Riello RTT 378 User manual

cod. Doc-0079324 rev. 1 03/2016
RT T 378-930
EN ASSEMBLY MANUAL

2
RANGE
MODEL CODE
RTT 378 20093090
RTT 448 20091316
RTT 506 20091318
RTT 564 20091321
RTT 610 20091325
RTT 663 20091326
RTT 715 20091329
RTT 773 20091334
RTT 831 20091335
RTT 878 20091337
RTT 930 20091339
ACCESSORIES
For the RTT 378-930 r boilers the following accessories are avail-
able:
a. Two stage kit – 4031067
b. Storage heater probe – 20010103
In some parts of the booklet, some symbols are used:
9 = for actions requiring special care and adequate preparation
0 = for actions THAT MUST NOT be performed
Dear client,
Thank you for choosing a Rboiler, a modern and high quality
product, providing you with the utmost well-being and with a
high level of reliability and safety; and this is particularly the
case if entrusted to a RTechnical Assistance Centre which is
specically capable of carrying out routine maintenance, keep
it running at maximum efciency, with low running costs and
which has original spare parts if required.
This instruction booklet contains important information and
suggestions that should be observed for easy installation and
better use of the RTT 378-930 boiler.
Thank you once again
Riello S.p.A.
CONFORMITY
TheRTT 378-930 r boilers comply with:
−2009/142/EC (ex 90/396/EEC-Gas Directive)
−92/42/EEC (Efciency Directive)
−2006/95/EC (ex 73/23/EEC-Low voltage Directive)
−2004/108/EC (ex 89/336/EEC-Electromagnetic Compatibility
Directive)
−EN 303/1-2-3
−EN 60335-1/2
−EN55014-1/2
−EN 61000
This booklet, Cod. Doc-0079324 - Rev. 1 (03/2016) is composed of 12 pages.

3
1.1 INSTALLATION SPECIFICATIONS OF RTT CAST IRON
BOILERS
This manual is for personnel authorised and qualied to install
and provide technical assistance both domestically and over-
seas and should be used in order to correctly install the cast iron
boiler.
9 The technical personnel should always put the machine in a
safe condition both before and during installation.
9 In order to avoid injury, pay particular attention in trans-
porting the heavy cast iron sections, both before and during
the assembly and installation.
9 before starting the installation, check both the boiler room
and the support plate. If they have any defects, do not start
the installation until they have been resolved.
9 Before installing the appliance, carefully read and under-
stand this manual.
9 The components and the equipment for the installation are
supplied together with the boiler. They include also the sili-
con for the assembly, the silicon applicator, the ttings, the
protective gloves and the dust mask.
9 Do not damage the boiler body and the coating of the casing
during and after the installation and in the burner and gas
ue pipe connection phase. Instruct also the other techni-
cians in this regard.
9 If there are any questions about the installation, contact the
manufacturer or the technical assistance centre.
9 The installation of the cast iron boilers requires at least 2
people.
9 If the boiler is installed correctly it will have a long life.
Thank you for taking the time to read our warnings and our ad-
vice and we wish you the best of success in your work.

4
• Install the frame for assembling the boiler (with the
equipped part facing the other and facing back) on the con-
crete plate.
• The concrete plate should be at to ensure the boiler will
be stable.
• Position the rear section of the boiler on the frame vertically.
The holes on it should line up with those on the frame. Fix it
using 4 M12x50 mm nuts.
• For a simpler assembly, insert the bolts from the bottom and
place the nuts on top.
• Clean the grooved ue gas seal of the rear section with a
brush or a cloth, then insert the silicon.
• Glue the insulating cord supplied in the grooving as shown
in the gure, using the silicon already inserted.
• Put the waterproof gaskets on the axle coupling, then insert
it into the relative hole.
• For a simpler assembly, it is possible to use silicon to prevent
the O-ring or the tting falling.
• For a simpler assembly, glue the insulating cords onto the
grooves of the cast iron sections before assembling them.
• The insulating cords should be applied carefully to the rel-
ative grooves.
• There should be no empty spaces at the connection points
of the insulating cords.

5
• After applying the insulating cord, the axle connection and
the O-ring to the rear section, install the intermediate sec-
tion sliding it on the frame.
• The intermediate section with the hole for the thermostat
should be installed second, before the front one (section
number 3).
• Connect the M10x 240 section xing pins to the assembly
brackets balancing them, then connect the intermediate
section to the rear one.
• The section xing pins are used for their assembly. They are
not insulating elements that can prevent leaks.
• Repeat the operation a number of times that is suitable for
the capacity, namely for the number of intermediate sec-
tions of the boiler. In this way t all the intermediate sec-
tions.
• After installing the intermediate sections, do the same also
for the front section.
• The insulating cord applied to the grooved ue gas seal pro-
le of the last intermediate section (the one right before the
front section) cannot be installed in the pipes between the
2nd and 3rd pass of the ue gases.
• Connect the boiler-xing pins after nishing installing all
the sections.
• Connect 4 boiler xing pins using the stabilisation holes on
the front and rear sections. Put in the nuts and bolts and
screw them in so as to balance them.
• Tightening torque: 6 kg·m
The section xing pins should never be removed.
These pins will be used for installing the casing.
Assembling the expanding springs:
• Remove the 4 xing pins in the front part and the relative
nuts one at a time, and put in the expanding springs. The
screw back in the nuts and bolts.
Tightening torque: 3 kg·m
• Put in the expanding springs one at a time.

6
• Insert the expanding springs, nuts and bolts as indicated in
the gure below.
• The distance of the spring joints should be about 0.5 mm.
• After installing the sections and the boiler-xing pins, t
the rear door of the boiler's discharge pipe and the water
inlet-outlet attachments.
• To prevent leaks, t the boiler's discharge pipe rear door x-
ing it with 4 M12 x 95 pins.
• To prevent leaks, t the water inlet-outlet connections using
the washers and x them with 4 bolts.
• Fit the water inlet attachment (connection on the bottom)
so that the 1 ½” discharge valve is facing down or toward
the sides.
• Fit the water inlet attachment inserting in order the cou-
pling washer, the pipe with ange, the washer and the at-
tachment.
• The 1 ½” outlet attachment should be facing up or towards
the sides.
• After installing the boiler's water inlet and outlet attach-
ments, check that the appliance is waterproof by putting in
water for 10 minutes at a pressure of 9 bar without connect-
ing the front door of the burner.
Results of the test:
• If leaks are detected, repair the boiler, nding the place
where the boiler is leaking. If there are no leaks, begin t-
ting the retarder turbulators.
1 = COMBUSTION GASES OF THE BOILER (1st PASS)
2 = COMBUSTION GASES OF THE BOILER (2nd PASS)
3 = COMBUSTION GASES OF THE BOILER (3rd PASS)
• Install the retarder turbulators in the pipes as shown in the
table.
• Install 2 small turbulators in each pipe of the 2nd pass of the
ue gases. The large turbulators need to be inserted in the
pipes of the 3rd pass of the ue gases.

7
• Insert the turbulators in the passage starting with the front
section.
Table 1 - Installation of Retarder Turbulators Table
Model Second pass Third pass
RTT 378 1+1+1+1 1+1+1+1
RTT 448 1+1+1+1 1+1+1+1
RTT 506 1+1+1+1 1+1+1+1
RTT 564 1+1+1+1 1+1+1+1
RTT 610 1+1+1+1 1+1+1+1
RTT 663 1+1+1+1 1+1+1+1
RTT 715 1+1+1+1 1+1+1+1
RTT 773 1+1+1+1 none
RTT 831 1+1+1+1 none
RTT 878 none none
RTT 930 none none
• Insert the turbulators through the intermediate part of the
front section.
After installing the turbulators in the ue gases pipes of the
boiler, t the burner door to the front section.
• Connect 4 hinges of the front section to the arms of the
hinges on the burner door.
• Attach the door, xing it with 4 M10x80 mm bolts according
to the side you want to open and based on the hydraulic
connections and the boiler room.
• After inserting the bolts, x them with 4 M16 nuts and bolts
and screw them in balancing them.
• To prevent leaks, do not leave any space between the burner
door and the front section.
• After installing the boiler body and after carrying out the
waterproof test, to prevent leaks of ue gas apply Blakite®
between the sections (supplied with the other components
to be assembled).

8
• To install the walls of the casing, connect the assembly
brackets of the casing to the pins on the feet of the boiler.
• Connect the assembly brackets of the casing walls to the
pins used for connecting the sections, as shown in the g-
ure. Then x the pins.
Table (2) - Assembly Brackets Table
Model
Detail of
casing
assembly
Casing
length
Number
of casing
assembly
brackets
Section numbers
for
connecting as-
sembly
brackets
RTT 378 4+2 1090 61.2+3.4+5.6
RTT 448 4+3 1,250 61.2.+4.5+6.7.
RTT 506 4+4 1,410 61.2.+4.5.+7.8.
RTT 564 4+5 1,570 61.2.+4.5.+8.9.
RTT 610 5+5 1,730 61.2.+5.6.+9.10.
RTT 663 6+5 1,890 61.2.+6.7.+10.11.
RTT 715 4+mid-
dle+3 2,050 81.2.+4.5.+9.
10.+11.12.
RTT 773 5+mid-
dle+3 2,210 81.2+5.6.+10.
11.+12.13.
RTT 831 5+mid-
dle+4 2,370 81.2.+5.6.+10.
11.+13.14.
RTT 878 5+mid-
dle+5 2,530 81.2.+5.6.+10.
11.+14.15.
RTT 930 6+mid-
dle+5 2,690 81.2.+6.7.+11.
12.+15.16.
• Table 2 shows the assembly brackets needed for the sections
and for the casing walls.
• After connecting the brackets of the walls of the casing on
both sides of the boiler body, x the assembly shelves of the
casing walls on the top part of the boiler body.
• If there are no xing pins for connecting the brackets and
the shelves on the section, take these pins from other sec-
tions.
Table (3) - Assembly Shelves Table
Model
Detail of
casing
assembly
Casing
length
Number
of casing
assembly
shelves
Section numbers
for
connecting as-
sembly
shelves
RTT 378 4+2 1,090 3front+4.5+back
RTT 448 4+3 1,250 3FRONT
S.+4.5.+BACK S.
RTT 506 4+4 1,410 3FRONT
S.+4.5.+BACK S.
RTT 564 4+5 1,570 3FRONT
S.+4.5.+BACK S.
RTT 610 5+5 1,730 3FRONT
S.+5.6.+BACK S.
RTT 663 6+5 1,890 3FRONT
S.+6.7.+BACK S.
RTT 715 4+mid-
dle+3 2,050 4F.S.+4.5.+9.
10.+D.B.
RTT 773 5+mid-
dle+3 2,210 4F.S.+5.6.+10.
11.+D.B.
RTT 831 5+mid-
dle+4 2,370 4F.S.+5.6.+10.
11.+D.B.
RTT 878 5+mid-
dle+5 2,530 4F.S.+5.6.+10.
11.+D.B.
RTT 930 6+mid-
dle+5 2,690 4F.S.+6.7.+11.
12.+D.B.
• Connect the assembly shelves of the casing's walls to the
xing pins at the top as shown in the gure. Then x the
nuts, tightening them slightly to keep them in position.

9
• After installing the brackets and shelves of the casing walls,
apply the insulation and the walls of the casing onto the
boiler body.
• Prepare 8 cm of insulation for the boiler body based on the
dimensions of the appliance and apply it to the boiler body.
• Cut the insulation around the points connecting the assem-
bly shelves.
• Cut the insulation around the opening for the thermostat
socket.
• Use a 2 point stainless steel wire to connect the insulation to
the boiler body in such a way that it is stable.

10
• Line up the holes on the walls of the casing rst with the
pins on the assembly brackets and then with the assem-
bly shelves of the casing walls, xing them with two M8x20
bolts as shown in the gure.
• Proceed in the same way for the installation on the boiler
body of the additional walls of the right and left casing.
After installing the side walls, connect the control panel on the
top front wall of the casing.
• Insert the thermocouples (sensors) of the control panel
(thermostat, safety thermostat, thermometer) in the slots of
the panel.
• Rest the two support brackets on the top panel, with the
side with more holes facing upwards and lining up the
holes of the bottom side of the bracket with those of the
cover panel.
• Fix each bracket with three self-tapping screws 4.2x9.5 (not
supplied).
• Remove the cover of the electrical panel.
• Place the base of the control panel on the support brack-
ets, matching up the holes, then use six self-tapping screws
(supplied with the electrical panel) to secure it.
• After inserting the ends of the sensors, secure them so they
do not come out, then put back the cover of the control
panel on the base.
• Put the oil supplied in the hole of the thermostat so as to
improve the sensitivity of the sensors.