RBI Water heaters Installation And Operation Instructions Manual

Finned copper tube gas boilers (cb), & water heaters (cw) & pool heaters (cp)

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Th is manual is intended only for use by a qualifi ed 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. Th e 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.

Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service

technician, and to follow all guidelines in the User' s Information Manual.

Finned copper tube

Gas boilers (CB), &

Water heaters (CW) &

Pool heaters (CP)

Boiler manual

Installation and operation

instructions

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Summarization of Contents

Finned copper tube Gas boilers & Water heaters - Boiler Manual

Boiler Manual: Installation and Operation Instructions

Comprehensive guide for applying, installing, operating, and maintaining Futera Series boilers and water heaters.

Critical Safety Warnings for Installers

Manual is for qualified installers; failure to follow instructions can cause severe injury, death, or damage.

Before You Start

Pre-Operation Safety Guidelines

Includes handling flammable vapors, gas leak procedures, and importance of proper venting for safety.

Boiler/Water Heater Installation Requirements

Covers essential prerequisites like qualified installation, gas safety, and venting for safe operation.

Installation Requirements and Guidelines

Ratings and Capacities

Check unit sizing, gas type, electrical supply, combustion air, and vent system for proper installation.

Boiler/Water Heater Location Selection

Guidelines for choosing an optimal site, considering access, clearances, structural support, and environmental factors.

Combustion Air and Ventilation

Ensures adequate air supply for combustion, critical for preventing carbon monoxide buildup and ensuring safety.

Combustion Air Supply and Ventilation Requirements

Air Quality and Contamination Risks

Avoids combustion air contamination from chemicals or construction dust to prevent damage and warranty voidance.

Air Supply Options for Confined Spaces

Details requirements for air intake from inside or outside the building, including duct sizing and openings.

Outdoor Air Intake Guidelines

Specifies requirements for intake air from outdoors, including minimum free area calculations for ducts and openings.

Venting System Options and Guidelines

General Venting Requirements

Ensures proper venting to prevent carbon monoxide, complying with codes and preventing severe injury or death.

Category IV Venting Systems

Details direct, side wall, and vertical positive pressure venting options for Category IV appliances.

Category II Venting for Common Systems

Explains requirements for negative pressure venting, typically used for common venting of multiple boilers.

Direct Vent System Configurations

Horizontal Direct Vent Systems

Covers material requirements, installation, clearances, and termination for horizontal direct vent systems.

Vertical Direct Vent Systems

Details requirements for vertical direct vent systems, including terminal height and roof penetration.

Combination Direct Vent Systems

Describes venting vertically with horizontal intake, following specific guidelines for air and general venting.

Alternative Venting System Configurations

Side Wall Venting

Details side wall venting, requiring combustion air from the space and following horizontal vent guidelines.

Vertical Venting with Metal Chimney

Covers vertical venting into a metal chimney system, including requirements for masonry chimneys.

Vertical Chimney Venting (Negative Pressure)

Addresses Category II venting for multiple boilers using a common vent, requiring negative pressure and a metal chimney.

Chimney and Outdoor Venting Procedures

Category II Chimney Inspection and Sizing

Guidelines for inspecting and sizing Category II chimneys, including minimum riser sizes and clearance requirements.

Category II Vent Connections

Details on connecting Category II vents, emphasizing proximity to chimney, slope, and clearances to combustibles.

Outdoor Venting Requirements

Covers installation requirements for outdoor units, including hood, air adapter, terminal placement, and protection from elements.

Piping and System Component Requirements

General Piping Requirements

Emphasizes proper piping to avoid warranty voidance and ensure boiler failure prevention, addressing water hardness and flow rates.

Freeze Protection Measures

Precautions for installations in freezing areas, including continuous flow, antifreeze mixture, and draining procedures.

Condensate and Relief Valve Piping

Details on routing condensate and relief valve discharge to prevent hazards and ensure proper system operation.

Heating System Piping and Pump Configuration

Flow Switch Installation and Function

Ensures proper water flow for boiler operation; incorrect installation can damage the heat exchanger.

General Heating System Piping Rules

Covers installation standards, clearances, minimum pressure, and system expansion considerations.

Pump Requirements and Operation

Details pump sizing, flow rates, temperature rise limits, and delay functions for optimal boiler performance.

Expansion Tank and Air Separation

Specifies the need for expansion tanks and air separators to manage thermal expansion and trapped air.

Domestic Water Supply Piping and Chemistry

Domestic Water Supply Piping

Proper controls and components are needed to prevent scalds and ensure safe domestic water supply.

Water Chemistry and Heat Exchanger Selection

Addresses water hardness, pH, and dissolved solids impact on heat exchangers and pump selection.

Pump Requirements for Water Heaters

Ensures continuous minimum water flow for heater efficiency and longevity, preventing erosion or scaling.

Gas Supply Piping and Capacity

Gas Supply Piping Requirements

Ensures correct gas type, compliance with codes, and proper pipe sizing for safe and effective operation.

Gas Pipe Capacity and Sizing

Provides tables for sizing gas piping based on pipe length and capacity for natural and propane gas.

Gas Supply Connection Diagram

Illustrates the proper connection of the boiler to the gas supply piping, including shut-off valves and sediment traps.

Electrical Wiring and General Operation

Electrical Power Connections

Details wiring standards, shut-off switch requirements, grounding, and wire sizing for safe electrical connections.

General Operation and Safety

Emphasizes reading instructions, understanding safety warnings, and procedures for emergency shutdown.

Hydronic Boiler Filling Procedure

Step-by-step process for filling the boiler and system with water, purging air, and setting system pressure.

Operating Instructions and Safety Procedures

Pre-Operation Checklist and Safety

Essential steps before operation, including reading safety info, checking for gas leaks, and handling emergencies.

Step-by-Step Operating Instructions

Detailed sequence for starting the boiler, including setting controls, purging gas, and checking flame.

Emergency Shutdown Procedures

Instructions on how to turn off the gas supply to the appliance in case of malfunction or emergency.

Boiler Sequence of Operation and Shutdown

Startup Sequence Overview

Describes the operational steps from no demand to pilot run and main run phases for boiler ignition.

Boiler Shutdown Procedures

Outlines steps to turn off the gas supply and electrical power to the boiler for maintenance or shutdown.

Operational States: Demand and No Demand

Explains boiler states like Standby, Pre-Purge, Main Run, and Post-Purge based on heating demand.

Checking and Adjusting Boiler Settings

Spark Gap Adjustment

Procedure for checking and adjusting the spark gap for strong and continuous ignition.

Pilot Pressure Adjustment

Steps to check and adjust pilot pressure using a manometer for correct ignition.

Gas Pressure and Input Rate Verification

Ensuring correct gas pressure and input rate, including calculations for altitude adjustments and gas meter readings.

Control System Description and Diagnostics

Boiler Control Components Explained

Describes Low Water Cutoff, Operating Control, High Limit Aquastat, and Flow Switch functions.

Status Screen Fault Display

Explains how the display indicates operational status, faults, and error messages for troubleshooting.

High Limit and Interlock Faults

Details High Limit trips and spare interlock inputs, their display messages, and connection locations.

Boiler Fault and Error Code Diagnostics

Common Boiler Faults and Alarms

Explains faults related to Variable Frequency Drive, Flow Switch Error, Gas Pressure, Ignition Control, and IRI Alarm.

Interlock Spare Faults and Usage

Describes the function and usage of spare interlock inputs for future expansion or field interlocks.

Advanced Boiler Fault and Warning Conditions

Combustion Air Damper Faults

Covers faults related to the combustion air damper, including proof switch issues and clearing procedures.

Sensor Faults and Temperature Warnings

Details faults for shorted or open sensors, and warnings for high temperature differentials or low return temperatures.

Delta T and Return Temperature Limits

Explains protection mechanisms for high temperature differentials and implications of low return temperatures.

Boiler Maintenance and Component Cleaning

General Maintenance Precautions

Safety warnings for disconnecting power and gas before maintenance; service by trained technicians.

Burner Removal and Inspection

Step-by-step guide for removing the burner assembly for cleaning, inspection, or replacement.

Heat Exchanger Cleaning and Repair

Procedures for cleaning, inspecting, repairing, or replacing the heat exchanger, including tube replacement.

Air Intake and Vent System Inspection

Instructions for inspecting air intake, vent systems, and air filters for blockages, corrosion, or leaks.

Control Operation and Burner Flame Monitoring

Review of Boiler Controls

Reiterates checking controls, flushing LWCO, flow switch contacts, relief valve, and aquastat settings.

Pilot and Main Burner Flame Inspection

Visual check of pilot and main burner flames for proper operation, noting yellow flame indicates combustion air issues.

Troubleshooting Startup Issues

Diagnosing Tripped Interlocks

Guides on identifying and resolving tripped 24 VAC and 120 VAC interlocks and internal alarms using a multimeter.

Internal Alarm Checks and Sensor Voltages

Covers checks for open/shorted sensors and combustion air damper issues, including voltage measurements.

Repair Parts Identification

Overview of Repair Parts Diagram

Diagram showing various components of the boiler system for identification purposes.

Detailed Repair Parts Views

Repair Parts View A Components

Illustrates specific repair parts, including control panels and electronic modules, with reference numbers.

Repair Parts View B Components

Shows various plumbing and gas components, such as valves and regulators, with corresponding reference numbers.

Boiler Start-Up and Commissioning Report

Pre-Startup Checklist

Ensures all essential checks are completed before initiating boiler startup procedures.

Boiler Startup Sequence Steps

Detailed steps for safely starting the boiler, including disabling calls for heat and checking flame stability.

Recording Startup Parameters

Instructions for recording combustion and manifold pressure at minimum and maximum firing rates.

Commissioning and Combustion Analysis

Combustion Analysis and Safety Tests

Guides on performing combustion analysis, checking safety controls, and verifying piping/control integrity.

Commissioning Procedures and Delta T

Covers final checks, customer instruction, and critical Delta T readings before completing installation.

Massachusetts Specific Installation Requirements

Massachusetts Installation Notice

Installation must be by licensed plumber/gas fitter; details requirements for carbon monoxide detectors and signage.

Venting and Carbon Monoxide Safety

Highlights requirements for proper venting to prevent excessive carbon monoxide levels, ensuring severe personal injury or death prevention.

Limited Warranty Information

Warranty Coverage Details

Specifies warranty periods for heat exchangers and other parts, excluding damage from misuse or improper installation.

Warranty Exclusions and Conditions

Outlines conditions that void the warranty, such as improper maintenance, chemical damage, or external factors.