Commissioning; Preparing For Initial Startup; Third Party Control Units; Hydraulic Connection To The Heating System - Riello RTC-80 Series Installation, Operation And Service Manual

3 COMMISSIONING

3.1 Preparing for initial startup

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NOTICE: Risk of boiler damage through contaminated com-
bustion air.
− Never operate the boiler in very dusty conditions, e.g. if
building work is taking place in the installation room.
− Ensure adequate ventilation.
− Never use or store chlorinated cleaning agents or haloge-
nated hydrocarbons (as contained in spray cans, solvents
or cleaning agents, paints and adhesives, for example) in
the boiler room.
− A burner contaminated during building work must be
cleaned before commissioning.
− All cover plates, enclosures, clean out ports, and guards
must be in place at all times, except during maintenance
and servicing.
− Never burn garbage or paper in the unit, and never leave
combustible materials around it.

3.2 Third party control units

Control panels are not supplied.
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NOTICE: System damage due to incorrect sensor position!
Safety cut-out and thermostat sensors of third party control units
must be fitted in the instrument tapping of the outlet of
the boiler.
− The third party control unit (building management system
or PLC controllers) must ensure a maximum internal boil-
er water temperature that is sufficiently different from the
high limit safety cut-out. It must also be ensured that the
digital burner controller rather than the boiler water tem-
perature regulator switch the burner on and off.
− The control unit must ensure that the burner is switched to
low fire before being shut down.
− Select control equipment that allows a gentle start-up with
a time delay when the system is cold.
− After the burner demand, an automatic timer (for example)
should limit the burner to low fire for a period of approx.
180 seconds. This restricted heat demand will prevent un-
controlled starting and stopping of the burner.
− It must be possible to show the number of burner starts on
the control unit used.

3.3 Hydraulic connection to the heating system

− If the system temperatures are different, use both return
connectors high temperature and low temperature. For an
optimum energy yield, we recommend supplying a flow
rate of > 10 % of the total nominal flow rate via the low
temperature flange, with a return temperature below the
dew point. If there are no varying return temperatures,
only the low temperature flange needs to be connected.
− Size the pumps correctly. High flow rates and oversized
pumps can result in the accumulation of sludge or deposits
on the heat exchanger surfaces.
− Before connecting the boiler, flush sludge and dirt out of
the heating system.
− Ensure that no oxygen enters the heating water during op-
eration.
− Only operate the boiler in sealed unvented systems.

3.4 Making the electrical connection

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DANGER: Danger to life through electric shock!
− Before opening the boiler, isolate the heating system across
all live phases and secure against unintentional reconnec-
tion.
− Carefully route the cables/leads and capillary tubes.
− Ensure that capillaries are never kinked.
− Only carry out electrical work if you are a competent per-
son. If you are not suitably qualified, arrange for a quali-
fied electrician to make the electrical connections.
− Observe local installation regulations.
− Create all electrical connections in accordance with Nation-
al Electrical Code or the applicable and local regulations.
9
NOTICE:
− The phase-neutral polarity must be respected.
− A ground (earth) connection is obligatory.
Wiring diagrams related to the burner installation may be found in
the burner installation manual.

3.5 Fitting temperature sensors

9
NOTICE: System damage through damaged capillaries or in-
correctly fitted temperature sensor.
− Ensure that the capillaries are neither kinked nor flattened
when uncoiling and routing them.
− Always push the temperature sensor completely into the
bottom of the sensor well.
− Insert the temperature sensor set as far as it will go into
the test point (to the bottom). Mark the sensor to deter-
mine if it is correctly installed.
− Secure the temperature sensor set in the test point with a
sensor retainer.
− Never kink excess lengths of capillaries.
− Route the sensor lead through the cable conduit to the
control unit.
− Connect the sensor lead to the control unit.
− Complete the commissioning report.
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COMMISSIONING