RBI Dominator Series Installation & Operating Instructions Manual
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RBI Dominator Series Installation & Operating Instructions Manual

Finned copper tube gas boilers & water heater
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See also: Operation & Installation Manual
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 (DB) &
Water heaters (DW)
Boiler  manual
Installation and operation
instructions
Construction dust and particulate, particularly drywall dust, will cause contamination
DOM-I0M-7
82-0262
01/10 Copyright 2008 Mestek, Inc.

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  • Page 1 DOM-I0M-7 82-0262 Finned copper tube Gas boilers (DB) & Water heaters (DW) Boiler  manual Installation and operation instructions 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.

  • Page 2: Table Of Contents

    • Si vous ne purvez rejoindre le fournisseur, appelez le This manual covers the application, installation, operation and service des incendies. maintenance of a Dominator Series finned copper heating boiler/ water heater/(pool heater- Canada only). L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié...

  • Page 3: Ratings & Capacities

    3. Ensure that the floor is structurally sound and will support the Direct all questions to your RBI distributor or contact the weight of the boiler/water heater. RBI Customer Service Department, 260 North Elm Street, Westfield, MA 01085 for U.S.
  • Page 4 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il To operate properly and safely this boiler/water heater requires a Never operate the Dominator in an environment continuous supply of air for combustion. NEVER store objects on subjected to a negative pressure unless the air intake or around the boiler/water heater! is connected to the outdoors.
  • Page 5 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Vertical Venting using a Masonry Chimney and Inside Air Figure 2 Horizontal Venting using Inside Air Figure 3 1/4 IN. PER F00T 20 mm/m 1.5 FT 0.5 m Table 2 MINIMUM VERTICAL RISE...
  • Page 6 The certified combustion air terminal from burners, there shall be a permanent air supply opening(s) having RBI must be used and installed as shown in Figures 4 and 5. a cross-sectional area of not less than 1 in...
  • Page 7 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Horizontal Combustion Air and Venting for a Single Unit Figure 4 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 1.5 FT 0.5 m 2000 &...
  • Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Vertical Combustion Air and Venting, Metal Chimney System Shown Figure 6 Locate exhaust terminal downwind from air intake to reduce potential for fl ue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m...

  • Page 9: General Venting Guidelines

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il GENERAL VENTING GUIDELINES VENT SYSTEM OPTIONS The Dominator may be vented the following ways: The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas 1) Vertical/Chimney Venting, Negative Pressure, Category Code, ANSI Z223.1/NFPA 54-latest revision or I - uses an approved metal chimney system or properly lined...

  • Page 10: Vertical/Chimney Venting

    Pipe Diameter to UL 1738 for installations in the United States, ULS636 for Model Size installations in Canada. The certified vent terminal from RBI must 300 - 400 also be used. The maximum equivalent length for the horizontal vent and combustion air pipes is 35 ft, 10.7 m for each.

  • Page 11: Outdoor Venting

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Horizontal vent systems shall terminate at least 4 ft, 1.2 m below, Horizontal vent systems shall terminate at least 4 ft, 1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft, 0.3 m above any door, window 4 ft, 1.2 m horizontally from or 1 ft, 0.3 m above any door, window or gravity air inlet into any building.

  • Page 12: Common Vent Systems

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il COMMON VENT SYSTEMS Outdoor Venting Figure 8 If an existing boiler/water heater is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it.

  • Page 13: General Piping Requirements

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il e) Test for spillage at the draft hood relief opening aft er 5 minutes GENERAL PIPING REQUIREMENTS of main burner operation. Use the fl ame of a match or candle, or smoke from a cigarett e, cigar or pipe.

  • Page 14: Relief Valve

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Relief Valve Table 7 Temperature Rise Table Pipe the discharge of the pressure relief valve to prevent scalding in ΔT = 15°F ΔT = 8.3°C the event of a discharge, see Figure 10.

  • Page 15: Heating System Piping

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il HEATING SYSTEM PIPING Expansion Tank & Air Separator An expansion tank or other means to control thermal expansion must be installed in the heating system. An expansion tank must General Piping Requirements be installed close to the boiler on the suction side of the pump.
  • Page 16 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Typical Primary/Secondary Piping Figure 11 (See Notes) Pump Gate Valve Globe Valve Angle Valve NOTES: 1. Boiler circuit piping must be sized Bufferfly Valve large enough to handle maximum fl ow through unit.
  • Page 17 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Low Temperature Piping Figure 12A (See Notes and Adjustment Procedures) Pump Gate Valve Globe Valve NOTES: Angle Valve 1. Boiler circuit piping must be sized large enough to handle Adjustment Procedure Bufferfly Valve...

  • Page 18: Domestic Water Supply Piping

    Households with small children may require water temperatures less than RBI water heaters are designed to run scale free. Due to the extreme 120°F, 49°C. Local codes must be complied with! variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling.
  • Page 19 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Table 8A Dominator Heat Exchanger Selection Graph Table 8B Dominator Pumping Performance Requirement...

  • Page 20: Expansion Tank

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il A balancing valve should be installed on the outlet side of the water Expansion Tank heater for purposes of adjusting the fl ow rate through the heat An expansion tank or other means to control thermal expansion exchanger.
  • Page 21 Angle Valve D-1 Rev 6 Bufferfly Valve Aquastat Union Balance Valve Pressure Switch Attention: Not all RBI stock storage tanks incorporate this tapping: See Note 1. Ball Valve Gas Pressure Regulator Multiple Water Heating Piping (DW Models only) Figure 15...

  • Page 22: Gas Supply Piping

    If for any reason the boiler/water heater is not for the tighten the piping entering the gas valve body or gas type of gas available at the installation site, call your RBI representative valve failure may result! to resolve the problem.

  • Page 23: Electrical Wiring

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il ELECTRICAL WIRING GENERAL OPERATION Before proceeding read and fully understand the instructions contained in this manual. Do not att empt Electrical Power Connections to operate this boiler/water heater if it has not been Label all wires prior to disconnection when servicing installed in accordance with the guidelines set forth in controls.

  • Page 24: Boiler/Water Heater Operation

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il BOILER/WATER HEATER OPERATION Pressure Switch Settings Diff erential pressure switches are provided in the Dominator to shut down gas fl ow under a blocked fl ue or inlet condition. One low fi re Staging Operation and one high fi re pressure switch are used for the 300 through 900 models.

  • Page 25: Operation Sequence, 2 Stage D300 Through D900

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il On the four stage units, the left low fi re and high fi re switches OPERATION SEQUENCE, 2 STAGE will interrupt power to the control module under a blocked fl ue or D300 THROUGH D900 inlet condition.

  • Page 26: Operation Sequence, 4 Stage D1050 Through D2100

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 6. If the second ignition att empt is unsuccessful the gas valves will High Limit, Low Water Flow, Low Gas Pressure, High Gas lockout, but the blower, pump and power venter will remain Pressure, Power Venter Interlock Faults on.
  • Page 27 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Ignition Trial: Demand Satisfi ed: 1. Once energized, the fl ame sense module (FSM) initiates 4 sec- 1. Stage switch 1 opens, TDR1 de-energizes. ond diagnostic cycle before sending 24V ac to the PV terminal 2.

  • Page 28: Operating Instructions

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il C. Do not use this appliance if any part has been under water. OPERATING INSTRUCTIONS Immediately call a qualifi ed service technician to inspect the FOR YOUR SAFETY READ BEFORE OPERATING appliance and to replace any part of the control system and any gas control that has been under water.

  • Page 29: Instructions De Mise En Marche

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 11. Turn the knob on the pilot valve to on, Figure 18. Table 19 Pilot & Manifold Settings 12. Turn the knob on the main gas valve to on, 300 and 400 models, Natural Gas Figure 18.

  • Page 30: Pilot Adjustment

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il CHECKING & ADJUSTMENTS Pilot Adjustment Th e pilot burner is actually an isolated main burner that 1. With the burners in operation, close the manual shutoff valve in stages with the other burners.

  • Page 31: Control Description

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il NATURA L GAS: Optimum results are obtained when the boiler/ Operating Control water heater is operated with the manifold pressure(s) set per Table Th e preferred control sett ing for potable hot water is 130°F, 54°C. 19.
  • Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Mode 2: Setpoint control. Dominator piped in primary/ Relay Board secondary confi guration. An additional system sensor is required Th e relay board is located in the control tray. It provides sequencing to properly control the system supply (primary loop) temperature.

  • Page 33: Maintenance

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il OUTDOOR RESET WITH DHW OPERA TION - A DHW Th e ceramic combustion chamber contains crystalline tank controlled by a pump provides reset override whenever silica.
  • Page 34 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 8. If there are no signs of damage, sooting or corrosion reassemble 10. Remove the "V" baffl e straps and "V" baffl es. the unit following the previous steps in reverse order. 11.

  • Page 35: Vent System

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 5. Th e aquastat high limit controls the maximum water Heat Exchanger Upper Rail Screws Figure 21 temperature in the boiler. It should be set at least 20°F, 11°C above the operator setpoint.
  • Page 36 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il TROUBLE-SHOOTING PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION No Power To Unit Power not connected Wire unit to line voltage External circuit breaker open Reset breaker Relay board fuse (24V) blown Replace fuse Transformer circuit breaker open (4 stage)

  • Page 37: Trouble-Shooting

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il TROUBLE-SHOOTING PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Unit Sparks But Will Not Fire Low gas pressure Check gas supply pressure, adjust as necessary Pilot valve manual knob closed Open pilot valve manual knob Pilot wires disconnected Reconnect wires...

  • Page 38: Repair Parts

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS Replacement Parts Figure 23...
  • Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Jacket Lower Front Panel 70-2716 70-2717 70-2718...
  • Page 40 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Jacket Left Side Panel 03-1822 Jacket Left Side Panel (SS) 03-1822.1...
  • Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Jacket Top Panel 03-1801 03-1802 03-1803...
  • Page 42 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Jacket Base Panel 03-1847 03-1848 03-1849...
  • Page 43 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Comb Chamber Lower Left Side Panel 70-2772 Comb Chamber Lower Right Side Panel 70-2773...
  • Page 44 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Flue Outlet Assembly 70-2736.1 70-2737.1 70-2738.1...
  • Page 45 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Pilot Orifi ce, NG 10-0089 Pilot Orifi ce, LP 10-0090...
  • Page 46 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Heat Exchanger Assembly (Cupronickel) 70-2836 Cast Iron Headers 70-2838...

  • Page 47: Start Up Form

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 O Ring, Inlet/Outlet & Return Headers 06-0001 Stud, Inlet/Outlet &...
  • Page 48 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 High Gas Pressure Switch (Manual Reset) 11-0411 Main Board Assembly (2 Stage) 70-2925...
  • Page 49 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 900 1050 1350 1500 1950 2100 Barometric Damper 6” 09-0405 Barometric Damper 7”...
  • Page 50 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 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...
  • Page 51 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS PRESSURE AT ELBOW TEST POR T INCHES W.C .

  • Page 52: Installation Requirements

    Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels of tion must be performed by a licensed plumber or gas carbon monoxide which can cause severe personal fi tter.
  • Page 53 Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. 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.
  • Page 54 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il...
  • Page 55 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il...
  • Page 56 260 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 www.rbiwaterheaters.com Copyright 2008 Mestek, Inc.

This manual is also suitable for:

Dominator 300Dominator 400Dominator 1500-2100Dominator 600Dominator 750-900Dominator 1050-1350 ... Show all

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