Ritek UNIVERSAL RG Series User manual

Heating boiler
“UNIVERSAL RG”series
Operating Manual. Passport.
EN 303-5: 2012
Technical Conditions TC 4931-007-82749029-2007
Technical Conditions TC 4931-008-82749029-2007
Registration #
Dear customer!
The manufacturer conducts constant work on improvement of construction and design of the boiler, as
well as on improvement of the efficiency of its work. The manufacturer reserves the right to make design
changes, therefore, there can be differences between the passport data and the boiler you have purchased,
which do not affect its technical characteristics and consumer properties.
When purchasing a boiler, check the completeness, appearance of the product and the passport’s
availability.
Carefully read this operating manual. Violation of the rules of transportation, installation and
operation of the boiler can lead to a decrease in its operating performance or failure, as well as to the loss of
the warranty repair rights.
The manufacturer also carries out an additional supply of items that are not included in the mandatory
delivery set, but are necessary for normal operation and running of the boiler (boiler plant).

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The manufacturer also provides additional services for installation of boilers (boiler plants) and
putting them into operation or, at the request of the buyer, sending a specialist to advise on the installation of
the boiler (boiler plant) by the buyer (installation supervision).
At your request, the manufacturer can provide you with the schemes of typical boiler plant
projects. You can also find them on the manufacturer’s web-site www.Ritek.ee
The warranty period of the boiler manufactured in accordance with EN 303-5: 2012 GOST
20548, TC 4931-007-82749029-2007, is 24 months from the date of sale via a retail network.
The warranty period for a boiler manufactured in accordance with EN 303-5: 2012 GOST
30735-2001, TC 4931-008-82749029-2007 is 18 months from the date of commissioning, but not
more than 24 months from the date of sale.
We ask you to comply with the following requirements and, above all, to provide the annual monitoring and
maintenance by a specialized organization. This will ensure the long-term trouble-free operation of the boiler
in your and our interests.

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CONTENTS
1. GENERAL INFORMATION............................................................................................................4
2. PURPOSE............................................................................................................................................4
3. COMPLETENESS..............................................................................................................................4
4. TECHNICAL SPECIFICATION......................................................................................................4
5. CONSTRUCTION AND PRINCIPLE OF OPERATION..............................................................5
6. RULES OF INSTALLATION AND OPERATION........................................................................6
6.1. BOILER INSTALLATION ....................................................................................................................7
6.2. CHIMNEY INSTALLATION.................................................................................................................7
6.3. THE PROCEDURE FOR REPLACING THE GRATE..................................................................................8
6.4. HEATING SYSTEM INSTALLATION ....................................................................................................8
6.5. THE BOILER IGNITION PROCEDURE ..................................................................................................8
6.6. BOILER SHUTDOWN PROCEDURE .....................................................................................................9
6.7. BOILER OPERATION .........................................................................................................................9
7. SYSTEM TESTING. SAFETY DEVICES.....................................................................................10
8. SAFETY RULES FOR INSTALLATION, MAINTENANCE AND OPERATION OF THE
BOILER.................................................................................................................................................11
9. FAULTS DURING THE BOILER’S OPERATION AND HOW TO ELIMINATE THEM....12
10. LIST OF PRODUCTS AND SPARE PARTS NOT INCLUDED INTO THE PRODUCT
PACKAGE (SOLD SEPARATELY)..................................................................................................12
11. PREVENTION AND TECHNICAL CERTIFICATION. PERIODICITY. .............................13
PASSPORT............................................................................................................................................14

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1. General information
1.1. The boilers of the UNIVERSAL RG series are a part of the heating system and are produced in
accordance with EN 303-5: 2012 TC 4931-007-82749029-2007, TC 4931-008-82749029-2007.
1.2. The boiler works on solid fuel (coal, firewood, sawdust, pellets, combustible waste, etc.) and does not
require the constant staff presence. Manual fuel loading is performed 2–4 times a day, as necessary. The boiler
is economical in its operation; its efficiency is up to 80%. Efficiency can be increased by installing an
economizer.
1.3. When installing multiple boilers (energy module), the total heat output increases proportionally. Any
number of boilers is allowed for installation into modules.
1.4. When installing additional equipment, you can get hot water for household and domestic needs.
1.5. To simplify maintenance and repair, the boiler has a detachable construction made of two parts: a heat
exchanger and an ashpit. Cleaning the boiler from the ash is made without stopping it.
1.6. In standard package, the boiler comes with a heat-insulating casing. Thermal insulation of the boiler
and pipelines significantly reduces heat loss in the heating system and protects the staff from the effects of
elevated temperature of the heated parts. Thermal insulation of pipelines is made of affordable thermal
insulating materials (mineral wool, etc.).
1.7. As a rule, the boiler is installed directly in the vicinity of the heated facility or directly on the facility
(when a height of the boiler plant is at least 2.8 m). When installing the boiler outside the insulated room, the
insulation of the boiler, as well as of all pipelines, is required in case of emergency shutdown in order to avoid
unnecessary heat loss and rapid freezing of the system.
1.8. Maintenance, proper operation and preventive cleaning of the boiler, the gas flue, the chimney and the
heating system is carried out by the owner of the boiler.
1.9. CO emission is less than 0.7%.
1.10. The boilers of the UNIVERSAL RG series are not subject to registration in supervisory authorities
when operating in low-pressure heating systems with a heat exchange liquid temperature less than 100 °C.
2. Purpose
2.1. The boilers of the UNIVERSAL RG series are intended for heating and hot water supply of residential,
office and production facilities, buildings, shops, etc.
3. Completeness
3.1. The standard package includes:
boiler –1 pc;
safety devices (thermometer –1 pc, monometer –1 pc, safety valve –1 pc, automatic air vent –1 pc);
installation and operation instruction;
product passport with warranty obligations –1 pc;
the platform, the scoop, and the scraper are not included into the standard package and are completed
separately at the client’s request.
4. Technical specification
4.1. Heat transfer liquid is water and special non-freezing liquids.
Temperature condition of the heat transfer liquid:
Maximum –75С –65С (flow – return flow).
Optimum –75С –60С.

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4.2. Technical characteristics and parameters of the boiler:
Marking
The
volume of
the heated
room, m³
Weight,
kg
Dimensions,
mm
Joining.
nozzles
diameter,
mm
The gas
flue
diameter,
mm
Bunker
capacity
for coal,
(with a
bulk
density
of 900
kg/m3),
kg
Water
volume
in the
boiler, l
Thermal
power,
Gcal/
Hour
250-400
750
930x900x2040
57
200
40
132
0.01
4.3. The boiler operates (mainly) on coal; it is ignited once and operates continuously through the entire
heating season.
4.4. Coal or any other lump fuel is fed under its own weight to the combustion zone through a coal bunker.
4.5. Combustion of fuel occurs in a thin upper layer, which virtually eliminates the formation of carbon
monoxide and provides the boiler with efficiency of up to 84% when operating in optimal mode.
4.6. The average seasonal fuel consumption (calorific value of 6,000 kcal/kg) for residential premises is 70-
80 grams per 1 m3a day or less than 200 g per 1 kW, which is 10-30% less than in traditional boilers and
furnaces.
4.7. Fuel loading weight of 40kg allows:
a) maintaining the nominal temperature for 8-24 hours;
b) protecting the system from freezing for up to 36 hours.
Fuel consumption depends on the insulation of the premises.
5. Construction and principle of operation
The boiler layout is shown in fig. 1.
1. ashpit door
14. heat exchanger casing
2. air regulator
15. clamp lock
3. furnace revision door
16. furnace
4. upper air regulator
17. arm of grate movement

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5. gas flue thermometer
18. bunker
6. air vent valve
19. gas flues
7. safety valve
20. grate
8. working environment manometer + thermometer
21. ashpit
9. bunker lid
22. boiler support
10. slide gate
23. combustion zone
11. gas flue pipe
24. nozzle
12. handle of the upper part of the bunker removal
25. supply nozzle
13. upper removable part of the bunker
5.1. The boiler is a steel gas heat exchanger (14) of cylindrical shape with an internal bunker (18)
for solid fuel and a rectangular ashpit (21) with grates (20). All parts of the boiler are welded of 5
mm thick sheet steel. To increase the product service life, all steel parts of the boiler that are subject
to strong heating are protected by a water jacket.
5.2. Fuel is loaded into the loading bunker (13) from the top after removing the bunker lid (9).
Due to its own weight, the fuel enters through the bunker into the combustion zone with subsequent
heat transfer to the heat transfer liquid inside the heat transfer zone (23). Flue gases escape through
the boiler gas flue (19). The heat transfer liquid enters through the nozzle (24), heats up in the heat
transfer zone and enters the heating system through the supply nozzle (25). The remains of the
burned fuel in the form of ash enter the ashpit (21) through the grates (20) and are periodically
removed through the ashpit door (1). Adjusting the air supply to the combustion zone (23) can be
carried out through the air regulator (2) for the boiler’s ignition, and then the air regulator (2) closes
and the upper air regulator (4) opens for the upper combustion mode of the fuel.
5.3. Regular removal of ash and fine fraction rock (up to 16 mm) is carried out on the operating
boiler by “shaking” grates (20) fixed on rotating shafts using two arms (17) located on the front part
of the ashpit. Ash and unburned particles of coal pour down into the ashpit (20), from where, as it is
filled, they are removed with a shovel or a scraper. Cleaning the boiler grates from larger pieces of
rock, unburned residues, etc., is made through the furnace revision door (3).
5.4. During boiler’s operation, the loading bunker must be closed with a lid (9).
6. Rules of installation and operation
Installation of a boiler or a boiler plant on the basis of several “UNIVERSAL RG”boilers, as well
as of a heating system, is recommended to be carried out by a specialized installation organization
having experience in heating system installation. Installation is carried out by any means of
mechanization that allow working in specific conditions of the boiler plant.
Installation is carried out in accordance with the boiler plant project (recommended) and ensuring
the layout dimensions specified in the “Rules for arrangement and safe operation of steam boilers 10-
574-03”, put into effect on 06/18/2003. When installing and operating the boiler, follow the technical
documentation:
- EN 303-5: 2012;
- the present instruction and the boiler’s passport;
- “Rules for arrangement and safe operation of steam boilers with a steam pressure of no more
than 3 kgf/cm2, water boilers and water heaters with the water heating temperature not higher than
85°C”;
- “Rules for arrangement and safe operation of steam and hot water pipelines”;
- Building Codes and Regulations 3.05.05 “Technological equipment and pipelines”;
- Building Codes and Regulations 3.01.01 “Organization of building production”;
- Departmental Building Codes 217 “Preparation and organization of construction and installation
work for the construction of boiler plants”;

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- Building Codes and Regulations 31.01.04 “Acceptance into operation of completed construction
objects”;
- GOST 27303 “Steam and hot water boilers. Rules of acceptance into operation after
installation”;
- Standard instruction for boiler plant personnel;
- Fire Safety Rules 01 “Fire Safety Rules in the Russian Federation”.
6.1. Boiler installation
6.1.1. The boiler is installed on a reinforced concrete foundation, made at the same time with the floor.
When installing a boiler module, a common frame or foundation is installed on which the supports (22) of the
boilers are mounted.
6.1.2. The supports (22) are installed on the foundation so that the distance from the back wall of the ashpit
to the wall of the boiler plant is at least 0.9 m, and its door is located conveniently for maintenance and does
not touch the foundation. The support is connected to the foundation rigidly on the anchor bolts in order to
avoid displacements during the assembly and disassembly of the boiler (heat exchanger) during its cleaning,
repair, and technical inspection. The arms (17) of the grate (20) must be secured with a clamp lock (15) in a
vertical position.
6.1.3. The heat exchanger is installed on the exposed ashpit in the center of the ashpit seat. In order to avoid
air leaks, the junction of the heat exchanger and the ashpit is sealed with fireproof fiber material.
6.1.4. When installing the heat exchanger, the boiler gas flue pipe should be directed towards the wall of
the boiler plant (when installing one boiler) or towards the gas collector (when installing several boilers).
6.1.5. Between the boilers, loading scaffolds with ladders are rigidly placed on the foundation. When
installing one boiler or installing a scaffold to the side of the last boiler, it is necessary to install a railing for
the scaffold and the ladder.
6.1.6. Valves (ball valves, shutters, etc.) are mounted on the supply and return pipes of the boiler, through
which the boiler is connected to the heating system. When several boilers are installed inside one boiler plant,
the boilers are connected to the heating system through a supply and return manifold, mounted between the
boilers and the wall of the boiler plant.
6.2. Chimney installation
6.2.1. A vertical chimney with a manhole for cleaning the pipe (if necessary) is mounted, as a rule,
between the boiler and the wall of the boiler plant. The required chimney draft is 39 Pa. The chimney is made
of sheet steel with a minimum thickness of 2 mm. The diameter of the boiler chimney depends on the power of
the boiler, its height, but cannot be less than the diameter of the boiler flue pipe. The height of the pipe is
determined by calculation, and its minimum height cannot be less than 6 m and must be higher than the ridge
of the building of the boiler plant or the building adjacent to the boiler room, not less than 1 meter. The pipe
must be insulated. The pipe must be heated to eliminate condensate in the pipe.
6.2.2. When two or three boilers are connected with one chimney, the diameter and length of the latter is
determined by calculation, and in places where chimneys are installed, the combining gas collector must have
a cross-sectional area 1.2-1.5 times larger than the total cross-sectional area of the chimneys inserted into it.
6.2.3. The boiler flue pipe is cut into the chimney at an angle of no more than 45 degrees (relative to the
axis of the chimney). At the same time, it is not allowed to reduce the diameter of the gas flue being cut in
compared with the gas flue of the boiler. If necessary, the boiler flue may be cut into the chimney through a
special angular flange insert. With this insertion, the flue of the boiler is disconnected from the chimney in
case of the heat exchanger dismantling (the boiler dismantling or repair).
6.2.4. The chimney is assembled at a zero mark on a specially laid platform by the site level. All the joints
are welded, then with the help of a lifting mechanism the pipe is lifted vertically and securely fastened to the
wall of the building. In the absence of a wall or for other reasons, the pipe can be mounted on stretches made
of wire (rod) with a diameter of at least 8 mm.

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6.3. The procedure for replacing the grate
6.3.1. During the boiler’s operation, it may be necessary to replace the grates (20) with the new ones. In the
boilers of this series, the grates are rigidly fixed on the shafts with heat-resistant bolts. This work can be
carried out either through the door of the ashpit, without dismantling the heat exchanger, or on top of the
ashpit after dismantling the heat exchanger.
6.3.2. The manufacturer, at the request of the boiler’s owner, supplies repair kits for the replacement of the
grates (grates - 2 pcs, shafts - 2 pcs).
6.4. Heating system installation
6.4.1. The boiler can be used in heating systems, with both forced and natural circulation of the heat
transfer liquid. In a forced heating system, pumps must be equipped with a bypass line with a non-return
valve that allows water to naturally circulate for a while after an emergency power outage or pump repair.
6.4.2. When installing the boiler in a system with natural circulation, the following requirements must be
observed:
- The diameter of the flow and return pipes in the place of direct connection to the heat exchanger should
not be changed into a less diameter.
- The return water pipe must also be installed with observance of the slope towards the boiler.
- In all heating systems, the installation must be carried out in such a way that the heat transfer liquid is
completely drained when the system is empty. If there are separate “pockets” in the system, where the heat
transfer liquid can remain, the process pipe with the drain valve is welded to the bottom.
- The capacity of the expansion tank in the heating system must be at least 10% of the capacity of the
entire system.
6.4.3. It is recommended to fill the system with “soft” water that does not contain salts and other
impurities, which, being deposited on the walls of pipes and jacket of the boiler, impair heat transfer and their
efficiency, which leads to excessive fuel consumption and, ultimately, can lead to obstruction of pipes and
failure of the entire heating system.
6.4.4. After installation, it is strongly recommended to carry out hydraulic tests of the entire heating
system for its leak tightness.
6.4.5. When replacing a centralized heat supply source with an autonomous one using “” boilers, it is
necessary to get a comprehensive consultation from specialists or at the factory about the possibility of
operating your heating system with these boilers and the amount of work required to modify (adapt) it.
6.5. The boiler ignition procedure
The boiler is ignited in the following sequence:
6.5.1. Set the grate arms in a vertical position and secure them with a clamp lock.
6.5.2. Install temperature sensors (thermometers) on the supply and return pipes, as well as manometers.
Open the boiler, the pump, the heating system, and the expansion tank shut-off valves. Turn on the pump in
systems with forced circulation of heat transfer liquid; make sure that the heat transfer liquid circulates
through the system.
6.5.3. Pour about two buckets of flammable material (crumpled paper or dry coarse chips) into the boiler
bunker.
6.5.4. Load 4–5 kg of dry small wood up to 20 cm into the bunker.
6.5.5. Pour about 20 kg (2 buckets) of sorted coal with a fraction not larger than 50-70 mm.
6.5.6. Close the boiler’s lid.
6.5.7. Ignite the torch and then use the torch through the furnace door to ignite the kindling material,
poured into the grate part of the boiler through the loading bunker.
6.5.8. At the initial moment, the fume can possibly come out of the ashpit due to poor traction (warm
weather, low atmospheric pressure, etc.).

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6.5.9. The ignition process is controlled by the temperature of the heat transfer liquid in supply and return
pipelines. Approximately in 15-30 minutes the temperature of the heat transfer liquid should rise by 15 –5 °С
higher than the initial one.
6.5.10. After the coal ignites, the charging chamber is filled with 30 kg of fuel, and then it is necessary to
shake the grates and close the lid.
6.5.11. The ashpit regulator (2) can be set to the operating position immediately or after some time,
depending on the draft in the chimney.
6.5.12. The heating system launch is considered complete when the heat transfer liquid temperature reaches
the optimum value (600 °С). At the same time, during boiler ignition, it is necessary to constantly monitor the
heat transfer liquid pressure in the system according to the readings of the manometer and not to exceed it, as
compared with the maximum permissible pressure indicated in the boiler passport. This is especially true for
closed heating systems, where the pressure reduction in the system should occur by draining excess heat
transfer liquid through any drain valve. Pressure must be compensated by an expansion tank built into the
system.
6.5.13. After the boiler reaches its operating temperature, close the ashpit regulator (2) and open the upper
air regulators (4); experimentally set the gap; the water temperature should not exceed 75 °C.
6.6. Boiler shutdown procedure
6.6.1. A gradual shutdown of the boiler will occur within one day after the fuel supply is stopped.
6.6.2. Emergency shutdown of the boiler is performed when the temperature of the heat transfer liquid on
the supply pipe reaches the maximum value (850 °C) and continues to increase. This can occur when the
system is depressurized; when there is water shortage in the system due to its “airiness” in cases when the
pumps are stopped, there is no circulation of heat transfer liquid or circulation along a small or one of the
heating system circuits due to its unregulated or obstructed pipes, etc.).
6.6.3. Emergency shutdown of the boiler is performed as follows:
- Tightly close the ashpit door, close the ashpit air regulator (2), close the upper regulators (4), release the
grate arms by removing the retainer-clamp and turn the arms 90 degrees. At the same time burning coal will
fall into the ashpit and go out.
- Ash and coal residues are removed with a shovel from the ashpit into special boxes or to a fireproof place
where the ash is finally extinguished by water.
6.6.4. IT IS STRICTLY FORBIDDEN to lower the maximum allowable temperature of the
heat transfer liquid in the heat exchanger by adding cold water into the system, since at the
contact of cold and boiling water, instantaneous boiling up and a hydraulic shock occur that
are able to break the expansion tank, piping or water jacket of the boiler.
6.7. Boiler operation
6.7.1. The launch of the “UNIVERSAL RG” boiler into operation is made by the organization which had
installed it.
6.7.2. The boiler is maintained in manual mode by one person 2-3 times a day for 10-15 minutes by adding
a portion of coal, shaking the grate bars and cleaning the ashpit from the ash (once every 2 days). The
frequency of maintenance can be increased when using other types of fuel or coal with a high content of dust
and fine chips (dust coal), with low calorie, high ash content, moisture, high sintering, and high content of
rock.
6.7.3. The boiler is loaded with fuel through the loading door (13) located under the boiler lid (9) 2–4 times
a day as the fuel burns no more than 40 kg. When using non-optimal fuel or when the boiler is operating in its
maximum mode, the loading frequency is different and is determined by the buyer independently.
6.7.4. Grates are shaken periodically after 1–8 hours (depending on the fuel’s ash content) to remove the
burnt slag and ash from the grates. Shaking is performed by energetically repeatedly rocking the grate arms
without removing the clamp lock, until fallen coal appears in the ashpit.

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6.7.5. The removal of burnt slag and ash from the boiler ashpit is carried out as they accumulate, but at
least one time per day. Excessive accumulation of ash and slag in the ashpit prevents air from entering the
combustion zone of the boiler and reduces the efficiency of its operation; therefore, the ashpit is not allowed to
fill up more than a half of its volume.
6.7.7. The boiler works most economically and steadily, with high heat transfer, on coals of such grades as:
T (lean), SS (weakly caking) and D (long-flame), as well as on other grades with a low yield of volatile
substances. The size of the coarse fraction of coal is limited by the size (diameter) of the loading bunker. It is
ideally to use a fraction of 100-200 mm. Dust and fine coal dust should be no more than 20% of the volume of
fuel loaded into the boiler. The efficiency of work decreases when burning wet coal or coal with snow;
therefore, it is recommended to store fuel reserves under a shed or in a closed warehouse.
6.7.8. For efficient boiler’s operation, a constant supply of oxygen (air) is required in the combustion zone,
for which it is necessary to provide ventilation openings in closed boiler plants to ensure the supply of
sufficient oxygen.
6.7.9. The power of the boiler in manual mode is regulated by the opening value of the ashpit regulator or
the upper air supply regulators. The slide gate (if there is any) must always be open. The efficiency of the
boiler in optimal and especially in maximum mode can be achieved only with the elimination of all air inflow
in gas ducts, gas collector and chimney due to high-quality welding of joins. In order to avoid suction, the
chimney cleaning hatch, the gas flue’s flange insert, the economizer and the ashpit junction with the heat
exchanger are carefully sealed with fireproof gaskets and cords.
6.7.10. The boiler’s construction allows its cleaning from rocks and large pieces of ash as they accumulate.
6.7.11. To analyze and monitor the operation of the boiler plant and the heating system, rational use of fuel,
as well as increasing staff responsibility, it is recommended to keep a shift log of the boiler operation. During
shift changeover, it is proposed to reflect the following information in a free-form journal:
- air temperature outside;
- temperature of the heat exchange liquid in the supply and return pipelines;
- water pressure in the system (water level in the expansion tank) and the amount of water added to the
system per shift;
- the amount of fuel filled during a shift;
- comments on the operation of boilers and the heating system, the occurrence of emergency situations and
their elimination.
6.7.12. DO NOT OPERATE BOILER:
- without expansion tank;
- with closed taps (gate valves) and the absence of circulation in the heating system;
- in the absence of water in the expansion tank;
- in the absence of electricity in the forced heating systems (i.e., with non-circulating pumps);
- in case of water pumping or hot water leaks from the heating system;
- without a bypass line on the pumps of the forced systems;
- without safety valves and thermometers;
- without a control manometer in closed systems.
7. System testing. Safety devices.
7.1. The manufacturer conducts hydraulic tests of all produced heat exchangers (100%) at a pressure of at
least 10 kgf/cm2. It is allowed to operate “UNIVERSAL RG”boilers in heating systems with pressure up to
3 kgf/cm2.
7.2. After installation, before starting the boiler, the installation organization must inspect the heating
system and the places of its connection to the boiler for the leak tightness. Even a slight leakage of water in the
boiler, water jacket or the heating system as a whole is not allowed.

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7.3. Before the heating season launch, it is also recommended to test the heating system with one and a half
working pressure.
7.4. In the forced heating system, the natural circulation of water is first checked, that is, by launching the
boiler into operation, the pump is not turned on, and the system is checked for the possibility of working
without a pump.
7.5. A safety valve (with a diameter corresponding to the boiler power) is installed on the nozzles which are
directly connected to the boiler (supply nozzle) or pipeline without intermediate shut-off systems in
accordance with the “Rules for arrangement and safe operation of steam boilers with a steam pressure of no
more than 3 kgf/cm2, water boilers and water heaters with the water heating temperature not higher than 85°C”
and instructions from the manufacturing plant attached to safety valves.
7.6. IT IS FORBIDDEN to alter the design, decorative casing and insulation of the boiler, the
dimensions and threads of the connecting pipes, to change boiler’s functions or operate it in a faulty
condition.
7.7. IT IS FORBIDDEN to break sintered coal and rock found on the grates through the charging
port due to possible damage to the grates. Sintered coal can be torn by a metal rod through the
charging port. The accumulated rock is removed only through the ashpit by an emergency shutdown
of the boiler, by cleaning without shutting down or at the end of the heating season.
8. Safety rules for installation, maintenance and operation of the boiler
8.1. It is prohibited to operate the boilers in violation of installation, maintenance and operation procedures.
8.2. Only adult personnel who are familiar with the general safety regulations of the company operating the
boiler and the safety rules for the installation and maintenance of “” boilers are allowed to maintain the boiler.
In addition, the staff must have experience and understanding of the operation of heating boilers and systems,
be aware of these instructions, as well as must know and put into practice the ways to eliminate all possible
emergencies.
8.3. The boiler is fireproof. The temperature of its outer surfaces does not exceed the normalized values,
but during its operation, the gas flue pipes and chimney are heated to a high temperature. In order to avoid
burns, the heating parts of the boiler must be insulated, and the maintenance personnel must work in a suit
made of thick fabric and gloves.
8.4. In order to avoid fire and burns during an emergency shutdown of the boiler, the boiler plant must be
equipped with fire extinguishing agents (sand, water, fire extinguishers, etc.), and the staff must have shoes on
a solid sole with a closed top.
8.5. In order to avoid a face burn, it is prohibited to remove the boiler lid when inspecting the boiler or
loading fuel into the bunker with the ashpit door open.
8.6. Do not use flammable liquids for the boiler ignition and during its operation. It is not allowed to fill
them through the loading door or in any other way in order to increase the boiler’s nominal power.
8.7. It is prohibited to store fuel behind the boiler (ashpit) or near the boiler at a distance of less than 10 m.
It is prohibited to place objects and flammable liquids on the boiler, as well as at a dangerous distance from
the boiler (less than 10 m).
8.8. When transporting the boiler, loading and unloading work, follow the general rules of accident
prevention appropriate for this type of work.
8.9. When installing the boiler follow the general rules of accident prevention when installing equipment.
In order to avoid deformation or depressurization of the boiler and its parts, it is prohibited to drop or throw
them from a height of more than 0.1 m.
8.10. In order to avoid injuries in case of falling of the installation and operating personnel, it is forbidden
to work from random objects and loose scaffolds and stairs. When non-factory-made scaffold is used as a site
for maintaining the boiler, it should be fenced.
8.11. Operating and installation personnel must have safety helmets and gloves.
8.12. In a prominent place in the boiler plant there should be an instruction developed by the company
operating the boilers, obliging the fireman to observe safety precautions, as well as defining the procedure and
actions of the fireman during emergency situations in the heating system of the enterprise.

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8.13. It is not allowed to leave children near the boiler unattended.
8.14. The boiler plant must be equipped with fire extinguishing equipment in accordance with the standards
for firefighting appliances and equipment established by the Fire Safety Regulations for Energy Companies –
Regulatory Guide 34.03.301-87 (Fire Safety Rules 139-87).
9. Faults during the boiler’s operation and how to eliminate them
Possible Fault
Cause
Solution
The heat exchange liquid
temperature in the boiler is above
95 C, the heating devices in the
heating system are cold.
Impaired circulation of the heat
exchange liquid in the system.
Possible reasons:
- leakage of water from the
system;
- pump shutdown;
-the formation of an airlock in the
system.
Repair the leak, open the bypass
valve and repair or replace the
pump, eliminate the air plug.
The boiler does not reach to the
established capacity and fumes.
Worsened traction. Possible
reasons:
- soot deposition on chimney
walls;
- the presence of foreign objects in
the chimney;
- very fine coal (dust coal) is used;
- low-quality fuel is used;
- a large amount of ash on the
grates or in the ashpit.
- fuel stall in the bunker.
Clean the chimney, remove
foreign objects.
Replace fuel with a higher quality
one; fine fraction (dust) should not
exceed 20% of the volume of fuel.
Clean or shake the grates. Clean
ash from ashpit
Push the coal into the load bunker
with a metal bar.
10. List of products and spare parts not included into the product package (sold separately)
10.1. The manufacturer may carry out the additional delivery of the following products necessary to launch
the boiler (s) into operation
Scaffolding with ladder;
Scoop for ash;
Ashpit scraper.
10.2. Additional elements and products according to paragraph 10.1, necessary for installation and
operation of the boiler, are supplied by the manufacturer for an additional fee or can be manufactured by the
buyer himself.
10.3. At the buyer’s request, the manufacturer can provide additional supply of the following individual
parts of the boiler for their repair or replacement:
Heat exchanger;
Ashpit (complete);
Grate;
Grate shaft.

13
11. Prevention and technical certification. Periodicity.
11.1. The enterprise administration is obliged to appoint one of the managers to be responsible for the good
condition and safe operation of the boiler by the administrative order with logging the number and date of the
order in the boiler passport.
11.2. The boiler should be subject to technical certification by the administration prior to its launching into
operation, periodically during its operation and earlier when it is necessary. The technical examination of the
boiler must be carried out by the person responsible for the good condition and safe operation of the boiler.
11.3. During the boiler’s operation, soot and tar settle on the walls of the heat exchanger water jackets. It
reduces the heat exchange, the efficiency of the boiler, and its capacity. It is recommended to carry out
preventive cleaning of the boiler (heat exchanger) every 2 months.
11.4. The heat exchanger cleaning is done by pulling the upper removable part of the bunker (13) by its
handles out of the heat exchanger.
11.5. When cleaning and washing the boiler, it is necessary to conduct its technical examination by
specialists of the owner’s enterprise. When technical examination of the boiler is carried out, the act reflecting
its condition, changes that occurred since its launch, as well as the date of the next examination (periodical
examination should be carried out annually) is made.
11.6. Inspection is carried out by visual examination of the internal surfaces of the heat exchanger, as well
as by checking the tightness of welded joints when filled with water. Hydraulic test should be carried out at
least once every two years.
11.7. When examining the boiler’s operation, the work of the grates is also checked and the ashpit is
completely cleaned. If necessary, the chimneys are cleaned.

14
Passport
When transferring the boiler to another owner, this form is transmitted along with the boiler.
1.1. Manufacturing Information:
Production date: « »
General Information
______________________________________
Year, month of manufacture
______________________________________
Factory number
_________________________________
Type (model)
Water heating for domestic
and industrial heating systems
Purpose
Solid fuel (coal, firewood, sawdust, etc.)
Type of fuel
Water temperature, 60С- 75С
Water pressure, 3 kgf/cm2)
Design parameters
____________________________________
Heat output
_________________132___________________
Water volume in the boiler
2.1. Certificate of acceptance
The Universal RG boiler, factory number ___________,
was manufactured in accordance with the requirements
of the “Rules for arrangement and safe operation of
steam and hot water boilers with a steam pressure of no
more than 3 kgf/cm2, hot water boilers, water heaters
with water heating temperature not higher than 75С”,
EN 303-5: 2012. GOST 20548, TC 4931-007-82749029-
2007, GOST 30735-2001, TC 4931-008-82749029-2007
and recognized as serviceable.
Chief engineer of the manufacturer
«______»________________201___
______________________________________
(Signature, surname, stamp)
Head of the Quality Department
«______»________________201___
______________________________________
(Signature, surname, stamp)
3.1. Information about equipment for measurement,
alarm control, regulation and automatic protection
3.2. Information on the installation site
Enterprise
name
Location of the boiler and its
address
Installation date
3.3. Information on the installed valve
Name
Amount
GOST
or TC
Conditional
pass, mm
Conditional
pressure,
MPa
Installation
site
3.4. Information on feeding devices
Name
Type
Amount
Parameters
Drive type
Nominal
flow, m3/ h
Pressure,
MPa
Name
Amount
Type (model)
EN.GOST or TC

15
3.5. Information on water treatment equipment
Name
Amount
Technical characteristics
4.1. Information on repair of the boiler and
replacement of pressure elements
Date
Information on repair or replacement
Signature of the
person responsible
5.1. The person responsible for good condition and
technical operation
Order
№
Position, surname, name,
patronymic name
Date of
knowledge
test
Signature
5.2. The person responsible for good condition and
technical operation
Date
The result of the examination
Date of the
next
examination
Signature of
the person
responsible
6.1. Registration*
The “UNIVERSAL RG” boiler______________________
(water heating)
is registered «_____»____________________201____ #____________
__________ sheets, including drawings on __________ sheets and separate documents of
__________ sheets according to the attached inventory list were stitched in the passport.
____________________________________ __________________
(Position and name of the person who registered the boiler) (Signature)
* Boilers “” do not require mandatory registration with the boiler inspection authorities.

16
Manufacturer’s warranty
The warranty period of the boiler manufactured according to EN 303-5: 2012 GOST 20548, TC
4931-007-82749029-2007, is 24 months from the date of sale through a retail network.
In case of detection of manufacturing defects and in case of failure of the boiler due to the fault
of the manufacturer, the manufacturer replaces poor-quality parts and assemblies or repairs for free.
ATTENTION! To ensure trouble-free operation of the boiler, the buyer must call in an
authorized service center specialist to verify the correctness of the boiler installation. To
call in a specialist you need to contact an authorized service center. If the place of work
of the boiler is outside 100 km from the location of the authorized center, the buyer pays the
transportation cost. Upon detection of violations of the boiler installation or the conditions of its work
by an authorized service center specialist, recommendations are given to eliminate violations in the
act of acceptance of the boiler into operation. Repeated call in a specialist is paid by the buyer.
Terms of warranty validity:
Acceptance of the boiler into operation should be carried out only with the participation of an
authorized service center specialist. When operating the boiler, it is necessary to conduct annual
maintenance. Annual maintenance work can only be performed by employees of a specialized
organization that has the relevant documents for this type of work.
The warranty does not apply in case:
- the conditions for the entry into force of warranty obligations are not met;
- installation, maintenance, or operation of the boiler were made in violation of the instructions
for installation and operation of “” heating boilers, the requirements of this passport, as well as the
applicable building codes and regulations;
- the heating boiler was not used for its intended purpose;
- the parameters in the hydraulic, electrical, fuel supply networks do not correspond to the
technical characteristics of the boiler.
Warranty does not apply to consumable materials, namely: cast-iron doors, metal doors, grates,
bump stops and the boiler lid (doors, bump stops, sealing cords).
DATE OF SALE ___________________20___
SELLER DETAILS:

Küttekatel
seeria “UNIVERSAL RG”
Käitusjuhend. Pass.
EN 303-5: 2012
TN 4931-007-82749029-2007
TN 4931-008-82749029-2007
Registreerimisnumber
Lugupeetud ostja !
Tehas-tegija teeb pidevat katli konstruktsiooni ja disaini täiustustööd ja sama seda töö effektiivsuse
tõstmistööd. Tehas-tegija jättis endale õigust võtta arvele erinevusi passiandmete ja Teie poolt ostetud katli,
mis ei mõju teda tehnilisi iseloomujooni ja tarbimisomadused.
Katli ostes, kontrollige komplektsust, seadme välimust ja passi olemasolut.
Ettevaatlikult tutvuge käesoleva juhendiga. Transporteerimisreeglite rikkumine, katli montaaži ja
ekspluateerimisreeglite rikkumine võib ajendada tarbimisomaduste alandust või tõrge, ja sama
garanteerimisremonti õiguse kaotamine.
Tehas-tegija sama teeb täiendava seadmete hange, mis pole lülitatud kohustavasse varutuskomplektisse,
vaid kohustuslikku katli normaalse töö ja ekspluatatsiooni jaoks.
Tehas-tegija sama osutab katli paigaldamise lisateenuseid ja nende töösse sisse lülitamise või, ostja soovi
järgi, komandeerib spetsialisti konsultatsiooni läbiviimiseks katli montaaži ostja jõudu arvel (šeff-montaaž)
Teie päringu järgi tehas-tegija võib anda Teile katli tippproekti skeeme. Sama Te võite neid ise otsida
tehas-tegija veebilehelt www.Ritek.ee
Katli garanteerimisaeg, mis on tehtud EN 303-5: 2012 ГОСТ 20548, TN 4931-007-82749029-2007 jä-
rgi, on 24 kuud müügipäevast müügivõrgustiku kaudu,

2
Katli garanteerimisaeg, mis on tehtud EN 303-5: 2012 ГОСТ 30735-2001, TN 4931-008-82749029-
2007 järgi, составляет on 18 kuud ekspluatatsioonipäeva sisse lülitamiseks, vaid mitte rohkem kui 24 kuud
müügipäevast.
Palume Teid järgida alltoodud nõudmisi ja kõigepealt, igaaastase kontrolli läbiviimist ja spetsialiseeritud
organisatsiooni hooldust. See võib tagada katli pikaajalist tööd ilma avariita, mis on Teie ja meie hu-
vides.

3
SISUKORD
1.ÜLDANDMED............................................................................................................................................4
2.EESMÄRK. .................................................................................................................................................4
4.TEHNILINE ISELOOMUSTUS.................................................................................................................5
5.SEADE JA TÖÖ PÕHIMÕTTED...............................................................................................................5
6.EKSPLUATATSIOONI JA MONTAAŽIREEGLID .................................................................................6
6.1. KATLI MONTAAŽ ............................................................................................................................6
6.3. KÜTUSESÜSTEEMI MONTAAŽ.....................................................................................................7
6.4. KATLI PÕLETAMISE KORD...........................................................................................................8
6.5. KATLI PEATAMISE KORD .............................................................................................................8
6.6. KATLI EKSPLUATEERIMINE ........................................................................................................9
7.SÜSTEEMI KATSED. KAITSEVAHENDEID ......................................................................................... 9
8. MONTAAŽI, TEENINDAMISE JA EKSPLUATEERIMISE OHUTUSREEGLID 10
9.KATLI TÖÖ KORRASTUSED JA NENDE EEMALDAMISEVIISID ..................................................10
10. SEADMETE JA VARUOSADE NIMEKIRI, MIS POLE SISSE LÜLITATUD KATLI
KOMPLEKTEERIMISSE (MÜÜAKSE ERALDI)......................................................................................11
11. PROFILAKTIKA JA TEHNILINE ÜLEVAATLUS. PERIOODSUS................................................... 13
12. PASS…...................................................................................................................................................14

4
1. Üldandmed
1.1.Katlid seeriast «UNIVERSAL RG»- on kütussüsteemi osa ja tootakse EN 303-5: 2012 T 4931-007-
82749029-2007, ТУ 4931-008-82749029-2007 järgi.
1.2. Katel töötab jäike kütuse järgi (süsi, puid, saepuru, pelletid, põletusjäätme jms) ja ei nõua teenindajate
pidevat olemasolud. Täitmine kütustega käerežiimiga tehakse vajadusel 2-4 korda ööpäevas. Ökonoomne töös,
kasuliku tegevuse koeffitsient on 80%. Kasuliku tegevuse koeffitsient võiks olla suurendatud ökonimaisera
installeerimise arvel.
1.3. Mõnede katlite installeerimisel (energeetiline moodul) kogu soevõimsus proportsionaalselt suurendab.
Moodulisse montaaž võimaldab erineva katlite arv.
1.4. Lisaseadmete installerimisel võiks võtta kuuma vett tarbimis- ja olmenõude jaoks.
1.5. Remondi ja tehnilise teeninduse lihtsustamiseks katlil on liidendikoostis kahest osast: soojusvahetus ja
tuhakast. Katli tuhasest puhastamine toimub ilma selle peatuta.
1.6. Standartse komplektatsioonil katel tuleb soojusisoleerimis kaitsekatega. Katli ja torustiku soojusiso-
leerimis tõsiselt vähendab sooju kaotamist kütüssüsteemis ja kaitseb teenindajaid kuumendatud osade liigtem-
peratuuri tegutsemist. Torustikute soojusisoleerimis toimub jõukohaste soojusisoleerimismaterjalidega
(mineraalvill jne).
1.7. Katel, reeglina, installeeritakse otse soojusobjekti lähedal või otse objektil (katliruumise kõrgel mitte
vähem, kui 2,8 m). Katli installeerimine soojustatud ruumi väljaspool katli soojusisoleerimine, ja sama
kõikide torustiku, õigustamata soojukaotamise ja kiire süsteemi ümberkülmetamise vältimiseks,
avariipeatamises ilmtingimatu.
1.8. Teenundus, õige ekspluatatsioon ja katli, auriku, lõõru ja kütusesüsteemi profilakteerimispuhastus teeb
katli omanik.
1.9. CO atmosfääriheitis on vähem, kui 0,7%.
1.10. Katlid seeriast «UNIVERSAL RG» pole vaja järelvalveorganites registeerida, kui töö on
madalpaines kütussüsteemis Katlid seeriast «UNIVERSAL RG» pole vaja järelvalveorganites
registeerida, kui töö on madalpaines kütussüsteemis soojukandja temperatuuriga vähem kui 1000С.
2. Eesmärk
2.1.Katlid «UNIVERSAL RG»- on eesmärgitud kütuseks ja elav-, administratiiv-, tööstusruumide,
hoonete, tsehhide, jne kuuma veevarustusele.
3. Komplektsus
3.1. Standartne tootmiskomplekt koosneb :
katel -1 t.
Ohutusseadmed (termomeeter -1t, monomeeter -1t, kaitseklapp -1t, automaatiline õhu langus -1t)
Montaaži ja ekspluatatsiooni kasutusjuhend.
Eseme pass garanteerimistagamine -1t
Väljak, kühvel, kabits pole sisse lülitatud standartsesse pakki ja komplekteeritakse eraldi kliendi
soovil.
4. Tehniline iseloomustus
4.1. Soojuskandja –vesi ja spetsiaalsed kinnikülmumatu vedelikud.
Soojuskandja temperatuurirežiim:
Maksimaalne –750С–650С(andis –ümbertöötmine).
Optimaalne –750С –600С.
Markeerimine
Kütutatud
ruumide maht,
m³
Kaal,
kg
Suurus, mm
Otsakute
liitmise
diameeter,
mm.
Auriku
diameeter.
Bunkeri süsi,
(tihedusrikase
900 kg/m3), kg
Veemaht
katlis, l
Soojusvõims
us,
Gkal./tund