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Copyright 2008 Mestek, Inc.
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
Page 1: ...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...
Page 2: ...blocked air inlet 11 DP switch blocked flue 12 DP switch blower prov ing 13 DP switch pilot air prov ing 14 Ignitor 15 Pilot gas valve and pilot gas pressure regulator 16 Flow switch 17 Low water cut...
Page 3: ...he Commonwealth of Massachusetts you MUST FOLLOWtheadditionalinstructionscontainedinRBI sinstruction sheet MACODE 3 located in the back of this manual The owner should maintain a record of all service...
Page 4: ...er water heater in a location that would restrict the introduction of combustion air into the unit or subject it to a negative pressure see GENERAL VENTING GUIDELINES 6 NEVER place this boiler water h...
Page 5: ...have a minimum mesh size of 1 4 inch 6 4 mm If the free area through a louver or grill is not known ducts should be sized per Table 2 Canadian installations must comply with CSA B149 1 when air suppl...
Page 6: ...d windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance...
Page 7: ...the vent system manufacturer s instructions Whenhorizontalventrunsexceed5ft 1 5mtheymustbesupported at 3 ft 0 9 m intervals with overhead hangers The vent system must be pitched down toward the vent...
Page 8: ...ntal combustion air and venting for single or multiple units exhaust and combustion air terminals must be installed on the same plane outside wall in order to prevent pressure differences due to preva...
Page 9: ...0 feet each See Table 3 or 4 for min pipe diameters Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation Failure to complycouldresultinsevere personal injury...
Page 10: ...nry chimneys should not be used unless properly lined to prevent condensation and draft problems Table 4 lists the equivalent breeching and flue sizes required for the boiler water heater Vent connect...
Page 11: ...UP TO 100 FEET MAXIMUM In this configuration the boiler water heater blower is used to push the flue products horizontally to the outdoors see Figure 7 The air for combustion is taken from the space...
Page 12: ...ORY II CHIMNEY INSPECTION SIZING Masonry chimneys when used must be lined with a metal liner certified for Category IV venting A thorough inspection of the masonry chimney must be performedtoensuretha...
Page 13: ...designed using accepted engineering practices and the design calculations prove there is no need for barometric dampers the barometric dampers may be omitted When required by applicable codes install...
Page 14: ...e Pipe the discharge of the pressure relief valve as shown in Figure 9 page 15 Never install any type of valve between the boiler waterheaterandthereliefvalveoranexplosioncausing extensive property da...
Page 15: ...eriseoutsideoftherangelistedinTable7 willresultindamagetotheheatexchanger voidingthe warranty The maximum allowable temperature rise through the boiler is 35o F 19 4o C The maximum allowable flow rate...
Page 16: ...umps orsystemsthathaveexcessiveflowratesorreturnwatertemperatures lessthan140o F 60o Cmustbeisolatedfromthesesystemstoprotect the boiler Variable water flows Figure 10 shows a typical primary secondar...
Page 17: ...iler design flow requirements 3 All boilers furnished with factory mounted outlet water temperature gauge 4 Boiler pump purging required Use termi nals supplied These drawings show suggested piping co...
Page 18: ...actory mounted outlet water temperature gauge 4 Boiler pump purging required Use terminals supplied 5 Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units F...
Page 19: ...F water heater is 260 GPM 16 4 L when equipped with coppertubes Thecupronickelheatexchangerallowsfor 315 GPM 19 9 L s See Table 9 page 20 RBI water heaters are designed to run scale free Due to the ex...
Page 20: ...itional precautions must be observed due to unusual characteristics of the local water supply Call the nearest RBI representative for details To properly size the pump a grain hardness andpHtestmustbe...
Page 21: ...l 6 90o elbows full pipe size 5 CAUTION MEASURE WATER HARDNESS AND pH AT JOB SITE 6 The pH and water hardness must be measured before selecting heat exchanger and pump Consult the Heat Exchanger Graph...
Page 22: ...assupplypipinghasthecapacitytomeetthedemand Figure 16 depicts the proper way to connect the boiler water heatertothegassupplypiping Themanualshut offvalveMUSTbe installedinthesupplypiping Itshouldbein...
Page 23: ...size Fitting or valve 90o elbow Tee branch flow Gate valve Gas cock 2 5 2 10 3 1 2 3 0 2 6 2 12 3 1 4 3 5 3 7 7 15 3 1 8 4 5 4 10 1 20 2 2 4 6 0 5 12 6 25 2 2 9 7 3 6 15 2 30 4 3 5 13 4 Equivalent le...
Page 24: ...lose the make up water valve and check and clean the strainers and make up water pressure reducing valve Open the make up water valve and adjust the system pressure if necessary The system should be c...
Page 25: ...at minimum ignition setting See the calibration section in the HeatNet Control IOM to enter the calibration menus 2 The ignition transformer is energized The pilot solenoid valve opens for the 10 sec...
Page 26: ...tNet control board to the LOW FIRE position 14 The boiler will begin the start up sequence 15 Allow the boiler to pre purge and enter the pilot ignition cycle 16 Ifpilotlights indicatedbyagoodflamesig...
Page 27: ...y combustion readings Leave the manometer connected to the test manifold It will be needed for high fire operation testing Verify high fire operation 1 Jumper the AA terminals on the HeatNet board and...
Page 28: ...ion and control methods Reference the XLF HeatNet Control IOM TO TURN OFF GAS TO APPLIANCE 1 Set the operating control to its lowest setting 2 Turn off all electric power to the boiler if service is t...
Page 29: ...is firing at full rate Low gas pressure could indicate undersized gas line or insufficient gas supply 2 Staticandoperatinggaspressurerequiredatthegasvalveinletis listed in the Table above If the gas...
Page 30: ...y lines and turn off electrical power to the boiler water heater 2 RemoveburnerfollowingtheinstructionsintheBurnerRemoval section 3 Remove the front jacket panel and combustion chamber door 4 Inspect...
Page 31: ...ied service technician to have it inspected NEVERtrytocleanorrepairthereliefvalve Ifthevalve fails to operate properly have it replaced 5 Theaquastathighlimitcontrolsthemaximumwatertemperature in the...
Page 32: ...F d b b l h B l M l Finned copper tube gas boilers water heaters Boiler Manual 32 F F Figure 23 Futera XLF pressure sensor hose routing...
Page 33: ...F d b b l h B l M l Finned copper tube gas boilers water heaters Boiler Manual 33 F F Figure 24 Exploded view REPAIR PARTS...
Page 34: ...F d b b l h B l M l Finned copper tube gas boilers water heaters Boiler Manual 34 F F REPAIR PARTS CONTINUED Figure 25 Figure 20 Electrical components...
Page 35: ...1 1 1 1 12 Bottom Corner 04 0542 4 4 4 4 13 Base Legs Left Side 04 1018 1 1 1 1 Base Legs Right Side 04 1022 1 1 1 1 15 Burner 10 0322 1 10 0297 1 10 0323 1 10 0300 1 15a Burner O ring 06 0006 1 1 1 1...
Page 36: ...Assembly 70 3510 1 1 1 1 30 Lower Rear Jacket Panel 03 3786 1 03 3787 1 03 3788 1 03 3789 1 NS Rear Panel Outdoor 03 3810 1 03 3811 1 1 1 NS Left Hand Rear Panel Outdoor 70 4113 1 70 4115 1 1 1 31 Upp...
Page 37: ...1 1 1 1 NS Latch 20 0045 2 2 2 2 41 Drain Valve Assembly MB 70 2562 1 1 1 1 Drain Valve Assembly MW 70 2564 1 1 1 1 NS Drain Valve Gaskets 06 0084 1 1 1 1 43 External Pilot Train Assembly 1 70 3655 1...
Page 38: ...0104 1 2 2 2 NS Alarm Button 48 0003 1 1 1 1 NS Alarm Toggle Bracket 03 3754 1 1 1 1 NS Terminal Block 6P 48 0157 1 1 1 1 NS Terminal Block 18P 48 0159 1 1 1 1 NS Relay 2P 24V optional 15 0121 1 1 1 1...
Page 39: ...71 Pump Contactor 3PH 15 0211 1 1 1 1 72 Relay Overload 5 5 8 Amp 15 0214 1 1 1 1 Relay Overload 9 13 Amp 15 0215 1 1 1 1 Relay Overload 2 5 4 Amp 15 0216 1 1 1 1 Relay Overload 4 6 Amp 15 0217 1 1 1...
Page 40: ...om right of the electrical panel on the main HeatNet board Also locate the manometer test manifold in the bottom of the electrical panel 1 Disable any external call for heat and toggle the remote loca...
Page 41: ...60o C Operating atlowerreturntemperaturesislikelytocausecondensationintheprimaryheatexchanger resultingincorrosionandpossible failure of the heat exchanger COMMISSIONING THE BOILER WATER HEATER UNIT C...
Page 42: ...ith the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GASVENTDIRECTLYBELOW KEEPCL...
Page 43: ...ty Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer s warranty See Installation Instructio...
Page 44: ...ht 2008 Mestek Inc 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 rbiwaterhe...
