Related Manuals for Riello RTC Series
Summary of Contents for Riello RTC Series
- Page 1 RTC 3000-4000-5000-6000 RTC 8000-10000 US INSTALLATION OPERATION AND SERVICE MANUAL...
- Page 2 RTC 5000 20107179 quickly, easily, and correctly. RTC 6000 20107180 RTC 8000 20112393 Please accept our thanks and our congratulations on your choice RTC 10000 20112394 of product. Riello S.p.A. CONFORMITY Commercial Boilers AHRI Standard BTS-2000 ENGLISH...
-
Page 3: Table Of Contents
CONTENTS 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 COMMISSIONING . -
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, and local codes, rules, and regulations. system from the electrical power supply by shutting off −...
-
Page 6: Description Of The Appliance
GENERAL 1.3 Description of the appliance 1.4 Identification RTC stainless steel boilers are triple flue pass, condensing boil- The products are identified by: ers for installation in a boiler room. They are designed for cen- tral heating purposes but can also produce domestic hot water in conjunction with a suitable storage cylinder. -
Page 7: System Layout
GENERAL 1.5 System layout RTC 3000-RTC 4000-RTC 5000-RTC 6000 Burner Flame inspection window with pressure measurement point Door Casing Central heating supply Safety valve connection Central heating return - High Temperature (HT) Combustion chamber Central heating return - Low Temperature (LT) 10 Flue gas box Flue gas exhaust 12 Inspection window... - Page 8 GENERAL RTC 8000-RTC 10000 Burner Flame inspection window with pressure measurement point Door Casing Central heating supply Safety valve connection Central heating return - High Temperature (HT) Combustion chamber Central heating return - Low Temperature (LT) 10 Flue gas box Flue gas exhaust 12 Inspection window 13 Condensate outlet...
-
Page 9: Technical Specifications
GENERAL 1.6 Technical specifications 1.6.1 Ratings Description RTC 3000 RTC 4000 RTC 5000 RTC 6000 RTC 8000 RTC 10000 Min Input 1000 Max Input 3000 4000 5000 6000 8000 10000 Condition 1 2550 3400 4250 5100 6800 8500 Output Condition 2 2940 3920 4900... -
Page 10: Intended Use
GENERAL 1.7 Intended use Safety limits Safety limits Value This boiler must only be used for the purpose specified by the Maximum allowable temperature: 210°F (99°C) manufacturer and for which it is designed. Maximum Allowable Working Pressure The RTC can be operated with gas, oil, and combination burners. 160 psi (11 bar) (MAWP) For a list of the approved burners, see specific paragraph in this... -
Page 11: Suitable Fuels
GENERAL 1.11 Burners b) EXEMPTIONS: The following equipment is exempt from 248 CRM 5.08(2)(a) 1 through 4: − The equipment listed in Section 10 entitled “Equipment Not Follow the burner manufacturer’s instructions when fitting the Required To Be Vented” in the most current edition of NFPA burner. -
Page 12: Burner Plate Accessories Kit
GENERAL BURNERS BOILERS BURNERS BOILERS MODEL MODEL 3000 4000 5000 6000 8000 10000 3000 4000 5000 6000 8000 10000 x ● RS120/E RS130/E x ● x ● RS160/E RS190/E RS68/EV RS280/E 20126364 x ● RS120/EV RS300/E 20126364 x ● x ● RS160/EV RS310/E MIXED OIL/GAS... -
Page 13: Upper Door Accessories Kit
GENERAL 1.11.3 Upper door accessories kit In the following table are shown the codes for the upper door kit that shall be ordered as accessory for some matching boil- er-burner. BURNERS BOILERS MODEL 3000 4000 5000 6000 8000 10000 RX1500 20136220 20136221 RX1800 20136220 20136221... -
Page 14: Installation
Keep the documentation envelope in a safe place. Any re- 79.1" 82.9" 86.8" 92.3" 76.8" 81.7" inch placement documents must be ordered from Riello S.p.A. who Net weight 5,578 6,702 7,485 9,087 12,747 16,149 reserve the right to charge for the cost of the replacement. -
Page 15: Moving And Removing The Packing
INSTALLATION 2.3 Moving and removing the packing 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 Wear suitable personal protection equipment when moving with applicable legislation. -
Page 16: Installation Premises
INSTALLATION 2.4 Installation premises 2.4.1 Installation clearances RTC boilers must be installed in a dedicated boiler room that con- This figure shows the installation clearances that must be respect- forms to applicable laws and standards. The boiler room must ed in order to allow proper maintenance of the boiler. have adequately sized vents that also conform to applicable laws and standards. -
Page 17: Water Connections
INSTALLATION 2.5 Water connections The following table gives the dimensions and positions of the water fittings on RTC boilers. Before installing the boiler, flush out all the pipes of the central heating circuit to remove any machining residues. RTC 3000-RTC 4000-RTC 5000-RTC 6000 4”... -
Page 18: Positioning Of Sensor Sockets
INSTALLATION 2.6 Positioning of sensor sockets RTC 3000-RTC 4000-RTC 5000-RTC 6000 a) 3/4"NPT b) 1/2" NPT Boiler RTC 3000 RTC 4000 RTC 5000 RTC 6000 Thermowell lenght min. max. min. max. min. max. min. max. 2.5" 3.75" 2.5" 6" 2.5" 6"... - Page 19 INSTALLATION RTC 8000-RTC 10000 a) 3/4"NPT b) 1/2" NPT Boiler RTC 8000 RTC 10000 Thermowell lenght min. max. min. max. 2.5" 7.5" 2.5" 7.5" 1 - Outlet operating temperature sensor (1/2" NPT) 63mm 190mm 63mm 190mm 2.5" 9.5" 2.5" 9.5" 2 - Over- temperature protection (1/2"...
-
Page 20: Water-Side Pressure Drop
INSTALLATION 2.6.1 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 3000 1.56 0.86 0.58 0.34 RTC 4000 0.63 0.39 0.29 0.19 RTC 5000... -
Page 21: Flow Limits
INSTALLATION 2.6.2 Flow limits RTC boilers does not require a minimum flow rate in order to maintain warranty. The boiler has been designed to operate with a tem- perature difference between the supply and return of up to 100 °F . Flow should be initiated with the start of the burner to minimize temperature fluctuations and control deviations. -
Page 22: Reconditioning Old Heating Systems
INSTALLATION 2.6.7 Elimination 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 23: Typical Water System Schematics
INSTALLATION 2.7 Typical water system schematics The choice of system components and the method of their installation are left up to the heating engineer installing the The following P&ID represent the typical arrangement for the most system. Installers must use their expertise to ensure proper common types of installation and they are only a suggestion for installation and functioning in conformity to all applicable the installer that is resposible for all equipment and details re-... - Page 24 INSTALLATION Single Boiler Combination Heating & Domestic Water Plant LT (*) CENTRAL HEATING CENTRAL RETURN HEATING SUPPLY MAKE-UP WATER 3 12 10 3 HT (*) INLET CENTRAL HEATING RETURN DHW USER POINTS FLOW RETURN RETURN WATER INLET Boiler Non-return valve Burner Air separator Isolation valves...
- Page 25 INSTALLATION Multiple Boiler Piping Schematic with Sequencing Panel LT (*) HT (*) MAKE-UP CENTRAL CENTRAL WATER HEATING HEATING RETURN RETURN CENTRAL HEATING SUPPLY FLOW RETURN RETURN WATER INLET FLOW RETURN RETURN FLOW RETURN RETURN Boiler Condensate outlet Burner Drain Isolation valves Isolation valve Central heating system pump Non-return valve...
- Page 26 INSTALLATION Multiple Boiler Piping with Primary and Secondary Piping MAKE-UP WATER CENTRAL FLOW HEATING SUPPLY RETURN LT (*) CENTRAL HEATING RETURN FLOW WATER INLET RETURN FLOW RETURN Boiler Siphon Burner Condensate outlet Isolation valves Drain Central heating system pump Isolation valve Non-return valves Non-return valve Automatic vent valve...
- Page 27 INSTALLATION Multiple-Boiler Piping with Motorized Sequencing Valves CENTRAL CENTRAL HEATING HEATING RETURN SUPPLY FLOW RETURN WATER INLET FLOW RETURN FLOW RETURN Boiler Siphon Burner Condensate outlet Isolation valves Drain Central heating system pump Isolation valve Non-return valves Motorized sequencing valve Automatic vent valve Boiler safety valve Pressure gauge...
- Page 28 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 29 INSTALLATION Multi-Boiler Combination CENTRAL LT (*) HEATING SUPPLY CENTRAL HEATING RETURN MAKE-UP WATER 16 17 FLOW RETURN WATER INLET 17 16 FLOW RETURN 17 16 FLOW RETURN Boiler Siphon Burner Condensate outlet Isolation valves Drain Central heating system pump Isolation valve Non-return valves Control valve Automatic vent valve...
-
Page 30: Draining The Condensate
INSTALLATION 2.8 Draining the condensate 2.9 Neutralising the condensate RTC condensing boilers produce a flow of condensate that varies Installation of a condensate neutralisation kit is always recom- 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 31: Combustion Gas Exhaust
INSTALLATION 2.10 Combustion gas exhaust RTC 8000-RTC 10000 The flue pipe (1) and the connection to the stack (2) must conform to applicable national and local laws and standards. Flue pipe must be rigid, impermeable to fumes, able to withstand mechan- ical strain, heat, and the action of combustion gases and the con- densate formed by them. -
Page 32: Venting Requirements
INSTALLATION 2.10.1 Venting Requirements Vertical Terminations: − Roof penetrations should follow all appliance codes and the vent manufacturer‘s instructions. The vent should never be installed at less than the required clearances to WARNING: Risk of system damage or personal injury! combustible materials per UL, NFPA and local codes. -
Page 33: Combustion Air From An Adjacent Room
INSTALLATION 2.10.4 Combustion Air from an adjacent room Where combustion air is to be used from within the building, air must be provided into the equipment room through two perma- nent openings into the inferior building. Each opening must have a minimum free area of 1 square inch for each 1,000 Btu/hr of the total input rating of all fuel burning equipment in the space. -
Page 34: Door Hinges
INSTALLATION 2.11 Door hinges 2.11.1 Changing the direction of door opening Two different door hinge systems have been used to meet differ- The boiler door hinges are fitted on the right of the door in the ent design requirements factory. If you need to reverse the direction of opening, remove −... - Page 35 INSTALLATION Door - RTC 8000 - RTC 10000 Remove the four nuts (7) and remove the bracket (8). Open the door, unscrew the nuts (1) securing the cover bracket (2) and remove the bracket. Fit the hinge on the opposite side, reversing the steps described Hermetically close the door again by tightening the bolts (3) until above.
-
Page 36: Earth Connection
INSTALLATION 2.12 Earth connection RTC 8000-RTC 10000 A ground connection is provided on the rear head (models RTC 3000-RTC 6000), and at the centre of the frame (models RTC 8000- RTC 10000) for connection to an efficient earth system. Proceed as follows: −... -
Page 37: Fitting The Casing Panels
INSTALLATION 2.13 Fitting the casing panels − Fit the front top panel (8) over the pins provided. RTC 3000-RTC 4000-RTC 5000-RTC 6000 Proceed as follows to fit the boiler casing panels: − Push out the pre-formed cutouts in the boiler’s side panel (2) or (3) depending on what side you want to install the control panel) corresponding to the oval cable grommets in the control panel. - Page 38 INSTALLATION − Fit the top panels (13, 14, 15 and 16) RTC 8000-RTC 10000 Proceed as follows to fit the boiler casing panels: − Push out the pre-formed cutouts in the side panel (3) or (4) (depending on what side you want to install the con- trol panel) corresponding to the oval cable grommets in the control panel.
- Page 39 INSTALLATION − Fit the side panels (1, 2, 3, 4, 5, 6, 7 and 8) over the boiler's − Fit the top rear panel (13) over the pins provided. top profiles. − Fit eight AVP pins in the holes in the front of the panels 9, 10, 11 and 12 (two per panel) and fit the top panels −...
-
Page 40: Control Panel Support Kit
INSTALLATION 2.14 Control panel support kit − Fit the central rear panels (15, 16), inserting them from the sides to engage the pins in the top and bottom panels. (*) Control panel support kit: accessory not supplied as standard. − Fit the front profile 17 over the pins on the top panels. -
Page 41: 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 life phases and secure against unintentional reconnec- NOTICE: Risk of boiler damage through contaminated com- tion. -
Page 42: 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 43: 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 44: 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 45: Inspection And Maintenance
SHUTDOWN 5 INSPECTION AND MAINTENANCE 5.4 Adjusting the door Make sure that the door presses uniformly all around the double 5.1 Why is regular maintenance important? seal to prevent dangerous fumes escaping into the air. Proceed as follows to adjust the door seals: Heating systems require regular maintenance and service for the RTC 3000-RTC 4000-RTC 5000-RTC 6000 following reasons:... -
Page 46: Cleaning The Boiler
SHUTDOWN 5.5 Cleaning the boiler 5.6 External cleaning Clean the outside of the boiler casing with a soft cloth damped in soapy water. DANGER: Risk to life from electric shock! To remove stubborn marks, use a cloth damped in a 50% mix of −... -
Page 47: Boiler Inspection - Water-Side
SHUTDOWN 5.8 Boiler inspection - water-side RTC 8000 - RTC 10000 models Carrying out the inspection is important in order to check the con- dition of thermal exchange surfaces and the presence of sludge or lime scale. The boiler's inner can be inspected through dedicated openings The inspection must be carried out with the boiler in the off position, in safe mode and cold (room temperature), with all system shut-off valves closed except the discharge valve. -
Page 48: Inspection And Maintenance Reports
SHUTDOWN 5.8.1 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 49: Troubleshooting
SHUTDOWN 5.9 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 gas flow burner. − Check and adjust the burner. ture. -
Page 50: 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 52 RIELLO S.p.A. Via Ing. Pilade Riello, 7 37045 - Legnago (VR) www.rielloboilers.com RIELLO NORTH AMERICA 35 Pound Park Road Hingham, Massachusetts U.S.A. 02043 2165 Meadowpine Blvd Mississauga, Ontario Canada L5N 6H6 www.rielloboilers.com The manufacturer strives to continuously improve all products: appearance, dimensions, technical specifications, standard equipment and...