RBI Boiler Installation And Operation Instructions Manual
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RBI Boiler Installation And Operation Instructions Manual

Condensing, high effi ciency water heaters (iw) and boilers (ib)
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This 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. Construction dust and particulate, particularly drywall dust, will cause 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.
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.
Condensing,
High Effi ciency
Water Heaters (IW)
and Boilers (IB)
Boiler Manual

Installation and Operation

Instructions
62403588 R00 Feb. 18, 2014
IE2-IOM-1
82-0147

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Summary of Contents for RBI Boiler

  • Page 1: Installation And Operation

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

  • Page 2: Safety Instructions

    SAFETY INSTRUCTIONS WARNING: If the information in these instructions is not followed exactly, a fi re or explosion may result causing property damage, personal injury or death. - Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
  • Page 3 SAFETY INSTRUCTIONS...
  • Page 4 SAFETY INSTRUCTIONS AVERTISSMENT: Assurez vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort - Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides infl...
  • Page 5 SAFETY INSTRUCTIONS...
  • Page 6 SAFETY INSTRUCTIONS NOTICE! Local approval of the fl ue WARNING!!! WARNING!!! system and the condensate Flue gas/air connection to the public sewer Installer: Read all instructions, intake: You are only permitted system may be required. including this manual, before to operate this appliance with installing.
  • Page 7 SAFETY INSTRUCTIONS WARNING!!! ATTENTION!!! WARNING!!! WARNING!!! En cas de When Only use the surchauffe ou si l’alimentation servicing heater, to avoid severe heater in the combinations and de gaz ne peut être coupée, burns, allow heater to cool with the accessories and spares ne pas couper ni débranch before performing maintenance.

  • Page 8: Table Of Contents

    4.1.1 Intended use and functions of the IB boiler ........................ 29 4.1.2 Intended use and functions of the IW water heater ....................29 4.2 - Effi ciency up to 98% (IB boiler only) ........................29 5 - INSTALLATION - Location ......................30 5.1 - Choosing the installation location ........................
  • Page 9 TABLE OF CONTENTS 10.1.5 - Connection to the MODBUS interface........................54 10.2 - Connecting the IB boiler to an indirect water heater ..................55 10.2.1 Indirect water heater priority selection ........................55 10.3 - Connecting the IW water heater to a storage tank ................... 55 10.4 - Connecting the heater in cascade ........................
  • Page 10 14.4 - Start-up procedure ............................96 14.5 - IW supply water temperature adjustment ......................96 14.6 - IB boiler - Indirect water heater temperature adjustment ................. 97 14.7 - IB boiler - Heating temperature adjustment ..................... 97 14.8 - IB boiler - Outdoor reset adjustment ........................ 97 14.8.1 - Outdoor reset applications .............................
  • Page 11 15.13 - 399 to 1000 models wiring diagram ......................120 16 - TECHNICAL DATA .........................124 17 - SPARE PARTS ........................126 18 - READ OUT FLOW CHART ....................148 19 - FACTORY MENU ........................149 20 - SEQUENCE OF OPERATION for BOILER ................152 21 - SEQUENCE OF OPERATION for WATER HEATER .............153...

  • Page 12: Code Requirements

    Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 NOTICE! Install CO detectors per local regulations. NOTICE! IB Boiler version meets the safety and other performance requirements as specifi ed in ANSI Z21.13 standard. NOTICE! IW Water heater version meets the safety and other performance requirements as specifi...

  • Page 13: Commonwealth Of Massachusetts

    1 - CODE REQUIREMENTS owner shall have a period of thirty 2. A complete parts list for the venting 1.2- Commonwealth (30) days to comply with the above system design or venting system. of Massachusetts requirements; provided, however, that (d) MANUFACTURER REQUIREMENTS during said thirty (30) day period, a Installation –...

  • Page 14: General Information

    750 = maximum power input 750,000 Btu/hr (220 kW) and minimum 50,000 Btu/hr (14,7 kW). 1000 = maximum power input 999,000 Btu/hr (292,8 kW) and minimum 50,000 Btu/hr (14,7 kW). IB = Tankless fully modulating, gas-fi red, condensing hot water boiler IW = Tankless fully modulating, gas-fi red, condensing potable water heater...

  • Page 15: Main Components

    3 - MAIN COMPONENTS 12 13 020009.01.004 1 - Air / gas mixing device 10 - Burner unit return connection 2 - Gas valve 11 - Support arrangement 3 - Air intake silencer 12 - Plug (present on BURNER 2, 3 and 4 if any) 4 - High limit temperature safety switch (UL 353 listed) 13 - Water pressure sensor (present on Burner 1 only) 5 - Burner unit supply temperature sensor (par.
  • Page 16 3 - MAIN COMPONENTS 020009.01.005 19 - Burner surface 26 - Return temperature sensor (par. 1007) 20 - Burner unit condesate discharge 27 - Left ignition electrode 21 - Detection electrode 28 - Right ignition electrode 22 - Thermal insulation 29 - Motorized valve body (optional) 23 - Sight glass 30 - Gasket...
  • Page 17 3 - MAIN COMPONENTS 020010.01.027 1 - Levelling feet 12 - Flue exhaust connection 2 - Condensate hose that coming from heater’s fl ue exhaust 13 - Modbus, 0-10Vcc, and cascade communication board 3 - Condensate neutralizer box (Optional) 4 - Heat exchanger 14 - Electrical terminals (Junction box) 5 - Condensate discharge hose 15 - Control panel cover...
  • Page 18 3 - MAIN COMPONENTS 020010.01.028 22 - Top cover 31 - Water Return connection 23 - Main electrical switch 32 - Flue blocked pressure switch pipe connection 24 - Flue blocked pressure switch 33 - Condensate blocked drain magnectic switch 25 - Electrical board 34 - Flue gas manifold cap 28 - Flue gas temperature sensor (Blue color connector)
  • Page 19 3 - MAIN COMPONENTS 020010.01.002 1 - Levelling feet 13 - Modbus, 0-10Vcc, and cascade communication board 2 - Condensate hose that coming from heater’s fl ue exhaust 14 - Electrical terminals 3 - Condensate neutralizer box 15 - Control panel cover 4 - Heat exchanger 16 - Display 5 - Condensate discharge hose...
  • Page 20 3 - MAIN COMPONENTS BURNER 2 BURNER 1 (Master) 020010.01.003 22 - Top cover 31 - Water Return pipe 23 - Main electrical switch 32 - Flue blocked pressure switch pipe 24 - Flue blocked pressure switch 33 - Condensate blocked drain magnetic switch 25 - Electrical Board 34 - Flue gas manifold cap 28 - Burner unit fl...
  • Page 21 42 - Pressure and temperature gauge 43 - Headers (For IW water heaters they are always made in stainless steel. For IB boiler they can optionally made of carbon steel or stainless steel) Figure 3-7 Main components for models 399 and 500...
  • Page 22 3 - MAIN COMPONENTS 020009.01.002 1 - Levelling feet 14 - Electrical terminals 2 - Condensate hose that coming from heater’s fl ue exhaust 15 - Control panel cover 3 - Condensate neutralizer box 16 - Display 4 - Heat exchanger of the “Burner 1” (Master) 17 - Control keys 5 - Condensate discharge hose 18 - Power control boards (the highest power control board is not...
  • Page 23 3 - MAIN COMPONENTS 020009.01.003 BURNER 2 (Not present on model 750) BURNER 1 (Master) BURNER 3 BURNER 4 22 - Top cover 34 - Flue gas manifold cap 23 - Main electrical switch 28 - Burner unit fl ue gas temperature sensor (Blue color connector) 29 - Burner unit high limit fl...
  • Page 24 42 - Pressure and temperature gauge 43 - Headers (For IW water heaters they are always made in stainless steel. For IB boiler they can optionally made of carbon steel or stainless steel) Figure 3-10 Main components for models 750 and 1000...

  • Page 25: Function Overview

    4 - FUNCTION OVERVIEW Key to fi gures 4-1: 1 - Air inlet 2 - Flue exhaust 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit fl...
  • Page 26 4 - FUNCTION OVERVIEW Key to fi gures 4-2: 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit fl...
  • Page 27 4 - FUNCTION OVERVIEW Key to fi gures 4-3 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent (Boiler only) 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor...
  • Page 28 4 - FUNCTION OVERVIEW Key to fi gures 4-4: 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent (boiler only) 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor...

  • Page 29: Intended Use And Functions

    An outdoor air temperature sensor When connecting the water heater The boiler version, is designed to be must also be connected to the boiler for to the storage water heater size the used for central heating system for civil an outdoor reset supply temperature correct circulator pump.

  • Page 30: Installation - Location

    5.1 - Choosing the 5.1.1 Location of an IB WARNING!!! boiler LIQUEFIED installation location PETROLEUM (L.P.) PROPANE When locating the boiler the following GAS-FIRED HEATER factors must be considered: LOCATION REQUIRES  WARNING!!! the location of vent/air intake SPECIAL ATTENTION: 1994 Do not store terminals;...

  • Page 31: Closet And Alcove Installations

    5 - INSTALLATION - Location  NOTICE! Service clearances are not Appliances located in residential WARNING!!! mandatory, but are recommended to garages and in adjacent spaces that Do not ensure ease of service should it be open to the garage and are not part of attempt to install the heater required.
  • Page 32 5 - INSTALLATION - Location Figure 5-2 Recommended minimum clearance distances for proper installation and servicing for model 199 (G = Center of gravity) Figure 5-3 Recommended minimum clearance distances for proper installation and servicing for models 399 and 500 (G = Center of gravity)
  • Page 33 5 - INSTALLATION - Location Figure 5-4 Recommended minimum clearance distances for proper installation and servicing for models 750 and 1000 (G1 = Center of gravity for 1000 model G2 = Center of gravity for the 750 model)

  • Page 34: Installation - Mounting The Heater

    6 - INSTALLATION - Mounting the heater 6.1 - Transporting the heater WARNING!!! Always lift and carry the heater with a hand truck or special equipment. Failure to comply with this provisions could result in severe personal injury, death or substantial property damage.

  • Page 35: Dimensions

    6 - INSTALLATION - Mounting the heater 4. take the two factory supplied eyebolts “A” (Figure 6-3) and install them on the upper side of the heater (see Figure 6-3); 5. Using a proper equipment (check the weight of the unit in Section 16), and lift the unit from the wood pallet and move it to the installation location;...
  • Page 36 6 - INSTALLATION - Mounting the heater 1 = Water supply connection (1” 1/2) 4 = Flue exhaust connection (3”) 2 = Water return connection (1” 1/2) 5 = Gas connection (1”) 3 = Air intake connection (3”) 6 = Condensate hose Figure 6-6 Dimensions for models 199 1 = Water supply connection (2”) 4 = Flue exhaust connection (4”)
  • Page 37 6 - INSTALLATION - Mounting the heater 1 = Water supply connection (2” 1/2) 4 = Flue exhaust connection (6”) 2 = Water return connection (2” 1/2) 5 = Gas connection (1” 1/4) 3 = Air intake connection (6”) 6 = Condensate hose Figure 6-8 Dimensions for models 750 and 1000...

  • Page 38: Installation - Ib Boiler Water Connection

    7 - INSTALLATION - IB boiler water connection of circulator replacement, valves, and 7.1 - IB boiler water CAUTION!!! others. Continual fresh connections make-up water will reduce boiler life. Mineral buildup in the heat Low water cutoff device The boiler comes with the connections...

  • Page 39: Near Boiler Heating Piping Components

    7 - INSTALLATION - IB boiler water connections 2. Boiler system pump: Field supplied. CAUTION!!! CAUTION!!! The system pump MUST be Any additives It is up to the sized to meet the specifi ed fl ow added to the heating system installer to ensure the minimum requirements.

  • Page 40: Relief Valve

    7 - INSTALLATION - IB boiler water connections 7.2.2 - Relief valve This boiler is supplied with a Safety Relief valve installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. Pipe the relief valve discharge like on Figures 7-1 or 7-2 to prevent scalding in the event of a discharge.

  • Page 41: Local Boiler Pump And Ch Pump

    An anti-scald mixing valve is and CH pump pump current draw is grater than 3 mandatory on the domestic hot water This boiler must be fi tted with a local amps. outlet of the indirect water heater pump. To connect the local pump to the boiler see Figures 7-4 and 7-5 7.2.5 - Sizing heating...
  • Page 42 7 - INSTALLATION - IB boiler water connections CAUTION!!! This is a concept drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the...
  • Page 43 7 - INSTALLATION - IB boiler water connections CAUTION!!! This is a concept drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the...

  • Page 44: Installation - Iw Water Connections

    ANSI/ASME could result in a restricted fl ow rate Water heater system piping MUST be Boiler and Pressure Vessel Code, through the water heater. sized considering the pressure drops Section IV. All applicable local 9. Anti-scald mixing valve: Field...

  • Page 45: Temperature And Pressure Relief Valve

    This water heater is supplied with a Safety Temperature and Pressure Relief valve which discharge connection must be piped in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, to prevent scalding in the event of a discharge. 0010.01.008 Pipe the discharge of the safety relief valve like on Figures 8-2 or 8-3.

  • Page 46: Expansion Tank

    8 - INSTALLATION - IW water connections 8.2.6 - Sizing storage 8.2.3 - Expansion Tank 8.3 - Scalding If a water heater is installed in a tank This water heater can deliver scalding closed water supply system, such temperature water at any faucet in the Storage tank can be sized for two as one having a backfl...

  • Page 47: Water Chemistry

    8 - INSTALLATION - IW water connections 8.4 - Water b) If the water is 8 to 18 grain CAUTION!!! Water with a per gallon, this is NORMAL chemistry hardness of less than 5 grains water and you have to size per gallon will usually have a the system for a 4 to 8 ft/sec The water heater pressure drops (see...
  • Page 48 8 - INSTALLATION - IW water connections 1 = Water heater CAUTION!!! This is a concept 2 = Manual gas shut-off valve (Install manual drawing only. It is up to the gas shut-off valve 5 ft (1.5m) above fl oor) system designer to determine 3 = Storage tank Pump (Local pump) the necessary components,...
  • Page 49 8 - INSTALLATION - IW water connections CAUTION!!! This is a concept drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the designer are appropriate, in order to properly size, confi...

  • Page 50: Installation - Condensate Disposal

    9 - INSTALLATION - Condensate disposal 9.1 - Condensate CAUTION!!! The condensate disposal discharge line must be of materials approved by the authority having jurisdiction. In WARNING!!! the absence of other authority, PVC and CPVC pipe must condensate trap is the same comply with ASTM D1785 or condensate neutralizer box D2845.
  • Page 51 9 - INSTALLATION - Condensate disposal A = Pipe connected to the heaters’ fl ue exhaust system B = Condensate neutralizer box C = Condensate drain pipe D = Cover of the box 020010.01.029 Figure 9-1 Condensate neutralizer box (see also Figures 3-3 throgh 3-10, Item 3) A = Condensate drain pipe B = Floor drain or drain pan (Below this point there must be a trap capable of preventing the return of sewer gas)

  • Page 52: Installation - Electrical Connections

    10 - INSTALLATION - Electrical connections  10.1 - Electrical Check that the electrical system is adequate for the power consumption connections: indicated on the rating plate or in Section 16. overview  Line voltage fi eld wiring of any WARNING!!! controls or other devices must ELECTRICAL...

  • Page 53: Connecting The Power Supply Cable

    Connect the outdoor temperature sensor electrical power supply cable, follow the 3. connect the cable leads to the “10” to the boiler to terminals “14” and “15” steps below while referring to Figures 10- and “11” terminals as shown in Figure (See fi...

  • Page 54: Connection To An Analogic 0-10Vcc Input

    10 - INSTALLATION - Electrical connections 10.1.4 - Connection to an analogic 0-10Vcc input On appliances model 399, 500, 750 and 1000 it is factory supplied a 0-10Vcc interface (199 model can be equipped on demand). This 0-10Vcc interface give you the opportunity to drive the appliance via a 0-10Vcc analogic input.

  • Page 55: Connecting The Ib Boiler To An Indirect Water Heater

    4. Set the boiler so that it detects the in parameter 2063. At the end of that indirect water heater sensor, as time period, the boiler will switch to...
  • Page 56 10 - INSTALLATION - Electrical connections Figure 10-4 Electrical customer connection for IB boilers...
  • Page 57 10 - INSTALLATION - Electrical connections Figure 10-5 Electrical customer connection for IW water heaters connected to small instantaneous storage tank (see section 8.2.6, letter b))
  • Page 58 10 - INSTALLATION - Electrical connections Figure 10-6 Electrical customer connection for IW water heaters connected to big storage tank (see section 8.2.6, letter a))

  • Page 59: Connecting The Heater In Cascade

    10 - INSTALLATION - Electrical connections 10.4 - Connecting the heater in cascade To connect the heater in cascade you have to follow the electrical connections as per Figure 10-7. A maximum of 8 heaters can be connected in cascade (Figure 10-7 shows the connection of 4 heaters).

  • Page 60: Installation - Vent And Combustion Air

    11 - INSTALLATION - Vent and combustion air (d) Place in operation the appliance 11.1 - Removing (c) Dans la mesure du possible, being inspected. Follow the lighting fermer toutes les portes et les of a heater from a instructions. Adjust thermostat so fenêtres du bâtiment et toutes appliance will operate continuously.

  • Page 61: Prevent Combustion Air Contamination

    11 - INSTALLATION - Vent and combustion air when the outside air temperature is 11.2 - Prevent 11.3 - Venting and cold. This is a simply water vapor, a combustion air air piping systems purely natural phenomenon and not a reason for concern.
  • Page 62 11 - INSTALLATION - Vent and combustion air Figure 11-1 Side wall two Figure 11-2 Vertical two pipes Figure 11-3 Side wall air pipes (Direct venting). (Direct Venting). intake, vertical vent (Direct venting). Figure 11-6 Side wall (or vertical in a roof) one pipe venting, combustion air from Figure 11-5 Side wall Figure 11-4 Vertical...

  • Page 63: Minimum / Maximum Allowable Combustion Air And Vent Piping Lengths

    11 - INSTALLATION - Vent and combustion air 11.4 - Minimum / 11.5 - Install vent WARNING!!! Use of Maximum allowable and combustion air cellular core PVC and CPVC or Radel for venting system is combustion air and piping not allowed. Use of improper vent piping lengths materials can result in excessive levels of carbon...
  • Page 64 11 - INSTALLATION - Vent and combustion air Approved vent manufacturers and items Item Family of Manufacturer/supplier Applicable Manufactur. the Material to models Part Number 3” Concentric roof or wall terminal IPEX (System 636) 196006 4” Concentric roof or wall terminal IPEX (System 636) 399, 500 196021...

  • Page 65: Air Inlet Pipe Materials

    11 - INSTALLATION - Vent and combustion air 11.6 - Air inlet pipe 11.6.1 - Sealing of PVC, CPVC or ABS air inlet materials: pipe The PVC, CPVC, or ABS air inlet pipe WARNING!!! should be cleaned and sealed with the The air pipe manufacturer’s recommended inlet pipe(s) must be sealed.

  • Page 66: Pvc/Cpvc Vent Piping Materials

    11 - INSTALLATION - Vent and combustion air 11.7 - PVC/CPVC 11.7.1 - Installing PVC/ WARNING!!! CPVC vent and air piping All vent vent piping pipes must be glued, properly supported, and the exhaust NOTICE! Use only cleaners, primers, materials must be pitched a minimum of and solvents that are approved for the a 1/4 inch per foot back to the...

  • Page 67: Pvc/Cpvc Air Intake Connection

    11 - INSTALLATION - Vent and combustion air 11.7.2 - PVC/CPVC air 11.7.3 - PVC/CPVC vent WARNING!!! intake connection connection Do not insulate PVC/CPVC exhaust pipe nor install into an Combustion Air Intake Vent connection (see Figure enclosure, closet, alcove or .

  • Page 68: Stainless Steel Vent Piping Materials

    11 - INSTALLATION - Vent and combustion air 11.8 - Stainless WARNING!!! Improper steel vent piping installation of Stainless steel systems may result in injury or materials death. WARNING!!! WARNING!!! Use only the Use only materials, vent systems, and water-based lubricants on joints. terminations listed in Figures Never use hydrocarbons-based 11-7 and 11-8.

  • Page 69: Stainless Steel Air Intake Connection

    11 - INSTALLATION - Vent and combustion air 11.8.1 - Stainless steel air 11.8.2 - Stainless steel intake connection vent connection Combustion Air Intake Vent connection (Figure 11- connection (see Figure 11-11 is used to provide 11 item “C”) This connection is used a passageway for conveying Item “M”).

  • Page 70: Polypropylene Vent Piping Materials

    11 - INSTALLATION - Vent and combustion air 11.9 - Polypropylene WARNING!!! Improper vent piping materials installation of Polypropylene systems may result in injury or death. WARNING!!! Use only the materials listed in Figures WARNING!!! 11-7 and 11-8 for vent pipe, Use only and fi...

  • Page 71: Polypropylene Air Intake Connection

    11 - INSTALLATION - Vent and combustion air 11.9.1 - Polypropylene air 11.9.2 - Polypropylene intake connection vent connection Combustion Air Intake connection Vent connection (Figure 11-13 item (see Figure 11-13 Item “M”) is used “C”) is used to provide a passageway to provide combustion air directly to for conveying combustion gases the heater from outdoors.

  • Page 72: Single Pipe Vent (Not Sealed Combustion)

    11 - INSTALLATION - Vent and combustion air NOTICE! Vent pipe system shall 11.10 - Single pipe WARNING!!! be installed in a way to prevent Use only vent (not sealed accumulation of condensate; the materials, vent systems, and terminations listed in Figures combustion) 11.10.1 - Combustion Air 11-7 and 11-8.

  • Page 73: Determine Location

    11 - INSTALLATION - Vent and combustion air 3000 Btu/hr (700 mm 2 /kW) of the total 4. Maintain clearances as expected input rating of all appliances located in by “Venting of Equipment,” of the the room National Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances”...

  • Page 74: Sidewall Termination - Two Pipes

    11 - INSTALLATION - Vent and combustion air 11.11 - Sidewall 11.11.2 - Determine location termination - Two Locate the vent/air terminations using the following guidelines: pipes 1. The total length of piping for vent or air must not exceed the limits given 11.11.1 - Vent/air in the Section 11.4.
  • Page 75 11 - INSTALLATION - Vent and combustion air 3. The air piping must terminate in a down-turned elbow as shown in Figures 11-15 and 11-16. This arrangement avoids recirculation of fl ue products into the combustion air stream. 4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in Figures 11-15 and 11-16.

  • Page 76: Prepare Wall Penetrations

    11 - INSTALLATION - Vent and combustion air 11.11.3 - Prepare wall penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2.

  • Page 77: Sidewall Termination - Concentric Vent

    11 - INSTALLATION - Vent and combustion air 11.12 - Sidewall termination – Concentric vent 11.12.1 - Description and usage The termination kit must terminate outside the structure and must be installed as shown in Figure 11-19. The required concentric termination kit as well as combustion air and vent pipe materials are listed in Figures 11-7 and 11-8.

  • Page 78: Multiventing Sidewall Terminations

    11 - INSTALLATION - Vent and combustion air 11.12.3 - Multiventing sidewall terminations When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 11-21. It is important that vent terminations be made as shown to avoid recirculation of fl...

  • Page 79: Vertical Termination - Two Pipes

    11 - INSTALLATION - Vent and combustion air 11.13 - Vertical 11.13.1 - Determine 11.13.2 - Prepare roof location penetrations termination - Two Locate the vent/air terminations using 1. Air pipe penetration: cut a hole for the following guidelines: the air pipe. Size the air pipe hole pipes 1.

  • Page 80: Multiple Vent/Air Terminations

    11 - INSTALLATION - Vent and combustion air 11.13.4 - Multiple vent/air terminations 1. When terminating multiple heaters, Air intake Vent Air intake terminate each vent/air connection Vent as shown in Figures 11-23 and 11- vertically from vent outlet to WARNING!!! any air inlet Terminate all...

  • Page 81: Vertical Termination - Concentric Vent

    11 - INSTALLATION - Vent and combustion air 4. Cut one (1) hole into the structure 11.14 - Vertical 11.14.3 - Vertical to install the termination kit. termination installation termination – 5. Install the Concentric vent kit following the concentric kit 1.

  • Page 82: Multiventing Vertical Terminations

    11 - INSTALLATION - Vent and combustion air 11.14.4 - Multiventing vertical terminations When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see Figure 11-27). WARNING!!! NEVER common vent or breach vent this appliance to avoid possibility of severe personal injury, death, or substantial...

  • Page 83: Installation - Gas Supply

    12 - INSTALLATION - Gas supply 12.1 - Gas supply WARNING!!! WARNING!!! Do not Never use piping attempt to support the weight of an open fl ame to test for gas the piping with the heater or its leaks. Always use an approved accessories.

  • Page 84: Pipe Sizing For Natural Gas

    12 - INSTALLATION - Gas supply 12.2 - Pipe sizing 12.3 - Propane Gas Propane supply pressure requirements: for natural gas 1. Adjust propane supply regulator provided by the gas supplier for WARNING!!! These heaters 13”W.C. maximum pressure. Refer to Figure 12-2 for pipe length are typically shipped ready 2.

  • Page 85: Check Inlet Gas Supply Pressure

    12 - INSTALLATION - Gas supply 12.4 - Check CAUTION!!! Never force the inlet gas supply pressure connection screw or the gas valve will be damaged! pressure WARNING!!! Never use an WARNING!!! open fl ame to check for gas DO NOT leaks, or a fi...

  • Page 86: Convert A Heater Model 199 From Natural Gas To Propane Gas Or Viceversa

    12 - INSTALLATION - Gas supply 1 - turn off the power to the heater; 12.6 - Convert a 2 - gain access to the Factory Menu heater model 199 in the follow way: press and hold in the same time buttons RESET and from Natural Gas and then, turn the power on;...
  • Page 87 12 - INSTALLATION - Gas supply 19 - turn the power on to the heater; WARNING!!! 20 - turn completely counter clockwise All combustion the screw “E” of Figure 12-6; measurements must be 21 - Checking gas supply pressure performed with calibrated following Section 13.7.

  • Page 88: Convert A Heater Model 399, 500, 750 Or 1000 From Natural Gas To Propane Gas Or Viceversa

    12 - INSTALLATION - Gas supply 12.7 - Convert a Contents: The conversion kit (supplied with the heater model 399, heater) is composed of the following elements, which are necessary for the 500, 750 or 1000 gas change: - a label rating stating the new gas from Natural Gas setting;...
  • Page 89 12 - INSTALLATION - Gas supply After converting all burners: 15. connect plug “B” to plug “A” (See Figure 12-10) 16. check the inlet gas pressure of the unit, following Section 13.7; 17. check the capacity input of the unit following Section 13.9;...

  • Page 90: Start-Up

    2. open the fi ll valve and proceed to If heater stays phone. Follow the gas supplier’s fi ll the heating system and boiler off for more than 3 months, instructions. until the pressure gauge, item “M” in repeat the above operation to ...

  • Page 91: Natural Gas

    After placing the heater in operation, the 13.5.1 - Start-up of the IB ignition control’s safety shutoff function must be tested as follow: boiler 1. turn the power switch (item “T” in 1. Open the manual gas shut off valve Figure 14-1) to on;...

  • Page 92: Gas Supply Pressure Checking

    13 - START-UP 2. follow the steps in Section 15.2 to unit to verifi y the system is able to 13.7 - Gas supply remove the front cover; dissipate all heat generated. pressure checking 3. turn the screw in pressure port “D” 8.

  • Page 93: Checking And Adjusting Co2 Levels

    13 - START-UP 6. compare the CO2 reading with the 13.8 - Checking and 13.8.2 - Checking CO2 high fi re range given in Figure 12-7, level on units model 399 adjusting CO2 levels making sure to use the range for the gas type in use.

  • Page 94: Check The Capacity Input

    13 - START-UP 4. if the capacity input is too low, 7. when CO2 level match the value of WARNING!!! check: Figure 12-7, seal screw “E” (Figure Once the a) that there are no obstructions in 13-1) with red paint or nail polish to cap “L”...

  • Page 95: Use

    14 - USE 020010.01.023 A - Key to reduce the supply water temperature; B - Multifunctional key: reset any lockouts; access to user and installer menu. C - Key to increase the supply water temperature; D - Flame icon, is present when the fl ame is present; E - Radiator icon.

  • Page 96: Check Water Pressure

    The range within which the water can 4. press key Leaks in boiler or piping must be set is 68°F (20°C) to 176°F (80°C). setup the supply temperature be repaired at once to prevent desired, then press RESET key to makeup water entering the boiler.

  • Page 97: Ib Boiler - Indirect Water Heater Temperature Adjustment

    24 hours in order to see the cold winter) and 2024 (during spring result; The boiler supply hot water at the season), to rise or lower the calculated temperature set by adjusting keys C - the closer the adjustment curve...
  • Page 98 14 - USE Outdoor temperature (°F) 2021 Par. 2023 Par. 2020 Par. 3015 Par. = Maximum supply temperature 3016 Par. = Minimum supply temperature 2020 Par. = Warm weather shutdown temperature 2021 Par. = Winter outdoor temperature 2022 Par. = Winter supply temperature 2023 Par.

  • Page 99: Delays, Alarms And Protective Actions

    14 - USE 14.9 - Delays, CAUTION!!! do not demandate alarms and the antifreeze protection of your house to the heater. protective actions Because the heaters’ function depends from the electrical To protect the life of the appliance, supply and from the gas improve comfort, and maximize energy supply and because a trouble savings, the following timings have...

  • Page 100: Users' Menu

    14 - USE start showing parameters from 1000. 1 (Master)” are applicable for that 14.13 - “Users’ burner only. If you want to see the Press keys menu” same parameters for other burners scroll all parameters inside this menu. you have to connect the display to Pressing RESET key for 2 seconds, All parameters into this “Users’...

  • Page 101: Installer's Menu

    14 - USE also Section 18 to better understand 14.14 - “Installer’s the several menus) proceed as follow: than 5 seconds until the icon menu” 1. press and hold together buttons stops to be displayed. CAUTION!!! RESET and for 5 seconds NOTICE! If no key is pressed for Changing these more than 60 seconds, the control...

  • Page 102: Diagnostic

    14 - USE 2043 Burner 1 anti cycling: differential temperature °F 0 to 36 2062 DHW post pump time 10 to 255 2063 DHW max priority time 1 to 60 2067 DHW priority 0 = (TIME), DHW has priority to CH during DHW max priority time (2063) 1 = (OFF), CH always has priority to DHW.

  • Page 103: Diagnostic: Lockouts "Loc

    14 - USE   14.16 - Diagnostic: burner icon ( ) in fail, that blink. To try to reset the Lockout Lockouts “Loc” you have to press the RESET button. Then display will show the Lockout To RESET a lockout on units model number.
  • Page 104 14 - USE Loc 22 Internal software error Replace the power control board Loc 23 Internal software error Replace the power control board Loc 24 Internal software error Replace the power control board Loc 25 Gas valve circuit a - Check LWCO connection b - Check Flue blocked pressure switch WARNING!!! c - Check High limit temperature switch...

  • Page 105: Diagnostic: Blocking Errors "Err

    14 - USE 14.17 - Diagnostic: state, you’ll see icon and the Blocking errors  corresponding burner icon (  “Err” ) in fail that blink. To know the Blocking errors are generated by a blocking error code you have to press permanent fault.

  • Page 106: Flue Blocked Pressure Switch

    14 - USE Err 110 Flapper valve not open error a) Check for any obstruction into the exhaust system b) Check the fl apper valve (See Figure 3-2 item 24) Err 111 Flapper valve not closed error Check the fl apper valve (See Figure 3-2 item 24) Err 112 Internal software error Replace the power control board Err 113 Internal software error...

  • Page 107: Maintenance

    15 - MAINTENANCE Installer should discuss contents of 15.1 - Care and WARNING!!! Section 14 (User’s section) with the Servicing, maintenance user. inspection and adjustment A trained and qualifi ed service This section must be brought to the must be done by a trained technician should perform the inspection attention of the user by the installer so technician in accordance with...

  • Page 108: Address Reported Problems

    15 - MAINTENANCE from meter to appliance including 15.1.5 - Check control WARNING!!! all pipes and fi ttings and heater settings Never store connection. Use liquid soap solution combustible materials, gasoline 1. Set heaters setpoint to low enough for all gas testing. or any product containing to end call for heat (see Sections fl...

  • Page 109: Check Fl Ame Signal

    15 - MAINTENANCE 15.1.10 - Check fl ame 15.1.12 - Check heater 15.1.14 - Check vent piping 1. Visually inspect the vent outlet signal area termination to be sure it is 1. Start unit and perform the WARNING!!! unobstructed. Visually inspect the procedure of Section 13.8 to check To prevent entire length of the fl...

  • Page 110: Shut Heater Down

    15 - MAINTENANCE 15.1.18 - Shut heater 15.1.20 - Reset button 15.2 - Removing the down (low water cutoff) casing 1. Follow “To Turn Off Gas to Testing the low water cut-off shuts the In order to remove the casing, follow Appliance”...

  • Page 111: Cleaning The Burner And Primary Heat Exchanger, Fl Ue Gas Side

    15 - MAINTENANCE 15.3 - Cleaning the burner and 020009.01.012 primary heat exchanger, fl ue gas side Burner and primary heat exchanger must be checked every year and cleaned if required. To correctly clean the burner and the fl ue gas side of the heat exchanger follow the steps below: WARNING!!! Before proceeding to the next...
  • Page 112 15 - MAINTENANCE 16. using only water, wash the inside of the combustion chamber, detail “H” in Figure 15-7. The water, will drain into the condensate drain; 17. replace gasket “G” as per Figure 15-5 (Part number for this gasket is 60703047).

  • Page 113: Correct Positioning Of The Ignition And Fl Ame Detection Electrodes

    15 - MAINTENANCE 15.4 - Correct positioning of the ignition and fl ame detection electrodes For the heater to work properly the electrodes must be positioned as shown in Figure 15-8:  the distance between the ignition electrodes “A” and “B”, must be between 0.08 in (2 mm), and 0.10 in (2.5 mm);...

  • Page 114: Condensate Trap And Neutralizing Box Maintenance And Cleaning

    15 - MAINTENANCE 15.6 - Condensate trap and neutralizing box maintenance and cleaning The condensate trap and neutralizing box must be checked every year and cleaned if required. Follow the steps below to properly inspect, recharge or substitute condensate neutralizing box and media: Monitor the level of the neutralization media in the box periodically.

  • Page 115: Connection Of The Display To Other Burners

    15 - MAINTENANCE 15.7 - Connection of the display to other burners On unit models 399 to 1000, because they are multiburners, display of Figure 14-1, is always connected directly to “Burner 1 (Master)”. All parameters readed into the display (see Sections 14.13, 14.14 and 19), Burner 2 addressed to “Burner 1 (Master)”...

  • Page 116: How To Move A Control Board

    15 - MAINTENANCE 15.8 - How to move a control board Multiburner units models 399 to 1000 are confi gured to be drived by one control board (named Burner 1 (Master)). On this board are connected all external devices such as: room thermostat, outdoor sensor, pumps commands, LWCO, and some internal safety devices such as: blocked drain magnetic switch, fl...

  • Page 117: Draining The Water From The Heater

    15 - MAINTENANCE 15.9 - Draining the water from the heater To drain the water from the unit, follow the steps below: 1. cool down the unit setting the control temperature to the minimum (see section 14.6 and 14.7) and wait the temperature gauge “N”...

  • Page 118: 199 Model Wiring Diagram

    15 - MAINTENANCE 15.12 - 199 model wiring diagram For the legend see section 15.13. WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!
  • Page 119 15 - MAINTENANCE WARNING!!! ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fi ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien est terminé.

  • Page 120: 399 To 1000 Models Wiring Diagram

    15 - MAINTENANCE 15.13 - 399 to 1000 WARNING!!! Label all wires prior to disconnection when servicing models wiring controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can diagram cause extensive property damage, severe personal injury or death!
  • Page 121 15 - MAINTENANCE WARNING!!! ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fi ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien est terminé. Continue...
  • Page 122 15 - MAINTENANCE...
  • Page 123 15 - MAINTENANCE Legend to electrical schemes: 6 - High limit supply temperature switch 7 - Supply temperature sensor 9 - Flue gas temperature sensor 10 - High limit fl ue gas temperature fuse 11 - Control board 13 - Ignition electrodes 14 - spark generator 15 - Return temperature sensor 16 - Modulating PWM fan...

  • Page 124: Technical Data

    16 - TECHNICAL DATA Heater MODEL Category of discharge chimney Maximum Heat input Btu/hr 199,500 Minimum heat input Btu/hr 50,000 Turndown ratio Number of burners Gas fl ow rate (Natural gas) ft3/hr 199.5 Gas fl ow rate (LP gas) ft3/hr Min / Max gas pressure (Nat.
  • Page 125 16 - TECHNICAL DATA 1000 399,000 500,000 750,000 999,000 50,000 50,000 50,000 50,000 10:1 15:1 20:1 3 / 13 3 / 13 3 / 13 3 / 13 68 / 190 68 / 190 68 / 190 68 / 190 8 / 160 8 / 160 8 / 160...

  • Page 126: Spare Parts

    17 - SPARE PARTS Spare parts...
  • Page 127 17 - SPARE PARTS Spare parts for models: DESCRIPTION DESCRIPTION BOILER 199 WATER HEATER 199 WARNING!!! Only use the heater in combinations and with the spare parts listed in this manual. Failure to do so can cause severe personal injury or...
  • Page 128 17 - SPARE PARTS USER’S INSTALLER’S INSTRUCTION INSTRUCTION 020010.03.005...
  • Page 129 17 - SPARE PARTS 48 50 020010.03.006...
  • Page 130 17 - SPARE PARTS 105 104 020010.03.007...
  • Page 131 SENSOR 10K D6X45 L=2500 T 62630185 LP TO NAT CONVERSION KIT 62630184 NAT TO LP CONVERSION KIT 62417021 IB and IW - RBI 199-1000 USER INSTRUCTIONS 62403588 IB and IW - RBI 199-1000 INSTALLER INSTRUCTIONS 60702081 GASKET D.119 H.10 I.94 60702080 GASKET D.66 H.10 I.45...
  • Page 132 17 - SPARE PARTS DESCRIPTION MOD. DESCRIPTION MOD. BOILER 199 WATER HEATER 199 CODE DESCRIPTION 61405254 6 BUTTONS SWITCH 62110089 DISPLAY TYPE 885LB01 61405264 DISPLAY GLASS 62610100 ABS 287X600 BASE BLACK 62610099 ABS 287X600 BASE GREY 61205023 SAFETY VALVE 3/4P M ASME NPT 50 PSI...
  • Page 133 62629045 FIBER BURNER D.70 H200 60701019 KERASIL GASKET 325R SQ Ø 80.5 MM 62651052 AXIAL BURNER GROUP 58-70KW 60504265 FAN CABLE UL 885 60801021 BOLT 5X12 CROSS HEAD 61901036 BOILER FAN 135 KW 115V 60703047 SIL. GASKET D.200 F.188 H.7,2...
  • Page 134 17 - SPARE PARTS 399 to 500 Spare parts for models: DESCRIPTION DESCRIPTION BOILER 399 WATER HEATER 399 BOILER 500 WATER HEATER 500 WARNING!!! Only use the heater in combinations and with the spare parts listed in this manual. Failure to do so can cause severe personal injury or death.
  • Page 135 17 - SPARE PARTS 399 to 500 USER’S INSTALLER’S INSTRUCTION INSTRUCTION 020010.03.001...
  • Page 136 17 - SPARE PARTS 399 to 500 020010.03.002...
  • Page 137 17 - SPARE PARTS 399 to 500 110 109 020010.03.004...
  • Page 138 ABCD 62630185 LP TO NAT CONVERSION KIT 62630192 LP TO NAT CONVERSION KIT 62630184 NAT TO LP CONVERSION KIT ABCD 62417021 IB and IW - RBI 199-1000 USER INSTRUCTIONS ABCD 62403588 IB and IW - RBI 199-1000 INSTALLER INSTRUCTIONS ABCD...
  • Page 139 17 - SPARE PARTS 399 to 500 DESCRIPTION MOD. DESCRIPTION MOD. DESCRIPTION MOD. BOILER 399T WATER HEATER 399 ALL MODELS WITH MOTORIZED VALVE BOILER 500T WATER HEATER 500 ALL MODELS WITHOUT MOTORIZED VALVE CODE DESCRIPTION 61405347 WATER PROTECTION COVER FAN GROUP...
  • Page 140 AXIAL BURNER GROUP 58-70KW ABCD 60504265 FAN CABLE UL 885 ABCD 60801021 BOLT 5X12 CROSS HEAD ABCD 61901036 BOILER FAN 135 KW 115V ABCD 60807002 SPRING FOR 3/4" RING NUT ABCD 60108006 SENSOR TRAP ABCD 60703047 SIL. GASKET D.200 F.188 H.7,2...
  • Page 141 750 to 1000 Spare parts for gas-fi red condensing hot water heaters series: 1000 DESCRIPTION DESCRIPTION BOILER 750 WATER HEATER 750 BOILER 1000 WATER HEATER 1000 WARNING!!! Only use the heater in the combinations and with the spare parts listed in this manual. Failure to do so can cause severe personal injury or death.
  • Page 142 17 - SPARE PARTS 750 and 1000 USER’S INSTALLER’S INSTRUCTIONS INSTRUCTIONS 020009.03.001...
  • Page 143 17 - SPARE PARTS 750 and 1000 37 50 020009.03.002...
  • Page 144 17 - SPARE PARTS 750 and 1000 020010.03.003...
  • Page 145 17 - SPARE PARTS 750 and 1000 DESCRIPTION MOD. DESCRIPTION MOD. DESCRIPTION MOD. BOILER 750 WATER HEATER 750 ALL MODELS WITH MOTORIZED VALVE BOILER 1000 WATER HEATER 1000 ALL MODELS WITHOUT MOTORIZED VALVE CODE DESCRIPTION 60801066 6X12 SCREW WITH WASHER...
  • Page 146 17 - SPARE PARTS 750 and 1000 DESCRIPTION MOD. DESCRIPTION MOD. DESCRIPTION MOD. BOILER 750T WATER HEATER 750 ALL MODELS WITH MOTORIZED VALVE BOILER 1000T WATER HEATER 1000 ALL MODELS WITHOUT MOTORIZED VALVE CODE DESCRIPTION 61206002 AIR VENT VALVE ABCD...
  • Page 147 62630192 LP TO NAT CONVERSION KIT ABCD 62630184 NAT TO LP CONVERSION KIT ABCD 62417021 IB and IW - RBI 199-1000 USER INSTRUCTIONS ABCD 62403588 IB and IW - RBI 199-1000 INSTALLER INSTRUCTIONS ABCD 62801022 NEUTRALISING LIMESTONE 25 KG ABCD 60703047 SIL.

  • Page 148: Read Out Flow Chart

    18 - READ OUT FLOW CHART Gain access to installers’ Changing menu (see Section of the 14.14) parameters’ value Gain access to users’ menu (see Section 14.13) Parameters shown during Installers’ normal operations menu (See Section parameters 14.15) (see Section 14.14) User’s menu parameters...

  • Page 149: Factory Menu

    19 - FACTORY MENU The heater’s micro-processor makes WARNING!!! this menu of parameters available to Changing the qualifi ed technician for the setting these parameters could cause of the appliance. the heater and the system to To enter this menu operate as follow: malfunction.
  • Page 150 19 - FACTORY MENU IB boilers’ parameters Ref. Parameter’s description Range Factory Single burner Burner 1 Burner 2 to 4 settings (mod. 199) (Master) (mod. 399, (mod. 399, 500, 500, 750 and 750 and 1000 1000 3001 Burner logic address 0 = No cascade, 1 = Burner 1 (Master), 2 to 4...
  • Page 151 19 - FACTORY MENU IW water heaters’ parameters Single burner Burner 1 (Master) Burner 2 to 4 Column for (mod. 199) (mod. 399, 500, (mod. 399, 500, custom. 750 and 1000 750 and 1000 values 2 to 4 Set this parameter follow Figure 12-7 Enab Enab dISA...

  • Page 152: Sequence Of Operation For Boiler

    20 - SEQUENCE OF OPERATION for BOILER...

  • Page 153: Sequence Of Operation For Water Heater

    21 - SEQUENCE OF OPERATION for WATER HEATER...
  • Page 154 260 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...

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