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Table of Contents
Related Manuals for Riello RTC-80 Series
Summary of Contents for Riello RTC-80 Series
- Page 1 RTC-80 1000-5500 INSTALLATION, OPERATION AND SERVICE MANUAL...
- Page 2 20166937 quickly, easily, and correctly. RTC 2300-80 20166942 RTC 3000-80 20166947 Please accept our thanks, and congratulations on your choice of RTC 3800-80 20166962 product. Riello S.p.A. RTC 4700-80 20166970 RTC 5500-80 20166987 CONFORMITY Commercial Boilers AHRI Standard BTS-2000 ENGLISH...
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Page 3: Table Of Contents
CONTENTS 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Typical water system schematics . -
Page 4: General
GENERAL GENERAL If the boiler is not going to be used for an extended period of time, perform the operations described later in this manual. 1.1 General safety information 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 Check that the product is complete, undamaged and as or-... - Page 5 GENERAL NOTICE! DANGER: Risk of personal injury or death from electric shock! − The installation must comply with all applicable national, − Before removing the front panel, disconnect the heating state/provincial, and local codes, rules, and regulations. system from the electrical power supply by shutting off −...
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Page 6: Description Of The Appliance
GENERAL 1.3 Description of the appliance 1.4 Identification RTC-80 stainless steel boilers are triple-pass, condensing boilers The products are identified by: for installation in a boiler room. While they are designed for cen- tral heating purposes, they can also be used in conjunction with a suitable plate exchanger and storage tank to produce domestic hot water. -
Page 7: System Layout
GENERAL 1.5 System layout 6 (*) 8 (**) Burner 14 Inspection window Flame inspection window with pressure measurement 15 Condensate outlet point 16 Boiler drain Door 17 Turbulators Casing 18 Flue gas pipes Outlet 19 Second flue pass Safety device fitting Heating return (high temperature) Heating return (low temperature) Blind plug... -
Page 8: Technical Specifications
GENERAL 1.6 Technical specifications 1.6.1 Ratings (natural gas firing) RTC-80 Description 1000 1300 1700 2300 3000 3800 4700 5500 Minimum Input (kW) (29.3) (38.1) (49.8) (67.4) (87.9) (111.4) (137.7) (161.2) 1000 1300 1700 2300 3000 3800 4700 5500 Maximum Input (kW) (293.1) (381.0) -
Page 9: Specifications
GENERAL 1.6.3 Specifications RTC-80 Description 1000 1300 1700 2300 3000 3800 4700 5500 Boiler category ASME Section IV Maximum allowable working pressure 80 psi 80 psi 80 psi 80 psi 80 psi 80 psi 80 psi 80 psi Maximum allowable working temperature 210°F 210°F 210°F... -
Page 10: Intended Use
GENERAL 1.7 Intended use The local regulations regarding minimum pressure detectors, maximum relief valves and low water safety cutouts must be ob- This boiler must only be used for the purpose specified by the served. Installation and operation must comply with the device manufacturer and for which it is designed. -
Page 11: Suitable Fuels
GENERAL 1.10 Suitable fuels APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. Permissible fuels − Natural gas from the public gas supply in accordance with SIGNAGE: A metal or plastic identification plate shall be perma- national regulations with a total sulphur content <... -
Page 12: Recommended Burners And Burner Plate Accessories Kit
RX 850 (20-9 ppm) (30 ppm) ● 20169560 ● 20169560 RX1000 (20-9 ppm) (30/20 ppm) 0 feet altitude (●) 6000 feet altitude Sliding Burners are approved to UL Standard UL 295 and CSA Standard CGA 3.4 Riello file number MP 3252... -
Page 13: Installation
NOTE: Keep the documentation envelope in a safe place. Any replacement documents must be ordered from Riello S.p.A. who reserve the right to charge for the cost of the replace- ment. -
Page 14: Overall Dimensions And Weights
INSTALLATION 2.2 Overall dimensions and weights RTC-80 Description Unit 1000 1300 1700 2300 3000 3800 4700 5500 29 1/2 29 1/2 31 1/8 31 1/8 38 9/16 38 9/16 42 1/8 44 1/2 A: Base width inch (mm) (750) (750) (790) (790) (980) -
Page 15: Moving And Removing The Packaging
INSTALLATION 2.3 Moving and removing the packaging Wear suitable personal protection equipment when moving the boiler and removing the packing. Only use lifting equip- ment that is suitable for the weight involved. The product can be moved in two ways: −... -
Page 16: Installation Premises
INSTALLATION 2.4 Installation premises 2.4.1 Installation clearances RTC-80 boilers must be installed in a dedicated boiler room that Single Boiler configuration conforms to applicable laws and standards. The boiler room must have adequately sized vents that also conform to applicable laws This figure shows suggested installation clearances. -
Page 17: Minimum Clearance To Combustibles
INSTALLATION Two-Boilers configuration RTC-80 Unit Minimum distances 1000 inch 1300 inch 1700 inch 2300 inch 3000 inch 3800 inch 4700 inch 5500 inch WARNING: Make sure that the door is properly oriented. 5” 2.4.2 Minimum clearance to combustibles 24” Three-Boilers configuration 6”... -
Page 18: Water Connections
INSTALLATION 2.5 Water connections The following table gives the dimensions and positions of the water fittings on RTC-80 boilers. Before installing the boiler, flush out all the pipes of the central heating circuit to remove any machining residues, oils, scale, dirt and debris. - Page 19 INSTALLATION RTC-80 Description Unit 1000 1300 1700 2300 3000 3800 4700 5500 2-1/2" 1 – Heating supply 3" #150 4" #150 4" #150 5" #150 5" #150 6" #150 6" #150 #150 2 – Heating return 1 (Low 2-1/2" 3" #150 4"...
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Page 20: Sensor Manifold Installation
INSTALLATION 2.6 Sensor manifold installation 1000 1300 1700 2300 3000 3800 4700 5500 Sensor manifold type 2-1/2" #150 3” #150 4” #150 5” #150 6” #150 Ø NPS... -
Page 21: Sensor Manifold Connections
INSTALLATION 2.7 Sensor manifold connections Sensor manifold 2-1/2" #150 3” #150 4"#150 5” #150 6"#150 type 3-17/64" 3-17/64" 3-5/32" 3-5/32" 3-5/32" 83 mm 83 mm 80 mm 80 mm 80 mm 3-15/16" 3-15/16" 3-47/64" 3-47/64" 3-47/64" 100 mm 100 mm 95 mm 95 mm 95 mm... -
Page 22: Positioning Of Sensor Sockets
INSTALLATION 2.8 Positioning of sensor sockets RTC 1000-80 ÷ RTC 4700-80 LWCO a) 3/4"NPT b) 1/2" NPT On the models RTC 3000-80 to RTC 5500-80 the safety fitting is flanged. Outlet operating temperature thermowell (G 1/2") for n.2÷3 instrument bulb. Internal diameter probe sockets 7 mm. Thermow- ell length L170 mm Over-temperature protection thermowell (G 1/2") for n.1 instrument bulb. - Page 23 INSTALLATION RTC 5500-80 LWCO a) 3/4"NPT b) 1/2" NPT On the models RTC 3000-80 to RTC 5500-80 the safety fitting is flanged. Outlet operating temperature thermowell (G 1/2") for n.2÷3 instrument bulb. Internal diameter probe sockets 7 mm. Thermow- ell length L170 mm Over-temperature protection thermowell (G 1/2") for n.1 instrument bulb.
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Page 24: Water-Side Pressure Drop
INSTALLATION 2.8.1 Water-side pressure drop ∆T=20°F ∆T=30°F ∆T=40°F ∆T=60°F Pressure Pressure Pressure Pressure Model Flow rate Flow rate Flow rate Flow rate drop drop drop drop (GPM) (*) (psi) (GPM) (*) (psi) (GPM) (*) (psi) (GPM) (*) (psi) RTC 1000-80 0.67 0.30 0.19... -
Page 25: Flow Limits
INSTALLATION 2.8.2 Flow limits NOTICE: If it proves impossible to treat the heating system water RTC-80 boilers do not require a minimum flow rate in order to supply properly because the water charging system is maintain warranty. The boiler has been designed to operate with automatic and uncontrolled, if there are no barriers a temperature difference between the supply and return of up installed to prevent water oxygenation and if the heating... -
Page 26: Reconditioning Old Heating Systems
INSTALLATION 2.8.7 Elimination of air and gas from central heating NOTICE: system − Loss of water from the system, and the consequential need to add water, can be caused not only by leaks from the circuit, but also from the incorrect sizing of the expansion When designing new heating systems, it is necessary to eliminate vessel or precharge pressure. -
Page 27: Typical Water System Schematics
INSTALLATION 2.9 Typical water system schematics The selection and the installation of the components of the system is the responsibility of the installer, who must operate The following P&ID represent the typical arrangements for the in accordance with good practice and current Legislation. most common types of installation and they are only a suggestion for the installer that is resposible for all equipment and details If needed, water supplies and recovery circuits must be condi-... - Page 28 INSTALLATION Single Boiler Piping Schematic Type B RTC 5500-80 LT (*) CENTRAL CENTRAL HEATING HEATING SUPPLY RETURN MAKE-UP WATER FLOW LT RETURN WATER INLET Boiler Water softener filter Burner Siphon Isolation valves Condensate outlet Central heating system pump Drain Non-return valves Isolation valve Automatic vent valve Non-return valve...
- Page 29 INSTALLATION Single Boiler Combination Heating & Domestic Water Plant LT (*) HT (*) CENTRAL CENTRAL HEATING HEATING RETURN RETURN CENTRAL HEATING SUPPLY MAKE-UP WATER 3 12 10 3 INLET DHW USER POINTS FLOW RETURN LT RETURN (**) WATER INLET Boiler Non-return valve Burner Air separator...
- Page 30 INSTALLATION Multiple Boiler Piping Schematic with Sequencing Panel LT (*) HT (*) CENTRAL CENTRAL MAKE-UP HEATING HEATING WATER RETURN RETURN CENTRAL HEATING SUPPLY FLOW RETURN RETURN (**) WATER INLET FLOW HT RETURN RETURN (**) FLOW HT RETURN RETURN(**) Boiler Isolation valve Burner Non-return valve Isolation valves...
- Page 31 INSTALLATION Multiple Boiler Piping with Primary and Secondary Piping MAKE-UP WATER CENTRAL HEATING FLOW SUPPLY RETURN (**) LT (*) CENTRAL HEATING RETURN FLOW WATER RETURN (**) INLET FLOW RETURN (**) Boiler Drain Burner Isolation valve Isolation valves Non-return valve Central heating system pump Mixer tank Non-return valves Pressure gauge...
- Page 32 INSTALLATION Multiple-Boiler Piping with Motorized Sequencing Valves CENTRAL CENTRAL HEATING HEATING RETURN SUPPLY FLOW RETURN (**) WATER INLET FLOW RETURN (**) FLOW RETURN (**) RIT BT Boiler Siphon Burner Condensate outlet Isolation valves Drain Central heating system pump Isolation valve Motorized sequencing valve Non-return valves Automatic vent valve...
- Page 33 INSTALLATION Two-Boiler Combination Heating & Domestic Water Plant HT (*) CENTRAL LT (*) CENTRAL CENTRAL HEATING HEATING HEATING RETURN RETURN SUPPLY MAKE-UP 16 17 WATER 4 5 3 3 12 10 3 INLET FLOW RETURN RETURN (**) WATER INLET DHW USER 16 17 16 POINTS FLOW...
- Page 34 INSTALLATION Multi-Boiler Combination LT (*) CENTRAL CENTRAL HEATING SUPPLY HEATING RETURN MAKE-UP WATER 16 17 FLOW RETURN (**) WATER INLET 17 16 FLOW RETURN (**) 17 16 FLOW RETURN (**) Boiler Drain Burner Isolation valve Isolation valves Control valve Central heating system pump Air separator Non-return valves Pressure gauge...
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Page 35: Draining The Condensate
INSTALLATION 2.10 Draining the condensate 2.11 Neutralizing the condensate RTC-80 condensing boilers produce a flow of condensate that var- Installation of a condensate neutralization kit is always recom- ies according to operating conditions. mended. The following table states the rate of condensate flow The maximum hourly production of condensate for each model is produced by the boiler. -
Page 36: Combustion Gas Exhaust
INSTALLATION 2.12 Combustion gas exhaust RTC-80 Description Symbol Unit The flue pipe (1) and the connection to the stack (2) must conform 1000 1300 1700 2300 to applicable national and local laws and standards. Flue pipe Height of flue inch 21 1/16 must be rigid, impermeable to fumes, able to withstand mechan- gas outlet... -
Page 37: Venting Requirements
INSTALLATION 2.12.1 Venting requirements 2.12.2 Code required vent terminations Horizontal Terminations: − Vent terminations should be at least 4 feet below, 1 foot WARNING: Risk of system damage or personal injury! above or 4 feet horizontally from any window, door or The vent system could fail, causing flue gas leakage, resulting gravity air inlet of a building. -
Page 38: Combustion Air From Outside The Building
INSTALLATION 2.12.3 Combustion air from outside the building 2.12.4 Combustion air from an adjacent room Two permanent openings method Where combustion air is to be used from within the building, air If outside combustion air is required, the room shall have two per- must be provided into the equipment room through two perma- manent louvered openings to the outdoors. -
Page 39: Door Hinges
INSTALLATION 2.13 Door hinges Smaller sizes The boilers are pre-fitted with three hinges so that the direction of (system A) opening of the door can be rapidly reversed. Once you have checked that the default direction of opening is as required, or have reversed the direction of opening as instructed in the ‘Changing the direction of door opening’... - Page 40 INSTALLATION System B - Larger sizes Open the door and use a hacksaw or file Hermetically close the door again by tightening the bolts (2) until the door compresses to remove the cutouts (top and bottom) the braided seal. on the opposite side of the head. Remove the plug (1) taking care not to lose the compressed spring inserted in the threaded tube.
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Page 41: Removing The Hinge Assembly "B
INSTALLATION 2.15 Removing the hinge assembly "B" 2.16 Earth connection System A A terminal is provided on the front boiler head to connect the − First ensure that the side safety bolt (2) is tight and then boiler body to an efficient earth system. remove the main fixing bolt (1) Proceed as follows: −... -
Page 42: Fitting The Casing Panels
INSTALLATION 2.17 Fitting the casing panels Proceed as follows to fit the boiler casing panels: − Fit the top panels (14), (15), (16) and (17) Attach the front side panels ((2) and (3)) and rear side panels ((4) − Smaller models have only two top panels, one over the and (5)) over the boiler frame (1) and to the top side beams. -
Page 43: Commissioning
COMMISSIONING 3 COMMISSIONING 3.4 Making the electrical connection 3.1 Preparing for initial startup DANGER: Danger to life through electric shock! − Before opening the boiler, isolate the heating system across all live phases and secure against unintentional reconnec- NOTICE: Risk of boiler damage through contaminated com- tion. -
Page 44: Flushing The Heating System
COMMISSIONING 3.6 Flushing the heating system 3.8 Preparing the heating system for operation If the heating system contains several heating circuits, these must Observe the following points during commissioning: be flushed one after the other. − Before commissioning, vent the heating system via the To prevent contamination in the boiler, flush the heating system ventilation facilities provided for this purpose. -
Page 45: Commissioning Report
COMMISSIONING 3.10 Commissioning report The boiler can be operated with a gas or dual fuel burner. − Carefully complete the commissioning report for the relevant approved burner. − Sign all completed commissioning work and enter the date. COMMISSIONING STEPS COMMENTS (SIGNATURE) Flush the heating system. -
Page 46: Shutdown
SHUTDOWN 4 SHUTDOWN CAUTION: Risk of system damage through frost. When there is a frost, the heating system can freeze up if it is not operational, e.g. because of a fault shutdown. − When there is a risk of frost, protect your heating system against freezing up. -
Page 47: Inspection And Maintenance
SHUTDOWN 5 INSPECTION AND MAINTENANCE System A - B − To open the door, simply remove the main fixing bolts (2) under the caps (3) holding the door in place. 5.1 Why is regular maintenance important? Heating systems require regular maintenance and service for the following reasons: −... -
Page 48: Cleaning The Boiler
SHUTDOWN 5.3 Cleaning the boiler If necessary, replace the seal (8). Clean the boiler and remove any carbon deposits from the sur- faces of the heat exchanger at least once a year. This not only ex- tends the boiler’s working life, but also keeps it efficient in terms of heat output and fuel consumption. -
Page 49: External Cleaning
SHUTDOWN 5.4 External cleaning Sealed unvented systems Clean the outside of the boiler casing with a soft cloth dampened with soapy water. NOTICE: System damage through frequent topping up. To remove stubborn marks, use a cloth dampened in a 50% mix Subject to the water quality, your heating system can be of water and denatured alcohol or a suitable cleaning product. -
Page 50: Inspection And Maintenance Reports
SHUTDOWN 5.5.1 Inspection and maintenance reports The inspection and maintenance reports provide an overview of the required inspection and service steps that should be carried out annually. Warranty: − Annual inspection and service are part of the warranty terms. Complete these reports after inspections and service. The report can also be used as copying template: −... -
Page 51: Troubleshooting
SHUTDOWN 5.6 Troubleshooting PROBLEM CAUSE TROUBLESHOOTING TROUBLESHOOTING Heat exchanger dirty. − Clean the flue gas pipes. Heat exchanger and burner mismatched. − Check specifications and settings. The boiler does not reach its set tempera- Insufficient burner gas flow. − Check and adjust the burner. ture. -
Page 52: Environmental Protection/Disposal
ENVIRONMENTAL PROTECTION/DISPOSAL 6 ENVIRONMENTAL PROTECTION/DISPOSAL Environmental protection is one of the fundamental company policies of the Riello. We regard quality of performance, economy and environmental protection as equal objectives. Environmental protection laws and regulations are strictly ad- hered to. To protect the environment, we use the best possible technology and materials taking into account economic points of view. - Page 56 RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) - Italy www.rielloboilers.com North America: 35 Pond Park Road Hingham, Massachusetts U.S.A. 02043 2165 Meadowpine Blvd. Mississauga, ON L5N6H6 CANADA www.rielloboilers.com The manufacturer strives to continuously improve all products: appearance, dimensions, technical specifications, standard equipment and...