Riello Condexa PRO Series User manual

A Carrier Company
Condensing generators
Condexa Pro
Wall-hung gas condensing modules
Stand alone installation
In conformity with Directive 2009/125/EC
Condensing thermal modules for indoor applications
Modular design to ensure an easy and fast installation
Low polluting emissions, Class 6 (DIN EN 15502)

2
CONDENSING GENERATORS
Wall-hung gas condensing modules
Condexa Pro
PRODUCT OVERVIEW
Condexa PRO is the new Riello proposal as a modular condensing wall-hung system, capable to ensure extremely high
performance levels and to cover a wide range of applications for indoor installation, with sealed combustion; stand alone or
cascade configurations are possible with heat outputs up to 970 kW.
The range consists of 3 models with thermal modules from 45 up to 97 kW. 70 P and 100 P models are equipped with the innovative
heat exchanger with patented geometries, consisting of two smooth concentric stainless steel pipes, each having a pentagonal
inner section and a circular outer section, designed to maximize the exchange surface and offer maximum corrosion resistance.
The 50 P model is equipped with an helical, single principle exchanger, with a “P” shaped cross section.
The primary circuit pump with modulating regulation allows working with a settable constant DT, reducing set-up plant
regime times and maximizing condensation. The basic electronics include climate control, module cascade management, with
integrated master / slave functions, automatic summer / winter switching and the possibility of managing both a direct zone
and a DHW tank.
The electronics also offers the possibility of remote management via 0-10V input or with the Modbus protocol. Standard
equipment includes: boiler drain tap, safety valves, LPG conversion kit, wall support and the condensate drain syphon. Through
appropriate accessories there is also the possibility of managing the distribution of the secondary circuit, up to 16 mixed zones.
The optimal combustion management and the high modulation ratios from 1 up to 50 for the cascade installations with 10
thermal modules allow high efficiencies and low pollutant emissions (Class 6, UNI EN 15502-1).
– Service continuity is guaranteed by the system modularity: even in the case of a module failure, the overall operation it is
not prejudiced;
– The anti-freeze and anti-seize functions ensure operation in all weather conditions
– Maximum operating pressure: 3 bar
– A wide range of accessories is available to ensure a simple, fast and complete cascade installation.

3
Condexa Pro
CONDEXA PRO 50 P - 70 P - 100 P
TECHNICAL DATA
MODEL CONDEXA PRO
50 P
CONDEXA PRO
70 P
CONDEXA PRO
100 P
Material Steel Steel Steel
Efficiency class > 93 + 2 log Pn > 93 + 2 log Pn > 93 + 2 log Pn
Fuel NG-LPG NG-LPG NG-LPG
Test room temperature °C 20 20 20
Max. rated heat input at furnace (LCV) kW 45,0 68,0 97,0
Min. rated heat input at furnace (LCV) kW 9,0 14,0 19,4
Max. rated heat output (80-60°C) kW 44,2 67,0 95,2
Min. rated heat output (80-60°C) kW 8,9 13,5 19,2
Max. rated heat output (50-30°C) kW 48,8 72,9 105,1
Min. rated heat output (50-30°C) kW 9,9 14,9 21,1
Efficiency at max. rated heat output (80-60°C) %98,3 97,9 98,1
Efficiency at min. rated heat output (80-60°C) %98,9 98,9 98,8
Efficiency at max. rated heat output (50-30°C) %108,6 108,1 108,2
Efficiency at min. rated heat output (50-30°C) %109,7 109,3 109,2
Useful efficiency at 30% %109,2 108,8 109,0
Heat loss in standby mode %0,1 0,1 0,1
Chimney losses with burner on at P.max %2,3 2,3 2,6
Chimney losses with burner on at P.min %0,1 0,1 0,2
Blanket losses with burner on with 70°C average
Temperature %1,1 0,9 0,9
Blanket losses with burner off with 70°C average
Temperature %1,1 0,9 0,9
Flue gas temperature at max. and min. power 80-60°C °C 67,5 / 61,0 72,0 / 61,0 78,0 / 62,0
Flue gas temperature at max. and min. power 50-30°C °C 45,0 / 32,0 46,0 / 33,0 49,0 / 35,0
Excess air at max.power 1,27 1,27 1,27
Excess air at min.power 1,27 1,27 1,27
Max-min flue gas mass flow rate kg / s 0,0200-0,0050 0,0300-0,0070 0,0460-0,0072
Available useful discharge head P.max Pa 480 630 610
Available useful discharge head P.min Pa 45 35 32
Flue side pressure drop mbar --- --- ---
NOx mg/kWh 43,9 36,4 38,7
Water-side resistance (DT 20°C) mbar --- --- ---
Available useful discharge head (DT 20°C) mbar 250 390 350
Water-side resistence (DT 10°C) mbar --- --- ---
Available useful discharge head (DT 10°C) mbar --- --- ---
Water content l 5 15 17
Maximum working pressure bar 333
Expansion tank capacity l--- --- ---
Power supply V/Hz 230-50 230-50 230-50
Electrical protection level IP IPX4D IPX4D IPX4D
Electrical consumption with boiler at max. power W200 175 345
Electrical consumption with boiler at min. power W34 30 31
Electrical consumption with pumps at max. power W--- --- ---
Electrical consumption with pumps at min. power W--- --- ---
Flue gas discharge diameter mm 80 80 110
Empty weight kg 66 78 81
Category according to UNI 10642 II 2H3P appliance II 2H3P appliance II 2H3P appliance
Boiler water content l--- --- ---
Boiler losses W / K --- --- ---
Boiler material --- --- ---
Insulation thickness mm --- --- ---
Boiler circulator absorption W--- --- ---
Sanitary expansion vessel l--- --- ---
Noise dB(A) 52 54 56
Nominal/min natural gas pressure supply (G20) mbar 20 / 17 20 / 17 20 / 17
Nominal/min natural gas pressure supply (G31) mbar 37 / 25 37 / 25 37 / 25

4
CONDENSING GENERATORS
Wall-hung gas condensing modules
ErP TECHNICAL DATA
MODEL CONDEXA PRO
50 P
CONDEXA PRO
70 P
CONDEXA PRO
100 P
Seasonal efficiency class in
central heating mode A A ---
Seasonal efficiency class in water heating --- --- ---
Useful (rated) heat output Pn kW 44,2 68 95
Seasonal efficiency class in room heating mode ηs%94 94 94
USEFUL THERMAL POWER
At useful heat output and at high temperature capacity
(*) P4 kW 44,2 67 95,3
At 30% of useful heat output and at low temperature
capacity (**) P1 kW 14,7 22,3 31,7
EFFICIENCY
At useful heat output and at high temperature capacity
(*) η4%88,4 88,2 88,2
At 30% of useful heat output and at low temperature
capacity (**) η1%98,2 98,0 98,0
AUXILIARY ELECTRICAL CONSUMPTION
At full load elmax W105 77 203
At partial load elmin W34 30 31
In standby mode PSB W 9 13 6
OTHER PARAMETERS
Thermal losses in Stand-by mode Pstby W57,0 87,0 124,0
Pilot flame energy consumption Pign W--- --- ---
Yearly energy consumption QHE GJ 91 141 ---
Noise level, indoor (sound power) LWA dB 52 54 56
Nitrogen oxide emissions (NOx) NOx mg/kWh 43,9 36,4 38,7
FOR COMBINED HEATING EQUIPMENT
Declared load profile
Energy efficiency class in water heating ηwh %--- --- ---
Daily electrical energy consumption Qelec kWh --- --- ---
Daily fuel consumption Qfuel kWh --- --- ---
Annual electrical energy consumption AEC kWh --- --- ---
Annual fuel consumption AFC GJ --- --- ---

5
Condexa Pro
BOILER MODELS CONDEXA
PRO 50 P
CONDEXA
PRO 70 P
Condexa
PRO 100 P
MAXIMUM THERMAL POWER
Useful (80/60°C) kW 44,2 67 95,2
Useful (50/30°C) kW 48,8 73,9 105,1
Furnace kW 45,0 68 97
MINIMUM THERMAL POWER
Useful (80/60°C) kW 8,9 13,5 19,2
Useful (50/30°C) kW 9,9 14,9 21,1
Furnace kW 9,0 14 19,4
EFFICIENCY
Useful (80/60°C) %98,34-
98,9 98,1-98,9 98,1-98,8
Useful (50/30°C) %108,6-119,7 108,1-109,3 108,2-109,2
With reduced load 30% (return 30°C) % 109,2 109 109
COMBUSTION
Chimney and blanket losses with
burner on %2,3-1,1 2,3-0,9 2,6-0,9
Chimney losses with burner off %0,1 0,1 0,1
Flue flow rate kg / s 0,020 0,03 0,046
GAS EMISSION VALUES AT MAX AND MIN FLOW RATES G20 (**)
MAXIMUM
CO s.a. less than (***) ppm 73 90 92
CO2% 9 9 9
NOx (EN 677) (***) ppm 30 30 30
Flue temperature °C 67,5 72 78
DT flue - return water K 7,50 12 18
MINIMUM
CO s.a. less than (***) ppm 2,3 6,5 7,5
CO2% 9 9 9
NOx (EN 677) (***) ppm 30 30 30
Flue temperature °C 61 61 62
DT flue - return water K 1 1 2
NOx class 6 6 6
Electric power: circulator, total 105 77 203
(**) Verification carried out with concentric pipe Ø 60-100 mm length 0.85 m; water temperatures 80-60 °C.
(***)Graphs for intermediate power values are also available. The expressed data must not be used to certify the plant; for certification the data
indicated in the "installation manual" measured at the time of the first ignition must be used.
LAW TABLE 10

6
CONDENSING GENERATORS
Wall-hung gas condensing modules
OVERALL DIMENSIONS
LP
H
Fumi Aria (opz)
Ritorno
G 1” 1/2
Gas
G 1”
Mandata
G 1” 1/2
Scarico condensa
Ø 24 mm
Ø Ø
96 92
96
92
SYSTEM LAYOUT
Condexa PRO 50 P
Commercial
description
H
mm
L
mm
P
mm
Ø fumes/
air
mm
Net
weight
kg
CONDEXA PRO 50 P 1000 600 435 80 66
CONDEXA PRO 70 P 1000 600 435 80 78
CONDEXA PRO 100 P 1000 600 435 110 81
Fumes Air (acc)
1
3
6
23
22
24
7
17
9
2
5
4
1
2
3
4
6
5
7
8
10
9
11
24
21
22
23
25
17
18
19
20
16
13 14 1512
1 烟气分析检测口
2 烟气排气管
3 燃气阀
4 风机
5 烟气压差开关
6 燃烧室
7 主控板
8 最小压力开关(0.7 bar)
9 烟气温度传感器
10 冷凝水收集器
11 排水阀
12 电源开关
13 采暖回水口
14 燃气供气管
15 采暖供水管
16 冷凝水排放管
17 流量传感器
18 循环泵
19 回水温度传感器
20 控制面板
21 过热保护（需手动复位）
22 流量传感器
23 自动排气阀
24 点火/火焰检测电极
25 外壳

7
Condexa Pro
Condexa PRO 70 P
Condexa PRO 100 P
1
4
5
6
10
16
2
20
21
22
3
15
1211 13 14
1
2
3
4
5
6
7
8
9
10
21
19
20
22
23
16
18
24
17
1 烟气分析检测口
2 烟气排气管
3 燃气阀
4 风机
5 燃烧室
6 主控板
7 烟气止回阀
8 排水阀
9 最小压力开关（0.7bar）
10 循环泵
11 电源开关
12 供暖回水管
13 燃气供气管
14 采暖供水管
15 冷凝水排放管
16 流量传感器
17 烟气温度传感器
18 回水温度传感器
19 控制面板
20 点火/火焰检测电极
21 过热保护（需手动复位）
22 流量传感器
23 自动排气阀
24 外壳
109 11 12
1
2
3
4
5
6
7
8
18
22
14
20
19
21
16
15
17
23
1
3
4
5
14
2
20
21
13
24
1 烟气分析检测口
2 烟气排气管
3 风机
4 燃烧室
5 主控板
6 烟气止回阀
7 排水阀
8 最小压力开关（0.7−bar）
9 电源开关
10 供暖回水管
11 燃气供气管
12 采暖供水管
13 冷凝水排放管
14 流量传感器
15 燃气阀
16 烟气温度传感器
17 回水温度传感器
18 控制面板
19 点火/火焰检测电极
20 过热保护（需手动复位）
21 流量传感器
22 自动排气阀
23 外壳
24 循环泵

8
CONDENSING GENERATORS
Wall-hung gas condensing modules
HYDRAULIC CIRCUIT
1. Heat exchanger
2. Circulator
3. Drain tap
4. Minimum pressure switch
5. NTC return probe
6. NTC flow probe
7. Safety thermostat temperature sensor
8. Automatic bleed valve
9. Flow meter
F Central heating flow
R System return
2
9
MR
1678
3
4
5
CIRCULATORS
0
100
200
300
400
500
600
700
800
900
1000
1100
0 1,5 2 2,5 3 3,510,5 4 4,5 5
Condexa PRO 50 P
Condexa PRO 70 P
Condexa PRO 100 P

9
Condexa Pro
Vista frontale
Vista inferiore
RF
B
A
F
H
C
D
E
RG F
CD
HYDRAULIC CONNECTIONS AND FUMES DISCHARGE
The dimensions and position of thermal module's hydraulic connections are shown in the table below.
DESCRIPTION Condexa PRO
50 P 70 P 100 P
Amm 387 387 387
Bmm 143,5 143,5 143,5
Cmm 63,5 63,5 63,5
Dmm 283,5 283,5 283,5
Emm 98,5 98,5 98,5
Fmm 92,5 92,5 92,5
H(optional 3-way
valve connection)
mm 202,5 - -
F(System flow) ØG 1 ”1/2 M G 1 ”1/2 M G 1 ”1/2 M
R(System return) ØG 1 ”1/2 M G 1 ”1/2 M G 1 ”1/2 M
CD (condensate drain) Ø mm 25 25 25
GGas input ØG 1" M G 1" M G 1" M
Front view
Bottom view

10
CONDENSING GENERATORS
Wall-hung gas condensing modules
WATER IN THE PLANT
Before connecting the thermal module, it is necessary to clean the system. This step is absolutely required when the appliance
replaces another one on pre-existing systems.In order to carry out this cleaning activity, if the old generator is still installed
on the system, it is advisable to:
• Add a de-scaling additive.
• Operate the system with the generator on for around 7 days.
• Discharge dirty system water and flush the system one or more times with clean water.
If the system is very dirty, repeat the last procedure one more time.In case of new installation or if the old generator is not
present or available, use a pump to circulate the additive water in the system for about 10 days and carry out the final washing
as described in the previous paragraph.
Once the cleaning has been completed, it is recommended to add a suitable protective fluid to the system's water before
installing the thermal module.
Do not use incompatible liquid detergents, including acids (eg chloridric acid and similar) in any concentration.
Do not subject the exchanger to cyclical pressure variations because the fatigue stress is very dangerous for the integrity of the
system components.
Sludge, limestone and contaminants present in the water can lead to irreversible damage to the heat generator, even in short
times and regardless of the quality level of the materials used.
The quality of the water used in the heating system must comply with the following parameters:
Parameters Value Unit
General characteristic Colorless, without sediment
PH value Min 6.5; Max 8 PH
Dissolved oxygen <0.05 mg / l
Total iron (Fe) <0.3 mg / l
Total Copper (Cu) <0.1 mg / l
Na2SO3 <10 mg / l
N2H4 <3 mg / l
PO4 <15 mg / l
CaCO3 Min 50; Max 150 ppm
Trisodium phosphate None ppm
Chlorine <100 ppm
Electrical conducibility <200 microsiemens / cm
Pressure Min 0.6; Max 6 bar
Glycol Max 40% (only propylene glycol) %
All the data in the table refer to the water contained in the system after 8 weeks' operation.
Do not use excessively softened water. Excessive water softening (total hardness < 5° f) results in corrosion due to contact with
metal elements (pipes or thermal module components).
Immediately repair any leaks or drips that could result in air entering the system.
Excessive pressure fluctuations can cause stress and fatigue to the heat exchanger.
Maintain a constant operating pressure.
Water used to fill a system for the first time and water used to top it up must always be filtered (using synthetic or metal mesh
filters with a filtration rating of no less than 50 microns) to prevent sludge from forming and triggering deposit corrosion. If
oxygen enters a circuit continuously or even intermittently (e.g. in under-floor heating systems whose pipes are not protected
by impermeable synthetic sheaths, in circuits with open expansion vessels, or in circuits that require frequent top-ups) always
separate the boiler’s water circuit from the central heating circuit.
It is prohibited to top up the heating system constantly or frequently, since this can damage the thermal module's heat
exchanger. The use of automatic topping up systems should be avoided for this reason.
To sum up, in order to eliminate contact between air and water (and to prevent the latter from becoming oxidized), it is
necessary:
• that the expansion system be a closed vessel, correctly sized and with the correct pre-loading pressure (to be regularly
checked);
• that the system be always at a pressure higher than the atmospheric one at any point (including the pump suction side)
and under any operating conditions (all seals and hydraulic couplings in a system are designed to withstand pressure
towards the outside, but not underpressure);
• the installation be not made with gas-permeable materials (e.g. plastic pipes without oxygen barrier for underfloor
heating systems).
Damages suffered by the thermal module, caused by encrustations and corrosion, are not covered by warranty.