Page 1
Finned Copper
Gas Boilers (HB) &
CI0M-12
82-0252
Water Heaters (HW)
Boiler Manual
Installation and Operation
Instructions
is manual is intended only for use by a qualied 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.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service
technician, and to follow all guidelines in the User’s Information Manual.
03/16 Copyright 2014 Mestek, Inc.
Page 2
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 2
If the information in this manual is not followed
exactly, a re or explosion may result causing
property, personal injury or loss of life.
Do not store or use gasoline or other ammable vapors
and liquids in the vicinity of this or any other appliance
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a phone outside
of the building. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the re
department.
Installation and service must be performed by a qualied installer, service agency or the gas supplier.
A ssurez -vous de bien suiv re les instr uctions données
dans cee notice pour réduire au minimum le risque
d’incendie ou d’explosion ou pour éviter tout
dommoge matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides inammables à proximité de cet
appareil ou de tout autre appareil.
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 gas
depuis un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez
le service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualié ou par le
fournisseur de gaz.
CONTENTS
Before You Start ................................................page 2
Ratings & Capacities ......................................... page 3
Boiler/Water Heater Location ............................page 3
Combustion Air & Ventilation ............................. page 4
Chimney & Vent Pipe Connections ....................page 8
Common Vent Systems .....................................page 9
General Piping Requirements .........................page 10
Heating System Piping .................................... page 10
Domestic Water Supply Piping ........................ page 15
Gas Supply Piping ........................................... page 19
Electrical Wiring ............................................... page 20
General Operation ........................................... page 20
Operating Instructions .....................................page 21
Checking & Adjustments .................................. page 22
Control Description .......................................... page 24
Maintenance .................................................... page 25
Trouble-Shooting ............................................. page 27
Repair Parts, 8900 ...........................................page 29
Repair Parts, 8800 ...........................................page 38
BEFORE YOU START
This manual covers the application, installation, operation
and maintenance of a Series 8800 and 8900 nned
copper heating boiler/water heater/(pool heater - Canada
Only).
To obtain the safe, dependable, efcient operation and
long life for which this heating boiler/water heater was
designed, these instructions must be read, understood
and followed.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION IV
FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED
ADJACENT TO THE HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR
FUTURE PURPOSES.
The Series 8800 and 8900 finned copper heating
boiler/water heaters have been design certied by CSA
for use with natural and propane gas under the latest
revision of ANSI-Z21.10.3/CSA 4.3, Gas Water Heaters,
ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam
and Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired
Pool Heaters (Canada Only) and CAN1-3.1, Industrial
and Commercial Gas Fired Packaged Boilers. Each unit
has been constructed and hydrostatically tested for a
maximum working pressure of 160 psi, 1103 kPa in
accordance with Section IV of the A.S.M.E. Boiler and
Pressure Vessel Code.
Page 3
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 3
All aspects of the boiler/water heater installation must
conform to the requirements of the authority having
jurisdiction, or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1/NFPA
54-latest revision. Where required by the authority
having jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
In Canada, the installation must be in accordance with the
requirements of CAN/CGA B149.1 or .2, Installation Code
for Gas Burning Appliances and Equipment.
If installed in the Commonwealth of Massachusetts, you
MUST FOLLOW the additional instructions contained in
RBI's instruction sheet MACODE-3. If you do not have a
copy, call your RBI distributor or contact the RBI Customer
Service Department.
The owner should maintain a record of all service work
performed with the date and a description of the work
done. Include the name of the service organization for
future reference.
Direct all questions to your RBI distributor or contact the
RBI Customer Service Department, 260 North Elm Street,
Westeld, MA 01085 for U.S. or 7555 Tranmere Drive,
Mississauga ONT L5S 1L4 for Canada. Always include
the model and serial numbers from the rating plate of the
boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Series 8800
and 8900 boiler/water heater check the rating plate to
ensure that the unit has been sized properly for the job.
The “Net Ratings” specify the equivalent amount of direct
copper radiation that the unit can supply under normal
conditions. Also ensure that the unit has been set up for
the type of gas available at the installation site. Other
important considerations are the availability of an
adequate electrical supply, fresh air for combustion and
a suitable chimney or vent system.
BOILER/WATER HEATER LOCATION
1. Locate the boiler/water heater in an area that
provides good access to the unit. Servicing may
require the removal of jacket panels.
minimum clearances between adjacent construction
and the boiler/water heater as listed in Table 1 or 1A.
NOTE: Service clearances are not mandatory, but
are recommended to ensure ease of service should
it be required.
Table 1 (8800)
Clearance to Service
Combustibles Clearance
in mm in mm
Top 24 610 18 457
Back 24 610 18 457
Left Side 24 610 24 610
Right Side 24 610 24 610
Front 48 1220 48 1220
Flue 6 152 6 152
Table 1A (8900)
Clearance to Service
Combustibles Clearance
in mm in mm
Top 24 610 18 457
Back 18 457 18 457
Left Side 18 457 18 457
Right Side 18 457 18 457
Front 48 1220 36 914
Flue 6 152 6 152
2. An optimum site will be level, central to the piping
system, close to a chimney and have adequate fresh
air for combustion. Ensure that the boiler/water
heater is level from front to back and from side to
side. Use metal shims to level the boiler/water heater.
Electrical and electronic components must also be
protected from exposure to water during operation
and maintenance. DO NOT install this boiler/water
heater in a location that would subject any of the gas
ignition components to direct contact with water or
excessive moisture during operation or servicing.
Allow the
Page 4
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 4
3. Ensure that the oor is structurally sound and will
support the weight of the boiler/water heater.
NOTE: Never install a Series 8800 or 8900 boiler/
water heater on a concrete oor that contains wires,
cables, water pipes or hoses. This boiler/water
heater is designed for noncombustible oors only!
Never install this boiler/water heater on combustible
materials or carpeting even if a non-combustible
foundation material is placed over them!
4. Locate the boiler/water heater in an area that will
prevent water damage to adjacent construction
should a leak occur or during routine maintenance.
If such a location doesn’t exist, a suitable drain pan
that’s adequately drained must be installed under
the unit. The
combustion air to the unit.
5.
DO NOT place this boiler/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 heater in a location
that would subject it to temperatures at or near
freezing.
WARNING: Never store combustible materials,
gasoline or any product containing ammable vapors
or liquids in the vicinity of the boiler/water heater.
Failure to comply with this warning can result in an
explosion or re causing extensive property damage,
severe personal injury or death!
pan must not restrict the flow of
COMBUSTION AIR & VENTILATION
WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
Section 5.3, Air for Combustion & Ventilation, of
the latest revision of the National Fuel Gas
Code, ANSI Z223.1/ NFPA 54 and all applicable
local building codes. Canadian installations
must comply with CAN/ CGA B149.1 or .2
Installation Code for Gas Burning Appliances
and Equipment, or applicable provisions of the
local building codes. Failure to provide adequate
combustion air for this boiler/water heater can
result in excessive levels of carbon monoxide
which can result in severe personal injury or
death!
To operate properly and safely this boiler/water heater
requires a continuous supply of air for combustion.
NEVER store objects on or around the boiler/water heater!
CAUTION: Combustion air contaminated with
uorocarbons or other halogenated compounds
such as cleaning solvents and refrigerants will
result in the formation of acids in the combustion
chamber. These acids will cause premature failure
of the boiler/water heater voiding the warranty!
CAUTION: If the boiler/water heater is operated
while the building is under construction it MUST be
protected from wood, concrete, sheet rock and
other types of dust. Failure to properly protect the
unit from construction dust will damage the unit
voiding the warranty!
All Air From Inside The Building
If the boiler/water heater is to be located in a conned
space minimum clearances listed in Table 1 or 1A must
be maintained between the boiler/water heater and any
combustible construction. When installed in a conned
space, Figures 1, 2, 3, 4 and 5, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
sufcient volume to meet the criteria for an unconned
space. The total air requirements of all gas utilization
equipment, fireplaces, wood stoves or any type of
exhaust fan must be considered when making this
determination. Each opening must have a minimum free
area of 1 in2/1000 Btu/hr, 2200 mm2/kW based on the
total input rating of ALL gas utilization equipment in the
conned area. Each opening must be no less than
100 in2, 64,516 mm2 in size. 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, 305 mm of, but not less
than 3 in, 76 mm from, the bottom of the enclosure.
All Air From Outside The Building
When installed in a conned space two permanent
openings communicating directly with, or by ducts
to, the outdoors or spaces that freely 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, 305 mm of, but not less
than 3 in, 76 mm from, the bottom of the enclosure.
Where directly communicating with the outdoors
or communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area
of 1 in2/4000 Btu/hr, 550 mm2/kW of the total input
rating of all of the equipment in the enclosure.
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SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 5
Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr, 1100 mm2/kW of the total
input rating of all of the equipment in the enclosure.
When ducts are used, they must have the same crosssectional area as the free area of the opening to which
they connect.
Canadian installations must comply with CSA B149.1
when air supply is provided by natural air ow from the
outdoors for natural draft, partial fan-assisted, fanassisted, or power draft-assisted burners, there shall
be a permanent air supply opening(s) having a crosssectional area of not less than 1 in2 per 7,000 Btuh
(310 mm2 per kW) up to and including 1 million Btuh,
plus 1 in2 per 14,000 Btuh (155 mm2 per kW) in excess
of 1 million Btuh.
When calculating the free area necessary to meet
the make-up air requirements of the enclosure,
consideration must be given to the blockage effects
of louvers, grills and screens. Screens must have
a minimum mesh size of 1/4 in, 6.4 mm. If the free
area through a louver or grill is not known, ducts
should be sized per Table 2.
Table 2 - Make-up Air Louver Sizing
Required Cross Sectional Area
Input 1/4 in 6.4 mm
(MBH) Wire Screen Metal Louvers Wooden Louvers
in2 cm
75% Free Area 25% Free Area
2
in
2
cm
2
in
2
cm
2
420 105 677 140 903 420 2710
530 133 858 177 1142 530 3419
630 158 1019 210 1355 630 4064
735 184 1187 245 1581 735 4742
840 210 1355 280 1806 840 5419
950 238 1535 317 2032 950 6129
1050 263 1697 350 2258 1050 6774
1160 290 1871 387 2497 1160 7484
1260 315 2032 420 2710 1260 8129
1370 343 2213 457 2948 1370 8839
1470 368 2374 490 3161 1470 9484
1580 395 2548 527 3400 1580 10,194
1685 421 2716 562 3626 1685 10,871
1790 448 2890 597 3852 1790 11,548
1900 475 3065 633 4084 1900 12,258
2000 500 3226 667 4303 2000 12,903
2400 600 3871 800 5161 2400 15,483
2800 700 4516 933 6019 2800 18,064
3200 800 5161 1067 6884 3200 20,645
3600 900 5806 1200 7742 3600 23,226
4000 1000 6452 1333 8600 4000 25,806
Figure 1 - Vertical Venting Using A Metal Chimney And Inside Air (8900/8800 Series)
2 FT .6 m
10 FT 3.4 m
3 FT 1 m
3 FT 1 m
5 FT 1.52 m
RIOM-40
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SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 6
Figure 2 - Vertical Venting Using A Masonary Chimney And Inside Air (8900/8800 Series)
10 FT 3.1 m
3 FT 1 m
3 FT 1 m
5 FT 1.52 m
Figure 3 - Dual Flue Outlets And Inside Air (8900/8800 Series)
2 FT .6 m
10 FT 3.4 m
3 FT 1 m
10 FT 3.4 m
5 FT 1.5 m
RIOM-41
RIOM-42
Page 7
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 7
Figure 4 - Common Vents and Inside Air (8900/8800 Series)
10FT 3.1m
3FT 1m
5FT 1.52 m
3FT 1m
Figure 5 - Common Vents and Inside Air (8800/8900 Series) Dual Flue
10 FT
3.1 m
3 FT
1 m
RIOM-43
3 FT
1 m
5 FT
1.52 m
Figure 6 - Horizontal Venting And Inside Air (8900/8800 Series)
BUILDING OVERHANG
4FT 1.2 M MAX.
PITCH PIPE DOWN TOWARDS TERMINAL
CAP 1/4IN. PERFOOT 20MM/M OF RUN TO
3FT .9 m
1.5FT 0.5m MINIMUM DISTANCE FROM
EXHAUST TO MAXIMUM SNOW LINE.
ALLOW FOR CONDENSATE DRAINAGE
3FT 1 m
5FT 1.52 m
RIOM-44
RIOM-45
Page 8
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 8
CHIMNEY & VENT PIPE
CONNECTIONS
WARNING: The vent installation must be in
accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1/NFPA
54-latest revision or applicable provisions of
the local building codes. Canadian installations
must comply with CAN/CGA B149.1 or .2
Installation Code. Improper venting can result in
excessive levels of carbon monoxide which can
result in severe personal injury or death!
Chimney Inspection & Sizing
A thorough 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 lined to prevent
condensation and draft problems. Table 3 and 4 lists
the equivalent breeching and ue sizes required for the
boiler/water heater. Uninsulated single-wall vent pipe
shall not be used outdoors for regions where the design
temperature is below 32°F, 0°C.
When more than one appliance is connected to the
same chimney ue, the ue must be large enough to
safely vent the combined output of all the appliances.
WARNING: If an appliance using any type of a
mechanical draft system operating under
positive pressure is connected to a chimney
ue, never connect any other appliances to this
ue. Doing so can result in the accumulation of
carbon monoxide which can cause severe
personal injury or death!
Vent Connections
Always use a type B or single wall galvanized metal vent
pipe the same diameter as the draft diverter ue collar.
Use the shortest, straightest vent system possible for
the installation. If horizontal runs exceed 6 ft, 1.8 m they
must be supported at 6 ft, 1.8 m intervals with overhead
hangers. The vent system should be sloped up toward
the chimney at a minimum rate of 1/4 in/ft, 20 mm/m
and terminate ush with the inside of the chimney ue.
Fasten each connection with at least 3 corrosion
resistant sheet metal screws.
Table 3 - Equivalent Breeching & Chimney Size
Model Size Model Size
Size in mm Size in mm
420 10 254 1580 18 457
530 10 254 1685 18 457
630 12 305 1790 20 508
735 14 356 1900 20 508
840 14 356 2000 22 559
950 14 356 2400 24 610
1050 16 406 2800 26 660
1160 16 406 3200 28 711
1260 16 406 3600 30 762
1370 18 457 4000 30 762
1470 18 457
Note: These sizes are based on a 20 ft, 6.1m chimney height.
Table 4 - Equivalent Breeching & Chimney Size Dual Flue
Model Size Model Size
Size in mm Size in mm
840 10 254 1790 16 406
950 10 254 1900 16 406
1050 12 305 2000 14 356
1160 12 305 2400 16 406
1260 12 305 2800 18 457
1370 14 355 3200 20 508
1470 14 355 3600 22 559
1580 14 355 4000 22 559
1685 14 355
Note: Minimum vertical rise off top dual ue units: 3 ft, 1 m (sizes
840-3200), 5 ft, 1.5 m (sizes 3600-4000).
Always provide a minimum clearance of 6 in, 152 mm
between type C vent pipe and any combustible
materials. Type B1 vent may be used, clearance
between it and any combustible material must be as
listed.
To determine the appropriate power venter for the boiler/
water heater, see Table 5, Power Venter Sizes. Follow
the power venter manufacturer’s installation instructions.
Table 5 - Power Venter Sizes
8900 Power Venter Max. Pipe Length
Model Size FT m
420-530 HS-2 100 31
630 HS-3 100 31
735-1160 HS-4 100 31
1260-1900 HS-5 100 31
Models 2000-4000 - Consult Tjernlund
WARNING: Never modify or alter any part of the
boiler’s draft diverter. This includes the removal
or alteration of any bafes. Never install a vent
pipe of a diameter different than that of the
boiler draft hood ue collar. Failure to comply
with this warning can result in severe personal
injury or death.
WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a re causing
extensive property damage, severe personal
injury or death!
Page 9
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 9
COMMON VENT SYSTEMS
If an existing boiler/water heater is removed from a
common venting system, the common venting system
may then be too large for the proper venting of the
remaining appliances connected to it. At the time of
removal of an existing boiler/water heater, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining
connected to the common venting system are not in
operation.
Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’évacuation
commun et qui fonctionne alors que d’autres appareils
toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation
a) Seal any unused openings in the common venting
system.
Sceller toutes les ouvertures non utilisées du sys-
tème d’évacuation.
b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deciencies which could cause an unsafe condition.
Inspecter de façon visuelle le système d’évacu-ation
pour déterminer la grosser et l’inclinaison
horizontale qui conviennent et s’assurer que le
système est exempt d’obstruction, d’étranglement
de fruite, de corrosion et autres défaillances qui
pourraient présenter des risques.
c) Insofar as is practical, close all building doors and
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
not connected to the common venting system. Turn
on any exhaust fans, such as range hoods and
bathroom exhaust, so they will operate at maximum
speed. Do not operate a summer exhaust fan for a
boiler installation. Close replace dampers.
Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l’espace où les appareils toujours
raccordés du système d’évacuation sont installés et
les autres espaces du bâtiment. Mettre en marche
les sécheuses, tous les appareils non raccordés au
système d’évacuation commun et tous les
ventilateurs d’extraction comme les hottes de
cuisinère et les ventilateurs des salles de bain.
S’assurer que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les
ventilateurs d’été. Fermer les registres des
cheminées.
d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de
façon que l’appareil fonctionne de façon continue.
e) Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the ame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
Faire fonctionner le brûleur principal pendant 5 min
ensuite, déterminer si le coupe-tirage déborde à
l'ouverture de décharge. Utiliser la amme d'une
allunette ou d'une chandelle ou la fumée d'une
cigarette, d'un cigare ou d'une pipe.
f) After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas-burning appliance to
their previous condition of use.
Une fois qu’il a été d éterminé, selon la métode
indiquée ci-dessus, que chaque appareil raccordé
au système d’évacuation est mis à l’air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.
g) Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and or CAN/CGA-B149 Installation
Codes.
Tout mauvais fonctionnement du systéme d'évacu-
tion commun devrait étré corrigé de façor que
l'installation soit conforme au National Fue Gas
Code, ANSI Z223.1/NFPA 54 et (ou) aux codes
d'installation CSA-B149. Si la grosseur d'une
section du système d'évacuation doit étré modiée,
le système devrait étré modié pour respecter les
valeurs minimales des tableaux pertinents de
l'appendice F du National Fuel Gas Code, ANSI
Z223.1/NFPA 54 et (ou) des codes d'installation
CSA-B149.
Page 10
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 10
GENERAL PIPING REQUIREMENTS
CAUTION: Improper piping of this boiler/water heater
will void the manufacturer’s warranty and can cause
boiler failure resulting in flooding and extensive
property damage! Excessive water hardness causing
lime build-up in the copper heat exchanger tubes is
NOT covered under the manufacturer’s warranty.
Excessive pitting and erosion of the internal surface
of the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result
of high water ow rates, see Table 7. Return water
temperatures below 110°F, 43°C will result
in heat exchanger damage from excessive
condensation voiding the manufacturer’s warranty,
see Primary/Secondary Piping Figure 8.
NOTE: Shut off valves and unions should be
installed at the inlet and outlet connections of the
boiler/hot water heater to provide for isolation of the
unit should servicing be necessary.
Relief Valve
Pipe the discharge of the pressure relief valve to prevent
scalding in the event of a discharge, see Figure 7. The
discharge piping must be sized the same as the
pressure relief valve outlet and installed to allow
complete drainage of both the relief valve and the
discharge piping.
Figure 7
1" (25mm) CLEARANCE MUST
BE MAINTAINED BETWEEN HOT
WATER PIPING AND COMBUSTIBLE
CONSTRUCTION.
CAUTION: Failure to properly install the ow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualied
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section
IV, and ANSI/ASME CSD-1, Standard for Controls and
Safety Devices for Automatically Fired Boilers. All
applicable local codes and ordinances must also be
followed. A minimum clearance of 1 in, 25 mm must be
maintained between heating system pipes and all
combustible construction. All heating system piping must
be supported by suitable hangers not the boiler.
The thermal expansion of the system must be
considered when supporting the system. A minimum
system pressure of 12 psig, 82.7 kPa must be
maintained.
Heating Boiler Piping Connections
The supply and return connections should be sized to
suit the system, see Table 6.
Table 6 - Supply & Return Pipe Sizing
Model Supply Return
8900 21/2" NPT 21/2" NPT
8800 3" Victaulic 3" Victaulic
*Models 420-950 may have 21/2" x 2" reducing tting
installed.
DISCHARGE PIPE SIZE TO
EQUAL VALVE OUTLET.
OUTLET
INLET
RIOM-46
DO NOT RESTRICT FLOW.
DISCHARGE SO AS TO AVOID
EXPOSURE OF PERSONS TO
HOT LIQUID OR VAPOR AND
ALLOW COMPLETE DRAINAGE
0F RELIEF VALVE AND PIPING
.
WARNING: Never install any type of valve
between the boiler/water heater and the relief
valve or an explosion causing extensive
property damage, severe personal injury or
death may occur!
Flow Switch
The ow switch supplied with the boiler/water heater
must be wired to the terminal strip in the junction box
to prevent the boiler from ring unless there’s adequate
water ow through the unit. The ow switch must be
installed in the supply piping adjacent to the boiler outlet
connection.
Pump Requirements
This low mass boiler requires a continuous minimum
water ow for proper operation. The system pump must
be sized to overcome the head loss of the boiler and
the heating system in order to achieve the required
temperature rise. Table 7 provides the heat exchanger
pressure drop and temperature rise figures. The
temperature rise across the boiler must never exceed
35°F, 19.4°C. The pump delay turns the pump on each
time the burners re and runs the pump for up to 10
minutes after the call for heat is satised.
CAUTION: A temperature rise outside of the range
listed in Table 7 indicates that the ow rate through
the heat exchanger is incorrect which will damage
the heat exchanger voiding the warranty!
The maximum allowable ow rate through an 8900
boiler with copper heat exchanger is 92 GPM,
5.8 L/s.
The maximum allowable ow rate through an 8800
boiler with copper heat exchanger is 185 GPM,
11.7 L/s.
Page 11
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 11
Table 7 - Temperature Rise Table — 2 Pass Headers
20°F
Press
Flow
Model
420
530
630
735
840
950
1050
1160
1260
1370
1470
1580
1685
1790
1900
2000
2400
2800
3200
3600
4000
*Flow exceeds recommended maximum use a greater temperature rise or consult manufacturer. Cupro-nickel heat exchanger should be considered.
GPM Ft
34.0
42.9
51.0
59.5
68.0
77.0
85.1
94.0*
164.0
196.8*
Rate
—
—
—
—
—
—
—
—
—
—
—
Drop
0.4
0.7
1.1
1.6
2.4
3.3
4.4
5.8
—
—
—
—
—
—
—
4.1
6.8
—
—
—
—
11.1°C
Press
Flow
Drop
Rate
L/s kPa
1.1
2.1
2.0
2.7
3.2
3.2
4.8
3.8
7.0
4.3
9.8
4.9
12.9
5.4
17.0
5.9
—
—
—
—
—
—
—
12.0
10.3
20.0
12.4
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
25°F
Flow
Rate
GPM Ft
—
34.3
40.8
47.6
54.4
61.6
68.0
75.2
81.6
88.8
95.3*
—
—
—
—
131.2
157.4
183.7
—
—
—
Press
Drop
—
0.4
0.7
1.1
1.6
2.2
2.9
3.8
4.8
6.1
7.4
—
—
—
—
2.7
4.5
6.9
—
—
—
13.9°C
Press
Flow
Rate
Drop
L/s kPa
—
1.3
2.2
2.1
2.6
3.2
3.0
4.6
3.4
6.5
3.9
8.6
4.3
11.2
4.7
14.2
5.2
17.9
5.6
21.8
6.0
—
—
—
—
8.0
8.3
13.2
9.9
20.3
11.6
—
—
—
—
—
—
—
—
—
—
—
30°F
Flow
Rate
GPM Ft
—
—
34.0
39.7
45.4
51.3
56.7
62.6
68.0
74.0
79.4
85.3
91.0
96.7*
—
109.3
131.2
153.1
174.9
196.8*
—
Press
Drop
—
—
0.5
0.8
1.1
1.6
2.1
2.7
3.4
4.3
5.3
6.5
7.7
9.2
—
1.9
3.2
4.9
7.2
10.0
—
16.7°C
Press
Flow
Drop
Rate
L/s kPa
—
—
—
—
2.1
1.5
2.5
2.3
2.9
3.3
3.2
4.6
3.6
6.1
4.0
8.0
4.3
10.1
4.7
12.8
5.0
15.6
5.4
19.0
5.7
22.8
6.1
27.0
—
—
6.9
5.7
8.3
9.4
9.7
14.5
11.0
21.1
12.4
29.3
—
—
35°F
Flow
Rate
GPM Ft
—
—
—
34.0
38.9
44.0
48.6
53.7
58.3
63.4
68.0
73.1
78.0
82.9
87.9
93.7
112.5
131.2
149.9
168.7
187.4*
Press
Drop
—
—
—
0.6
0.8
1.2
1.6
2.0
2.6
3.3
4.0
4.8
5.8
6.9
8.1
1.4
2.4
3.7
5.4
7.5
10.1
19.4°C
Press
Flow
Drop
Rate
L/s kPa
—
—
—
2.1
1.7
2.5
2.5
2.8
3.5
3.1
4.6
3.4
6.0
3.7
7.6
4.0
9.6
4.3
11.7
4.6
14.3
4.9
17.1
5.2
20.3
5.5
23.9
5.9
4.3
7.1
7.1
8.3
10.9
9.5
15.8
10.6
22.0
11.8
29.6
—
—
—
Page 12
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 12
Low Water Cutoff
If a boiler is installed above any radiation elements it
must be tted with a low water cutoff device.
Refer to the wiring diagram supplied with the boiler/
water heater for proper wiring connections.
Expansion Tank
An expansion tank or other means to control thermal
expansion must be installed in the heating system. An
expansion tank must be installed close to the boiler on
the suction side of the pump.
Primary/Secondary Piping
Boilers connected to heating systems using zone
valves, zone pumps, or systems that have excessive
ow rates or return water temperatures less than 110°F,
43°C must be isolated from these systems to protect the
boiler.
Variable Water Flows
Figure 8 shows a typical primary/secondary piping
system. A dedicated pump is used to maintain a
constant water ow through the boiler. This secondary
pump is sized to overcome the head loss of the boiler
and secondary piping system while supplying the ow
rate required to maintain the desired temperature rise
across the boiler. The primary pump is sized to provide
the required ow to the heating system. The secondary
piping connections to the primary system piping must
not be more than 6 pipe diameters apart to ensure zero
pressure drop in the primary system, see Figure 8.
Low Return Water Temperatures
To prevent the problems associated with condensation
of the products of combustion due to low return water
temperatures a primary/secondary piping system with
a bypass and bypass valve must be installed, see
Figure 9 and 10. The bypass and bypass valve must be
sized the same as the secondary piping. A balancing
valve must also be installed in the supply side of the
secondary piping downstream of the bypass. The
balancing valve should be adjusted to divert some of
the heated discharge water into the return water until
the required inlet water temperature is achieved. The
primary and secondary pumps should be sized to
provide the required ow through each system. The
secondary piping connections to the primary system
piping must not be more than 6 pipe diameters apart to
ensure zero pressure drop in the primary system, see
Figure 9 and 10.
Multiple Boiler Systems
Systems using multiple boilers can also be installed
using a primary/secondary manifold system, Figure 11.
Piping For Use With Cooling Units
The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be
used to prevent the chilled water from entering the
boiler.
When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling
device, the piping system must be equipped with ow-
control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.
Page 13
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 13
Figure 8 - Typical Primary/Secondary Piping System
(See Notes)
NOTES:
1. Boiler circuit piping must be sized
large enough to handle maximum
ow through unit.
2. Boiler pump sized to boiler design
ow requirements.
3. All boilers furnished with factory
mounted outlet water temperature
gauge.
4. Boiler pump purging required. Use
terminals supplied.
Notice: These drawings show suggested
piping conguration and valving.
Check with local codes and ordinances for
specic requirements.
H-1 Rev 4
Pump
Gate Valve
Globe Valve
Angle Valve
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
Self-Operated
Valv e
Figure 9 - Low Temperature Piping
(See Notes and Adjustment Procedures)
H-3 Rev 6
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
BackflowPrevention
Device
3-Way Valve
NOTES:
1. Boiler circuit piping must be sized large enough to
handle maximum ow through unit.
2. Boiler pump sized to boiler design ow requirements.
3. All boilers furnished with factory mounted outlet water
temperature gauge.
4. Boiler pump purging required. Use terminals supplied.
Notice: These drawings show suggested piping
conguration and valving.
Check with local codes and ordinances for specic
requirements.
Adjustment Procedure
To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min=110°F For Atmospheric
T1-Temp-Min=125°F Sealed Combusion
1. Turn heater on and open valves A & B.
2. After steady-state operation, if T1 is less than Temp-Min slowly
close valve B until T1 climbs to desired operating temperature
above Temp-Min.
3. If T1 is greater than desired operating temperature, slowly close
valve A to adjust to lower desired temperature above Temp-Min.
4. Check after system operating temperature has stabilized. Make
nal adjustments.
5. Follow same adjustment procedure for sealed combustion.
Expansion
Tank
Page 14
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 14
Tank
Figure 10 - Low Temperature Piping with Thermostatic Valve
(See notes and adjustment procedures)
Pump
Gate Valve
Globe Valve
H-18 Rev 3
Figure 11 - Multiple Boiler Piping
(See Notes)
NOTES:
1. For pump selection consult factory.
2. Boiler pump sized to boiler and
thermostatic 3-way valve design
ow requirements.
3. Boiler circuit piping must be sized
large enough to handle maximum
ow through unit.
4. All boilers furnished with factory
mounted outlet water temperature
gauge.
5. Boiler pump purging required. Use
terminals supplied.
6. Valve is precalibrated for 140°F
return temperature.
Notice: These drawings show
suggested piping conguration and
valving. Check with local codes and
ordinances for specic requirements.
Angle Valve
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
Self-Operated
Valv e
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
NOTES:
1. Boiler circuit piping must be large enough to handle
maximum ow through unit.
2. Boiler pump sized to boiler design ow requirements.
3. All boilers furnished with factory 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 ow through all units.
Notice: These drawings show suggested piping conguration and valving.
Check with local codes and ordinances for specic requirements.
H-15 Rev 5
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
BackflowPrevention
Device
3-Way Valve
Expansion
Page 15
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 15
DOMESTIC WATER SUPPLY PIPING
CAUTION: Proper controls must be used to prevent
water supplied for domestic use from exceeding
130°F, 54 °C or a scald injury will occur! When
higher water temperatures are required for
appliances such as a dishwasher, a mixing valve or
some other tempering means must be installed.
Households with small children may require water
temperatures less than 120°F, 49 °C. Local codes
must be complied with!
General Piping Requirements
Ensure that the water heater is equipped with bronze
headers. Piping and components connected to the water
heater must be suitable for use with potable water. The
water heater must not be connected to any heating
system piping or components previously used with a
non-potable water heating appliance. Toxic chemicals,
such as those used for boiler treatment, are not to be
introduced into any potable water used for space
heating. If a hot water storage tank is used in the system
it must be equipped with a temperature and pressure
relief valve that complies with ANSI Z21.22 or CAN-4.4
and CAN-4.6.
NOTE: The storage tank must be located as close
to the water heater as possible to prevent excessive
head loss which will reduce ow.
Water Chemistry
The required temperature rise across the water heater
is based on water having a hardness between 8 and
18 grains per gallon with a level of dissolved solids not
exceeding 350 ppm. Water having a hardness less than
8 grains can cause excessive corrosion of the heat
exchanger. Water that has a hardness greater than 18
grains per gallon and/or a level of dissolved solids
exceeding 350 ppm will require a recalculation of the
pump size and temperature rise.
A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water
conditions are encountered. See Table 8.
CAUTION:
through a water heater with copper heat exchanger
on an 8900 is 92 GPM, 5.8 L/s. The cupro-nickel heat
exchanger allows for 100 GPM, 6.3 L/s.
The maximum allowable flow rate through a water
heater with copper heat exchanger on an 8800 is
185 GPM, 11.7 L/s. The cupro-nickel heat exchanger
allows for 200 GPM, 12.6 L/s. See Table 7.
RBI water heaters are designed to run scale free. Due
to the extreme variables of water conditions world wide
it is necessary to consider pH values and water
hardness in relationship to scaling. It is crucial to
consider these two variables when making heat
exchanger and pump selections. If local water
conditions are extreme, follow the guidelines in the Heat
Exchanger Selection Table (Table 8) and the Pumping
Performance Table (Table 9). Scale free operation can
be achieved by using water with a hardness between 8
and 18 and by maintaining the pH between 5 and 9.
Follow the conditions listed under NORMAL in the table.
In some areas of the country additional 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 and pH test
must be taken at the installation site before the order is
placed. Proper pump sizing will improve heater
performance and help ensure heater longevity.
Expansion Tank
An expansion tank or other means to control thermal
expansion must be installed in the water heating system
if back ow prevention devices are installed.
The maximum allowable flow rate
Page 16
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 16
Pump Requirements
This low-mass water heater requires a continuous minimum water flow for proper operation. The factory
recommended circulating pump has been sized to
overcome the head loss of the water heater plus a 30
foot piping loop under normal water conditions. Table 9
provides the heat exchanger pressure drop chart and
temperature rise table. The temperature rise across
the water heater must never exceed 35°F, 19.4°C.
Cold Water Supply
The cold water supply must be piped to the water
heater’s outlet piping between the water heater and the
hot water storage tank. This will prevent untempered
water from entering the water heater, see the
temperature rise control section below. A typical water
heating system is shown in Figure 12 and 13.
Temperature Rise Control
Water returned to the water heater inlet must not be less
than 110°F, 43°C or excessive condensation of the
products of combustion will damage the water heater
voiding the warranty. The method outlined below can be
employed to prevent this condition from occurring.
A balancing valve should be installed on the outlet side
of the water heater for purposes of adjusting the ow
rate through the heat exchanger. Thermometers are
installed on both the inlet and outlet of the water heater
for determining the temperature rise through the unit.
The proper velocity through the water heater must
be maintained in accordance with Table 9 for efcient
operation and long life. If the temperature rise through
the water heater is lower than recommended the water
velocity is too high. Premature erosion of the heat
exchanger will occur. Conversely, if the temperature rise
is higher than recommended in Table 9 the ow rate is
too low. Scaling and softening of the heat exchanger
will occur.
Thermostatic Mixing Valve
- Water Above 140°F, 60°C
Water can be stored at temperatures above 140°F, 60°C
provided that a thermo-statically controlled mixing valve
is used to temper the hot water to an acceptable
temperature before it’s supplied for domestic use.
The mixing valve MUST be set to prevent a scald injury
from occurring, see the caution against scalding.
Storage of water for domestic use above 140°F, 60°C
will provide an increased quantity of tempered water and
help prevent growth of water born bacteria.
Table 8 - 8800 and 8900 Heat Exchanger Selection Graph
Page 17
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 17
Table 9 - 8900 Pumping Performance Requirement Table
Table 10 - 8800 Pumping Performance Requirement Table
Page 18
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 18
Pressure Switch
e
Temperatu
Figure 12 - Typical Water Heating Piping (HW Models Only)
(See Notes)
Pump
3
8
2
1
4
7
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Attention:
Figure 13 - Multiple Water Heating Piping (HW Models Only)
(See Notes)
4
3
6
8
D-1 Rev 6
Valve
Globe Valve
Angle Valve
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valv
Solenoid
Operated Valve
Self-Operated
Valve
Pressure
Reducing Valve
Check Valve
Pressure
4
Relief Valve
1
7
2
NOTES:
1. Optional cold water make up and recirculation line location.
2. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.
3. Thermal expansion tank may be required, check local codes.
4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.
5. CAUTION: TEST WATER HARDNESS AND pH AT JOB SITE.
The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and
Pumping Performance Table before making selection.
6. Common piping must be sized for maximum combined heater ow.
7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.
Notice: These drawings show suggested piping conguration and valving.
Check with local codes and ordinances for specic requirements.
Flow Switch
Thermometer
7
2
D-4 Rev 6
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Aquastat Union
Gas Pressure
Regulator
Automatic
Air Vent
re &
Pressure
Relief Valve
Vacuum
Relief Valve
Drain Valve
(Typ.)
Page 19
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 19
GAS SUPPLY PIPING
WARNING: Check the boiler/water heater rating
plate to make sure that the boiler/water heater
is for the type of gas that will be used. If it isn’t,
do not connect the boiler/water heater to the gas
supply. Gas supply piping must be in
accordance with the National Fuel Code, ANSI
Z223.1-latest revision or applicable provisions of
the local building codes. Canadian installations
must comply with CAN/CGA B149.1 or .2
Installation Code. Failure to comply with this
warning can result in extensive property
damage, severe personal injury or death!
The Series 8800 and 8900 come from the factory ready
to be piped to the gas supply. If for any reason the
boiler/water heater is not for the type of gas available at
the installation site, call the nearest RBI representative
to resolve the problem.
NOTE: A minimum gas supply presssure of 6 in,
152 mm W.C. natural or 11 in, 279 mm W.C. propane
and maximum 14 in, 356 mm W.C. natural or
propane, must be available at the safety shutoff
valve inlet with the unit(s) operating.
Table 11 - Gas Pipe Capacity
A ground joint union should be installed between the
boiler gas controls and the supply piping. Each of these
items are needed to ensure long life and ease of
servicing. Always use a pipe sealant that is suitable for
use with LP gas.
Table 12 - Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size, (in)
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
Notes: 1. For ow through branch.
2. For ow at full open.
Type of pipe tting
90°
Elbow
Tee
Equivalent of pipe length (ft)
5.2
2.6
6.9
3.5
8.0
4.0
10.3
5.2
12.3
6.2
15.3
7.7
15.3
7.7
Gate
Valve
0.6
0.8
0.9
1.2
1.4
1.8
1.8
2
1
Gas
Cock
1.5
1.9
2.3
3.0
3.7
4.5
4.5
2
CAUTION: Always use a square jawed wrench on
the gas valve body when making gas connections
to it. Never over-tighten the piping entering the gas
valve body or gas valve failure may result!
Figure 14 - Gas Supply Piping
Table 11 should be used to ensure that the gas supply
piping is sized properly. If more than one appliance is
supplied by the same supply pipe, the piping must be
sized based on the maximum possible demand. Do not
neglect the pressure drop due to pipe ttings. Table 11
should be used in conjunction with Table 12 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 supply piping. The manual shutoff valve MUST be installed in the supply piping. It
should be installed 5 ft, 1.5 m above the oor where
required by local codes. Provide a sediment trap at the
bottom of the vertical section of the gas supply pipe
upstream of the gas controls.
Maximum pipe capacity in ft3/hr based on 0.60 specic gravity gas
at a pressure of 0.5 psig or less and a 0.3" W.C. pressure drop.
Nominal
Iron Pipe
Size, (in)
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
Note: Multiply the gas volume by 0.62 for propane ow capacity in ft3/hr.
Multiply the propane ow capacity by 2500 Btu/ft3 to determine the propane Btu/hr
capacity for a given pipe size and length.
10
520
1050
1600
3050
4800
8500
17,500
20
350
730
1100
2100
3300
5900
12,000
Pipe length in feet
30
40
50
Maximum gas volume of pipe, (ft
285
245
215
590
500
440
890
760
670
1650
1450
1270
2700
2300
2000
4700
4100
3600
9700
8300
7400
60
195
400
610
1150
1850
3250
6800
80
3
/hr)
170
350
530
990
1600
2800
5800
100
150
305
460
870
1400
2500
5100
150
120
250
380
710
1130
2000
4100
RIOM-47
When applicable, provisions for vent, bleed and gas
relief lines must be made in accordance with the latest
revision of ANSI Z223.1/NFPA 54.
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler. All gas connections MUST be leak tested
before putting the boiler into operation.
WARNING: Never use an open ame to test for
gas leaks. Always use an approved leak
detection method. Failure to comply with this
warning can cause extensive property damage,
severe personal injury or death!
Page 20
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 20
Whenever the gas supply piping is pressure tested the
boiler/water heater gas controls must be protected.
If the test pressure is equal to, or less than 1/2 psig,
3.5 kPa isolate the boiler/water heater by closing it’s
manual shut off valve, see Figure 14. If the test pressure
is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect
the boiler/water heater and its individual shut-off valve.
ELECTRICAL WIRING
Electrical Power Connections
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper
operation after servicing!
ATTENTION. Au moment de l’entretien des
commandes, étiquetez tous les ls avant de les
débrancher. Des erreurs de câblage peuvent
entraîner un fonctionnement inadéquat et
dangereux. S’assurer que l’appareil fonctionne
adéquatement une fois l’entretirn terminé.
The electrical connections to this boiler/water heater
must be made in accordance with all applicable local
codes and the latest revision of the National Electrical
Code, ANSI /NFPA-70. Installation should also conform
with CSA C22.1 Canadian Electrical Code Part I if
installed in Canada.
GENERAL OPERATION
WARNING: Before proceeding read and fully
understand the instructions contained in this
manual. Do not attempt to operate this boiler/
water heater if it has not been installed in
accordance with the guidelines set forth in this
manual. Failure to comply with this warning can
result in extensive property damage, severe
personal injury or death!
Should overheating occur or the gas supply fail to shut
off, turn off the manual gas control valve to the
appliance. Do not interrupt water ow through the boiler/
water heater.
En cas de surchauffe ou si l’alimentation en gaz ne
s’arrête pas, fermez manuellement le robinet d’arrêt de
l’admission de gaz.
Hydronic Heating Boilers
Open the make-up water valve and slowly ll the boiler
and all of the radiation with water. Ensure that all bleed
and drain valves are closed.
Adjust the make-up water pressure regulator so a
minimum 12 psig, 82.7kPa system pressure is
maintained at the highest point in the system piping. If
a make-up water pump is used adjust it to maintain a
minimum 12 psig, 82.7 kPa system pressure.
Install a separate 120 volt 15 amp circuit for the boiler/
water heater. A shut-off switch should be located at the
boiler/water heater. The boiler/water heater must be
grounded in accordance with the authority having
jurisdiction, or if none, the latest revision of the National
Electrical Code, ANSI/NFPA-70.
Line voltage eld wiring of any controls or other devices
must conform to the temperature limitation of type T wire
at 95°F, 35°C above room temperature. Use copper
conductors with a minimum size of #14 awg.
Refer to the wiring diagram supplied with the boiler/
water heater for proper wiring connections.
Open the system bleed and drain valves, one at a time,
to purge the air trapped in the heating system piping.
With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed
valves. If strainers are used in the system piping, the
make-up water valve should be closed and the strainers
checked and cleaned.
The system expansion tank should be checked to
ensure that the correct water level in the tank is
maintained. The tank should be less than half full
of water with the system full and adjusted to the correct
operating pressure.
Start the boiler as described in the “OPERATING
INSTRUCTIONS” section. Run the boiler for at least an
hour. The system pump(s) and all radiation units must
be operated during this time. Ensure that the make-up
water valve is open.
Page 21
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 21
Shut the boiler off and open the bleed valves to purge
the air trapped in the heating system piping. Close 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 checked
and bled after three days of operation.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE
A. This appliance is equipped with an ignition device
which automatically 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 veilleuse manuellement.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next to the
oor because some gas is heavier than air and will
settle on the oor.
DANGER: 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 qualied licensed professionals install,
service and maintain this appliance and your gas
system in accordance with all applicable codes.
• Install a nationally listed combustible gas
detector(s) in your home.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not attempt 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 re
department.
AVANT DE FAIRE FONCTIONNER, reniez tout autour
de l’appareil pour déceler une odeur de gaz. Reniez
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 qualied 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 qualifié et remplacez
toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
CAUTION: To prevent being burned, stand clear of
the boiler during ignition and do not touch any hot
metal parts!
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.”
2. Set the operating control or thermostat to off or its
lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand.
5. Close the manual main and pilot gas shut-off valves.
6. Wait ve (5) minutes to clear out any gas. Then
smell for gas, including near the oor. If you smell
gas, STOP! Follow “B” in the safety information
above. If you don’t smell gas go to next step.
7. Connect a manometer having a minimum capacity of
20 in, 508 mm W.C. to the outlet pressure port of the
gas valve. Make sure that the gas supply piping has
been purged of air and that all gas joints up to the gas
valve have been thoroughly checked for leaks.
8. Open the manual pilot valve.
9. Turn on all electric power to the boiler.
10. Set the operating control or thermostat to the
desired setting.
11. The pilot(s) should automatically light. Do not try to
light the pilot(s) by hand!
12. With the pilot(s) lit, open the main gas shut-off valve.
13. The burners should light
with proper boiler operation.
14. The pilot and manifold pressures should match
those listed in Table 13. To adjust the manifold
gas pressure see the
instructions in the
section.
“CHECKING AND ADJUSTMENTS”
Gas Pressure Adjustment
Page 22
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 22
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train
as follows:
LP Nat
Minimum (in W.C.) 11 6
Maximum (in W.C.) 14 14
Measure pressure when the boiler is ring at full rate.
Low gas pressure could indicate undersized gas line or
insufcient gas supply.
"Static and operating gas pressure required at the gas
valve inlet is between 6" W.C. and 14" W.C. for natural
gas and 11" W.C. and 14" W.C. for propane. If the gas
pressure is above this limit, a lock-up style regulator
suitable for dead end service such as an Equimeter
or Fisher must be installed to prevent increase (creep)
of gas pressure when the units are not operating.
This pressure regulator (supplied by others) may be
installed at the service entrance to each unit or a
"master" regulator sized to handle multiple units may
be utilized. Consult local gas utility or regulator
manufacturer for recommendations to meet specic job
site requirements."
Table 13 - Pilot & Manifold Settings
inches W.C. mm W.C.
Natural 3.5 (± .2) 89 (± 5)
Propane 10 (± .2) 254 (± 5)
Instructions De Mise En Marche
1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.
2. Réglez le thermostat à la température la plus basse.
3. Coupez l’alimentation électrique de l’appareil.
4. Cet appareil est muni d’un dispositif d’allumage qui
allume automatiquement la veilleuse. Ne tentez pas
d’allumer la veilleuse manuellement.
5.
Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
6. Attendre cinq (5) minutes pour laisser échapper tout
le gaz. Reniez tout autour de l’appareil, y compris
près du plancher, pour déceler une odeur de gaz. Si
vous sentez une odeur de gaz, ARRÊTEZ! Passez
à l’étape B des instructions de sécurité sur la portion
supérieure de cette étiquette. S’il n’y a pas d’odeur
de gaz, passez à l’étape suivante.
7.
Ouver la vanne manuelle d’arrêt d’alimintation de gaz.
8. Mettez l’appareil sous tension.
9. Réglez le thermostat à la température désirée.
10. Si l’appareil ne se met pas en marche, suivez les
instructions intitulées «Comment couper l’admission
de gaz de l’appareil» et appelez un technicien
qualié ou le fournisseur de gaz.
To Turn Off Gas To Appliance
1. Set the operating control or thermostat to its lowest
setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Close the manual main and pilot gas shut-off valves.
COUPER L’ADMISSION DE GAZ DE L’APAREIL
1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut
procéder à l’entretien.
3.
Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
CHECKING & ADJUSTMENTS
1. With the burners in operation, close the manual
shutoff valve in the gas supply line. As soon as the
main burner ames go out, open the manual shutoff
valve. A normal ignition sequence should take place.
If the burners fail to light, the system will make one
more ignition attempt. If the burners have not lit after
the last ignition try, the gas valve will close and the
system will go into lock out on CSD-1 units or
continuous retry. DO NOT attempt to reset the
system until the ignition system has been inspected
and the problem resolved. The pilot and manifold
pressures should match those listed in Table 13.
2. With the burners in operation, interrupt the power
to the control circuit by lowering the operating
control or thermostat. The main burners should go
out. Reset the operating control or thermostat, a
normal ignition sequence should follow.
3. To test the ignition safety shutoff device, close the
manual shutoff valve in the gas supply line. Within
5 seconds of main burner ame extinction, the main
gas valve solenoid should close with an audible
noise.
4. A sparking noise should be heard while the ignition
module tries to relight the pilot. After 15 seconds the
module should lockout and the trial for ignition end.
After 5 minutes a second trial for ignition should
occur. Open the manual shutoff valve in the gas
supply line and reset the ignition control system. A
normal ignition sequence should take place.
Page 23
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 23
Pilot Adjustment
The pilot burner ame should envelope 3/8" to 1/2" of
the ame sensing probe, Figure 15. To adjust the pilot
the following steps must be taken:
1. Remove the pilot gas pressure regulator cap.
2. Turn the pressure regulator adjustment screw clock-
wise to increase the ame and counterclockwise to
decrease it.
3. Replace the pressure regulator adjustment screw
cap.
Figure 15 - Pilot Flame Adjustment
Gas Pressure Adjustment
CAUTION: The maximum inlet gas pressure listed
on the rating plate must not be exceeded or damage
to the boiler/water heater may occur voiding the
warranty!
The minimum supply pressure listed on the rating plate
is for input adjustment.
NATURAL GAS: Optimum results are obtained when the
boiler/water heater is operated with the manifold
pressure(s) set per Table 13. The manifold pressure
should not vary outside this range. The gas valve
pressure regulator has been preset at the factory. If
adjustment is necessary the following steps must be
followed:
1. Attach a 20 in, 508 mm W.C. manometer to the tap
on the manifold.
2. Remove the regulator adjustment screw cap from
the gas regulator. On systems that do not use a
separate gas regulator, remove the adjustment
screw cap from the gas valve body on the valve
closest to the gas supply piping.
3. Rotate the regulator adjustment screw clockwise to
increase the manifold pressure, counterclockwise to
decrease it.
4. Replace the regulator adjustment screw cap and
manifold pressure tap plug.
PROPANE GAS: Optimum results are obtained when
the boiler/water heater is operated with the manifold
pressure(s) set per Table 10. If the manifold pressure is
off by more than 5% adjust it according to steps 1
through 4 above.
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation
with no adjustment required at elevations up to 2000 ft.,
610 m. At elevations above 2000 ft, 610 m input ratings
should be reduced by 4% for each additional 1000 ft,
305 m.
Check the input rate as follows:
1. Turn off all other gas appliances that use the same
gas meter as the boiler/water heater.
2. Call your gas supplier and ask for the heating value
of the gas.
3. Start the boiler/water heater and let it run for 15
minutes.
4. Using the gas meter and a stopwatch, clock the time
that it takes to burn 10 ft3, 0.28m3 of gas and divide
this time by 10.
5. Insert the heating value and the time, in seconds,
into the formula below.
6. Input = (heating value, Btu/hr)(3600)/(time, seconds)
7. If the computed rate deviates by more than 5% from
the rated input value of the unit adjust the manifold
pressure accordingly. DO NOT adjust the manifold
pressure by more than 5%. If a proper rate cannot
be maintained without adjusting the manifold
pressure beyond the 5% limit, the main burner
orices must be replaced. If the input rate is too low,
go to the next larger size of main burner orices. If
the input rate is too high, go to the next smaller size.
CAUTION: Never increase the input to the boiler/
water heater above that for which it is rated. Doing
so can cause premature failure of the unit!
CAUTION: Never force the regulator adjustment
screw beyond the stop limits or damage to the
regulator will occur!
Page 24
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 24
CONTROL DESCRIPTION
Boiler Thermostat
If a thermostat is to be used to control the boiler always
follow the instructions included with the thermostat.
Proper location of the thermostat will ensure efcient
trouble-free operation of the boiler. Mount the thermostat
to an inside wall at a height approximately ve feet
above the oor.
Avoid placing the thermostat in areas that will not
provide an accurate measurement of the room
temperature. Locating the thermostat behind a door, in
an alcove, close to a source of thermal radiation or in a
drafty area will cause poor or sporadic heating.
For a thermostat that employs an adjustable heat
anticipator, adjust the anticipator to match the current
measured in the thermostat circuit. An increased
anticipator setting may be necessary if the unit cycles
frequently. If the room temperature over-shoots the
thermostat setting, reduce the anticipator setting.
Operating Control
The preferred control setting for potable hot water is
130°F, 54°C. The operating control should be set to the
lowest setting that will satisfy the consumer's needs.
High Limit (Aquastat)
The high limit is located in the top control area of the
boiler/water heater. A remote capillary bulb is run to a
well on the outlet side of the supply header. The high
limit can be reset by depressing the black rubber plug
in the front top jacket panel.
The water heater high limit should be set a minimum of
20°F, 11°C higher than the operating control. Refer to
the HOT WATER SUPPLY section for the proper supply
water temperature.
Flow Switch
A ow switch is provided in the water outlet piping to
prevent the boiler/water heater from firing without
adequate water ow through the heat exchanger.
Low Water Cutoff
If the boiler is to be installed above radiation or if
required by other codes or regulations, install a low
water cutoff in appropriate piping. Wire the switch and
any external controls in series to the "Interlock" contacts
in the junction box (see the attached Connection
Diagrams for details). Ensure that the low water cutoff
device(s) will function properly.
WARNING: Setting the thermostat or operation
control too high can result in scalding resulting
in severe personal injury!
Page 25
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 25
MAINTENANCE
WARNING: Disconnect electrical power and
close the manual gas shut off valve before
performing maintenance or severe personal
injury may result!
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause
property damage, personal injury, exposure to
hazardous materials or loss of life. Installation
and service must be performed by a qualied
installer, service agency or the gas supplier who
must read and follow the supplied instructions
before installing, servicing or removing this
boiler. This boiler contains crystalline silica
materials that have been identified as
carcinogenic or possibly carcinogenic to
humans when inhaled.
AVERTISSMENT: Une instqallation, un réglage,
une réparation ou un entretien non comforme
aux normes peut entraîner des dommages
matériels, des blessures,exposition à des
matiéres dangereuses ou la mort. L’installation
et l’entretien doivent être effectués par un
installateur ou un service d’entretien qualié ou
le foumisseur de gaz qui doivent avoir lu les
instructions foumies avant de faire l’installation,
l’entretien ou l’enlèvement de la chaudière et les
respecter, Cette chaudière contient des
matériaux qui ont été identiés comme étant
cancérogènes ou pouvant l’être.
CAUTION: Servicing, inspection and adjustment
must be done by a trained technician in accordance
with all applicable local and national codes.
Improper servicing or adjustment can damage the
boiler/water heater!
WARNING: The ceramic combustion chamber
contains crystalline silica. Wear a tightly tted
dust mask when removing the burners or heat
exchanger to prevent inhalation of airborne
fibers. Crystalline silica fibers have been
identified as carcinogenic, or possibly
carcinogenic when inhaled.
The boiler/water heater should be cleaned and inspected
once a year and before each heating season. Make sure
that the burner and ignition components are free from
dust, soot, dirt, corrosion or other deposits that would
impair the boiler/water heater’s performance. Refer to
page 29 (8900) or page 38 (8800) for component
identication.
Combustion Chamber Inspection
1. Remove the left or right lower jacket end panel, item
5 or 24 (8900) or item 5 or 24 (8800).
2. Remove the upper end refractory brackets and
carefully remove the end refractory panel.
3. Inspect the combustion chamber, heat exchanger
and burner tray components for sign of corrosion
and/or deterioration.
4. Clean or replace components as required.
CAUTION: Improper burner servicing can result in
premature burner failure voiding the warranty.
Burner Drawer & Burner Removal
1. Close the manual shutoff valves in the gas supply
lines and turn off electrical power to the boiler/water
heater.
2. Disconnect the gas train from the gas supply piping
at the ground joint union, Figure 14.
3. Remove the ame roll-out shield, 8900 only.
4. Remove the two bolts that attach the burner drawer
to the base frame.
5. Disconnect the pilot tubing from the solenoid valve
and the ignition lead from the ignition control.
6. Pull the burner drawer out until the burners are fully
exposed.
7. Inspect each burner for damage or signs of
deterioration. Use a brush or compressed air to
remove any debris from the burner ports.
8. DO NOT install damaged or badly corroded burners,
replace them.
9. Install the burners making sure that they are
properly seated in the burner drawer.
10. Replace the burner drawer and ame roll out shield,
8900 only, following the removal steps in reverse
order.
Heat Exchanger Inspection & Cleaning
1. Close the shut off valves in the inlet and outlet
piping. Relieve the system pressure from the boiler
by carefully lifting the relief valve or opening the
drain valve.
2. Disconnect the boiler/water heater from the system
piping.
3. Remove the left and right headers and mounting
studs.
4. Remove the left & right upper and left & right lower
jacket end panels, items 5 & 24 (8900) or items 5
& 24 (8800).
5. Remove the left & right front corner trim panels,
8900.
6. Remove the ue collector front panel.
7. Remove the upper front refractory channel
assembly and front refractory panels.
8. Slide the heat exchanger out and thoroughly
inspect it.
Page 26
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 26
NORMAL
(HARD FLAME)
LIFTING
(TOO MUCH AIR)
YELLOW TIPPING
(MARGINAL)
YELLOW FLAME
(TOO LITTLE AIR)
9. The outside surfaces of the copper tubes should be
free of any soot deposits. A slight black smudge is
normal 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 with water and the problem resolved
before the boiler/water heater is returned to service.
10. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
11. The torque values for the bolts that secure the
removable headers are 17-20 ft lbs. Once bolts
have been started and secured the tightening
sequence is as follows:
1) Middle Top
2) Middle Bottom
3) Right Top
4) Left Bottom
5) Left Top
6) Right Bottom
Heat Exchanger Replacement
1. Sagging or distorted heat exchanger tubes are an
indication of low water ow through the system.
2. A damaged heat exchanger must be replaced and
the condition that caused the damage resolved
before the boiler/water heater is returned to service.
4. The relief valve should not weep or discharge
water at normal system pressure. If it does contact
a qualied 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. The aquastat high limit controls the maximum
water temperature in the boiler and should be 20°F,
11°C above set point temperature. If the water
temperature reaches the set temperature before
the demand for heat has been met, the aquastat
high limit should shut the boiler off. The water
temperature should never exceed the maximum
set point of 240°F, 116 °C. The aquastat high limit
cannot be repaired. If it fails to function properly,
replace it.
6. Visually check the pilot and main burner ames to
ensure proper operation, see Figures 15 & 16.
WARNING: A yellow, oating ame indicates a
lack of combustion air. A lifting ame indicates
too much combustion air. Do not operate the
boiler/water heater until the problem is solved
or severe personal injury or death may occur!
Figure 16 - Main Burner Flames
Vent System
Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage. Immediately replace any
unsound vent system piping.
Controls
Use the “GENERAL OPERATION” and “CHECKING
AND ADJUSTMENTS” sections of this manual for
reference.
1. Check the thermostat or operating controls for
2. A oat type low water cutoff device must be ushed
3. The ow switch contacts must be open when water
proper operation.
out per the manufacturers’ instructions. The probe
on a probe low water cut off must be removed,
cleaned and inspected at least once a year. Ensure
that the low water cutoff operate properly. If not,
replace them.
ow is not present.
RIOM-49
Page 27
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 27
TROUBLE-SHOOTING FLOW CHART FOR HONEYWELL
OR UTC IGNITION MODULE (24V CONTROL SYSTEM)
Proper line voltage
L1 to L2 on heater
terminal strip
24V on secondary
terminals of heater
transformer
24V across 24V and 24V
(GND) terminals of
ignition module
On application of 24V,
control produces audible
spark at pilot
Pilot
Ignites
Adjust the pilot gas
pressure using the
pilot regulator. Pilot
ignition problems
can be caused by
high or low pilot
pressure.
Pilot ignites
Check for tripped breaker or open safety
/ limit switch in supply voltage circuit.
Check for broken or loose
connection to transformer, if none
replace transformer.
Check for open limit in this 24V circuit
operating control, high limit, flow switch,
LWCO, high / low gas pressure switches,
remote operating controls, etc.
Check for loose or broken ignition lead. Check for shorted pilot electrode.
If pilot and ignition lead test good replace module.
During pilot ignition period (audible spark present) check
for 24V between PV and MV/PV terminals of module.
24V at pilot gas
valve leads
A tripped manual reset
high limit may
indicate insufficient
water flow.
Check for loose or
broken wire between
pilot valve and
PV-MV/PV terminals.
Replace
module.
Main Flame
Ignites
Manifold pressure in proper
range (3.5”-4.2” N.G.,
10”-11” L.P.). If no pressure on
manifold, during main flame
trial for ignition period, check
for pressure at tappings of each
main valve. Replace valve
that shows no pressure at
downstream tapping while
powered with pressure at
upstream tapping.
With pilot lit: 24V
between the MV and
MV/PV terminals of
the module
24V at terminals of
all valves in main
gas train
Pilot valve opens.
Confirm that gas is
present at pilot valve
inlet.
Insure pilot line and
pilot orifice are clear
and that the pilot is
undamaged. The pilot
ignites.
Check for loose or
broken wire between
MV-MV/PV terminals.
Replace pilot solenoid
valve.
Replace the pilot
assembly.
Replace
module.
main valves and
Page 28
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 28
Trouble-Shooting
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
Boiler Pounds or Knocks Low or no water flow Ensure that pump is operating
properly - look for voltage through
ow switch.
Ensure that all system valves are
open.
Ensure that all air has been bled
from the system.
Ensure that maximum temperature
rise of 35°F, 19°C has not been
exceeded.
Low or no system pressure Ensure that water makeup valve is
open and functioning.
Heat exchanger blocked Remove return header and inspect
the heat exchanger tubes.
Relief Valve Leaks System pressure too high Ensure relief valve is properly sized
for the system - never exceed
160 psi.
Expansion tank is waterlogged Ensure expansion tank is properly
sized for the system.
Expansion tank is isolated Ensure valve between expansion
tank and system is open.
Sooting of Heat Exchanger Return water temperature to low Adjust balancing valves for a
minimum return water temperature
of 110°F, 43 °C.
Inadequate combustion air Ensure that the make up air supply
is adequate per NFPA 54/ANSI
Z223.
Ensure that the vent system is sized
properly, is not blocked or restricted
and that there is adequate draft
present in the breeching.
Rated input has been exceeded Ensure that the input rate is correct.
Incorrect fuel type Ensure that the fuel type supplied
matches the rating plate.
Page 29
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 29
PARTS LIST (MODELS 420-1900)
36
33
Page 30
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 30
SERVICE AND REPLACEMENT PARTS LIST (MODELS 420-1900)
8900
Ref # Name of Part
6 Inlet/Outlet Header, Cast Iron 01-0001S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Inlet/Outlet Header, Bronze 01-0003.1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Inlet/Outlet Header, Cast Iron (Mod) 01-0001M 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Inlet/Outlet Header, Bronze (Mod) 01-0003M 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 Return Header, Cast Iron 01-0002S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Return Header, Bronze 01-0004.1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 O Ring (pkg of 20) 21-2010 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS
NS Burner Shield 03-0092 1
03-0093 1
03-0094 1
03-0095 1
03-0096 1
03-0097 1
03-0098 1
03-0099 1
03-0100 1
03-0101 1
03-0102 1
03-0103 1
03-0104 1
03-0105 1
03-0106 1
13, 13a Burner Tube 10-0277 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
Burner Tube w/Bracket 70-0635 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Burner Spacers 03-0309 1
03-0310 1
03-0311 1
03-0312 1
03-0313 1
03-0314 1
03-0315 1
03-0316 1
03-0317 1
03-0318 1
03-0319 1
03-0320 1
03-0321 1
03-0322 1
03-0323 1
Stud, Inlet/Outlet & Return Headers ASME
Nut, Inlet/Outlet & Return Headers ASME
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
57-0223 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
57-0492 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
8900 Model Size with Item Quantities Below
Page 31
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 31
8900
Ref # Name of Part
15 Firing Valve, 1" 11-0456 1 1 1 1 1/2* 1/2* 2* 2* 2* 2* 2* 2* 2*
Firing Valve, 1-1/4" 11-0457 1 1 1 1 1 1 1 2* 2*
Firing Valve, 1-1/2" 11-0458 1 1
16 Main Gas Valve, V83042 11-0084 2*
Main Gas Valve, V8944B, 1" 11-0171 1 1 1 1 1 1/2* 2* 2* 2* 2* 2* 2* 2*
Main Gas Valve, V8944B, 1-1/4" 11-0172 1 1 1 1 1 1 1 2* 2*
Main Gas Valve, V8944B, 1-1/2" 11-0173 1 1
17 “A” Valve, 1" 11-0465 1 1 1 1 1 1
“A” Valve, 1-1/4" 11-0466 1 1 1 1 1 1 1
“A” Valve, 1-1/2" 11-0467 1 1
NS Bracket Refractory Upper End 03-0306 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
NS Bracket Refractory Lower End 03-0307 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
18 End Refractory Panel, Left & Right 05-0001 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
19 Center Refractory Panel 05-0002 2
05-0003 2
05-0004 2 2 2 2 4 4 4 4 4 4
20 Corner Refractory Panel 05-0005 4
05-0006 4
05-0007 4
05-0008 4
05-0009 4
05-0010 4
05-0011 2
05-0012 4
05-0013 4
05-0014 4
05-0015 6
05-0016 6
05-0017 6
18, 19, Tile Kit 70-0226K 1
20 70-0227K 1
70-0228K 1
70-0229K 1
70-0230K 1
70-0231K 1
70-0232K 1
70-0233K 1
70-0234K 1
70-0235K 1
70-0236K 1
70-0237K 1
70-0238K 1
70-0239K 1
70-0240K 1
8900 Model Size with Item Quantities Below
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
Page 32
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 32
8900
Ref # Name of Part
NS Bracket Refractory Front/Rear 03-0308 2 2 3 3 3 4 4 5 5 5 6 6 6 7 7
NS Upper Front Refractory Channel 70-0177 1
70-0178 1
70-0179 1
70-0180 1
70-0181 1
70-0182 1
70-0183 1
70-0184 1
70-0185 1
70-0186 1
70-0187 1
70-0188 1
70-0189 1
70-0190 1
70-0191 1
NS Upper Rear Refractory Channel 70-0162 1
70-0163 1
70-0164 1
70-0165 1
70-0166 1
70-0167 1
70-0168 1
70-0169 1
70-0170 1
70-0171 1
70-0172 1
70-0173 1
70-0174 1
70-0175 1
70-0176 1
29
Burner Drawer Side Rail Assy, Left & Right
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
70-0362 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
8900 Model Size with Item Quantities Below
Page 33
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 33
8900
Ref # Name of Part
NS Heat Exchanger Assembly (Copper) 70-0072 1
Cast Iron Headers 70-0073 1
70-0074 1
70-0075 1
70-0076 1
70-0077 1
70-0078 1
70-0079 1
70-0080 1
70-0081 1
70-0082 1
70-0083 1
70-0084 1
70-0085 1
70-0086 1
Heat Exchanger Assembly (Cupronickel) 70-0087 1
Cast Iron Headers 70-0088 1
70-0089 1
70-0090 1
70-0091 1
70-0092 1
70-0093 1
70-0094 1
70-0095 1
70-0096 1
70-0097 1
70-0098 1
70-0099 1
70-0100 1
70-0101 1
Individual copper/cupronickel tubes* available for eld repair *model and serial number required
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
8900 Model Size with Item Quantities Below
Page 34
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 34
8900
Ref # Name of Part
Tube Expansion Tool 30-0761 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Heat Exchanger Assembly (Copper) 70-0102 1
Bronze Headers 70-0103 1
70-0104 1
70-0105 1
70-0106 1
70-0107 1
70-0108 1
70-0109 1
70-0110 1
70-0111 1
70-0112 1
70-0113 1
70-0114 1
70-0115 1
70-0116 1
Heat Exchanger Assembly (Cupronickel) 70-0117 1
Bronze Headers 70-0118 1
70-0119 1
70-0120 1
70-0121 1
70-0122 1
70-0123 1
70-0124 1
70-0125 1
70-0126 1
70-0127 1
70-0128 1
70-0129 1
70-0130 1
70-0131 1
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
8900 Model Size with Item Quantities Below
Page 35
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 35
8900
Ref # Name of Part
30 Tube Bundle (Copper) 70-0132 1
70-0133 1
70-0134 1
70-0135 1
70-0136 1
70-0137 1
70-0138 1
70-0139 1
70-0140 1
70-0141 1
70-0142 1
70-0143 1
70-0144 1
70-0145 1
70-0146 1
30 Tube Bundle (Cupronickel) 70-0147 1
70-0148 1
70-0149 1
70-0150 1
70-0151 1
70-0152 1
70-0153 1
70-0154 1
70-0155 1
70-0156 1
70-0157 1
70-0158 1
70-0159 1
70-0160 1
70-0161 1
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
8900 Model Size with Item Quantities Below
Page 36
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 36
8900
Ref # Name of Part
NS Heat Exchanger “V” Bafes 03-0244 7
03-0245 7
03-0246 7
03-0247 7
03-0248 7
03-0249 7
03-0250 14
03-0251 14
03-0252 14
03-0253 14
03-0254 14
03-0255 14
03-0256 14
03-0257 14
03-0258 14
NS Heat Exchanger Edge Bafes 03-0259 2
03-0260 2
03-0261 2 4
03-0262 2 4
03-0263 2 4
03-0264 2
03-0265 4
03-0266 4
03-0267 4
03-0269 4
03-0271 4
03-0273 4
31 Safety Valve, V88A, 1" 11-0156 1 1 1 1 1 1
Safety Valve, V88A, 1-1/4" 11-0157 1 1 1 1 1 1 1
Safety Valve, V88A, 1-1/2" 11-0158 1 1
32 Ignitor, PSE-NA29 70-9013 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Ignitor, PSE-NA185 70-9014 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Ignitor, PSE-NA29, LP 70-0631 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Ignitor, PSE-NA185, LP 70-0632 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
33 Solenoid Valve w/Regulator, NG, 24V 11-0373 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Solenoid Valve w/Regulator, LP, 24V 11-0375 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 Manual Pilot “B” Valve 11-0031 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
36 Ignition Module, S8610M 16-0054 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Ignition Module, UTC 1003 (CSD-1 Only) 16-0058 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Alarm Board, (CSD-1) 16-0023 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS BTC 4 Stage 14-0307 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Spark Generator 16-0036 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Ignition Cable Assembly 120V 16-0201 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
37 Transformer, 50VA 15-0007 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8900 Model Size with Item Quantities Below
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
Page 37
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 37
8900
Ref # Name of Part
NS Rocker Switch 48-0001 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Relay, 24V AC 15-0113 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Pump Contactor 1PH 15-0118 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Pump Contactor 3PH 15-0111 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS
NS
38 High Limit, L4008E, (HB) 14-0112 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
High Limit, L4008E, (HW) 14-0105 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
39 High Limit Well, 3/8 x 3 3/16 13-0105 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
40 Operator, L4008A,(HB), On/Off 14-0102 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Operator, L6008A, (HW) 14-0106 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Operator, L6008G, (2 stage) 14-0107 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Operator, T6031A, (pool heaters) 14-0003 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
41 Orice, #29, NG 10-0016 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Orice, #47, LP 10-0009 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
NS Pressure Relief Valve 50# 13-0040 1 1 1 1
Pressure Relief Valve 50# 30-0360 1 1 1
Pressure Relief Valve 50# 30-0374 1 1 1 1 1
Pressure Relief Valve 50# 30-0379 1 1 1
NS Pressure Relief Valve 125# 30-0364 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Tridicator 13-0308 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Thermometer 13-0302 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
42 Thermometer Well, 3/8 x 2 5/8 13-0103 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Thermometer w/well 13-0320 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Flow Switch 14-0203 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Flow Switch (Potter) 14-0201 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Rating Plate 82-0054 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NS Vent Termination Hood 6" 09-0112 1 1
Vent Termination Hood 8" 09-0113 1 1 1 1 1 1
Vent Termination Hood 10" 09-0115 1 1 1 1 1 1 1
*4 Stage Only
Low Gas Pressure Switch (Manual Reset)
High Gas Pressure Switch (Manual Reset)
Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900
11-0410 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
11-0411 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8900 Model Size with Item Quantities Below
Page 38
21a
21
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 38
PARTS LIST (MODELS 2000-4000)
19
18
22
25
7
36
33
42
39
3086
Page 39
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 39
SERVICE AND REPLACEMENT PARTS LIST (MODELS 2000-4000)
8800
Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000
6 Inlet/Outlet Header, Bronze 01-0012.1 1 1 1 1 1 1
7 Return Header, Bronze 01-0013.1 1 1 1 1 1 1
8 O Ring (pkg of 20) 21-2010 2 2 2 2 2 2
NS Stud, Inlet/Outlet & Return Headers ASME 57-0223 24 24 24 24 24 24
Nut, Inlet/Outlet & Return Headers ASME 57-0492 24 24 24 24 24 24
NS Heat Exchanger “V” Bafe 03-1147 15
03-1148 30
03-1149 30
03-1150 30
03-1151 30
03-1152 30
NS Heat Exchanger Edge Bafe 03-1181 2
03-1182 4
03-1183 4
03-1184 4
8800 Model Size with Item Quantities Below
03-1185 4
03-1186 4
NS Heat Shield 70-1733 2
70-1734 2
70-1735 2
70-1736 1 1
70-1737 1 1
70-1738 1 1
13, 13a Burner Tube, Aluminized Steel 10-0256 19 23 27 30 34 38
Burner Tube, Aluminized w/ Bracket 70-1851 1 1 1 2 2 2
Burner Tube, Stainless Steel 10-0258 19 23 27 30 34 38
Burner Tube, Stainless w/ Bracket 70-1852 1 1 1 2 2 2
16 Main Gas Valve, V8944B, 1-1/4" 11-0172 2* 2* 2* 2/2*
Main Gas Valve, V8944B, 1-1/2" 11-0173 1 2/2* 2/2*
Main Gas Valve, V8944B, 2" 11-0174 1 1
NS Safety Valve, V88A, 1-1/2" 11-0158 1
Safety Valve, V88A, 2" 11-0159 1* 1/1* 2/2* 2/2* 2/2* 2/2*
17 “A” Valve, 1-1/2" 11-0467 1
“A” Valve, 2" 11-0454 1* 1/1* 1/1* 1/1* 1/1* 1/1*
18 End Refractory Panel, Left & Right 05-0050 2 2 2 2 2 2
19, 20 Center Refractory Panel 853413 8 8 10 12 12 14
Page 40
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 40
Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000
18, 19, Tile Kit 70-1739K 1
20 70-1740K 1
70-1741K 1
70-1742K 1
70-1743K 1
70-1744K 1
NS Bracket Refractory Front/Rear 03-0308 3 3 4 4 5 5
NS Upper Front/Rear Refractory Support 03-1155 2
03-1156 2
03-1157 2
03-1158 2
03-1159 2
03-1160 2
NS Upper Right/Left Refractory Support 03-1161 2 2 2 2 2 2
NS Tube Bundle (Copper) 70-1696 1
8800
8800 Model Size with Item Quantities Below
70-1697 1
70-1698 1
70-1699 1
70-1700 1
70-1701 1
Tube Bundle (Cupronickel) 70-1702 1
70-1703 1
70-1704 1
70-1705 1
70-1706 1
70-1707 1
30 Heat Exchanger (Copper) 70-1684 1
70-1685 1
70-1686 1
70-1687 1
70-1688 1
70-1689 1
Individual copper/cupronickel tubes* available for eld repair *model and serial number required
Page 41
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 41
8800
Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000
Tube Expansion Tool 30-0761 1 1 1 1 1 1
Heat Exchanger (Cupronickel) 70-1690 1
70-1691 1
70-1692 1
70-1693 1
70-1694 1
70-1695 1
NS 3" Gruvlok Coupling 53-0100 2 2 2 2 2 2
3" x 4" Gruvlok Nipple 53-0300 2 2 2 2 2 2
3" x 4" Gruvlok Nipple, Brass 53-0600 2 2 2 2 2 2
32 Ignitor, PSE-NA29 70-9013 1 1 1 1 1 1
Ignitor, PSE-NA185 70-9014 1 1 1 1 1 1
Ignitor, PSE-NA29, LP 70-0631 1 1 1 1 1 1
Ignitor, PSE-NA185, LP 70-0632 1 1 1 1 1 1
33 Solenoid Valve w/Regulator, NG, 24V 11-0373 1 1 1 1 1 1
8800 Model Size with Item Quantities Below
Solenoid Valve w/Regulator, LP, 24V 11-0375 1 1 1 1 1 1
35 Manual Pilot “B” Valve 11-0031 1/2* 1/2* 1/2* 2/2* 2/2* 2/2*
NS Spark Generator 16-0036 1 1 1 1 1 1
36 Ignition Module, S8610M 16-0054 1 1 1 1 1 1
Ignition Module, UTC 1003 (CSD-1 Only) 16-0058 1 1 1 1 1 1
BTC Staging Control, 4 Stage 14-0307 1 1 1 1 1 1
NS Alarm Board (CSD-1) 16-0023 1 1 1 1 1 1
37 Transformer, 50 VA 15-0007 1 1 1 1 1 1
Transformer, 75 VA 15-0008 1 1 1 1 1 1
NS Rocker Switch (illuminated) 48-0001 1 1 1 1 1 1
NS Relay, 24V AC 15-0113 1 1 1 1 1 1
NS Relay, 120V AC 15-0114 1 1 1 1 1 1
NS Pump Contactor 1PH 15-0118 1 1 1 1 1 1
Pump Contactor 3PH 15-0111 1 1 1 1 1 1
NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 1 1 1 1 1
NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1
38 High Limit, L4008E, (HB) 14-0112 1 1 1 1 1 1
High Limit, L4008E, (HW) 14-0105 1 1 1 1 1 1
39 High Limit Well, 3/8 x 13/16 13-0105 1 1 1 1 1 1
40 Operator, L4008A, (HB), On/Off 14-0102 1 1 1 1 1 1
Operator, L6008A, (HW), On/Off 14-0106 1 1 1 1 1 1
Operator, L6008G, 2 stage 14-0107 1 1 1 1 1 1
Operator, T6031A (pool heater) 14-0003 1 1 1 1 1 1
Page 42
SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 42
8800
Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000
41 Orice, #17, NG 10-0014 20 24 28 32 36 40
Orice, #34, LP 10-0021 20 24 28 32 36 40
NS Pressure Relief Valve 50# 30-0379 1
Pressure Relief Valve 50# 13-0002 1
Pressure Relief Valve 50# 30-0382 1 1 1
Pressure Relief Valve 50# 30-0384 1
Pressure Relief Valve 125# 30-0364 1 1
Pressure Relief Valve 125# 13-0009 1
Pressure Relief Valve 125# 13-0003 1 1
Pressure Relief Valve 125# 13-0053 1
NS Tridicator 13-0305 1 1 1 1 1 1
NS Thermometer (HB) 13-0302 1 1 1 1 1 1
Thermometer (HW) 13-0302 2 2 2 2 2 2
42 Thermometer Well, 3/8 x 2 5/8 13-0103 1 1 1 1 1 1
NS Flow Switch 14-0203 1 1 1 1 1 1
8800 Model Size with Item Quantities Below
NS Flow Switch (Potter) 14-0201 1 1 1 1 1 1
NS Rating Plate 82-0054 1 1 1 1 1 1
*4 Stage Only
Page 43
NOTICE!
Commonwealth of Massachusetts
Installation Requirements
MACODE-3
In the Commonwealth of Massachuses, the
installation must be performed by a licensed plumber
or gas er.
1. For all side wall horizontally vented gas fueled equipment
installed in every dwelling , building or structure used in whole
or in part for residential purposes, including those owned
or operated by the commonwealth and where the side wall
exhaust vent termination is less than seven (7) feet above
nished grade, in the area of the venting, including but not
limited to decks and porches, the following requirements shall
be satised:
d. INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing
plumber or gaser shall observe that a hard wired
carbon monoxide detector with an alarm and baery
back-up is installed on the oor level where the gas
equipment is to be installed. In addition, the installing
plumber or gas er shall observe that a baery operated
or hard wired carbon monoxide detector with an alarm is
installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented
gas fueled equipment. It shall be the responsibility of
the property owner to secure the services of qualied
licensed professionals for the installation of hard wired
carbon monoxide detectors.
i. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an
aic, the hard wired carbon monoxide detector with
alarm and baery back-up may be installed on the next
adjacent oor level.
ii. In the event that the requirements of this subdivision
can not be met at the time of completion of installation,
the owner shall have a period of thirty (30) days
to comply with the above requirements; provided,
however, that during said thirty (30) day period, a
baery operated carbon monoxide detector with an
alarm shall be installed.
e. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720
and be ANSI/UL 2034 listed and IAS certied.
f. SIGNAGE. A metal or plastic identication plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented
gas fueled heating appliance or equipment. e sign shall
read, in print size no less than one-half (1/2) inch in size,
“GAS VENT DIRECTLY BELOW. KEEP CLE AR OF ALL
OBSTRUCTIONS”.
g. INSPECTION. e state or local gas inspector of the side
wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the
inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
2. Exemptions — e following equipment is exempt from
248CMR 5.08(2)(a) 1 through 4:
a. e equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
b. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in
part for residential purposes.
3. MANUFACTURER REQUIREMENTS — GAS
EQUIPMENT VENTING SYSTEM PROVIDED.
a When the manufacturer of Product Approved side wall
horizontally vented gas equipment provides a venting
system design or venting system components with the
equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
i. Detailed instructions for the installation of the venting
system design or the venting system components; and
ii. A complete parts list for the venting system design
or venting system.
4. MANUFACTURER REQUIREMENTS — GAS
EQUIPMENT VENTING SYSTEM NOT PROVIDED.
a When the manufacturer of a Product Approved side wall
horizontally vented gas fueled equipment does not provide
the parts for venting the ue gases, but identies “special
venting systems”, the following requirements shall be
satised by the manufacturer:
i. e referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
ii. e “special venting systems” shall be Product
Approved by the Board, and the instructions for that
system shall include a parts list and detailed installation
instructions.
5. A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance
or equipment at the completion of the installation.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Page 44
LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial,
Commercial, and other Non-Residential Use Boiler (the “Product”) will be free from defects in material or workmanship
for ten (10) years from the date of installation. Additional twenty one (21) year thermal shock warranty on heat exchanger.
If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the
warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be
defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship
for one (1) year from date of installation or 18 months from date of shipment from RBI.
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the
Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in material
or workmanship for ve (5) years from the date of installation. Additional twenty one (21) year thermal warranty on heat
exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship
during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown
to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and
workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
This limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has
not been installed, maintained or operated in accordance with the furnished written instructions, or has been
altered or modied in any way.
These include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment
and is not covered under the manufacturer’s warranty.
• 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 Instructions 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 in the boiler room as it rapidly destroys the
heating equipment and voids the warranty.
• All copper n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric
combustion, 125°F, 52°C fan assist combustion. If a lower temperature is required, an external bypass should be
installed to prevent condensation. The manufacturer’s warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or
parts thereof.
(c) to damage as a result of settlement, distortion, collapse, or cracking of any foundation area, beams or pipes
surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United
States or Canada.
This limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned
with prior written approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with
respect to such repaired or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND
EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN
ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE
WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY
PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER
OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY
BY EACH JURISDICTION.
260 North Elm Street 7555 Tranmere Drive
Westeld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
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