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Riello Array AR 3000 - User Manual

Riello Array AR 3000
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cod. Doc-0079789 rev. 5
09/2018
Array AR 3000 - AR 4000
US INSTALLATION AND OPERATION MANUAL

Table of Contents

Questions and Answers

  • B
    Benjamin MasonSep 23, 2025
    How to fix DHW_SHORTED error on Riello Array AR 3000?
    • W
      William HouseSep 23, 2025
      If your Riello Boiler displays a DHW_SHORTED error, check the wiring for damage and replace if necessary. Also, verify that the temperature sensor has the correct resistance values and replace the sensor if the values are incorrect.
  • A
    alexandraklineAug 23, 2025
    What to do if Riello Boiler displays TOO_MANY_FLAME_LOSS?
    • J
      Jennifer GalvanAug 25, 2025
      If your Riello Boiler displays the TOO_MANY_FLAME_LOSS error, check the wiring for any damage and replace any damaged wires. Also, verify proper combustion settings; if these are correct, consider replacing the spark/fal merod.
  • J
    Joshua DeleonAug 25, 2025
    How to fix MAX_TEMP_ERROR on Riello Boiler?
    • E
      Elizabeth NelsonAug 26, 2025
      If your Riello Boiler is showing a MAX_TEMP_ERROR, try changing or restarting the pump. Ensure that the valves on the hydraulic circuit are open. If the issue persists, consider changing the high limit switch.
  • E
    ewilliamsAug 27, 2025
    What to do if my Riello Array AR 3000 Boiler displays HIGH_TEMP_ERROR?
    • B
      Barbara HessAug 27, 2025
      If your Riello Boiler displays a HIGH_TEMP_ERROR, you can try the following: 1. Change or restart the pump. 2. Open the valves on the hydraulic circuit. 3. Check the temperature sensor's resistance values and replace the sensor if the values are incorrect.
  • M
    michael53Aug 27, 2025
    How to troubleshoot FAN_ERROR_NOT_RUNNING on Riello Array AR 3000?
    • C
      Christopher MunozAug 27, 2025
      If your Riello Boiler is displaying the FAN_ERROR_NOT_RUNNING error, check the following: * If there's no 120 VAC voltage present, replace the power control board. * If there's no PWM signal, replace the power control board. * Replace the fan.
  • A
    Alan JohnsonSep 16, 2025
    How do I fix a SUPPLY_OPEN error on my Riello Boiler?
    • J
      john47Sep 16, 2025
      If your Riello Boiler shows a SUPPLY_OPEN error, check the wiring for damage and replace if necessary. Also, verify that the temperature sensor has the correct resistance values and replace the sensor if the values are incorrect.
  • P
    Paul RamirezSep 13, 2025
    What should I do if my Riello Array AR 3000 Boiler shows FLAME_BEFORE_IGNIT error?
    • C
      Courtney SchmidtSep 13, 2025
      If your Riello Boiler displays a FLAME_BEFORE_IGNIT error, replace the gas valve.
  • N
    nortizSep 15, 2025
    How to fix LWCO_1_ERROR on Riello Array AR 3000?
    • C
      cynthia62Sep 15, 2025
      If your Riello Boiler displays a LWCO_1_ERROR, verify that there is water in the boiler. Also, verify that there is a good connection between the control module and the low water probe.
  • N
    Nancy BenderSep 5, 2025
    What is WD_ERROR_REGISTER on Riello Boiler and how to resolve it?
    • J
      james08Sep 5, 2025
      If your Riello Boiler displays a WD_ERROR_REGISTER, the suggested solution is to replace the power control board.
  • K
    Kimberly SnowSep 3, 2025
    What to do for SAFETY_RELAY_ERROR on Riello Array AR 3000 Boiler?
    • M
      moramichaelSep 3, 2025
      If your Riello Boiler is showing a SAFETY_RELAY_ERROR, replace the power control board.

Summary

General Information

Warnings and Cautions

General warnings and cautions for installation and operation.

Safety Instructions

Detailed safety instructions for installation and operation.

General Warning

General warnings and compliance with codes.

Product Description

Introduction to Product

Overview of Array boilers' design and purpose.

Scope of Delivery

Lists components included with the boiler system.

Proper Usage Guidelines

Specifies intended applications and proper usage guidelines.

Environmental Responsibility and Disposal

Outlines environmental policies and disposal considerations.

Emergency Shutdown Procedure

Procedure for emergency shutdown of the appliance.

Prolonged Shutdown

Procedures for shutting down the unit for extended periods.

Size and Connections

Provides dimensions and connection points for the boiler.

Technical Data

Detailed technical specifications including input/output, pressure, and electrical requirements.

Assembly Components

Illustrates and lists various internal components of the boiler.

Efficiency Curves

Graphs showing thermal efficiency at different operating conditions.

Regulations and Compliance

Compliance with Standards and Regulations

Details standards and regulations for boiler installation.

Operating Limits of the Boiler

Specifies operational limits and ASME code compliance.

Installation Procedures

Installation Introduction

Introduces the installation procedures and manual.

Receiving the Unit

Instructions for receiving and inspecting the boiler unit.

Unpacking the Unit

Guidance on safely unpacking the boiler and its components.

Installation Clearances

Specifies minimum required clearances around the boiler for service.

Setting the Unit

Instructions for positioning and securing the boiler unit on its location.

Boiler Location

Guidelines for selecting an appropriate and safe location for the boiler.

Water Quality Guidelines

Outlines acceptable water quality parameters and guidelines for the system.

Supply and Return Piping

Details the connection of supply and return water piping to the boiler.

Low Water Cutoff System

Explains the low water protection system and its functionality.

High Limit Safety Switch

Description of the high limit safety switch and its operation.

Pressure Relief Valve Installation

Information on the installation and function of pressure relief valves.

Condensate Drain and Piping

Procedures for connecting the condensate drain and piping system.

Gas Supply Piping

Requirements and guidelines for gas supply piping installation.

Gas Supply Specifications

Specifies gas supply input requirements and pressure for natural gas.

Manual Gas Shutoff Valve

Installation requirement for a manual gas shutoff valve upstream of the boiler.

External Gas Supply Regulator

Recommendations and specifications for external gas supply regulators.

Gas Type Conversion

Procedure and safety warnings for converting the gas type.

Adjusting and Setting O2 Limits

Steps for adjusting and setting oxygen (O2) limits for optimal combustion.

AC Electrical Power Wiring

Instructions for connecting AC electrical power to the unit.

Electrical Power Requirements

Specifies voltage requirements and wiring for the boiler's electrical power.

Field Control Wiring

Overview of field control wiring and connections for optional features.

Enable;Disable (Room thermostat connection)

Instructions for connecting a room thermostat for enable/disable function.

Air Damper Connection

Instructions for connecting and configuring an air damper.

Outdoor Temperature Sensor

Instructions for connecting and installing an outdoor temperature sensor.

Venting Requirements

Comprehensive guide to venting requirements and materials.

Combustion Air Supply

Details requirements and methods for supplying combustion air to the boiler.

Commissioning Procedures

Commissioning Introduction

Introduction to boiler commissioning and installer responsibilities.

Filling the Condensate System

Procedure for filling the condensate system prior to start-up.

Filling the Boiler Heating System

Steps for filling the boiler and heating system with water.

Gas Supply Warnings

Safety warnings related to gas supply verification and connection.

Confirming Units Gas Type

How to confirm the boiler's gas type and supply pressure settings.

Gas Type Conversion

Information on converting the boiler for different gas types.

Boiler Startup Procedure

Step-by-step guide for starting up the boiler unit.

Minimum Water Flow Protection

Explains the self-protection feature for low water flow.

Heating System Pressure Test

Procedure for testing the heating system pressure after filling.

Multiple Boiler Cascade Installation and Start-Up

Guide for installing and starting up multiple boilers in a cascade system.

Boiler Cascade: Set Boiler Address

Procedure for assigning a boiler address in a cascade setup.

Boiler Cascade: Set Power Switch S1

Instructions for setting the S1 power switch in a cascade configuration.

Operation of the Boiler

Operation Introduction

Introduction to operating the boiler using the control panel.

Control Panel Description

Overview of the touchscreen control panel and its functions.

Touchscreen Control Panel Menus

Description of the menu structure and major screens.

Riello Screen

Description of the main RIELLO logo screen.

Cascade Screen Overview

Overview of the screen displaying cascaded boilers and plant configuration.

Boiler Screen Details

Details actions and information available on the boiler screen.

Module Screen Functions

Information and actions for individual boiler modules.

Performance Screen

Displays real-time performance data of the plant, boiler, or modules.

Error Screen Information

Shows a list of recent errors, categorized by type.

Service Screen Details

Displays service reminder parameters and history.

Module Test Screen

Supports installer and service activities with test functions.

Shutdown Procedures

Shutting Down the Heating System

Procedure for normal shutdown of the heating system.

Emergency Heating System Shutdown

Emergency shutdown procedures for critical situations.

Environmental Protection and Disposal

Appendix

Appendix A: Wiring Diagram

Detailed wiring diagram for the boiler system components.

Wiring Diagram: Managing Left Door

Wiring diagram specific to the managing unit's left door.

Wiring Diagram: Dependent Left Door

Wiring diagram for dependent units' left door connections.

Wiring Diagram: Right Door Components

Wiring diagram for the right door components.

Wiring Diagram: Dependent Right Door

Wiring diagram for dependent units' right door connections.

Appendix B: Connection Diagram

Connection diagram for the 905MN control board.

Connection Diagram: 905 PB Display

Diagram for the 905PB display and its connections.

Connection Diagram: Touchscreen and Display

Diagrams showing connections between touchscreen and display units.

Appendix C: Maintenance Schedule

Schedule and procedures for routine boiler maintenance.

Appendix D: Head Available for System

Data on head available for the system with and without glycol.

Appendix E: De-Rating for Altitude Installation

Guidance on de-rating boiler input capacity based on altitude.

Appendix F: Troubleshooting Table

Table of lockout codes, descriptions, checks, and solutions.

Appendix G: Boiler Installation Drawings

Illustrative examples of boiler system piping concepts.

Appendix H: Venting Size Data

Data table for calculating venting system size requirements.

Appendix I: Exhaust Terminals and Air Inlet Clearances

Clearances and guidelines for exhaust terminals and air inlets.

Appendix J: Sensor Resistance

Table of sensor resistance values at different temperatures.

Appendix K: List of Parameters

Comprehensive list of adjustable parameters with their ranges and default values.

Appendix L: Flowcharts

Flowcharts illustrating single module operation logic.

Burner Ignition Sequence Flowchart

Flowchart detailing the burner ignition sequence.

Module Cascade Flowchart

Flowchart for standalone module cascade operation.

Module Cascade: Add;Remove Module Flowchart

Flowchart for adding or removing modules in a standalone cascade.

Boiler Cascade Flowchart

Flowchart for overall boiler cascade operation logic.

Boiler Cascade: Add;Remove Boiler Flowchart

Flowchart for adding or removing boilers in a cascade system.

Error Checking Cycle Flowchart

Flowchart detailing the error checking cycle for the system.

Riello Array AR 3000 Specifications

General IconGeneral
ModelArray AR 3000
CategoryBoiler
TypeCondensing
FuelNatural Gas / LPG
Output3000 kW
Modulation10:1

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