RBI CK1500 Installation And Operation Instructions Manual
Stainless steel condensing
boilers
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Also See for CK1500:
- Installation and operation instructions manual (48 pages) ,
- Control manual (136 pages) ,
- Installation and operation instructions manual (52 pages)
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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified
service technician, and to follow all guidelines in the User' s Information Manual.
Boiler Manual
Installation and Operation
Instructions
Stainless Steel Condensing
Boilers CK1500, CK3000,
CK4500 & CK6000
Also read and follow:
HeatNet Control Manual
Scan Boiler QR Code for Online Monitoring
Construction dust and particulate, particularly drywall dust, will cause contamination of
FCR-IOM-2
82-0651
09/15 Copyright 2015 Mestek, Inc.
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Table of Contents
Related Manuals for RBI CK1500
Summary of Contents for RBI CK1500
- Page 1 82-0651 Boiler Manual Installation and Operation Instructions Stainless Steel Condensing Boilers CK1500, CK3000, CK4500 & CK6000 Also read and follow: HeatNet Control Manual Scan Boiler QR Code for Online Monitoring This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
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Page 2: Table Of Contents
FlexCore Stainless Steel Condensing Boilers – Installation Manual CONTENTS If the information in this manual is not followed exactly, a fire or explosion may result causing Before Your Start..........page 2 property, personal injury or loss of life. Ratings & Capacities .......... page 3 Location .............. -
Page 3: Ratings & Capacities
4. Locate the boiler in an area that will prevent water damage to adjacent construction should a leak Direct all questions to your RBI distributor or contact the occur or during routine maintenance. RBI Customer Service Department at: 260 North Elm Street, Westfield, MA 01085. - Page 4 FlexCore Stainless Steel Condensing Boilers – Installation Manual Buildings will require the installation of a fresh air duct Where communicating with the outdoors through hori- or other means of providing make-up air if the intake zontal ducts, each opening shall have a minimum free air option isn't used.
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Page 5: Venting Guidelines
FlexCore Stainless Steel Condensing Boilers – Installation Manual All joints in metal intake air systems must be A barometric damper or blast gate as secured using corrosion resistant fasteners required, must be installed if a Category II and sealed using a suitable Silicone caulk. If vertical vent system produces a negative PVC or CPVC is used, the joints must be draft in excess of 0.10 in, 2.5 mm WC at the... - Page 6 Table 4 - “Category IV Equivalent Length per Fitting” chart is meant as a guideline for preliminary sizing. If vent length approaches 75% of maximum length listed, an engineered vent system calculation must be performed. Consult factory. Table 4 - Category IV Maximum Equivalent Vent Length & Equivalent Length per Fitting CK1500 CK3000 CK4500 CK6000 Model/Outlet Diameter 6"...
- Page 7 FlexCore Stainless Steel Condensing Boilers – Installation Manual Avoid terminal locations likely to be affected by winds, The top of a vertical vent system must extend at least ft, 1.8 m above the roof surface that it passes snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue through, 4 ft, 1.3 m above the intake air cap, see Figure gases.
- Page 8 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 1 - Multiple Boiler Common Venting "B" FLUE VENT "C" ALL CONNECTIONS DOUBLE ACTING TO BE "T-WYE" BAROMETRIC DAMPER "D" THERMAL SPILL SWITCH "F" BOILER #2 BOILER #4 BOILER #3 BOILER #1 (IF REQUIRED) (IF REQUIRED) (IF REQUIRED)
- Page 9 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System 10 ft (3.1 m) Figure 3 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems...
- Page 10 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m 5 FT 1.5 m Figure 5 - Combination Direct Vent Systems 3 FT.
- Page 11 FlexCore Stainless Steel Condensing Boilers – Installation Manual SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION SECTION In this configuration the boiler blower is used to push the must be followed! The vent guidelines under the flue products horizontally to the outdoors, see Figure 6.
- Page 12 Negative Pressure - Single Boiler FIRESTOP JOIST FRAMING MEMBERS BETWEEN JOISTS Breech & Flue Diameter Model Size INSULATION CK1500 CLEARANCE PER VENT MANUFACTURER'S INSTRUCTIONS CK3000 CK4500 Pending CK6000 These sizes are based on a 20 ft, 6.1m chimney height. Vent Connections Locate the boiler as close to the chimney system as possible.
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Page 13: Common Vent Systems
FlexCore Stainless Steel Condensing Boilers – Installation Manual EXISTING COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où... -
Page 14: General Piping Requirements
*∆T Across Model personal injury or death may occur! (GPM) Heat Exchanger Size Min. Max. Min. * Max. Flow Switch CK1500 28.5 142.7 20°F 100°F The factory mounted flow switch, as shown in Figure 9, CK3000 58.1 290.5 20°F 100°F... -
Page 15: Heating System Piping
Supply Return Pump Requirements Size Size Size This boiler requires a continuous minimum water flow CK1500 2-1/2" NPT 2-1/2" NPT for proper operation. The system pump must be sized CK3000 3" NPT 3" NPT to overcome the head loss of the boiler and the heating CK4500 4"... - Page 16 FlexCore Stainless Steel Condensing Boilers – Installation Manual Primary/Secondary Piping When a boiler is connected to a heating coil that may Although acceptable, the system is not as cost effective be exposed to refrigerated air from an air handling as reverse return piping. Figure 12 shows a typical device, the piping system must be equipped with flow- primary/secondary piping system.
- Page 17 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local manufactures representative for assistance.) AIR SEPARATOR ALTERNATE LOCATION SYSTEM...
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Page 18: Domestic Water Supply Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual DOMESTIC WATER SUPPLY PIPING The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce flow. Proper controls must be used to prevent water supplied for domestic use from Expansion Tank exceeding 130°F, 54°C or a scald injury will... - Page 19 FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping COLD WATER MAKE-UP FLOW FLOW FLOW COLD WATER FLOW MAKE-UP COLD WATER BRONZE MAKE-UP/FILL PUMP FLOW FLOW CIRCULAR FLOW RETURN FLOW SUPPLY ONZE PUMP...
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Page 20: Condensate Piping
FlexCore Stainless Steel Condensing Boilers – Installation Manual CONDENSATE PIPING Figure 17 depicts the proper way to connect the boiler to the gas supply piping. The manual shut-off valve The condensate trap provided with the boiler must be MUST be installed in the supply piping. It should be attached to the bottom pan and piped to a suitable floor installed 5 ft, 1 m above the floor where required by drain (consult local code) or condensate pump. -
Page 21: Electrical Wiring
230 volt 1Ø with neutral 20 amp circuit for each CK1500 boiler. A properly rated shut-off switch should be Always use a wrench on the gas valve body located at the boiler. The boiler must be grounded in when making gas connections to it. -
Page 22: Boiler Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual BOILER OPERATION The system should be checked and bled after three days of operation. Before proceeding read and fully understand OPERATING INSTRUCTIONS the instructions contained in this manual. Do not attempt to operate this boiler if it has not FOR YOUR SAFETY READ BEFORE OPERATING. - Page 23 FlexCore Stainless Steel Condensing Boilers – Installation Manual Operating Instructions 15. When the main display reads "PILOT RUNNING" 1. STOP! Read the safety information above. If, at any and the flame current is 5VDC, switch the Honey time, the appliance will not operate properly, follow the well 7800 to the "test"...
- Page 24 FlexCore Stainless Steel Condensing Boilers – Installation Manual 21. Create a minimum input demand as before (enable c. Adjust low fire 02-C02 by opening the low fire low fire switch on the HeatNet board). The boiler will adjustment door located on the forward facing begin the start sequence.
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Page 25: Sequence Of Operation
FlexCore Stainless Steel Condensing Boilers – Installation Manual SEQUENCE OF OPERATION Main Run %Input 1. The main gas valve opens. NO DEMAND 2. The ignition transformer is de-energized. Standby 1. The boiler is idle with no interlocks in the fault 3. - Page 26 **Located on outlet flange of gas valve. (Figure 17, page 21) Due to job conditions, deviation from specified may be required – allow ± (0.2)% range adjustment. Table 12 - Pressure Signal (P) - (Nat. Gas) CK1500 CK3000 CK4500 CK6000...
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Page 27: Ignition Troubleshooting
FlexCore Stainless Steel Condensing Boilers – Installation Manual FireTube Series "HeatNet Control" Troubleshooting (Firing the FireTube Boiler) Variable Frequency FireTube Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4. -
Page 28: Checking & Adjustment
FlexCore Stainless Steel Condensing Boilers – Installation Manual CHECKING, ADJUSTMENT & OPERATION To adjust the pilot the following steps must be taken: 1. Remove the pilot gas pressure regulator cap. Spark Gap The gap has to be measured and adjusted with the 2. -
Page 29: Diagnostics
FlexCore Stainless Steel Condensing Boilers – Installation Manual DIAGNOSTICS Ignition Safety To test the ignition safety shutoff device, close the The FlexCore has a display that indicates the sequence manual shutoff valve 1 (Figure 17) in the gas supply line. of operation, Figure 18. -
Page 30: Maintenance
FlexCore Stainless Steel Condensing Boilers – Installation Manual MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. Disconnect electrical power and close the 1. Check the operating controls for proper operation. manual gas shut off valve before performing maintenance or severe personal injury may 2. -
Page 31: Pressure Switches
FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 22 - CK1500 Pressure Switches RIOM-0218.A... -
Page 32: Wiring
FlexCore Stainless Steel Condensing Boilers – Installation Manual Figure 23 - RBI Field Wiring to HeatNet Board 3.0 (CK1500) -
Page 33: Start-Up
FlexCore Stainless Steel Condensing Boilers – Installation Manual 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 BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL... - Page 34 FlexCore Stainless Steel Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS INLET PRESSURE (WC) INCHES WC I NCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC...
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Page 35: Warranty
FlexCore Stainless Steel Condensing Boilers – Installation Manual FlexCore Series Water Boiler Limited Warranty One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the FlexCore Series modulating water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation or eighteen (18) months from the date of shipment from the factory whichever comes first. - Page 36 260 North Elm Street 7555 Tranmere Drive Westfield, 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...