Riello 20031973, Installation, Operation, Maintenance And System Management Manual

Page 1: ...S T E E L B O I L E R S INSTALLATION OPERATION MAINTENANCE AND SYSTEM MANAGEMENT MANUAL RTS 3S ...

Page 2: ...ers up to 400 kW are used in conjunction with a fuel oil burner they conform to the Energy Related Products Directive 2009 125 EC and to the EU Delegated Regulation 813 2013 CONFORMITY RANGE MODEL CODE RTS 90 3S 20042418 RTS 115 3S 20031973 RTS 166 3S 20031974 RTS 217 3S 20031976 RTS 255 3S 20031977 RTS 349 3S 20031978 RTS 448 3S 20031979 RTS 511 3S 20031980 RTS 639 3S 20042417 RTS 850 3S 20044152...

Page 3: ...larly by an authorised r Technical Assistance Centre Their personnel are specially trained to keep your boiler efficient and cheap to run Technical Assistance Centres also stock any original spare parts that might be required This instruction manual contains important instructions and precautions that must be observed to ensure the trouble free installation and efficient functioning of your r RTS ...

Page 4: ...STEM MENAGER 15 Start up 15 Temporary shutdown 16 Preparing for extended periods of disuse 17 Cleaning 17 Maintenance 18 Useful information 18 INSTALLER 19 Unpacking the product 19 Overall dimensions and weights 20 Handling 20 Place of installation 21 Installation in older systems and systems requiring modernisation 22 Water connections 22 Anti condensate pump 24 Combustion gas exhaust 24 Boiler d...

Page 5: ...ical power and water demands that a number of fundamental safety precautions be respected bPeriodically check that operating pressure in the water circuit is over 1 bar but below the maximum limit specified for the boiler If this is not the case contact r s Technical Assistance Service or a professionally qualified heating engineer bIf the boiler is not going to be used for an extended period of t...

Page 6: ...f the tube bundle the flue gases pas through a chamber at the rear of the boiler and into the vent flue Their special design with tube bundle over the combus tion chamber makes these boilers far narrower than conventional pressurised boilers and therefore easier to install in boiler rooms with narrow doors or where space is limited The burner is installed in a hinged door to permit the adjustment ...

Page 7: ...low ACCESSORIES Immersion temperature sensor 1 1 1 1 Solar collector temperature sensor 1 Pipe temperature sensor 1 1 CLIMA COMFORT STANDARD Control by control panel with assistance of accessories listed below ACCESSORIES Immersion temperature sensor 1 1 1 Solar collector temperature sensor 1 Pipe temperature sensor 1 1 Two stage burner control kit 1 1 mixed zone kit 1 CLIMA MIX STANDARD Control b...

Page 8: ... 3474632 RL 70 3475032 RL 100 3475232 RL 130 3475432 20043900 RL 42 BLU Low NOx 20027567 4031188 MODULATING RL 50 M 3471602 RL 70 M 3477012 RL 100 M 3477212 RL 130 M 3477412 20043900 RL 55 M BLU Low NOx 3899210 4031196 RL 85 M BLU Low NOx 3896011 RL 28 M 3471002 1 1 4031198 1 RL 38 M 3471402 R Reference burner used during performance qualification tests to derive the technical data declared b bTo ...

Page 9: ...S 130 M 3789810 20043900 RS 150 M 20044638 ELECTRONIC CAM MODULATION RS 55 E BLU t c Low NOx 20038491 4031196 RS 68 E BLU t c Low NOx 3897432 4031196 RS 68 E BLU t c Low NOx 3897432 4031197 RS 120 E BLU t c Low NOx 3897632 RS 160 E BLU t c Low NOx 3788032 To be used together only for heat outputs up to max 1300 kW b bTo assemble disassemble the burners equipped with recirculation tube it might be ...

Page 10: ...mic insulation A supplied with the boiler a aDo not re use old burners if their blast tube lengths are below those specified in the table RTS 3S 90 115 166 217 255 349 448 511 639 850 1160 1450 L min 128 128 128 128 155 155 195 195 200 200 205 205 mm Diameter of door hole 140 140 162 162 180 180 205 205 205 230 230 270 Ø mm Thickness of door 93 93 93 93 103 103 118 118 119 119 119 119 mm L S S L I...

Page 11: ...er kW pn Collegamento di terra obbligatorio Raccordement à la terre obligatoire PER CATEGORIA COMBUSTIBILE E PAESI DI DESTINAZIONE VEDI ETICHETTA BRUCIATORE POUR CATEGORIE COMBUSTIBLE ET PAYS DE DESTINATION VOIR ETIQUETTE BRULEUR Portata term Débit therm min Hi Q kW Pot utile Puiss utile kW min 60 80 P Tmax Surface d échange m Superficie di scambio mbar bar kW RIELLO S p A Via Ing Pilade Riello 7 ...

Page 12: ...ful efficiency at min Pn 80 60 C HCV LCV 89 8 95 2 89 6 95 0 89 9 95 3 90 2 95 6 89 6 95 0 89 9 95 3 Efficiency at rated heat input in Low temperature mode h1 with return at 37 C HCV LCV 94 0 99 7 94 1 99 8 94 2 99 9 94 2 99 9 94 1 99 8 94 1 99 8 Heat loss in standby mode 240 300 360 430 500 600 W Flue gas temperature T 106 103 103 106 100 106 C Flue gas mass flow rate Pn Max 0 040 0 050 0 072 0 0...

Page 13: ...rature T 106 103 103 106 100 106 C Flue gas mass flow rate Pn Max 0 040 0 050 0 072 0 094 0 110 0 151 Kg s Furnace pressure 1 0 1 4 1 8 2 7 2 9 3 6 mbar Furnace volume 75 0 121 0 176 0 176 0 240 0 296 0 dm3 Total volume of flue gas side 112 176 2 535 2 615 3 575 443 dm3 Surface area for heat exchange 3 8 5 3 7 3 8 2 10 1 12 9 m2 Volumetric heat load Pn Max 1 203 947 941 1 229 1 066 1 180 kW m3 Spe...

Page 14: ...bar Furnace volume 453 453 613 812 1065 1297 dm3 Total volume of flue gas side 682 682 899 1209 1656 2088 dm3 Surface area for heat exchange 18 58 18 58 23 45 30 60 40 40 51 82 m2 Volumetric heat load Pn Max 988 1127 1043 1046 1089 1118 kW m3 Specific heat load Pn Max 23 0 26 3 26 0 26 5 27 4 26 7 kW m2 Maximum operating pressure 6 bar Maximum admissible temperature 110 C Maximum operating tempera...

Page 15: ...as cock and heating water cock are open While the system is still cold check that working pres sure in the water circuit is over 1 bar but below the maximum limit specified for the boiler If the system is equipped with a temperature controller or timer thermostat make sure that it is switched on Adjust the timer thermostat s or temperature controller to the desired temperature 20 C Turn the system...

Page 16: ...ites Repeat this operation 2 3 times at the most If the prob lem persists after that call r s Technical Assistance Service If you need to shut down the system for a short period proceed as follows Turn the control panel power switch OFF and make sure that the green power indicator goes out Turn the mains power switch OFF bDo NOT perform this procedure if outdoor tempera ture falls below ZERO risk ...

Page 17: ...ped in soapy water to clean the boiler s external casing To remove stubborn marks use a cloth damped in a 50 mix of water and denatured alcohol or a suitable clean ing product Carefully dry the boiler after cleaning aDo not use abrasive cleaning pads or powder detergents aNever clean the boiler without first disconnecting it from the mains electricity supply by turning the main power switch and th...

Page 18: ...E AND COMBUSTION EFFICIENCY MEASUREMENTS r s Technical Assistance Service is qualified to satisfy these legal requirements and can also provide useful information on MAINTENANCE PROGRAMMES designed to guarantee greater safety compliance with applicable legislation freedom from the risk of fines in the event of spot checks Date Work done Date Quantity supplied Date Quantity supplied Date Quantity s...

Page 19: ...truction manual is an integral part of the boiler Once located read it thoroughly and keep it safe 2 THE CASING PANELS complete with assembly accessories 3 THE FRONT COVER to fit on top of the front door IMPORTANT For the boiler to function correctly it must be connected to a r TECH control panel and dedicated control accessories A A RTS 90 511 3S RTS 1160 1450 3S RTS 639 850 3S Casing panels supp...

Page 20: ...760 820 820 890 890 1000 1047 1147 1237 mm A1 Base width 580 640 690 690 750 750 790 790 900 980 1070 1160 mm B Depth 1155 1330 1500 1500 1660 1960 2085 2085 2375 2657 2954 3173 mm B1 Base depth 860 1010 1180 1180 1296 1596 1692 1692 1965 2236 2533 2754 mm C Height 1205 1285 1390 1390 1524 1490 1685 1685 1830 1920 2080 2222 mm D Burner height 380 380 400 400 468 468 510 510 560 570 625 650 mm E Fl...

Page 21: ...safety and control devices and to permit easy maintenance b bIf the specific weight of the gas supply to the bur ner is greater than the specific weight of air install all electrical parts at least 500 mm above floor level a aDo not install the boiler outdoors It is not designed to work outdoors and is not fitted with the necessa ry automatic anti frost systems to do so 1 m A B 1 m L 1 m 10 cm H R...

Page 22: ...ecirculation water so demands Refer to the reference values listed in the table alongside REFERENCE VALUES PH 6 8 Electrical conductivity below 200 μS cm 25 C Chlorine ions below 50 ppm Sulphuric acid ions below 50 ppm Total iron below 0 3 ppm Alkalinity M below 50 ppm Total hardness 35 F Sulphur ions none Ammonia ions none Silicon ions below 30 ppm A B C SC S Ø D E F MI AS RI G RTS 3S 90 115 166 ...

Page 23: ...9 6 12 3 3 4 5 3 3 2 3 17 8 11 6 7 3 10 15 3 3 3 3 2 17 1 r RTS 3S 0 30 60 90 1 Boiler 2 Central heating manifolds 3 Disconnect valves 4 Pumps 5 Non return valves 6 Automatic vent valve 7 Boiler safety valve 8 Boiler drain cock 9 Storage cylinder safety valve 10 System filling cock 11 CH expansion vessel 12 Remote storage cylinder r 7200 13 Storage cylinder drain cock 14 DHW expansion vessel 15 So...

Page 24: ... upstream from the water fitting to measure effective water return temperature and control the anti condensate pump or the temperature controller stabilisation function b bAny temperature controllers installed remotely from the control panel must be compatible with the system s electrical connections and functioning logic 0 30 60 90 Ø H The flue gas exhaust and its connection to the stack must be ...

Page 25: ...door hinges are factory fitted on the right of the door If you need to reverse the direction of opening remove the boiler s side panel and proceed as follows The boilers has 3 hinge points so that the direction of 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 Chan...

Page 26: ...r b bIf it proves difficult to align the bolt 6 with the hole in the door slightly loosen the door fixing bolts 1 and lift the door gently to align the hole with the bolt 6 Only lift the door by means of equipment that is suitable for the weight invol ved using suitable safety equipment Once the bolt 6 has engaged its hole re tighten the door fixing bolts 1 Insert a spanner through the slot in the...

Page 27: ...e opposite side of the door and fix it in place with the safety bolts 4 b bMake sure that the safety bolts 2 and 4 are securely tightened before attempting to open the door Completely unscrew the main fixing bolts 1 and open the door These bolts are captive in the door and cannot be removed Remove the spare hinge assembly B bolt 9 bushing 10 and washer 11 opposite the hinged side of the door ...

Page 28: ...t with the bolts 2 Remove the plug 1 taking care not to lose the spring from inside the threaded tube Remove the bolt 3 and the nuts 4 and pull the hinges out from their seats Fit the hinges on the opposite side making sure that the pivots above the nuts 6 engage the door correctly If neces sary screw down the nut 6 to raise the pivot Finally tighten the bolt 3 to secure the hinge System B RTS 448...

Page 29: ... size and complies with legislation in the country of installation Fit the nut and washer 1 to the earth terminal and tighten the nut 1 2 1 Connect the other end of the cable to the system s earth bar b bAnother hole in the left side of the boiler head can also be used to earth the appliance If you wish to use this hole for the earth connection remove the terminal fittings from the right of the he...

Page 30: ... the top rails 1 running between the front and rear heads Secure the side panels in place with the top cross beams 7 and the screws provided Fit your chosen control panel on the left panel 4 or right panel 5 as instructed in the control panel s own instruction manual Route the electrical cables and insert the sensors in their sockets b bUse the copper socket P to insert the sensors of the safety d...

Page 31: ...ase then hook their top lips over the top rails 1 running between the front and rear heads Secure the side panels in place with the top cross beams 7 and the screws provided Fit your chosen control panel on the left panel 4 or right panel 5 as instructed in the control panel s own instruction manual Route the electrical cables and insert the sensors in their sockets b bUse the copper socket P to i...

Page 32: ...32 INSTALLER P Clip Sensor Sensor Sensor BOILER SAFETY DEVICE sensor Guide b bInsert the sensors belonging to the safety devices into the copper socket P Location of sensors LOCATION OF SENSORS ...

Page 33: ...rly charged The working pressure in the water circuit is over 1 bar but below the maximum limit specified for the boiler The water circuits have been properly bled The mains power connections to the boiler and its accessories burner pump control panel thermo stats etc have been properly made b bThe phase neutral polarity has been respected A ground earth connection is obligatory Preparing for init...

Page 34: ...urner should now ignite and remain in operation until the set temperature is reached If any ignition faults or malfunctions occur the burner performs a LOCKOUT SHUTDOWN This is shown by the red button light on the burner and by the warning light on the control panel b bIf a LOCKOUT SHUTDOWN occurs wait about 30 seconds before resetting the burner To reset the burner press the red button light on t...

Page 35: ...from around the door seal If there is any leakage of combustion gases adjust the door as instructed on page 36 Make sure that all the pumps in the system are free and rotate in the right direction Turn off the main power switch to the boiler and make sure that the boiler shuts down properly Provided all the above conditions are satisfied start the boiler up again then analyse the combustion fumes ...

Page 36: ...lts 1 and open the door These bolts are captive in the door and can not be removed b bThe first time you open the door remove the spare hinge assembly B bushing 10 bolt 9 and washer 11 opposite the hinged side of the door ADJUSTING THE DOOR Make quite sure that the door presses uniformly all around the double seal to prevent dangerous fumes escaping into the air from the pressurised furnace Procee...

Page 37: ... cleaning rods 3 or other tools of suitable size and shape to clean inside the tubes Remove any built up deposits from the flue gas box through the access door opening b bIf you are using fuel oil burners with a smoke scale reading higher than 3 perform the following actions every 300 hours of operation Clean the boiler s heat exchange surfaces Check and clean the turbulators Replace if worn or da...

Page 38: ...ler dirty Clean the flue gas pipes Boiler and burner mismatched Check specifications and settings Insufficient air fuel flow to burner Check and adjust the burner Control thermostat problem Check the functioning of the thermostat Check the temperature setting The boiler does not reach its temperature setpoint The boiler becomes dirty very quickly Burner badly adjusted Blockage in stack Burner air ...

Page 39: ...oiler has reached the set temperature but the radiators are still cold Bleed the circuit Pump malfunctioning Check unseize the pump Problem with minimum tempera ture thermostat if present Check the temperature setting Fumes escaping into the air There is a smell of fumes Clean the boiler body Clean the flue gas pipes Check that the boiler flue gas pipes and stack are all properly sealed Check that...

Page 40: ...Tel 0442630111 Fax 0442630371 www riello it As part of the company s ongoing commitment to perfecting its range of products the appearance dimensions technical data equipment and accessories may be subject to variation Cod 20030350 ...