RBI ENCORE RB0350 Manual

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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.

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.

Boiler Manual

Installation and Operation

Instructions

Stainless Steel Condensing Boilers

Models RB0350, RB0400, RB0500,

RB0600, RB0725, RB0850

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Summary of Contents for RBI ENCORE RB0350

Page 1 ECR-IOM-2 82-0968-001 Boiler Manual Installation and Operation Instructions Stainless Steel Condensing Boilers Models RB0350, RB0400, RB0500, RB0600, RB0725, RB0850 Also read and follow: HeatNet Control Manual ENERGY STAR ENERGY STAR 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
If installed in the Commonwealth of Massachusetts, you ADJACENT TO THE BOILER. MUST FOLLOW the additional instructions contained in RBI's instruction sheet MACODE-3. Which is located in CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE the back of this manual. REFERENCE PURPOSES.
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 Encore 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 air sectional area as the free area of the opening to which option isn't used.
Page 5: Venting Guidelines
Encore Stainless Steel Condensing Boilers – 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 (5X) pipe diameters straight length between fittings. The RBI Encore is supplied with a factory installed PVC/CPVC flue outlet adapter. The RBI Encore has been approved for use with the optional Polypropylene and Stainless Steel vent adapters. Use only listed manufacturers/materials (Table 5), terminations (Table 6), and transition adapters/terminals (Table 7).
Page 7 Encore Stainless Steel Condensing Boilers – Installation Manual Table 5 - Approved Vent Manufacturers/Materials Approved Stainless Steel Vent Manufacturers (CAT II/IV) Make Model M&G DuraVent FasNSeal Vent Heatfab Saf-T Vent Metal-Fab CORR/GUARD Security Chimneys Secure Seal Schebler Chimney Systems e Vent Z-Flex Z-Vent Jeremias...
Page 8 Encore Stainless Steel Condensing Boilers – Installation Manual Table 6 - Approved Intake/Exhaust Terminations (CAT IV - Direct Vent, Side Wall)* Exhaust Exhaust Exhaust 90 deg 45 deg Exhaust Exhaust Exhaust Non Metalic Termination Straight Vent Option Hood *with bird screen...
Page 9 0500 0600 The RBI Encore is supplied with a factory installed PVC/CPVC flue outlet adapter. The RBI Encore has been approved for use with the optional Polypropylene and Stainless Steel vent adapters. Use only listed manufacturers/materials (Table 5), terminations (Table 6), and transition adapters/terminals (Table 7). A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems.
Page 10 Encore Stainless Steel Condensing Boilers – Installation Manual PVC/CPVC NON-METALIC VENT 1. Cut pipe ends squarely and remove all burrs, ridges and foreign matter using the appropriate tools and These instructions are specific to using schedule 40 materials. PVC/CPVC pipe as the vent system for the Encore. The instructions contained in the Encore Installation and Failure to remove burrs or ridges will result in Operation Manual, including all applicable Combustion...
Page 11 Encore Stainless Steel Condensing Boilers – Installation Manual VERTICAL TERMINATION - Cleaners and primers are intended for different functions and should not be CONCENTRIC VENT considered inter- changeable. Verify with When vented vertically the termination kit is installed vent material manufacturer for specific through the roof.
Page 12 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 1 - Concentric w/Single Termination Pitched Roof Termination 1.5 FT .5 m Minimum Vent Distance From Vent to Maximum Snow Line Combustion Strap Field Supplied Elbow Field Supplied Air Intake Exhaust Flat Roof Termination 10 FT 3.1 m Minimum to Wall or...
Page 13 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 2 - Concentric w/Multiple Terminations Side Wall Termination 12 IN, 305 mm Minimum to Overhang or Roof 12 IN, 305 mm Minimum 1" min, 2" max 1.5 FT .5 m Minimum Distance From Vent to Maximum Snow Line Roof Termination...
Page 14 Encore Stainless Steel Condensing Boilers – Installation Manual POLYPROPYLENE NON-METALIC MANUFACTURERS VENT TERMINALS VENT OPTION When vented horizontally the vent and air intake sys tem s m us t b e ter m inate d us in g s t a n da r d En c ore ha s b een a p p r ove d for us e wi th the Polypropylene fitting, (Table 8.
Page 15 Encore Stainless Steel Condensing Boilers – Installation Manual DIRECT VENT Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials POSITIVE PRESSURE, CATEGORY IV and vegetation from degradation caused by the In this configuration the boiler blower is used to push the flue gases.
Page 16 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 3 - Horizontal Air Intake and Venting for a Single Direct Vent System PITCH PIPE DOWN TOWARDS BOILER 1/4 INCH PER FOOT PITCH PIPE DOWN TOWARDS TERMINAL 1/4 INCH PER FOOT 10 FT EXHAUST MINIMUM...
Page 17 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 5 - 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 6 - Combination Direct Vent Systems (.5 m) (3.1 m)
Page 18 Encore Stainless Steel Condensing Boilers – Installation Manual SIDE WALL VENT POSITIVE PRESSURE, CATEGORY IV In this configuration the boiler blower is used to push the flue products horizontally to the outdoors, see Figure 7. To ensure proper operation, boilers that are vented sidewall and use room air must not exceed a 6:1 turndown.
Page 19 Encore Stainless Steel Condensing Boilers – Installation Manual MULTIPLE BOILER VERTICAL VENT Vent Connections Locate the boiler as close to the chimney system as NEGATIVE PRESSURE - CATEGORY II possible. Use the shortest, straightest vent connector The Encore is listed as a Category II appliance when possible for the installation.
Page 20 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 10 - Multiple Boiler Common Venting FLUE VENT "B" "C" DOUBLE ACTING BAROMETRIC DAMPER "D" THERMAL SPILL SWITCH ALL CONNECTIONS TO BE "T-WYE" "F" BOILER #4 BOILER #2 BOILER #3 BOILER #1 (IF REQUIRED) (IF REQUIRED) (IF REQUIRED)
Page 21: Common Vent Systems
Encore 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 If an existing boiler is removed from a common venting portes entre l'espace où les appareils toujours system, the common venting system may then be too raccordés du système d'évacuation sont installés et large for the proper venting of the remaining appliances...
Page 22 Encore Stainless Steel Condensing Boilers – 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 23 Encore Stainless Steel Condensing Boilers – 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 24 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Encore Stainless Steel Condensing Boilers – 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 25 Encore Stainless Steel Condensing Boilers – Installation Manual OUTDOOR VENTING Outdoor Installations When installed outdoors the Encore Line must be fitted The Encore Boiler is certified for outside installations in a temperate climate not with the factory supplied outdoor hood, air intake subject to freezing temperatures.
Page 26: General Piping Requirements
Encore Stainless Steel Condensing Boilers – 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 will void the provided. The following precautions MUST be observed: manufacturer’s warranty and can cause 1.
Page 27 Encore Stainless Steel Condensing Boilers – Installation Manual Flow Sensor In order to maintain boiler capacity, increase The factory mounted SIKA flow sensor, as shown in flow rates approximately (10%) and pump Figure 13, is wired to prevent the boiler from firing head (25%) for mixtures up to 50% glycol.
Page 28: Heating System Piping
Encore Stainless Steel Condensing Boilers – Installation Manual HEATING SYSTEM PIPING Water Treatment This boiler was designed to operate in a closed loop heating system. System fill water must not contain more General Piping Requirements than 500 ppm of total dissolved solids, less than 150 All heating system piping must be installed by a ppm chloride concentration and no greater than 200 qualified technician in accordance with the latest...
Page 29 Encore Stainless Steel Condensing Boilers – Installation Manual Expansion Tank & Air Separator Flow must be properly accounted for in the design of An expansion tank or other means to control thermal primary/secondary systems. In order to prevent boiler(s) expansion must be installed in the heating system. It is short cycling the system flow must be equal to or higher recommended the expansion tank is installed close to the than the boiler(s) local flow.
Page 30 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our manufactures representative for assistance.) AIR SEPARATOR ALTERNATE LOCATION SYSTEM RETURN...
Page 31: Domestic Water Supply Piping
Encore 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 32 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 19 - Typical Multiple Boiler with Indirect Storage Tank Piping COLD WATER MAKE-UP FLOW FLOW FLOW COLD WATER MAKE-UP/FILL WATER E-UP BRONZE FLOW PUMP FLOW CIRCULATOR RETUIRN FLOW SUPPLY COLD WATER MAKE-UP FLOW FLOW...
Page 33: 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 34: Electrical Wiring
Encore Stainless Steel Condensing Boilers – Installation Manual Whenever the gas supply piping is pressure tested A minimum of (4 in WC) and maximum of (14 the boiler gas controls must be protected. If the test in WC) must be maintained to the inlet of the pressure is equal to, or less than 1/2 psig, 3.5 kPa boiler gas train not to exceed a maximum of (1 isolate the boiler by closing its' manual shut off valve,...
Page 35 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 21 - Gas Supply Piping FROM GAS SUPPLY MAIN GAS VALVE GROUND UNION MANUAL SHUT-OFF VALVE SUPPLY PRESSURE TEST SEDIMENT TRAP PORT AND DRIP LEG PRESSURE REGULATOR SUPPLIED BY OTHERS LOW GAS PRESSURE SWITCH (ON APPLICABLE MODELS) EBM VALVE (350-500 N G /LP)
Page 36: Boiler Operation
Encore 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 37 Encore Stainless Steel Condensing Boilers – 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 display.
Page 38 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 22 - Control Panel Components CSD-1 RESET TOUCH SCREEN POWER SWITCH CABINET LOW WATER LIGHT CUTOFF RESET LOCAL/REMOTE SWITCH e. When the adjustment is satisfactory, press the check key to save the setting. 18.
Page 39 Encore Stainless Steel Condensing Boilers – Installation Manual c. MODELS (0600-0850), DUNGS MBC Valve: The high fire trim adjustment is located on the outlet flange, (Figure 21), of the gas valve. Figure 25 provides further illustration of the gas valve high fire location. Rotating the adjustment screw clock-wise will increase the CO2 and lower the O2;...
Page 40: Sequence Of Operation
Encore Stainless Steel Condensing Boilers – Installation Manual SEQUENCE OF OPERATION Measure flame current 1. With the boiler operating at low fire, measure the flame current. NO DEMAND 2. Attach microammeter leads to the flame current test Standby pins of the Fenwal ignition module as in Figure 23. 1.
Page 41 Encore Stainless Steel Condensing Boilers – Installation Manual Figure 25 - Gas Adjustments Models (0350 - 0500) NG & (0350 - 0850) LP Models (0600 - 0850) NG Low Fire Setting Dungs Gas Valve Shutter Flange EBM Gas Valve Throttle Adjustment (High Fire Setting) Dungs High Fire Trim Adjustment...
Page 42 Encore Stainless Steel Condensing Boilers – Installation Manual Table 15 - Combustion Settings Encore Series Whirlwind 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 10.3 50°F 10.5 60°F 10.6...
Page 43: Ignition Troubleshooting
Encore Stainless Steel Condensing Boilers – Installation Manual Encore Series "HeatNet Control" Troubleshoot ing (Firing the Encore Boiler) FireTu be Con trol Functions Ignition Contrrol Ametek Blower Hand Shake Ignition Sequence (Fenwal) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2. AA 3.
Page 44: Checking & Adjustment
Encore Stainless Steel Condensing Boilers – Installation Manual DIAGNOSTICS Ignition Safety To test the ignition safety shutoff device, close the manual The Encore ha a display that indicates the sequence shutoff valve 1 (Figure 21) in the gas supply line. Within of operation, Figure 22.
Page 45: Maintenance
Encore Stainless Steel Condensing Boilers – 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 sensor, close the ball valve installed upstream...
Page 46: Pressure Switches
Encore Stainless Steel Condensing Boilers – Installation Manual Figure 27 - Pressure Switches...
Page 47: Wiring
Encore Stainless Steel Condensing Boilers – Installation Manual Figure 28 - 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 48: Repair Parts
Encore Stainless Steel Condensing Boilers – Installation Manual Exploded View VIEW "A & B" VIEW "C" VIEW "D & E" VIEW "H" VIEW "G" VIEW "F" Heat Exchanger Parts Breakdown...
Page 49 Encore Stainless Steel Condensing Boilers – Installation Manual Exploded View Models Models Models 350 to 400 500 & 725 to 800 only only only Models 350 to 500 only...
Page 50 Encore Stainless Steel Condensing Boilers – Installation Manual Exploded View Models 600 to 800 only...
Page 51 Encore Stainless Steel Condensing Boilers – Installation Manual Exploded View 108A...
Page 52 Encore Stainless Steel Condensing Boilers – Installation Manual Exploded View...
Page 53 Encore Stainless Steel Condensing Boilers – Installation Manual Encore Repair Parts List Model Size with Quantities Below Ref # Name of Part Part # Assembly, Front Upper Front Door Panel 75-0816-001 Assembly, Front Lower Door Panel 75-0818-001 Assembly, Front Bottom Jacket Panel 75-0819-001 Assembly, Side Jacket Panel 03-4526-001...
Page 54 Encore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part # Weldment, Blower to Upper Cover Adaptor 74-1203-001 Air Diverter, Blower 03-4821-001 30-4821-002 Insulation, Heat Exchanger Top 05-0606-001 05-0606-002 Insulation, Heat Exchanger Shell 05-0607-001 05-0607-002 Gasket, Air Diverter...
Page 55 Encore Stainless Steel Condensing Boilers – Installation Manual Model Size with Quantities Below Ref # Name of Part Part # Fuse Block Cover, Class CC 48-0690-002 Fuse, 15A, LP-CC 48-0627 Fuse, 20A, LP-CC 48-0639 LWCO & Bracket 75-0030-001 Touch Screen w/Enclosure 40-0091-002 Latch, Quarter Turn 20-0042...
Page 56: Start-Up
Encore Stainless Steel Condensing Boilers – Installation Manual START-UP REPORT START-UP REPORT DATE: DATE: JOB NAME: JOB NAME: TECHNICIAN: TECHNICIAN: LOCATION: LOCATION: COMPANY: COMPANY: MODEL: MODEL: PHONE NUMBER: PHONE NUMBER: SERIAL #: SERIAL #: PRE-STA PRE-STA T T RTUP CHECK LIST T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT NO VISIBLE DAMAGE TO UNIT...
Page 57 Encore Stainless Steel Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS MINIMUM FIR N I G RATE 1 00% FIR N I G RATE GAS INLET PRESSURE (WC) INCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC INCHES WC...
Page 58: Mass Code
Encore 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 59: Warranty
Encore Stainless Steel Condensing Boilers – Installation Manual Encore Series Water Boiler LIMITED WARRANTY One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the Encore 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 60 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada  Phone: (413) 564-5515 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...

This manual is also suitable for:

Encore rb0400 Encore rb0500 Encore rb0600 Encore rb0725 Encore rb0850