RBI 8800 series Installation And Operation Instructions Manual
Finned copper
gas boilers (hb) &
water heaters (hw)
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- Installation & operation manual (48 pages) ,
- Installation & operation manual (48 pages) ,
- Installation and operation manual (32 pages)
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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
of the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualified service
technician, and to follow all guidelines in the User' s Information Manual.
Finned Copper
Gas Boilers (HB) &
Water Heaters (HW)
Boiler Manual
Installation and Operation
Instructions
Construction dust and particulate, particularly drywall dust, will cause contamination
CI0M-12
82-0252
03/16 Copyright 2014 Mestek, Inc.
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Table of Contents
Related Manuals for RBI 8800 series
Summary of Contents for RBI 8800 series
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Page 1: Installation And Operation
CI0M-12 82-0252 Finned Copper Gas Boilers (HB) & Water Heaters (HW) Boiler Manual Installation and Operation Instructions This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. -
Page 2: Table Of Contents
Page 2 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS CONTENTS If the information in this manual is not followed exactly, a fire or explosion may result causing Before You Start ..........page 2 property, personal injury or loss of life. Ratings &... -
Page 3: Ratings & Capacities
If installed in the Commonwealth of Massachusetts, you Table 1 (8800) MUST FOLLOW the additional instructions contained in Clearance to Service RBI's instruction sheet MACODE-3. If you do not have a Combustibles Clearance copy, call your RBI distributor or contact the RBI Customer Service Department. -
Page 4: Combustion Air & Ventilation
Page 4 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 3. Ensure that the floor is structurally sound and will To operate properly and safely this boiler/water heater support the weight of the boiler/water heater. requires a continuous supply of air for combustion. NEVER store objects on or around the boiler/water heater! NOTE: Never install a Series 8800 or 8900 boiler/ water heater on a concrete floor that contains wires,... - Page 5 8600 4000 25,806 4000 1000 1333 Figure 1 - Vertical Venting Using A Metal Chimney And Inside Air (8900/8800 Series) 2 FT .6 m 10 FT 3.4 m 3 FT 1 m 3 FT 1 m 5 FT 1.52 m...
- Page 6 Page 6 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Figure 2 - Vertical Venting Using A Masonary Chimney And Inside Air (8900/8800 Series) 10 FT 3.1 m 3 FT 1 m 3 FT 1 m 5 FT 1.52 m...
- Page 7 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 7 Figure 4 - Common Vents and Inside Air (8900/8800 Series) 10 FT 3.1 m 3 FT 1 m 3 FT 1 m 5 FT 1.52 m RIOM-43 Figure 5 - Common Vents and Inside Air (8800/8900 Series) Dual Flue 10 FT 3.1 m...
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Page 8: Chimney & Vent Pipe Connections
Page 8 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS CHIMNEY & VENT PIPE When more than one appliance is connected to the same chimney flue, the flue must be large enough to CONNECTIONS safely vent the combined output of all the appliances. WARNING: The vent installation must be in WARNING: If an appliance using any type of a accordance with Part 7, Venting of Equipment, of... -
Page 9: Common Vent Systems
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 9 COMMON VENT SYSTEMS vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des If an existing boiler/water heater is removed from a cheminées. common venting system, the common venting system may then be too large for the proper venting of the d) Place in operation the appliance being inspected. -
Page 10: General Piping Requirements
Page 10 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS GENERAL PIPING REQUIREMENTS CAUTION: Failure to properly install the flow switch may result in damage to the boiler/water heater heat exchanger voiding the warranty! CAUTION: Improper piping of this boiler/water heater will void the manufacturer’s warranty and can cause HEATING SYSTEM PIPING boiler failure resulting in flooding and extensive... - Page 11 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 11 Table 7 - Temperature Rise Table — 2 Pass Headers 11.1°C 13.9°C 16.7°C 19.4°C 20°F 25°F 30°F 35°F Flow Press Flow Press Flow Press Flow Press Flow Press Flow Press Flow Press Flow...
- Page 12 Page 12 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Low Water Cutoff Low Return Water Temperatures If a boiler is installed above any radiation elements it To prevent the problems associated with condensation must be fitted with a low water cutoff device. of the products of combustion due to low return water temperatures a primary/secondary piping system with Refer to the wiring diagram supplied with the boiler/...
- Page 13 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 13 Figure 8 - Typical Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. Boiler circuit piping must be sized large enough to handle maximum Balance Valve flow through unit.
- Page 14 Page 14 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Figure 10 - Low Temperature Piping with Thermostatic Valve (See notes and adjustment procedures) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. For pump selection consult factory. 2.
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Page 15: Domestic Water Supply Piping
200 GPM, 12.6 L/s. See Table 7. General Piping Requirements Ensure that the water heater is equipped with bronze RBI water heaters are designed to run scale free. Due headers. Piping and components connected to the water to the extreme variables of water conditions world wide heater must be suitable for use with potable water. - Page 16 Page 16 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Pump Requirements installed on both the inlet and outlet of the water heater This low-mass water heater requires a continuous mini- for determining the temperature rise through the unit. mum water flow for proper operation. The factory recommended circulating pump has been sized to The proper velocity through the water heater must overcome the head loss of the water heater plus a 30...
- Page 17 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 17 Table 9 - 8900 Pumping Performance Requirement Table Table 10 - 8800 Pumping Performance Requirement Table...
- Page 18 Bufferfly Valve Balance Valve D-1 Rev 6 Ball Valve Attention: Motorized Valve Not all RBI stock storage tanks incorporate this tapping: See Note 1. Solenoid Operated Valve Figure 13 - Multiple Water Heating Piping (HW Models Only) (See Notes) Self-Operated...
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Page 19: Gas Supply Piping
If for any reason the 2. For flow at full open. boiler/water heater is not for the type of gas available at the installation site, call the nearest RBI representative CAUTION: Always use a square jawed wrench on to resolve the problem. -
Page 20: Electrical Wiring
Page 20 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Whenever the gas supply piping is pressure tested the GENERAL OPERATION boiler/water heater gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, WARNING: Before proceeding read and fully 3.5 kPa isolate the boiler/water heater by closing it’s understand the instructions contained in this... -
Page 21: Operating Instructions
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 21 QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: Shut the boiler off and open the bleed valves to purge • Ne pas tenter d’allumer d’appareil. the air trapped in the heating system piping. Close the •... -
Page 22: Checking & Adjustments
Page 22 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS To Turn Off Gas To Appliance Required Gas Pressure 1. Set the operating control or thermostat to its lowest Provide gas supply pressure at inlet to boiler gas train setting. as follows: 2. - Page 23 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 23 Pilot Adjustment PROPANE GAS: Optimum results are obtained when The pilot burner flame should envelope 3/8" to 1/2" of the boiler/water heater is operated with the manifold the flame sensing probe, Figure 15. To adjust the pilot pressure(s) set per Table 10.
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Page 24: Control Description
Page 24 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS CONTROL DESCRIPTION High Limit (Aquastat) The high limit is located in the top control area of the boiler/water heater. A remote capillary bulb is run to a Boiler Thermostat well on the outlet side of the supply header. The high If a thermostat is to be used to control the boiler always limit can be reset by depressing the black rubber plug follow the instructions included with the thermostat. -
Page 25: Maintenance
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 25 MAINTENANCE Combustion Chamber Inspection 1. Remove the left or right lower jacket end panel, item 5 or 24 (8900) or item 5 or 24 (8800). WARNING: Disconnect electrical power and 2. - Page 26 Page 26 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 9. The outside surfaces of the copper tubes should be 4. The relief valve should not weep or discharge free of any soot deposits. A slight black smudge is water at normal system pressure. If it does contact normal with some types of gases.
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Page 27: Trouble-Shooting
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 27 TROUBLE-SHOOTING FLOW CHART FOR HONEYWELL OR UTC IGNITION MODULE (24V CONTROL SYSTEM) Proper line voltage Check for tripped breaker or open safety L1 to L2 on heater / limit switch in supply voltage circuit. terminal strip Check for broken or loose 24V on secondary... - Page 28 Page 28 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Trouble-Shooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Boiler Pounds or Knocks Low or no water flow Ensure that pump is operating properly - look for voltage through flow switch. Ensure that all system valves are open.
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Page 29: Repair Parts, 8900
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 29 PARTS LIST (MODELS 420-1900) - Page 30 Page 30 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS SERVICE AND REPLACEMENT PARTS LIST (MODELS 420-1900) 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Inlet/Outlet Header, Cast Iron 01-0001S Inlet/Outlet Header, Bronze...
- Page 31 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 31 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Firing Valve, 1"...
- Page 32 Page 32 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Bracket Refractory Front/Rear 03-0308 Upper Front Refractory Channel...
- Page 33 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 33 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Heat Exchanger Assembly (Copper) 70-0072 Cast Iron Headers...
- Page 34 Page 34 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Tube Expansion Tool 30-0761 Heat Exchanger Assembly (Copper)
- Page 35 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 35 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Tube Bundle (Copper) 70-0132 70-0133...
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Page 36: Ignitor, Pse-Na185
Page 36 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Heat Exchanger “V”... - Page 37 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 37 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Rocker Switch 48-0001 Relay, 24V AC...
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Page 38: Repair Parts, 8800
Page 38 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS PARTS LIST (MODELS 2000-4000) - Page 39 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 39 SERVICE AND REPLACEMENT PARTS LIST (MODELS 2000-4000) 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Inlet/Outlet Header, Bronze 01-0012.1 Return Header, Bronze 01-0013.1...
- Page 40 Page 40 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 18, 19, Tile Kit 70-1739K 70-1740K 70-1741K 70-1742K 70-1743K 70-1744K Bracket Refractory Front/Rear 03-0308...
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Page 41: Ignitor, Pse-Na29, Lp 70-0631
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 41 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Tube Expansion Tool 30-0761 Heat Exchanger (Cupronickel) 70-1690 70-1691 70-1692 70-1693 70-1694... - Page 42 Page 42 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Orifice, #17, NG 10-0014 Orifice, #34, LP 10-0021 Pressure Relief Valve 50# 30-0379 Pressure Relief Valve 50# 13-0002...
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Page 43: Installation Requirements
NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 g. INSPECTION. The state or local gas inspector of the side In the Commonwealth of Massachusetts, the wall horizontally vented gas fueled equipment shall not installation must be performed by a licensed plumber or gas fitter. - Page 44 All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI. This limited warranty does not apply:...