply with all applicable national,
state, and local codes, rules, and regulations.
−The operator is responsible for the operational safety and
regulatory compliance of the heating system.
−In the Commonwealth of Massachusetts, the appliance
must be installed by a licensed plumber or gas tter.
9 DANGER: Risk of personal injury or death from ue gas poi-
soning!
−Do not install a thermostatic ue gas damper downstream
of the draft hood.
−Do not tamper with, remove, or attempt to repair the
blocked vent switch.
−When replacing the blocked vent switch, install the new
part in the original location.
−A blocked vent switch tripping more than once indicates a
problem with the venting system or chimney which must
be repaired immediately.
−Ensure none of the vent pipes and chimneys are damaged
or blocked.
−Connect only one appliance to each venting system or
chimney.
−The venting system must not feed into or route through an-
other air extraction duct.
−The venting system must be inspected annually. All parts
that show any signs of damage or corrosion must be re-
placed.
−Never close off or reduce the size of the combustion air
openings.
−The boiler must not be operated until any obstructions
have been removed.
9 DANGER: Risk of personal injury or death from explosion!
−Work on gas components may only be carried out by a
trained and certied installer or service company.
−Appliance installation, the connection of gas and vent pip-
ing, initial commissioning, electrical connections and ser-
vice and maintenance must only be carried out by a trained
and certied installer or service company.
9 DANGER: Risk of personal injury or death from re!
−Do not use ammable or combustible material in the boiler
room.
−It is recommended not to store any items within 16 inches
(415mm) of the appliance.

7
GENERAL INFORMATION
9 CAUTION: Appliance damage from contaminated combustion
air!
−Keep the combustion air free of corrosive substances, e.g.
halogenated hydrocarbons from painting operations or
beauty salons.
−Keep combustion air free from dust and lint, e.g. from
laundry or agricultural operations.
−If clean room air is not available, fresh outdoor combustion
air must be provided.
9 DANGER: Risk of personal injury or death from electric shock!
−Before removing the front panel, disconnect the heating
system from the electrical power supply by shutting off
the emergency shutoff switch or the heating system circuit
breaker.
−It is not enough to switch off the control panel. Power to
the panel must be disconnected! Ensure that the power is
not restored unintentionally by following proper lock out/
tag out procedures.
−Only qualied electricians are permitted to carry out elec-
trical work.
9 DANGER: Safety devices!
−Never shut off safety valves!
−Hot water may escape from the safety valve at any time
when the appliance is running.
9 DANGER: Risk of personal injury or death after a ood!
−Do not attempt to operate an appliance if any part of it has
been under water.
−An appliance that was subject to ooding must be re-
placed.
9 NOTICE!
−Upon completion of the installation, these instructions
should be handed to the owner and operator of the ap-
pliance.
−The installer must instruct the owner and operator on the
functionality of the components and the proper operation
of the boiler and the heating system.
−The boiler must be serviced annually including the main
burner, ignition burner, the entire venting system, and
the combustion air supply. All parts that show any signs of
damage or corrosion must be replaced.
1.3 Description of the appliance
Condexa PRO NA it is a condensing, pre-mixed thermal module
consisting in a modulating thermal element.
It's available in two models of power: 75 kW (255,900 BTU/hr) and
117 kW (399,000 BTU/hr)
Optimal combustion management supports high yields (over
109%, calculated over NVC, in condensation regime) and low pol-
luting emissions.
The thermal module is designed for sealed chamber operation.
The appliance in standard conguration is envisaged for indoor
installation to guarantee an IPX4D protection level. The appliance
may also be installed outdoors by tting a special accessory that
increases its electric protection to IPX5D.
9 Appliances may be cascaded Condexa PRO NA to reach a max-
imum power of 700 kW (2,388,500 BTU/hr).
The appliance's key technical features are
−helicoidal heat exchanger with double coil with smooth
stainless steel pipe, to guarantee good corrosion resistance
and the option of operating with high ∆ts (up to 104°F), re-
ducing system set-up times;
−maximum exhaust ue exit temperature 212°F;
−microprocessor management and control with self-diag-
nostics, shown by means of a display, and logging of main
errors;
−Anti-Frost function;
−pre-setting for room/heat demand thermostat for low and
high temperature ranges;
−option to manage a CH circuit and a DHW circuit with stor-
age tank;
−high-efciency and high residual discharge head circula-
tor;
−climate control function (available only when using the
outdoor temperature sensor accessory).

8
GENERAL INFORMATION
1.4 Safety devices
All appliance functions are electronically controlled by a dual pro-
cessor technology board approved for safety functions.
Any malfunction results in the appliance being shut down and the
automatic closure of the gas valve.
The following is installed on the water circuit:
−Safety thermostat.
−Flow sensor capable of monitoring the main circuit's ow
on an ongoing basis and of stopping the appliance in the
event of insufcient ow.
−Temperature probes on delivery and return lines that mea-
sure the temperature difference (∆t) between input and
output uid and enable activation of the control.
−Minimum pressure switch.
The following is installed on the combustion circuit:
−Gas solenoid with pneumatic gas ow compensation de-
pending on the suction line's air ow rate.
−Ignition/detection electrode.
−Flue gases temperature probe.
9 The triggering of safety devices indicates the malfunction of
a potentially hazardous thermal module. Therefore, contact
Technical Assistance Service immediately. After a brief pause,
it is possible to try and restart the appliance (see Paragraph "
Initial startup").
9 Safety devices must be replaced by Technical Assistance Ser-
vice, using only original parts. Refer to the spare parts cata-
logue supplied with the appliance. After making the repair,
check that the appliance is working properly.
0 The appliance must not be put in service, even temporarily,
when tampered safety devices are not in operation or have
been tampered with.
1.5 Identication
The products are identied by:
2
Gross output
Net IBR rating
Certified by RIEL
_____________________
LO S.p.A. (ITALY)
_____________________
EVOBA
FRONT
_____________________
_____________________
MINIMUM CLEARANCES TO COMBUSTIBLE CONSTRUCTION
FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY
ALL OF THE INSTRUCTIONS MUST BE FOLLOWED EXACTLY
_____________________
_____________________
_____________________
_____________________
SIDES
AND REAR
DRAFT HOOD
VENT CONNECTOR
BAROMETRIC DAMPER
4
” ( )
r
kW
Mbtu/hr
Mbtu/h
CHIMNEY CONNECTOR
Mo
____
del
bar kPa psi
°F°C
m
kg/h lb/hr
Mbtu/hr
kW
gph=xaMhpg
kW /
kW
MAWP Water
Maximum water temp.
Heating surface
Minimum relief valve capacity
Electrical rating (burner)
SERIAL NUMBER
mm
)
mm
18” (457
mm
)
Less than 12 Amperes
Min. & Max. input gas:
18” (457
mm
)
2
6
” (
152
610
::roferusserPtelnI
Design Manifold Pressure for: NG ___ "
wc to ___ "wc or LP ___"wc to ___ "wc
SQ FT
NG ___ " wc to ___ "wc or LP ___"wc to ___ "wc
Min =
Min. & Max. input oil: Min =
Max =
/Mbtu/h
r
Year built:
________ _________
Approved for use with Natural Gas (NG), Liquid Petroleum Gas (LPG), and/or
fuel oil not heavier than # 2 per ASTM D396.
Consult the Installation Manual for approved boiler and burner combinations.
,
Data plate
This lists the technical specications and performance of the
product. This is supplied inside the document bag and MUST BE
APPLIED to the boiler by the installer on completion of instal-
lation. If you damage or lose this label, order a replacement
immediately from Technical Assistance Service.
9 If these plates or any other means of clearly identifying the
product are defaced, removed or lost, proper installation and
servicing may be rendered difcult.

9
GENERAL INFORMATION
1.6 System layout
Condexa PRO NA 75 P
4
3
24
23
22
17
5
6
10
16
2
1
4
5
6
7
8
10
9
26
25
24
23
22
21
20
19
16
15
11
12 13 14
3
18
17
1 Flue gas exhaust connection
2 Exhaust ue probe
3 Gas valve
4 Fan
5 Combustion chamber
6 Electrical panel
7 Smoke-exhaust ue non-return valve
8 Drain cock
9 Minimum Pressure Switch set at 0,5 bar
10 Pump
11 Main switch
12 Central heating return
13 Gas supply
14 Central heating supply
15 Condensate drain connection
16 Flow-meter
17 Intake pressure for ue gas pressure switch
18 Return probe
19 Flue gases pressure switch
20 Control panel
21 Ignition/detection electrode
22 Safety Thermostat with manual reset by PCB
23 Flow probe
24 Automatic bleed valve
25 Ignition transformer
26 Casing

10
GENERAL INFORMATION
Condexa PRO NA 117 P
26
25
20
10
24
23
22
2
1
3
4
5
6
7
8
14
131211
21
19
18
17
16
15
9
1
3
4
5
15
24
18
23
1 Flue gas exhaust connection
2 Exhaust ue probe
3 Fan
4 Combustion chamber
5 Electrical panel
6 Smoke-exhaust ue non-return valve
7 Drain cock
8 Minimum Pressure Switch set at 0,5 bar
9 Pump
10 Main switch
11 Central heating return
12 Gas supply
13 Central heating supply
14 Condensate drain connection
15 Flow-meter
16 Gas valve
17 Intake pressure for ue gas pressure switch
18 Return probe
19 Flue gases pressure switch
20 Control panel
21 Ignition/detection electrode
22 Safety Thermostat with manual reset by PCB
23 Flow probe
24 Automatic bleed valve
25 Ignition transformer
26 Casing