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RBI Boiler User Manual

RBI Boiler
154 pages
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IE2-IOM-1
82-0147
Boiler Manual
Installation and Operation
Instructions
This manual is intended only for use by a quali 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.
Af x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a quali ed service
technician, and to follow all guidelines in the User’s Information Manual.
Condensing,
High Ef ciency
Water Heaters (IW)
and Boilers (IB)
62403588 R00 Feb. 18, 2014

Table of Contents

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RBI Boiler Specifications

General IconGeneral
BrandRBI
ModelBoiler
CategoryBoiler
LanguageEnglish

Summary

1 - CODE REQUIREMENTS

1.1 - Regulations and guidelines

Installation must conform to applicable codes and standards, including NFPA and CSA.

1.2 - Commonwealth of Massachusetts Installation Requirements

Specific installation requirements for Massachusetts, including CO detector and signage mandates.

2 - GENERAL INFORMATION

2.1 - Key to symbols used

Explains the meaning of Warning, Caution, and Notice symbols used in the manual.

2.3 - Description of models:

Details model numbers, power inputs, and distinctions between IB and IW types.

3 - MAIN COMPONENTS

Component Diagrams

Illustrates and labels the various internal and external components of different heater models.

4 - FUNCTION OVERVIEW

4.1 - Intended use and functions

Describes the intended applications for IB boilers and IW water heaters, highlighting system water quality importance.

4.2 - Efficiency up to 98% (IB boiler only)

Explains how outdoor reset control optimizes boiler efficiency by adjusting supply temperature.

5 - INSTALLATION - Location

5.1 - Choosing the installation location

Guidelines for selecting a suitable location, considering clearances, ventilation, and safety.

5.4 - Clearances for installation and servicing

Specifies minimum clearance distances required for installation and maintenance access.

5.6 - Vent and combustion air piping

Details requirements for vent and combustion air piping systems, including direct vent and room air options.

5.7 - Prevent combustion air contamination

Instructions to prevent contamination of combustion air, listing potential contaminants.

6 - INSTALLATION - Mounting the heater

6.1 - Transporting the heater

Safety warnings and instructions for safely lifting and transporting the heater unit.

6.2 - Mounting the heater

Step-by-step instructions for physically mounting the heater unit, including removing packaging.

6.3 - Dimensions

Refers to figures that provide all dimensions for each heater model.

7 - INSTALLATION - IB boiler water connection

7.2 - Supply and return piping

Details requirements for supply and return piping, including safety valves and material considerations.

7.2.1 - Near boiler heating piping components

Lists and describes essential piping components required near the boiler for proper operation.

7.2.3 - Expansion Tank and Makeup Water

Guidelines for installing and sizing expansion tanks to manage thermal expansion.

7.2.6 - Domestic Hot Water system Piping when using an indirect water heater

Recommends piping configurations for indirect water heaters, ensuring DHW priority.

8 - INSTALLATION - IW water connections

8.2 - Hot and Cold water piping

Covers requirements for hot and cold water piping, including pressure relief valves and material codes.

8.2.1 - Near water heater piping components

Lists necessary piping components for the water heater, considering pressure drops.

8.3 - Scalding

Warning about potential scald injuries from high water temperatures and recommending mixing valves.

8.4 - Water chemistry

Discusses water quality parameters and their impact on pressure drops and scaling.

9 - INSTALLATION - Condensate disposal

9.1 - Condensate disposal

Instructions for proper disposal of condensate, including material requirements and potential hazards.

10 - INSTALLATION - Electrical connections

10.1 - Electrical connections: overview

General safety precautions and requirements for electrical connections to the heater.

10.1.1 - Connecting the power supply cable

Steps for connecting the main power supply cable, including fused disconnect requirements.

10.2 - Connecting the IB boiler to an indirect water heater

Steps for connecting the IB boiler to an indirect water heater for domestic hot water.

10.3 - Connecting the IW water heater to a storage tank

Instructions for connecting an IW water heater to a storage tank for domestic hot water.

10.4 - Connecting the heater in cascade

Details the electrical connections required for operating multiple heaters in a cascade system.

11 - INSTALLATION - Vent and combustion air

11.3 - Venting and air piping systems

General requirements for vent and air piping systems, including code compliance and support.

Vent Pipe Materials and Installation

Covers approved vent materials, installation procedures, and sealing for PVC/CPVC, stainless steel, and polypropylene.

Vent Termination Methods

Details various vent termination types (single pipe, two pipes, concentric) and location requirements.

12 - INSTALLATION - Gas supply

12.1 - Gas supply piping

Instructions for connecting the gas supply, including unions, shut-off valves, and leak testing.

12.4 - Check inlet gas supply pressure

Steps for checking and verifying the inlet gas supply pressure for proper operation.

12.6 - Convert a heater model 199 from Natural Gas to Propane gas or viceversa

Detailed procedure for converting the model 199 heater between natural gas and propane.

12.7 - Convert a heater model 399, 500, 750 or 1000 from Natural Gas to Propane gas or viceversa

Procedure for converting multiburner models (399-1000) between natural and propane gas.

13 - START-UP

13.1 - Operating

Essential instructions for users on how to operate the heater safely and efficiently.

13.4 - Gas type conversion

Information on gas type conversion requirements and the need for qualified technicians.

13.5 - Start-up

Step-by-step procedures for starting up both IB boilers and IW water heaters.

13.8 - Checking and adjusting CO2 levels

Guide for performing combustion analysis and adjusting CO2 levels for optimal performance.

14 - USE

14.1 - Check water pressure

Instructions for checking water pressure in IB boilers and IW water heaters to prevent errors.

14.5 - IW supply water temperature adjustment

How to adjust the domestic hot water temperature for the IW water heater.

14.6 - IB boiler - Indirect water heater temperature adjustment

Setting the temperature for an indirect water heater connected to an IB boiler.

14.7 - IB boiler - Heating temperature adjustment

Adjusting the heating supply temperature for IB boilers based on ambient conditions.

14.8 - IB boiler - Outdoor reset adjustment

Explains the outdoor reset feature for optimizing heating efficiency and comfort.

14.14 - “Installer’s menu”

Accessing and adjusting parameters via the installer menu for diagnostics and setup.

14.15 - Diagnostic

Overview of diagnostic information displayed on the unit, including error codes.

15 - MAINTENANCE

15.1 - Care and maintenance

Outlines the importance of regular care and maintenance, detailing schedules for technicians and users.

15.1.2 - Check all piping for gas leaks

Procedure for inspecting gas piping for leaks using a soap solution.

15.1.17 - Check heater piping (gas and water)

Inspecting gas and water piping for leaks and general condition.

15.3 - Cleaning the burner and primary heat exchanger, flue gas side

Step-by-step guide for cleaning the burner and heat exchanger for optimal performance.

15.6 - Condensate trap and neutralizing box maintenance and cleaning

Procedures for maintaining and cleaning the condensate trap and neutralizing box.

15.7 - Connection of the display to other burners

How to connect the display to different burners on multiburner units.

15.8 - How to move a control board

Instructions for moving or replacing a control board on multiburner units.

16 - TECHNICAL DATA

Technical Data Table

Provides specifications for heater models, including heat input, gas flow, and operating parameters.

17 - SPARE PARTS

Spare Parts Identification and Model Breakdown

Lists spare parts and their corresponding model numbers for different heater series.

Detailed Spare Parts Lists

Detailed breakdown of spare parts for model 199, with part numbers and descriptions.

18 - READ OUT FLOW CHART

Flow Chart and Legend

Explains how to navigate menus and understand parameter changes with flowcharts and symbol definitions.

19 - FACTORY MENU

Parameter Descriptions

Lists and describes parameters available in the factory menu for appliance settings and diagnostics.

20 - SEQUENCE OF OPERATION for BOILER

Boiler Operation Sequence Flowchart

Visual representation of the operational sequence for IB boilers, detailing steps and conditions.

21 - SEQUENCE OF OPERATION for WATER HEATER

Water Heater Operation Sequence Flowchart

Visual representation of the operational sequence for IW water heaters, detailing steps and conditions.

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