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Finned copper tube gas boilers & water heaters – Boiler Manual

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OPERATING INSTRUCTIONS 

FOR YOUR SAFETY READ BEFORE OPERATING. 

POUR VOTRE SÉCURITÉ LISEZ AVANT DE 
METTRE EN MARCHE

A.   Th is appliance is equipped with an ignition device which auto-

matically lights the pilot. Do not try to light the pilot by hand.

 

Cet appareil est muni d’un dispositif d’allumage qui allume 

automatiquement la veilleuse. Ne tentez pas d’allumer la veil-
leuse manuellement.

B.   BEFORE OPERA

  TING smell all around the appliance area 

for gas. Be sure to smell next to the fl oor because some gas is 
heavier than air and will sett le on the fl oor.

Propane gas may not always be detected by smell. 
Propane gas is heavier than air and can collect in low 

areas.

 

Propane gas can ignite or explode if an ignition source 

is present and result in death, serious injury and 
property damage!

FOR YOUR SAFETY

•  Have only qualifi ed licensed professionals install, service and 

maintain this appliance and your gas system in accordance with 
all applicable codes.

•  If you suspect a leak:

1.  Have everyone leave the building immediately.

2.  Do not att empt to light any appliance.
3.  Do not touch any electrical or electronic switches in the 

building.

4.  Do not use any phone in the building.

5.  Call your gas supplier from a phone outside of the building.

6.  If you cannot reach your gas supplier call the fi re department.

AVANT DE FAIRE FONCTIONNER, reniflez tout autour de 

l’appareil pour déceler une odeur de gaz. Reniflez près du 
plancher, car certains gaz sont plus lourds que l’air et peuvent 
s’accumuler au niveau du sol.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: 

•   Ne pas tenter d’allumer d’appareil. 
•   Ne touchez à aucun interrupteur; ne pas vous servir des 

téléphones se trouvant dans le bâtiment. 

•   Appelez immédiatement votre fournisseur de gaz depuis un 

voisin. Suives les instructions du fournisseur. 

•   Si vous ne pouvez rejoindre le fournisseur, appelez le service 

de incendies.

C.  Do not use this appliance if any part has been under water. 

Immediately call a qualifi ed service technician to inspect the 

appliance and to replace any part of the control system and any 
gas control that has been under water.

 

N’utilisez pas cet appareil s’il a été plongé dans l’eau, même 

partiellement. Faites inspecter l’appareil par un tecnicien qualifi é 
et remplacez toute partie du système de contrôle et toute 
commande qui ont été plongés dans l’eau.

Operating Instructions

1.  

STOP!

 Read the safety information above. If, at any time, 

the appliance will not operate properly, follow the instructions 

“TO TURN OFF GAS TO APPLIANCE” and call your service 

technician or gas supplier. 

2.   Set the operating control to off  and disable any outside (BMS) 

call for heat.

3.   Turn off  all electric power to the appliance.
4.   Close main isolation gas valve (fi eld supplied), Figure 14. 
5.   Purge the gas piping up to the manual valve ahead of the main 

gas control of air. When the bleeding is complete, check all gas 
joints up to the gas valve for leaks.

6.   Wait fi ve (5) minutes to clear out any gas. 

7.   Install a fi tt ing at the supply test port and connect a manometer 

having a minimum range of 

20 in

508 mm

 WC to it, Figure 

14.

8.   Remove the 1/8 in pipe plug from the pilot test port located 

on the CV100 pilot/reg combination gas valve and connect a 
manometer having a minimum range of 

6 in

154 mm

 WC to 

it, Figure 15.

9.   Open the main isolation gas valve (fi eld supplied), Figure 14

10.   Place  the “Remote/Local” switch to Remote inside control 

cabinet, Figure 16.

11.  Turn the power switch on the front of the boiler to “on”. It will 

light up when the power is on. If all interlocks are properly 
closed, the display will say “Standby”, Figure 16. 

12. Slide the Low Fire Hold Switch (on HeatNet control board) 

to Low Fire position.

13. Th e boiler will begin the start sequence. 
14.  When the main display reads “PILOT RUNNING” and the 

fl ame current is 5 VDC, switch the Honeywell 7800 to the “test” 
position, Figure 16. Th is will hold the Honeywell 7800 in its 
ignition state..

15.   Adjust the pilot pressure per the CHECKING, ADJUSTMENT 

& OPERA

 TION section. 

16.  Remove the demand from the 7800 control by disabling the 

Low Fire switch, allowing the boiler to stop.

Summary of Contents for Gas boilers

Page 1: ...ction 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 ca...

Page 2: ...RESSURE VESSEL CODE SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRES SURE OF 160 PSI 1103 kPa WATER BEFORE YOU START 2 RATINGS CAPACITIES 3 BOILER WATER HEATER LOCATION 3 COMBUSTION AIR VENTILATION 3 G...

Page 3: ...se to a chimney or outside wall and have adequate fresh air forcombustion Ensurethattheboiler waterheaterislevelfrom front to back and from side to side Use metal shims to level the boiler water heate...

Page 4: ...ely communicate with the outdoors must be present The upper opening must be within 12 in 305 mm of but not less than 3 in 76 mm from the top of the enclosure The bottom opening must be within 12 in 30...

Page 5: ...e building structure and not by the boiler water heater Appropriate thimbles and fire stops must be used where required Common vent systems must be properly engineered and sized please contact the fac...

Page 6: ...exceed5 ft 1 5 m they must be supported at 3 ft 0 9 m intervalswith overhead hangers Theventsystemmust bepitcheddown towardthe ventterminal 1 4 in ft 20 mm m If anypartofasinglewallmetalventsystempass...

Page 7: ...on air and venting for single or multiple units exhaust and combustion air terminalsmustbeinstalledonthesameplane outsidewall in order to prevent pressure differences due to prevailing winds Incoldcli...

Page 8: ...3 Vertical Air Intake and Venting for a Direct Vent System Locate exhaust terminal downwind to reduce flue gas recirculation Figure 4 Horizontal Air Intake and Venting for Multiple Direct Vent Systems...

Page 9: ...ng A through inspection of the masonry chimney must be performed to ensure that the chimney is clean properly constructed lined and sized Exterior masonry chimneys should not be used unless properly l...

Page 10: ...If horizontal runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The vent connector should be sloped up toward the chimney at a minimum rate of 1 4in ft 21 mm...

Page 11: ...served 1 AcontinuousflowofwaterthroughtheunitMUSTbemaintained The pump responsible for flow through the boiler water heater must run continuously 2 An ethylene glycol water mixture suitable for the mi...

Page 12: ...the pump on each time the burner fires and runs the pump for 20 to 600 seconds after the call for heat is satisfied The maximum allowable primary heat exchanger temperature rise is 35 F 19 4 C The max...

Page 13: ...Drain Valve Typ 3 Way Mixing Valve Item Number Description 1 3 Way Valve 2 Air Purging Valves 3 Flow Switch 4 Circulator 5 Pressure Relief Valve 6 T P Gauge 7 Primary Heat Exchanger Drain Valves 8 Co...

Page 14: ...boiler is filled Use purge valves provided Purge valve may be located on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 3 All boiler...

Page 15: ...m 3 way valve after the boiler is filled Use purge valves provided Purge valve may be located on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for...

Page 16: ...be consulted when these water conditions are encountered See Table 8 RBI water heaters are designed to run scale free Due to the extreme variables of water conditions world wide it is necessary to con...

Page 17: ...w Rate gph t deg f Flow Rate gph t deg f Flow Rate gph t deg f 60 614 96 833 106 1050 112 1460 101 1664 106 1859 111 2118 111 80 753 76 998 86 1245 92 1768 81 2000 86 2205 91 2520 91 100 999 56 1268 6...

Page 18: ...d heater flow 5 Hot water tanks should be equipped with a combination temperature pressure relief valve 6 MA Code requires an 1 8 in hole in check valve to compensate for thermal expansion 7 Boiler an...

Page 19: ...mum combined heater flow 5 Hot water tanks should be equipped with a combination temperature pressure relief valve 6 MA Code requires an 1 8 in hole in check valve to compensate for thermal expansion...

Page 20: ...hould be used in conjunction with Table 11 to ensure that the gas supply piping has the capacity to meet the demand Figure 14 depicts the proper way to connect the boiler water heater to the gas suppl...

Page 21: ...of 14 awg Use appropriate wiring materials for units installed outdoors The wire size must be compatible with the total amp draw of the circuit Refer to the wiring diagram supplied with the boiler wa...

Page 22: ...if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water N...

Page 23: ...lbow pressure Table 13 The low fire O2 CO2 can be adjusted in the field by opening the low fire adjustment door located on the forward facing side of the main gas valve see Figure 15 Inserting an alle...

Page 24: ...setting 2 Turnoffallelectricpowertotheboilerifserviceistobeperformed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 R glez le thermostat la tem...

Page 25: ...follows LP Nat Minimum in WC 2 2 Maximum in WC 14 14 Measure pressure when the boiler is firing at full rate Low gas pressure could indicate undersized gas line or insufficient gas supply Static and...

Page 26: ...20mA signal can be used to control HeatNet equipped boilers Method 1 A 4 20mA signal can be used to directly modulate each boiler from a remote panel or building management system On multiple boiler i...

Page 27: ...nned copper tube gas boilers water heaters Boiler Manual Finned copper tube gas boilers water heaters Boiler Manual 27 F RIOM 86 Figure 19 RBI Field Wiring to HeatNet Board BoardRevision 2 0 and Great...

Page 28: ...he display will also list faults should the unit fail to operate An explanation of each status message and fault can be locatedinHeatNetControlManualunderstatusscreenfaultdisplay section STATUS SCREEN...

Page 29: ...on or use as a field interlock The interlock is located on J11B SPARE 4 FAULT SYSTEM SET 160 F INTERLOCK SPARE 4 FLOW SWITCH ERROR Once the Futera Fusion series boiler receives a call for heat it clos...

Page 30: ...TEM SET 160 F OPEN OUTSIDE SENSOR SHORTED SENSOR If the shorted sensor fault is displayed the sensor in the position reported was originally detected but has since shorted The boiler will shut down on...

Page 31: ...l with some types of gases Black soot indicates poor combustion Green deposits indicate condensation due to low return water temperatures In either case the heat exchanger must be cleaned thoroughly a...

Page 32: ...pressure If it does contact a qualified service technician to have it inspected NEVER try to clean or repair the relief valve If the valve fails to operate properly have it replaced 5 Theaquastathighl...

Page 33: ...k for 24 VAC on J11A J11B to identify which interlock has tripped Reset the Interlock or check for disconnected wiring or shorts The Air Pressure from UV Sensor interlock if displayed will allow the b...

Page 34: ...Fi d b b il h B il M l Finned copper tube gas boilers water heaters Boiler Manual 34 F F Figure 21 Repair Parts REPAIR PARTS 34...

Page 35: ...Finned copper tube gas boilers water heaters Boiler Manual Finned copper tube gas boilers water heaters Boiler Manual 35 F REPAIR PARTS CONTINUED...

Page 36: ...ket 06 0022 1 1 1 1 1 1 1 NS Gas Injectors NG 10 1009 1 1 1 1 Gas Injectors NG 10 1002 1 1 1 Gas Injectors LP 10 1010 1 1 1 1 1 1 1 21 Firing Valve 1 11 0456 1 1 Firing Valve 1 1 4 11 0457 1 1 Firing...

Page 37: ...on prior to 0209 must replace 70 2516 1R 1 combustion chamber top panel 36 70 2517 1R 1 70 2518 1R 1 70 2519 1R 1 70 2520 1R 1 70 2521 1R 1 Heat Exchanger Assembly Copper 70 2186 1R 1 Bronze 70 2187 1...

Page 38: ...4 Main Board HeatNet green 16 0038 1 1 1 1 1 1 1 55 Display Board HeatNet 40 0088 1 1 1 1 1 1 1 NS Ribbon Cable 40 0115 1 1 1 1 1 1 1 NS Power Switch 48 0013 1 1 1 1 1 1 1 NS Toggle Switch Remote Loca...

Page 39: ...1 1 1 1 1 Pilot Orifice LP 10 0139 1 1 1 1 1 1 1 82 Mini Peeper C7027A 16 0009 1 1 1 1 1 1 1 85 Turbo Pilot Torch 70 2559 1 1 1 1 1 1 1 86 1 2 Aluminum Tubing 62 0103 1 1 1 1 1 1 1 NS Spark Rod Assem...

Page 40: ...the bottom of the electrical panel Disable any external call for heat and toggle the remote local switch to REMOTE 1 Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignitio...

Page 41: ...F 15 TIMES THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROP ER FLOW BEFORE YOU LEAVE THE JOB SITE YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 35o F 19 4o C NOR BE LO...

Page 42: ...t 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 GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBST...

Page 43: ...tructions for proper pump performance Chemical corrosion no corrosive chemical freon dry cleaning chemicals degreasing liquids chlorine or any chemicals that produce hydrochloric acid can be present i...

Page 44: ...ht 2012 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...

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