Riva
HEAT ONLY
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.
Manufactured by:
Distributed By:
Biasi S.p.A.
Verona, Italy
Quincy Hydronic Technologies, Inc.
80 Rochester AVE. Suite # 12
Portsmouth, NH 03801
Phone: 603-334-6400
Fax: 603-334-6401
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Dear Customer:
Thank you for buying a Biasi Riva Heating Only Boiler System.
The Riva Heating Only is a high efficiency, non-condensing, wall mounted gas boiler
which provides central heat supply water.
We realize that it is not possible to answer all questions about the Riva boiler system in
this manual. Reading this installation manual does not make the reader an expert in all
aspects of installation and operation, and does not replace the need for a qualified,
licensed heating contractor. We urge you to contact your installing contractor or distributor
if you are in question about any aspect of your boiler's performance. Our main concern is
that you are satisfied with your boiler and its performance. We require that your contractor
complete efficiency tests using instruments.
The external controls and accessories listed in this manual (excluding those supplied
inside the boiler) are intended to serve as guidelines rather than specific
recommendations. We realize that other makes and models of such devices are available
and can be used as successfully as those we specify. The installing contractor is the best
judge of a system's specific requirements, as well as the local availability of certain makes
and models of controls and accessories. The preceding does not apply, however, to the
equipment that comes with every boiler, such as the overheat control and pressure relief
valves. The installation of the specific devices supplied with every boiler is
absolutely necessary to the safe operation of the boiler and protection of the
heating system.
All BIASI wall hung boilers are built in accordance with the ASME boiler and pressure
vessel code, and bear the "H" stamp. The Entire range of applications for the Riva boiler
has been tested to standard CSA 4.9 and is CSA compliant.
This Riva Heating Only boiler has a 2 year warranty, a copy of which is provided with the
boiler. Please be sure to return the warranty registration card as the warranty will be void
without your boiler's serial numbers (located on the ratings label affixed to the boiler), date
of installation and the name of your installer being on record in our files.
Thank you for purchasing our Riva Heating Only boiler. If you have questions or
comments, please don't hesitate to contact us immediately. Our goal is 100% customer
satisfaction.
QHT inc.
3
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Table of Contents
Section Title
Section Number
Page Number
Warnings
-
-
6-7
8
Important Information
General Information
1
9
Technical Information (M130.30CR)
Parts List
2
9-10
11
3
Internal Piping and Parts List
Electric Diagrams
4
12
5
13
Installation Location
6
14
Exhaust Pipe Location
Mounting Bracket
7
15
8
16
Venting
9
17-20
17
Restrictor Sizing
9.1
9.2
9.3
10
11
12
12.1
12.2
12.3
12.4
12.5
13
13.1
13.2
14
14.1
14.2
Fitting the Flue System
Choice of Flue
17
18-20
21
Pipe Connections
Gas Pipe Connections
Electrical Connections/Wiring
Power Connection
22
23-25
23
Connection to the Electricity Supply
Room Thermostat Connection
Relay Panel Control Connection
Zone Valve Microswitch Connection
Circulator Sizing
23
24
24
25
26
Circ. Cap. as a Function of Flow Rate
Expansion Vessel
26
26
Piping
27-29
27
Primary-Secondary Piping
Primary-Secondary with Zone Valves
28
4
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Table of Contents
Section Title
Section Number
Page Number
Manifold Piping with Zone Valves or Circ. 14.3
Commissioning
Initial Filling of the System
29
30-35
30
15
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
16
Lightning the Boiler
30
Checking the Gas Pres. at the Burner
Adjustment of the Gas Pressure
Checking the Ignition Device
Checking the Burner Ignition
Adjustment of the Useful c.h. Output
Labels Placement
31
32
32
33
33
34
Checking the Flue System and Comb.
Instructing the User
35
35
Gas Conversion
36
Annual Maintenance
Warnings
17
37-38
37
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
18
Dismantelling the External Panels
37
Emptying the C.h. System
Cleaning the Primary Heat Exch.
Checking the Pressuris. in C.h. Vess.
Cleanig the Burner
37
37
38
38
Checking the Flue
38
Visual Inspection of Appliance
Gas Pressures and Soundness
38
38
Installer Notes
39
5
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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.
6
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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.
• Stale or smelly air.
• The presence of soot or carbon in or
around the appliance.
• Flames coming out around the appliance.
• Yellow colored flames in 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 HEAT ONLY BOILER.
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IMPORTANT INFORMATION
Please read this page carefully.
•
•
ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL,
STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES 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
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
CSA International
8501 E. Pleasant Valley Road
Cleveland, OH 44134-5575
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1. General Information
The Riva Heat Only is a high efficiency, non-condensing, wall mounted gas boiler
which provides central heat. The boiler features a gas valve which modulates the energy
input from 44,000 BTU/h to 108,000 BTU/h. The boiler is shipped fully assembled with the
components listed on page 11. All units are pressure and combustion tested at the factory
prior to shipping.
Key Features:
• Wall mountable - saving valuable floor
space.
• Several flue options available
• Electronic spark ignition
• 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
• 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.
• Diagnostic information system
equipped with three LED diagnostic
lights for quick error assessment.
2. Technical Information (M130.30CR)
GENERAL
Height
CENTRAL HEATING
Maximum working temp.
Temp. Regulation range*
Maximum pressure
in
in
in
lb
°F
°F
27.7
15.7
12.8
79.4
185
100-176
30.0
Width
Depth
psi
psi
Weight
Minimum pressure
4.35
Max head loss (at 4.4 GPM) ft
*At the minimum useful output
10
9
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2.Technical Information Cont.
ENERGY CAPACITY
INJECTORS
Natural
No.
14
Size
130
89
Nominal heat input
(0/2000ft)
MBH
MBH
MBH
MBH
122.8
116.7
49.5
Propane
14
Nominal heat input
(2000/4500ft)
GAS FLOW RATE
Minimum heat input
Gas
Min
Max
121.1
5.55
Maximum useful output
(0/2000ft)
Maximum useful output
(2000/4500ft)
100.7
Natural
ft³/h
48.7
2.23
Propane
lb/h
MBH
MBH
95.9
37.0
Minimum useful output
ELECTRICAL
Voltage
V
Hz
A
120
60
GAS SUPPLY PRESSURE
Frequency
Gas
Natural
Propane
Normal
Min
3.5
8.0
Max
10.5
12.0
Current
< 1.6
176
inwc
inwc
7.0
Power consumption
W
11.0
FLUE GAS FIGURES
Gas
GAS PRESSURE AT BURNER
Min
Max
7.2%
8.1%
Gas
Natural
Propane
Min
0.8
1.4
Max
Ignition
2.4
CO2
O2
2.5%
inwc
inwc
5.3
16.5%
9.0
5.2
FLUE DESIGN
Minimum Venturi pressure inwc
0.64
Flue pipe diameter
2.25/4
3.25/5
Coaxial
in
in
Twin split pipes
3.25/3.25
Nominal heat flow rate
(0/2000ft)
MBH
122.8
Nominal heat flow rate
(2000/4500ft)
MBH
116.7
Min Exhaust temperature
Max Exhaust temperature
°F
°F
262
324
10
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3. Parts List
Primary Components:
12
11
9
10
8
7
6
19
3
5
15
14
4
1
16
18
2
13
26
20
1 Pump
2 Pump vent plug
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
3 Automatic air purger valve
4 Modulation gas valve
5 Flame-detecting electrode
6 Ignition electrodes
7 Burner
23 Venturi device
8 Combustion chamber
9 Primary heat exchanger
10 Fan
24 Flue outlet pipe
25 Air Intake Pipe
26 Control panel
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
27 Safety thermostat probe
28 Pressure reducing automatic fill valve
29 Backflow preventer
30 Gas supply line cock
31 Water supply inlet cock
11
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4. Internal Piping & Parts List
25
23
24
10
11
27
9
3
7
1
6
5
15
18
20
17
4
14
16
19
22
21
30
29
28
31
Note: Pressure Relief Valve (#19) should be piped to a drain or to the floor as lose as
possible to a drain.
12
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5. Electric Diagrams
Electric supply
terminal
Fan
Safety
Air Pressure
Switch
Ignition
Flame Detection
Electrode
Thermostat
Electrodes
block
NC
NO
External controls
terminal
L
N
bn
bu
rd
block
M
~
COM
rd
bk
3
2
1
bn gnye bu
wh
gy
gnye
rd
rd
bu
1
ye wh bu
rd
bk
gy
gnye
gnye
bu bn
gnye
ye bk wh gy bu
rd
rd
rd
wh
gy
bk
bk rd bu bu
bu
bk bk
bn
gy gy
gnye bu gy
gy
bk
rd
wh
bu
bk
rd
bu
gnye gy bu
gy
gy
COM
bk
bu
M
~
*
bk
bu
t
NO
Primary Circuit
Flow Switch
C.h. temperature
probe NTC
Pump
Gas
Valve
bn - brown
bu - blue
bk - black
wh - white
rd - red
* ---> directly connected to the electronic ignition board
gy - grey
Caution: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
ye - yellow
gnye - green/yellow
Verify proper operation after servicing
13
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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.
1 2 .8 in
i n
10.0
3 . 0 i n
2.0 in
CLOSET INSTALLATION
MINIMU M PER MA NANT
CLEARANCE
2.0 in
2 7 .7 in
1 8 .0 in
CLOSET INSTALLATION
SERVICECLEARANCE
1 5 .8 in
8 .0 in
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.
0 to 12"
Air Opening
Note: For boilers in an enclosed
space it is recommended to install
a CO detector in the boiler room.
Each opening free area =
1 sq. inch per 2,000 BTU/h
Outside
Air Opening
0 to 12"
Figure 6.2
When choosing an installation location insure the exhaust and intake pipes comply with
NFPA 54. The drawing on the next page illustrates the restrictions on exhaust locations.
14
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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 4 feet below, 4 feet horizontally, or 1 foot above
any door, window or gravity inlet into any building.
3. The Vent hood shall not be less than 2 feet from an adjacent building.
4. The Vent hood shall be not less than 7 feet above grade when located adjacent to
public walkway.
5. The Vent hood shall be located so that flue gasses are not directed to jeopardize
people, overheat combustible structures, materials or enter buildings.
6. Minimum of 4 feet horizontal clearance from electric meters, gas meters, regulators
and relief equipment.
7. All joints in system are to be sealed to prevent leakage of products of
combustion in the building.
8. Avoid installing exhaust hood on the North, West, or the side of the house receiving
the prevailing winds.
15
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8. Mounting Bracket
After a suitable installation location is chosen, verify that the mounting wall is
properly braced and strong enough to support the 80 pound weight of the unit
when filled with water.
NOTE: The boiler shall be installed such that the gas ignition system components
are protected from water and liquids in general (dripping,spraying, rain, etc)
during the appliance operation and service.
Use the paper template provided with the boiler to determine the location of the mounting
bracket. Securely mount the bracket to the wall using appropriate hardware for the
particular wall construction.
Mounting Steps:
1.
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 the vertical slot.
4.
5.
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.
6.
ø3.1
ø3.1
ø4.0
B
C
9.3
5.8
C
A
3.7
7.9
9.8
7.6
A&B
0.8
4.5
4.5
0.6
1.0
3.2
4.6
2.8
5.1
15.7
13.0
Figure 8.1
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9. Venting
The Riva is a mechanical draft, side wall vented boiler. There are two flue options
available - separate and coaxial. The coaxial option has one configuration shown on the
next page. The separate option has two possible configurations shown on the following
pages.
9.1 Restrictor Sizing:
Each exhaust option is shipped standard with 3 feet of exhaust pipe, 3 feet of intake air
pipe. There is also a restrictor kit in which there are some restrictors that must be placed
in exhaust breech of fan on the top of the boiler (Fig. 9.1) according to the flue
configuration used.
If additional flue piping is need for a particular application, it can be ordered separately in
3 feet increments. Depending on the final flue pipe length, an alternative restrictor may be
required. Refer to the tables 9.1 for proper restrictor ring sizing
Coaxial 2.5/4.0
From 1.65 to 3.30 (ft)
From 3.30 to 8.86 (ft)
Restrictor Size
41
44
Separate 3.25/3.25
Restrictor Size
For 1.65 (in) and 1.65 (out)
38
41
From 3.30 to 39.40 (in+out)
Table 9.1
Figura 9.1
9.2 Fitting the flue system:
In general, it has to be taken in consideration that the orizontal sections of the flue
pipe must have an horizontal sloping not less than 1.5 degree (0.3 in per ft) towards
the boiler.
In the standard horizontal flue kit the flue pipe is angled within the air duct therefore the air
duct must be horizontally installed.
If one or more exstensions have to be used they must be adequately supported so that
there is no sag in the flue pipe and a minimum fall of 1.5 degree (0.3 in per ft) over the
whole lenght towards the boiler is ensured.
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9. Venting Cont.
9.3 Choice of flue:
The following flue kits are available for connecting to the boiler:
Standard coaxial horizontal flue kit (Exhaust & intake outside)
A
Figure 9.3 (Coaxial 2.4/4.0 inches – nominal lenght 3.3 ft)
It can be fitted to allow discharge to the rear or either side of the boiler via the
flanged boiler adapter elbow. Minimum lenght required is 1 ft. Maximum equivalent
lenght of 32.8 ft can be achieved utilising extensions. This flue system can only be
used to discharge horizontally, it is not designed to enable termination in the
vertical plane.
Installation:
•
•
•
•
•
•
•
•
Drill hole A (on the wall template) through the outside wall.
Cut the pipe as necessary so that a no more than 6” protrudes from the house.
Slide the intake and exhaust pipes through the hole.
Slide one rubber wall trim piece on the pipe from inside and one from outside.
Connect exhaust (inner) pipe to concentric elbow.
Connect intake (outer) pipe to concentric elbow.
Secure elbow to boiler using gasket and four screws provided.
Secure end cap on the intake pipe outside the house.
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9. Venting Cont.
B
Standard separate horizontal flue kit (Exhaust & intake outside)
Figure 9.4 (Twin pipe φ 3.25 in)
Various twin (split) pipes kits and optional accessories (elbows) are available to
assist in the termination of the flue where the boiler is installed in a location remote
to an outside wall. These kits allow for separation of the air supply pipe from the
pipe that discharges the exhaust gasses. Consequently it is possible to extend the
flue system to a greater distance than that provided by the standard coaxial
horizontal flue.
If either an additional 45° or 90° accessory elbow is used then the maximum
permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.
The sum of the lenghts of the two horizontal part must be less than 131 ft.
Installation:
•
•
Drill holes B & C (on the wall template) through the outside wall.
Cut the pipes as necessary so that no more than 6” of intake pipe protrudes
from the house and the exhaust pipe is a minimum of 4 inches longer than the
intake pipe.
•
•
•
•
•
•
Slide the Intake and exhaust pipes through the respective holes.
Slide one rubber wall trim piece on each pipe from inside and one from outside.
Attach each collar to the boiler with the gasket and screws provided.
Insert each elbow into its corresponding collar.
Connect each pipe to its corresponding elbow (as shown in the diagram).
Secure end cap on the intake and exhaust pipe outside the house.
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9. Venting Cont.
C
Alternative separate kit (Exhaust outside & intake inside)
Exhaust Pipe End Cap
Rubber Wall Trim (2X)
Exhaust Pipe
Exhaust Elbow
Air Intake Elbow
Air Intake Pipe
Exhaust Collar
Air Intake Collar
Test Ports
Figure 9.5 (Twin Pipe Φ 3.25 in)
This configuration of the twin pipe kit allows to discharge the exhaust gasses
outside. The air supply is obtained with an air intake pipe. This allows to take air
from the room where the boiler is installed.
If either an additional 45° or 90° accessory elbow is used then the maximum
permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.
Note: When utilizing this option, see page 14 for room ventilation details.
Installation:
•
•
•
•
•
•
•
Drill hole C (on the wall template) through the outside wall.
Cut the pipe as necessary so that no more than 6” protrudes from the house.
Slide the exhaust pipe through the hole.
Slide one rubber wall trim piece on the pipe from inside and one from outside.
Attach each collar to the boiler with the gasket and screws provided.
Insert each elbow into its corresponding collar.
Connect each pipe to its corresponding elbow.
20
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10. Pipe Connections
The Riva boiler is supplied with a 3/4” stainless steel gas pipe (A in figure 10.1), 2 - 3/4”
copper pipe (C,D in figure 10.1), located in a plastic bag in the boiler package.
A) Stainless steel gas
pipe
B) Main circuit drain
cock
C) C.h. return copper
pipe
B
D) C.h. supply copper
pipe
E) C.h. PRV discharge
A
D
C
copper pipe
E
Figure 10.1
Installation:
• Remove the
use the proper
gaskets for the pipe
connections.
• If the c.h. system is
above the boiler level,
it is advisable to
protective caps off
boiler connections
(Figure 10.1).
• Before connecting the
boiler to the heating
system piping, review
the suggested piping
diagrams in Section 4
(page 12).
install c.h. cocks
close to the boiler for
servicing operation
• Thoroughly clean the
connections.
• Attach the supplied
components to the
boiler connections
(see Figures 10.1).
Be sure to
21
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11. Gas Pipe Connections
Gas supply piping is to be sized and installed properly in order to provide a supply of gas
sufficient to meet the maximum demand without undue loss of pressure between the
meter and the boiler. Consult with the National Fuel Gas Code ANSI Z223.1 for proper
sizing of gas piping for various lengths and diameters.
Direction of flow
A)
B)
C)
D)
E)
F)
Manual T-handle Shutoff Valve
Pressure Gauge Port
Flexible Gas Line to Burner
Male Union ¾” NPT
Pipe Cap
A
1” X 1” X ¾” TEE
B
Note: Height of valve above ground
level to conform to local codes, if
any.
C
F
Massachusetts statecode
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 individual shut-off valve must be disconnected from the gas supply
piping during any pressure testing of that piping at test pressures in excess of ½ psi.
WARNINGS
DO NOT USE A FLAME FOR CHECKING GAS LEAKS
R12.ElectricalConnections/Wiring
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12.1 Power Connection:
Removing Side Panel:
• Remove screws B
• Move the lower part of
the side panels (figure
12.3).
A
A
• Pull the control panel.
When completely pulled
out, the panel can rotate
45° downward.
C
C
B
B
D
D
B
B
D
Figure 12.2
Removing Control Panel:
• Remove screws C.
Figure 12.4
• Loosen screws D and
remove the service
panel (Fig. 12.4).
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
Figure 12.3
For the electrical connection to the boiler use electric wires which conform to local
regulations.
12.2 Connection to the electricity supply:
• Connect the electrical supply cable coming from the fused spur isolation switch to the
power supply terminal block of the boiler (as shown in figure 12.5) keeping the same
connections for the live wire and the neutral wire.
120 VAC
15 AMP BREAKER
Service Man's Switch
Fire - O - Matic
To fused spur
isolation switch
WARNING
Note: Do not connect live wires to
thermostat terminals 1-3.
N
L
Power supply
terminal block
3
2
1
External controls
terminal block
Figure 12.5
• Connect the earth wire(yellow/green). Boiler must be wired directly to earth ground on
breaker panel.
12. Electrical Connections/Wiring Cont.
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12.3 Room Thermostat Connection:
• Any external controls
and connection lines
• The room thermostat
must be connected to
the terminal block
situated next to the
control panel
T
Room thermostat
(120V rating)
must be rated at 120
VAC but under no
circumstances should
external live voltage
L
N
To fused spur
isolation switch
L
N
be connected to the
room thermostat link
on the boiler
Power supply
terminal block
Power supply
terminal block
3
2
1
External controls
terminal block
• When connecting any
type of external
3
2
1
J
Figure 12.7
Connect the room
External controls
terminal block
control, the jumper J
in Fig. 12.6 must be
removed.
•
thermostat between
terminals 1 and 3 as
shown in Fig. 12.7.
120 VAC Control
Terminal Block
•
The room thermostat
must be connected to
the “Control Terminal
Block” (Fig 12.7).
Figure 12.6
12.4 Relay Panel Connection:
• When connecting any
type of relay control,
the jumper J in Fig.
12.8 must be
• The relay control must
be connected to the
terminal block
T
Generic Relay Control
(120V rating)
situated next to the
control panel
L
N
removed.
• Connect the dry
contact switch of the
Power supply
terminal block
3
2
1
To fused spur
isolation switch
L
N
External controls
terminal block
Power supply
terminal block
relay panel to the 120
VAC control terminal
block (Fig 12.9).
Figure 12.9
3
2
1
J
• Connect the dry
contact switch to
terminals 1 and 3
shown in Fig. 12.9.
External controls
terminal block
120 VAC Control
Terminal Block
Figure 12.8
12. Electrical Connections/Wiring Cont.
R
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12.5 Zone Valve Micro Switch Connection:
• The zone valve micro
• When connecting the
zone valve switch, the
jumper J in Fig. 12.10
must be removed.
• Connect the micro
switch must be
connected to the
terminal block
situated next to the
control panel
switch of the zone
valve to terminals 1
and 3 as shown in
figure 12.11
Zone
Valve
Room
Thermostat
• Connect the zone
valve switch to the
room thermostat as
shown in figure 12.11
V
T
To fused spur
isolation switch
L
N
Power supply
terminal block
N
L
3
2
1
J
External controls
terminal block
3
1
120 VAC Control
Terminal Block
120 VAC
Control Terminal
Block
Figure 12.10
Figure 12.11
12.6 Finishing
• Route the electrical
supply cord and the
external control cord
as illustrated in Fig.
12.12
• Lock the cords in
place with the flexible
cord clamps.
• Replace the control
panel reversing the
steps on page 23.
To the external
control device
To the fused spur
isolation switch
Figure 12.12
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13. Circulator Sizing
13.1 Circulator capacity as a function of flow rate:
Figura 13.1
The hydraulic specification in Fig 13.1 represent the pressure (available head for
the central heating system) as a function of the flow rate. The pressure loss due to
the internal piping in the boiler has already been substracted.
When determining proper piping of the heating system, verify that the internal boiler
circulator will overcome the head loss of the system at the designed flow rate using the
graph above.
If the internal circulator is adequate, direct system piping can be utilized. See section 4
page 12 for suggested direct supply/return piping.
If the internal circulator is inadequate, a secondary circulator must be utilized. See
sections 14 for suggested primary/secondary piping.
13.2 Expansion vessel:
The height difference between the C.h. PRV (19 on page 11) and the highest point in the
system may be 23 ft at most. For greater differences, increase the pre-load pressure in
the C.h. expansion vessel (17 on page 11) and the system when cold, by 0.1 bar for
additional 3.3 ft. For systems with volumes greater than 154l, an additional expansion
vessel must be provided.
26
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14. Piping
14.1 Primary – Secondary Piping:
All external piping components are to be supplied by the installer.
It is very important to use an hydraulic separator before secondary circulators.
25
23
24
10
11
27
9
3
7
1
6
5
15
16
18
20
17
4
14
19
22
21
30
29
28
Hydraulic Separator
Min. Spacing 12"
Max. Spacing
4x Primary Pipe
Dia. Typ.
Secondary Circulator
Secondary Loops
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14. Piping Cont.
14.2 Primary – Secondary Piping with Zone Valves:
All external piping components are to be supplied by the installer.
It is very important to use an hydraulic separator before secondary circulators.
25
23
24
10
11
27
9
3
7
1
6
5
15
18
20
17
4
14
16
19
22
21
30
28
29
Supply Lines
to System
Zone Valve
zone
valve
zone
valve
zone
valve
Secondary Circulator
Return Lines
from System
Hydraulic Separator
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14. Piping Cont.
14.3 Manifold Piping with Zone Valves or Circulators (shown conn. to radiators):
All external piping components are to be supplied by the installer.
25
23
24
10
27
11
9
3
1
7
6
5
15
18
20
17
14
4
16
19
22
21
30
28
29
Return Water
Temperature
Gauge
By-pass
Valve
Shut Off Valve
System Return
Manifold
System Supply
Manifold (with
zone valves or
circulators
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15. Commissioning
15.1 Initial filling of the system:
• Remove the front
panel of the case.
• Unscrew the cap on
the automatic air
purger valve 3 (Fig
15.1) one full turn and
leave open
• Open each radiator
air vent starting at the
lower point and close
it only when clear
water, free of
bubbles, flows out.
• Purge the air from the
pump by unscrewing
the pump plug 2 (Fig.
15.2); release the
pump by turning the
rotor in the direction
indicated by the arrow
on the information
plate.
• 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.
permanently.
• Inspect the boiler and
the system for water
soundness and
3
2
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.
Figure 15.1
• Open the installer
supplied automatic fill
valve between the
cold water inlet and
Central Heating
2
System (See 28 on
piping diagrams in
previous section).
figura 15.2
• Close the pump plug.
15.2 Lighting the boiler:
Note: If external controls are fitted (e.g. room thermostat) ensure they "call for heat".
A
B
C
D
• Turn on the electricity
supply to the boiler,
switching on the circuit
breaker switch. The
appliance operation
light A will flash every 4
seconds.
• Turn the function
selector B as in Fig.
15.3. The appliance
operation light A will
flash every 2 seconds.
Figure 15.3
The boiler will now go through an ignition sequence and the burner will light.
If during the ignition attempt period the boiler fails to light, the full sequence control p.c.b.
will go to lockout and the lock-out signal lamp D will appear.
To reset the boiler turn the knob B (figure 15.3) on the 0 position and then press and
release the boiler reset button C (Fig. 15.3).
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15. Commissioning Cont.
15.3 Checking the gas pressure at the burner:
This boiler has been tested to the highest quality control standards.
The maximum and minimum gas pressures are already set during this quality
control process however the checking procedure must be followed to ensure
maximum operating efficiency from the boiler.
• Remove the front
panel of the case.
• Loosen the internal
screw 15 (Figure
15.4) on the Outlet
Pressure Test Point
of the Gas Valve and
connect a pressure
gauge using a
fitted (e.g. room
thermostat) ensure
they "call for heat".
• Switch on the boiler.
• Check the maximum
gas pressure and
removing the electrical
connector E (Figure
15.4).
• Switch on the boiler.
• Check the minimum
gas pressure and
compare the value on
the gauge with the
value indicated in the
Section 2 on page 10
(gas pressures at the
burner).
compare the value on
the gauge with the
value indicated in the
Section 2 on page 10
(gas pressures at the
burner).
suitable hose.
15
• Check the maximum
gas flow at the gas
meter and compare
the value indicated in
the section 2 on page
10 (gas flow rate).
• Switch off the boiler.
• Disconnect the gas
modulator coil by
• Switch off the boiler
and re-connect the
electrical connector E
to the modulator coil.
• Switch on the boiler.
• Check that the boiler
lights up uniformly.
• Switch off the boiler,
turn off the hot water
taps and disconnect
the pressure gauge.
Important: after the
checks all of the test
points must be sealed.
E
16
Figure 15.4
• Set the c.h.
temperature control
knob to its maximum
position. If external
controls are
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15. Commissioning Cont.
15.4 Adjustment of the gas pressure:
• Remove the front
panel of the case.
• Open the gas valve
inlet pressure test
point (16 in Fig. 15.5)
at the valve input,
connect a suitable
pressure gauge and
check the gas
pressure of the supply
network.
• Remove the gauge
and close the
• Remove the
• 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
protection cap I (Fig.
15.6) from the
mechanical pressure
adjustment
components levering
with a flat screwdriver
in the slots H.
adjustment (G in Fig.
15.5) until you obtain
the required pressure
(by rotating clockwise
the pressure
• Start the boiler at its
maximum power.
H
I
increases).
pressure test point
16.
• Turn the boiler off and
re-connect the wire to
the modulating
operator.
• Start the boiler and
check again the
• Open the gas valve
outlet pressure test
point (15 in Fig. 15.5)
and connect the
gauge.
Figure 15.6
maximum gas
pressure setting.
• Ensure that the boiler
is not range rated.
• Rotate the maximum
gas pressure
F
• Turn the boiler off and
disconnect the gauge.
Important: after the
checks all of the test
points must be sealed.
G
15
E
16
adjustment (F in Fig.
15.5) until you obtain
the required pressure
(by rotating clockwise
the pressure
increases).
Figure 15.5
15.5 Checking the ignition device:
With the burner on high flame close the gas cock. After three ignition attempts (within
about three minutes), the lock-out signal lamp must appear (D on Figure 15.3). To reset
the boiler turn the knob B (figure 15.3) on the 0 position and then press and release the
boiler reset button (C on Figure 15.3).
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15. Commissioning Cont.
15.6 Checking the burner ignition:
+
RISC
• Turn the boiler OFF.
• Open the gas valve
outlet pressure test
point 15 (figure 15.5)
and connect the
gauge.
• Turn the boiler ON
positioning the
• Watch the gauge and
check to see if the
ignition pressure
+
ACC
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.
ON
1
2
3
4
OFF
Figure 15.9
• Adjust the gas
pressure at the
function selector B in
the position shown in
figure 15.7 and
ensure that the room
thermostat is set to
injectors to the value
indicated in the tables
of section 2. By
rotating the device
clockwise the
“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.
15.9) and use the
device (ACC).
B
pressure increases.
• After the adjustment
operations bring the
selector 3 of figure
15.9 back to the
normal position (ON).
• Reassemble the
service panel.
• Close the gas valve
outlet pressure test
point 15 (figure 15.5).
• Reassemble the front
pannel of the case.
Important: after the
checks all of the test
points must be sealed.
Figure 15.7
• Loosen screws D and
remove the service
panel (figure 15.8).
D
D
D
Figure 15.8
15.7 Adjustment of the useful c.h. output:
• Turn the boiler OFF.
• Open the gas valve
outlet pressure test
point 15 (figure 15.5)
and connect the
gauge.
• Turn the boiler ON
positioning the
thermostat is set to
“heat demand”.
• Adjust the gas
pressure at the burner
to the value according
to the useful c.h.
output wanted (Tab.
15.1).
• Loosen screws D and
remove the service
panel (figure 15.8).
• To carry out the
adjustment use the
adjustment device
(RISC) with the help
of a screwdriver.
• Reassemble the
service panel.
function selector B in
the position shown in
figure 15.7 and
• Close the gas valve
outlet pressure test
point 15 (figure 15.5).
• Reassemble the front
pannel of the case.
33
• By rotating the device
clockwise the
ensure that the room
pressure increases.
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15. Commissioning Cont.
15.8 Labels placement:
3
2
4
5
1
Figure 15.10
Warning: The installation is not complete unless labels supplied are placed on the
boiler as shown in Figure 15.10.
All the labels supplied with the boiler are numbered for reference.
According to Figure 15.10 place all the labels on the boiler. Use label numbered as 1
(already installed in the front panel) to begin the placement in the correct way.
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15. Commissioning Cont.
15.9 Checking the flue system and combustion:
• The flue system should be visually checked for soundness. Check all clamps, gaskets
and fixings are secure and tight.
• Ensure that the flue terminal is sited correctly in accordance with the flue fitting
instructions.
To check the exhaust gas:
• Remove the plugs
indicated (Fig. 15.11).
• Insert the analyzer
probe in the exhaust
gas sampling point or
in the air intake
• Reference tables are
given in the Sections
2 on page 10 of this
manual for proper
CO2 levels.
Air-Flue exhaust
sampling points
sampling point.
Figure 15.11
15.10 Instructing the user:
• Hand over the User manual, this Installation,Operation and Service manual to the end
user and explain how to use the unit in Central Heating mode.
• Take the User step by step through the lighting instructions.
• Show the User how to switch off the appliance quickly and indicate the position of the
electric service switch and the boiler on/off switch.
• Explain the proper use and adjustment of all system controls; this will ensure the
greatest possible safety and fuel economy.
• Explain the function and use of the function switch.
• Explain how to turn off the appliance for both short and long periods and advise on the
precautions necessary to prevent damage should the appliance be inoperative when
freezing conditions may occur.
• Fill in the details required on the Boiler Guarantee Certificate and hand to the User
advising them to return the correct section for boiler Guarantee registration. Finally,
advise the User that, for continued safe and efficient operation, the appliance must be
serviced by a competent person at least once a year.
KW
10.8
12.0
14.0
17.0
20.0
23.0
26.0
29.5
Useful output
Kcal/h 9288 10320 12040 14620 17200 19780 22360 25370
Pa
inwc
m³/h
Pa
inwc
lb/h
220
0.88
48.7
360
1.45
2.2
250
1.00
53.0
420
1.69
2.4
330
1.32
60.7
560
2.25
2.8
470
1.89
72.4
800
3.21
3.3
640
2.57
84.0
830
3.33
1050 1330
4.22 5.34
Natural
96.0 107.7 121.1
1080 1400 1760 2230
4.34
3.9
Propane
Tab 15.1
5.62
4.4
7.06
8.95
4.9
5.5
35
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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:
Natural gas
ON
L.P.G.
ON
• 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
type of gas, replacing
the burner injectors
correctly.
2
3
4
1
3
4
1
2
OFF
OFF
• Re-assemble the
burner, the front panel
of the combustion
chamber and the lid
of the sealed
Figure 16.3
• Close the service
panel.
• Turn on the boiler.
• Calibrate the gas
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)
Maintenance –
Dismantelling the
External Panels).
• Take off the lid of the
sealed chamber.
• Remove the front
panel of the
valve according to the
instructions given in
section 15.4 of this
manual.
• Set the correct gas
pressure for central
heating output
D
combustion chamber.
A
D
D
required.
7
• Stick on the inside of
the left hand side
panel adjacent to the
data badge the self-
adhesive label
Figure 16.2
• Set correctly the dip-
switch "2" to the
correct position (Fig.
16.3) in accordance
with the following
table.
(included with the
conversion kit)
indicating the type of
gas, and the gas
pressures to which
the appliance has
been set.
A
Figure 16.1
• Loosen the screws A
and remove the
burner 7 (Figure
16.1).
• Carry out the
conversion for the
Position of
the switch 2
Gas supply
Natural gas
L.P.G.
On
Off
• Reassemble the front
and side panels of the
case.
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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:
A
• Loosen the screws A
A
(Fig. 17.1)
• Lift and remove the
panel.
Side Panels:
C
C
• Loosen the screws B
B
B
(Figure 17.2). Bring
the bottom of the
panels away from the
boiler and lift them,
freeing them from the
top hooks.
B
B
Figure 17.2
Figure 17.1
17.3 Emptying the Central Heating System:
• Close the pressure reducing automatic fill valve (28 on
Section 4)
• Open the central heating drain cock (F in Fig. 17.3).
• Empty the c.h. system.
• Close the central heating drain cock (F in Fig. 17.3).
• Open the pressure reducing automatic fill valve (28 on
Section 4)
F
Figure 17.3
17.4 Cleaning the primary heat exchanger:
• Take off the front panel of the case, then the sealed chamber lid and the front panel of
the combustion chamber.
If you notice dirt on the fins of the primary heat exchanger (9 on page 10), cover the
sloping surfaces of the burner (7 on page 10) entirely in a protective layer (sheets of
newspaper or similar). Brush out the primary heat exchanger (9 on page 10) with a bristle
paintbrush.
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17. Annual Maintenance Cont.
17.5 Checking the pressurization in the expansion vessel:
Empty the central heating system as described in section 17.3 of this chapter and check
that the pressure in the expansion vessel is not less than 1 bar (14.5 psi). See also
section 13.2 page 26 of this manual. If the pressure should be lower, take steps to correct
the pressure level.
17.6 Cleaning the burner:
The sloping and multi-gas type burner (7 on page 11) does not need special maintenance,
but it is sufficient to dust it with a bristle paintbrush.
17.7 Checking the flue:
Have the integrity of the flue outlet pipe (24 on page 12) air intake pipe (25 on page 12),
checked periodically, the venturi device (23 on page 12) cleaned and the efficiency of the
flue safety circuit checked at least once a year. For all the above maintenance operations
it is advisable to call an approved Service Engineer.
To check the pressure at the venturi device, use the test points (12 on page 11).
• Remove the caps of
the pressure test
points and connect a
differential pressure
gauge.
• Compare the value on
the gauge with the
minimum values of
venturi pressure
Venturi test
points
indicated in the
• Switch on the boiler
Section 2 on page 10.
Figure 17.4
17.8 Visual inspection of appliance:
Visually inspect all water joints, seals and connections for any evidence of leakage and
retighten, grease or replace them as necessary.
17.9 Gas pressures and soundness:
Check appliance for gas soundness. Recheck operational pressures and adjust as
necessary as described in Section 15.4 page 32 of this manual.
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18. Installer Notes
System Checkout:
Boiler Model No.___________________
Serial No._______________
Installer:
Original Purchaser:
___________________________
_______________________
___________________________
___________________________
_______________________
_______________________
_____________________________________________________________________
Performance Tests:
GROSS STACK TEMPERATURE __________________
ROOM TEMPERATURE (AMBIENT) ________________
NET STACK TEMPERATURE _____________________
CO2 __________________
O2 ___________________
SMOKE READING ___________________
COMBUSTION EFFICIENCY _________________
COMMENTS
___________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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*1796212741*
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