Riello RSS R Manual

cod. 20124623 rev. 2 09/2018
1
2
3
4
5
0 6
RSS R
EN INSTALLATION AND MAINTENANCE MANUAL

2
GENERAL INFORMATION
This manual, Code 20124623 - Rev. 2 (09/2018)
comprises 16 pages.
GENERAL INFORMATION
RANGE
MODEL CODE
RSS R 20116168
Dear heating engineer,
We would like to congratulate you on having recommended a
Rsolar station unit: a modern product that's capable of en-
suring a high degree of reliability, efciency, quality and safety.
While your technical skills and knowledge will certainly be more
than sufcient, this booklet contains all the information that
we have deemed necessary for the device's correct and easy in-
stallation.
Thank you again, and keep up the good work,
Riello S.p.A.
CONTENTS
ENGLISH
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 This product must be installed by a legally qualied heat-
ing engineer. On completion of the installation, the install-
er must issue the owner with a declaration of conformity
conrming that the installation has been completed to the
highest standards in compliance with the instructions pro-
vided by Rin this instruction manual, and that it con-
forms to all applicable laws and standards.
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 prop-
erty or injury to persons or animals caused by improper in-
stallation, adjustment, maintenance or use.
9 The product must be serviced at least once a year. Servicing
must be arranged in advance with the RTechnical Assis-
tance Service.
9 All servicing and repairs must be performed by a qualied
heating engineer.
9 This instruction manual is an integral part of the product. It
must be kept safe and must ALWAYS accompany the product,
even if it is sold to another owner or transferred to another
user or to another installation. If you lose this manual, or-
der a replacement immediately. Keep the product purchase
documents to be presented to the Rauthorised Technical
Assistance Service to request a service call under warranty.
9 Size the solar expansion tank so as to ensure complete ab-
sorption of the expansion of the uid contained within the
system, with reference to the prevailing regulations on the
matter. In particular, consider uid characteristics, consid-
erable uctuation of service temperature and vapour that
might be generated during solar collector stagnation stage.
Proper size of expansion tank ensures setting off of all vol-
ume changes of the heat transfer uid, avoiding excessive
pressure increase. Limited pressure changes avoid reach-
ing safety valve opening pressure and the consequent uid
drainage.
At the end of its life, the product should be
not be disposed of as solid urban waste,
but rather it should be handed over to a
differentiated waste collection centre.
Generalinformation
The following symbols are used in this manual:
9 CAUTION! = Identies actions that require caution and
adequate preparation.
0 STOP! = Identies actions that you MUST NOT do.
Thismanual,Code
-Rev.
comprises
pages.
GENERAL INFORMATION
1 General Safety Information ......................2
2 Precautions..................................3
3 Description of the appliance .....................3
4 Safety and control devices.......................3
5 Identication ................................3
6 System layout ................................4
7 Technical specications.........................4
INSTALLATION
8 Unpacking the product .........................5
9 Installation premises ..........................5
10 Assembly ...................................5
11 Water connections ............................6
12 Pump controller ..............................6
13 Electrical connections ..........................8
COMMISSIONING AND MAINTENANCE
14 System ushing ..............................9
15 System lling cock............................ 10
16 Device cleaning and maintenance ................11
17 Interventions on the hydraulic system .............11
18 Recycling and disposal ........................ 12

3
GENERAL INFORMATION
GENERAL INFORMATION
2 PRECAUTIONS
The operation of any appliance that uses electrical power de-
mands that a number of fundamental safety precautions be re-
spected. In particular:
0 Never attempt to install the system without using suitable
personal protection equipment and without following all
applicable occupational safety standards.
0 It is forbidden to touch the device while barefoot or with
wet or moist body parts.
0 It is forbidden to perform any technical or cleaning opera-
tions before having disconnected the device from its elec-
trical power supply, by setting the system's main switch to
"off".
0 It is forbidden to pull, detach, or twist the electrical cables
protruding from the device, even if it is disconnected from
its electrical power supply.
0 Do not expose the storage cylinder to the elements. It is not
designed for use outdoors.
0 If solar plant pressure decreases, it is forbidden to top up
with only water as there is a danger of freezing and over-
heating.
0 Do not use connections or safety devices or ttings (expan-
sion vessels, pipes, insulation) that are not specically de-
signed and tested for use in solar water heating systems.
0 Do not allow children or inrm persons to operate the sys-
tem unsupervised.
0 Do 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 com-
pliance with applicable legislation.
3 DESCRIPTION OF THE APPLIANCE
The solar station RSS R allows transferring sun power from col-
lectors to a storage system.
The solar station Ris enclosed in an EPP (Polypropylene foam)
insulating casing and is designed to perform:
−system ushing
−system lling and emptying
−circulator removal.
The key components are:
−high-efciency circulator running at xed or variable
speed
−non-return shut-off valve
−thermometer
−pressure gauge
−tting for connection to a solar expansion tank
−suitable safety device, as indicated in paragraph "Safety
and control devices"
−ow-meter with ow-rate regulator.
4 SAFETY AND CONTROL DEVICES
The solar station safety is ensured by a safety valve with inter-
vention pressure of 6 bar.
5 IDENTIFICATION
The solar stations by R can be identied by:
Serial number plate
This species the serial number and model.
Cod. :
Via Ing. Pilade Riello 7 - 37045 Legnago (VR) - Italia
RIELLO S.p.A.
TqelRI100
Serial N.° :
Mod. :
MAX W
IP Pmax bar
Made in Italy
9 If these plates or any other means of clearly identifying
the product are defaced, removed or lost, proper instal-
lation and servicing may be rendered difcult.
In case of loss, request a duplicate to RTechnical Assistance
Service.

4
GENERAL INFORMATION
GENERAL INFORMATION
6 SYSTEM LAYOUT
1
234
5
0 6
R
RB
7
8
6
SV
VE
10
9
11
1
2
4
5
3
1 Return Valve (solar plant return) with built-in non-re-
turn valve
2 Return temperature gauge
3 Insulation
4 Flow regulator
5 Flow-meter
6 Tap A for system lling/draining
7 Pump
8 Fixing bracket
9 Tap B for system lling/draining
10 Pressure gauge
11 Safety valve (6 bar)
R Solar circuit return. Outlet of heat transfer uid towards
solar collector.
RB Storage system return. Inlet of heat transfer uid from
solar storage system.
SV Safety valve drain
VE Expansion tank tting
7 TECHNICAL SPECIFICATIONS
DESCRIPTION Return solar station
Maximum working pressure 6bar
Maximum operating temper-
ature 110 °C
Dimensions LxHxP 264x362x215 mm
Net weight with insulation 3,8 kg
Power supply 230~50 V~Hz
Min/max electrical current
draw 0,04 ÷ 0,48 A
Min/Max power consumption 2 ÷ 45 W
Useful head available
Return solar station
USEFUL HEAD AVAILABLE (mbar)
800
700
600
0
500
400
300
200
100
0 200 400 600 800 1000
FLOW RATE (l/h)
Values referring to a mix of water and glycol at 30% and
bend (4) 7.5 m.
The speed of the circulator is set to a xed factory value (ON-
OFF), but can be controlled by means of the PWM signal and
changes according to the temperature difference between solar
collectors and storage.
Pay attention to the system overall ow resistance (exchanger,
solar collectors and pipes) at the maximum ow rate conditions
provided.

5
INSTALLATION
INSTALLATION
8 UNPACKING THE PRODUCT
Package content
1
2
3
4
1 Solar Station
In a plastic bag, the following material is also supplied:
2 Instruction manual
3 Circulator cover with logo (to be mounted during installa-
tion)
4 Wirings.
9 The instruction manual is an integral part of the appliance;
therefore, it should be read and stored carefully.
9 INSTALLATION PREMISES
9 When installing the boiler, allow sufcient space around it
to access all safety and control devices and to permit easy
maintenance.
9.1 Recommended minimum distances
Recommended distances for assembly and maintenance are
300 mm on each side (including expansion tank).
Put the solar station at a proper hight to allow thermometer and
pressure gauge reading.
≥ 0,3 m
≥ 0,3 m
≥ 0,3 m
Installation
10 ASSEMBLY
−Remove the front insulation (1)
−Mark mounting points (F) on the wall and drill
−Insert blocks (not supplied)
F
F
70mm
1
1
23
0
55mm
9 Use suitable wall-mounting bolts and blocks.
−Set solar station at the centre
−Fasten the solar station with the xing bracket (4), the
screws (2) and the washers (3) not supplied.
4
2
3 3

6
INSTALLATION
INSTALLATION
11 WATER CONNECTIONS
T
E
R
RB
SV
VE
60mm72mm
RSolar circuit return (3/4" M). Outlet of heat transfer
uid towards solar collector.
RB Storage system return (3/4" M). Inlet of heat transfer
uid from solar storage system.
SV Safety valve drain
VE Expansion tank tting
ESolar expansion tank (not supplied)
TSafety valve outlet pipe (not supplied)
−Connect the return tting (R) in the upper part of the so-
lar station to the solar plant
−Connect the return tting (RB) in the lower part of the
solar station to the accumulation system
−Connect the safety valve drain to a pipe (T) to avoid burns
from expelled uid and to permit the heat transfer uid
to be recovered
−Connect expansion tank (E), suitable for solar plant ap-
plications, to 1/2” tting (VE).
9 Fasten expansion tank as explained in the instruction sheet
supplied with the accessory.
9 For hydraulic connections, use silicone seals having a hard-
ness of at least 80SH. If no seals can be used, seal ttings
with high-temperature sealant (>180°C) suitable for solar
applications.
12 PUMP CONTROLLER
The circulator leaves the factory congured for management
with "direct speed control function" and with a maximum dis-
charge head of 7.5m (bend 4).
USER INTERFACE
The user interface consists of a push-button (1), a red/green LED
(2) and four yellow LEDs (3).
1 2 3
LED 1 LED 2 LED 3 LED 4 LED 5
When necessary, the user interface provides access to:
−Functioning (performance display) mode. Pump perfor-
mance is displayed during functioning as a % of current
draw with respect to rated load. Alarm conditions can be
seen from the colour of LED.
−Setting Mode: Press button (1) to enter setting mode and
select the type of pump curve.
FUNCTIONING MODE
Performance display
When the pump is running, LED no.1 is green. The four yellow
LEDs indicate the pump's instantaneous electrical power con-
sumption as shown in the table.
Nr. displayed Meaning % power
LED 1 ashing green Stand-by 0
LED 1 green and LED 2 yellow,
both lit Low load 0-25
LED 1 green and LEDs 2, 3 yel-
low, all lit
Low-medium
load 25-50
LED 1 green, LEDs 2, 3, 4 yel-
low, all lit
Medium-high
load 50-75
LED 1 green, LEDs 2, 3, 4, 5
yellow, all lit High load 75-100

7
INSTALLATION
INSTALLATION
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 with the highest priority. Alarm priority follows
the order of the table.
When no alarm is active, the user interface automatically dis-
plays pump performance.
Nr. displayed Meaning Function Action
LED 1 red and
LED 5 yellow,
both lit
The pump ro-
tor is blocked
The pump
automatically
attempts to
start every 1.5
seconds
Wait or check
that the
pump rotor is
free to rotate
LED 1 red and
LED 4 yellow,
both lit
Supply voltage
too low
Indica-
tion only.
The pump
continues to
function
Check the
voltage of the
power supply
LED 1 red and
LED 3 yellow,
both lit
Electronic
controller
error
The pump has
stopped be-
cause supply
voltage is too
low or be-
cause an error
has occurred
in the internal
electronic
controller
Check the
voltage of the
power supply
or replace the
pump
−Make sure that all the pumps in the system are free and
rotate in the right direction;
SETTING MODE
Setting display
To switch from performance display to setting display, press but-
ton (1). The LED indicate the current setting. For the interpreta-
tion of the LED, refer to the following tables.
Setting display mode shows the type of pump control or the
currently selected pump curve. Settings cannot be changed in
performance display mode. After 2 seconds, the display returns
to performance display mode.
LED no.1: if red it reveals an alarm or an external control; if green
it indicates the circulator performance or internal control pos-
sibility.
LEDs no. 2 and 3 indicate different control mode possibility and
LEDs no.4 and 5 indicate the curve type setting (1,2,3 or 4). These
LEDs are yellow.
PWM mode
LED 1 LED 2 LED 3 LED 4 LED 5
Curve 1 (4.5m) Red -Yellow - -
Curve 2 (5.5m) Red -Yellow Yellow -
Curve 3 (6.5m) Red -Yellow Yellow Yellow
Bend 4 (7.5m) Red -Yellow -Yellow
Direct speed control function (ON-OFF).
LED 1 LED 2 LED 3 LED 4 LED 5
Curve 1 (4.5m) Green Yellow Yellow - -
Curve 2 (5.5m) Green Yellow Yellow Yellow -
Curve 3 (6.5m) Green Yellow Yellow Yellow Yellow
Curve 4 (7.5m) (*) Green Yellow Yellow -Yellow
(*) Factory setting
Button lock/unlock function
The button lock function serves to prevent improper use or acci-
dental changes to pump settings.
When the button lock is active, pressing the button has no ef-
fect. This prevents users from accidentally accessing setting
mode while allowing them to use setting display mode.
If the button (1) is pressed for more than 10 seconds, it can be
switched to enable / disable the lockout function. In doing so, all
the LEDs, with the exception of the red LED, are ashing for one
second to indicate that the lockout function has been switched.
Setting mode
To modify settings, press the button (1) for 2 to 10 seconds. The
user can select new settings provided that the button lock func-
tion is disabled.
Available settings are displayed in a pre-dened sequence that
is repeated every time the button is briey pressed and released.
If the button is not pressed for over 10 seconds, the pump exits
setting mode and returns to performance display mode.
See the table above for the meanings of the LED sequences.
> 10 s .
SETTING MENUPERFORMANCE
> 2 s.
X
10 s.
2 s.
SELECTED SETTING

8
INSTALLATION
INSTALLATION
13 ELECTRICAL CONNECTIONS
9 The following is mandatory:
−have an omnipolar magneto-thermal circuit breaker and
a disconnecting switch compliant with the prevailing
standards of the installation country
−respect the polarity of the L1 (Phase) - N (Neutral) con-
nections
−use cables with insulation and cross section conforming
to applicable standards (minimum cross section 1.5 mm2)
−make sure the appliance is connected to an efcient
ground (earth).
0 It is strictly forbidden to use pipes of any kind to ground the
appliance.
The manufacturer is not responsible for any damages due to
the missing device grounding.
Refer to the manual supplied with the solar controller for de-
tails of all electrical connections, programming, etc..
The power supply and PWM signal connections must be ar-
ranged by the technician.
To carry out the electric connections:
−remove the frontal insulation (1).
−the cables must be inserted through the proper passages
(F).
1
F
−connect the connectors as shown in the gure.
1 PWM CONNECTOR
Brown - Input PWM
Blue - Reference signal
2 POWER SUPPLY
Brown - F
Blue - N
Yellow/green - ⏚
1
2
To control the circulator in on/off mode, the PWM cable is not
required.
To control the circulator in modulating mode by using a solar
regulator, verify the compatibility between the chosen regula-
tor and the PWM signal (see following paragraph "CONTROL SIG-
NALS").
CONTROL SIGNALS
The circulator can be controlled with a low voltage PWM digital
signal (pulse width modulation). The speed changes according
to the input signal, as indicated in paragraph "PWM input sig-
nal".
Here below are the main characteristics required of the PWM
signal output by the associated regulator.
9 Check the characteristics of your regulator PWM signal to en-
sure they comply with the features below. Different signals
could irreversibly damage the circulator on-board electron-
ics.
PWM low-voltage digital signal
The PWM square wave signal was designed for a frequency in-
terval between 100 and 4000 Hz. The PWM signal is used to set
circulator speed.
Example of Duty cycle
T
U
iH
UiL
t
TPeriod
dDuty cycle (t/T)
UiH High voltage level of input signal
UiL Low voltage level of input signal
IiH Input signal current
Example Evaluation
T = 2 ms (500 Hz) UiH = 4-24 V
t = 0,6 ms UiL ≤1 V
d % = 100 x 0.6 / 2 = 30 % IiH ≤10 mA (depending on UiH)

9
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE
PWM input signal
With a low input value (<5 % PWM), the pump cannot start. The
pump stops when input signal is 5 to 8% of PWM signal or when
PWM signal is not present, for safety reasons. If the pump re-
ceives no input, due for instance to failure of the signal cable, it
will stop in order to avoid solar system overheating.
Speed (%)
0 5 10
100
20 30 40 50 60 70 80 90 100
PWM input signal (%)
Electronic circuit
PWM output
PWM input
Reference
signal
Opto-isolator
Pump electronics
Technical specications
Maximum power Symbol Value
PWM input frequency f100-4000 Hz
Consumption in stand-by < 1 W
High voltage level of input
signal UiH 4-24 V
Low voltage level of input
signal UiL < 1 V
Input signal current IiH < 10 mA
Input Duty cycle PWM 0-100%
14 SYSTEM FLUSHING
Before lling the system with mixture of water and glycol, it is
necessary to ush the pipes of the solar system to eliminate all
residues of uid or scale.
Proceed as follows.
−Verify the ow-meter (C) is completely open
−Turn handle on valve (VR) clockwise
−Open taps (A) and (B) on the return tube
−Flush water in through the cock (B) and wait for it to
come out of the cock (A)
−Allow water to come out for at least 30 seconds
−Turn handle on valve (VR) counter clockwise
−Close taps (A) and (B).
9 During system ushing, pay attention to water coming out
of the taps as vapour could be released with risk of burns or
scalds. Use suitable personal protective equipment.
A
VR
B
RC
90°
0°
R
Position of the knob
of the return valve VR
Flow in
single direction
(non-return
valve function)
Flow
stopped
Commissioningandmaintenance

10
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE
9 If copper piping has been used and joints have been hot
brazed, ush out the system to remove any brazing resi-
dues. Seal test the system after you have ushed it out.
9 The solar circuit must be immediately lled with a mixture
of water and glycol, that avoids freezing and corrosion.
15 SYSTEM FILLING COCK
Before lling the system:
−Cut power off to the solar station and to the connected
integration system, by setting the system's main switch
and the device's main switch to OFF
9 Always use a mixture of water and glycol suitable for solar
applications. Choose the mixture according to the minimum
temperature that can be reached at the installation site and
to the maximum service temperature of solar collectors. For
further information, please refer to the glycol safety data
sheet.
When using glycol not pre-mixed:
−Do NOT part ll the circuit with pure glycol then add water
later.
−Ensure that lling water characteristics comply with pre-
vailing regulations; if that is not so, lling water must be
treated. Use portable treatment systems, for instance. In
particular, when chlorine content is very high (> 50ppm)
you must use distilled water for the mixture.
VR
B
A
C
Mixture
of glycol
and water
PC
PC Heat transfer uid lling pump
To ll the system, proceed as follows:
−Verify the ow-meter (C) is completely open
−Connect the lling pump (PC) as shown
−Turn handle on valve (VR) clockwise
Open taps (A) and (B) on the return tube
−Open manual degassing tap and any bleeder valve, lo-
cated at the highest points of the system, and keep them
open throughout the lling procedure.
−Pump the heat transfer uid around the circuit with an
external lling pump until all air bubbles have been
eliminated. Close the manual bleed valve and any vent
valves opened previously.
−Turn handle on valve (VR) counter clockwise
−Temporarily raise the pressure in the system to 4 bar.
−Start up the system for about 20 minutes.
−Repeat air bleeding operation until system is completely
free of air bubbles.
−set the system pressure.
−Close taps (A) and (B).
9 The set pressure must ensure that the one measured at the
solar collectors is positive with respect to the ambient one
(avoid depression in the solar eld) and must be set con-
sidering both the safety valve opening pressure (6) and the
solar expansion reservoir pre-charge pressure. To set the
system pressure correctly, refer to the design manual.
0 Do not ll the system in bright, sunny conditions or if the
collectors are hot.
9 Use a manual bleed valve, which should be installed at the
highest point in the system, to ensure that all air bubbles
have been eliminated from the circuit.

11
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE
9 When operating with the PWM speed control of the circula-
tor, the regulator (D) and the ow meter (C) must always be
open. When operating with direct speed control (ON-OFF) to
decrease the ow rate the desired bend must be set, pass-
ing to a bend lower than the factory setting (see the para-
graph "Setting mode"for more information). In addition, for
a ner adjustment of the ow, you can operate the regula-
tor (D) as shown in the gure.
OPEN
CLOSED
C
D
Graduated scale
2 - 16 l/h
ø6 mm
16 DEVICE CLEANING AND MAINTENANCE
9 Service the system at least once a year and carry out the
inspections specied in the relevant manual.
The following operations must be exclusively performed by
Technical Assistance Service.
16.1 Checking the seals
After commissioning, check hydraulic tting sealing. Make
sure there is no leakage close to electric components to avoid
short-circuits.
16.2 External cleaning
If dust accumulates on the insulation, clean it with a dry cloth.
0 Do not use abrasive products, petrol or triethylene.
17 INTERVENTIONS ON THE HYDRAULIC SYSTEM
17.1 Draining the system
−Connect a rubber hose to taps (A) and (B)
−Connect the opposite end to a vessel
−Open system drain taps and allow full drainage
−Close system drain taps and remove the rubber hose
−The exhausted heat transfer uid must be disposed of
according to the prevailing regulations, pursuant to the
instructions provided in the safety data sheet supplied
with the glycol.
17.2 Disassembling the circulator
9 Remove the circulator when system has cooled down.
Before removing circulator (C):
−Cut power off to the solar station and to the connected
integration system, by setting the system's main switch
and the device's main switch to OFF

12
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE
−Disconnect circulator power by removing connectors (D)
and (E)
−Move away any wiring and electric devices below to pro-
tect them against any leakage of heat transfer uid
−Close the valve (VR) by turning the handle 90° clockwise
−Open taps (A) and (B) and drain the solar circuit
−Loosen ring nuts (H1) and (H2) and remove circulator (C).
R
RB
VR
A
B
C
H2
H1
E
D
Reverse the above steps to t the new pump.
Fill the solar circuit as described in paragraph "System lling
cock".
18 RECYCLING AND DISPOSAL
The device is primarily composed of:
Material Component
metal materials tubes, circulator
EPP (polypropylene foam) insulation
electrical and electronic
components cable and wiring, circulator
At the end of the device's useful life, these components must be
separated and disposed of according to current regulations in
the country of installation.

13
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE

14
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE

15
COMMISSIONING AND MAINTENANCE
COMMISSIONING AND MAINTENANCE

RIELLO S.p.A.
Via Ing. Pilade Riello, 7
37045 - Legnago (VR)
www.riello.com
The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specications, standard equipment
and accessories are therefore liable to modication without notice.