RS Series Cast Iron Boiler
Installation,Operation & Maintenance Manual
RS Series Range Of Floor Standing Oil / Gas Fired Boiler
Cast Iron Sections
Triple Pass Design
76 kW - 145 kW
REV.01 / 2011-RS
Contents :
Description
3
Certifications , Symbols
3
General Warnings
4
Safety Instructions
5
General Characteristics of RS series Boilers
6
Boiler Dimensions , Delivery Conditions
7
Information on the Boiler Plate
8
Technical Parameters
9
Recommended Minimum Distance for Installation
10
Important Instructions About Boiler Room
11
RS Series Cast Iron Boiler Parts and Spare Parts List
12
Cast Iron Sections with High Efficiency Design , Boiler Room Ventilation
13
Plumbing Instructions
14
Gas Side Resistance and Exit Flue Gas Temperature
15
Important Instructions About Flue and Connecting the Fuel Tank
16
Boiler Control Panels
17
Standart Control Panel Electric Diagram
18
Operating Instructions , Loading and Unloading The Boiler Water
19
Checking and Starting the Boiler
20
Care Instructions , Cleaning the Boiler
21
Burner Door and Burner Connection
22
Instructions for Product Disposal , Positioning the Boiler
23
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EN 303/1: Heating boilers with forced draught burners - Terminology, general
requirements, testing and marking
EN 303/2: Heating boilers - Part 2: Heating boilers with forced draught burners - Special
requirements for boilers atomizing oil burners
EN 303/3: Heating boilers-Part 3: Gas fired heating boilers-Assembly comprising a boiler
body and a forced draught burner
Please , consider on the standards in installation.
Caution , Danger
Important
Info
Please do not touch or remove any parts of the boiler for starting,adjusting or repairing the boiler except the processes
written in this manual.
Our licensed frenchisers and services will give you instructions about working principals,conditions and care instructions
after installing and starting the boiler.
EC Directives :
(90/396/EEC) Gas Appliances Directive
Symbols :
RS series boilers are in compliance with ;
(89/336/EEC) Electromagnetic Compatability Directive
Certifications :
Our professionals will be glad to answer all your questions at any time.
Description :
(92/42/EEC) Efficiency Directive
RS SERIES CE approved, No: CE-1015BR0260
In this manual you will find the instructions for Rima three pass cast iron boilers suitable for both gas and liquid fuel. RS
series hot water boilers and related informaton for installation,operation and maintenance of the boiler. For high efficiency
and proper working conditions please read this manual carefully. For more information please check the product brochure or
get in touch with Rima technical services.
Please call Rima services and technical officials for installing the boiler.
3
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The periodical controls of the boiler and the burner must be done. If not, the boiler may lose efficiency and the fuel amount
used may increase.
In this manual you will find informations only for the boilers. Please do not forget to get the instruction manual of the burner
that you purchase from the manufacturer of it. Burner is not delivered with the boiler. In this case we do not give any
guarantee for the burner that you purchase. Please get the guarantee certificate for the burner from your supplier.
In the assembling of the boiler; there must be a proper and safe concrete platform for to put the boiler on.
RS series boilers are delivered without burners. For suitable burner selection please get in touch with Rima technicians.
Suitable burners must be selected for taking high efficiency.
If the boiler is stopped automatically because of overheating do not add cold water to the boiler for re-starting. In this case
wait for the boiler to cool down and re- try starting.If it does not start ,please get in contact with technical services.
RS series cast iron boilers are designed for working with hot water heating and/or hot water plumbing and produced with
the proper technology and materials suitable for this design.This design is restricted to use out of it's aim of use.
General Warnings :
RS series boilers are delivered as sections and services assemble the boilers in the operation area.The assembling of the
boiler must be made by Rima technical services . Removing or re - assembling of the boiler should also be made by
licensed Rima services, if not the risk of damage is high.
Starting and first operation of the boiler must be made by authorized Rima technicians.
Please be sure that the front door (burner door) for the boiler is strictly closed and burner connections are properly made as
the boiler is working.
The periodical and yearly controls of the boiler must be done properly and on time.Natural gas is a clean fuel and doesn't
make a lot of dirt in the boiler.But the boilers that liquid fuels are used as fuels are much more easily get dirt. Controls and
care operations of the boiler is needed for keeping high efficiency and long life of the boiler.
RS series boilers are produced for heating only. For heating the sanitary water another equipment such as water heater or
heat exchanger is needed.For proper efficiency in this operation,correct water heater or heat exchanger must be selected.
The electricity of the burner and boiler is supplied by city electric network.In this case the electric and lighting systems of the
boiler room, burner and boiler electrical connections, grounding line of control panel and boiler must be made by
professionals under the required and related standards.
In the assembling of the boiler,an empty space must be left from sides for safety requirements and for future repairing
operations.
In summer months, when the boiler is off for a long term, for preventing probable problems with circulation pumps, must
be started 1 -2 times per month for 5 minutes. (The water with chalk can cause problems , if the pump is not used for long
time period.)
Repairing and periodical controls of RS series boilers requires profession.In this manual the responsibilities and required
information for users of the boiler is declared. Besides these declared operations, boiler must not be started by a person
rather than the user or one of our technicians.Please do not try to make adjustment or do not touch any parts of the boilers.
In cleaning, repair and other care operations the original spare parts which approved and manufactured by Rima , must be
used.
The capacity choice of the boiler must be made according to the projects that prepared properly in the terms of related
standards.If not , the boiler efficiency will be low.
Do not add or pump water to the boiler or plumbing system as it is working and hot . For adding water to the boiler or to the
system please wait for water temperature to reach 40ºC. Circulation pump must surely be started while adding water to the
system . If not , the sections may crack.
If the boiler will be kept off for a long time the electric system must be shut down from the main fuse.The electric must be
cut off from the main shelter/fuse as the boiler is in repair,service or cleaning.
4
Safety Instructions :
...
If you smell gas :
.................
.
Caution!
Risk of damage!
.
Do not use sprays, solvents, chlorinated cleaning agents, paint, adhesives or similar substances in the vicinity of the
appliance. These substances can cause corrosion, including in the flue system.
Do not touch hot water connections or the flue outlet when the boiler is operating.
Danger!
Notify your gas supplier or a suitably qualified heating engineer.
Close the gas stop cock.
Do not use or store explosive or easily flammable substances such as petrol or paint in the same room as the applience.
Never put the safety devices out of operation or tamper with them so as to impair their function.
Get out of the house.
Risk of poisoning and explosion due to a malfunction.
Safety Caution!
Inappropriate alterations can cause damage!
Under no circumstances should you ever attempt to make alterations to the gas heating boiler or other parts of the
system.Never try to carry out maintenance work or repairs on the appliance yourself.
Inflammable mixtures of gas and air may explode.
Do not damage or remove seals on components.Only suitably qualified heating engineer or our customer service may
removed sealed components.
Do not smoke.
Always perform the following steps prior to inspection work.
Do not switch lights on or off.
Always observe the following safety instructions and regulations.
Danger!
If you smell gas, risk of poisoning and explosion due to a malfunction!
Open the windows and doors.
Warn other residents.
Do not use a telephone in the area of the hazard.
Do not use naked flames (such as matches or cigarette lighters).
Do not use any other electrical switches.
Close the gas shut-off valve.
Close the heating feed and return.
5
General Characteristics of RS series Boilers :
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.
RS series boilers are cast iron sectioned boilers.This brings easy assembling and easy capacity increasing by adding
sections to the boiler. The transportation and installation of the boiler is easy because of the boiler is assembled in boiler
rooms. It is easily to carry or shift position without breaking walls etc.
RS series boilers are produced from special cast iron alloy EN GJL 200 , which gives high resistance against corrosion and
thermal expansions. They are long life boilers according to this special cast iron alloy.
With the help of horizontal and three pass specially designed sections burning gases pass three times in the boiler and
transmits burning energy to the water inside the sections at high level.
RS series boilers are high efficiency boilers. ( According to the fuel max. heating value % 91 – 93 ). With this high efficiency
and perfect isolation more energy is gained with less fuel. Heat loses are minimized on RS series boilers.
By appropriate burning room, heat transfer surface, turbulator, collector and isolation high heat transfer and optimum flue
gas emission results are provided.
In RS series boilers,heat transfer surface areas are increased by the special wings in the burning room and chimney
ways.This increases the heat transfer ability of cast iron boiler to the maximum level.
RS series boilers operating pressure is 6 bar maximum, and working temperature is 90 °C maximum.
RS series boilers are, blowing burner, cast iron sectioned, between the capacities 76 – 145 kW with proper burner
connection, works with gas or liquid fuel in 5 different ( 5 – 9 sections) type.
6
Boiler Dimensions :
Delivery Conditions :
.
Boiler sections are delivered as not - assembled according to the boiler room specifications and dimensions.In not
assembled deliveries, sections and assembling aparats are delivered on a pallet, cabins,isolation and other elements are
delivered in a box. Rima technicians make the assembling of the boiler.
7
Information on the Boiler Plate :
The identification plate is mounted on the back side of the boiler cabin.
RS -05 , RS-06 , RS - 07 …
8
Technical Parameters :
9
Recommended Minimum Distance for Installation:
Do not put flammable materials on top of the boiler or near the boiler than specified safety distance.
.
.
There must be space for the tools that will be
used in boiler room.
The measurements of the boiler room and the empty spaces must be arranged properly for future assembling repairing, reassembling, burner connecting issues.
* The concrete platform must be in the mentioned dimensions.
* Concrete platfrom must not be coated with slipper materials such as ceramics etc.
* If sound isolaton will be made , first do the sound isolation than make the concrete for platform.
* Platfroms must be made of BS 25 concrete and scales.
In RS series boilers burner doors can be opened to
both sides. According to this the required empty
spaces for the both sides are given equal
(min. 700 mm). This will gives advantages for operations.
If the boiler room area is not enough for this
you can choose one side and leave the big empty
space there. Half of this empty space will be enough
for the other side in these conditions.
10
Important Instructions About Boiler Room:
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Boiler must not be installed on carpet.
.
There must not be any other equipments such as aspirator, air condition central etc. in the boiler rooms. These kind of
equipments can make vacuum effect and defect boilers pull force. This can cause burner failures.
The ceiling of the boiler room can be isolated for sound and heat isolation. The position and place of the boiler is important
for sound isolation of the boiler.
Boiler room must have a good lighting and control switches of lighting must be outside of the boiler room.
There must not be equipments like water pump,contactor etc.. in the boiler room.
Gas alarm equipments must be placed to the proper highth as mentioned on standards.
No one except the responsible person should get in to the boiler room.
Children must not enter to the boiler room. A second key must be kept in safe place for urgent matters.
Fuel tanks must be put in another place which is rounded by walls.Natural air conditioning is needed for this place.
Boiler room must be air conditioned by natural or other ways.
Humidity must be prevented in boiler room.
Boiler room must have the requested dimensions .
There must not be any kind of explosive , burning and flammable materials in the boiler room.
There must not be any kind of explosive , burning and flammable gases in the boiler room atmosphere.
For the efficiency of the burner and the boiler,boiler room must be kept clean and dry.
For feeding water to the boiler,water line must be arranged near the boiler. And for filling out the water of the boiler in
necesarry conditions, there must be a connection to drainage in the system.
If there are any electric keys, cables etc. Which can cause short circuits must be fixed, renewed as soon as possible.
In Natural Gas or LPG use ; boiler room,flue,system and plumbing issues must be under parameters of EN standarts and
gas offices orders. Rima is not responsible for any failure or problems that will be occured because of inadequate or not
sufficiently qualified conditions of boiler room, plumbing and other systems.
The instructions of local gas delivery must be applied.
Before painting , keep flammable materials out.
Before any welding operation in boiler room, boiler must be stopped and the gas flow must be stopped by turning of the gas
valve.
Do not touch the boiler when it is hot.
Switch off the boiler immediately if there is danger of burning or explosion ( elecricity problem, gas leakage, liquid gas , etc.).
11
RS Series Cast Iron Boiler Parts :
RS Series Cast Iron Boiler Spare Parts List :
12
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.
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If the fuel is natural gas
* If natural ventilation system is used.
** Ventilated airing system is used.
*** Bottom value shows the clean
air input up shows the air output.
Cast Iron Sections with High Efficiency Design :
3 draught design forces the flue gas to circulate inside the body of the boiler three times before the chimney exit,
transferring all usefull energy to the water inside the sections. The optimized combustion chamber combined with perfect
heat insulation provides maximum fuel efficiency.
The combustion room of the boiler is positive pressure. Boiler is working under horizontal 3 pass principal.
Boiler Room Ventilation :
There are three reasons for fresh air in boiler rooms.
1.The air needed for the burning in the boiler.
2.The air needed for prevention of dirt and dust,for releasing the gases and fuel to put out.
3.The air needed for overheating in the boiler room.
Ventilation for first two reasons are continously needed.The third one is needed especially for the boilers which
are working on summer time.
Maximum temperature for the boiler room must be 32 °C and boiler room must be protected against freezing.
13
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Plumbing Instructions :
Fresh water must be added periodically to the plumbing. The chalk and other chemicals will connect with the system and
become solid . For avoiding this , closed expansion tank must be used in the system.In the systems that closed expansion
tanks are used, water will flow in closed system so it will not evaporate and lost.So in this kind of systems the water level
wiill stay same and fresh water addition will not be necessary. This will prevent chalk and dust and the life of the sytem will
be long.
The water in the radiator or heating system is not healthy.Do not use this water as drinking or cleaning water.Do not take
water from the system.If the water level is low , water addition is needed.
For avoiding chalk and other chemical dust problems soft water must be used in the system.Plumbing system water quality :
Ph ≥ 7,2 Th ≤ 25 °Fr
If the city sanitary water is not in requested quality water addition from wells or other sources must be made after testing
it.For reaching the requested quality additional processes must be applied to the water if needed.
For avoiding the chalk and other dust to get in to the boiler, or from boiler to plumbing system dust holders must be placed
in and out line of the system.
Circulation pump must be connected to the water output of the boiler and the capacity of the pump must be suitable to the
boiler capacity. If not,problems may occur in flowing of the water and heating efficiency of the boiler.
For working the system properly 4 way mixture valve or thermostatic control by-pass pump must be used for increasing
return water temperature.
By connecting a three way motor valve between the forward and return line of heating system,the water that flows to the
system can be controlled in ratios.
There must be water inside of the boiler every time. If not , corrosion can occur in the boiler and the plumbing system. If the
boiler will not be used in winter season, for avoid freezing , anti-freeze solution must be used.
14
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*** RS series boiler is designed,forced circulation hot water heating systems only.
For healthy working conditions of the boiler,temperature difference between water forward and water return must not be
more than 20 °C.And boiler must not be started or work under the water volumes which is mentioned in the below table.
Gas Side Resistance and Exit Flue Gas Temperature :
15
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Important Instructions About Flue :
Important Instructions About Connecting the Fuel Tank :
The platform of the fuel tank must be strong to carry the tank. If the fuel tank is outside tank , connection pipes must be
isolated. Fuel tank must be placed in higher level than the burner.The height difference between the burner and fuel tank ( H
) must be more than 4 m. In the seasons that the boiler is not used,fuel tank must be empty for avoiding corrosion.
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Standart Control Panel (Single Stage): (Dual Stage) :
1- Main ON/OFF Switch 1- Main ON/OFF Switch
2- Boiler Thermostat 2- Boiler (TRZ)Thermostat
3- Boiler Thermometer 3- Boiler Thermometer
5- Defect Indicator 5- Defect Indicator
6- Working Indicator 6- Working Indicator
7- Reset Button 7- Reset Button
8- Fuse 8- Fuse
9- Water pressure defect indicator 9- Water pressure defect indicator
10- Ecopanel mounting place 10- Ecopanel mounting place
Eco Control Panel :
1- Manual mode key / Emission Measurement key (not applicable for district heating controllers)
2- Operating mode key for permanent and temporary operating modes (Basic display)
3- Heating characteristics key
4- Information key for the display of temperatures and operating status
5- Multi-functional Display
6- Cover clip for the service jack
7- Daytime room temperature setpoint key
8- Night-time room temperature setpoint key
9- DHW daytime temperature setpoint key
10- Rotary pushbutton (push and turn)
11- Operating modes symbols
Boiler Control Panels :
4- Safety Thermostat with manual reset (set to 100 °C) 4- Safety Thermostat with manual reset (set to 100 °C).
17
Single Stage :
Dual Stage :
Standard Control Panel Electric Diagram :
18
Heating System :
.
Fuel and Electrical Connections :
.
.
Unloading Water of the boiler :
.
Loading Water of the boiler :
.
Operating Instructions :
In the system , the difference between direct flow temperature and the return temperature of the water must not be over 20
°C. The return water temperature must be over 50-55 °C. Boiler protection pump must be used for increasing the return
water temperature. The water level of the system must be measured every day (if it is open system by hydrometer,if it is
closed system by manometer) and water must be added if the level is measured low. But this water addition must not be
made while the system is hot. If there are problems that cause water leakages they must be fixed as soon as possible.
Plumbing system must be made by certificated professionals, under the terms of EN standards. EN approved materials
must be used in the system.
These connections must be made by certified professionals under the terms of EN standards.EN approved materials must
be used in the system.Burner,control panel, ecopanel etc. Manufacturer or distrubutor warnings, instruction manuals must
be read .Burner must not be started before boiler circulation starts.If circulation or protection pump has a failure burner must
be switched off. This system must work coordinate. Turning the pumps on when the water heat reachs over 40 °C is
completely wrong. Circulation pump and burner must work simultaneously.
Protection pump must be chosen properly accoridng to the capacity of the boiler.The connection of the pump to the
collectors must be done correctly with valve and thermostat connection. This way,system may stop in adjusted
temperature.In any failure situation (contactor,thermic failure,electricity cut ,other failures.) when the pumps are not working
( heating and protection pumps etc..) burner must not start. System must do this automatically.Electrical system must be
made according to all above information.
Loading and Unloading the Boiler Water :
Plumbing and all radiator valves must be opened if the boilers water will be unloaded. All the systems water can be
unloaded by boilers drainage as if the boiler is in the bottom of the system.If some part of heating system is under the boiler
room,unloading the water process can be made at a point at the bottom of the system.
Water must be loaded from the tap over the plumbing system to the boiler.During the loading process all valves of the
plumbing system and the radiators must be opened.For preventing air fill to the system this operation must be made slowly
and the stopper in the top must be opened. When water comes from this stopper it means that the process is finished. Air
must be taken from every radiator.
Water must be in quality which mentioned on ''plumbing instructions''.
Boiler must not be filled up with water when it is hot. This can cause cracks in sections.
19
Checking Before Started :
.........
.
Getting Started :
.....
Stopping the Boiler :
.....
Failure First Controls :
.......
Checking and Starting the Boiler :
Following controls must be done before starting the boiler.If there are any problems or failure, boiler must not be started.
Water level of the boiler must be controlled. Water must be added to the boiler if the water level is low.
Please call Rima technicians if there is a water leakage. Leakage must be prevented before starting the boiler. If there is a
leakage in the plumbing system,boiler must be started after repair.
Flue connections must be controlled. Boiler must not be started before repairing the connection if there is a problem.
Area must be properly air conditioned.
Gas valves must be checked as if they are on if gas fuel is used in the boiler.
Liquid fuel level of the tank must be controlled and fuel valve must be opened if liquid fuel is used in the boiler. Fuel - burner
connection must be controlled.If there are any problems , filters must be cleaned.
Working and the directions of the pumps must be controlled.
Electric system of the control panel must be controlled.
All water and gas valves of the boiler must be opened.
*** All other connections must be checked according to the system options.
Turn the main electric switch of the boiler room on. Working lamp will be on.
Start the circulation pump.
Turn the ''on / off '' switch of the burner to the mode ''on'' (Check the burner instruction manual.) The indicator light will be
on .
Adjust the boiler temperature from the thermostat.If the burner is dual level, adjust the boiler temperature same the single
stage.Dual stage (TRZ) thermostat adjust the temperature changes own by own ( + 8 °C ).
If the burner does not start , follow the instructions written on the manual of the burner.If the burner does not start after
applying the written operations in the manual,call the technical service of the burner.
Turn the ''on / off'' switch of the burner to the '' off '' position
Turn the ''on / off'' switch of the control panel to the '' off '' position.
Turn of the circulation pump.
Turn of the fuel valves.
Turn off the main fuse switch of the boiler room.
When a problem or failure occurs in the boiler or the burner,please make the following first controls before calling technical
services. Don't do anything rahter than mentioned controls. After these controls call Rima technical services.
If boiler stops working and doesn't start again ; Safety thermostate may have stopped the boiler because of overheating at
boiler water.In this case wait for the boiler to cool down and please make the following controls.
Check if fuel is coming to the burner or not. If not , make fuel to come to the burner.
Check if pump is working or not. If not , this could be the reason of overheating.Please get in touch with pump manufacturer
or distributor.
Check if the valves are on or off.Open the valves if they are closed.
Please push the safety thermostate switch after the boiler is cold enough.
Burner must start.
If the boiler doesn't start or if the safety thermostate stop the boiler again please call Rima technical services.
If the burner safety light is on ; Please check the burner instruction manual or get in contact with the burner manufacturer or
distrubutor services.
20
Daily Controls :
Periodic Controls :
.......
.
Yearly Controls :
.........
.
Smoke Channels Cleaning :
Care Instructions :
Boiler and burner controls are made in three programs.Daily (in everyday use ),periodic and yearly.
These are the processes that the user must apply every day in season of everyday use. Please read and apply the
instructions and controls mentioned in ''Pre Control'' section of the manual for daily controls.
For efficient use, preventing the possible failures and optimum life of the boiler periodic controls are important.It is
recommended that periodical controls for the boiler must be made by once in every three months.These periodical controls
are made by Rima technicians by applying following processes.
Boilers burning room and smoke channels check and cleaning if needed.
Leakage controls of water input - water output of the boiler and flue connections.
Valves check
Pumps check
Fuel filter control and cleaning if needed
Burning control (with eye).Burning and flame adjustments if needed.
Control of the liquid fuel sensor.Cleaning if needed.
Working and safety controls of burner and the boiler.
Yearly controls of the boiler must be made by Rima technicians before the season starts. Flue and flue lines must be
cleaned before calling technicians for yearly controls. In yearly controls rima technicians apply the following processes.
Situation and the leakproof of the sections and rope isolations controls.
Working pressure test for burning adjustment with the flue gas measurement system if needed.
Sensors and connection of the sensors test.
Boiler burning room and possible soot layers on smoke channels are checks and cleanings.
Connection and the leakproof of the boilers door test.
Leakproof of the connections of the boiler test.
Valves test for proper opening and closing.
Fuel filter test. Cleaning if needed.
Sensor of the burner liquids tests.Cleaning or renewing if needed .
Working and safety controls of burner and the boiler.
Cleaning the Boiler :
Before applying mentioned services to the boiler;electric must be cut off from the main switch,fuel valves must be closed,
control panel and the burner must be protected for avoiding any possible damage.
Because of the soot layer on heating surfaces, 100 °C increase on flue temperature brings out a % 5 decrease on
efficiency.By pulling out the M16 screws and stamps on the 4 hinges which connects door to the front section,open the
burner door. Clean the burning room, take turbulators out and clean horizontal smoke channels (2nd and 3rd pass). Than
clean the turbulator and put them in to the channels. Close the burner door strictly.In this cleaning operation soot layer may
occur in flue area.This soot particules can be cleaned by seperating horizontal smoke channels from boiler flue. After this
operation these two screws must be connected again and must be tested for leakage.
The time period for cleaning service is variable according to the fuel type of the boiler and period of use.In boiler cleaning
operation ceramic ropes that isolate front door with front section and flue with back section must be controlled and must be
renewed if needed.
21
Burner Door and Burner Connection :
In burner connection process there must not be any
empty space left between the front door and the
burner barrel.All connection points must be covered
with isolation material for avoiding any air leakage
possibility.
A metal flange is used for easier assembling of the
burner to the door. This metal flange is made of 10
mm thickness and in the dimensions of 198x198 mm ,
and burner hole dimension 110 mm (3).
The isolation of the burner door is made of a special
thermal ceramic which is durable up to 1250ºC and
has no defections on human health (1). Please be
sure that this isolation plate is carried carefully and
intensivly during transportation.
There is a ceramic rope fit in to the channels of isolation
door.This prevents leakages between isolation
door and front section of the boiler. After repairing
or cleaning service the doors connection with the
front section must be done properly,strictly.
RS series boilers doors are available for opening to
both sides. This brings advantages of assembling,
reparing and other operations.
A tempered ceramic glass is placed on to the burner
door for watching flame inside (2).
3
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