Biasi RIVA plus Installation & Operation Instructions

INSTRUCTIONS WALL HUNG GAS BOILER FOR CENTRAL HEATING SUPPLY Please Read Instructions Carefully Save for Future Reference Do not store or use gasoline or other fl ammable 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. Fol- • low the gas supplier’s instructions. If you can not reach your gas supplier call the fi re department. • Installation and service must be performed by a qualifi ed installer, — service agency or the gas supplier. WARNING: If the information in this manual is not followed exactly, a fi re or explosion may result causing property dam- age, personal injury or loss of life. Riva PLUS Riva PLUS

Dear Customer: Thank you for buying a Biasi Riva Plus Boiler System. The Riva Plus is a high ef ciency 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 quali ed, 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 satis ed with your boiler and its performance. We require that your contractor complete ef ciency 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 speci c recommendations. We re- alize that other makes and models of such devices are available and can be used as suc- cessfully as those we specify. The installing contractor is the best judge of a system’s speci c 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 spe- cifi c 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 Plus 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 af xed to the boiler), date of installation and the name of your installer being on record in our les. Thank you for purchasing our Riva Plus boiler. If you have questions or comments, please don’t hesitate to contact us immediately. Our goal is 100% customer satisfaction. QHT inc.

3 Table of Contents Section Title Section Number Page Number Warnings - 5-6 Important Information - 7 General Information 1 8 Technical Information (M135.30CR) 2 8-9 Parts List 3 10 Internal Piping and Parts List 4 11 Electric Diagrams 5 12-13 Sequence of Operation 5.1 13 Installation Location 6 14 Exhaust Pipe Location 7 15 Mounting Bracket 8 16 Venting 9 17-19 Restrictor Sizing 9.1 18 Fitting the Flue System 9.2 18 Choice of Flue 9.3 19-24 Pipe Connections 10 25 Gas Pipe Connections 11 26 Electrical Connections/Wiring 12 27-29 Power Connection 12.1 27 Connection to the Electricity Supply 12.2 27 Room Thermostat Connection 12.3 28 Relay Panel Control Connection 12.4 28 Zone Valve Microswitch Connection 12.5 29 Finishing 12.6 29 Circulator Sizing 13 30 Circ. Cap. as a Function of Flow Rate 13.1 30 Expansion Vessel 13.2 30 Piping 14 31-34 Primary-Secondary Piping 14.1 32 Primary-Secondary with Zone Valves 14.2 33 Manifold Piping with Zone Valves or Circ. 14.3 34

Table of Contents Section Title Section Number Page Number Commissioning 15 35-40 Initial Filling of the System 15.1 35 Lightning the Boiler 15.2 35 Checking the Gas Pres. at the Burner 15.3 36 Adjustment of the Gas Pressure 15.4 37 Checking the Ignition Device 15.5 37 Checking the Burner Ignition 15.6 38 Adjustment of the Useful c.h. Output 15.7 38 Labels Placement 15.8 39 Checking the Flue System and Comb 15.9 40 Instructing the User 15.10 40 Gas Conversion 16 41 Annual Maintenance 17 42-44 Warnings 17.1 42 Dismantelling the External Panels 17.2 42 Emptying the C.h. System 17.3 42 Cleaning the Primary Heat Exch. 17.4 43 Checking the Pressuris. in C.h. Vess. 17.5 43 Cleanig the Burner 17.6 43 Checking the Combustion Fan 17.7 43 Checking the Flue 17.8 43 Visual Inspection of Appliance 17.9 44 Gas Pressures and Soundness 17.10 44 Condensate trap 17.11 44 Venting Spare Parts 18 45-47 Separate Vent 18.1 45 Coaxial Vent 18.2 46 Roof Vent 18.3 47 Installer Notes 19 48

5 WARNING DANGER Boiler is certi ed as an indoor appliance. Do not install boiler outdoors or locate where it will be exposed to freezing temperatures. Caution: Do not store or use fl ammable materials, chemicals or fl ammable 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 qualifi ed service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water. Do not store or use gasoline or other fl ammable 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 build- • ing. 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 fi re department. • Installation and service must be performed by a qualifi ed installer, ser- — vice agency or the gas supplier. WARNING: If the information in this manual is not followed exactly, a fi re or explosion may result causing property dam- age, personal injury or loss of life.

WARNING Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of pro- ducing 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 in uenza, and the highest incidence of poisoning occurs at the onset of cold weather or during u 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 ames 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 SER- VICE COMPANY OR THE GAS COMPANY OR THE FIRE DEPARTMENT. ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR BIASI RIVA PLUS BOILER.

7 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 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 fl ammable • 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 fi re 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) CSA International Battery March Park 8501 E. Pleasant Valley Road Quincy, Massachusetts, 02269 Cleveland, OH 44134-5575 http://www.nfpa.org http://www.csa-international.org

General Information 1. Technical Information (M135.30CR) 2. The Riva Plus is a high ef ciency condensing, wall mounted gas boiler which provides central heat. The boiler features a gas valve which modulates the energy input from 49476 BTU/h to 116008 BTU/h. The boiler is shipped fully assembled with the components list- ed on page 11. All units are pressure and combustion tested at the factory prior to shipping. Key Features: Wall mountable - saving valuable oor • space. Several ue options available • Electronic spark ignition • Safety ow switch - positioned on the • main circuit, which monitors the ow 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 dam- age 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 control- led system test to ensuring the motorized components within the boiler do not be- come inoperable due to lack of use. Gas valve modulation - the gas input • modulates based off central heating tem- perature to within ± 2 ºF Diagnostic information system equipped • with three LED diagnostic lights for quick error assessment. GENERAL Height in 31.6 Width in 15.8 Depth in 13.8 Weight lb 98.1 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 8.3 *At the minimum useful output

9 2. Technical Information Cont. ENERGY CAPACITY Nominal heat input (0/2000ft) MBH 116.0 Nominal heat input (2000/4500ft) MBH 110.2 Minimum heat input MBH 49.5 Maximum useful output (0/2000ft) MBH 102.0 Maximum useful output (2000/4500ft) MBH 97.2 Minimum useful output MBH 41.6 GAS SUPPLY PRESSURE Gas Normal Min Max Natural inwc 7.0 3.5 10.5 Propane inwc 11.0 8.0 13.0 GAS PRESSURE AT BURNER Gas Min Max Ignition Natural inwc 1.0 4.8 2.4 Propane inwc 2.0 10.3 5.1 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 ow rate (0/2000ft) MBH 116.0 Nominal heat ow rate (2000/4500ft) MBH 110.2 Min Exhaust temperature °F 158 Max Exhaust temperature °F 158 INJECTORS No. Size Natural 14 130 Propane 14 85 GAS FLOW RATE Gas Min Max Natural ft³/h 48.7 115.1 Propane lb/h 2.23 5.25 ELECTRICAL Voltage V 120 Frequency Hz 60 Current A 1.6 Power consumption W 180 FLUE GAS FIGURES Gas Min Max CO2 2.5% 6.3% O2 16.5% 9.7% CLEARANCE TO COMBUSTIBLES Front in 18 Back in 0 Top in 8 Sides in 2 Bottom in 8 Flue pipe enclosed in 2 Flue pipe free air in 0

Parts List 3. 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 ow 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 ll valve 29 Back ow preventer 30 Gas supply line cock 31 Water supply inlet cock 32 Condensate trap 33 Condensing heat exchanger 34 Flue termostat

11 Internal Piping & Parts List 4. 14 4 15 16 7 9 11 27 3 1 18 20 22 21 19 17 24 15 25 33 10 5 c 32 Note: Pressure Relief Valve (#19) should be piped to a drain or to the oor as lose as pos- sible to a drain.

Electric Diagrams 5. ye bk wh gy bu rd bk gy gy gy M ~ t C.h. temperature probe NTC Pump Gas Valve COM NO M ~ COM NO NC 1 2 3 bk bu bn rd rd gnye gy wh bu rd bk bu wh gy bu gnye bkbk u b e y n g y g bk bk bu bu bu bu rd bk y g y g L N rd bu bn gnye gnye gnye bu bn bu rd gnye Primary Circuit Flow Switch 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 wh gy rd rd bk bu bn gy ye wh burd bk rd Thermostat Flue Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause im- proper and dangerous operation. Verify proper operation after servicing

Installation Location 6. 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 oor respectively. Each vent will have a free area of 54 square inches. 8.0 in 31.6 in 15.2 in 3.0 in 18.0 in 2.0 in 15.8 in 10.0 in 2.0 in CLOSET INSTALLATION MINIMUM PERMANANT CLEARANCE FRONTV I S W E I DE VIEW CLOSET INSTALLATION CLOSET INSTALLATION SERVICECLEARANCE Figure 6.2 Outside Air Opening Air Opening Each opening free area = 1 sq. inch per 2,000 BTU/h 0 to 12" 0 to 12" 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. Note: For boilers in an enclosed space it is recommended to install a CO detector in the boiler room.

15 Exhaust Pipe Location 7. 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: The Vent hood shall not be less than 3 feet above any forced air inlet to the house. 1. The Vent hood shall not be less than 1 feet below, 1 foot horizontally, or 1 foot above any door, 2. window or gravity inlet into any building. The Vent hood shall not be less than 2 feet from an adjacent building. 3. The Vent hood shall be not less than 7 feet above grade when located adjacent to public 4. walkway. The Vent hood shall be located so that ue gasses are not directed to jeopardize people, overheat 5. combustible structures, materials or enter buildings. Minimum of 4 feet horizontal clearance from electric meters, gas meters, regulators and relief 6. equipment. All joints in system are to be sealed to prevent leakage of products of combustion in the 7. building. Avoid installing exhaust hood on the North, West, or the side of the house receiving the prevailing 8. winds. The vent should not be situated so that the ue gases are directed towards brickwork, siding, 9. or other construction, in such a manner that may cause damage from heat or condensate from the ue gases

Mounting Bracket 8. 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 fi lled 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: Tape the paper template to the wall in the chosen location. Be sure to level the template. 1. Pre-drill two holes in the center of the “oval” slots on the mounting bracket, sized for the 2. hardware being used. Mount the bracket to the wall. Be sure to level the bracket by adjusting the screw in the 3. vertical slot. Pre-drill the remaining hole in the mounting bracket and secure the nal screw. 4. Mark and drill the exhaust/intake pipe holes through the house. If you are using a coaxial 5. 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. 6. Figure 8.1 A, B, C 8.9 6.9 gas 6.5 7.9 15.2 B Ø 3.1 Ø 3.1 27.6 9.6 15.8 7.7 Ø 4.0 C 2.9 7.9 .9 1 2 1.4 4.5 5.6 0.6 1.2 1.4 4.6 2.5 2.6 10.1 3.9 2.4 2.4 Condense A 31.6

17 Venting 9. The Riva is a mechanical draft, side wall vented boiler. There are two side wall ue options available – separate and coaxial. The coaxial option has one con guration shown on the next page. The separate option has two possible con gurations 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 sec- tion 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 provi- sions of the local building codes. If the Biasi Riva 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 con- nected 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 de ciencies 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 replace 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 opera- tion. Use the ame 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, replace 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 de- termined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes.

Restrictor sizing 9.1 fi tting the fl ue system 9.2 Figure 9.1 Figure 9.2 Table 9.1 9. Venting Cont.

19 Choice of fl ue: 9.3 The following ue kits are available for connecting to the boiler: A Standard coaxial horizontal fl ue kit (Exhaust & intake outside) (Coaxial 2.4/4.0 inches – nominal lenght 3.3 ft) Figure 9.3 It can be tted to allow discharge to the rear or either side of the boiler via the anged boiler adapter elbow. Minimum lenght required is 2.9 ft. Maximum equivalent lenght of 8.8 ft can be achieved utilising extensions. This ue system can only be used to dis- charge horizontally; it is not designed to enable termination in the vertical plane. 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. • 9. Venting Cont.

9. Venting Cont. B Standard separate horizontal fl ue kit (Exhaust & intake outside) (Twin pipe Figure 9.4 φ 3.25 in) Various twin (split) pipes kits and optional accessories (elbows) are available to assist in the termination of the ue 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 ue system to a greater distance than that provided by the standard coaxial horizontal ue. If either an additional 45° or 90° accessory elbow is used then the maximum permis- sible 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 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. •

21 9. Venting Cont. C Alternative separate confi guration (Exhaust outside & intake inside) (Twin pipe Figure 9.5 φ 3.25 in) This con guration 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 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. • 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. • 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

9. Venting Cont. D Alternative separate kit (Exhaust outside & intake inside) (Twin Pipe Figure 9.6 φ 3.25 in) This con guration 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 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. • 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. •

23 9. Venting Cont. E Alternative separate kit (Exhaust & intake outside) (Twin Pipe Figure 9.7 φ 3.25 in) 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 ue system to a greater dis- tance than that provided by the standard coaxial horizontal ue. If either an additional 45° or 90° accessory elbow is used then the maximum permis- sible 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 49. 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. •

9. Venting Cont. F Standard Vertical-roof kit (Exhaust & intake outside) (vertical pipe Figure 9.8 φ 3.1 / φ 4.9 in) This kit allows vertical termination of the ue pipe through the roof. The kit is 1.2 min length. Extension pieces (Co--axial) are also available which allows the ue system to be extended to a total overall maximum permissible length. Optional 45° and 90° elbows can be used to offset the ue route. Each additional elbow reduces the overall acceptable length of the ue system as fol- lows: 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. • 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. •

25 Pipe Connections 10. The Riva boiler is supplied with a 3/4” stainless steel gas pipe (A in gure 10.1), 2 - 3/4” copper pipe (C,D in gure 10.1), located in a plastic bag in the boiler package. Figure 10.1 Stainless steel gas pipe A) Main circuit drain cock B) C.h. supply copper pipe C) C.h. return copper pipe D) C.h. PRV discharge copper pipe E) Condensate trap F) 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. Attach the condensate trap to an appropriate drain pipe. • Before connecting the boiler to the heating system piping, review the suggested piping dia- • grams in Section 4 (page 11). 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 Condensate trap: The condensate trap allows the discharge of the condensate via the condensate drain pipe avoiding in the mean timethe escape of combustion products. A plastic ball closes the trap outlet in case that the trap is empty. The condenste trap is provided with two electrodes: if the drain pipe is plugged or in any case in which the condensate isn’t correctly evacuated, the condensate level in the trap rises putting in contact the electrodes thus causing the boiler lock- out.

Gas Pipe Connections 11. Gas supply piping is to be sized and installed properly in order to provide a supply of gas suf - cient 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. Figure 11.1 Direction of flow B A F E D C Manual T-handle Shutoff Valve A) Pressure Gauge Port B) Flexible Gas Line to Burner C) Male Union ¾” NPT D) Pipe Cap E) 1” X 1” X ¾” TEE F) Note: Height of valve above ground level to conform to local codes, if any. Massa- chusetts 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 oor 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 lique ed petro- leum 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 shutoff valve must be disconnected from the gas supply piping sys- tem during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). WARNINGS DO NOT USE A FLAME FOR CHECKING GAS LEAKS

27 Electrical Connections/Wiring 12. 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 A A B B C C B B Removing Control Panel: Remove screws C. • Figure 12.3 Move the lower part of the side panels ( gure • 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). D D D Power Connection: 12.1 For the electrical connection to the boiler use electric wires which conform to local regulations. The boiler, when installed ,must be electricallybonded to ground in accordance with the require- ments of the authority having jurisdiction or, in the absence of such requirements,with the Na- tional Electrical Code,ANSI/NFPA 70 and/or Canadian Electrical Code Part I CSA C22.1, Electrical Code. Connection to the electricity supply: 12.2 Connect the electrical supply cable coming from the fused spur isolation switch to the power supply • terminal block of the boiler (as shown in gure 12.5) keeping the same connections for the live wire and the neutral wire Figure 12.5 Connect the earth wire(yellow/green). Boiler must be wired directly to earth ground on breaker panel. • 1 2 L N 3 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 WARNING Note: Do not connect live wires to thermostat terminals 1-3.

12. Electrical Connections/Wiring Cont. Room Thermostat Connection: 12.3 The room thermostat must be connected • to the terminal block situated next to the control panel. Figure 12.6 Any external controls and connection lines • must be rated at 120 VAC but under no circumstances should external live volt- age be connected to the room thermostat link on the boiler. 1 2 L N 3 To fused spur isolation switch Power supply terminal block External controls terminal block J 120 VAC Control Terminal Block Relay Panel Connection: 12.4 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). Figure 12.7 Connect the room thermostat between • terminals 1 and 3 as shown in Fig. 12.7. Power supply terminal block External controls terminal block T Room thermostat 1 2 L N 3 (120V rating) The relay control must be connected to • the terminal block situated next to the control panel. Figure 12.8 When connecting any type of relay con- • trol, the jumper J in Fig. 12.8 must be re- moved. 1 2 L N 3 To fused spur isolation switch Power supply terminal block External controls terminal block J 120 VAC Control Terminal Block Connect the dry contact switch of the re- • lay panel to the 120 VAC control terminal block (Fig 12.9). Figure 12.9 Connect the dry contact switch to termi- • nals 1 and 3 shown in Fig. 12.9. Power supply terminal block External controls terminal block Generic Relay Control 1 2 L N 3 (120V rating) T

29 12. Electrical Connections/Wiring Cont. Zone Valve Micro Switch Connection: 12.5 The zone valve micro switch must be con- • nected to the terminal block situated next to the control panel. Figure 12.10 When connecting the zone valve switch, • the jumper J in Fig. 12.10 must be re- moved. 1 2 L N 3 To fused spur isolation switch Power supply terminal block External controls terminal block J 120 VAC Control Terminal Block Figure 12.11 Connect the micro switch of the zone • valve to terminals 1 and 3 as shown in g- ure 12.11 Connect the zone valve switch to the room • thermostat as shown in gure 12.11 120 VAC Control Terminal Block 1 L N 3 V T Zone Valve Room Thermostat Finishing 12.6 Route the electrical supply cord and the external control cord as illustrated in Fig. 12.12. • Figure 12.12 Lock the cords in place with the exible cord clamps. • Replace the control panel reversing the steps on page 27. • To the fused spur To the external control device isolation switch

Circulator Sizing 13. Circulator capacity as a function of fl ow rate: 13.1 Figure 13.1 The hydraulic specifi cation in Fig 13.1 represent the pressure (available head for the central heating system) as a function of the fl ow rate. The pressure loss due to the in- ternal 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 ow rate using the graph above. If the internal circulator is adequate, direct system piping can be utilized. See section 4 page 11 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. Expansion vessel: 13.2 The height difference between the C.h. PRV (19 on page 10) and the highest point in the sys- tem 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 154l, an additional expansion vessel must be provided.

31 Piping 14. 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 us the central heating ow restrictor supplied with the boiler. The ow restrictor ensures that there will be enough back pressure to make the central heating ow switch in a low head loss piping system like primary secondary. Installation of ow restrictor: The ow restrictor is installed inside the pipe tail that attaches to the boiler. Place the ow restrictor into the gasket for the central heating supply pipe tail. Place the gasket on the pipe tail so the ow 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 rst 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 ow switch will operate properly. 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 perfor- mance. Must be less than 8" Boiler Return Boiler Supply System Return System Supply 1 ¼” ¾” 2" No more than 8" At least 16" 1 ¼” ¾” System supply System return Boiler supply Boiler Return

Primary – Secondary Piping: 14.1 All external piping components are to be supplied by the installer. It is very important to use a hydraulic separator before secondary circulators. 14. Piping Cont.

33 14. Piping Cont. Primary – Secondary Piping with Zone Valves: 14.2 All external piping components are to be supplied by the installer. It is very important to use an hydraulic separator before secondary circulators.

14. Piping Cont. Manifold Piping with Zone Valves (shown conn. to radiators): 14.3 All external piping components are to be supplied by the installer.

35 Commissioning 15. Initial fi lling of the system: 15.1 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 ll • valve between the cold water inlet and Central Heating System (See 28 on pip- ing diagrams in previous section). Open each radiator air vent starting at the • lower point and close it only when clear water, free of bubbles, ows out. Purge the air from the pump by unscrew- • ing the pump plug 2 (Fig. 15.2); release the pump by turning the rotor in the direc- tion indicated by the arrow on the informa- tion plate. Figure 15.2 Close the pump plug. • Continue lling 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 wa- • ter soundness and remedy any leaks dis- covered. Cold ush the system to remove any loose • particles and any system debris before starting the boiler for the rst time. Reassemble the front panel of the case. • Return ll valve to automatic position. • Lighting the boiler: 15.2 Note: If external controls are tted (e.g. room thermostat) ensure they “call for heat”. WARNING: 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 ash every 4 seconds. Turn the function selector B as in Fig. 15.3 • The appliance operation light A will ash ev- ery 2 seconds. Figure 15.3 B A C D 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 lock- out and the lock-out signal lamp D will appear. To reset the boiler turn the knob B ( gure 15.3) on the 0 position and then press and release the boiler reset button C (Fig. 15.3).

15. Commissioning Cont. Checking the gas pressure at the burner: 15.3 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 operat- ing effi ciency from the boiler. Remove the front panel of the case. • Take off the lid of the sealed chamber. • 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 tted (e.g. room thermostat) ensure they “call for heat”. Switch on the boiler. • Check the maximum gas pressure and com- • pare the value on the gauge with the value indicated in the Section 2 on page 9 (gas pressures at the burner). Check the maximum gas ow at the gas • meter and compare the value indicated in the section 2 on page 9 (gas ow rate). Switch off the boiler. • Disconnect the gas modulator coil by remov- • ing the electrical connector E (Figure 15.4). Switch on the boiler. • Check the minimum gas pressure and com- • pare the value on the gauge with the value indicated in the Section 2 on page 9 (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. Close the lid of the sealed chamber. • Important: after the checks all of the test points must be sealed.

37 15. Commissioning Cont. Adjustment of the gas pressure: 15.4 Remove the front panel of the case. • Take off the lid of the sealed chamber. • 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 compo- nents levering with a at 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. • Close the lid of the sealed chamber. • Important: after the checks all of the test points must be sealed. Checking the ignition device: 15.5 With the burner on high ame close the gas cock. After three ignition attempts (within about three min- utes), the lock-out signal lamp must appear (D on Figure 15.3). To reset the boiler turn the knob B ( gure 15.3) on the 0 position and then press and release the boiler reset button (C on Figure 15.3).

15. Commissioning Cont. Checking the burner ignition: 15.6 Turn the boiler OFF. • Open the gas valve outlet pressure test point • 15 ( gure 15.5) and connect the gauge. Turn the boiler ON positioning the function se- • lector B in the position shown in gure 15.7 and ensure that the room thermostat is set to “heat demand”. Figure 15.7 Loosen screws D and remove the service • panel ( gure 15.9). Figure 15.8 Watch the gauge and check to see if the ig- • nition 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 gure 15.7. D D D Repeat this process two to three times leav- • ing 30 second intervals between each igni- tion. 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). 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 in- creases. After the adjustment operations bring the se- • lector 3 of gure 15.9 back to the normal posi- tion (ON). Reassemble the service panel. • Close the gas valve outlet pressure test point • 15 ( gure 15.5). Reassemble the front pannel of the case. • Important: after the checks all of the test points must be sealed. 2 3 4 OFF ON 1 ACC RISC + + Adjustment of the useful c.h. output: 15.7 Turn the boiler OFF. • Open the gas valve outlet pressure test point 15 ( gure 15.5) and connect the gauge. • Turn the boiler ON positioning the function selector B in the position shown in gure 15.7 and ensure • that the room thermostat is set to “heat demand”. Loosen screws D and remove the service panel ( gure 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 ( gure 15.5). • Reassemble the front pannel of the case. •

39 15. Commissioning Cont. Labels placement: 15.8 Figure 15.10 Warning: The installation is not complete unless labels supplied are placed on the boil- er 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. 1 4 2 3 5

15. Commissioning Cont. Checking the fl ue system and combustion: 15.9 The ue system should be visually checked for soundness. Check all clamps, gaskets and • xings are secure and tight. Ensure that the ue terminal is sited correctly in accordance with the ue tting instruc- • tions. 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 Sec- • tions 2 on page 9 of this manual for proper CO2 levels. Figure 15.11 Air-Flue exhaust sampling points Instructing the user: 15.10 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 elec- • tric 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 pre- • cautions necessary to prevent damage should the appliance be inoperative when freezing conditions may occur. Fill in the details required on the Boiler Guarantee Certi cate and hand to the User advis- • ing them to return the correct section for boiler Guarantee registration. Finally, advise the User that, for continued safe and ef cient operation, the appliance must be serviced by a competent person at least once a year. Useful output KW 16.7 18.9 21.1 23.2 25.4 27.5 29.6 31.8 BTU/h 56983 64490 71996 79161 86668 93833 101000 108506 Natural Pa inwc. 290 1.16 370 1.48 460 1.84 560 2.24 660 2.65 780 3.13 900 3.61 1040 4.17 m³/h 1.76 2.00 2.23 2.46 2.69 2.91 3.14 3.36 ft³/h 5.77 6.56 7.31 8.07 8.82 9.54 10.30 11.02 Propane Pa inwc. 680 1.45 860 1.69 1060 2.25 1270 3.21 1500 4.34 1740 5.62 2000 7.06 2270 8.95 Kg/h 1.3 1.5 1.7 1.9 2.0 2.2 2.3 2.5 lb/h 3.0 3.3 3.7 4.1 4.4 4.8 5.1 5.5 Table 15.1

41 Gas Conversion 16. WARNINGS: Procedures to adapt the boiler to the type of gas available must be car- ried 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) tted 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 Main- tenance – 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 cor- rectly. 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 ser- • vice panel ( gure 16.2) A A 7 Figure 16.2 Set correctly the dip-switch “2” to the cor- • rect position (Fig. 16.3) in accordance with the following table. Gas supply Position of the switch 2 Natural gas On L.P.G. Off 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 self- adhesive label (included with the conver- sion 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. D D D ON OFF 1 2 3 4 ON OFF 1 2 3 4 Natural gas L.P.G.

Annual Maintenance 17. Warnings: 17.1 The procedures detailed in this chapter must be carried out only by a professionally quali ed person. Thus you are advised to contact an Authorised Service Agent. For ef cient and con- tinuous 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 sup- ply 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. Dismanteling the external panels: 17.2 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. Figure 17.1 A A Figure 17.2 B B C C B B Emptying the Central Heating System: 17.3 Close the pressure reducing automatic ll • 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 ll • valve (28 on Section 4) Figure 17.3

43 17. Annual Maintenance Cont. Cleaning the primary heat exchanger: 17.4 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 ns 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. Checking the pressurization in the expansion vessel: 17.5 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 30 of this manual. If the pressure should be lower, take steps to correct the pressure level. Cleaning the burner: 17.6 Follow the instructions for removing the ex- ternal panels from 17.2. Remove the nine screws labelled C in gure 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 suf cient to dust it with a bristle paintbrush. Figure 17.4 Checking the combustion fan: 17.7 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 vis- ible impeller ns are free of any dirt or obstructions. Checking the fl ue: 17.8 Have the integrity of the ue outlet pipe (24 on page 10) air intake pipe (25 on page 10), checked periodically, the venturi device (23 on page 10) cleaned and the ef ciency of the ue safety circuit checked at least once a year. For all the above maintenance operations it is ad- visable to call an approved Service Engineer. Remove the four Phillips head screws • from the vent connector on the boiler. Remove the vent connector from the boil- • er by pulling vertically on it. Remove the rst elbow from the horizon- • tal run of the exhaust to the outside. Using a ashlight inspect each length of • vent pipe for obstructions and dirt buildup. Clean any that is found with an appropri- ate sized brush. Inspect the venture device inside the out- • let 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 ns facing the male end of the pipe. Reinstall the elbow onto the horizontal • run of the pipe rst by simply pushing the To check the pressure at the venturi device, use the test points (12 on page 10). parts together. Push the vent adapter down onto the top • of the boiler and reinstall the four Phillips head screws. 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 indi- cated in the Section 2 on page 9. Figure 17.5 Venturi test points Visual inspection of appliance: 17.9 Visually inspect all water joints, seals and connections for any evidence of leakage and re- tighten, grease or replace them as necessary. Gas pressures and soundness: 17.10 Check appliance for gas soundness. Recheck operational pressures and adjust as necessary as described in Section 15.4 page 37 of this manual. Condensate trap: 17.11 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 wirings from the trap. • Reassemble carrying out the removal op- • erations in reverse order. The trap should be serviced once a year dur- ing the annual service. Figure 17.6 17. Annual Maintenance Cont.

45 Vent Part Spares 18. Separate venting: 18.1 Description Order Number Twin pipe kit 10999.0393.0

Coaxial venting: 18.2 Description Order Number Coaxial ue kit 10999.0387.0 18. Vent Part Spares Cont.

47 Roof venting 18.3 Part Description Order Number A Roof ue kit 10999.0392.0 For any spare parts, please contact QHT Inc. at 800-501-7697. 18. Vent Part Spares Cont.

Installer Notes 19. 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 ___________________________________________________________ _______________________________________________________________________ _______________________________________________________________________