RBI Dominator Series Installation And Operation Instructions Manual
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RBI Dominator Series Installation And Operation Instructions Manual

Finned copper tube gas boilers (db) & water heaters (dw)
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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 Tube
Gas Boilers (DB) &
Water Heaters (DW)
Boiler  Manual
Installation and Operation
Instructions
Construction dust and particulate, particularly drywall dust, will cause contamination
DOM-I0M-11
82-0262
03/16 Copyright 2014 Mestek, Inc.

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  • Page 1 DOM-I0M-11 82-0262 Finned Copper Tube Gas Boilers (DB) & Water Heaters (DW) 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

    • Si vous ne purvez rejoindre le fournisseur, appelez le This manual covers the application, installation, operation and service des incendies. maintenance of a Dominator Series finned copper heating boiler/ L’installation et l’entretien doivent être assurés par un water heater/(pool heater-Canada only).

  • Page 3: Ratings & Capacities

    3. Ensure that the floor is structurally sound and will support the Direct all questions to your RBI distributor or contact the weight of the boiler/water heater. RBI Customer Service Department, 260 North Elm Street, Westfield, MA 01085 for U.S.
  • Page 4 Finned copper tube gas boilers & water heaters – Boiler Manual To operate properly and safely this boiler/water heater requires a Never operate the Dominator in an environment continuous supply of air for combustion. NEVER store objects on subjected to a negative pressure unless the air intake or around the boiler/water heater! is connected to the outdoors.
  • Page 5 Finned copper tube gas boilers & water heaters – Boiler Manual Vertical Venting using a Masonry Chimney and Inside Air Figure 2 Horizontal Venting using Inside Air Figure 3 1/4 IN. PER F00T 20 mm/m 1.5 FT 0.5 m Table 2 MINIMUM VERTICAL RISE VENT PIPE DIAMETER OFF THE TOP OF UNIT "A"...
  • Page 6 The certified combustion air terminal from burners, there shall be a permanent air supply opening(s) having RBI must be used and installed as shown in Figures 4 and 5. a cross-sectional area of not less than 1 in...
  • Page 7 Finned copper tube gas boilers & water heaters – Boiler Manual Horizontal Combustion Air and Venting for a Single Unit Figure 4 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 1.5 FT 0.5 m 2000 & Larger 1201 To 2000 901 To 1200 200 To 900 1000 BTU'S...
  • Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual Vertical Combustion Air and Venting, Metal Chimney System Shown Figure 6 Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT...

  • Page 9: General Venting Guidelines

    Finned copper tube gas boilers & water heaters – Boiler Manual GENERAL VENTING GUIDELINES VENT SYSTEM OPTIONS The Dominator may be vented the following ways: The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas 1) Vertical/Chimney Venting, Negative Pressure, Category Code, ANSI Z223.1/NFPA 54-latest revision or I - uses an approved metal chimney system or properly lined...

  • Page 10: Vertical/Chimney Venting

    The vent materials used in horizontal vent systems must be certified to UL 1738 for installations in the United States, ULS636 for 300 - 400 installations in Canada. The certified vent terminal from RBI must also be used. 900 - 1050...

  • Page 11: Outdoor Venting

    Finned copper tube gas boilers & water heaters – Boiler Manual When horizontal vent runs exceed 5 ft, 1.5 m they must be supported Table 5a Category III Vent Pipe Diameter at 3 ft, 0.9 m intervals with overhead hangers. The vent system must Pipe Diameter be pitched down, toward the vent terminal, 1/4 in/ft, 20 mm/m.

  • Page 12: Common Vent Systems

    Finned copper tube gas boilers & water heaters – Boiler Manual COMMON VENT SYSTEMS Figure 8 Outdoor Venting If an existing boiler/water heater is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it.

  • Page 13: General Piping Requirements

    Finned copper tube gas boilers & water heaters – Boiler Manual GENERAL PIPING REQUIREMENTS e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. Improper piping of this boiler/water heater will void the manufacturer' s warranty and can cause boiler failure Faire fonctionner le brûleur principal pendant 5 min ensuite,...
  • Page 14 Finned copper tube gas boilers & water heaters – Boiler Manual Relief Valve Table 7 Temperature Rise Table Pipe the discharge of the pressure relief valve to prevent scalding in ∆T = 15°F ∆T = 8.3°C the event of a discharge, see Figure 10. The discharge piping must be Model Flow Rate Pres.

  • Page 15: Heating System Piping

    Finned copper tube gas boilers & water heaters – Boiler Manual HEATING SYSTEM PIPING Expansion Tank & Air Separator An expansion tank or other means to control thermal expansion must be installed in the heating system. An expansion tank must General Piping Requirements be installed close to the boiler on the suction side of the pump.
  • Page 16 Finned copper tube gas boilers & water heaters – Boiler Manual Typical Primary/Secondary Piping Figure 11 (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 17 Finned copper tube gas boilers & water heaters – Boiler Manual Low Temperature Piping Figure 12A (See Notes and Adjustment Procedures) Pu m p G a te Val v e G l obe Val v e A ngl e Val v e NOTES: 1.

  • Page 18: Domestic Water Supply Piping

    Table 8B the flow rate is too low. Scaling and softening of the heat exchanger will occur. RBI water heaters are designed to run scale free. Due to the extreme variables of water conditions world wide it is necessary to consider Thermostatic Mixing Valve - pH values and water hardness in relationship to scaling.
  • Page 19 Finned copper tube gas boilers & water heaters – Boiler Manual Table 8A Dominator Heat Exchanger Selection Graph Table 8B Dominator Pumping Performance Requirement...
  • Page 20 Angle Valve D-1 Rev 6 Bufferfly Valve Aquastat Union Balance Valve Attention: Pressure Switch Not all RBI stock storage tanks incorporate this tapping: See Note 1. Ball Valve Gas Pressure Regulator Multiple Water Heating Piping (DW Models only) Figure 15...

  • Page 21: Gas Supply Piping

    If for any reason the boiler/water heater is not for the Always use a square jawed wrench on the gas valve type of gas available at the installation site, call your RBI representative body when making gas connections to it. Never over- to resolve the problem.

  • Page 22: Electrical Wiring

    Finned copper tube gas boilers & water heaters – Boiler Manual ELECTRICAL WIRING GENERAL OPERATION Before proceeding read and fully understand the Electrical Power Connections instructions contained in this manual. Do not attempt to operate this boiler/water heater if it has not been Label all wires prior to disconnection when servicing installed in accordance with the guidelines set forth in controls.

  • Page 23: Boiler/Water Heater Operation

    Finned copper tube gas boilers & water heaters – Boiler Manual BOILER/WATER HEATER OPERATION Pressure taps are provided in the control compartment for taking the differential pressure readings, Figure 17. Table 14 lists the differential pressure settings for all of the models. Staging Operation Pressure Switch Tap(s) Figure 17...
  • Page 24 Finned copper tube gas boilers & water heaters – Boiler Manual Prepurge: Table 15 Pressure Switch Control, D300-D2100 – DB300 On/Off Only 1. Prepurge timer TDR1 energizes. A 40 second delay on make Stage Pressure Switch Mode (DOM) timing cycle begins. Low Fire 2.
  • Page 25 Finned copper tube gas boilers & water heaters – Boiler Manual Demand Satisfied: Prepurge: 1. Stage switch 1 opens, TDR1 de-energizes and the N.O. contact 1. TDR1 energizes starting a 40 second prepurge cycle. “TDR1-1” opens. TDR4 also de-energizes but the N.O. contact 2.

  • Page 26: Operation Sequence, 4 Stage D1050 Through D2100

    Finned copper tube gas boilers & water heaters – Boiler Manual OPERATION SEQUENCE, 4-STAGE Normal Operation D1050 THROUGH D2100 • Staging will be controlled from the staging controller. • The front control panel separately monitors limit, gas pressure, Refer to the included connection and wiring diagrams water flow and airflow.

  • Page 27: Operating Instructions

    Finned copper tube gas boilers & water heaters – Boiler Manual High Limit, Low Water Flow, Low Gas Pressure, High Gas 6. If the second ignition attempt is unsuccessful the gas valves will lockout, but the blower, pump and power venter will remain Pressure, Power Venter Interlock Faults on.
  • Page 28 Finned copper tube gas boilers & water heaters – Boiler Manual FOR YOUR SAFETY Operating Instructions 1. STOP! Read the safety information above. If, at any time, • Have only qualified licensed professionals install, service and maintain this appliance and your gas system in accordance with the appliance will not operate properly, follow the instructions all applicable codes.
  • Page 29 Finned copper tube gas boilers & water heaters – Boiler Manual 11. Turn the knob on the pilot valve to on, Figure 18. Table 19 (D300-D2100) Pilot & Manifold Settings – (D300 On/Off Only) 12. Turn the knob on the main gas valve to on, 300 and 400 models, Natural Gas Figure 18.

  • Page 30: Checking & Adjustments

    Finned copper tube gas boilers & water heaters – Boiler Manual CHECKING & ADJUSTMENTS Pilot Adjustment The pilot burner is actually an isolated main burner that 1. With the burners in operation, close the manual shutoff valve in stages with the other burners. It is controlled by a separate pilot the gas supply line.

  • Page 31: Control Description

    Finned copper tube gas boilers & water heaters – Boiler Manual Operating Control NATURAL GAS: Optimum results are obtained when the boiler/ water heater is operated with the manifold pressure(s) set per Table The preferred control setting for potable hot water is 130°F, 54°C. 19.
  • Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual Relay Board Mode 2: Setpoint control. Dominator piped in primary/ secondary configuration. An additional system sensor is required The relay board is located in the control tray. It provides sequencing to properly control the system supply (primary loop) temperature.

  • Page 33: Maintenance

    Finned copper tube gas boilers & water heaters – Boiler Manual OUTDOOR RESET WITH DHW OPERATION - A DHW The ceramic combustion chamber contains crystalline tank controlled by a pump provides reset override whenever silica. Wear a tightly fitted dust mask when removing DHW generation is required.
  • Page 34 Finned copper tube gas boilers & water heaters – Boiler Manual 10. Remove the "V" baffle straps and "V" baffles. 8. If there are no signs of damage, sooting or corrosion reassemble the unit following the previous steps in reverse order. 11.
  • Page 35 Finned copper tube gas boilers & water heaters – Boiler Manual 5. The aquastat high limit controls the maximum water Heat Exchanger Upper Rail Screws Figure 21 temperature in the boiler. It should be set at least 20°F, 11°C above the operator setpoint. If the water temperature reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the boiler off.

  • Page 36: Trouble-Shooting

    Finned copper tube gas boilers & water heaters – Boiler Manual TROUBLE-SHOOTING SYMPTOM CHECK ACTION No Power To Unit 1. Power not connected 1. Wire unit to line voltage 2. External circuit breaker open 2. Reset breaker 3. Relay board fuse (24V) blown 3.
  • Page 37 Finned copper tube gas boilers & water heaters – Boiler Manual TROUBLE-SHOOTING SYMPTOM CHECK ACTION Unit Does Not Spark 1. Incorrect spark gap or shorted ignitor lead 1. Adjust ignitor rod or correct short 2. Bad ground on flame sense module 2.

  • Page 38: Repair Parts

    Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS Replacement Parts Figure 23...
  • Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Filter (Indoor) 09-0488 09-0489 09-0497 09-0498 Filter (Outdoor) 09-0490 09-0491 Cerablanket Insulation (per square foot)
  • Page 40 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 24, 25, Tile Kit 05-0202 05-0203 05-0204 05-0205 05-0206 05-0207...
  • Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Heat Exchanger Assembly (Copper) 70-2826 Cast Iron Headers 70-2827 70-2828 70-2829...
  • Page 42 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Tube Bundle (Copper) 70-2901 70-2902 70-2903 70-2904 70-2905 70-2906 70-2907...
  • Page 43 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Firing Valve, 3/4” 11-0461 Firing Valve, 1” 11-0456 Firing Valve, 1 1/4”...
  • Page 44 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Main Board (blue) 40-0065R Timer Board 40-0067 Ribbon Cable 44-0057 LED Indicator Board...

  • Page 45: Start Up Form

    External BMS System Boiler Pump Supply Voltage Utilize Boiler BTC For Control Voltage Down Stream of Transformer BTC CONTROL SET UP: (Not all settings are used for every mode. (Dominator Series Only)) : Mode : Boiler Max : Purge DT...
  • Page 46 Finned copper tube gas boilers & water heaters – Boiler Manual COMBUSTION/SAFETY REPORT FACTORY FIRE TEST REPORT: Low Fire High Fire These results are affixed to the side of the heater Manifold Gas Pressure: "WC" on a small white label. Air Differential Pressure: "WC"...
  • Page 47 Finned copper tube gas boilers & water heaters – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels of tion must be performed by a licensed plumber or gas carbon monoxide which can cause severe personal fitter.
  • Page 48 Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. 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.

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