Table of Contents
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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/water heater during construction.
contamination 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/water heater. 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.
Boiler &
Water Heater
Manual
Installation and Operation
Instructions
Stainless Steel Water Tube Gas
Boilers (WB) & Water Heaters (WW)
Models 1250, 1500, 2000, 2500,
3000 & 4000
Also read and follow:
HeatNet Control Manual
Construction dust and particulate, particularly drywall dust, will cause
TRS-IOM-2
82-0954-001
07/2020 Copyright 2019 Mestek, Inc.
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Table of Contents
Related Manuals for RBI Torus WB1250
Summary of Contents for RBI Torus WB1250
- Page 1 TRS-IOM-2 82-0954-001 Boiler & Water Heater Manual Installation and Operation Instructions Stainless Steel Water Tube Gas Boilers (WB) & Water Heaters (WW) Models 1250, 1500, 2000, 2500, 3000 & 4000 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.
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Page 2: Table Of Contents
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual CONTENTS If the information in this manual is not followed exactly, a fire or explosion may result causing Before Your Start ..........page 2 property, personal injury or loss of life. Ratings &... -
Page 3: Ratings & Capacities
4. Locate the boiler/water heater in an area that will For sales and technical assistance please call the RBI prevent water damage to adjacent construction Manufacturer's Representative at 877-316-5074. should a leak occur or during routine maintenance. - Page 4 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Where directly communicating with the outdoors or If the boiler/water heater is operated while communicating with the outdoors through vertical ducts, the building is under construction it must be each opening shall have a minimum free area of 1in protected from wood, concrete, sheet rock 4000 Btu/hr, 550 mm...
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Page 5: Venting Guidelines
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual All joints in metal intake air systems must be For Category II and IV appliances the vent secured using corrosion resistant fasteners shall not terminate: and sealed using a suitable Silicone caulk. If 1) over public walkways;... - Page 6 *Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings. The RBI Torus 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.
- Page 7 Torus Stainless Steel Condensing Boilers & Water Heaters – 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.
- Page 8 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Table Y - Approved Intake/Exhaust Terminations (CAT IV - Sidewall/Horizontal Direct Vent) Exhaust Exhaust Exhaust Exhaust Exhaust Termination 90 deg 45 deg Straight Hood *with bird screen Table Z - Approved Manufacturers Stainless Steel Boiler Transition Adapters (CAT II/IV) M&G DuraVent Metal-Fab (DuraSeal)
- Page 9 EVD-UNAK-12R *Factory Installed The RBI Torus 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...
- Page 10 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 1 - Multiple Boiler Common Venting "B" "C" DOUBLE ACTING "D" BAROMETRIC VENT PIPE DAMPER & CAP THERMAL SPILL SWITCH "F" BOILER #4 BOILER #3 BOILER #2 BOILER #1 (IF REQUIRED) (IF REQUIRED) (IF REQUIRED)
- Page 11 Torus Stainless Steel Condensing Boilers & Water Heaters – 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 Torus Stainless Steel Condensing Boilers & Water Heaters – 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...
- Page 13 Torus Stainless Steel Condensing Boilers & Water Heaters – 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/water heater blower is used must be followed! The vent guidelines under the to push the flue products horizontally to the outdoors,...
- Page 14 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual VERTICAL VENT (Optional) Vent Connections Locate the boiler/water heater as close to the chimney NEGATIVE PRESSURE - CATEGORY II system as possible. Use the shortest, straightest vent The Torus is listed as a Category II appliance when connector possible for the installation.
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Page 15: Common Vent Systems
Torus Stainless Steel Condensing Boilers & Water Heaters – 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/water heater is removed from a l'espace où... - Page 16 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
- Page 17 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) supply inlet horizontally...
- Page 18 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Other Than Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air supply 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) inlet horizontally...
- Page 19 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual OUTDOOR VENTING Outdoor Installations When installed outdoors the Torus Line must be fitted The Torus Boiler/Water Heater is certified for outside installations in temperate climates with the factory supplied outdoor hood, air intake only.
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Page 20: General Piping Requirements
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual GENERAL PIPING REQUIREMENTS Freeze Protection Installations in areas where the danger of freezing exists are not recommended unless proper freeze protection is Improper piping of this boiler/water heater will provided. -
Page 21: Heating System Piping
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual HEATING SYSTEM PIPING Table 6 - Temperature Rise Table Water Flow Rates (GPM) Model General Piping Requirements Full/Min Input Full Input Size Min (gpm) * Max (gpm)* All heating system piping must be installed by a qualified 1250 40.2 241.3... - Page 22 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Primary/Secondary Piping For systems requiring glycol for freeze protection use a glycol/water mix that prevents foaming. Air entrapped Although acceptable, the system is not as cost effective within foam significantly decreases heat transfer and as reverse return piping.
- Page 23 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local manufactures representative for assistance.) AIR SEPARATOR AIR SEPARATOR TYPICAL LOCATION...
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Page 24: Domestic Water Supply Piping
49°C. Local codes must be complied with! water softner system. General Piping Requirements RBI water heaters are designed to run scale free. Due to The Piping and components connected to the water heater the extreme variables of water conditions world wide it must be suitable for use with potable water. - Page 25 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 14 - Typical Single Boiler with Indirect Storage Tank Piping NOTES: 1. LOCATE HEATNET SENSOR WITH WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND. 2.
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Page 26: Condensate Piping
" 1600 1100 610 530 call your RBI representative to resolve the problem. 2" 3050 2100 1650 1450 1270 1150 " 4800 3300 2700 2300 2000 1850 1600 1400 1130 Table 9 should be used to ensure that the gas supply 3"... -
Page 27: Electrical Wiring
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Whenever the gas supply piping is pressure tested the A minimum of (3 in WC) and maximum of boiler gas controls must be protected. If the test pressure (14 in WC) must be maintained to the inlet of is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler the boiler/water heater gas train not to exceed by closing its' manual shut off valve, see Figure 17. -
Page 28: Boiler Operation
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual BOILER/WATER HEATER 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 FOR YOUR SAFETY READ BEFORE OPERATING. - Page 29 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Operating Instructions 15. When the main display reads "MAIN IGNITION", the 1. STOP! Read the safety information above. If, at any burner will light at the "Ignition (%)" shown on the time, the appliance will not operate properly, follow the display.
- Page 30 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 18 - Control Panel Components BLOWER PROVE AUTO HIGH LIMIT ON APPLICABLE MODELS TOUCH SCREEEN PRESSURE TAPS MANUAL RESET HIGH LIMIT POWER SWITCH BLOWER RELAY 12V POWER SUPPLY CABINET LIGHT LOCAL / REMOTE HEATNET...
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Page 31: Sequence Of Operation
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Measure flame current d. When the adjustment is satisfactory press the check key to save the setting. When complete, 1. With the boiler operating at low fire, measure the flame place the ‘S2’... - Page 32 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Table 11 - Combustion Settings Torus Series Whirlwind BlueJet 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...
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Page 33: Ignition Troubleshooting
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Torus Series "HeatNet Control" Troubleshooting (Firing the Torus Boiler/Water Heater) FireTube Control Functions Ignition Control Hand Shake Ametek Blower Ignition Sequence (Fenwal) DISPLAY: INPUTS: 1. MODBUS STANDBY CALL FOR 2. -
Page 34: Diagnostics
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual DIAGNOSTICS Ignition Safety To test the ignition safety shutoff device, close the manual The Torus has a display that indicates the sequence shutoff valve 1 (Figure 17) in the gas supply line. Within of operation, Figure 18. -
Page 35: Maintenance
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual MAINTENANCE 3. The flow sensor isolation valves must be open in order for proper operation. Disconnect electrical power and close the In the unlikely event that the SIKA flow sensor manual gas shut off valve before performing requires cleaning, in order to flush the flow maintenance or severe personal injury may... -
Page 36: Pressure Switches
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 21 - Pressure Switches L.P. N.G. VALVE VALVE TO FILTER BOX THRU FILTER BOX TO SIGNAL BLOWER PROVE SWITCH TO FILTER BOX TO FLUE COLLAR TAP OPEN BLOCKED FLUE SWITCH ELECTRICAL... -
Page 37: Wiring
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 23 - Relays, Interlocks and Boiler Status The Highest priority SYSTEM FLOW PROVE --------- Low Water Cutoff------------------- Variable Frequency Drive -------- Gas Pressure (High & Low) ----- Spare for user or Factory ------ Operator------------------------------ Water Flow Switch----------------- Factory ------------------------------... -
Page 38: Repair Parts
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure 24 - Exploded View and Replacement Parts RIOM-0319_A RIOM-0319_A... - Page 39 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual RIOM-0319_A FRONT DOOR GASKET REPLACEMENT BURNER FRONT DOOR...
- Page 40 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual MBC 1000 VALVE GAS TRAIN MBC 2500 VALVE GAS TRAIN MBC 4000 VALVE GAS TRAIN RIOM-0319_A SUPPLY HEADER 1250-2000 COMPONENT PLACEMENT VERTICAL SUPPLY HEADER 1250-4000 COMPONENT PLACEMENT SUPPLY HEADER 3000-4000 COMPONENT PLACEMENT RIOM-0319_A...
- Page 41 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual 1250 TO 1500 FILTER BOX COMPONENTS 2000 FILTER BOX COMPONENTS 3000 FILTER BOX COMPONENTS 4000 FILTER BOX COMPONENTS RIOM-0319_A...
- Page 42 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual -001 (ASSEMBLY, ELECTRICAL PANEL, WB & WW1250 TO 1500) SHOWN -001 (ASSEMBLY, ELECTRICAL PANEL, WB & WW1250 TO 1500) SHOWN RIOM-0319_A...
- Page 43 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Torus Parts List Model Size with Quantities Below Ref # Name of Part Part No. 1250 1500 2000 2500 3000 4000 Base Frame 74-1013-001 74-1013-002 74-1013-003 74-1013-004 74-1013-005 Heat Exchanger, WB 74-1003-001 74-1003-002 74-1003-003...
- Page 44 20-0042 Handle 20-0044 Front Door Panel 74-1017-001 74-1017-002 LWCO Board 14-0258 Display Board (Touchscreen) 40-0091-002 HeatNet/RBI Overlay for Touchscreen Enclosure 82-0756-001 Switch, Red 48-0013 Switch, Green 48-0016 "A" Valve, 1 1/2" 11-0467 "A" Valve, 2" 11-0454 Low Gas Pressure Switch...
- Page 45 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Model Size with Quantities Below Ref # Name of Part Part No. 1250 1500 2000 2500 3000 4000 Collar, 8" 03-4710-001 Collar, 10" 03-4710-002 Collar, 12" 03-4710-003 Filter Box Wrapper Panel 03-4708-001 03-4708-002 03-4708-003...
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Page 46: Start-Up
Torus Stainless Steel Condensing Boilers & Water Heaters – 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... - Page 47 Torus Stainless Steel Condensing Boilers & Water Heaters – 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)
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Page 48: Warranty
All other RBI supplied Boiler 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 boiler is designed to operate in a closed loop heating system.