Verona Riva Installation & Operating Instructions Manual

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Page 1

Riva HEAT ONLY

WALL HUNG GAS BOILER FOR

CENTRAL HEATING SUPPLY

BOILER INSTALLATION, OPERATION

INSTRUCTIONS

Please Read Instructions Carefully

Save for Future Reference

— Do not store or use gasoline or other flammable vapors and liquids

in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

• If you can not reach your gas supplier call the fire department.

— Installation and service must be performed by a qualified installer,

service agency or the gas supplier.

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Manufactured by:

Biasi S.p.A.

Verona, Italy

Distributed By:

Quincy Hydronic Technologies, Inc.

80 Rochester AVE. Suite # 12

Portsmouth, NH 03801

Phone: 603-334-6400

Fax: 603-334-6401

RIVA HEAT ONLY MANUAL - REV

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RIVA HEAT ONLY MANUAL - REV A

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Dear Customer:

Thank you for buying a Biasi Riva Heating Only Boiler System.

The Riva Heating Only is a high efficiency, non-condensing, wall mounted gas boiler which provides central heat supply water.

We realize that it is not possible to answer all questions about the Riva boiler system in this manual. Reading this installation manual does not make the reader an expert in all aspects of installation and operation, and does not replace the need for a qualified, licensed heating contractor. We urge you to contact your installing contractor or distributor if you are in question about any aspect of your boiler's performance. Our main concern is that you are satisfied with your boiler and its performance. We require that your contractor complete efficiency tests using instruments.

The external controls and accessories listed in this manual (excluding those supplied inside the boiler) are intended to serve as guidelines rather than specific recommendations. We realize that other makes and models of such devices are available and can be used as successfully as those we specify. The installing contractor is the best judge of a system's specific requirements, as well as the local availability of certain makes and models of controls and accessories. The preceding does not apply, however, to the equipment that comes with every boiler, such as the overheat control and pressure relief

valves. The installation of the specific devices supplied with every boiler is

absolutely necessary to the safe operation of the boiler and protection of the heating system.

All BIASI wall hung boilers are built in accordance with the ASME boiler and pressure vessel code, and bear the "H" stamp. The Entire range of applications for the Riva boiler has been tested to standard CSA 4.9 and is CSA compliant.

This Riva Heating Only boiler has a 2 year warranty, a copy of which is provided with the boiler. Please be sure to return the warranty registration card as the warranty will be void without your boiler's serial numbers (located on the ratings label affixed to the boiler), date of installation and the name of your installer being on record in our files.

Thank you for purchasing our Riva Heating Only boiler. If you have questions or comments, please don't hesitate to contact us immediately. Our goal is 100% customer satisfaction.

QHT inc.

RIVA HEAT ONLY MANUAL - REV A

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Table of Contents

Section Title Section Number Page Number

Warnings - 6-7

Important Information - 8

General Information 1 9

Technical Information (M130.30CR) 2 9-10

Parts List 3 11

Internal Piping and Parts List 4 12

Electric Diagrams 5 13

Installation Location 6 14

Exhaust Pipe Location 7 15

Mounting Bracket 8 16

Venting 9 17-20

Restrictor Sizing 9.1 17

Fitting the Flue System 9.2 17

Choice of Flue 9.3 18-20

Pipe Connections 10 21

Gas Pipe Connections 11 22

Electrical Connections/Wiring 12 23-25

Power Connection 12.1 23

Connection to the Electricity Supply 12.2 23

Room Thermostat Connection 12.3 24

Relay Panel Control Connection 12.4 24

Zone Valve Microswitch Connection 12.5 25

Circulator Sizing 13 26

Circ. Cap. as a Function of Flow Rate 13.1 26

Expansion Vessel 13.2 26

Piping 14 27-29

Primary-Secondary Piping 14.1 27

Primary-Secondary with Zone Valves 14.2 28

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Table of Contents

Section Title Section Number Page Number

Manifold Piping with Zone Valves or Circ. 14.3 29

Commissioning 15 30-35

Initial Filling of the System 15.1 30

Lightning the Boiler 15.2 30

Checking the Gas Pres. at the Burner 15.3 31

Adjustment of the Gas Pressure 15.4 32

Checking the Ignition Device 15.5 32

Checking the Burner Ignition 15.6 33

Adjustment of the Useful c.h. Output 15.7 33

Labels Placement 15.8 34

Checking the Flue System and Comb. 15.9 35

Instructing the User 15.10 35

Gas Conversion 16 36

Annual Maintenance 17 37-38

Warnings 17.1 37

Dismantelling the External Panels 17.2 37

Emptying the C.h. System 17.3 37

Cleaning the Primary Heat Exch. 17.4 37

Checking the Pressuris. in C.h. Vess. 17.5 38

Cleanig the Burner 17.6 38

Checking the Flue 17.7 38

Visual Inspection of Appliance 17.8 38

Gas Pressures and Soundness 17.9 38

Installer Notes 18 39

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Boiler is certified as an indoor appliance. Do not install boiler outdoors or locate where it will be exposed to freezing temperatures.

ARNING

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

• If you can not reach your gas supplier call the fire department.

— Installation and service must be performed by a qualified installer, service agency or the gas supplier.

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Caution: Do not store or use flammable materials, chemicals or flammable liquids, especially gasoline, in the vicinity of this heating appliance.

DANGER

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Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of producing carbon monoxide (CO). Carbon Monoxide (CO) is a gas which is odorless, colorless and tasteless but is very toxic. CO is lighter than air and thus may travel throughout the building.

BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF CO, OR

PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY

RESULT IN CARBON MONOXIDE POISONING. EXPOSURE CAN BE

FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT

IN THE SUDDEN ONSET OF SYMPTOMS INCLUDING

UNCONSCIOUSNESS.

Symptoms of CO poisoning include the following:

dizziness vision problems shortness of breath

headache loss of muscle control unclear thinking nausea weakness unconsciousness

The symptoms of CO poisoning are often confused with those of influenza, and the highest incidence of poisoning occurs at the onset of cold weather or during flu season. A victim may not experience any symptoms, only one symptom, or a few symptoms.

Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home.

The following signs may indicate the presence of carbon monoxide:

ARNING

• Hot gasses from appliance, venting system pipes or chimney, escaping into the living space.

• Flames coming out around the appliance.

• Yellow colored flames in the appliance

If any of the symptoms of CO occur, or if any of the signs of carbon monoxide are

present, VACATE THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED

HEATING SERVICE COMPANY OR THE GAS COMPANY OR THE FIRE DEPARTMENT.

ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR BIASI RIVA HEAT ONLY BOILER.

• Stale or smelly air.

• The presence of soot or carbon in or around the appliance.

• Very high unexplained humidity inside the building.

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IMPORTANT INFORMATION

Please read this page carefully.

• ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES AN D ORDINANCES, AS WELL AS THE REGULATIONS OF THE SERVING ELECTRICAL, WATER AND GAS UTILITIES.

• All systems should be designed by competent contractors, and only persons knowledgeable in the layout and installation of heating systems should attempt the installation of any boiler. It is the responsibility of the installing contractor to see that all controls are correctly installed and operating properly when the installation is completed.

• This boiler is intended for use, only with propane or natural gas. All flammable liquids (especially gasoline), chemicals, rags, paper, wood scraps, debris, etc., should be kept away from the boiler at all times. Keep the boiler area clean and free of all fire hazards.

• Please read the literature and warranties supplied by the manufacturers of the various accessory equipment. This equipment is warranted by the respective manufacturers, not by Quincy Hydronic Technologies, Inc. Each piece of equipment must be installed and used according to the recommendations of the manufacturer.

Codes and Regulations:

Installation of the boiler and related equipment must conform to national, state and

local regulating agencies and codes applicable to the installation of the equipment. In the absence of local requirements, the following codes apply:

A. ANSI/NFPA - #70 National Electric Code B. ANSI/NFPA - #211 Chimneys and Vents C. ANSI/NFPA - #Z223.1 National Fuel Gas Code C. ANSI/NFPA - Domestic Gas Conversion Burner D. CAN/CGA - B149 Installation Codes E. ANSI/ASME - CSD-1

The above codes are available from:

National Fire Protection Association (NFPA) Battery March Park Quincy, Massachusetts, 02269 http://www.nfpa.org

CSA International 8501 E. Pleasant Valley Road Cleveland, OH 44134-5575 http://www.csa-international.org

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1. General Information

The Riva Heat Only is a high efficiency, non-condensing, wall mounted gas boiler which provides central heat. The boiler features a gas valve which modulates the energy input from 44,000 BTU/h to 108,000 BTU/h. The boiler is shipped fully assembled with the components listed on page 11. All units are pressure and combustion tested at the factory prior to shipping.

Key Features:

• Wall mountable - saving valuable floor

space.

• Several flue options available

• Electronic spark ignition

• Safety flow switch - positioned on the

main circuit, which monitors the flow and protects the main heat exchanger from thermal shock should there be a lack of water in the system.

• Frost protection - contains an integral

frost protection system to prevent frost damage which can occur in areas susceptible to very cold weather conditions.

• Boiler operation recognition system should the boiler not be used for longer than 24 hours, it then performs a controlled system test to ensuring the motorized components within the boiler do not become inoperable due to lack of use.

• Gas valve modulation - the gas input modulates based off central heating temperature to within ± 2 ºF

• Diagnostic information system equipped with three LED diagnostic lights for quick error assessment.

2. Technical Information (M130.30CR)

GENERAL

Height in

27.7

Width in

15.7

Depth in

12.8

Weight lb

79.4

CENTRAL HEATING

Maximum working temp. °F

185

Temp. Regulation range* °F

100-176

Maximum pressure psi

30.0

Minimum pressure psi

4.35

Max head loss (at 4.4 GPM) ft

*At the minimum useful output

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2.Technical Information Cont.

ENERGY CAPACITY

Nominal heat input

(0/2000ft)

MBH 122.8

Nominal heat input

(2000/4500ft)

MBH 116.7

Minimum heat input MBH 49.5

Maximum useful output

(0/2000ft)

MBH 100.7

Maximum useful output

(2000/4500ft)

MBH 95.9

Minimum useful output MBH 37.0

GAS SUPPLY PRESSURE

Gas Normal Min Max

Natural inwc 7.0 3.5 10.5

Propane inwc 11.0 8.0 12.0

GAS PRESSURE AT BURNER

Gas Min Max Ignition

Natural inwc 0.8 5.3 2.4

Propane inwc 1.4 9.0 5.2

FLUE DESIGN

Minimum Venturi pressure inwc 0.64

Flue pipe diameter

Coaxial in

2.25/4

3.25/5

Twin split pipes in 3.25/3.25

Nominal heat flow rate

(0/2000ft)

MBH 122.8

Nominal heat flow rate

(2000/4500ft)

MBH 116.7

Min Exhaust temperature °F 262

Max Exhaust temperature °F 324

INJECTORS No. Size

Natural 14 130

Propane 14 89

GAS FLOW RATE

Gas Min Max

Natural ft³/h 48.7 121.1

Propane lb/h 2.23 5.55

ELECTRICAL

Voltage V 120

Frequency Hz 60

Current A < 1.6

Power consumption W 176

FLUE GAS FIGURES

Gas Min Max

CO2 2.5% 7.2%

O2 16.5% 8.1%

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3. Parts List

Primary Components:

1 Pump 2 Pump vent plug 3 Automatic air purger valve 4 Modulation gas valve 5 Flame-detecting electrode 6 Ignition electrodes 7 Burner 8 Combustion chamber 9 Primary heat exchanger 10 Fan 11 Air pressure switch 12 Air switch pres. Test points 13 Safety thermostat 14 Modulation operator 15 Gas valve outlet pres. Test point 16 Gas valve inlet pres. Test point

17 Central heating expansion vessel 18 Central heating temp. Probe NTC 19 Central heating pressure relief valve 20 Primary circuit flow switch 21 Main circuit drain cock 22 By-pass valve 23 Venturi device 24 Flue outlet pipe 25 Air Intake Pipe 26 Control panel 27 Safety thermostat probe 28 Pressure reducing automatic fill valve 29 Backflow preventer 30 Gas supply line cock 31 Water supply inlet cock

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4. Internal Piping & Parts List

Note: Pressure Relief Valve (#19) should be piped to a drain or to the floor as lose as

possible to a drain.

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5. Electric Diagrams

ye bk wh gy bu rd

probe NTC

C.h. temperature

COM

123

bubn

gnyegywh

gybugnye

bk bk

gygnye bu

bubu

rdbk

gygy

L N

rd bu bn gnye gnye

gnye bubn

burd

gnye

Flow Switch

Primary Circuit Pump

Valve

Gas

External controls

terminal

block

Electric supply

terminal

block

Fan Safety

Thermostat

Air Pressure

Switch

Ignition

Electrodes

Flame Detection

Electrode

bn - brown

bu - blue

bk - black

wh - white

rd - red

gy - grey

ye - yellow

gnye - green/yellow

ye wh bu

* ---> directly connected to the electronic ignition board

Caution: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing

RIVA HEAT ONLY MANUAL - REV A

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The installation location chosen must:

• Comply with all clearances listed below.

• Provide suitable location for the exhaust and intake venting.

• Not be installed in an unheated space.

• Comply with all local codes and standards.

Note: Dimensions shown are minimums. Greater clearances will simplify

installation and service.

Figure 6.1

WARNING: Do not install the boiler on carpeting

If the boiler is to be installed in an enclosed room with no fresh air intake, the room must have proper vent louvers installed. There should be two louvers, place each within 12” of the ceiling and floor respectively. Each vent will have a free area of 54 square inches.

Outside

Air Op ening

Each opening free area = 1 sq. inch per 2,000 BTU/h

0 to 12"

Figure 6.2 When choosing an installation location insure the exhaust and intake pipes comply with NFPA 54. The drawing on the next page illustrates the restrictions on exhaust locations.

6. Installation Location

12.8 in

10.0

3.0 in

2.0 in

LOSET IN STA LL A TION

MINIMUM PER

MA NAN T

LEA RA NCE

FRON

TVIEW SIDE VIEW CLOSET

INST

ALLA

TION

LOSET INSTA LLATION

SER VIC ECLE

A RA

N CE

18.0 in

27.7 in

15.8 in

8.0 in

Note: For boilers in an enclosed

space it is recommended to install a CO detector in the boiler room.

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7. Exhaust Pipe Location

CAUTION

EXTERNAL VENT SURFACES ARE HOT.

The Exhaust Hood must be installed on the leeward side of house and conform to

the following guidelines:

1. The Vent hood shall not be less than 3 feet above any forced air inlet to the house.

2. The Vent hood shall not be less than 4 feet below, 4 feet horizontally, or 1 foot above any door, window or gravity inlet into any building.

3. The Vent hood shall not be less than 2 feet from an adjacent building.

4. The Vent hood shall be not less than 7 feet above grade when located adjacent to public walkway.

5. The Vent hood shall be located so that flue gasses are not directed to jeopardize people, overheat combustible structures, materials or enter buildings.

6. Minimum of 4 feet horizontal clearance from electric meters, gas meters, regulators and relief equipment.

7. All joints in system are to be sealed to prevent leakage of products of combustion in the building.

8. Avoid installing exhaust hood on the North, West, or the side of the house receiving the prevailing winds.

IT IS RESPONSABILITY OF THE HOMEOWNER TO KEEP THE VENT

TERMINAL CLEAR OF SNOW AND ICE

NOTE: USE ONLY LISTED COMPONENTS SUPPLIED WITH THE BOILER.

SURFACE DISCOLORATION OF THE BUILDING MAY OCCUR DUE TO IMPROPER INSTALLATION. QHT WILL NOT ACCEPT RESPONSIBILITY OR LIABILITY FOR SUCH DISCOLORATION.

RIVA HEAT ONLY MANUAL - REV A

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8. Mounting Bracket

After a suitable installation location is chosen, verify that the mounting wall is properly braced and strong enough to support the 80 pound weight of the unit when filled with water. NOTE: The boiler shall be installed such that the gas ignition system components

are protected from water and liquids in general (dripping,spraying, rain, etc) during the appliance operation and service.

Use the paper template provided with the boiler to determine the location of the mounting bracket. Securely mount the bracket to the wall using appropriate hardware for the particular wall construction. Mounting Steps:

1. Tape the paper template to the wall in the chosen location. Be sure to level the template.

2. Pre-drill two holes in the center of the “oval” slots on the mounting bracket, sized for the hardware being used.

3. Mount the bracket to the wall. Be sure to level the bracket by adjusting the screw in the vertical slot.

4. Pre-drill the remaining hole in the mounting bracket and secure the final screw.

5. Mark and drill the exhaust/intake pipe holes through the house. If you are using a

coaxial pipe system, drill the hole marked A (ø 4”) in the drawing below and on the paper template. If you are using a separate pipe system drill holes marked B and

C (ø 3.25”) shown below as well as on the paper template.

6. Remove paper template and hang boiler on bracket.

ø3.1

ø4.0

15.7

7.93.7

9.8

7.6

27.6

0.6

4.5

1.0

0.8

5.1

4.6

2.83.2

13.0

9.3

5.8

A&B

Figure 8.1

RIVA HEAT ONLY MANUAL - REV A

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9. Venting

The Riva is a mechanical draft, side wall vented boiler. There are two flue options available - separate and coaxial. The coaxial option has one configuration shown on the next page. The separate option has two possible configurations shown on the following pages.

9.1 Restrictor Sizing:

Each exhaust option is shipped standard with 3 feet of exhaust pipe, 3 feet of intake air pipe. There is also a restrictor kit in which there are some restrictors that must be placed in exhaust breech of fan on the top of the boiler (Fig. 9.1) according to the flue configuration used.

If additional flue piping is need for a particular application, it can be ordered separately in 3 feet increments. Depending on the final flue pipe length, an alternative restrictor may be required. Refer to the tables 9.1 for proper restrictor ring sizing

Figura 9.1

Coaxial 2.5/4.0 Restrictor Size

From 1.65 to 3.30 (ft)

From 3.30 to 8.86 (ft)

Separate 3.25/3.25 Restrictor Size

For 1.65 (in) and 1.65 (out)

From 3.30 to 39.40 (in+out)

Table 9.1

9.2 Fitting the flue system:

In general, it has to be taken in consideration that the orizontal sections of the flue pipe must have an horizontal sloping not less than 1.5 degree (0.3 in per ft) towards the boiler.

In the standard horizontal flue kit the flue pipe is angled within the air duct therefore the air duct must be horizontally installed. If one or more exstensions have to be used they must be adequately supported so that there is no sag in the flue pipe and a minimum fall of 1.5 degree (0.3 in per ft) over the whole lenght towards the boiler is ensured.

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9. Venting Cont.

9.3 Choice of flue:

The following flue kits are available for connecting to the boiler:

Standard coaxial horizontal flue kit (Exhaust & intake outside)

Figure 9.3 (Coaxial 2.4/4.0 inches – nominal lenght 3.3 ft)

It can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow. Minimum lenght required is 1 ft. Maximum equivalent lenght of 32.8 ft can be achieved utilising extensions. This flue system can only be used to discharge horizontally, it is not designed to enable termination in the vertical plane.

Installation:

• Drill hole A (on the wall template) through the outside wall.

• Cut the pipe as necessary so that a no more than 6” protrudes from the house.

• Slide the intake and exhaust pipes through the hole.

• Slide one rubber wall trim piece on the pipe from inside and one from outside.

• Connect exhaust (inner) pipe to concentric elbow.

• Connect intake (outer) pipe to concentric elbow.

• Secure elbow to boiler using gasket and four screws provided.

• Secure end cap on the intake pipe outside the house.

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9. Venting Cont.

Standard separate horizontal flue kit (Exhaust & intake outside)

Figure 9.4 (Twin pipe φ 3.25 in)

Various twin (split) pipes kits and optional accessories (elbows) are available to assist in the termination of the flue where the boiler is installed in a location remote to an outside wall. These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses. Consequently it is possible to extend the flue system to a greater distance than that provided by the standard coaxial horizontal flue. If either an additional 45° or 90° accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.

The sum of the lenghts of the two horizontal part must be less than 131 ft.

Installation:

• Drill holes B & C (on the wall template) through the outside wall.

• Cut the pipes as necessary so that no more than 6” of intake pipe protrudes from the house and the exhaust pipe is a minimum of 4 inches longer than the intake pipe.

• Slide the Intake and exhaust pipes through the respective holes.

• Slide one rubber wall trim piece on each pipe from inside and one from outside.

• Attach each collar to the boiler with the gasket and screws provided.

• Insert each elbow into its corresponding collar.

• Connect each pipe to its corresponding elbow (as shown in the diagram).

• Secure end cap on the intake and exhaust pipe outside the house.

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9. Venting Cont.

Alternative separate kit (Exhaust outside & intake inside)

Test Ports

Exhaust Collar

Exhaust Elbow

Exhaust Pipe

Rubber Wall Trim (2X)

Exhaust Pipe End Cap

Air Intake Elbow

Air Intake Pipe

Air Intake Collar

Figure 9.5 (Twin Pipe Φ 3.25 in)

This configuration of the twin pipe kit allows to discharge the exhaust gasses outside. The air supply is obtained with an air intake pipe. This allows to take air from the room where the boiler is installed. If either an additional 45° or 90° accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.

Note: When utilizing this option, see page 14 for room ventilation details.

Installation:

• Drill hole C (on the wall template) through the outside wall.

• Cut the pipe as necessary so that no more than 6” protrudes from the house.

• Slide the exhaust pipe through the hole.

• Slide one rubber wall trim piece on the pipe from inside and one from outside.

• Attach each collar to the boiler with the gasket and screws provided.

• Insert each elbow into its corresponding collar.

• Connect each pipe to its corresponding elbow.

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10. Pipe Connections

The Riva boiler is supplied with a 3/4” stainless steel gas pipe (A in figure 10.1), 2 - 3/4” copper pipe (C,D in figure 10.1), located in a plastic bag in the boiler package.

Figure 10.1

Stainless steel gas

pipe

B) Main circuit drain

cock

C) C.h. return copper

pipe

D) C.h. supply copper

pipe

E) C.h. PRV discharge

copper pipe

Installation:

• Remove the protective caps off boiler connections (Figure 10.1).

• Thoroughly clean the connections.

• Attach the supplied components to the boiler connections (see Figures 10.1). Be sure to

use the proper gaskets for the pipe connections.

• Before connecting the boiler to the heating system piping, review the suggested piping diagrams in Section 4 (page 12).

• If the c.h. system is above the boiler level, it is advisable to install c.h. cocks close to the boiler for servicing operation

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11. Gas Pipe Connections

Gas supply piping is to be sized and installed properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the

meter and the boiler. Consult with the National Fuel Gas Code ANSI Z223.1 for proper

sizing of gas piping for various lengths and diameters.

Direction of flow

Figure 11.1

A) Manual T-handle Shutoff Valve B) Pressure Gauge Port C) Flexible Gas Line to Burner D) Male Union ¾” NPT E) Pipe Cap F) 1” X 1” X ¾” TEE

Note: Height of valve above ground

level to conform to local codes, if any. Massachusetts statecode requires gas shut off to be a tee handled gas cock.

Locate a drop pipe adjacent to, but not in front of the boiler. Locate a tee (F) in the drop pipe at the same elevation as the gas inlet connection to the boiler. Extend the drop line with a nipple towards the floor and cap to form a sediment trap (E). Install a shut off valve (A) before the tee with sediment trap and a union after the tee before the combination gas valve (D). When installing the boiler, make sure a pipe compound resistant to the action of liquefied petroleum is used. Check piping for leaks. Always check leaks with a water and soap solution. The boiler and its individual shut-off valve must be disconnected from the gas supply piping during any pressure testing of that piping at test pressures in excess of ½ psi.

ARNINGS

DO NOT USE A FLAME FOR CHECKING GAS LEAKS

RIVA HEAT ONLY MANUAL - REV A

12. Electrical Connections/Wiring

Page 23

12.1 Power Connection:

Figure 12.1

Removing Front Panel:

• Remove the front panel by removing screws A and sliding the front panel up and away from the boiler

Removing Side Panel:

• Remove screws B

Figure 12.2

Removing Control Panel:

• Remove screws C.

Figure 12.3

• Move the lower part of the side panels (figure

12.3).

• Pull the control panel. When completely pulled out, the panel can rotate 45° downward.

Figure 12.4

• Loosen screws D and remove the service panel (Fig. 12.4).

For the electrical connection to the boiler use electric wires which conform to local regulations.

12.2 Connection to the electricity supply:

• Connect the electrical supply cable coming from the fused spur isolation switch to the power supply terminal block of the boiler (as shown in figure 12.5) keeping the same connections for the live wire and the neutral wire.

To fused spur isolation switch

Power supply terminal block

External controls terminal block

120 VAC

15 AMP BREAKER

Service Man's Switch

Fire - O - Matic

Figure 12.5

• Connect the earth wire(yellow/green). Boiler must be wired directly to earth ground on breaker panel.

Note: Do not connect live wires to

thermostat terminals 1-3.

ARNING

RIVA HEAT ONLY MANUAL - REV A

12. Electrical Connections/Wiring Cont.

Page 24

12.3 Room Thermostat Connection:

• The room thermostat

must be connected to the terminal block situated next to the control panel

To fused spur isolation switch

Power supply terminal block

External controls terminal block

120 VAC Control Terminal Block

Figure 12.6

• Any external controls

and connection lines must be rated at 120 VAC but under no circumstances should external live voltage be connected to the room thermostat link on the boiler

• When connecting any type of external control, the jumper J in Fig. 12.6 must be removed.

• The room thermostat must be connected to the “Control Terminal Block” (Fig 12.7).

Power supply terminal block

External controls terminal block

Room thermostat

(120V rating)

Figure 12.7

• Connect the room thermostat between terminals 1 and 3 as shown in Fig. 12.7.

12.4 Relay Panel Connection:

• The relay control must be connected to the terminal block situated next to the control panel

To fused spur isolation switch

Power supply terminal block

External controls terminal block

120 VAC Control Terminal Block

Figure 12.8

• When connecting any type of relay control, the jumper J in Fig.

12.8 must be removed.

• Connect the dry contact switch of the relay panel to the 120 VAC control terminal block (Fig 12.9).

Power supply terminal block

External controls terminal block

Generic Relay Control

(120V rating)

Figure 12.9

• Connect the dry contact switch to terminals 1 and 3 shown in Fig. 12.9.

RIVA HEAT ONLY MANUAL - REV A

12. Electrical Connections/Wiring Cont.

Page 25

12.5 Zone Valve Micro Switch Connection:

• The zone valve micro switch must be connected to the terminal block situated next to the control panel

To fused spur isolation switch

Power supply terminal block

External controls terminal block

120 VAC Control Terminal Block

Figure 12.10

• When connecting the zone valve switch, the jumper J in Fig. 12.10 must be removed.

120 VAC

Control Terminal

Block

Zone Valve

Room

Thermostat

Figure 12.11

• Connect the micro switch of the zone valve to terminals 1 and 3 as shown in figure 12.11

• Connect the zone valve switch to the room thermostat as shown in figure 12.11

12.6 Finishing

•

Route the electrical

supply cord and the external control cord as illustrated in Fig.

12.12

To the fused spur

To the external control device

isolation switch

Figure 12.12

• Lock the cords in place with the flexible cord clamps.

• Replace the control panel reversing the steps on page 23.

RIVA HEAT ONLY MANUAL - REV A

Page 26

13. Circulator Sizing

13.1 Circulator capacity as a function of flow rate:

Figura 13.1

The hydraulic specification in Fig 13.1 represent the pressure (available head for the central heating system) as a function of the flow rate. The pressure loss due to the internal piping in the boiler has already been substracted.

When determining proper piping of the heating system, verify that the internal boiler circulator will overcome the head loss of the system at the designed flow rate using the graph above.

If the internal circulator is adequate, direct system piping can be utilized. See section 4

page 12 for suggested direct supply/return piping.

If the internal circulator is inadequate, a secondary circulator must be utilized. See

sections 14 for suggested primary/secondary piping.

13.2 Expansion vessel:

The height difference between the C.h. PRV (19 on page 11) and the highest point in the system may be 23 ft at most. For greater differences, increase the pre-load pressure in the C.h. expansion vessel (17 on page 11) and the system when cold, by 0.1 bar for additional 3.3 ft. For systems with volumes greater than 154l, an additional expansion vessel must be provided.

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Page 27

14. Piping

14.1 Primary – Secondary Piping:

All external piping components are to be supplied by the installer.

It is very important to use an hydraulic separator before secondary circulators.

Max. Spacing 4x Primary Pipe Dia. Typ.

Min. Spacing 12"

Secondary Loops

Secondary Circulator

Hydraulic Separator

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Page 28

14. Piping Cont.

14.2 Primary – Secondary Piping with Zone Valves:

All external piping components are to be supplied by the installer.

It is very important to use an hydraulic separator before secondary circulators.

RIVA HEAT ONLY MANUAL - REV A

zone valve

Secondary Circulator

Supply Lines to System Zone Valve

Return Lines from System

draulic Separato

Page 29

14. Piping Cont.

14.3 Manifold Piping with Zone Valves or Circulators (shown conn. to radiators):

All external piping components are to be supplied by the installer.

RIVA HEAT ONLY MANUAL - REV A

System Return Manifold

System Supply Manifold (with zone valves or circulators

By-pass Valve

Return Water Temperature Gauge

Shut Off Valve

Page 30

15. Commissioning

15.1 Initial filling of the system:

• Remove the front panel of the case.

• Unscrew the cap on the automatic air purger valve 3 (Fig

15.1) one full turn and leave open permanently.

Figure 15.1

• Open the installer supplied automatic fill valve between the cold water inlet and Central Heating System (See 28 on piping diagrams in previous section).

• Open each radiator air vent starting at the lower point and close it only when clear water, free of bubbles, flows out.

• Purge the air from the pump by unscrewing the pump plug 2 (Fig.

15.2); release the pump by turning the rotor in the direction indicated by the arrow on the information plate.

figura 15.2

• Close the pump plug.

• Continue filling the system. The actual reading should ideally be 1.3 bar (19 psi) and not less than 0.3 bar (4.3 psi).

• Close all air release valves on the c.h. system.

• Inspect the boiler and the system for water soundness and remedy any leaks discovered.

• Cold flush the system to remove any loose particles and any system debris before starting the boiler for the first time.

• Reassemble the front panel of the case.

• Return fill valve to automatic position.

15.2 Lighting the boiler:

Note: If external controls are fitted (e.g. room thermostat) ensure they "call for heat".

• Turn on the electricity supply to the boiler, switching on the circuit breaker switch. The appliance operation light A will flash every 4

seconds.

• Turn the function selector B as in Fig.

15.3. The appliance operation light A will flash every 2 seconds.

C D

Figure 15.3 The boiler will now go through an ignition sequence and the burner will light. If during the ignition attempt period the boiler fails to light, the full sequence control p.c.b. will go to lockout and the lock-out signal lamp D will appear. To reset the boiler turn the knob B (figure 15.3) on the 0 position and then

press and

release the boiler reset button C (Fig. 15.3).

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Page 31

15. Commissioning Cont.

15.3 Checking the gas pressure at the burner: This boiler has been tested to the highest quality control standards. The maximum and minimum gas pressures are already set during this quality control process however the checking procedure must be followed to ensure maximum operating efficiency from the boiler.

• Remove the front

panel of the case.

• Loosen the internal

screw 15 (Figure

15.4) on the Outlet Pressure Test Point of the Gas Valve and connect a pressure gauge using a suitable hose.

Figure 15.4

• Set the c.h.

temperature control knob to its maximum position. If external controls are

fitted (e.g. room

thermostat) ensure

they "call for heat".

• Switch on the boiler.

• Check the maximum gas pressure and compare the value on the gauge with the value indicated in the Section 2 on page 10 (gas pressures at the burner).

• Check the maximum gas flow at the gas meter and compare the value indicated in the section 2 on page 10 (gas flow rate).

• Switch off the boiler.

• Disconnect the gas modulator coil by

removing the electrical

connector E (Figure

15.4).

• Switch on the boiler.

• Check the minimum gas pressure and compare the value on the gauge with the value indicated in the Section 2 on page 10 (gas pressures at the burner).

• Switch off the boiler and re-connect the electrical connector E to the modulator coil.

• Switch on the boiler.

• Check that the boiler lights up uniformly.

• Switch off the boiler, turn off the hot water taps and disconnect the pressure gauge.

Important: after the checks all of the test points must be sealed.

RIVA HEAT ONLY MANUAL - REV A

Page 32

15. Commissioning Cont.

15.4 Adjustment of the gas pressure:

•

Remove the front

panel of the case.

• Open the gas valve

inlet pressure test point (16 in Fig. 15.5) at the valve input, connect a suitable pressure gauge and check the gas pressure of the supply network.

• Remove the gauge

and close the pressure test point

16.

• Open the gas valve

outlet pressure test point (15 in Fig. 15.5) and connect the gauge.

Figure 15.5

• Remove the

protection cap I (Fig.

15.6) from the mechanical pressure adjustment components levering with a flat screwdriver in the slots H.

• Start the boiler at its

maximum power.

Figure 15.6

• Ensure that the boiler

is not range rated.

• Rotate the maximum

gas pressure adjustment (F in Fig.

15.5) until you obtain the required pressure (by rotating clockwise the pressure increases).

• Turn the boiler off

and disconnect one of the two connectors (E in Fig. 15.5).

• Start the boiler and

rotate the minimum gas pressure adjustment (G in Fig.

15.5) until you obtain the required pressure (by rotating clockwise the pressure increases).

• Turn the boiler off and

re-connect the wire to the modulating operator.

• Start the boiler and

check again the maximum gas pressure setting.

• Turn the boiler off and

disconnect the gauge.

Important: after the checks all of the test points must be sealed.

15.5 Checking the ignition device:

With the burner on high flame close the gas cock. After three ignition attempts (within about three minutes), the lock-out signal lamp must appear (D on Figure 15.3). To reset the boiler turn the knob B (figure 15.3) on the 0 position and then press and release the boiler reset button (C on Figure 15.3).

RIVA HEAT ONLY MANUAL – REV A

Page 33

15. Commissioning Cont.

15.6 Checking the burner ignition:

• Turn the boiler OFF.

• Open the gas valve

outlet pressure test point 15 (figure 15.5) and connect the gauge.

• Turn the boiler ON

positioning the function selector B in the position shown in figure 15.7 and ensure that the room thermostat is set to “heat demand”.

Figure 15.7

• Loosen screws D and remove the service panel (figure 15.8).

Figure 15.8

• Watch the gauge and check to see if the ignition pressure registerd corresponds to the values given in the Technical Data. Turn off the boiler and reignite it by turning the function selector B to the 0 position and then back to that indicated in figure

15.7.

• Repeat this process two to three times leaving 30 second intervals between each ignition. Check the ignition pressures and visually check that the burner lights uniformly and in a controlled manner.

• To carry out the adjustment move the function selector 3 to the OFF position (Fig.

15.9) and use the device (ACC).

OFF

ACC

RISC

Figure 15.9

• Adjust the gas pressure at the injectors to the value indicated in the tables of section 2. By rotating the device clockwise the pressure increases.

• After the adjustment operations bring the selector 3 of figure

15.9 back to the normal position (ON).

• Reassemble the service panel.

• Close the gas valve outlet pressure test point 15 (figure 15.5).

• Reassemble the front pannel of the case.

Important: after the checks all of the test points must be sealed.

15.7 Adjustment of the useful c.h. output:

• Turn the boiler OFF.

• Open the gas valve

outlet pressure test point 15 (figure 15.5) and connect the gauge.

• Turn the boiler ON

positioning the function selector B in the position shown in figure 15.7 and ensure that the room

thermostat is set to “heat demand”.

• Loosen screws D and remove the service panel (figure 15.8).

• To carry out the adjustment use the adjustment device (RISC) with the help of a screwdriver.

• By rotating the device clockwise the pressure increases.

• Adjust the gas pressure at the burner to the value according to the useful c.h. output wanted (Tab.

15.1).

• Reassemble the service panel.

• Close the gas valve outlet pressure test point 15 (figure 15.5).

• Reassemble the front pannel of the case.

RIVA HEAT ONLY MANUAL – REV A

Page 34

15. Commissioning Cont.

15.8 Labels placement:

Figure 15.10

Warning: The installation is not complete unless labels supplied are placed on the

boiler as shown in Figure 15.10.

All the labels supplied with the boiler are numbered for reference. According to Figure 15.10 place all the labels on the boiler. Use label numbered as 1 (already installed in the front panel) to begin the placement in the correct way.

RIVA HEAT ONLY MANUAL – REV A

Page 35

15. Commissioning Cont.

15.9 Checking the flue system and combustion:

• The flue system should be visually checked for soundness. Check all clamps, gaskets and fixings are secure and tight.

• Ensure that the flue terminal is sited correctly in accordance with the flue fitting instructions.

To check the exhaust gas:

• Remove the plugs indicated (Fig. 15.11).

• Insert the analyzer probe in the exhaust gas sampling point or in the air intake sampling point.

• Reference tables are given in the Sections 2 on page 10 of this manual for proper CO2 levels.

Air-Flue exhaust

sampling points

Figure 15.11

15.10 Instructing the user:

• Hand over the User manual, this Installation,Operation and Service manual to the end user and explain how to use the unit in Central Heating mode.

• Take the User step by step through the lighting instructions.

• Show the User how to switch off the appliance quickly and indicate the position of the electric service switch and the boiler on/off switch.

• Explain the proper use and adjustment of all system controls; this will ensure the greatest possible safety and fuel economy.

• Explain the function and use of the function switch.

• Explain how to turn off the appliance for both short and long periods and advise on the precautions necessary to prevent damage should the appliance be inoperative when freezing conditions may occur.

• Fill in the details required on the Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee registration. Finally, advise the User that, for continued safe and efficient operation, the appliance must be serviced by a competent person at least once a year.

Useful output

Kcal/h

10.8

9288

12.0

10320

14.0

12040

17.0

14620

20.0

17200

23.0

19780

26.0

22360

29.5

25370

inwc

220

0.88

250

1.00

330

1.32

470

1.89

640

2.57

830

3.33

1050

4.22

1330

5.34 Natural

m³/h 48.7 53.0 60.7 72.4 84.0 96.0 107.7 121.1

inwc

360

1.45

420

1.69

560

2.25

800

3.21

1080

4.34

1400

5.62

1760

7.06

2230

8.95

Propane

lb/h 2.2 2.4 2.8 3.3 3.9 4.4 4.9 5.5

Tab 15.1

RIVA HEAT ONLY MANUAL – REV A

Page 36

16. Gas Conversion

WARNINGS: Procedures to adapt the boiler to the type of gas available must be

carried out by a competent and responsible person. Components used to adapt it to the type of gas available must be genuine parts only.

Procedures:

• Check that the gas

cock (30 on Section

4) fitted on the gas supply pipe is turned off and the appliance is switched off at the circuit breaker.

• Remove the front and

side panels of the case (see the section

17.2 Annual Maintenance – Dismantelling the External Panels).

• Take off the lid of the

sealed chamber.

• Remove the front

panel of the combustion chamber.

Figure 16.1

• Loosen the screws A

and remove the burner 7 (Figure

16.1).

• Carry out the

conversion for the

type of gas, replacing the burner injectors correctly.

• Re-assemble the burner, the front panel of the combustion chamber and the lid of the sealed chamber.

• Extract the control panel as explained in the section 12.1 of this manual.

• Loosen the screws D and remove the service panel (figure

16.2)

Figure 16.2

• Set correctly the dipswitch "2" to the correct position (Fig.

16.3) in accordance with the following table.

Gas supply

Position of the switch 2

Natural gas On

L.P.G. Off

OFF

Natural gas L.P.G.

Figure 16.3

• Close the service panel.

• Turn on the boiler.

• Calibrate the gas valve according to the instructions given in section 15.4 of this manual.

• Set the correct gas pressure for central heating output required.

• Stick on the inside of the left hand side panel adjacent to the data badge the selfadhesive label (included with the conversion kit) indicating the type of gas, and the gas pressures to which the appliance has been set.

• Reassemble the front and side panels of the case.

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Page 37

17. Annual Maintenance

17.1 Warnings:

The procedures detailed in this chapter must be carried out only by a professionally qualified person. Thus you are advised to contact an Authorised Service Agent. For efficient and continuous operation of the boiler you are advised to have, at least once a year, maintenance and cleaning done by an Approved Service Person. Isolate the appliance from the electricity supply by turning off the fused spur isolation switch adjacent to the appliance and turn off the gas cock, before carrying out any procedures, whatsoever, for cleaning, maintenance, opening or dismantling boiler panels.

17.2 Dismanteling the external panels:

Front Panel:

• Loosen the screws A (Fig. 17.1)

• Lift and remove the panel.

Side Panels:

• Loosen the screws B (Figure 17.2). Bring the bottom of the panels away from the boiler and lift them, freeing them from the top hooks.

Figure 17.1

Figure 17.2

17.3 Emptying the Central Heating System:

• Close the pressure reducing automatic fill valve (28 on Section 4)

• Open the central heating drain cock (F in Fig. 17.3).

• Empty the c.h. system.

• Close the central heating drain cock (F in Fig. 17.3).

• Open the pressure reducing automatic fill valve (28 on Section 4)

Figure 17.3

17.4 Cleaning the primary heat exchanger:

• Take off the front panel of the case, then the sealed chamber lid and the front panel of the combustion chamber.

If you notice dirt on the fins of the primary heat exchanger (9 on page 10), cover the sloping surfaces of the burner (7 on page 10) entirely in a protective layer (sheets of newspaper or similar). Brush out the primary heat exchanger (9 on page 10) with a bristle paintbrush.

RIVA HEAT ONLY MANUAL – REV A

Page 38

17. Annual Maintenance Cont.

17.5 Checking the pressurization in the expansion vessel:

Empty the central heating system as described in section 17.3 of this chapter and check that the pressure in the expansion vessel is not less than 1 bar (14.5 psi). See also section 13.2 page 26 of this manual. If the pressure should be lower, take steps to correct the pressure level.

17.6 Cleaning the burner:

The sloping and multi-gas type burner (7 on page 11) does not need special maintenance, but it is sufficient to dust it with a bristle paintbrush.

17.7 Checking the flue:

Have the integrity of the flue outlet pipe (24 on page 12) air intake pipe (25 on page 12), checked periodically, the venturi device (23 on page 12) cleaned and the efficiency of the flue safety circuit checked at least once a year. For all the above maintenance operations it is advisable to call an approved Service Engineer. To check the pressure at the venturi device, use the test points (12 on page 11).

• Remove the caps of

the pressure test points and connect a differential pressure gauge.

• Switch on the boiler

• Compare the value on the gauge with the minimum values of venturi pressure indicated in the Section 2 on page 10.

Venturi test

points

Figure 17.4

17.8 Visual inspection of appliance:

Visually inspect all water joints, seals and connections for any evidence of leakage and retighten, grease or replace them as necessary.

17.9 Gas pressures and soundness:

Check appliance for gas soundness. Recheck operational pressures and adjust as necessary as described in Section 15.4 page 32 of this manual.

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Page 39

18. Installer Notes

System Checkout:

Boiler Model No.___________________

Original Purchaser:

___________________________

Serial No._______________

Installer: _______________________

_______________________

_____________________________________________________________________

Performance Tests:

GROSS STACK TEMPERATURE __________________

ROOM TEMPERATURE (AMBIENT) ________________

NET STACK TEMPERATURE _____________________

CO2 __________________

O2 ___________________

SMOKE READING ___________________

COMBUSTION EFFICIENCY _________________

COMMENTS ___________________________________________________________

_____________________________________________________________________

RIVA HEAT ONLY MANUAL - REV A

Page 40

*1796212741*

17962.1274.1 2906 (40A4)USA