RSB-i&s-05 INSTALLATION AND SERVICE MANUAL HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 45,000 - 500,000 Btu/hr MODELS IMPORTANT: This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier. WARRANTY Installation and service must be performed by a qualified service installer, service agency or the gas supplier.
USER WARNING CONTENTS The information contained in this manual is intended for use by qualified professional installers, service technicians or gas suppliers. Consult your local expert for proper installation or service procedures. Warranty ..................................................................................1 Safety Warnings ......................................................................1 Codes ..................................................................................
CODES The equipment shall be installed in accordance with installation regulations in force in the local area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1.
CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Clearances from Combustible Construction: 29" Right Side - 6" Rear - 6" Left Side - 18" (24" suggested for service) Front - 18" (24" suggested for service) Top - (measured from the top of the unit) 45,000 - 180,000 Btu/hr Models - 14" 199,999 - 500,000 Btu/hr Models - 29" All units have been approved for alcove installation (an ALCOVE is a closet enclosure without a front door). 6" 6" The boiler must not be installed on carpeting.
FIG. 5 Combustion Air Direct from Outside FIG. 7 Combustion Air from Interior Space 1. If air is taken directly from outside the building with no duct, provide two permanent openings: 3. a. Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5cm2 per kW). This opening must be located within 12" (30cm) of the floor.
Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. Table A lists the requirements for the appliance only, additional gas fired appliances located in the same room will require an increase in the net free area to supply adequate combustion air for all appliances.
EXHAUST FANS: Any fan or equipment which exhausts air from the room where the appliance is installed may deplete the combustion air supply and/or cause a down draft in the venting system, spilling flue products into the room. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.
On a conventionally vented, negative draft appliance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type “B” double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter. Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks. The Type “B” vent and accessories, such as firestop spacers, thimbles, caps, etc.
VENTING TERMINATION FIG. 12 Vent Termination from Flat Roof 10’ or Less from Parapet Wall FIG. 10 Vent Termination from Peaked Roof 10’ or Less from Ridge 10’ OR MORE MORE THAN 10' 10' 3’ RIDGE 2' MIN 3' MIN WALL OR PARAPET NOTE: NO HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FROM WALLS OR PARAPETS IS MORE THAN 10’. CHIMNEY FIG. 13 Vent Termination from Flat Roof More Than 10’ from Parapet Wall CHIMNEY The vent cap should have a minimum clearance of 4 feet (1.
To avoid a blocked vent condition, keep the vent cap clear of snow, ice, leaves, debris, etc. Flue gases will form a white plume in winter. Plume could obstruct window view. systems (Type “B” double wall or flexible or rigid metallic liners) are recommended. Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney. SIDEWALL VENTING Flue gas condensate can freeze on exterior surfaces or on the vent cap.
The part number for the automatic vent damper required on this heating boiler is printed on the rating plate. Vent damper regulations are design certified per the latest edition of ANSI Z21.66. AUTOMATIC VENT DAMPER This heating boiler is design certified for use with the automatic vent damper (FIG. 15) part number printed on the boiler’s rating plate. A vent damper must be installed on all residential heating boilers with inputs of less than 300,000 Btu/hr to comply with minimum efficiency requirements.
GAS PRESSURE TEST GAS SUPPLY 1. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5kPa). Verify that the appliance is supplied with the type gas specified on the rating plate. This appliance is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation.
TABLE - E SUGGESTED GAS PIPE SIZE SINGLE APPLIANCE INSTALLATIONS Btu/hr DISTANCE FROM METER (In Feet) INPUT 45,000 75,000 90,000 135,000 180,000 199,999 215,000 260,000 315,000 360,000 399,999 500,000 0-50 1/2" 1/2" 1/2" 3/4" 1" 1" 1" 1" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 51 - 100 1/2" 3/4" 3/4" 1" 1" 1" 1 1/4" 1 1/4" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 101 - 200 3/4" 1" 1" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/2" 2" 2" 2" 201 - 300 1" 1 1/4" 1 1/4" 1 1/4" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 2" 2" 2" 301 - 500 1 1/
TABLE - H MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING SIZE CHART Nominal Iron Pipe Size, Inches 10 Length of Pipe in Straight Feet 20 30 40 50 60 70 80 90 100 125 150 175 200 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 267 246 226 210 200 179 164 149 138 1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287 1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441 2 4,100 2,820 2,2
1. Turn the power “OFF” at the main disconnect switch. 2. Turn gas valve control knob to “PILOT” position on standing pilot models. Ensure that the standing pilot remains on. If the pilot goes out, follow the “Lighting Instructions” for standing pilot models to light the pilot. Turn gas valve control knob to “OFF” position on spark ignition models. 3. Remove the 1/8" hex plug located on the outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge.
14. Repeat the adjustment procedure for the second gas valve on the 500,000 Btu/hr model. 6. Turn on gas supply at the manual valve, turn on L.P. gas at tank if required. 15. Turn the gas valve control knob(s) to “ON” position. 7. Turn the power “ON” at the main disconnect switch. 16. Turn the power “ON” at the main disconnect switch. The appliance is now ready to operate. 8. Turn gas valve control knob to “PILOT” position on standing pilot models.
20. Set the thermostat to call for heat. The appliance is now ready to operate. IMPORTANT Upon completion of any testing on the gas system, leak test all gas connections with a soap solution while main burners are operating. Immediately repair any leak found in the gas train or related components. Do Not operate an appliance with a leak in the gas train, valves or related piping. Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly.
WATER FLOW SWITCH (IF EQUIPPED) RELIEF VALVE FIG. 24A Water Flow Switch Water Heater - Side Connections FIG. 23A Relief Valve - Water Heater FLOW SWITCH FLOW RELIEF VALVE FIG. 24B Water Flow Switch Boiler - Top Connections FIG. 23B Relief Valve - Boiler This appliance is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve(s) is mounted directly into the heat exchanger inside the header.
A water flow switch meets most code requirements for a low-water cut off device on boilers requiring forced circulation for operation. TABLE I MINIMUM FLOW RATE REQUIRED TO ACTUATE FLOW SWITCH Pipe Size GPM Flow Rate 1 1/2" 13 2" 18 4. To avoid serious damage, DO NOT energize the appliance until the system is full of water. Serious damage may result. 5. Provide the unit with proper overload protection. 6. Install a wall thermostat on the inside wall.
Temperature Control Settings There are three setting knobs on the temperature control unless your unit is specified as a boiler only with an outdoor air reset option. If your unit is a boiler only with an outdoor air reset option, there are additional controls for this option. They are explained under Outdoor Air Reset Option, page 22. The three setting knobs on the temperature control are for Set point, Differential, and High-Fire Offset (see Figure 28). FIG.
for water heater applications. Connect this sensor to the two blue wires in the upper left-hand corner of the control panel. Set Point The Set Point knob specifies the target outlet water temperature in degrees, Fahrenheit. After the water temperature reaches the set point, the temperature control shuts off the burners. Outdoor Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems. The outside air sensor is optional.
5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller. Ratio The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset. The allowable ratios are as low as 0.5:1 or as high as 1.5:1. Selecting the 0.5:1 ratio will increase the set point 0.5° for every 1.0° drop in outdoor air temperature up to the maximum set point temperature. Selecting the 1.5:1 ratio will increase the set point 1.5° for every 1.
Manual Reset High Water Temperature Limit Control (Standard Fixed Settings on Water Heaters and Optional Adjustable Settings on Boilers and Water Heaters) Water heaters are supplied with a fixed setting, manual reset high water temperature limit control. This manual reset temperature limit control has a fixed limit setting of 230°F (110°C). If water temperature exceeds this setting, the limit will break the control circuit and shut down the unit.
On boilers, the pump will operate whenever the “W” terminal is energized. LIGHTING INSTRUCTIONS FOR STANDING PILOT MODELS (F1) MODELS 90,000 THRU 270,000 Btu/hr INPUT FOR YOUR SAFETY READ BEFORE OPERATING B. Location - The appliance should be located within a room having a temperature safely above freezing [32°F(0°C)]. C.
3. Set the thermostat to the lowest setting (OFF). 4. Turn off all electrical power to the appliance. 5. Turn the gas control knob on the gas valve clockwise to the “OFF” position. FIG. 35 Lighting Wand NOTE: FIG. 33 F1 Gas Valve 90,000 - 270,000 Btu/hr Models 6. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. If you smell gas, STOP! Follow the steps in the“What To Do If You Smell Gas” section in the safety information on page 24.
TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to the OFF position. 2. Turn off all electric power to the appliance if service is to be performed. 3. Turn the gas control knob on the gas valve clockwise to the “OFF” position. Do not force. 5. After successful completion of test, turn the control knob on the gas valve clockwise to the “OFF” position. Do not force. 6. Carefully reconnect the thermocouple to the gas valve. 7.
TO TURN OFF GAS TO APPLIANCE OPERATING INSTRUCTIONS 1. STOP! Read the safety information first. 1. Set the thermostat to the OFF position. 2. Remove the control panel door. 2. 3. Set the thermostat to the lowest setting (OFF). Turn off all electric power to the appliance if service is to be performed. 4. Turn off all electrical power to the appliance. 5. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. 6a.
11. If ignition system fails to operate properly, repair work must be performed by a qualified serviceman or installer. INTERMITTENT PILOT SPARK IGNITION SYSTEM (F9/M9) The ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty ignition module must be replaced with a new module. 4.
5. Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system. a. Normal Flame: A normal flame is blue, with slight yellow tips, with a well defined inner cone and no flame lifting. b. Yellow Tip: Yellow tip can be caused by blockage or partial obstruction of air flow to the burner(s). WATER TREATMENT In hard water areas, water treatment should be used to reduce the introduction of minerals to the system.
INSPECTION CLEANING PROCEDURE e. Disconnect gas valve wiring and remove gas manifold assembly. WARNING f. Remove ignition wire leading to the pilot assembly from the ignition module. The combustion chamber lining in this appliance contains ceramic fiber materials. Ceramic fibers can transform into cristobalite (crystalline silica) when exposed to temperatures above 2192°F (1200°C) dependent upon the length of exposure time.* g.
o. Check “V” baffles on top of the heat exchanger. Remove and clean if necessary. p. Remove soot from the heat exchanger with a stiff bristle brush. Soot may also be removed from the heat exchanger by washing thoroughly with detergent and water. Remove the heat exchanger before using water for cleaning. Rinse thoroughly and dry before re-installing. Use a vacuum to remove loose soot from surfaces and inner chamber. 6.
IMPORTANT Upon completion of any testing on the gas system, leak test all gas connections with a soap solution while main burners are operating. Immediately repair any leak found in the gas train or related components. Do Not operate an appliance with a leak in the gas train, valves or related piping. GAS TRAIN AND CONTROLS expansion tank installed. Typically, an air charged diaphragm-type expansion tank is used.
TABLE - L HEAT EXCHANGER PRESSURE DROP CHART FOOT HEAD LOSS FIG. 41 Boiler Wiring - Circulation Pump to Junction Box CIRCULATOR PUMP SPECIFICATIONS 1. Maximum operating pressure for the pump must exceed system operating pressure. 2. Maximum water temperature should not exceed nameplate rating. 3. Cast iron circulators may be used for closed loop systems. 4. A properly sized expansion tank must be installed near the boiler and located on the suction side of the pump.
PRIMARY/SECONDARY BOILER PIPING The installer must ensure that the boiler has adequate flow without excessive temperature rise. The temperature rise on a multiple zone system should be made when only the zone with the longest length and/or highest head loss is open. Low system flow can result in overheating of the boiler water which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam.
Low flow rates can result in overheating of the boiler water which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. These conditions can cause operational problems and non-warrantable failures of the boiler. If a three way valve must be installed, please pipe in a primary/secondary system as shown in Figure 45. Based on boiler sizing and system flow requirements, this piping may still result in boiler short cycling.
TABLE - M MINIMUM REQUIRED FLOW FOR HEATING BOILER Input Btu/hr GPM Flow 45,000 1.9 75,000 3.1 90,000 3.7 135,000 5.6 180,000 7.4 215,000 8.9 260,000 10.7 315,000 13.0 360,000 14.9 399,999 16.5 500,000 20.7 PLACING THE BOILER IN OPERATION Filling the System: All air must be purged from the system for proper operation. An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve. 1.
10. Start the boiler according to the “Start-Up Instructions” in this manual. Operate the system, including the pump, boiler and radiation units, for one hour. INSTALLATION WITH A CHILLED WATER SYSTEM EXPANSION TANK 11. Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. Recheck pressure charge on diaphragm type tanks. HEATING AND COOLING COIL LOW WATER FLOW SWITCH PUMP 12.
BOILER OPERATING TEMPERATURE CONTROL The operating temperature control is located in the control panel, behind the control panel front access door. The sensing element for the operator is placed in a bulb well installed in the heat exchanger. Carefully observe the discharge water temperature on the initial boiler on cycles. The exact temperature set point is based on your system’s requirements. Turn the control set point dial to the desired operating water temperature.
tank tappings to ensure proper flow. See Table Q on page 40. This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and service sections apply to these instructions. Water heaters are designed for installation with a storage tank. The use of a properly sized pump and the control of water velocity, as explained below, is important for correct operation of your water heater. 6.
NOTE: Lower flows with soft water mean a higher temperature rise. A higher temperature rise may cause nuisance tripping of a high limit or opening of a relief valve when providing very hot water. If this presents a problem, increase the flow to the temperature rise specified for 8 to 25 grains hardness water. need to be increased. The tubes should not have a bright shiny copper look. This would indicate that the erosion process has begun and the flow rate will need to be decreased.
3. The pump must run continuously when the burners are firing. 4. Lubricate the pump to the manufacturers recommendations. Pump damage due to inadequate lubrication is non-warrantable. 5. A standard water heater/hot water supply boiler is furnished with a 1/6 HP, 120 VAC, 3.6 AMP circulating pump to be mounted on the units inlet water connection. This pump is sized based on installation of a single storage tank and heater in close proximity.
your gas supplier for local requirements governing the temperature setting. Remember, no water heating system will provide exact temperature at all times. Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs. • Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds. • Children, disabled and elderly are at highest risk of being scalded. • See instruction manual before setting temperature at heating appliance.
THERMAL EXPANSION A relief valve which discharges periodically may be due to thermal expansion in a closed system. A hot water supply boiler installed in a closed system, such as one with a backflow preventer or check valve installed in the cold water supply, shall be provided with means to control expansion. Contact the water supplier or local plumbing inspector on how to correct this situation.
TROUBLESHOOTING GUIDE 45,000 - 500,000 Btu/hr Models - Boilers & Water Heaters F9/M9 STEP 1: Is the spark igniter sparking? Check continuity of the spark cable. Check for 24VAC on the TH terminal (gray wire) on the ignition module. NO YES STEP 2: Is the pilot staying ON? NO Check the pilot tube for gas. Check for draft. NO Check for an open sensor. If not open, replace temperature controller. YES NO Replace ignition module.
TROUBLESHOOTING GUIDE 90,000 - 270,000 Btu/hr Models - Water Heaters F1 STEP 1: Is the pilot lit? Check for gas. Check the pilot assembly and thermocouple. Check the gas valve for proper operation. Clean and replace. NO YES STEP 2: Is the gas valve getting 24VAC? Check for an open sensor. If not open, replace temperature controller.
Schematic Diagram - F1 Unit 90,000 - 270,000 Btu/hr Models Wiring Diagram - F1 Unit 90,000 - 270,000 Btu/hr Models 46
Schematic Diagram - F9 Unit 90,000 - 399,999 Btu/hr Models Wiring Diagram - F9 Unit 90,000 - 399,999 Btu/hr Models 47
Schematic Diagram - M9 Unit 45,000 - 399,999 Btu/hr Models Wiring Diagram - M9 Unit 45,000 - 399,999 Btu/hr Models 48
Wiring Diagram - F9/M9 Unit 500,000 Btu/hr Models Schematic Diagram - F9/M9 Unit 500,000 Btu/hr Models 49
NOTES 50
NOTES 51
Revision 4 (RSB-i&s-04) reflects the removal of the inlet pipe and installing the inlet sensor inside the header. Revision 5 (RSB-i&s-05) reflects changes made to the O.A. section.