RBI CK1500, CK3000, CK4500, CK6000, CK2500 Installation And Operation Instructions Manual
...
FCR-IOM-2
82-0651
Boiler Manual
Installation and Operation
Instructions
Stainless Steel Condensing
Boilers CK1500, CK3000,
CK4500 & CK6000
Also read and follow:
HeatNet Control Manual
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 dustfree 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/water heater. 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.
Scan Boiler QR Code for Online Monitoring
09/15 Copyright 2015 Mestek, Inc.
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Donottrytolightanyappliance.
• 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 fire
department.
Installation and service must be performed by a qualified
installer,serviceagencyorthegassupplier.
Assurez-vous de bien suivre les instructions
données dans cette 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 inflammables à proximité de cet
appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Nepastenterd’allumerd’appareil.
• Netouchez à aucun interrupteur;ne pas vous servir
des téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gas
depuisunvoisin.Suivezlesintructionsdufournisseur.
• Sivousnepurvezrejoindrelefournisseur,appelezle
service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualifié ou par le
fournisseurdegaz.
Failure to properly vent this unit can cause
excessive amounts of carbon monoxide resulting
in severe personal injury or death!
Do not use automotive anti-freeze in the boiler
waterways. If the use of anti-freeze is necessary
an anti-freeze specifically formulated for hydronic
heating systems must be used or damage to the
boiler may occur voiding the warranty!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION IV
FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF100 PSI,700kPaWATER.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED
ADJACENT TO THE BOILER / WATER HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE PURPOSES.
2
CONTENTS
Before Your Start................................................. page 2
Ratings & Capacities .......................................... page 3
Location .............................................................. page 3
Combustion Air & Ventilation .............................. page 3
Venting Guidelines .............................................. page 5
Common Vent Systems ...................................page 13
General Piping Requirements ..........................page 14
Heating System Piping ..................................... page 15
Domestic Water Supply Piping ......................... page 18
Condensate Piping ........................................... page 20
Gas Supply Piping ............................................ page 20
Electrical Wiring ................................................ page 21
Boiler Operation ................................................page 22
Operating Instructions ......................................page 22
Sequence of Operation .....................................page 25
Ignition Troubleshooting .................................... page 27
Checking & Adjustment ....................................page 28
Diagnostics ....................................................... page 29
Maintenance ..................................................... page 30
Pressure Switches ............................................ page 31
Wiring ............................................................... page 32
Start-Up ............................................................ page 33
Warranty ...........................................................page 34
BEFORE YOU START
This manual covers the application, installation,
operation and maintenance of a FlexCore series boiler.
To obtain the safe, dependable, efficient operation and
long life for which this boiler was designed, these
instructions must be read, understood and followed.
The FlexCore boiler series has been design certified by
CSA for use with natural gas under the latest revision of
ANSI-Z21.13/CSA 4.9, Gas-Fired Hot Water Boilers 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.
All aspects of the boiler 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 CSA B149.1 or .2, Installation Code
for Gas Burning Appliances and Equipment.
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
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 at: 260 North Elm
Street, Westfield, MA 01085. Always include the model
and serial numbers from the rating plate of the boiler in
question.
RATINGS & CAPACITIES
Before installing the FlexCore boiler check the rating
plate to ensure that the unit has been sized properly
for the job. 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 vent system.
BOILER LOCATION
1. This boiler is suitable for indoor installations only.
Locate the boiler in an area that provides good
access to the unit. Servicing may require the
removal of jacket panels. Allow the minimum
clearances between adjacent construction and the
boiler as listed in Table 1.
Service clearances are not mandatory, but
are recommended to ensure ease of service
should it be required.
Table 1 - Clearances
Clearance to Combustibles Service Clearance
in mm in mm
Top 6 153 30 762
Back 6 153 24 610
Left Side 6 153 24 610
Right Side 6 153 24 610
Front 6 153 36 914
Flue 6 153
2. An optimum site will be level, central to the piping
system, close to a chimney or outside wall and have
adequate fresh air for combustion. Ensure that the
unit is level from front to back and from side to side.
Use metal shims if leveling is required. Electrical and
electronic components must be protected from
exposure to water during operation and maintenance.
DO NOT install this boiler in a location that would
subject any of the gas ignition and other electronic
components to direct contact with water or excessive
moisture during operation or servicing.
3. Ensure that the floor is structurally sound and will
support the weight of the boiler.
The FlexCore may be installed directly on
combustibleooring,butneveroncarpeting.
4. Locate the boiler in an area that will prevent water
damage to adjacent construction should a leak
occur or during routine maintenance.
5. DO NOT place this boiler in a location that would
restrict the introduction of combustion air into the
unit or subject it to a negative pressure unless the
combustion air is piped from the outside, see the
COMBUSTION AIR & VENTILATION section.
6. NEVER place this boiler in a location that would
subject it to temperatures at or near freezing.
Never store combustible materials, gasoline
or any product containing flammable vapors
or liquids in the vicinity of the boiler. Failure to
comply with this warning can result in an
explosion or fire causing extensive property
damage, severe personal injury or death!
COMBUSTION AIR & VENTILATION
This boiler 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 CSA 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 requires a
continuous supply of air for combustion. NEVER store
objects on or around the boiler!
Combustion air contaminated with fluoro-
carbons 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 voiding the
warranty!
If the boiler 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!
3
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Buildings will require the installation of a fresh air duct
or other means of providing make-up air if the intake
air option isn't used. Any building utilizing other gas
burning appliances, a fireplace, wood stove or any type
of exhaust fan must be checked for adequate
combustion air when all of these devices are in
operation at one time. Sizing of an outside air duct must
be done to meet the requirements of all such devices.
Never operate the FlexCore in an
environment subjected to a negative pressure
unless it is Direct Vented. Failure to comply
with this warning can result in excessive
levels of carbon monoxide causing severe
personal injury or death!
All Air From Inside The Building
If the boiler is to be located in a confined space the
minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confined space without the intake
air option two permanent openings communicating with
an additional room(s) are required. The combined
volume of these spaces must have sufficient volume to
meet the criteria for an unconfined 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 confined area. Each
opening must be no less than 100 in2, 64,516 mm2 in
size. The upper opening must be within 12 in, 300 mm
of, but not less than 3 in, 80 mm from, the top of the
enclosure. The bottom opening must be within 12 in,
300 mm of, but not less than 3 in, 80 mm from, the
bottom of the enclosure.
All Air From Outside The Building
When installed in a confined space without the intake
air option 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, 300 mm of,
but not less than 3 in, 80 mm from, the top of the
enclosure. The bottom opening must be within 12 in,
300 mm of, but not less than 3 in, 80 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 1in2/
4000 Btu/hr, 550 mm2/kW of the total input rating of all
of the equipment in the enclosure.
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.
Table2-Make-upAirDuctSizing
Required Cross Sectional Duct Area
Input
(MBH)
1500 375 2419 500 3226 1500 9677
3000 750 4838 1000 6452 3000 19354
4500 1125 7257 1500 9678 4500 29031
6000 1500 9676 2000 12904 6000 38708
1/4 in, 6.4 mm
Wire Screen
2
in
cm
2
Metal
Louvers
2
in
cm
Wooden
Louvers
2
2
in
cm2
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.
DirectIntakeAirOption-General
This configuration provides combustion air directly to the
boiler’s air intake using a dedicated pipe when using the
direct vent option. Combustion air can be drawn in
horizontally through an outside wall or vertically through
the roof, see Figures 2, 3, 4 & 5. It must be sized per
Table 3.
Single wall galvanized smoke pipe, single wall aluminum
pipe, flexible aluminum pipe, PVC or CPVC pipe can be
used for the intake air pipe.
Table3-IntakeAirPipeSizing
Model
Size
Pipe Diameter
in mm
1500 8 204
3000 8 204
4500 10 254
6000 12 305
4
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
All joints in metal intake air systems must be
secured using corrosion resistant fasteners
and sealed using a suitable Silicone caulk. If
PVC or CPVC is used, the joints must be
cleaned with a suitable solvent and connected
using a solvent based PVC cement. The
intake air system MUST be supported by the
building structure not the boiler.
DirectIntakeAirOption-Vertical
The maximum equivalent length for the vertical intake
air pipe is 100 ft, 30.5 m. Each 90° mitered elbow and
the intake air cap are equal to 10 ft, 3.3 m of straight
pipe. If 90° long sweep elbows are installed use the
manufacturers recommended equivalent length.
A listed, nonrestrictive intake air cap must be used. The
intake air cap must terminate as shown in Figure 4. The
penetration point in the roof must be properly flashed
and sealed.
DirectIntakeAirOption-Horizontal
The maximum equivalent length for the horizontal
intake air pipe is 100 ft, 30.5 m. Each 90° mitered elbow
and the intake air terminal are equal to 10 ft, 3.3 m of
straight pipe. If 90° long sweep elbows are installed use
the manufacturers recommended equivalent length.
Horizontal runs that exceed 5 ft, 1.5 m must be
supported at 3 ft, 0.98 m intervals with overhead
hangers. The intake air terminal must terminate as
shown in Figures 2, 3 or 5.
GENERAL VENTING GUIDELINES
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 CSA 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!
All vent systems must be fully supported by the building
structure and not by the boiler. Appropriate thimbles and
fire-stops must be used where required.
Improper installation of common positive
pressure vent systems can result in excessive
levels of carbon monoxide which can cause
severe personal injury or death!
A barometric damper or blast gate as
required, must be installed if a Category II
vertical vent system produces a negative
draft in excess of 0.10 in, 2.5 mm WC at the
flue outlet. Size the vent system per local
codes and the vent pipe manufactuers
requirements, using generally accepted
engineering practices).
VENT SYSTEM OPTIONS
The FlexCore may be vented the following ways:
1) Direct Vent (individual venting only) (page 9
& 10) - Positive Pressure, Category IV uses a
stainless steel vent system certified to UL 1738 for
installations in the United States, and a stainless
steel vent system certified to ULC S636 for
installations in Canada. Combustion air is piped
from the outdoors to the blower inlet.
2) Side Wall Vent (individual venting only) (page 11)
- Positive Pressure, Category IV uses a stainless
steel vent system certified to UL 1738 for
installations in the United States, and a stainless
steel vent system certified to ULC S636 for
installations in Canada. Combustion air is obtained
from the space in which the unit is installed.
To ensure proper operation, boilers that are
sidewall vented and use room air must not
be fired less than 33% input.
3) Vertical Vent (individual venting only) (page
11) - Positive Pressure, Category IV uses a
stainless steel vent system certified to UL 1738 for
installations in the United States, and a stainless
steel vent system certified to ULC S636 for
installations in Canada. Combustion air is obtained
from the space in which the unit is installed.
4) Vertical Vent (individual venting only) (page 12)
- Negative Pressure, Category II uses stainless
steel vent system certified to UL 1738 for
installations in the United States, and a stainless
steel vent system certified to ULC S636 for
installation in Canada. Combustion air is obtained
from the space in which the unit is installed.
5) Common Vent (page 8) - Negative Pressure,
Category II uses a stainless steel vent system
certified to UL 1738 for installations in the United
States, and a stainless steel vent system certified to
ULC S636 for installations in Canada.
5
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Use (Table 4) for the maximum Category (IV) equivalent vent length and the equivalent length per fitting.
Table 4 - “Category IV Equivalent Length per Fitting” chart is meant as a guideline for preliminary sizing. If
vent length approaches 75% of maximum length listed, an engineered vent system calculation must be
performed. Consult factory.
Table 4 - Category IV Maximum Equivalent Vent Length & Equivalent Length per Fitting
Model/Outlet Diameter
K*
Maximum Equivalent
Length (Catagory IV)
Standard Tee 1.25 25 ft 35 ft 40 ft 50 ft
Boot Tee 0.65 15 ft 15 ft 20 ft 25 ft
Cap - Low Res (UL) 0.50 10 ft 15 ft 15 ft 20 ft
45° w/Bird Screen 0.40 10 ft 10 ft 15 ft 15 ft
Elbow - 90° 0.38 10 ft 10 ft 15 ft 15 ft
Elbow - 45° 0.15 5 ft 5 ft 7 ft 7 ft
*Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings.
DIRECT VENT
POSITIVEPRESSURE,CATEGORYIV
In this configuration the boiler blower is used to push
the flue products to the outdoors while drawing
combustion air from the outdoors. The INTAKE AIR
OPTION instructions under the COMBUSTION AIR &
VENTILATION SECTION must be followed!
HorizontalDirectVentSystems-Figures2&3
The vent materials used in positive pressure vent
systems must be certified to UL 1738 for installations in
the United States, ULC S636 for installations in Canada.
To maximize the performance of single wall sheet metal
vent systems locate 90° elbows as far from the boiler as
possible and from one another. For best results,
horizontal vent systems should be as short and straight
as possible.
CK1500 CK3000 CK4500 CK6000
6" 8" 10" 12"
100' 100' 100' 100'
When horizontal vent runs exceed 5 ft, 1.5m they must
be supported at 3 ft, 0.98 m intervals with overhead
hangers. If any part of a single wall metal vent system
passes through an unheated space it must be insulated
with insulation rated for 400°F, 212°C.
Horizontal vent systems shall terminate at least 4 ft,
1.3 m below, 4 ft, 1.3 m horizontally from or 1 ft,
0.23 m above any door, window or gravity air inlet into
any building. It must not terminate less than 4 ft, 1.3 m
horizontally from, and in no case above or below, unless
a 4 ft, 1.3 m horizontal distance is maintained, from
electric meters, gas meters, regulators and relief
equipment and not less than 7ft, 2.3 m above adjacent
public walkway. The bottom of the vent terminal(s) shall
be located at least 5 ft, 1.5 m above the air intake
terminal(s) unless there is a 5 ft, 1.5 m distance between
them.
The vent system must be both gas and water tight.
All seams and joints in metal pipes must be joined and
sealed in accordance with the vent system manufacturer’s
instructions.
6
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Avoid terminal locations likely to be affected by winds,
snowdrifts, people and pets. Protect building materials
and vegetation from degradation caused by the flue
gases.
When running horizontal combustion air and venting for
single or multiple units, exhaust and combustion air
terminals must be installed on the same plane (outside
wall) in order to prevent pressure differences due to
prevailing winds. In cold climates, double-wall or insulated
inlet pipe recommended to prevent condensation.
Vertical Direct Vent Systems - see Figure 4
The vent materials used in positive pressure vent
systems must be certified to UL 1738 for installations in
the United States, ULC S636 for installations in Canada.
If any part of a single wall metal vent system passes
through an unheated space it must be insulated with
insulation rated for 400°F, 204°C. Structural penetrations
must be made using approved fire-stops.
The top of a vertical vent system must extend at least
51/2 ft, 1.8 m above the roof surface that it passes
through, 4 ft, 1.3 m above the intake air cap, see Figure
4. In addition the vent system must conform to the
dimensions shown in Figure 4. The penetration point in
the roof must be properly flashed and sealed.
The vent system must be gas tight. All seams and joints
in metal pipes must be joined and sealed in accordance
with the vent system manufacturer's instructions.
Combination Direct Vent Systems - see Figure 5
The boiler can be vented vertically with the intake air
piped horizontally through an outside wall. Follow the
instructions in the INTAKE AIR OPTION - HORIZONTAL
GUIDELINES on page 5. Also follow the general
instructions in the COMBUSTION AIR & VENTILATION
and GENERAL VENTING GUIDELINES sections.
7
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
FLUE VENT
BAROMETRIC DAMPER
Figure 1 - Multiple Boiler Common Venting
DOUBLE ACTING
THERMAL SPILL
SWITCH
BOILER #4
(IF REQUIRED)
ALL CONNECTIONS
TO BE "T-WYE"
BOILER #3
(IF REQUIRED)
"B"
"F"
BOILER #2
(IF REQUIRED)
"C"
"D"
BOILER #1
VERTICAL CHIMNEY VENTING - Vertical venting multiple boiler installations:
When sized for a (CAT II) configuration, a negative
pressure of 0.02 to 0.10 inches WC is required in each
boiler’s riser when all boilers are operating at full input.
A barometer damper must be installed as illustrated.
[Exception: if the vent system is designed using accepted
engineering practices, and the design calculations prove
there is no need for barometric dampers, the barometric
dampers may be omitted.] When required by applicable
codes, install a thermal spill switch on each barometric
damper.
It is recommended that the boiler nearest the
vertical chimney be fired first when the
horizontal distance exceeds 50% of the
vertical distance. Refer to the HeatNet
manual on how to select the lead boiler.
RIOM-0201_A
1. Connect each boiler riser to the common vent with a
Y connection or Boot T only.
2. Install an approved vent cap at each vent termination.
3. Dimensions:
B = breeching length
C = chimney height
D = breeching diameter
F = riser diameter
(No smaller than the dimension given in Table 4,
page 6.)
4. Size the chimney and breeching per local codes and
vent pipe manufacturer’s recommendations, using
generally accepted engineering practices. (Consult
factory for vertical heights beyond 100 ft.)
8
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Figure2-HorizontalAirIntakeandVentingforaSingleDirectVentSystem
10 ft (3.1 m)
Figure3-HorizontalAirIntakeandVentingforMultipleDirectVentSystems
9
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Figure4-VerticalAirIntakeandVentingforDirectVentSystem
4 FT
1.2 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
10 FT 3.1 m
Figure 5 - Combination Direct Vent Systems
3 FT. 1 m
5 FT
1.5 m
10 FT. 3.1 m
10
1.5 FT. .5 m
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
SIDE WALL VENT
POSITIVEPRESSURE,CATEGORYIV
In this configuration the boiler blower is used to push the
flue products horizontally to the outdoors, see Figure 6.
To ensure proper operation, boilers that are
vented sidewall and use room air must not
fire less than 33% input.
Figure 6 - Side Wall Venting
ELBOW
OR TEE
The air for combustion is taken from the space in which
the unit is installed. The applicable instructions under
the COMBUSTION AIR & VENTILATION SECTION
must be followed! The vent guidelines under the
HORIZONTAL DIRECT VENT SYSTEMS section must
also be followed.
PITCH PIPE DOWN TOWARDS BOILER
1/4 IN. PER FT. 20 nm/m OF RUN TO
ALLOW FOR CONDENSATE DRAINAGE.
EXHAUST
1.5 FT .5 m MINIMUM DISTANCE FROM
EXHAUST TO MAXIMUM SNOW LINE
VERTICAL VENT (Recommended)
POSITIVE PRESSURE - CATEGORY IV
In this configuration the boiler blower is used to push
the flue products vertically to the outdoors, see Figure
7. The air for combustion is taken from the space in
which the unit is installed. The applicable instructions
under the COMBUSTION AIR & VENTILATION
SECTION must be followed! The vent guidelines under
the VERTICAL DIRECT VENT SYSTEMS section must
also be followed.
RIOM-0202_A
Figure7-VerticalPositivePressureVenting
11
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
RIOM-208_A
VERTICAL VENT (Optional)
NEGATIVE PRESSURE - CATEGORY II
The FlexCore is listed as a Category II appliance when
vented vertically into a listed metal AL294C S.S.
chimney system, Figure 8. The chimney system must
provide a negative pressure of 0.02 to 0.10 in, 0.51 to
2.5 mm WC at the boiler flue collar with the unit running.
When using a listed metal chimney system
the chimney system manufacturer’s
instructions must be followed.
Multiple boiler vent systems must be
designed and verified by a qualified
professional and stack manufacturer. The
vent system must prevent backflow of
exhaust gas through idle boilers.
When more than one appliance is connected to the same
chimney system the system must be large enough to
safely vent the combined output of all of the appliances.
Table 5 lists the equivalent breeching and chimney
sizes required for a single boiler installation.
The vent system should be sloped up toward the
chimney at a minimum rate of 1/4 in/ft, 2 cm/m.
Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials.
Failure to maintain minimum clearances
between vent connectors and any
combustible material can result in a fire
causing extensive property damage, severe
personal injury or death!
Exit cones are favorable when used
to increase the velocity of the flue
gas exiting the stack and, may also
help, in cold climates, to reduce ice
build-up. Exit cone terminations must
be supplied by others, installed per
manufacturer’s instructions, and meet
generic exit cone
local and federal code.
Figure8-VerticalVentingwithaMetalChimneySystem
If an appliance using any type of a
mechanical draft system operating under
positive pressure is connected to a chimney
flue, never connect any other appliances to
this flue. Doing so can result in excessive
levels of carbon monoxide which can cause
severe personal injury or death!
Table 5 - Equivalent Breeching & Chimney Size,
Negative Pressure - Single Boiler
Model
Size
Breech & Flue Diameter
in mm
CK1500 8 204
CK3000 12 305
CK4500
CK6000
Pending
These sizes are based on a 20 ft, 6.1m
chimney height.
Vent Connections
Locate the boiler as close to the chimney system as
possible. Use the shortest, straightest vent connector
possible for the installation. If horizontal runs exceed
5 ft, 1.5 m they must be supported at 3 ft, 0.9 m
intervals with overhead hangers. Use the appropriate
vent connector of the same diameter as the flue collar
to connect the boiler to a listed metal chimney system.
Follow the chimney system manufacturer’s instructions
for proper assembly.
12
ROOF FLASHING
CLEARANCE PER VENT
MANUFACTURER'S INSTRUCTIONS
CAP
STORM COLLAR
CLEARANCES PER VENT
MANUFACTURER'S INSTRUCTIONS
OFFSET ONLY IF
NECESSARY
FIRESTOP
FRAMING MEMBERS
BETWEEN JOISTS
INSULATION
2 FT .6 m ABOVE
THE HIGHEST POINT
WITHIN 10 FT 3.1 m
JOIST
Note:
1) All building
structural
modifications
by others.
2) Firestopping
per local
building codes.
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
EXISTING COMMON VENT SYSTEMS
If an existing boiler 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, 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
deficiencies which could cause an unsafe condition.
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) 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.
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 fireplace dampers.
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.
f) 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
Appendix F in the National Fuel Gas Code, ANSI
Z223.1/ NFPA 54 and or CSA B149 Installation
Codes.
Tout mauvais fonctionnement du systéme d'évacu-
tion commun devrait étré corrigé de façor que l'installation soit conforme au National Fuel 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 modifiée, le système devrait
étré modifié 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.
13
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler will void the
manufacturer’s warranty and can cause boiler
failure resulting in flooding and extensive
property damage!
Shut off valves and unions should be
installed at the inlet and outlet connections
of the boiler to provide for isolation of the
unit should servicing be necessary.
Relief Valve
Pipe the discharge of the pressure relief valve as shown
in Figure 9. Mount on rear section or vertically on supply
nipple.
Never install any type of valve between the
boiler and the relief valve or an explosion
causing extensive property damage, severe
personal injury or death may occur!
FlowSwitch
The factory mounted flow switch, as shown in Figure 9,
is wired to prevent the boiler from firing unless there's
adequate water flow through the unit.
Failure to maintain the minimum flow rates listed
in Table 6 at the boiler outlet will prevent the
flow switch from closing. If a minimum flow rate
cannot be maintained at the boiler outlet the flow
switch will have to be relocated in the system.
Figure 9 - FlexCore Firetube Piping
DISCHARGE SO AS TO AVOID
EXPOSURE OF PERSONS TO HOT
LIQUID OR VAPOR AND FOLLOW
COMPLETE DRAINAGE OF RELIEF
VALVE AND PIPING.
PRESSURE RELIEF VALVE
Air Vent
The factory mounted air vent, as shown in Figure 9, is
installed to automatically purge unwanted air from the
boiler allowing the system to run more effectively. The
vent (Taco 409) will arrive with its air valve open.
Please note that after installing in a new
system or retofitting an old, close the vent
and flush out the disturbed dirt as well as
any oily film or solder paste entrained in the
system water. If this is not done, it is entirely
possible that the internal float mechanism will
become clogged open, causing the air vent
to leak. You may open the vent for automatic
operation once the system is flushed.
Table 6 - Temperature Rise Table
Model
Size
Water
Flow Rates
(GPM)
Heat Exchanger
*∆T Across
Min. Max. Min. * Max.
CK1500 28.5 142.7 20°F 100°F
CK3000 58.1 290.5 20°F 100°F
CK4500
CK6000
Pending
*Min/Max ∆t corresponds to full input, for applications
requiring operation above and/or below these parameters,
please consult manufacturer.
Increase flow rates approximately 30% for glycol
mixtures.
AIR VENT
FLOW SWITCH
SUPPLY OUTLET
TEMPERATURE GAUGE
FLUE OUTLET
RETURN INLET
14
CONDENSATE DRAIN
ASSEMBLY
LOW WATER CUTOFF
HI LIMIT
RIOM-0213_A
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualified
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
Where required, the piping must comply with 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 1in, 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, 84 kPa must be maintained at
boiler operating conditions. A minimum system pressure
of 25 psig, 172 kPa fill pressure is required, at boiler
operating conditions on glycol mixtures within a closed
loop.
Boiler Piping Connections
The supply and return connections should be sized to
suit the system, see Table 7.
Table7-Supply&ReturnPipeSizing
Model
Size
CK1500 2-1/2" NPT 2-1/2" NPT
CK3000 3" NPT 3" NPT
CK4500 4" NPT 4" NPT
CK6000 4" NPT 4" NPT
System Cleaning & Flushing: Prior to
commissioning the boiler(s), the piping/
system must be cleaned and flushed to
prevent contaminants from settling back
into the boiler and fouling the heat
exchanger.
Isolate the boiler from the system prior to the
cleaning process. Fill the system with water,
add the cleaning solution and follow the
solution manufacturer’s instructions. Once
clean, refill the system with clean water as
specified in the Water Treatment section.
Supply
Size
Return
Size
Water Treatment
This boiler was designed to operate in a closed loop
heating system. System fill water must not contain more
than 500 ppm of total dissolved solids and no greater
than 300 ppm hardness. Suspended solids such as
Magnetite, Iron Oxides must be flushed from the system
prior to commissioning the boiler(s). The PH level must
be within the 6.5-10 range. Where required, the system
must be protected by the addition of a corrosion inhibitor
per the chemical supplier’s instructions.
For systems requiring glycol for freeze protection use
a glycol/water mix that prevents foaming. Air entrapped
within foam significantly decreases heat transfer and
can result in damage to the sections. Products such
as DOWFROST, DOWTHERM, UCARTHERM or an
equivalent product must be used to ensure proper
protection to the boiler.
The water used for dilution of concentrated heat transfer
fluids must be distilled, de-ionized, or equivalently clean
as stated above. De-ionized water by itself can be
aggressive torwards many metals, but is perfectly safe
when used for dilution of DOWFROST, DOWTHERM or
UCARTHERM as specified by the manufacturer.
FAILURE TO ENSURE PROPER WATER QUALITY
CAN RESULT IN DAMAGE TO THE BOILER(S)
VOIDING THE WARRANTY.
Pump Requirements
This boiler requires a continuous minimum water flow
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.
If the system contains hydronic antifreeze this must be
considered when sizing the pump. The temperature rise
across the boiler must never exceed 100°F, 55.6°C.
LowWaterCutoff
Each boiler comes equipped with a factory installed low
water cutoff.
ExpansionTank&AirSeparator
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. An air scoop and
automatic air vent must also be installed to eliminate air
trapped in the system.
Reverse Return Piping (RECOMMENDED)
Systems using multiple boilers can also be installed
using a reverse return system, Figure 11.
15
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Primary/Secondary Piping
Although acceptable, the system is not as cost effective
as reverse return piping. Figure 12 shows a typical
primary/secondary piping system. A dedicated pump is
used to maintain a constant water flow through the
boiler. Systems using multiple boilers can be installed
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 flowcontrol valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.
using a primary/secondary manifold system, Figure 13.
It is essential that following boiler shut off,
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
the boiler pump continue to operate for
approximately (5) minutes to dissipate the
heat away from the heat exchanger.
in parallel with the boiler. Appropriate valves must be used
to prevent the chilled water from entering the boiler.
Figure 10 - Typical Single Boiler Piping (RECOMMENDED)
(Circulator pump must be sized for minimum water flow rate of boiler, including system pressure drop)
SYSTEM
RETURN
PUMP
GATE VALVE
BACKFLOW PREVENTION
DEVICE
16
SYSTEM
SUPPLY
PRESSURE
RELIEF VALVE
COLD WATER
MAKE-UP
THERMOMETER
EXPANSION TANK
AQUASTAT
PRESSURE
REDUCING VALVE
RIOM-0209_A
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
SUPPLY
SYSTEM
RETURN
SYSTEM
Pump
Tank
Expansion
Aquastat
Thermometer
Pressure
Relief Valve
Gate Valve
Pressure
Reducing Valve
Backflow-Prevention
Device
COLD WATER
MAKE-UP
SYSTEM
RETURN
AIR SEPARATOR
TYPICAL LOCATION
AIR SEPARATOR
ALTERNATE LOCATION
M
M
M
M
SYSTEM
SUPPLY
COLD WATER
MAKE-UP
Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED)
(Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local
manufactures representative for assistance.)
AIR SEPARATOR
ALTERNATE LOCATION
SYSTEM
RETURN
AIR SEPARATOR
TYPICAL LOCATION
M
M
M
M
M
SYSTEM
COLD WATER
SUPPLY
MAKE-UP
RIOM-205 REV A
NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be
necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12" from primary loop tee.
Figure 12 - Typical Single Boiler Primary/Secondary Piping
MINIMUM 3X PIPE DIAMETERS
MAXIMUM 10X PIPE DIAMETERS
SYSTEM
SUPPLY
AIR SEPARATOR
TYPICAL LOCATION
BETWEEN CENTERS
COLD WATER
MAKE-UP
SYSTEM
RETURN
AIR SEPARATOR
ALTERNATE LOCATION
RIOM-203 REV A
Motorized
Valve
NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be
necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12" from primary loop tee.
Figure 13 - Typical Multiple Boiler Primary/Secondary Piping
NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be
necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12" from primary loop tee.
SYSTEM
RETURN
SYSTEM
SUPPLY
AIR SEPARATOR
ALTERNATE LOCATION
COLD WATER
MAKE-UP
MINIMUM 3X PIPE DIAMETERS
MAXIMUM 10X PIPE DIAMETERS
BETWEEN CENTERS
AIR SEPARATOR
TYPICAL LOCATION
RIOM-204 REV A
17
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
PUMP
NOTES:
1. WHEN USING INTERMITTENT PUMP AND PUMP DELAY, LOCATE HEAT NET SENSOR WITH
WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
4. MA CODE REQUIRES AN 1/8" HOLE IN CHECK VALVES TO COMPENSATE FOR THERMAL
EXPANSION.
5. BOILER AND PUMP PURGING REQUIRED. AIR MUST BE PURGED FROM 3-WAY VALVE AFTER THE
BOILER IS FILLED. USE PURGE VALVES PROVIDED. PURGE VALVE MAY BE LOCATED ON PUMP
FLANGE. ON MULTIPLE BOILER INSTALLATIONS THE FLOW SWITCH MAY FAIL DUE TO TRAPPED AIR.
SEE MANUAL FOR PROCEDURE.
6. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR THE REQUIREMENTS
OF AN ACID NEUTRALIZATION KIT.
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
6. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR THE REQUIREMENTS
DOMESTIC WATER SUPPLY PIPING
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
The FlexCore boiler can be use in combination with an
indirect tank to provide hot water for domestic use. Piping
and components must be suitable for use with potable
water. The indirect storage tank must be equipped with
a temperature and pressure relief valve that complies
with ANSI Z21.22 or CAN-4.4 and CAN-4.6.
Figure14-TypicalSingleBoilerwithIndirectStorageTankPiping
ExpansionTank
An expansion tank or other means to control thermal
expansion must be installed in the water heating system
if back flow prevention devices are installed.
Two typical water heating systems are shown in Figures
14 & 15.
ThermostaticMixingValve-WaterAbove140°F,60°C
Water can be stored a temperatures above 140°F,
60°C provided that a thermostatically 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 above.
Storage of water for domestic use above 140°F, 60°C
will provide an increased quantity of tempered water and
help prevent the growth of water born bacteria.
The storage tank must be located as close
to the boiler as possible to prevent excessive
head loss which will reduce flow.
SUPPLY
2
4
COLD WATER
MAKE-UP
FLOW
GATE VALVE
CHECK VALVE
BACKFLOW PREVENTION
CIRCULAR
RETURN
DEVICE
BRONZE
PUMP
18
4
1
TEMPERATURE &
PRESSURE
RELIEF VALVE
2
RELIEF VALVE
COLD WATER
MAKE-UP
4
FLOW
FLOW
NOTES:
1. WHEN USING INTERMITTENT PUMP AND PUMP DELAY, LOCATE HEAT NET SENSOR WITH
WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
4. MA CODE REQUIRES AN 1/8" HOLE IN CHECK VALVES TO COMPENSATE FOR THERMAL
EXPANSION.
5. BOILER AND PUMP PURGING REQUIRED. AIR MUST BE PURGED FROM 3-WAY VALVE AFTER THE
BOILER IS FILLED. USE PURGE VALVES PROVIDED. PURGE VALVE MAY BE LOCATED ON PUMP
FLANGE. ON MULTIPLE BOILER INSTALLATIONS THE FLOW SWITCH MAY FAIL DUE TO TRAPPED AIR.
SEE MANUAL FOR PROCEDURE.
OF AN ACID NEUTRALIZATION KIT.
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
PRESSURE
VACUUM RELIEF
VALVE
THERMOMETER
EXPANSION
HEAT NET
TANK
SENSOR
RIOM-0206_A
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
NOTES:
1. WHEN USING INTERMITTENT PUMP AND PUMP DELAY, LOCATE HEAT NET SENSOR WITH
WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. COMMON PIPING MUST BE SIZED FOR MAXIMUM COMBINED HEATER FLOW.
4. HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
NOTES:
1. WHEN USING INTERMITTENT PUMP AND PUMP DELAY, LOCATE HEAT NET SENSOR WITH
WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. COMMON PIPING MUST BE SIZED FOR MAXIMUM COMBINED HEATER FLOW.
4. HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
5. MA CODE REQUIRES AN 1/8" HOLE IN CHECK VALVES TO COMPENSATE FOR THERMAL EXPANSION.
6. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR THE REQUIREMENTS
OF AN ACID NEUTRALIZATION KIT
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
COLD WATER
MAKE-UP/FILL
SUPPLY
CIRCULAR
RETURN
FLOW
FLOW
BRONZE
PUMP
COLD WATER
MAKE-UP
FLOW
FLOW
4
1
2
3
2
5
5
Figure15-TypicalMultipleBoilerwithIndirectStorageTankPiping
COLD WATER
MAKE-UP
2
FLOW
5
FLOW
3
COLD WATER
PUMP
GATE VALVE
MAKE-UP/FILL
CHECK VALVE
5
BACKFLOW PREVENTION
DEVICE
2
BRONZE
PUMP
CIRCULAR
4
RETURN
FLOW
FLOW
SUPPLY
1
NOTES:
1. WHEN USING INTERMITTENT PUMP AND PUMP DELAY, LOCATE HEAT NET SENSOR WITH
WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. COMMON PIPING MUST BE SIZED FOR MAXIMUM COMBINED HEATER FLOW.
4. HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
5. MA CODE REQUIRES AN 1/8" HOLE IN CHECK VALVES TO COMPENSATE FOR THERMAL EXPANSION.
6. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR THE REQUIREMENTS
OF AN ACID NEUTRALIZATION KIT
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
TEMPERATURE &
RELIEF VALVE
PRESSURE
PRESSURE
RELIEF VALVE
VACUUM RELIEF
VALVE
THERMOMETER
EXPANSION
HEAT NET
TANK
SENSOR
RIOM-0207_A
19
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
CONDENSATE PIPING
The condensate trap provided with the boiler must be
attached to the bottom pan and piped to a suitable floor
drain (consult local code) or condensate pump. If a
condensate neutralization device is required by local
code, it must be positioned prior to boiler room drain. Fill
the condensate trap with water, check and maintain water
level in trap during operation prior to start-up.
GAS SUPPLY PIPING
Check the boiler rating plate to make sure that
the boiler is for the type of gas that
will be used. If it isn’t, do not connect the
boiler to the gas supply. Failure to comply with
this warning can result in extensive property
damage, severe personal injury or death!
The FlexCore comes from the factory ready to be piped
to the gas supply. If for any reason the boiler is not for
the type of gas available at the installation site, call your
Advanced Thermal Hydronics representative to resolve
the problem.
Table 8 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 fittings. Table 8
should be used in conjunction with Table 9 to ensure
that the gas supply piping has the capacity to meet the
demand.
Figure 17 depicts the proper way to connect the boiler
to the gas supply piping. The manual shut-off valve
MUST be installed in the supply piping. It should be
installed 5 ft, 1 m above the floor 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.
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 with the type of gas (NG/LP) being used.
Table 8 - Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Iron Pipe
Size
11/4" 1050 730 590 500 440 400 350 305 250
11/2" 1600 1100 890 760 670 610 530 460 380
2 1/2" 4800 3300 2700 2300 2000 1850 1600 1400 1130
Note: Multiply the gas volume by 0.62 for propane flow capacity in
ft3/hr. Multiply the propane flow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
10 20 30 40 50 60 80 100 150
Maximum gas volume of pipe (ft3/hr)
1" 520 350 285 245 215 195 170 150 120
2" 3050 2100 1650 1450 1270 1150 990 870 710
3" 8500 5900 4700 4100 3600 3250 2800 2500 2000
4" 17,500 12,000 9700 8300 7400 6800 5800 5100 4100
Pipe length in feet
Figure 16 - FlexCore-Series Condensate Drain
20
CONDENSATE DRAIN
RIOM-0214_A
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Table 9 - Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size
1"
11/4"
11/2"
2"
21/2"
3"
4"
Notes: 1. For flow through branch.
2. For flow at full open.
90° Elbow Te e
2.6 5.2 0.6 1.5
3.5 6.9 0.8 1.9
4.0 8.0 0.9 2.3
5.2 10.3 1.2 3.0
6.2 12.3 1.4 3.7
7.7 15.3 1.8 4.5
7.7 15.3 1.8 4.5
Type of pipe fitting
1
Gas Valve2Gas Cock
Equivalent pipe length, (ft)
A lockup style regulator, supplied by others,
must be installed, see Figure 17, if gas
pressure exceeds (14 in WC). The regulator,
when installed as shown, must be installed
at a distance of at least 10 pipe diameters
from the boiler main gas valve. All boilers are
calibrated and factory test fired at
(7 in ± 1.0) WC.
A minimum of (3 in WC) and maximum of
(14 in WC) must be maintained to the inlet of
the boiler gas train not to exceed a maximum
of (1 in WC) drop when firing from minimum
input to full load of the gas supply line and all
the appliances running.
Always use a 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!
Whenever the gas supply piping is pressure tested the
boiler gas controls must be protected. If the test pressure
is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler
2
by closing its' manual shut off valve, see Figure 17. If the
test pressure is greater than, or equal to 1/2 psig, 3.5 kPa,
disconnect the boiler and its individual shut-off valve.
ELECTRICAL WIRING
ElectricalPowerConnections
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
com-mandes, étiquetez tous les fils 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 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. Install a
separate 230 volt 1Ø with neutral 20 amp circuit for each
CK1500 boiler. A properly rated shut-off switch should be
located at the boiler. The boiler must be grounded in
accordance with the authority having jurisdiction, or if none,
the latest revision of the National Electrical Code, ANSI/
NFPA-70.
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.
Never use an open flame 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!
Figure17-GasSupplyPiping
Line voltage field wiring of any controls or other devices must
use copper conductors with a minimum size of #14 awg.
Refer to point of connection diagram in back of this manual
and the wiring diagram supplied with the boiler for proper
wiring connections.
21
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
BOILER OPERATION
Before proceeding read and fully understand
the instructions contained in this manual. Do
not attempt to operate this boiler 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.
DoNotinterruptwaterowthroughtheboiler.
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 (Fill System)
Open the make-up water valve and slowly fill 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 5 psig, 82.7 kPa system pressure is
maintained at the highest point in the system piping. A
minimum system pressure of 12 psig, 84 kPa must be
maintained at boiler operating conditions. A minimum
system pressure of 25 psig, 172 kPa fill pressure is
required, at boiler operating conditions, on glycol
mixtures within a closed loop.
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 tank air pressure equals cold static fill
pressure.
Start the boiler as described in the OPERATING
INSTRUCTIONS below. 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.
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.
22
The system should be checked and bled after three days
of operation.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
ONLY QUALIFIED LICENSED SERVICE TECHNICIANSSHALLSTART,TROUBLESHOOT,AND
SERVICE THIS APPLIANCE WITH APPROVED
COMBUSTION ANALYZER.
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
floor because some gas is heavier than air and will
settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Donottrytolightanyappliance.
• Donottoughanyelectricswitch;donotuseanyphone
in your building.
• Immediatelycallyourgassupplierfromaphoneoutside
of the building. Follow the gas suppliers instructions.
• If you cannot reach your gas supplier, call the re
department.
AVANT DE FAIRE FONCTIONNER, reniflez tout autour
de l'appareil pour déceler une odeur de gaz. Reniflez
près du plancher, car certains gaz sont plus lourds que
l'air et peuvent s'accumuler au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
•Nepastenterd'allumerd'appareil.
•Netouchezàaucuninterrupteur;nepasvousservir
des téléphones se trouvant dans le bâtiment.
•Appelezimmédiatementvotrefournisseurdegaz
depuis un voisin. Suives les instructions du
fournisseur.
•Sivousnepouvezrejoindrelefournisseur,appelez
le service de incendies.
C. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of
the control system and any gas control that has
been under water.
N'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.
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Operating Instructions
1. STOP! Read the safety information above. If, at any
time, the appliance will not operate properly, follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your service technician or gas supplier.
2. Set the operating control to off and disable any
outside (BMS) call for heat.
3. Turn off all electric power to the appliance.
4. Remove the front cover.
5. Close manual main shut-off valves 1 and 2 and the
pilot gas shut-off valve, Figure 17.
6. Purge the gas piping up to the manual valve ahead of the
main gas control of air. When the bleeding is complete,
check all gas joints up to the gas valve for leaks.
7. Wait five (5) minutes to clear out any gas.
8. Install a fitting at the supply test port and connect a
manometer having a minimum range of 20 in, 508
mm WC to it, Figure 17.
15. When the main display reads "PILOT RUNNING"
and the flame current is 5VDC, switch the Honey
well 7800 to the "test" position, Figure 18. This will
hold the Honeywell 7800 in its ignition state.
16. Adjust the pilot pressure per the CHECKING,
ADJUSTMENT & OPERATION on page 28.
17. To adjust the IGNITION value as shown in the display,
place the ‘S2’ Calibration switch located on the 3.0
HeatNet board to the ‘CAL’ position. A reload message
will be displayed then the calibrate screen. Press the
‘Adjust’ button under the Ignition (%) setting. The
percentage value will turn green and the boiler will
ramp to the ignition setting. Set the Blower speed,
using the arrow keys, to provide the desired rate for
ignition. When the adjustment is satisfactory, press the
check key to save the setting. When complete place
the ‘S2’ switch back to the ‘NORM’ position.
9. See the "Gas Supply Piping" section for the required
static and run gas pressure.
10. Open the manual main shut-off valves 1 and 2 and
the pilot gas shut-off valve, Figure 17.
11. Place the "Remote/Local" switch to Remote.
12. Turn the power switch on the front of the boiler to
"on". It will light up when the power is on. If all
interlocks are properly closed, the display will say
"Standby", Figure 18.
13. Slide the HeatNet controls low fire switch (on the
HeatNet control board) to the low fire position.
14. The boiler will begin the start sequence.
AIR PRESSURE SWITCH SN2
AIR PUMP
18. Remove the demand from the 7800 control by
disabling the low fire switch allowing the boiler to stop.
19. Close manual main shut-off valve 2 and the pilot gas
shut-off valve, Figure 17. Connect both sides of a
manometer or pressure gauge to the manometer
pressure taps (differential pressure barbed
connections) on the pressure test manifold located
inside the upper control panel. (See Figure 22).
20. Switch the Honeywell 7800 back to "run".
50 VA TRANSFORMER
CUSTOMER CONNECTIONS
HEATNET
CONTROL BOARD
250 VA TRANSFORMER
BLOWER RELAY
CONTRACTOR
USB
LOCAL/ REMOTE SWITCH
LOW WATER CUTOFF
TOUCH SCREEN
RIOM-0212_A
CABINET LIGHT
POWER SWITCH
MANUAL HIGH LIMIT
FLAME SAFEGUARD
RIOM-0212_A
23
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
21. Create a minimum input demand as before (enable
low fire switch on the HeatNet board). The boiler will
begin the start sequence.
22. Monitor the flame current on the 7800. No flame
current should be detected and the 7800 should
lock out. If flame current is detected at any time up
to the 7800 locking out, the 120V wiring on the
ignition transformer must be reversed and the test
run again to insure that no flame is detected.
Improper wiring of the ignition transformer
can result in an explosion causing extensive
property damage, severe personal injury or
death!
23. Open both manual main shut-off valves and the pilot
gas shut-off valve.
24. Reset the Honeywell 7800. The boiler will start and
will run at minimum input rate.
25. Setting the Min VFD and Low Fire Combustion
values: The boiler will cycle and achieve low fire
status. Allow low fire to settle out for a few minutes
and observe the combustion reading.
c. Adjust low fire 02-C02 by opening the low fire
adjustment door located on the forward facing
side of the main gas valve, (Figure 17). Inserting
an allen wrench and rotating the allen screw
clock-wise will increase the C02 and lower the
02;rotatingcounterclock-wisewilldecreasethe
C02 and increase the 02.
d. When the adjustment is satisfactory, press the
check key to save the setting.
26. Setting the Max VFD and High Fire Combustion
values:
a. Verify the ‘S2’- Calibration switch located on the
3.0 HeatNet board is in the ‘CAL’ position.
NOTE: The Calibration (Min % & Max %) represents the
mapped signal sent to the blower and doesn’t reflect
the (modulation %) as indicated on the Master/
Member Screens.
a. Place the ‘S2’ - Calibration switch located on
the 3.0 HeatNet board to the ‘CAL’ position. A
reloading message will be displayed and then
the calibrate screen.
b. Press the ‘Adjust’ button under the Minimum (%)
setting. The percentage value will turn green. Adjust
the minimum value (%), using the arrow keys, to
achieve the required combustion - C02/02, (Table
11), and pressure – delta p, (Table 12), at low fire
based on the desired turn down. Measure the
pressure – delta p by pressing and holding the
service valve marked "Differential Valve".
24
b. Press the ‘Adjust’ button under the Maximum
(%) setting. The percentage value will turn
green and will change to 80% indicating that
it can be changed. Adjust the maximum value
(%), using the arrow keys, to achieve the
required combustion – CO2/O2 (Table 11),
and pressure – delta p, (Table 12). Measure the
pressure – delta p by pressing and holding the
service valve marked "Differential Valve".
c. The high fire trim adjustment is located on the
outlet flange, (Figure 17), of the gas valve.
d. When the adjustment is satisfactory press the
check key to save the setting. When complete,
place the ‘S2’ switch back to the ‘NORM’
position.
e. Allow the boiler to settle into min input and
observe combustion readings to ensure the
boiler is operating correctly. Make any required
adjustments. When complete disable the low fire
hold switch.
f. Follow the instructions in the HeatNet Control
manual to allow adjustments required for high
altitude installations.
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. The boiler is idle with no interlocks in the fault
condition.
DEMAND
Pre-Purge
1. The blower operates at purge RPM. The water flow
interlock must ‘make’ within 15 seconds after the
demand signal is initiated.
2. The Honeywell 7800 starts a 10 second purge delay
once the air prove switch contacts close.
Pilot Run - %Input
1. The blower operates at minimum ignition setting.
See the calibration section in the "FlexCore Series
Control IOM" to enter the calibration menus.
2. The ignition transformer is energized. The pilot
solenoid valve opens for the 10 second pilot ignition
trial.
Main Run %Input
1. The main gas valve opens.
2. The ignition transformer is de-energized.
3. The pilot solenoid valve closes.
4. The blower stays at the minimum input setting for
3 seconds then operates at demand % input. See
the calibration section in the "FlexCore Series
Control-IOM" to enter the calibration menus.
NO DEMAND
Post-Purge
1. The main gas valve closes.
2. The blower operates at purge RPM for 10 seconds.
3. The boiler is idle with no interlocks in the fault
condition.
25
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Table 11 - Combustion Settings
Trim**
Inlet
Air
Temp.
-40°F
-30°F
-20°F
-10°F
0°F
10°F
20°F
30°F
40°F
50°F
60°F
70°F
80°F
90°F
100°F
Low
Fire
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.0
8.1
8.2
8.3
8.4
8.5
8.6
CO2 %
NG LPG
High
Fire
8.0
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
9.0
9.1
9.2
9.3
9.4
Low
Fire
8.4
8.5
8.7
8.8
8.9
9.0
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
10.1
High
Fire
9.4
9.5
9.6
9.7
9.8
9.9
10.1
10.2
10.3
10.5
10.6
10.7
10.8
10.9
11.0
Low
Fire
8.3
8.1
7.9
7.8
7.6
7.4
7.2
7.1
6.9
6.7
6.5
6.4
6.2
6.1
5.9
O2 %
**Located on outlet flange of gas valve. (Figure 17, page 21)
Due to job conditions, deviation from specified may be required – allow ± (0.2)% range adjustment.
High
Fire
6.9
6.7
6.5
6.4
6.2
6.1
5.9
5.7
5.5
5.3
5.2
5.0
4.8
4.7
4.5
Table 12 - Pressure Signal (P) - (Nat. Gas)
Firing
Rate
CK1500 CK3000 CK4500 CK6000
(Delta P)
in WC
100% 10.00
33% 1.40
25% .65
20% .50
To determine signal in mm WC, multiply signal pressure by 25.4 - (See Factory Startup sticker for LP).
26
(Delta P)
in WC
7.00
1.
85
.
80
.50
Pending
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
FireTube Series "HeatNet Control" Troubleshooting (Firing the FireTube Boiler)
Variable Frequency
Drive
Operate Blower
Motor @ 0%
FireTube Control Functions
DISPLAY:
STANDBY
DISPLAY:
HEATING:
Ignition Sequence
CALL FOR
HEAT?
YES
Start Circulator
Interlocks OK?
NO
YES
Are we below the
Temp Band?
NO
YES, fire the boiler.
Close the Last
limit in the Limit
String to Ignition
Control
INPUTS:
1. MODBUS
2. AA
3.Heat Demand
4. 4-20ma
5. T1-T4
J13 "CIRC"
J5, J11A,J11 B
Setpoint - 1/2
Heat Band
J5 Pin 10
"LIMITS"
Hand Shake
LIMITS
Ignition Contrrol
(Honeywell S7800)
NO
Limits OK?
TERM 6
"LIMITS"
YES
Operate Blower
Motor @ 0%
Operate Blower
Motor @ ~55%
Operate Blower
Motor @ ~32%
Operate Blower
Motor @ Min Fire,
then Modulate to
maintain temp
J4 Pins 4 & 8
If Yes, do
not operate
blower.
J4 Pins 4 & 8
DISPLAY:
PRE PURGE
J4 Pins 4 & 8
DISPLAY:
PILOT:
J4 Pins 4 & 8
DISPLAY:
RUN % 25
Have We
NO
received the
"BLOWER"
signal?
YES
"MAIN VA LVE"
greater than 7 VA C
PRE_PURGE
NO
PILOT signal? PILOT
PILOT Ignition
NO
MAIN signal?
1. Minimum fire rate
2. Hold for (x) secs.
3. Modulate to temp
J5 Pin 3
"BLOWER"
YES
NO
J5 Pin 2
"PILOT"
YES
J5 Pin 1
"MAIN"
YES
BLOWER
MAIN
Send 120 VA C
BLOWER signal
TERM 4
"MOTOR"
TERM 8
"PILOT"
After 10 Seconds
send PILOT signal
FLAME?
YES
After 10 Seconds
send MAIN
VA LVE signal
TERM 9
"MAIN"
27
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
CHECKING,ADJUSTMENT&OPERATION
SparkGap
The gap has to be measured and adjusted with the
igniter removed from the boiler. Observe the trial for
ignition to confirm that the spark is strong and
continuous. If not, allow the electrodes to cool. Check
and adjust the spark gap as shown in Figure 19.
Electrode tips should face slightly downward.
Figure19-SparkGap
PilotAdjustment
Connect one side of a manometer or pressure gauge
having a minimum range of 6 in., 15 mm WC to the
manometer pressure tap (pilot gas barbed connection)
on the pressure test manifold located inside the upper
control panel. (See Figure 22). Leave the other side of
the manometer open to atmosphere. Open the pilot gas
shut-off valve. With the unit powered generate a call for
heat. When the prepurge is complete the ignition/pilot
trial will begin. At this point put the Honeywell 7895C test
switch in the test position. The control will hold in the
ignition/pilot sequence allowing you to check the
pressure. Measure the pilot pressure by pressing and
holding the service valve marked "Pilot Gas Valve". Verify
that the pilot gas pressure is within a range of (2.5 in.-3.5
in. WC). Check the pilot air pressure using the service
valve marked "Pilot Air Valve". The pilot air pressure
should be .60 in. WC (± 0.1 in.).
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 clockwise to increase the pressure and counterclockwise
to decrease it.
3. Replace the pressure regulator adjustment screw
cap.
Never force the regulator adjustment screw
beyond the stop limits or damage to the
regulator will occur!
Pilot flame UV signal
Before you check the pilot signal you need to make sure
the polarity of the 120v supply to the ignition transformer
is correct. To do this close the manual main shut-off
valve 2 (Figure 17) and the manual pilot shut-off valve.
With the unit powered generate a call for heat. The boiler
will start to go through it start up sequence. During the
ignition/pilot sequence observe the lights on the
Honeywell 7895C. The pilot light should come on but not
the flame light. If the flame light comes on along with
the pilot light, interrupt the call for heat and turn off the
main power. Reverse the 120v supply leads to the
Honeywell 652B ignition transformer and run this test
again. With this done the flame signal should be
between 3vdc and 5vdc. Check the voltage on the test
connections of the Honeywell 7895C's amplifier with a
dc voltmeter.
28
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Ignition Safety
To test the ignition safety shutoff device, close the
manual shutoff valve 1 (Figure 17) in the gas supply line.
Within 5 seconds of main burner flame extinction, the
main gas valve solenoid should close. The control board
will lockout and display “LOW GAS PRESSURE”. Open
the manual shutoff valve in the gas supply line and reset
the control board by toggling the power switch.
To confirm the input of the unit follow the instructions in
the INPUT RATE section below.
InputRate,NaturalGas
1. Turn off all other gas appliances that use the same
gas meter as the boiler.
2. Call your gas supplier and ask for the heating value
of the gas (Btu per cu/ft).
3. Start the boiler and let it run for 15 minutes.
4. With the boiler operation clock the time that it takes
to burn 10 cu/ft of gas at full fire.
5. Insert the heating value and the time, in seconds,
into the formula below.
DIAGNOSTICS
The FlexCore has a display that indicates the sequence
of operation, Figure 18. The display will also list faults
should the unit fail to operate. An explanation of each
fault is listed below.
STANDBY: Indicates that power is being supplied
to the unit and there is no call for heat.
STANDBY OPERATING LIMIT: Indicates that the
operating limit if used is open.
HONEYWELL ALARM “flashing”: Indicates that there
is a call for heat and the Honeywell 7895C is locked out.
STANDBY START DEMAND: Indicates that there is a
call for heat and the Honeywell 7895C is not functioning
or is locked out.
STANDBY WATER LIMIT: Indicates that either the high
limit, low water cut off, or both are open without a call
for heat.
LOCKOUT WATER LIMIT: Indicates that either the high
limit, low water cut off, or both are open with a call for
heat.
6. Input = 10 / seconds (Btu per cu/ft)(3600).
7. If the computed rate exceeds the desired input
follow section “operating instructions” to make the
appropriate adjustments.
Never increase the input to the boiler above
that for which it is rated. Doing so can cause
premature failure of the boiler!
LowWaterCutoff
Ensure that the low water cutoff device(s) function
properly.
Test in accordance with the manufacturer’s instructions
included with the device(s).
STANDBY GAS PRESSURE: Indicates that the low gas
pressure switch or the high gas pressure switch if used
is open without a call for heat.
LOCKOUT GAS PRESSURE: Indicates that the low gas
pressure switch or the high gas pressure switch if used
is open with a call for heat.
STANDBY FLOW SWITCH: Indicates that the water
flow switch is open without a call for heat.
LOCKOUT FLOW SWITCH: Indicates that the water
flow switch is open with a call for heat.
LWCO LOCKOUT: Indicates low or no water in the
boiler.
29
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
MAINTENANCE
Disconnect electrical power and close the
manual gas shut off valve before performing
maintenance or severe personal injury may
result!
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!
The boiler must be inspected at least once a year and
before each heating season. Make sure that combustion
readings and air box pressures are taken on each
boiler and match the desired emissions outlined under
the specification in the Installation Manual — adjust
as necessary. Accessing the burner compartment
isn't necessary during normal maintenance unless
combustion values or air box pressures don't meet
specification.
Improper burner servicing can result
in premature burner failure voiding the
warranty!
Burner Removal & Inspection
Wear a tightly fitted dust mask when
servicing the burner and gently handle the
burner and its gasket to prevent inhalation
of airborne fibers.
Controls
Use the BOILER OPERATION and CHECKING AND
ADJUSTMENT sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A float type low water cutoff device must be flushed
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 cutoffs operate properly. If not,
replace them.
3. The flow switch contacts must be open when water
flow is not present.
4. The relief valve should not weep or discharge water
at normal system pressure. If it does contact a
qualified service technician to have it inspected.
NEVER try to clean or repair the relief valve! If the
valve fails to operate properly, have it replaced!
5. The aquastat high limit controls the maximum water
temperature in the boiler. It is adjustable from 130°F,
54°C to 215°F, 102°C. 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 215°F,
102°C. The aquastat high limit cannot be repaired.
If it fails to function properly replace it.
6. Visually check the pilot and main burner flames to
ensure proper operation, see Figures 20 & 21.
Do not attempt to remove the burner without
having a burner gasket kit on hand.
Heat Exchanger Cleaning
In the unlikely event that the heat exchanger becomes
blocked consult the factory for the proper cleaning
procedure.
AirIntake&VentSystem
Thoroughly inspect the air intake and vent systems
for any signs of blockage, corrosion or leakage.
Immediately replace any unsound vent system piping.
Inspect the air filter and replace when required.
30
Visual flame appearance with proper
combustion will have a red and blue striped
appearance at low fire and flecked areas of
red with a majority of blue across the metal
mesh burner at high fire. Areas of deep red
indicate an infrared condition requiring a
combustion adjustment to reduce CO2 levels.
Figure 21 - Main Burner Flame
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Figure22-CK1500PressureSwitches
DIFFERENTIAL
PRESSURE
PILOT AIR
PILOT GAS
ASSEMBLY
PILOT VALVE
REAR P1 (+)
FRONT P2 (-)
ASCO AIR
SHUT-OFF VALVE
REAR (-)
FRONT (+)
REAR (-)
COMBUSTION BLOCKED INLET
PS3 - PRESSURE SWITCH
TO CONDENSATE PAN
RIOM-0218.A
SWITCH
BLOWER PROVEN
PS1
HUBBA SWITCH
ASSEMBLY
GAS VALVE
FRONT (+)
UV SCANNER
3.0
COMBUSTION BLOCKED FLUE
PS2 - PRESSURE SWITCH
AIR
PUMP
FILTER BOX
HOUSING
LEGEND
PSI MAIN BLOWER 0.2
PS2 BLOCKED FLUE 2.0
SWITCH SETTINGS IN "W.C."
SWITCH FOR SETTINGS
PS3 BLOCKED INLET
FLEXIBLE PLASTIC TUBING
POSITIVE PRESSURE TAP
NEGATIVE PRESSURE TAP
(-)
(+)
31
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Figure 23 - RBI Field Wiring to HeatNet Board 3.0 (CK1500)
32
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
START-UP REPORT
:
TEC
:
:
:
:
ST
T
N
D
D
D
L
V
D
S
R
f
.
.
T
.
.
.
.
.
Jump
.
.
.
0.
.
.
dby.
.
DATE
HNICIAN:
MPANY
PHONE NUMBER
PRE
NO VISIBLE DAMAGE TO UNI
IPING PROPERLY CONNECTE
BOILER CIRCULATOR WIRE
ENT/STACK CONNECTE
LE
Note: Locate the AA terminals and minimum hold switch in the bottom-right of the electrical panel on the main
HeatNet board. Also locate the manometer test mani
Disable any external call for heat and toggle the remote/local switch to REMOTE
.
oggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition
2
Set pilot pressure (follow section “Checking, Adjustment & Operation”) (flame signal should read 5.0 VDC).3.
Release boiler to main flame trial for ignition
4
heck for stable flame
.
ecord combustion and Delta P at minimum firing rate.
ecord combustion and Delta P at high firing rate.
emove the AA jumper to place the boiler at minimum rate
9
ake any final adjustments on low fire.1
heck all combustion results using a calibrated flue gas analyzer
11
elease the LOW FIRE switch to place boiler in stan
12
T
er the AA terminals to force 100% input
HECK LI
T
E
U
NCE
JOB NAME:
OCATION:
DEL
ERIAL #
INLET AIR FILTER INSTALLED AND CLEA
PROPER SERVICE CLEARANCES PROVIDE
UMP RUNNING, HEAT EXCHANGER FUL
GAS LINES PURGED, NO LEAKS, NO MISSING TEST
LUG
old in the bottom of the electrical panel
In addition to completing the FlexCore Series start-up report, complete the control set-up information in the
rear of the HeatNet manual.
33
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
A
YSIS
TE
00%
TE
O
)
E
ST
S
CH
D
S
B
R
S
D
D
L
T
R
______________________________________
)
_
DD
S
M
STI O N
GAS INLET PRESSURE (WC) INCHES WC I NCHES WC
C
F I N
1
F IN
CO ( PPM
NET S TA C K TEMPERAT U R
AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC INCHES WC
AF TY
L O W SWITCHE
OW WATER CUT-OFF
C O MMISSIONIN
NIT CYCLED MINIMUM O F 15 TIME
CUSTOMER INSTRUCTE
ALL COVERS REPLACE
UST O MER GIVEN MANUA
ARGET TEMPERAT U RE SET PER C U ST O ME
E S T
HE CK LI
(By Others)
IR S WIT
IGH LIMIT
I
E
M
FLAME SAFEGUAR
T HE D ELTA T B ETWEEN THE HEATE R IN -
LET AND OU TLET IS CRITICAL T O PR O P ER FL O W . BEF O RE Y OU LEAVE THE JO B S ITE, Y O U MUST REC O RD THE DELT A T .
T HIS READING SH O ULD N O T EXCEED
o
C, N O R BE L O WER THAN 2 0
F, 55
100
C.
11 . 1
F ,
COMMISSIONED BY:
DATE: ___________________________
A
34
TI ON
N O TE
C O MMENTS
SIGNATURE
D
ELTA T =
Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
FlexCore Series
Water Boiler
Limited Warranty
One-Year Warranty
The “Manufacturer” warrants to the original owner at the original installation site that the FlexCore Series modulating
water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation
or eighteen (18) months from the date of shipment from the factory whichever comes first. 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.
Ten-Year Warranty
The manufacturer further warrants to the original owner at the original installation site that the products Heat Exchanger
will be free from defects from condensate corrosion and in material and workmanship for a period of ten (10) years (non
prorated) from the date of shipment from the factory. 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
the Heat Exchanger of the product, which is shown to be defective.
Twenty-OneYearThermalShockWarranty
The manufacturer further warrants to the original owner at the original installation site that the products will be warranted
for twenty-one (21) years against thermal shock when installed in a closed loop hot water system. This warranty does not
cover damage due to corrosion, scaling, sooting or to improper installation practices. The inlet / outlet temperature
differential across the boiler heat exchanger must not exceed 100 degrees F. System water quality: dissolved solids must
be less than 500 ppm and no greater than 300 ppm hardness. Suspended solids such as magnetite, Iron Oxides must be
flushed from the system prior to commissioning the boiler(s). In addition, pH levels must be in the 6.5 – 10 range. Failure
to follow these guidelines will void the warranty.
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 modified
in anyway by any unauthorized person.
(b) To any expenses, including labor or material, incurred during the removal or reinstallation of the product or parts
thereof.
(c) To products which were not installed and or serviced by a qualified contractor and or serviceman.
(d) To burners, jackets, controls and other auxiliary equipment furnished by the manufacturer, but manufacturerd by
others. Any warranties for such items shall be limited to those warranties offered by the original equipment
manufacturer.
(e) To any workmanship by any installer of the product.
This limited Warranty is Conditional Upon:
(a) Shipment, to the manufacturer, of that part of the product thought to be defective. Goods may only be returned with
prior written approval of 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.
THISLIMITEDWARRANTYISINLIEUOFALLOTHERWARRANTIES,EITHEREXPRESSEDORIMPLIED,ANDALL
SUCHOTHERWARRANTIES,INCLUDINGWITHOUTLIMITATIONIMPLIEDWARRANTIESOFMERCHANTABILITY
ORFITNESSFORAPARTICULARPURPOSE,AREHEREBYDISCLAIMEDANDEXCLUDEDFROMTHISLIMITED
WARRANTY.INNOEVENTSHALLTHEMANUFACTURERBELIABLEINANYWAYFORANYCONSEQUENTIAL,
SPECIAL,ORINCIDENTALDAMAGESOFANYNATUREWHATSOEVER,ORFORANYAMOUNTSINEXCESSOF
THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED
WARRANTY GIVES THE OWNER AT THE ORIGINAL INSTALLATION SITE SPECIFIC LEGAL RIGHTS. YOU MAY
ALSOHAVEOTHERRIGHTS,WHICHMAYVARYBYEACHJURISDICTION.
35
260 North Elm Street 7555 Tranmere Drive
Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
Loading...