QUINCY HYDRONIC TECHNOLOGY Riva FP Installation manual

Riva

PLUS COMBI

WALL HUNG GAS BOILER FOR

CENTRAL HEATING SUPPLY

Please Read Instructions Carefully

Save for Future Reference

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.

— 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.

Quincy Hydronic Technology Inc.

3560 Lafayette Rd. Bldg. 2 Unit A

Portsmouth, NH 03801

Phone: 603-334-6400

Fax: 603-334-6401

RIVA PLUS COMBI MANUAL

Dear Customer:

Thank you for buying a Biasi Riva Plus Combi.

The Riva Plus Combi is a high efficiency 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 Plus Combi 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 Plus Combi has been tested to standard CSA 4.9 and is CSA compliant.

This Riva Plus Combi 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 Plus Combi. If you have questions or comments, please don’t hesitate to contact us immediately. Our goal is 100% customer satisfaction.

QHT inc.

2 RIVA PLUS COMBI MANUAL

Table of Contents

Section Title Section Number Page Number

Warnings

Important Information

General Information

Technical Information (M135.30CM)

Parts List

Internal Piping and Parts List

Electric Diagrams

Sequence of operation

Installation Location

Exhaust Pipe Location

Mounting Bracket

Venting

Requirements for Massachusetts

Restrictor Sizing

Fitting the Flue System

Choice of Flue

Pipe Connections

Gas Pipe Connections

Electrical Connections/Wiring

Power Connection

Connection to the Electricity Supply

Piping

Room Thermostat Connection

Relay Panel Control Connection

Zone Valve Microswitch Connection

Finishing

12.3

12.4

12.5

12.6

Installing the external temperature probe 12.7

Electric connection between the boiler and the outdoor reset temperature probe 12.8

Circulator Sizing 13

Circ. Cap. as a Function of Flow Rate

Expansion Vessel

Primary-Secondary Piping

13.1

13.2

14

14.1

Primary-Secondary with Zone Valves 14.2

Manifold Piping with Zone Valves or Circ. 14.3

9.2

9.3

10

11

12

12.1

12.2

5

5.1

6

7

8

9

-

9.1

- 5-6

- 7

1

2

3

4

8

8-9

10

11

32

32

33

33

34

12-13

13

14

15

16

17-28

18

19

19

20-28

29

30

31-33

31

31

34

35

35

35

36-39

37

38

39

RIVA PLUS COMBI MANUAL 3

Table of Contents

Section Title Section Number

Commissioning

Initial Filling of the System

Lightning the Boiler

Checking the Gas Pres. at the Burner

Adjustment of the Gas Pressure

Checking the Ignition Device

Checking the Burner Ignition

Setting the outdoor reset K coefficient

Adjustment of temperature WITH the outdoor temperature probe connected

Adjustment of the Useful C.h. Output

Labels Placement

Checking the Flue System and Comb

Instructing the User

Gas Conversion

Annual Maintenance

Warnings

Dismantling the External Panels

Emptying the C.h. System

Cleaning the Primary Heat Exch.

Checking the Pressures in C.h. Vess.

Cleaning the Burner

Checking the Combustion Fan

Checking the Flue

Visual Inspection of Appliance

Gas Pressures and Soundness

Cleaning the Primary Heat Exchanger

Cleaning the Domestic Heat Exchanger

Condensate trap

Venting Spare Parts

Separate Vent

Coaxial Vent

Roof Vent

PVC boiler adapter

PVC concentric vent

PVC roof vent

Installer Notes


15

15.1

15.2

15.3

15.4

15.5

15.6

15.7

17.11

17.12

17.13

18

18.1

18.2

18.3

18.4

18.5

18.6

19

17.3

17.4

17.5

17.6

17.7

17.8

17.9

17.10

15.8

15.9

15.10

15.11

15.12

16

17

17.1

17.2

Page Number

41

42

42

43

44

40-46

40

40

55

56

57

51

52

53

54

50

50

50

51-53

49

50

50

50

48

49

49

49

44

45

45

46

46

47

48-50

48

48

WARNING

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

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.

— 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.

DANGER

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

Caution: Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

Caution: Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.


WARNING

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 headache nausea vision problems loss of muscle control weakness shortness of breath unclear thinking 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:

• 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.

• Stale or smelly air.

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

• Very high unexplained humidity inside the building.

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 COMBI BOILER.


•

IMPORTANT INFORMATION

Please read this page carefully.

ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE

AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES AND ORDINANC-

ES, 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


1. General Information

The Riva Plus Combi is a high efficiency condensing, wall mounted gas boiler which provides central heat. The boiler features a gas valve which modulates the energy input from 49,476

BTU/h to 116,008 BTU/h. The boiler is shipped fully assembled with the components listed on page 10. 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 (M135.30CM)

GENERAL

Height

Width

Depth

Weight

ELECTRICAL

Voltage

Frequency

Current

Power consumption

V

Hz

A

W in lb in in

31.6

15.7

13.8

100.3

120

60

1.6

180

INJECTORS No. Size

Natural 14 130

Propane 14 85

CENTRAL HEATING

Maximum working temp.

Temp. Regulation range*

Maximum pressure

Minimum pressure

°F

°F psi psi

Max head loss (at 4.4 GPM) ft

194

100-189

30.0

4.35

8.25

*At the minimum useful output


2. Technical Information Cont.

ENERGY CAPACITY

Nominal heat input

(0/2000 ft)

Nominal heat input

(2000/4500 ft)

Minimum heat input

Maximum useful output

(0/2000 ft)

Maximum useful output

(2000/4500 ft)

Minimum useful output

MBH

MBH

MBH

MBH

MBH

MBH

GAS SUPPLY PRESSURE

Gas Normal Min

Natural inwc 7.0

Propane inwc 11.0

3.5

8.0

Max

10.5

13.0

GAS PRESSURE AT BURNER

Gas Min Max Ignition

Natural inwc

Propane inwc

1.0

2.0

4.8

10.3

2.4

5.2

FLUE DESIGN

Minimum Venturi pressure inwc

Flue pipe diameter

Coaxial

0.64

in

2.25/4

3.25/5 in 3.25/3.25

Twin split pipes

Nominal heat flow rate

(0/2000 ft)

Nominal heat flow rate

(2000/4500 ft)

MBH

MBH

116.0

110.2

Min Exhaust temperature

Max Exhaust temperature

°F

°F

140

190

116.0

110.2

49.5

102.0

97.2

41.6

GAS FLOW RATE

Gas

Natural

Propane ft³/h lb/h

Min

48.7

2.2

Max

115.1

5.2

CLEARANCE TO COMBUSTIBLES

Front in 18

Back

Top

Sides

Bottom

Flue pipe enclosed

Flue pipe free air

Hot water pipes in in in in in in in

2

8

2

0

10

0

1”

FLUE GAS FIGURES

Gas

CO 2

O 2

Min

2.5%

16.5%

Max

6.3%

9.7%

DOMESTIC HOT WATER

Maximum temperature °F

Minimum temperature °F

Maximum pressure psi

Minimum pressure

D.h.w. ΔT 25K

D.h.w. ΔT 30 K

D.h.w. ΔT 35 K

D.h.w. ΔT 40 K psi gpm gpm gpm gpm

131

95

145

4.35

4.5

3.8

3.2

2.8


7

6

23

9

8

3. Parts List

Primary Components

:

10

11

19

12

27 18 20 4

13 35 25 26

2 1

5

3

33

21

34

28

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. Three-way diverter valve

24. Venturi device

25. Flue outlet pipe

26. Air Intake Pipe

27. Control panel

28. Safety thermostat probe

29. Pressure reducing automatic fill valve

30. Backflow preventer

31. Gas supply line cock

32. Water supply inlet cock

33. Condensate trap

34. Condensing heat exchanger

35. Flue termostat

36. D.h.w heat exchanger

37. D.h.w flow switch

38. Domestic water circuit filter

39. D.h.w flow limiter

40. Domestic hot water temp.probe NTC

41. Domestic cold water inlet valve

42. D.h.w. outlet pipe


4. Internal Piping & Parts List

26

34

35

25

19

24

9

10

11

28

5

7

6

33

15

14

16

4

17

3

31

21

20

1

22

18

23

36

39

38

37

29

41

30

40

32

Note: Pressure Relief Valve (#22) should be piped to a drain or to the floor as close as possible to a drain.

Note: Figure is not intended to be a piping diagram, please refer to piping section of manual for piping practices and locations.


5. Electric Diagrams

Flue thermostat

Electric supply terminal block

L N

Fan wh or rd wh

NC

Air pressure switch

NO

Ignition electrodes

Flame detection electrode bn bu bk

COM

3 2 1 bn gnye bu

External controls temninal block rd bu wh gy gnye ye wh bu rd gnye eyng rd bu bn eyng ye bk wh gy bu rd bu bu g y g y bk rd b u b u rd rd rd wh bu

J10 bk bk wh bk rd gnye b u g y or rd wh gy bk bu bn gy wh bu bk rd bu bk rd rd wh bk rd rd

J10

Outdoor reset control board bu bu bk rd rd bk – black bn – brown bu – blue gnye – green/yellow or – orange

D.h.w. flow switch t bu wh

D.h.w.

NTC rd bk

Outdoor temp. probe terminal block

3 rd

COM

M

~

2 bk bu bk bu t

Three-way diverter valve

Primary circuit flow switch C.h. temperature probe NTC

1 gy – grey rd – red wh - white ye - yellow gny e gy bu

M

~

Pump gy gy

Gas valve

Caution:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.


5. Electric Diagrams Cont.

5.1 Sequence of Operation:


6. Installation Location

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.

15.2 in

10.0 i n

2.0 in

2.0 in

3 . 0 i n

CLOSET INSTALLATION

MINIMU M PER MANAN T

CLEARANCE

31.6 in

8 .0 in 1 5 .8 in

1 8 .0 in

CLOSET INSTALLATION

SERVICECLEARANCE

FRON TVIEW SIDE VIEW CLOSET

INSTALLATION

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.

Note: For boilers in an enclosed space it is recommended to install a CO detector in the boiler room.

0 to 12"

Each opening free area =

1 sq. inch per 2,000 BTU/h

0 to 12"

Air Opening

Outside

Air Opening

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.


7. Exhaust Pipe Location

CAUTION

EXTERNAL VENT SURFACES ARE HOT.

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.

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 1 foot below, 1 foot horizontally, or 1 foot above any door, window or gravity inlet into any building.

3. The vent hood shall not be less than 12” above normal snow level.

4. The vent hood shall not be less than 2 feet from an adjacent building.

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

6. The vent hood shall not be located under a deck or so that flue gasses are directed to jeopardize people, overheat combustible structures, materials or enter buildings.

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

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

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

10. The vent should not be situated so that the flue gases are directed towards brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the flue gases.


8. Mounting Bracket

After a suitable installation location is chosen, verify that the mounting wall is properly braced and strong enough to support the 110 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.

2.

3.

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

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

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

4.

5.

6. the vertical slot.

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

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.

Remove paper template and hang boiler on bracket.


Figure 8.1

9. Venting

The Riva Plus Combi is a mechanical draft, side wall vented boiler. There are two side wall 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. There is also a vertical roof venting option. Regardless of what vent kit is installed, they should all conform to the Provisions for combustion and ventilation air in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code,

ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of the local building codes.

If the Biasi Riva Plus Combi replaces a boiler that was attached to a common vent system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. To ensure the remaining appliances will function properly, the test procedure below should be followed:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the common venting system.

(b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

(c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation.

Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

(f) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.” (g) Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas

Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes.


9. Venting Requirements for the State of Massachusetts

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00

and 5.00 for installation of through – the – wall vented gas appliances as follows:

(a) For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall: a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector; b. Have battery back-up power; c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition);and d. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR.

3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

(b) For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall: a. Be located in the room that houses the appliance or equipment; b. Be either hard-wired or battery powered or both; and c. Shall comply with NFPA 720 (2005 Edition).

3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.


9. Venting Cont.

Separate 3.25/3.25 Restrictor Size Coaxial 2.5/4.0

From 3.30 to 49.2 ft (in+out) 55 From 0 to 3 ft (in+out)

From 49.3 to 100 ft (in+out) No restrictor From 3.1 to 9 ft (in+out)

-

Restrictor Size

No restrictor

In general, it has to be taken in to consideration that the horizontal sections of the flue pipe must hand a horizontal slope not less than 1.5 degrees (0.3 inches per foot) towards the boiler.



9.3 Choice of flue:

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

A Standard coaxial horizontal flue kit (exhaust & intake outside)

Figure 9.1 (Coaxial 2.4/4.0 inches – nominal length 3.3 ft)

It can be mounted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow. Minimum length required is 2.9 ft. Maximum equivalent length of 8.8 ft can be achieved utilizing extensions. This flue system can only be used to discharge horizontally, it is not designed to enable termination in the vertically.

Installation:

• Drill hole A (on the wall template) through the outside wall that is less than 18” thick.

• 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.


B


Standard separate horizontal flue kit (Exhaust & intake outside)

Figure 9.2 (Twin pipe Ø 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 length of either pipe must be reduced by 3.0 ft or 5.4 ft respectively. The sum of the lengths of the intake and exhaust must be less than 49.2 ft.

Installation:

• Drill holes B & C (on the wall template) through the outside wall that is less than 18”thick.

• 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


C


Alternative separate kit (exhaust outside & intake inside)

Figure 9.3 (Twin Pipe Ø 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 length of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.

Note: When utilizing this option, see page 16 for room ventilation details.

Installation:

• Drill hole C (on the wall template) through the outside wall that is less than 18”thick.

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

• Slide the exhaust pipe through the hole.


• 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.


D


Standard Vertical-roof kit (exhaust & intake outside)

Figure 9.4 (vertical pipe Ø 3.1 / Ø 4.9 in)

This kit allows vertical termination of the flue pipe through the roof. The kit is 1.2 min length.

Extension pieces (Co--axial) are also available which allows the flue system to be extended to a total overall maximum permissible length.

Optional 45° and 90° elbows can be used to offset the flue route.

Each additional elbow reduces the overall acceptable length of the flue system as follows:

45° reduce length by 1.6 ft.

90° reduce length by 3.2 ft.

Installation:

• Drill hole through the outside roof.

• Cut the pipe as necessary.

• Slide the intake and exhaust pipes through the hole.


• 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.



E PVC vent requirements

All piping that is used to vent the Riva boiler must conform to the standards listed below.

Parts

Exhaust and Intake

Piping

Pipe Cement /

Primer

Material

PVC

CPVC

PVC

CPVC

United States

ANSI/ASTM D1785

ANSI/ASTM DF441

ANSI/ASTM D2564

ANSI/ASTM F493

Canada

ULC S636

It is not permitted to use a cellular foam core pipe for venting the Riva boiler. All intake piping can be constructed of PVC pipe. The first 8 feet of exhaust pipe must be CPVC pipe. After that point it is permissible to assemble the rest of the vent in PVC.

Canadian Installations:

• PVC/CPVC vent pipe must be listed to ULC S636. Pipe, fittings, and cements are certified as a system and must be installed as such. Different manufacturers have different materials, joining systems and adhesives. Do not mix pipe, fittings, solvents, or joining methods from different BH Vent manufacturers, this can result in unsafe conditions.

• Consult PVC/CPVC manufacturer’s installation manual for correct joining of pipe for gas venting.

General installation:

1. Cut pipe to required lengths and dry fit the venting and intake system to ensure a proper fit.

2. Disassemble the system and de burr the inside and outside of the pipe ends.

3. Chamfer the outside of each end of the pipes.

4. Make sure that each pipe end and fitting are clean. Once they are do not handle the joining surfaces.

5. Apply primer to both the fitting and the pipe end.

6. While the primer is damp, apply a even coating of cement to the pipe end and the fitting.

7. Insert the pipe into the fitting making sure the pipe is completely seated.

8. Rotate the pipe 1/4 turn and hold in place for 30 seconds.

9. Wipe any excess cement away and check that there is a complete bead of sealant around the joint of the fitting.

10. Allow to cure for 2 hours before commissioning the boiler.

11. Install perforated metal pipe supports onto the pipe, making sure there is no sagging in the pipe. Place supports as close as possible to elbows to relieve stress on the joint.



12. F PVC boiler adapter

A

B

D

C

Figure 9.5

This kit is required to vent the Riva boiler using PVC/CPVC pipe. The kit includes a boiler connection adapted for PVC/CPVC. When venting with PVC/CPVC this boiler adapter is required in addition to one of the terminations on the following pages.

Canada: All PVC/CPVC pipe, fittings, and cement must be approved to ULC S636. Do not mix pipe and joining compounds from different manufacturers as this can result in an unsafe condition and void the certification.

Installation:

• Attach the collar (C) from the adapter kit to the top of the boiler using the supplied screws.

• Insert the boiler adapter (B) into the collar. Check that the exhaust gasket (D) is installed on the outlet of the boiler first.

• Once the adapter is positioned in place, tighten the clamp on the collar and install the supplied self tapping screw through the pre drilled hole on the collar.

• Insert the PVC adapters (A) into the boiler adapter (B).

• Slide the CPVC/PVC pipe into the PVC adapters (A), do not use any solvents or cement on this connection. It is a gasket connection that requires no sealing.



G PVC concentric vent kit

Figure 9.6

This kit allows horizontal termination of the flue pipe using PVC/CPVC pipe. The kit includes boiler connection and termination adapted for CPVC/PVC. 3” PVC/CPVC pipe may be added up to the total overall maximum permissible length of 100’ intake and exhaust combined. Optional

45° and 90° elbows can be used to offset the flue route. Each additional elbow reduces the overall acceptable length of the flue system as follows:

Max Length (intake + exhaust)

Min Length (intake + exhaust)

Venting Specifications

100 ft.

3 ft.

45° elbow

90° elbow

1.6 ft. equivalent

3.2 ft. equivalent


Installation:

• Drill 5.5” hole through the outside wall making sure there is 1 foot clearance above normal snow level.

• Insert the termination through the flexible exterior gasket and the building wall.

• Fix the exterior gasket to the wall using 4 contractor supplied fasteners.

• Slide the interior wall gasket over the termination and fix it to the wall using 4 user supplied fasteners.

• Assemble the gaskets into the twin pipe adapter.

• Install the twin pipe adapter onto the termination.

• Install the PVC adapters supplied onto the twin pipe adapter according the manufacturers instructions.

• Install piping pitched back toward the boiler making sure not to exceed the maximum allowable length.

• Intake air piping can be constructed of PVC pipe. Exhaust piping should be CPVC for the first 8 feet.

• Intake and exhaust piping should be assembled and secured according to the pipe manufacturers instructions.

• Install the vent adapter onto the top of the boiler using the gasket and screws provided.

• Install the pipe onto the boiler by simply pushing it into the adapters. Do not cement the pipe into the adapters, this is a gasket connection.



H PVC roof vent kit

Figure 9.7

This kit allows vertical termination of the flue pipe using PVC/CPVC pipe. The kit includes boiler connection and termination adapted for CPVC/PVC. 3” PVC/CPVC pipe may be added up to the total overall maximum permissible length of 100’ intake and exhaust combined. Optional

45° and 90° elbows can be used to offset the flue route. Each additional elbow reduces the overall acceptable length of the flue system as follows:




100 ft.

3 ft.

45° elbow

90° elbow

1.6 ft. equivalent

3.2 ft. equivalent


Installation:

• Choose the appropriate weather collar for the installation, Pitched or Flat.

• Drill a hole through the roof large enough to accommodate the 5.5” vent terminal.

• Fix the flue collar in place and insert the termination from outside the building.

• Fix the supplied wall clamp around the vent terminal but do not tighten it.

• Assemble the gaskets with the concentric pipe adapter. It may be necessary to use a small amount of water.

• Install the PVC adapters supplied onto the twin pipe adapter according the manufacturers instructions.

• Install piping to the boiler making sure not to exceed the maximum allowable length.


• Intake and exhaust piping should be assembled and secured according to the pipe manufacturers instructions.




I


PVC separate vent kit

Figure 9.8

This kit allows horizontal termination of the flue pipe using 3” PVC/CPVC pipe. The kit includes

PVC/CPVC boiler adapters and CPVC termination. PVC pipe may be added up to the total overall maximum permissible length. Optional 45° and 90° elbows can be used to offset the flue route. Each additional elbow reduces the overall acceptable length of the flue system as follows:




100 ft.

3 ft.

45° elbow

90° elbow

1.6 ft. equivalent

3.2 ft. equivalent


Installation:

• Drill two 4” holes through the outside wall or the roof.

• Insert the pipes from the boiler through the wall making sure they slope towards the boiler.


• Install the trim plate with the gasket facing the building using four field supplied screws.

• Secure the pipes in place inside the building using installer supplied hangers. Make sure there is no sagging or low spots for condensate to collect.

• Cut the intake and exhaust pipes so they extend at least 2 1/2” past the trim plate.

• Solvent cement a PVC elbow facing the ground onto the air intake. The Intake elbow must be at least 12” above normal snow level.

• Solvent cement a PVC/CPVC elbow facing up onto the exhaust outlet.

• Solvent Cement the 6” length of PVC/CPVC pipe into the elbow.

• Solvent Cement a PVC/CPVC elbow onto the pipe making sure the elbow faces away from the building.

• Install the rodent screens into the intake and exhaust. This is a friction fit.




10. Pipe Connections

The Riva Plus Combi 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), 2 - 1/2” (E, F in figure 10.1) located in a plastic bag in the boiler package.

B

A) Stainless steel gas pipe

B) Main circuit drain cock

C) C.h. supply copper pipe

D) C.h. return copper pipe

E) D.h.w. cold inlet pipe

F) D.h.w. hot outlet pipe

G) Condensate trap

G

C F A E D

Figure 10.1

Installation:

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

• Thoroughly clean the connections.

• Attach the supplied components to the boiler connections (Figures 10.1). Be sure to use the proper gaskets for the pipe connections.

• Attach the condensate trap to an appropriate drain pipe.

• Before connecting the boiler to the heating system piping, review the suggested piping diagrams in Section 4 (page 10).

• 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.

• A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cutoff device either as part of the boiler or at the time of boiler installation.

Condensate trap:

The condensate trap allows the discharge of the condensate via the condensate drain pipe while preventing the escape of combustion products. A plastic ball closes the trap outlet in case the trap is empty. The condensate trap is provided with two electrodes: if the drain pipe is plugged or if the condensate isn’t correctly evacuated, the condensate level in the trap rises shorting the electrodes thus causing the boiler lock-out.


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.

The boiler must be isolated from the gas supply piping system by closing its individual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

Direction of flow

F

A

B

C

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 state code requires gas shut off to be a tee handled gas cock.

E

D

Figure 11.1

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 gas connection must be leak tested before placing the boiler in operation.

The boiler and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa).

WARNINGS

DO NOT USE A FLAME FOR CHECKING GAS LEAKS.


12. Electrical Connections/Wiring

A

A

12.1 Power Connection:

Removing Side Panel:

• Remove screws B

C

C

• 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.

B

B

D

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

B

B

Figure 12.2

Removing Service Panel:

• Remove screws C.

Figure 12.3

D

D

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.

The boiler, when installed, must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements,with the National

Electrical Code,ANSI/NFPA 70 and/or Canadian Electrical Code Part I CSA C22.1, Electrical Code.

In the USA, maintain a clearance of at least 4 ft. horizontally from the vent terminal to gas meters, electric meters, regulators and relief equipment. In Canada, maintain a 6 ft. clearance between the vent terminal and these devices.

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.

120 VAC

15 AMP BREAKER

Service Man's Switch

Fire - O - Matic

External controls terminal block

3

To fused spur isolation switch

L

2 1

N

Power supply terminal block

WARNING

Note: Do not connect live wires to thermostat terminals 1-3.

o w b r n g r e e n u e b l

RIVA PLUS COMBI MANUAL Figure 12.5 31

12. Electrical Connections/Wiring Cont.

control panel.


L

12.3 Room Thermostat Connection:

• The room thermostat must be connected to the terminal block situated next to the

N

Power supply terminal block

• 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).

J

3 2 1

T

Room thermostat

(120V rating)

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 terminals 1 and 3 on the boiler.

L N

3 2 1 Power supply terminal block


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.

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

T

Generic Relay Control

(120V rating)


L N

Power supply terminal block L N

J

3 2 1

External controls terminal block

3 2 1 Power supply terminal block


Figure 12.9

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

Figure 12.8

• When connecting any type of relay control, the jumper J in Fig. 12.8 must be removed.



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.

Zone

Valve

V


L N

Power supply terminal block

J 3 2 1 moved.

120 VAC Control

Terminal Block

Figure 12.10

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

Room

Thermostat

T

N

L

3 1

120 VAC

Control Terminal

Block

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 external control device To the fused spur isolation switch

Figure 12.12

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

• Replace the control panel reversing the steps on page 31.



12.7 Installing the outdoor reset temperature probe:

The outdoor reset temperature probe must be installed on an external wall of the building, avoiding:

• Direct sun radiation.

• Wet walls or walls where mould tends to form.

• Installation near fans, exhaust or chimney vents.

12.8 Electric connection between the boiler and the outdoor reset temperature probe:

When connecting the outdoor reset temperature probe to the boiler, use electric wires with a minimum 20 AWG (0.032 in DIA).

The electric wires for connecting the outdoor reset temperature probe to the boiler must run through different conduit than line (120 VAC), as they are powered at a low safety voltage and the maximum length must not exceed 65 feet.

Figure 12.12

• Remove the two screws shown in Figure

12.12 and open the outdoor reset connection terminal board.

TO THE OUTDOOR RESET

TEMPERATURE PROBE

• Connect the two electric wires to terminals E1 and E2 on the terminal board as shown in Figure 12.13.

• Connect the same wires to the external probe terminals

Outdoor reset probe connection terminal board

Figure 12.13

The path of the outdoor reset temperature probe wires or cable must follow the indicated path and be fastened as shown in Figure

12.14.

to the room thermostat to the service switch to the outdoor rese temperature probe

Figure 12.14


13. Circulator Sizing

13.1 Circulator capacity as a function of flow rate:

Figure 13.1

The hydraulic specification in Fig 13.1 represents 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 subtracted.

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 14 page

36 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 vessels:

The height difference between the C.h. PRV (19 on page 10) 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 10) and the system when cold, by 0.1 bar for additional 3.3 ft.

For systems with volumes greater than (154 L), an additional expansion vessel must be provided.


14. Piping

All external piping components are to be supplied by the installer. It is very important to use a primary secondary piping scheme when an external circulator will be used. Also, when the boiler is piped in a primary secondary manner, it is necessary to use the central heating flow restrictor supplied with the boiler. The flow restrictor ensures there will be enough back pressure to make the central heating flow switch in a low head loss piping system like primary secondary.

Installation of flow restrictor:

The flow restrictor is installed inside the pipe tail that attaches to the boiler. Place the flow restrictor into the gasket for the central heating supply pipe tail. Place the gasket on the pipe tail so the flow restrictor seats into the pipe tail. Then install the pipe tail onto the boiler.

There are two methods for accomplishing a primary secondary piping system. The first is to use two closely spaced tees for the boiler supply and return. An example is shown below in Figure 14.1. The run legs should be sized so that there is no excessive head loss on the external circulator that is installed. In most circumstances 1 ¼” piping will be the best choice.

When the boiler is piped in this way, the external circulator will not have any hydraulic effect on the Riva boiler. This is essential to ensure that the flow switch will operate properly.

Boiler

Supply

Must be less than 8"

Boiler

Return

System

Supply

¾” System

Return

1 ¼”

Figure 14.1

The second method is a hydraulic separator. Hydraulic separators are available commercially; however you can also construct your own. An example of a hydraulic separator is given in Figure 14.2. It is important that the separator be at least 2” in size to ensure proper performance.

Boiler supply

No more than 8"

Boiler Return

¾”

1 ¼”

System supply

2"

System return


At least 16"

Figure 14.2

14. Piping Cont.

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.


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


Figure 14.3

37


14.2 Primary – Secondary Piping with Zone Valves:


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


Figure 14.4


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



Figure 14.5

39

15. Commissioning

15.1 Initial filling of the system:

• Remove the front panel of the case.

• Lift the cap on the automatic air purger valve 3 (Fig 15.1) one full turn and leave open permanently.

3

2

Figure 15.1

• Open the installer supplied automatic fill valve between the cold water inlet and

Central Heating System.

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

• 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”.

WARNINGS

THE BOILER AND ITS GAS CONNECTION MUST BE LEAK TESTED BEFORE THE

BOILER IS PLACED IN OPERATION

• 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. 15.2. The appliance operation light A will flash every

2 seconds.


A B

Figure 15.2

C D E

15. Commissioning Cont.

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 E will appear.

To reset the boiler turn the knob C (figure 15.2) on the 0 position and then press and release the boiler reset button D (Fig. 15.2).

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.


• Take off the lid of the sealed chamber.

• Loosen the internal screw 15 (Figure 15.3) on the Outlet Pressure Test Point of the Gas

Valve and connect a pressure gauge using a suitable hose.

• Switch off the boiler.

• Disconnect the gas modulator coil by removing the electrical connector E (Figure

15.3).

• 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.


• Check that the boiler lights up uniformly.

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

• Close the lid of the sealed chamber.

Figure 15.3

• 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”.


• 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).

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



15.4 Adjustment of the gas pressure:



• Open the gas valve inlet pressure test point (16 in Fig. 15.4) 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. 15.4) and connect the gauge.

•

Figure 15.4

• Remove the protection cap I (Fig. 15.5) from the mechanical pressure adjustment components levering with a flat screwdriver in slots H.

• Start the boiler at its maximum power.

Figure 15.5

• Ensure that the boiler is not range rated.

• Rotate the maximum gas pressure adjustment (F in Fig. 15.4) 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. 15.4).

• Start the boiler and rotate the minimum gas pressure adjustment (G in Fig. 15.4) 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.

• Close the lid of the sealed chamber.


15.5 Checking the ignition device:

With the burner on high fire close the gas cock. After three ignition attempts (within about three minutes), the lock-out signal lamp must appear (D on Figure 15.2). To reset the boiler turn the knob B (figure 15.2) on the 0 position and then press and release the boiler reset button (C on

Figure 15.2).



15.6 Checking the burner ignition:

• Turn the boiler OFF.

• Open the gas valve outlet pressure test point 15 (figure 15.4) and connect the gauge.

• Turn the boiler ON positioning the function selector B in the position shown in figure

15.6 and ensure that the room thermostat is set to “heat demand”.

• 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. 15.8) and use the device (ACC).

+

RISC

+

ACC

Figure 15.6

• Loosen screws D and remove the service panel (figure 15.7).

ON

1 2 3 4

D

D

D

Figure 15.7

• 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.

OFF

Figure 15.8

• 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 15.8 back to the normal position (ON).

• Reassemble the service panel.

• Close the gas valve outlet pressure test point 15 (figure 15.4).

• Reassemble the front pannel of the case.

•




probe.

C.h. flow temperature °F

K=3 K=2.4

K=1.9

185

15.7 Setting the outdoor reset K coefficient:

The boiler is set with a K coefficient equal to zero for boiler operation without a connected

K=1.5

Figure 15.9

K=1

176

167

158

149

140

131

122

113

104

68 61 53.5 46.5 39 32 25 17.5 10.5 -3 -4 -11

External temperature °F

When the outdoor reset temperature probe is installed, this parameter must be set based on the heating system efficiency to optimise the supply temperature (Figure 15.9).

Ex. To achieve a supply temperature to the heating system of 173°F with an outdoor temperature of 25°F, K must be set at 1.5 (dashed line in Figure 15.9).

• Position the handle C indicated in Figure

15.10.

K1 K1.5

K1.9

The K coefficient is a parameter that raises or lowers boiler supply temperature as the external temperature changes.

K2.4

C K3

Figure 15.10

15.8 Adjustment of temperature WITH the outdoor reset temperature probe connected:

In case of acting on the knob C Fig. 15.10 to turn off the boiler or to operate it for hot water only, put the knob in the same position when reactivating the central heating operation.

Your boiler automatically adjusts the temperature of the central heating flow as a function of the outdoor reset temperature.

The adjustment of the boiler must be carried out by the installer that will evaluate the appropriate central heating water flow temperature depending on the type of heating system.

The knob C Fig. 15.10 must remain on the position given by the installer. This will ensure the proper operation of the central heating system.



15.9 Adjustment of the useful c.h. output:

• Turn the boiler OFF.

• Open the gas valve outlet pressure test point 15 (figure 15.4) and connect the gauge.

• Turn the boiler ON positioning the function selector B in the position shown in figure 15.6 and ensure that the room thermostat is set to “heat demand”.

• Loosen screws D and remove the service panel (figure 15.7).

• 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 15.4).

• Reassemble the front panel of the case.

Useful output

Natural

Propane

KW

BTU/h

Pa inwc.

m³/h ft³/h

Pa inwc.

Kg/h lb/h

15 16.8

18.5

20.5

22 23.8

26

51225 58055 63177 70005 75130 81277 88790

290

1.16

1.76

5.77

680

1.45

1.3

3.0

370

1.48

2.00

6.56

860

1.69

1.5

3.3

460

1.84

2.23

7.31

1060

2.25

1.7

3.7

560

2.24

2.46

8.07

1270

3.21

1.9

4.1

660

2.65

2.69

8.82

1500

4.34

2.0

4.4

780

3.13

2.91

9.54

1740

5.62

2.2

4.8

900

3.61

3.14

10.30

2000

7.06

2.3

5.1

Table 15.1

28

95620

1040

4.17

3.36

11.02

2270

8.95

2.5

5.5

15.10 Labels placement:

4

5


Figure 15.11

1

3

2

45


Warning: The installation is not complete unless labels supplied are placed on the boiler as shown in Figure 15.11.

All the labels supplied with the boiler are numbered for reference.

According to Figure 15.11 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.

15.11 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. 15.12).

• 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 9 of this manual for proper CO2 levels.

Air-Flue exhaust sampling points

Figure 15.12

15.12 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 warranty card and hand to the User advising them to return it for proper warranty coverage. 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.


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 – Dismanteling the External Panels).


• Remove the front panel of the combustion chamber.

A 7

D

D

D

Figure 16.2

• Set correctly the dip-switch “2” to the correct position (Fig. 16.3) in accordance with the following table.

Gas supply

Natural gas

L.P.G.

Position of the switch 2

On

Off

Natural gas

ON

1 2 3 4

OFF

L.P.G.

ON

1

2

3 4

OFF

A

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 16.3

• 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.

47

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 three 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.

• 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 (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.

A

A

C

C

B

B

B

Figure 17.2

Figure 17.1

17.3 Emptying the d.h.w. system:

• Close the pressure reducing automatic fill valve

• 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


Figure 17.3

B

17. Annual Maintenance Cont.

17.4 Emptying the Domestic Hot Water circuit

• Close the inlet valve

• Open the system domestic hot water valves

17.5 Cleaning the primary heat exchanger:

Follow the instructions for removing the external panels from 17.2. Remove the nine screws labelled C in figure 17.4. Now you will have complete access to the combustion chamber. The sloping and multi-gas type burner (7 on page 10) does not need special maintenance, but it is sufficient to dust it with a bristle paintbrush.

C

Figure 17.4

17.6 Checking the combustion fan:

The combustion fan does not require any special maintenance. Lubrication is not necessary due to the fact that the ball bearings are sealed. Check that the fan operates and that the visible impeller fins are free of any dirt or obstructions.

17.7 Checking the flue:

Have the integrity of the flue outlet pipe (24 on page 11) air intake pipe (25 on page 11), checked periodically, the venturi device (23 on page 11) 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 qualified Service agent.

• Remove the four Phillips head screws from the vent connector on the boiler.

• Remove the vent connector from the boiler by pulling vertically on it.

• Remove the first elbow from the horizontal run of the exhaust to the outside.

• Using a flashlight inspect each length of vent pipe for obstructions and dirt buildup. Clean any that is found with an appropriate sized brush.

• Inspect the venture device inside the outlet of the combustion fan. Make sure that it is free of any dirt build up or blockage.

• Make sure the seals are properly seated in the female ends of the vent pipe with the fins facing the male end of the pipe.

• Reinstall the elbow onto the horizontal run of the pipe first by simply pushing the parts together.

• Push the vent adapter down onto the top of the boiler and reinstall the four Phillips head screws.


17. Annual Maintenance Cont.

17.8 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 of this manual. If the pressure should be lower, take steps to correct the pressure level. To check the pressure at the venturi device, use the test points (12 on page 10).

• 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 9.

Figure 17.5

17.9 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.

17.10 Gas pressures and soundness:

Check appliance for gas soundness. Recheck operational pressures and adjust as necessary as described in Section 15.4 page 42 of this manual.

17.11 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.

17.12 Cleaning the domestic hot water exchanger:

The descaling of the domestic hot water exchanger will be evaluated by the Authorised Assistance Centre Technician, who will carry out any cleaning, using specific products.

17.13 Condensate trap:

To clean the condensate trap:

• Remove the front and right case panels.

• Disconnect the trap from the drain pipe.

• Using pliers, remove the spring D moving it upwards.

• Disconnect the wire from the trap.

• Reassemble carrying out the removal operations in reverse order.

D

The trap should be serviced once a year during the annual service.

Figure 17.6


18. Vent Part Spares

18.1 Separate venting:

For any spare parts, please contact QHT Inc. at 800-501-7697.

Description

Twin pipe kit


Order Number

10999.0393.0

51

18. Vent Part Spares Cont.

18.2 Coaxial venting:


Description

Coaxial flue kit

Order Number

10999.0387.0



18.3 Roof venting


Part

A

Description

Roof flue kit

Order Number

10999.0392.0



18.4 Separate PVC venting:


Description

PVC Boiler Adapter

Order Number

PTA5808



18.5 PVC Sidewall venting:


Description

PVC Boiler Adapter

Order Number

RI - 10 0887



18.6 PVC Roof venting:


Description

PVC Boiler Adapter

Order Number

RI - 10 0885


19. 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 ___________________________________________________________

_______________________________________________________________________

_______________________________________________________________________



*1796214812*

17962.1481.2 2212 60A4 USA

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