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RBI Gas boilers User Manual

RBI Gas boilers
44 pages
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10/12 Copyright 2012 Mestek, Inc.
FTF-I0M-HN-4
82-0312
Boiler manual
Installation and operation
instructions
Also read and follow:
HeatNet control manual
is 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.  e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
A 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.
Finned copper tube
Gas boilers (CB), &
Water heaters (CW) &
Pool heaters (CP)
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RBI Gas boilers Specifications

General IconGeneral
BrandRBI
ModelGas boilers
CategoryBoiler
LanguageEnglish

Summary

FUTERA FUSION Boiler Manual Installation and Operation Instructions

Before You Start

Essential preliminary steps and considerations before installing the boiler unit.

Ratings and Capacities

Technical specifications and performance ratings of the boiler unit.

Boiler/Water Heater Location

Guidelines for selecting an optimal and safe installation location for the unit.

Combustion Air and Ventilation Requirements

Requirements for supplying adequate air for combustion and venting flue gases.

Combustion Air Sources

Procedures for providing combustion air from within the building's interior spaces.

Outdoor Combustion Air Intake

Procedures for providing combustion air directly from the building's exterior.

Intake Air Option Guidelines

Specific guidelines for utilizing the direct intake air option for combustion.

Vent System Options Overview

Overview of different methods and configurations for venting flue gases from the boiler.

General Venting Guidelines

Universal rules and safety precautions for all venting installations.

Direct Vent System Configurations

Details on direct venting using positive pressure for Category IV systems.

Horizontal Direct Vent Systems

Installation requirements and guidelines for horizontal direct vent configurations.

Vertical Direct Vent Systems

Installation requirements and guidelines for vertical direct vent configurations.

Combination Direct Vent Systems

Guidelines for systems combining direct venting with other air/venting methods.

Side Wall Venting

Installation of side wall venting systems with positive pressure for Category IV.

Vertical Venting Options

Installation of vertical venting systems for Category IV and common venting.

Vertical Chimney Venting

Venting through chimneys using negative pressure for Category II systems.

Vent Connections

Specific guidance on connecting vent pipes to the appliance and system.

Outdoor Venting

Procedures and considerations for installing the boiler outdoors.

General Piping Requirements

General rules for installing piping connected to the boiler unit.

Freeze Protection Measures

Measures to protect the boiler and piping from freezing in cold conditions.

Condensate Piping Installation

How to properly install and manage condensate drainage from the unit.

Pressure Relief Valve Installation

Installation and safety guidelines for the pressure relief valve.

Heating System Piping

Comprehensive guide for installing the heating system piping.

Flow Switch Functionality

Proper installation and function of the flow switch for safety.

Boiler Piping Connections

Details on connecting supply and return pipes for heating systems.

Pump Requirements and Selection

Specifications and requirements for the system pump.

Primary and Secondary Piping

Recommended configurations for primary/secondary piping systems.

Domestic Water Supply Piping

Guidelines for connecting and operating the domestic water supply.

Bleeding Air from Water Heater

Procedure for removing air from the water heater's heat exchangers.

Water Chemistry Considerations

Importance of water quality parameters like hardness and pH.

Expansion Tank Installation

Requirement and function of expansion tanks in the water heating system.

Thermostatic Mixing Valve

Installation and use of mixing valves for domestic hot water.

Gas Supply Piping

Critical instructions for safely connecting the gas supply to the boiler.

Electrical Wiring

Guidelines for making safe and compliant electrical connections.

General Operation

Overview of the boiler's operational principles and safety checks.

Hydronic System Fill

Steps for filling the hydronic heating system with water.

Operating Instructions

Step-by-step guide for safely starting up and operating the boiler.

Turn Off Gas Supply

Procedures for safely shutting off the gas supply to the appliance.

Sequence of Operation

Describes the boiler's operational steps from demand to shutdown.

Checking and Adjustments

Procedures for verifying and adjusting boiler settings for optimal performance.

Spark Gap Adjustment

How to check and adjust the spark gap for proper ignition.

Pilot Adjustment Procedure

Procedure for checking and adjusting pilot gas pressure.

Required Gas Pressure

Specifications for gas supply pressure at the boiler inlet.

Natural Gas Input Rate Verification

Method for verifying the natural gas input rate based on altitude.

HeatNet Field Wiring (Terminal Block)

Wiring instructions for connecting the HeatNet control board to field devices.

HeatNet Field Wiring Diagram

Detailed diagram for field wiring the HeatNet control board.

Control System Description

Explanation of the boiler's control system components and their functions.

Low Water Cutoff Device

Function and installation of the low water cutoff safety device.

Operating Control Settings

Setting the primary control for desired operating temperatures.

High Limit Aquastat

The function and reset procedure for the high limit aquastat.

Flow Switch Function

The role of the flow switch in preventing operation without water flow.

Diagnostics and Fault Display

How to interpret the boiler's diagnostic display for operational status.

Status Screen Fault Display

Explains fault messages and their meanings on the status screen.

Maintenance Procedures

Procedures for routine cleaning, inspection, and upkeep of the boiler.

Burner Removal

Step-by-step guide for safely removing the burner assembly.

Heat Exchanger Cleaning

Instructions for cleaning the primary heat exchanger.

Heat Exchanger Repair

Procedures for repairing or replacing heat exchanger components.

Air Intake and Vent System Maintenance

Inspection and maintenance of the air intake and venting systems.

Control System Checks

General checks and operational guidance for various boiler controls.

Burner Flame Inspection

Visual checks for proper pilot and main burner flame patterns.

Startup Troubleshooting

Guidance on diagnosing and resolving common startup issues.

Repair Parts Identification

Identification and part numbers for replacement components.

Start-Up Report

A checklist and sequence for the initial startup and commissioning of the boiler.

Pre-Startup Checklist

A list of essential checks to perform before initiating boiler startup.

Boiler Startup Sequence

The step-by-step procedure for safely starting the boiler.

Commissioning Checklist

Final steps and checks to ensure proper operation and customer satisfaction.

Massachusetts Installation Requirements

Specific installation mandates for Massachusetts, including safety regulations.

Limited Warranty Information

Details regarding the warranty terms and conditions for the boiler/water heater.

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