Riello RTT 163 User manual

cod. Doc-0079321 rev. 0 03/2016
RT T 163-355
EN INSTRUCTIONS FOR THE INSTALLER AND FOR THE TECHNICAL ASSISTANCE CENTRE

2
RANGE
MODEL CODE
RTT 163 20091302
RTT 195 20091303
RTT 227 20091304
RTT 259 20091305
RTT 291 20091306
RTT 323 20091308
RTT 355 20091309
ACCESSORIES
For the RTT 163-355 r boilers the following accessories are avail-
able:
a. Two stage kit – 4031067
b. Storage heater probe – 20010103
Dear client,
Thank you for choosing a Rboiler, a modern and high quality
product, providing you with the utmost well-being and with a
high level of reliability and safety; and this is particularly the
case if entrusted to a RTechnical Assistance Centre which is
specically capable of carrying out routine maintenance, keep
it running at maximum efciency, with low running costs and
which has original spare parts if required.
This instruction booklet contains important information and
suggestions that should be observed for easy installation and
better use of the RTT 163-355 boiler.
Thank you once again
Riello S.p.A.
CONFORMITY
TheRTT 163-355 r boilers comply with:
−2009/142/EC (ex 90/396/EEC-Gas Directive)
−92/42/EEC (Efciency Directive)
−2006/95/EC (ex 73/23/EEC-Low voltage Directive)
−2004/108/EC (ex 89/336/EEC-Electromagnetic Compatibility
Directive)
−EN 303/1-2-3
−EN 60335-1/2
−EN55014-1/2
−EN 61000

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1.1 General warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General characteristics of the RTT boilers.............. 5
1.3 Technical data.................................. 6
1.4 Boiler data plate .................................7
1.5 Dimensions.....................................7
1.6 Delivery........................................7
1.7 Installation of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Important information about the boiler room ......... 9
1.9 Hydraulic system................................10
1.10 Schematic diagram - system for heating and domestic
hot water production ............................10
1.11 Important instructions for connecting the fuel tank .....11
1.12 Important information about the ue pipe ...........11
1.13 Control panels that can be combined ................12
1.14 High performance cast iron elements ................12
1.15 Ventilation of the boiler room ......................12
1.16 Gas side resistor and output temperature of combustion
gases ........................................13
1.17 Instructions for use ..............................13
1.18 Conveyance and discharge of the boiler water .........14
1.19 Instructions for disposing of the product .............14
1.20 Fire prevention regulations for the boiler room.........14
1.21 Controls and starting the boiler.....................14
1.22 Maintenance instructions .........................15
1.23 Cleaning the boiler ..............................15
1.24 Burner door and burner connection.................16
1.25 Table of burner combinations......................17
1.26 Transport and storage ............................18
1.27 Useful information ..............................19
CONTENTS
In some parts of the booklet, some symbols are used:
9 = for actions requiring special care and adequate preparation
0 = for actions THAT MUST NOT be performed
This booklet, Cod. Doc-0079321 - Rev. 0 (03/2016) is composed of 20 pages.

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sonnel in compliance with the reference regulations and
standards.
9 The burner should be purchased separately, this manu-
al contains only information regarding the boilers and the
boiler warranty does not extend to the burner. It is neces-
sary to consult the burner's instruction manual and have
the Warranty Certicate issued for the burner by the dealer
where it was purchased.
9 Before starting the burner, make sure that the front door of
the boiler is closed tight and that the burner connections
have been carried out correctly.
9 Do not touch the hot water pipes and the ues gases dis-
charge pipe when the boiler is running.
1.1 General warnings
The boiler models that are the subject of this manual are sup-
plied disassembled of the boiler body.
9 The cast iron boilersRTT 163-355 are designed for heating
using water and/or supplying hot water systems and have
been designed with technologies and materials suitable for
this purpose. Use the product only for this intended use.
9 The installation of the appliance should be carried out on a
base that is suited to the weight and the dimensions.
9 The base of the boiler should be positioned and oriented in
such a way as to leave sufcient space on the sides of the
appliance to meet safety requirements and permit access to
the boiler for maintenance and repairs.
9 The commissioning and initial ignition of the boiler should
only be carried out by specialised installers.
9 It is forbidden to put or pump water into the boiler or the
hydraulic system when the appliance is running and is hot.
9 Before putting water in the boiler or the system, it is neces-
sary to wait for the water temperature to reach 40° C. When
putting water into the system, always run the circulation
pump to prevent breaking the elements.
9 When the boiler is off for a long period or when carrying out
repairs, maintenance or cleaning, the electrical supply must
be disconnected using the master switch.
9 Especially in summer, when the boiler is off for a long pe-
riod, to avoid problems of incrustation in the circulation
pumps, the boiler must be switched on 1-2 times a month
and the circulation pumps operated for at least 5 minutes.
Limescale in the water can cause problems if the pump is
unused for a long period.
9 Choose a boiler with the right dimensions for the project
in full compliance with applicable regulations. If the wrong
size is chosen, the performance will suffer.
9 The RTT 163-355 boilers are only to be used for heating. For
the production of domestic hot water, it is necessary to use
a storage heater or another heat exchanger. To attain an ap-
propriate performance, pay special attention to the size of
the domestic hot water circuit.
9 The RTT 163-355 boilers are delivered without the burner. To
choose the most suitable burner and to keep the perfor-
mance at a high level, contact technical personnel.
9 If the boiler goes into lockout automatically because of over-
heating, do not put cold water inside to get it going again.
Wait until the boiler cools down, and try to restart it. If this
does not happen, contact the Technical Assistance Service.
9 Periodically check the boiler and the burner. If these period-
ic controls are not carried out, the performance will worsen
and there will be an increase in fuel consumption. The peri-
odic and annual controls of the boiler should be carried out
precisely and at the scheduled time. Natural gas is a clean
fuel and does not dirty the appliance so much. Liquid fuel
burners, on the other hand, get the appliance very dirty and
the boiler controls and maintenance operations are neces-
sary to ensure a high performance and a long life.
9 Repairs and periodic controls of the boilers RTT 163-355
should be carried out by specialised technicians. This man-
ual contains an explanation of the user's responsibilities
and the information required for using the boiler. Beyond
these operations, the boiler should only be commissioned
by the user or by one of our technicians. Do not try to adjust
the boiler or tamper with any components.
9 The mains electrical connections to the boiler room, to the
burner and to the boiler itself, the earthing of the control
panel and the boiler should be carried out by qualied per-

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1.2 General characteristics of the RTT boilers
The RTT 163-355 boilers operate with forced draught burner, they
are made of cast iron elements, provide outputs of 163 to 355
kW when connected to the burner correctly, and are available
in 7 different models (from 5 to 11 elements) running on gas or
liquid fuel.
The RTT 163-355 boilers operate at a maximum pressure of 6 bar
and at a maximum temperature of 90 °C.
In the RTT 163-355 boilers, the surfaces that transfer the heat are
expanded by special ns in the burner chamber and in the ue
gas pipes. This system maximises the caloric value of the cast
iron boiler.
The RTT 163-355 boilers are boilers with cast iron elements. This
structure provides for easy assembly and allows you to increase
the capacity of the boiler by simply adding elements. Transport
and installation are simplied by the fact that the boiler is as-
sembled on site. Handling or changing its position are easy and
do not require the breaking of walls, etc.
The RTT 163-355 boilers have been produced with a special iron
alloy EN GJL 200, which provides a high degree of resistance to
corrosion and thermal expansion. This special material guaran-
tees the boilers have a long working life.
Thanks to the special horizontal gas elements with three pas-
sages, the combustion gases pass three times in the boiler ef-
fectively transferring the thermal energy to the water inside the
elements.
The RTT 163-355 boilers are high performance boilers (max. cal-
oric value 91−93% depending on the fuel used). The high lev-
el of efciency and the perfect insulation translate into greater
energy production with less fuel consumption. The RTT 163-355
boilers also provide minimal heat dispersion.
An efcient combustion chamber, a good heat transfer surface,
the turbulators, the manifold and the insulation provide a high
degree of thermal capacity and reduced discharge gas emis-
sions.

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1.3 Technical data
RTT BOILER MADE OF CAST IRON RTT 163 RTT 195 RTT 227 RTT 259 RTT 291 RTT 323 RTT 355 UM
Number of sections 5 6 7 8 9 10 11 pieces
Heat output 169 195 227 259 291 323 355 kW
140,000 167,500 195,000 222,500 250,000 277,500 305,000 kCal/h
Heat input 177 211 246 281 316 351 385 kW
Maximum operating temperature 90 °C
Temperature adjustment range 30-90 °C
Gas side resistor 1.25-1.60 1.35-1.70 1.55-1.90 1.78-2.20 2.08-2.50 2.37-2.80 2.65-3.10 mbar
Maximum operating pressure 6bar
Boiler water capacity 77 93 109 125 141 157 173 litres
0.077 0.093 0.109 0.125 0.141 0.157 0.173 m2
Diameter ue pipe tting see table pag. 12 mm
Combustion chamber
dimensions
width X
length 442 X 391 mm
L691 835 979 1,123 1,267 1,411 1,555 mm
Water input-output coupling G 3 DN (*)
Boiler gas volume 142.17 170.43 198.69 226.95 255.21 283.47 311.73 dm3
(lt.)
0.142 0.170 0.199 0.277 0.255 0.283 0.312 m2
Combustion chamber volume (gas side) 101.89 122.15 142.4 162.65 182.91 203.16 223.41 dm3
(lt.)
0.102 0.122 0.142 0.163 0.183 0.203 0.223 m2
Safety limit thermostat 110 °C
Type of fuel
Natural gas (I2H) gas
Extra Light Fuel Oil comb.
liquid
Flue gases output temper-
ature
full load 182-187 178-185 175-180 173-178 173-175 170-173 172-170 °C
partial
load 165-172 164-170 162-168 161-165 160-165 158-163 156-161 °C
Mass ow of the ue gases
full load 273 326 380 433 487 540 594 kg/h
partial
load 164 196 228 260 292 324 356 kg/h
Type of burner With short head
Dimensions of burner ange coupling 185 mm
Heat loss in stand-by 0.25 0.24 0.22 0.20 0.19 0.18 0.16 %
3,780 4,342 4,633 4,806 5,130 5,395 5,270 kCal/h
Boiler length (L) 1,070 1,215 1,360 1,505 1,650 1,795 1,940
Boiler net weight 485 565 650 735 810 895 975 Kg

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1.4 Boiler data plate
The data plate is applied to the rear of the boiler shell.
1.5 Overall dimensions
280
550
820
L
RTT
163 RTT 195 RTT 227 RTT 259 RTT 291 RTT 323 RTT 355
L(mm) 1,070 1,215 1,360 1,505 1,650 1,795 1,940
690
544
65
1.6 Delivery
The boiler sections are delivered either already assembled or
not, depending on the dimensions and the specications of the
boiler room.
For the delivery of the unassembled appliances, the various sec-
tions and the various components are delivered inside a pallet,
while the casing, the insulating layer and other elements are
delivered in a box. The assembly of the boiler is carried out by
specialist technicians.
Burner box (pallet and
cardboard box)
Casing walls and insulat-
ing covering (wood box)
Cast iron boiler elements
(pallet 80x120)
Box of assembly
pieces (cardboard
box)
Control panel
box (cardboard
box)
9 Comply with the meaning of the symbols on the packaging
for reasons of safety.

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1.7 Installation of the boiler
The boiler must be installed respecting the minimum indicated
distances to allow the necessary maintenance work to be car-
ried out. The position “A” depends on the burner model used.
650 mm
A ÷ 200
(min.
700 mm)
A ÷ 200
(min.
700 mm)
The recommended height for the boiler room is at least 2,200
mm, leave the minimum space free on the sides and in front of
the boiler as shown in the drawing.
Provide a base with a minimum height of 200 mm above the
oor for the installation of the burner of the boiler.
RTT
163 RTT 195 RTT 227 RTT 259 RTT 291 RTT 323 RTT 355
L(mm) 1,170 1,315 1,460 1,605 1,750 1,890 2,035
L
L- 200mm
200mm
800mm
A
Characteristics of the base:
−it should be made of BS 25 ber concrete
−it should have the indicated dimensions,
−it should not be covered with a slippery material like ce-
ramic, etc.
−and acoustic insulation should be made before the base.
In the RTT 163-355 boilers, the door of the burner can open on
both sides. For this reason, equal free distances are specied on
both sides (min. 700 mm). This characteristic is advantageous for
operations to be carried out on the boiler. If the space available
in the boiler room is not sufcient for the distances indicated,
you can choose the opening side and leave more space free on
that part. On the other part, half the indicated free distance is
sufcient.
Provide enough space for the tools to be used in the boiler room.

9
1.8 Important information about the boiler room
9 The boiler room should be well lit and the light switches
should be located outside the room itself.
9 Place any gas detection devices at a height conforming to
regulations in force.
9 Do not place devices like the water pump, the contactor,
etc., in the boiler room.
9 Repair or replace as soon as possible any electric locks, ca-
bles, etc., that could cause short-circuits.
9 Before carrying out any welding in the boiler room, switch
off the boiler and close the gas valve.
9 The boiler room should not contain any explosive, combus-
tible or inammable material.
9 The boiler room air should not contain any explosive, com-
bustible or inammable gas.
9 Children or non-technical persons should not be allowed in
the boiler room, except for the person who is responsible for
it. Keep a copy of the key for the boiler room in a safe place
for emergencies.
9 It is possible to insulate the boiler room against noise and
heat, also the position and the orientation of the boiler are
important for its acoustic insulation.
9 Place the fuel tanks in another room surrounded by walls
and with adequate natural ventilation.
9 Arrange for the creation of a branching of the water supply
line near the boiler and a drainage system for draining the
boiler water.
9 It is strongly recommended not to install extraction systems,
air conditioning systems or other devices in the boiler room
that, as a secondary effect, could cause the so-called "vac-
uum effect" and reduce the draught force of the boiler, with
the main consequence of damaging the burner.
9 Make sure that the boiler room receives sufcient air either
naturally or forced (using an aspirator).
9 To ensure the burner and the boiler work efciently keep the
boiler room clean and prevent the formation of humidity.
9 The boiler room should have the minimum dimensions
specied.
9 Do not store inammable material inside the room.
9 Do not touch the supply pipe tting or other hot parts of the
boiler when it is running.
9 Do not install the boiler on a rubber mat.
9 When using LPG or another liquid fuel, the boiler room, the
fuel, the system components and the hydraulic pipes need
to be in conformity with the parameters established by Eu-
ropean norms and by gas supplying companies. The com-
pany is not responsible for any faults or problems caused by
the inadequate conditions of the boiler room, the hydraulic
pipes and the other components of the system.
9 Follow the instructions of your local gas suppliers.

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1.9 Hydraulic system
Limescale and other chemical substances in the water can
solidify producing incrustations. To prevent this happening,
equip the system with a closed expansion tank. The water that
goes into the closed expansion tank does not evaporate and is
not dispersed. In this way the level of water in the system is
kept constant and it will not be necessary to add fresh water.
In addition, limescale and dust do not form and the system will
have a longer life.
−The water circulating in the system is not to be used for
washing or drinking.
−Do not take water from the system. If the water level is
low, top it up.
−To prevent damage due to limescale or chemical residues,
put water in the system with the following recommended
values: pH > 7.2 TH <25 °Fr. Check the water quality, and if
the quality of the water used does not meet the required
standards, subject the water to suitable corrective pro-
cesses to obtain the desired quality.
−To prevent the formation of limescale or sediments inside
the boiler or their passage from the boiler to the hydraulic
system, equip the system with suitable protections both
inside and on the outside.
−Connect the circulation pump to the boiler water outlet.
The power of the pump should be suitable for the boiler.
−Provide a 4-way mixing valve or a pump on the by-pass
section activated by a thermostatic control to raise the
temperature of the water in the return line.
−Provide a 3-way motorised valve connecting the supply
line and the return line of the heating system, to adjust
the ow rate of the water in the system according to the
desired performances.
−The amount of water in the system should be such that
there is always water in the boiler. Otherwise the boiler
could be subject to corrosion. If the boiler is not used in
winter, in order to prevent damage from freezing, use an
anti-freeze product, periodically measure the amount of
water in the boiler with a pressure gauge if it has a closed
expansion tank or with a water gauge if it has an open
expansion tank.
REFERENCE VALUES
pH less than 7.2
Electrical conductivity less than 200 μs/cm (25°C)
Chloride ions less than 50 ppm
Sulphuric acid ions less than 50 ppm
Total iron less than 0.3 ppm
M alkalinity less than 50 ppm
Total hardness less than 25° F
Sulphur ions none
Ammonia ions none
Silicon ions less than 30 ppm
The Thermostat (1) should be installed at a distance of 3-5 diam-
eters from the connection point to the return line.
D
1
3÷5 D
3
22
3
33
4
5
3
8
10 15
10
13
14
12
1
EAF
EAF
15
6
33
33
11
67
17 5
33
3
5
3
4
3
5
3
4
SYSTEM
OUTLET
SYSTEM
RETURN
LINE
DOMESTIC
WATER
UTILITIES
DISCHARGES DISCHARGES
1 Boiler
2 System manifolds
3 Shut-off valves
4 System pumps
5 Non-return valves
6 Automatic vent valve
7 Boiler safety valve
8 Boiler discharge tap
9 Storage heater safety valve
10 Charging the system
11 System expansion tank
12 Storage heater
13 Storage heater discharge tap
14 Domestic hot water expansion
tank
15 Softener filter
16 Pressure reducer
17 Condensation pump
1.10 Schematic diagram - system for heating and domestic hot water production