RBI 8900 Series Installation & Operation Manual

RBI 8900 Series Installation & Operation Manual

Finned copper gas boilers (model hb) & water heaters (model hw)

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SERIES 8800 & 8900 FINNED COPPER
GAS BOILERS (MODEL HB) &
WATER HEATERS (MODEL HW)
INSTALLATION & OPERATION MANUAL
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL
CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI,
1103 kPa WATER.
WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.
WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
260 North Elm Street
7555 Tranmere Drive
Westfi eld, MA 01085
Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571
Phone: (905) 670-5888
Fax: (413) 568-9613
Fax: (905) 670-5782
CIOM-8
82-0252
42-9134 R
05/10

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Summary of Contents for RBI 8900 Series

  • Page 1 CIOM-8 82-0252 42-9134 R SERIES 8800 & 8900 FINNED COPPER GAS BOILERS (MODEL HB) & WATER HEATERS (MODEL HW) INSTALLATION & OPERATION MANUAL DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
  • Page 2: Table Of Contents

    8900 fi nned copper heating boiler/water heater/pool MUST FOLLOW the additional instructions contained in heater. RBI's instruction sheet MACODE-3. If you do not have a copy, call your RBI distributor or contact the RBI Customer To obtain the safe, dependable, effi cient operation and Service Department.
  • Page 3: Ratings & Capacities

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 3 Direct all questions to your RBI distributor or contact the 2. An optimum site will be level, central to the piping RBI Customer Service Department, 260 North Elm Street, system, close to a chimney and have adequate fresh Westfi...
  • Page 4: Combustion Air & Ventilation

    Page 4 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS COMBUSTION AIR & VENTILATION All Air From Inside The Building If the boiler/water heater is to be located in a confi ned space minimum clearances listed in Table 1 or 1A must WARNING: This boiler/water heater must be be maintained between the boiler/water heater and any supplied with combustion air in accordance with...
  • Page 5 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 5 Table 2 - Make-up Air Louver Sizing Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum Required Cross Sectional Area free area of 1 in /2000 Btu/hr, 1100 mm /kW of the total Input...
  • Page 6 Page 6 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Figure 2 - Vertical Venting Using A Masonary Chimney And Inside Air (8900/8800 Series) 10 FT 3.1 m 3 FT 1 m 3 FT 1 m 5 FT 1.52 m RIOM-41 Figure 3 - Dual Flue Outlets And Inside Air (8900/8800 Series) 2 FT .6 m...
  • Page 7 3 FT 1 m 3 FT 1 m 5 FT 1.52 m RIOM-43 Figure 4A - Common Vents and Inside Air (8800/8900 Series) Dual Flue 10 FT 3.1 m 3 FT 1 m 3 FT 1 m 5 FT 1.52 m...
  • Page 8: Chimney & Vent Pipe Connections

    Page 8 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS CHIMNEY & VENT PIPE When more than one appliance is connected to the same chimney fl ue, the fl ue must be large enough to CONNECTIONS safely vent the combined output of all the appliances. WARNING: The vent installation must be in WARNING: If an appliance using any type of a accordance with Part 7, Venting of Equipment, of...
  • Page 9: Common Vent Systems

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 9 vitesse maximale. Ne pas faire fonctionner les COMMON VENT SYSTEMS ventilateurs d’été. Fermer les registres des If an existing boiler/water heater is removed from a cheminées. common venting system, the common venting system may then be too large for the proper venting of the d) Place in operation the appliance being inspected.
  • Page 10: General Piping Requirements

    Page 10 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS CAUTION: Failure to properly install the fl ow switch GENERAL PIPING REQUIREMENTS may result in damage to the boiler/water heater heat exchanger voiding the warranty! CAUTION: Improper piping of this boiler/water heater will void the manufacturer’s warranty and can cause HEATING SYSTEM PIPING boiler failure resulting in flooding and extensive...
  • Page 11 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 11 Table 6A - Temperature Rise Table — 2 Pass Headers 20°F 11.1°C 25°F 13.9°C 30°F 16.7°C 35°F 19.4°C Flow Press Flow Press Flow Press Flow Press Flow Press Flow Press Flow Press Flow...
  • Page 12 Page 12 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Low Water Cutoff Low Return Water Temperatures If a boiler is installed above any radiation elements it To prevent the problems associated with condensation must be fi tted with a low water cutoff device. of the products of combustion due to low return water temperatures a primary/secondary piping system with Refer to the wiring diagram supplied with the boiler/...
  • Page 13 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 13 Figure 7 - Typical Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. Boiler circuit piping must be sized large enough to handle maximum fl ow Balance Valve through unit.
  • Page 14 Page 14 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Figure 8A - Low Temperature Piping with Thermostatic Valve (See notes and adjustment procedures) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. For pump selection consult factory. 2.
  • Page 15: Domestic Water Supply Piping

    Tables 6A and 6B. General Piping Requirements Ensure that the water heater is equipped with bronze RBI water heaters are designed to run scale free. Due headers. Piping and components connected to the water to the extreme variables of water conditions world wide heater must be suitable for use with potable water.
  • Page 16 Page 16 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Pump Requirements installed on both the inlet and outlet of the water heater This low-mass water heater requires a continuous mini- for determining the temperature rise through the unit. mum water flow for proper operation. The factory recommended circulating pump has been sized to The proper velocity through the water heater must be overcome the head loss of the water heater plus a 30...
  • Page 17 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 17 Table 7B - 8900 Pumping Performance Requirement Table...
  • Page 18 Page 18 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Table 7B - 8800 Pumping Performance Requirement Table...
  • Page 19 Bufferfly Valve Balance Valve D-1 Rev 6 Ball Valve Attention: Motorized Valve Not all RBI stock storage tanks incorporate this tapping: See Note 1. Solenoid Operated Valve Figure 11 - Multiple Water Heating Piping (HW Models Only) (See Notes) Self-Operated...
  • Page 20: Gas Supply Piping

    Notes: 1. For fl ow through branch. boiler/water heater is not for the type of gas available at 2. For fl ow at full open. the installation site, call the nearest RBI representative CAUTION: Always use a square jawed wrench on the to resolve the problem.
  • Page 21: Electrical Wiring

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 21 Whenever the gas supply piping is pressure tested the GENERAL OPERATION boiler/water heater gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, WARNING: Before proceeding read and fully 3.5 kPa isolate the boiler/water heater by closing it’s understand the instructions contained in this...
  • Page 22: Operating Instructions

    Page 22 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Shut the boiler off and open the bleed valves to purge QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: • Ne pas tenter d’allumer d’appareil. the air trapped in the heating system piping. Close the •...
  • Page 23: Checking & Adjustments

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 23 Required Gas Pressure To Turn Off Gas To Appliance Provide gas supply pressure at inlet to boiler gas train 1. Set the operating control or thermostat to its lowest as follows: setting.
  • Page 24 Page 24 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Pilot Adjustment PROPANE GAS: Optimum results are obtained when The pilot burner fl ame should envelope 3/8" to 1/2" of the boiler/water heater is operated with the manifold the fl ame sensing probe, Figure 13. To adjust the pilot pressure(s) set per Table 10.
  • Page 25: Control Description

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 25 High Limit (Aquastat) CONTROL DESCRIPTION The high limit is located in the top control area of the boiler/water heater. A remote capillary bulb is run to a Boiler Thermostat well on the outlet side of the supply header. The high If a thermostat is to be used to control the boiler always limit can be reset by depressing the black rubber plug follow the instructions included with the thermostat.
  • Page 26: Maintenance

    Page 26 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS MAINTENANCE Combustion Chamber Inspection 1. Remove the left or right lower jacket end panel, item 5 or 24 (8900) or item 5 or 24 (8800). WARNING: Disconnect electrical power and 2.
  • Page 27 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 27 9. The outside surfaces of the copper tubes should be 4. The relief valve should not weep or discharge free of any soot deposits. A slight black smudge is water at normal system pressure. If it does contact normal with some types of gases.
  • Page 28: Trouble-Shooting

    Page 28 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS TROUBLE-SHOOTING FLOW CHART FOR HONEYWELL OR UTC IGNITION MODULE (24V CONTROL SYSTEM) Proper line voltage Check for tripped breaker or open safety L1 to L2 on heater / limit switch in supply voltage circuit. terminal strip Check for broken or loose 24V on secondary...
  • Page 29 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 29 Trouble-Shooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Boiler Pounds or Knocks Low or no water flow Ensure that pump is operating properly - look for voltage through fl ow switch. Ensure that all system valves are open.
  • Page 30: Repair Parts, 8900

    Page 30 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS PARTS LIST (MODELS 420-1900)
  • Page 31 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 31 SERVICE AND REPLACEMENT PARTS LIST (MODELS 420-1900) 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Jacket Lower Front Panel 03-0077 03-0078...
  • Page 32 Page 32 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Base Frame Assembly 70-0192 70-0193...
  • Page 33 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 33 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Valve Body, V5055B, 1"...
  • Page 34 Page 34 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Upper Front Refractory Channel 70-0177 70-0178...
  • Page 35 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 35 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Jacket Upper Front Panel 03-0043 03-0044...
  • Page 36 Page 36 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Heat Exchanger Assembly (Copper) 70-0072 Cast Iron Headers...
  • Page 37 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 37 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 Tube Bundle (Copper) 70-0132 70-0133...
  • Page 38 Page 38 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8900 8900 Model Size with Item Quantities Below Ref # Name of Part Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900 High Gas Pressure Switch (Manual Reset) 11-0411 Terminal Block 2P...
  • Page 39: Repair Parts, 8800

    SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 39 PARTS LIST (MODELS 2000-4000)
  • Page 40 Page 40 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS SERVICE AND REPLACEMENT PARTS LIST (MODELS 2000-4000) 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Jacket Lower Front Panel 03-1077 03-1078 03-1079...
  • Page 41 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 41 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Safety Valve, V88A, 1 1/2" 11-0158 Safety Valve, V88A, 2" 11-0159 Safety Valve, V48A, 1 1/2", 120V 11-0365...
  • Page 42 Page 42 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Jacket Top Panel (Dual Flue) 03-1057 03-1058 03-1059 03-1060 03-1061 03-1062 Jacket Top Channel, Left &...
  • Page 43 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 43 8800 8800 Model Size with Item Quantities Below Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000 Low Gas Pressure Switch (Manual Reset) 11-0410 High Gas Pressure Switch (Manual Reset) 11-0411 Terminal Block 2P 48-0151...
  • Page 44 Page 44 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi...
  • Page 45 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 45 MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fi tter. (b) Exemptions The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1.
  • Page 46 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. The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in...
  • Page 47 SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 47...
  • Page 48 260 North Elm Street 7555 Tranmere Drive Westfi eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782...

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8800 series

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