Riello RTT 378 User manual

cod. Doc-0079324 rev. 1 03/2016

RT T 378-930

EN ASSEMBLY MANUAL

RANGE

MODEL CODE

RTT 378 20093090

RTT 448 20091316

RTT 506 20091318

RTT 564 20091321

RTT 610 20091325

RTT 663 20091326

RTT 715 20091329

RTT 773 20091334

RTT 831 20091335

RTT 878 20091337

RTT 930 20091339

ACCESSORIES

For the RTT 378-930 r boilers the following accessories are avail-

able:

a. Two stage kit – 4031067

b. Storage heater probe – 20010103

In some parts of the booklet, some symbols are used:

9 = for actions requiring special care and adequate preparation

0 = for actions THAT MUST NOT be performed

Dear client,

Thank you for choosing a Rboiler, a modern and high quality

product, providing you with the utmost well-being and with a

high level of reliability and safety; and this is particularly the

case if entrusted to a RTechnical Assistance Centre which is

specically capable of carrying out routine maintenance, keep

it running at maximum efciency, with low running costs and

which has original spare parts if required.

This instruction booklet contains important information and

suggestions that should be observed for easy installation and

better use of the RTT 378-930 boiler.

Thank you once again

Riello S.p.A.

CONFORMITY

TheRTT 378-930 r boilers comply with:

−2009/142/EC (ex 90/396/EEC-Gas Directive)

−92/42/EEC (Efciency Directive)

−2006/95/EC (ex 73/23/EEC-Low voltage Directive)

−2004/108/EC (ex 89/336/EEC-Electromagnetic Compatibility

Directive)

−EN 303/1-2-3

−EN 60335-1/2

−EN55014-1/2

−EN 61000

This booklet, Cod. Doc-0079324 - Rev. 1 (03/2016) is composed of 12 pages.

1.1 INSTALLATION SPECIFICATIONS OF RTT CAST IRON

BOILERS

This manual is for personnel authorised and qualied to install

and provide technical assistance both domestically and over-

seas and should be used in order to correctly install the cast iron

boiler.

9 The technical personnel should always put the machine in a

safe condition both before and during installation.

9 In order to avoid injury, pay particular attention in trans-

porting the heavy cast iron sections, both before and during

the assembly and installation.

9 before starting the installation, check both the boiler room

and the support plate. If they have any defects, do not start

the installation until they have been resolved.

9 Before installing the appliance, carefully read and under-

stand this manual.

9 The components and the equipment for the installation are

supplied together with the boiler. They include also the sili-

con for the assembly, the silicon applicator, the ttings, the

protective gloves and the dust mask.

9 Do not damage the boiler body and the coating of the casing

during and after the installation and in the burner and gas

ue pipe connection phase. Instruct also the other techni-

cians in this regard.

9 If there are any questions about the installation, contact the

manufacturer or the technical assistance centre.

9 The installation of the cast iron boilers requires at least 2

people.

9 If the boiler is installed correctly it will have a long life.

Thank you for taking the time to read our warnings and our ad-

vice and we wish you the best of success in your work.

• Install the frame for assembling the boiler (with the

equipped part facing the other and facing back) on the con-

crete plate.

• The concrete plate should be at to ensure the boiler will

be stable.

• Position the rear section of the boiler on the frame vertically.

The holes on it should line up with those on the frame. Fix it

using 4 M12x50 mm nuts.

• For a simpler assembly, insert the bolts from the bottom and

place the nuts on top.

• Clean the grooved ue gas seal of the rear section with a

brush or a cloth, then insert the silicon.

• Glue the insulating cord supplied in the grooving as shown

in the gure, using the silicon already inserted.

• Put the waterproof gaskets on the axle coupling, then insert

it into the relative hole.

• For a simpler assembly, it is possible to use silicon to prevent

the O-ring or the tting falling.

• For a simpler assembly, glue the insulating cords onto the

grooves of the cast iron sections before assembling them.

• The insulating cords should be applied carefully to the rel-

ative grooves.

• There should be no empty spaces at the connection points

of the insulating cords.

• After applying the insulating cord, the axle connection and

the O-ring to the rear section, install the intermediate sec-

tion sliding it on the frame.

• The intermediate section with the hole for the thermostat

should be installed second, before the front one (section

number 3).

• Connect the M10x 240 section xing pins to the assembly

brackets balancing them, then connect the intermediate

section to the rear one.

• The section xing pins are used for their assembly. They are

not insulating elements that can prevent leaks.

• Repeat the operation a number of times that is suitable for

the capacity, namely for the number of intermediate sec-

tions of the boiler. In this way t all the intermediate sec-

tions.

• After installing the intermediate sections, do the same also

for the front section.

• The insulating cord applied to the grooved ue gas seal pro-

le of the last intermediate section (the one right before the

front section) cannot be installed in the pipes between the

2nd and 3rd pass of the ue gases.

• Connect the boiler-xing pins after nishing installing all

the sections.

• Connect 4 boiler xing pins using the stabilisation holes on

the front and rear sections. Put in the nuts and bolts and

screw them in so as to balance them.

• Tightening torque: 6 kg·m

The section xing pins should never be removed.

These pins will be used for installing the casing.

Assembling the expanding springs:

• Remove the 4 xing pins in the front part and the relative

nuts one at a time, and put in the expanding springs. The

screw back in the nuts and bolts.

Tightening torque: 3 kg·m

• Put in the expanding springs one at a time.

• Insert the expanding springs, nuts and bolts as indicated in

the gure below.

• The distance of the spring joints should be about 0.5 mm.

• After installing the sections and the boiler-xing pins, t

the rear door of the boiler's discharge pipe and the water

inlet-outlet attachments.

• To prevent leaks, t the boiler's discharge pipe rear door x-

ing it with 4 M12 x 95 pins.

• To prevent leaks, t the water inlet-outlet connections using

the washers and x them with 4 bolts.

• Fit the water inlet attachment (connection on the bottom)

so that the 1 ½” discharge valve is facing down or toward

the sides.

• Fit the water inlet attachment inserting in order the cou-

pling washer, the pipe with ange, the washer and the at-

tachment.

• The 1 ½” outlet attachment should be facing up or towards

the sides.

• After installing the boiler's water inlet and outlet attach-

ments, check that the appliance is waterproof by putting in

water for 10 minutes at a pressure of 9 bar without connect-

ing the front door of the burner.

Results of the test:

• If leaks are detected, repair the boiler, nding the place

where the boiler is leaking. If there are no leaks, begin t-

ting the retarder turbulators.

1 = COMBUSTION GASES OF THE BOILER (1st PASS)

2 = COMBUSTION GASES OF THE BOILER (2nd PASS)

3 = COMBUSTION GASES OF THE BOILER (3rd PASS)

• Install the retarder turbulators in the pipes as shown in the

table.

• Install 2 small turbulators in each pipe of the 2nd pass of the

ue gases. The large turbulators need to be inserted in the

pipes of the 3rd pass of the ue gases.

• Insert the turbulators in the passage starting with the front

section.

Table 1 - Installation of Retarder Turbulators Table

Model Second pass Third pass

RTT 378 1+1+1+1 1+1+1+1

RTT 448 1+1+1+1 1+1+1+1

RTT 506 1+1+1+1 1+1+1+1

RTT 564 1+1+1+1 1+1+1+1

RTT 610 1+1+1+1 1+1+1+1

RTT 663 1+1+1+1 1+1+1+1

RTT 715 1+1+1+1 1+1+1+1

RTT 773 1+1+1+1 none

RTT 831 1+1+1+1 none

RTT 878 none none

RTT 930 none none

• Insert the turbulators through the intermediate part of the

front section.

After installing the turbulators in the ue gases pipes of the

boiler, t the burner door to the front section.

• Connect 4 hinges of the front section to the arms of the

hinges on the burner door.

• Attach the door, xing it with 4 M10x80 mm bolts according

to the side you want to open and based on the hydraulic

connections and the boiler room.

• After inserting the bolts, x them with 4 M16 nuts and bolts

and screw them in balancing them.

• To prevent leaks, do not leave any space between the burner

door and the front section.

• After installing the boiler body and after carrying out the

waterproof test, to prevent leaks of ue gas apply Blakite®

between the sections (supplied with the other components

to be assembled).

• To install the walls of the casing, connect the assembly

brackets of the casing to the pins on the feet of the boiler.

• Connect the assembly brackets of the casing walls to the

pins used for connecting the sections, as shown in the g-

ure. Then x the pins.

Table (2) - Assembly Brackets Table

Model

Detail of

casing

assembly

Casing

length

Number

of casing

assembly

brackets

Section numbers

for

connecting as-

sembly

brackets

RTT 378 4+2 1090 61.2+3.4+5.6

RTT 448 4+3 1,250 61.2.+4.5+6.7.

RTT 506 4+4 1,410 61.2.+4.5.+7.8.

RTT 564 4+5 1,570 61.2.+4.5.+8.9.

RTT 610 5+5 1,730 61.2.+5.6.+9.10.

RTT 663 6+5 1,890 61.2.+6.7.+10.11.

RTT 715 4+mid-

dle+3 2,050 81.2.+4.5.+9.

10.+11.12.

RTT 773 5+mid-

dle+3 2,210 81.2+5.6.+10.

11.+12.13.

RTT 831 5+mid-

dle+4 2,370 81.2.+5.6.+10.

11.+13.14.

RTT 878 5+mid-

dle+5 2,530 81.2.+5.6.+10.

11.+14.15.

RTT 930 6+mid-

dle+5 2,690 81.2.+6.7.+11.

12.+15.16.

• Table 2 shows the assembly brackets needed for the sections

and for the casing walls.

• After connecting the brackets of the walls of the casing on

both sides of the boiler body, x the assembly shelves of the

casing walls on the top part of the boiler body.

• If there are no xing pins for connecting the brackets and

the shelves on the section, take these pins from other sec-

tions.

Table (3) - Assembly Shelves Table

Model

Detail of

casing

assembly

Casing

length

Number

of casing

assembly

shelves

Section numbers

for

connecting as-

sembly

shelves

RTT 378 4+2 1,090 3front+4.5+back

RTT 448 4+3 1,250 3FRONT

S.+4.5.+BACK S.

RTT 506 4+4 1,410 3FRONT

S.+4.5.+BACK S.

RTT 564 4+5 1,570 3FRONT

S.+4.5.+BACK S.

RTT 610 5+5 1,730 3FRONT

S.+5.6.+BACK S.

RTT 663 6+5 1,890 3FRONT

S.+6.7.+BACK S.

RTT 715 4+mid-

dle+3 2,050 4F.S.+4.5.+9.

10.+D.B.

RTT 773 5+mid-

dle+3 2,210 4F.S.+5.6.+10.

11.+D.B.

RTT 831 5+mid-

dle+4 2,370 4F.S.+5.6.+10.

11.+D.B.

RTT 878 5+mid-

dle+5 2,530 4F.S.+5.6.+10.

11.+D.B.

RTT 930 6+mid-

dle+5 2,690 4F.S.+6.7.+11.

12.+D.B.

• Connect the assembly shelves of the casing's walls to the

xing pins at the top as shown in the gure. Then x the

nuts, tightening them slightly to keep them in position.

• After installing the brackets and shelves of the casing walls,

apply the insulation and the walls of the casing onto the

boiler body.

• Prepare 8 cm of insulation for the boiler body based on the

dimensions of the appliance and apply it to the boiler body.

• Cut the insulation around the points connecting the assem-

bly shelves.

• Cut the insulation around the opening for the thermostat

socket.

• Use a 2 point stainless steel wire to connect the insulation to

the boiler body in such a way that it is stable.

• Line up the holes on the walls of the casing rst with the

pins on the assembly brackets and then with the assem-

bly shelves of the casing walls, xing them with two M8x20

bolts as shown in the gure.

• Proceed in the same way for the installation on the boiler

body of the additional walls of the right and left casing.

After installing the side walls, connect the control panel on the

top front wall of the casing.

• Insert the thermocouples (sensors) of the control panel

(thermostat, safety thermostat, thermometer) in the slots of

the panel.

• Rest the two support brackets on the top panel, with the

side with more holes facing upwards and lining up the

holes of the bottom side of the bracket with those of the

cover panel.

• Fix each bracket with three self-tapping screws 4.2x9.5 (not

supplied).

• Remove the cover of the electrical panel.

• Place the base of the control panel on the support brack-

ets, matching up the holes, then use six self-tapping screws

(supplied with the electrical panel) to secure it.

• After inserting the ends of the sensors, secure them so they

do not come out, then put back the cover of the control

panel on the base.

• Put the oil supplied in the hole of the thermostat so as to

improve the sensitivity of the sensors.

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