RBI CK1500 Installation And Operation Instructions Manual

Stainless steel condensing boilers

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Page 1 82-0651 Boiler Manual Installation and Operation Instructions Stainless Steel Condensing Boilers Models CK1500, CK2000, CK2500, CK3000, CK3500, CK4000, CK4500, CK5000 & CK6000 Also read and follow: HeatNet Control Manual 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.
Page 2: Table Of Contents
BOILER AND PRESSURE VESSEL CODE, SECTION IV MUST FOLLOW the additional instructions contained in FOR A MAXIMUM ALLOWABLE WORKING PRESSURE RBI's instruction sheet, MACODE-3. Please refer to the OF 160 PSI, 1103 kPa WATER. back of this manual for required regulations.
Page 3: Ratings & Capacities
4. Locate the boiler in an area that will prevent water damage to adjacent construction should a leak Direct all questions to your RBI distributor or contact the occur or during routine maintenance. RBI Customer Service Department at: 260 North Elm Street, Westfield, MA 01085.
Page 4 FlexCore Stainless Steel Condensing Boilers – Installation Manual Buildings will require the installation of a fresh air duct When ducts are used, they must have the same cross- or other means of providing make-up air if the intake sectional area as the free area of the opening to which air option isn't used.
Page 5: General Venting Guidelines
FlexCore Stainless Steel Condensing Boilers – Installation Manual All joints in metal intake air systems must be A barometric damper or blast gate as secured using corrosion resistant fasteners required, must be installed if a Category II and sealed using a suitable Silicone caulk. If vertical vent system produces a negative PVC or CPVC is used, the joints must be draft in excess of 0.10 in, 2.5 mm WC at the...
Page 6 *Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings. The RBI Flexcore is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems.
Page 7 FlexCore Stainless Steel Condensing Boilers – Installation Manual Avoid terminal locations likely to be affected by winds, The top of a vertical vent system must extend at least ft, 1.8 m above the roof surface that it passes snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue through, 4 ft, 1.3 m above the intake air cap, see Figure gases.
Page 8 FlexCore Stainless Steel Condensing Boilers – Installation Manual Table X - Approved Stainless Steel Vent Manufacturers (CAT II/IV) Make Model Simpson DuraVent FasNSeal Vent M&G DuraVent DuraSeal Vent Heatfab Saf-T Vent Metal-Fab CORR/GUARD Security Chimneys Secure Seal Schebler Chimney Systems e Vent VAN-PACKER Z-Flex Z-Vent...
Page 9 6000 *Factory Installed The RBI Flexcore is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers. Use only listed manufacturers (Table X), terminations (Table Y), and transition adapters (Table Z).
Page 10 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 1 - Multiple Boiler Common Venting "B" FLUE VENT "C" ALL CONNECTIONS DOUBLE ACTING TO BE "T-WYE" BAROMETRIC DAMPER "D" THERMAL SPILL SWITCH "F" BOILER #2 BOILER #4 BOILER #3 BOILER #1 (IF REQUIRED) (IF REQUIRED) (IF REQUIRED)
Page 11 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System 10 ft (3.1 m) Figure 3 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems...
Page 12 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m 5 FT 1.5 m Figure 5 - Combination Direct Vent Systems 3 FT.
Page 13 FlexCore Stainless Steel Condensing Boilers – Installation Manual SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION SECTION In this configuration the boiler blower is used to push the must be followed! The vent guidelines under the flue products horizontally to the outdoors, see Figure 6.
Page 14 FlexCore Stainless Steel Condensing Boilers – Installation Manual VERTICAL VENT (Optional) Vent Connections Locate the boiler as close to the chimney system as NEGATIVE PRESSURE - CATEGORY II possible. Use the shortest, straightest vent connector The FlexCore is listed as a Category II appliance when possible for the installation.
Page 15: Common Vent Systems
FlexCore Stainless Steel Condensing Boilers – Installation Manual EXISTING COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où...
Page 16: General Piping Requirements
FlexCore Stainless Steel Condensing Boilers – Installation Manual GENERAL PIPING REQUIREMENTS Relief Valve Pipe the discharge of the pressure relief valve as shown in Figure 9. Mount on rear section or vertically on supply nipple. Improper piping of this boiler will void the manufacturer’s warranty and can cause boiler Never install any type of valve between the failure resulting in flooding and extensive...
Page 17: Heating System Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual HEATING SYSTEM PIPING Flow Switch The factory mounted flow switch, as shown in Figure 9, is wired to prevent the boiler from firing unless there's General Piping Requirements adequate water flow through the unit. All heating system piping must be installed by a qualified technician in accordance with the latest revision of the Failure to maintain the minimum flow rates listed...
Page 18 FlexCore Stainless Steel Condensing Boilers – Installation Manual Water Treatment Primary/Secondary Piping This boiler was designed to operate in a closed loop Although acceptable, the system is not as cost effective heating system. System fill water must not contain more as reverse return piping.
Page 19 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local manufactures representative for assistance.) AIR SEPARATOR ALTERNATE LOCATION SYSTEM...
Page 20: Domestic Water Supply Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual DOMESTIC WATER SUPPLY PIPING The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce flow. Proper controls must be used to prevent water supplied for domestic use from Expansion Tank exceeding 130°F, 54°C or a scald injury will...
Page 21 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping COLD WATER MAKE-UP FLOW FLOW FLOW COLD WATER BRONZE MAKE-UP/FILL PUMP FLOW FLOW COLD WATER MAKE-UP CIRCULAR RETURN SUPPLY FLOW FLOW BRONZE PUMP NOTES:...
Page 22: Condensate Piping
If for any reason the boiler is not for Maximum gas volume of pipe (ft /hr) the type of gas available at the installation site, call your 1" RBI representative to resolve the problem. " 1050 400 350 "...
Page 23: Electrical Wiring
FlexCore Stainless Steel Condensing Boilers – Installation Manual Whenever the gas supply piping is pressure tested the Table 9 - Equivalent Pipe Length Chart boiler gas controls must be protected. If the test pressure Type of pipe fitting Nominal is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler Iron Pipe 90°...
Page 24 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 17 - Gas Supply Piping FROM GAS SUPPLY PILOT SHUT OFF VALVE PILOT REGULATOR AND SOLENOID VALVE MAIN GAS VALVE LOW GAS PRESSURE SWITCH TEST PORT HIGH GAS PRESSURE SWITCH (OPTIONAL ON CK 1500 TO 2500 MODELS) GROUND UNION HIGH FIRE GAS PRESSURE...
Page 25: Boiler Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual BOILER OPERATION The system should be checked and bled after three days of operation. Before proceeding read and fully understand OPERATING INSTRUCTIONS the instructions contained in this manual. Do not attempt to operate this boiler if it has not FOR YOUR SAFETY READ BEFORE OPERATING.
Page 26 FlexCore Stainless Steel Condensing Boilers – Installation Manual Operating Instructions 15. When the main display reads "PILOT RUNNING" 1. STOP! Read the safety information above. If, at any and the flame current is 5VDC, switch the Honey time, the appliance will not operate properly, follow the well 7800 test/run switch into the "test"...
Page 27 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 18 - Control Panel Components 18. Remove the demand from the 7800 control by 23. Open both manual main shut-off valves and the pilot disabling the low fire switch allowing the boiler to stop. gas shut-off valve.
Page 28: Sequence Of Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual b. Press the ‘Adjust’ button under the Minimum (%) d. When the adjustment is satisfactory press the setting. The percentage value will turn green. Adjust check key to save the setting. Follow the same the minimum value (%), using the arrow keys, to procedure for the rear module on units (CK3500- achieve the required combustion - C02/02, (Table...
Page 29 FlexCore Stainless Steel Condensing Boilers – Installation Manual Table 11 - Combustion Settings FlexCore-Series Whirlwind Bekaert Burner w/Gas Orifice Slide Trim** Inlet High High High Temp. Fire Fire Fire Fire Fire Fire -40°F -30°F -20°F -10°F 0°F 10°F 20°F 10.1 30°F 10.2 40°F...
Page 30: Ignition Troubleshooting
FlexCore Stainless Steel Condensing Boilers – Installation Manual FireTube Series "HeatNet Control" Troubleshooting (Firing the FireTube Boiler) Variable Frequency FireTube Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) DISPLAY: INPUTS: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4.
Page 31: Checking & Adjustment
FlexCore Stainless Steel Condensing Boilers – Installation Manual CHECKING, ADJUSTMENT & OPERATION To adjust the pilot the following steps must be taken: 1. Remove the pilot gas pressure regulator cap. Spark Gap The gap has to be measured and adjusted with the 2.
Page 32: Diagnostics
FlexCore Stainless Steel Condensing Boilers – Installation Manual DIAGNOSTICS Ignition Safety To test the ignition safety shutoff device, close the The FlexCore has a display that indicates the sequence manual shutoff valve 1 (Figure 17) in the gas supply line. of operation, Figure 18.
Page 33: Maintenance
FlexCore Stainless Steel Condensing Boilers – Installation Manual MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. Disconnect electrical power and close the 1. Check the operating controls for proper operation. manual gas shut off valve before performing maintenance or severe personal injury may 2.
Page 34: Pressure Switches
FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 21 - Pressure Switches RIOM-0218.B...
Page 35: Wiring
FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 23 - RBI Field Wiring to HeatNet Board 3.0...
Page 36: Repair Parts
FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 24 - Single Unit Replacement Parts SEE VIEW C SEE VIEW A SEE VIEW B SEE VIEW D SEE VIEW E SEE VIEW D VIEW A...
Page 37 FlexCore Stainless Steel Condensing Boilers – Installation Manual VIEW B VIEW B VIEW C VIEW D VIEW C VIEW D VIEW E VIEW E...
Page 38 FlexCore Stainless Steel Condensing Boilers – Installation Manual FlexCore Parts List (Single) Model Size with Quantities Below Ref # Name of Part Part No. 1500 2000 2500 3000 Profile, Corner Post, P 130/25 X 28-1/16" 03-0330-2806 Profile, Corner Post, P 130/25 X 36-1/16" 03-0330-3606 Profile, Onega Post, P 230/25 X 36-1/16"...
Page 39 FlexCore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part No. 1500 2000 2500 3000 Cover 74-0010-002 Blower Gasket 06-0209 Blower 12-0026-001 Gasket, Blower to Adapter 06-0210-002 Adapter 74-0014-001 Gasket, Adapter to Air Inlet 06-0211-001 T&P Gauge 13-0305...
Page 40 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 25 - Double Unit Replacement Parts SEE VIEW A SEE VIEW B SEE VIEW C SEE VIEW D SEE VIEW E...
Page 41 FlexCore Stainless Steel Condensing Boilers – Installation Manual VIEW C VIEW C VIEW B VIEW B VIEW E VIEW D VIEW E VIEW D...
Page 42 FlexCore Stainless Steel Condensing Boilers – Installation Manual FlexCore Parts List (Double) Model Size with Quantities Below 5000 Ref # Name of Part Part No. 3500 4000 4500 6000 Profile, Corner Post, P 130/25 X 30-1/16" 03-0330-3006 Profile, Corner Post, P 130/25 X 33-1/16" 03-0330-3306 Profile, Omega Post, P 230/25 X 33-1/16"...
Page 43 FlexCore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part No. 3500 4000 4500 5000 6000 Pilot Tube Assemlby 74-0011- Pilot Block Gasket 05-0504 Minipeeper 16-0009 Viewport Assembly Viewport Gasket 59-1064 Viewport Glass 60-4280 Viewport Cover...
Page 44: Start-Up
FlexCore Stainless Steel Condensing Boilers – Installation Manual START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STA T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL...
Page 45 FlexCore Stainless Steel Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS INLET PRESSURE (WC) INCHES WC I NCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC...
Page 46: Mass Code
FlexCore Stainless Steel Condensing Boilers – Installation Manual MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure installation must be performed by a licensed used in whole or in part for residential purposes, including plumber or gas fitter.
Page 47: Warranty
FlexCore Stainless Steel Condensing Boilers – Installation Manual FlexCore Series Water Boiler Limited Warranty One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the FlexCore Series modulating water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation or eighteen (18) months from the date of shipment from the factory whichever comes first.
Page 48 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada  Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...

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