RBI DB series, DW series Installation & Operation Manual

DOM-IOM-6

82-0262

DOMINATOR SERIES FINNED COPPER

GAS BOILERS (MODEL DB) &

WATER HEATERS (MODEL DW)

INSTALLATION & OPERATION MANUAL

MEA#117-96-E

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.

WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other fl 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 neighbor’s phone. Follow the gas
supplier’s instructions.

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

Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.

WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE UNIT.

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085  Mississauga, Ontario L5S 1L4 Canada
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 2

AVERTISSMENT. 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 infl ammables
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 qualifi é ou par le fournisseur de gaz.

CONTENTS

Before Your Start ...............................................page 2

Ratings & Capacities .........................................page 3

Boiler/Water Heater Location .............................page 3

Combustion Air & Ventilation ..............................page 3

General Venting Guidelines ................................page 9

Venting Options .................................................page 9

Vertical/Chimney Venting .................................page 10

Outdoor Venting ...............................................page 11

Common Vent Systems ................................... page 12

General Piping Requirements ..........................page 13

Heating System Piping ....................................page 15

Domestic Water Supply Piping ........................page 18

Gas Supply Piping ...........................................page 22

Electrical Wiring ...............................................page 23

General Operation ...........................................page 23

Boiler/Water Heater Operation .........................page 24

Operating Instructions ......................................page 28

Checking & Adjustments ..................................page 30

Control Description ..........................................page 31

Maintenance ....................................................page 34

Trouble-Shooting ..............................................page 37

Repair Parts ......................................................page 39

Start Up Form ...................................................page 47

BEFORE YOU START

This manual covers the application, installation,
operation and maintenance of a Dominator Series
fi nned copper heating boiler/water heater/pool heater.

To obtain the safe, dependable, effi cient operation and
long life for which this heating boiler/water heater was
designed, these instructions must be read, understood
and followed.

The Dominator Series fi nned copper heating boiler/water
heaters have been design certifi ed by CSA for use with
natural and propane gas under the latest revision of ANSI­Z21.10.3/CSA 4.3, Gas Water Heaters, and ANSI-Z21.13/
CSA 4.9, Gas-Fired Low Pressure Steam and Hot Water
Boilers and CAN 1-3.1 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/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 CSA 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
the back of this manual, MACODE-3.

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, Westfi eld, 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.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 3

RATINGS & CAPACITIES

Before undertaking the installation of the Dominator
Series boiler/water heater check the rating plate to
ensure that the unit has been sized properly for the job.
The "Net I=B=R 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. This boiler/water heater is suitable for indoor and
outdoor installations. Locate the boiler/water heater
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/water heater as listed in
Table 1.

NOTE: Service clearances are not mandatory, but
are recommended to ensure ease of service should
it be required.

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.

5. DO NOT place this boiler/water heater in a location
that would restrict the introduction of combustion air
into the unit or subject the air inlet to a negative
pressure, see “GENERAL VENTING GUIDELINES”.

WARNING: Never store combustible materials,
gasoline or any product containing fl ammable
vapors or liquids in the vicinity of the boiler/
water heater. Failure to comply with this warning
can result in an explosion or fire causing
extensive property damage, severe personal
injury or death!

6. NEVER place this boiler/water heater in a location
that would subject it to temperatures at or near
freezing. See the “Freeze Protection” section on
page 13.

CAUTION: Units installed outdoors MUST be
protected from ice and snow accumulation or the
unit may be damaged voiding the warranty!

Table 1
Clearance to Service
Combustibles Clearance
in mm in mm

Top 6 153 20 508
Back 6 153 24 610
Left Side 6 153 24 610
Right Side 6 153 24 610
Front 6 153 30 762
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
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.

3. Ensure that the fl oor is structurally sound and will
support the weight of the boiler/water heater.

NOTE: The Dominator may be installed directly on
combustible fl ooring, but never on carpeting.

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 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/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
fl 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!

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 4

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 Dominator is to be located in a confi ned space
the minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confi ned space without the intake
air option, Figures 1, 2 & 3, two permanent openings

communicating with an additional room(s) are required.
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 fi replace, 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.

The combined volume of these spaces must have

sufficient volume to meet the combustion 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 in

Btu/hr, 2200 mm2/kW based on the total input rating of

ALL gas utilization equipment in the confi ned area. Each

opening must be no less than 100 in2, 64,516 mm2 in

WARNING: Never operate the Dominator in an
environment subjected to a negative pressure
unless the air intake is connected to the
outdoors. Failure to comply with this warning can
result in excessive levels of carbon monoxide

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.

causing severe personal injury or death!

Figure 1 - Vertical Venting with a Metal Chimney System and Inside Air

2

/1000

10 FT

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 5

Figure 2 - Vertical Venting using a Masonry Chimney and Inside Air

Figure 3 - Horizontal Venting using Inside Air

1.5 FT 0.5 m

Table 2

VENT PIPE DIAMETER

IN. mm FT mm

5" TO 10"

12" TO 18"

127 TO 254
305 TO 457

1/4 IN. PER F00T 20 mm/m

MINIMUM VERTICAL RISE

OFF THE TOP OF UNIT "A"

12"
24"

305
610

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 6

All Air From Outside The Building
When installed in a confi ned space without utilizing
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, 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.

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 cross-sectional area
as the free area of the opening to which they connect.

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, 6.4mm. If the free area through a louver or grill is
not known, ducts should be sized per Table 3.

Table 3 - Make-up Air Louver Sizing

Required Cross Sectional Area

Input 1/4 in 6.4 mm

75% Free Area 25% Free Area

(MBH) Wire Screen Metal Louvers Wooden Louvers
in

2

cm

2

in

2

cm

2

in

2

cm

2

300 75 484 100 645 300 1935
400 100 645 133 860 400 2581
600 150 968 200 1290 600 3871
750 188 1210 250 1613 750 4839
900 225 1452 300 1935 900 5806
1050 263 1694 350 2258 1050 6774
1350 338 2177 450 2903 1350 8710
1500 375 2419 500 3226 1500 9677
1950 488 3145 650 4194 1950 12,581
2100 525 3387 700 4516 2100 13,548

Canadian installations must comply with CSA B149.1
when air supply is provided by natural air fl 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.

Intake Air Option - General Guidelines

This confi guration provides combustion air directly to the

boiler/water heater's air intake using a dedicated pipe

to obtain combustion air from the outdoors. Combustion

air can be drawn in horizontally through the same

outside wall which terminates the exhaust gases or

vertically through the roof, see Figures 4, 5, 6 & 7.

WARNING: Common intake air systems may be
used provided the common duct is sized properly
and an intake combustion air damper is installed
in the intake air pipe of each heater. Improper
installation can result in excessive levels of carbon
monoxide which can cause severe personal injury
or death!

Single wall galvanized smoke pipe, single wall aluminum

pipe or fl exible aluminum pipe can be used for the intake

air pipe. It must be sized per Table 4. All joints in metal

combustion air systems must be secured using

corrosion resistant fasteners and sealed using a suitable

Silicone caulk. The combustion air system MUST be

supported by the building structure not the boiler/

water heater.

Table 4 - Intake Air Pipe Sizing

Model Size Pipe Diameter

in mm

300 & 400 6 152

600 & 750 8 203

900 & 1050 10 254

1350 - 2100 12 305

CAUTION: A stack damper interlocked with the unit

should be installed in the intake air pipe when the

infi ltration of sub-freezing air could occur, otherwise

the unit could freeze up voiding the warranty!

Intake Air Option - Horizontal Guidelines

The maximum equivalent length for the horizontal

combustion air pipe on installations that used the Direct

Vent option is 35 ft, 10.8 m. The maximum equivalent

length for the horizontal combustion air pipe on

installations that use the Horizontal Power Vent option is

100 ft, 30.5 m. Each 90° elbow and the combustion air

terminal are equal to 10 linear ft, 3.0 m of pipe. If

horizontal runs exceed 5 ft, 1.5 m they must be supported

at 3 ft, 0.9 m intervals with overhead hangers. The

certifi ed combustion air terminal from RBI must be used

and installed as shown in Figures 4 and 5.

Intake Air Option - Vertical Guidelines

The maximum length for the vertical combustion air pipe

is 30 ft, 9.1 m plus two 90° elbows. A listed,

nonrestrictive combustion air cap must be used. The

combustion air cap must terminate as shown in Figure

6. The penetration point in the roof must be properly

fl ashed and sealed.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 7

Figure 4 - Horizontal Combustion Air and Venting for a Single Unit

1/4 IN. PER FOOT

20 mm/m

16 FT 4.9 m

1.5 FT 0.5 m

9

8

Y ,ecna

7

6

t

5

s

i
D l

4

acit

3

reV

2

1

0

05101520

Horiz ontal Distance , X

2000 & Larger

1201 To 2000

901 To 1200

200 To 900

1000 BTU'S

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.

Figure 5 - Horizontal Combustion Air and Venting for Multiple Units

2 IN. 5.0 cm

1.5 FT 0.5 m

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 8

Figure 6 - Vertical Combustion Air and Venting, Metal Chimney System Shown

Locate exhaust terminal downwind from air intake to reduce potential for fl ue gas recirculation.

10 FT 3.1 m

4 FT

1.2 m

1.5 FT

0.5 m

5 1/2 FT

1.7 m

5 FT

1.5 m

Figure 7 - Combination Air Intake And Venting, Masonry Chimney Shown

10 FT 3.1 m

3 FT 1 m

1.5 FT .5m

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 9

GENERAL VENTING GUIDELINES

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 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/water heater. Appropriate
thimbles and fi re-stops must be used where required.

WARNING: Common vent systems must be
properly engineered and sized to provide a
negative draft of .01 to 0.08 in, .25 to 2.0 mm W.C.
at the fl ue outlet! Common positive pressure
vent systems are not to be used. Improper
installation can result in excessive levels of
carbon monoxide which can cause severe
personal injury or death!

NOTE: A single acting barometric damper must
be installed directly to the boiler/water heater
flue outlet to ensure proper operation. This does
not apply to outdoor units or direct vent positive
pressure units.

NOTE: Some venting applications may require
the stop to be removed for smooth operation. The
barometric damper should be located after the
fl ue collector, refer to Figures 2, 3 and 7 for proper
location. Be sure that the damper is mounted
horizontally (never vertically). Carefully follow the
instructions provided with the barometric damper.
Check with local codes for specifi c requirements.

VENT SYSTEM OPTIONS

The Dominator may be vented the following ways:

1) Vertical/Chimney Venting, Negative Pressure,

Category I - uses an approved metal chimney system

or properly lined masonry chimney. Combustion air is

obtained from the space in which the unit is installed or

from the outdoors. A barometric damper must be

installed near the fl ue outlet when venting vertically. See

Figures 6 and 7. This also applies to any fan-assisted

chimneys or vents.

2) Direct Vent, Positive Pressure, Category III - for

horizontal vent runs equivalent to 35 ft, 10.7 m or less.

A stainless steel vent system certifi ed to UL 1738 for

installations in the United States, ULS636 for

installations in Canada must be used when combustion

air is ducted from outdoors, from the same wall.

3) Horizontal Vent, Negative Pressure, Category I - for

horizontal vent runs equivalent to more than 35 ft, 10.7 m

(90 degree elbow equals 10 equivalent feet). A

dedicated wall mounted power venter and barometric

damper must be used. The vent system can be single

wall galvanized steel or type B vent pipe. Combustion air

is obtained from the space in which the unit is installed

or from the outdoors.

A barometric damper must be installed when the

horizontal run is longer than 35 equivalent feet. (90

degree elbow = 10 equivalent feet). If this is the case,

a power venter must also be used.

If horizontal run is less than 35 equivalent feet, do not

use a barometric damper. Follow applicable instructions

under the "COMBUSTION AIR & VENTILATION" section.

4) Outdoor Installation - uses the outdoor option kit.

Barometric damper is not required.

In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.

WARNING: To avoid spillage into the room of
dangerous fl ue gas containing carbon monoxide,
the opening in damper must never face against
the fl ow of fl ue gas.

NOTE: All venting, combusiton air material supplied

by installer. All venting material must be approved

for the application. Consult the vent manufacturer’s

product literature.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 10

VERTICAL/CHIMNEY VENTING

The Dominator is listed as a Category I appliance when
vented vertically into a metal chimney system or properly
sized masonry chimney, Figures 1,2, 6 & 7. The chimney
must provide a negative pressure of .01 to 0.08 in, .25
to 2.0 mm W.C. at the boiler/water heater fl ue collar with
the unit running at full load. A barometric damper must
be installed between the flue collar and the vent
connector. Approved thimbles and fi re-stops must be
used when combustible construction is penetrated.

WARNING : If an appliance using any type of a
mechanical draft system operating under
positive pressure is connected to a chimney
fl ue, never connect any other appliances to this
fl ue. Doing so can result in excessive levels of
carbon monoxide which can cause 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 5 lists the
equivalent breeching and fl ue sizes required for the
boiler/water heater. When more than one appliance is
connected to the same chimney fl ue, the fl ue must be
large enough to safely vent the combined output of all
of the appliances.

Table 5 - Equivalent Breeching & Chimney Size

Model Size Pipe Diameter
in mm
300 - 400 6 152
600 7 178
750 8 203
900 - 1050 10 254
1350 12 305
1500 - 2100 14 356

Note: These sizes are based on a 20 ft, 6.1m chimney height.

Vent Connections

Locate the boiler/water heater as close to the chimney
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 a type B, single
wall stainless or single wall galvanized steel vent pipe
the same diameter as the fl ue collar to connect the
boiler/water heater to a masonry chimney. When using
an approved metal chimney system use the appropriate
vent connector. The vent connector should be sloped up
toward the chimney at a minimum rate of 1/4 in/ft,
20 mm/m. On masonry chimneys the connector must
terminate fl ush with the inside of the chimney fl ue,
Figure 2. Fasten each single wall vent connection with
at least 3 corrosion resistant sheet metal screws.

WARNING: Never install a vent pipe having a
diameter different than that of the boiler/water
heater fl ue collar. Failure to comply with this
warning can result in excessive levels of carbon
monoxide which can cause severe personal
injury or death.

Always provide a minimum clearance of 6 in, 152 mm

between single wall vent pipe and any combustible

materials. Type B1 vent may be used, clearance between

it and any combustible material must be as listed.

WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a fi re causing
extensive property damage, severe personal
injury or death!

DIRECT VENT,

POSITIVE PRESSURE, CATEGORY III

In this confi guration the boiler/water heater blower is

used to push the fl ue products to the outdoors while

drawing combustion air from the outdoors. The

equivalent length of the vent system must not exceed

35 ft, 10.7 m. The Intake Air Option instructions under

the “COMBUSTION AIR & VENTILATION” section must

be followed! The vent system must be sized per Table 5.

Horizontal Direct Vent Systems - Figures 4 & 5

The vent materials used in horizontal vent systems must

be certifi ed to UL 1738 for installations in the United

States, ULS636 for installations in Canada. The certifi ed

vent terminal from RBI must also be used.

The maximum equivalent length for the horizontal vent

and combustion air pipes is 35 ft, 10.7 m for each. Each

90° elbow and the vent and intake air terminals are

equal to 10 ft, 3.1 m of straight pipe. 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 straight as possible.

The vent system must be both gas tight and water tight.

All seams and joints in metal pipes must be joined and

sealed in accordance with the vent system

manufacturer’s instructions.

When horizontal vent runs exceed 5 ft, 1.5 m they must

be supported at 3 ft, 0.9 m intervals with overhead

hangers. The vent system must be pitched down, toward

the vent terminal, 1/4 in/ft, 21 mm/m. 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.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 11

Horizontal vent systems shall terminate at least 4 ft,

1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,

0.3 m above any door, window or gravity air inlet into

any building. It must not terminate less than 4 ft, 1.2 m
horizontally from, and in no case above or below, unless
a 4 ft, 1.2 m horizontal distance is maintained, from
electric meters, gas meters, regulators and relief
equipment and not less than 7 ft, 2.1 m from any
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 minimum
5 ft, 1.5 m horizontal separation between them. Avoid
terminal locations likely to be affected by winds, snow
drifts, people and pets. Protect building materials and
vegetation from degradation caused by the fl ue gases.

Vertical Direct Vent Systems - See Figure 6

The maximum length for the vertical vent and
combustion air pipes is 35 ft, 10.7 m plus two 90°
elbows for each. 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. Structual
penetrations must be made using approved fi re-stops.

A listed, nonrestrictive vent cap must be used. The top
of a vertical vent system must extend at least 51/2 ft,

1.7 m above the roof surface that it passes through,

4 ft, 1.2 m above the intake air cap, see Figure 6.

HORIZONTAL VENT,
NEGATIVE PRESSURE, CATEGORY I

In this confi guration a wall-mounted power venter must
be used to pull the fl ue products horizontally from the
unit and vent them to the outdoors, see Figures 3, 4 &

5. The air for combustion is taken from the space in
which the unit is installed, or from the outdoors. The
applicable instructions under the “COMBUSTION AIR
& VENTILATION” section must be followed!

To maximize the performace 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.

When horizontal vent runs exceed 5 ft, 1.5 m they must
be supported at 3 ft, 0.9 m intervals with overhead
hangers. The vent system must be pitched down, toward
the vent terminal, 1/4 in/ft, 20 mm/m. 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.

Horizontal vent systems shall terminate at least 4 ft,

1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,

0.3 m above any door, window or gravity air inlet into

any building. It must not terminate less than 4 ft, 1.2 m

horizontally from, and in no case above or below, unless

a 4 ft, 1.2 m horizontal distance is maintained, from

electric meters, gas meters, regulators and relief

equipment and not less than 7 ft, 2.1 m from any 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 minimum 5 ft, 1.5 m,

horizontal separation between them. Avoid terminal

locations likely to be affected by winds, snowdrifts, people

and pets. Protect building materials and vegatation from

degradation caused by the fl ue gases.

To determine the appropriate power venter for the boiler/

water heater, see Table 6, Power Venter Sizes. Follow

the power venter manufacturer’s installation instructions.

Table 6 - Power Venter Sizes

Dominator Power Venter Max. Pipe Length

Model Model FT m

300 HS-1 30* 9

400 HS-2 100 31

600 HS-2 67** 21

750-900 HS-3 100 31

1050-1350 HS-4 100 31

1500-2100 HS-5 100 31

*Choose HS-2 for 100 ft, 31 m, Max. Pipe length

**Choose HS-3 for 100 ft, 31 m, Max. Pipe Length

OUTDOOR VENTING

When installed outdoors the Dominator must be fi tted

with the factory supplied outdoor vent hood and air

intake hood, see Figure 8. Multiple units must be spaced

per Figure 9.

The boiler/water heater must be at least 10 ft, 3.0 m

from any door, window or gravity air inlet into any

building and at least 3 ft, 0.9 m from any overhang

unless local codes dictate differently.

Avoid locations where wind defl ection off of adjacent

walls, buildings or shrubbery might cause a down draft.

The unit(s) should be located at least 3 ft, 0.9 m from

structures. Outdoor installations are not recommended

in areas where the danger of snow blockage exists.

CAUTION: Do not place the boiler/water heater in a

location that would subject it to runoff from adjacent

buildings or damage may occur voiding the

warranty!

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 12

Figure 8 - Outdoor Venting

Figure 9 - Multiple Outdoor Units

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
defi ciencies 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 fi replace dampers.

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

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.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 13

e) Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the fl 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 fl 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, fi replace dampers
and any other gas-burning appliance to their
previous condition of use.

Une fois qu'il a été déterminé, selon la métode

indiquée cidessus, 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
Appendix F in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and or CAN/CGA-B149 Installation
Codes.

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 scaling 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

fl ow rates, see Table 7. Return water temperatures

below 125°F, 52°C will result in heat exchanger

damage from excessive condensation voiding the

manufacturer's warranty, see Primary/Secondary

Piping Figure 11.

NOTE: Shut off valves and unions should be

installed at the inlet and outlet connections of the

boiler/water heater to provide for isolation of the unit

should servicing be necessary.

Freeze Protection

This boiler/water heater is CSA designed certifi ed for

outdoor installation. Outdoor installations in areas where

the danger of freezing exists are not recommended

unless proper freeze protection is provided. If the unit

is to be installed in such an area the following

precautions MUST be observed:

1. A continuous fl ow of water through the boiler/water
heater MUST be maintained! The pump respon­sible for fl ow through the boiler/water heater must
run continuously!

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 modifiée, le
système devrait étré modifi é 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
CAN/CGA-B149.

2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed

to must be used. The pump must be capable of

producing a minimum of 15% more flow and
overcoming a 20% increase in head loss. Domestic
water systems must be isolated from the water
heater by the use of a heat exchanger or other
approved method.

3. If the boiler/water heater must be shut off for any
reason the electric, gas and water supplies MUST
be shut off and the unit and its pump completely
drained.

CAUTION: Improper outdoor installation of this
boiler/water heater can cause boiler failure voiding
the manufacturer's warranty!

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 14

Relief Valve

Pipe the discharge of the pressure relief valve to prevent
scalding in the event of a discharge, see Figure 10. 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 10 - Relief Valve 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 fl ow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to
prevent the boiler from fi ring unless there’s adequate
water fl ow through the unit. The fl ow switch must be
installed in the supply piping adjacent to the boiler outlet
connection.

CAUTION: Failure to properly install the fl ow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!

Table 7 - Temperature Rise Table

ΔT = 15°F ΔT = 8.3°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 34.0 0.22 2.1 0.6
400 45.4 0.49 2.9 1.5
600 68.1 1.30 4.3 3.8
750 85.1 2.35 5.4 6.9
900 102.1 3.84 6.4 11.3
1050 119.1* 6.23 7.5 18.4

ΔT = 20°F ΔT = 11.1°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 25.5* 0.13 1.6 0.4
400 34.0 0.29 2.1 0.9
600 51.1 0.76 3.2 2.3
750 63.8 1.38 4.0
900 76.6 2.25 4.8 6.6
1050 89.4 3.66 5.6 10.8
1350 114.9* 7.17 7.2 21.1

ΔT = 25°F ΔT = 13.9°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 20.4* 0.09 1.3 0.3
400 27.2* 0.19 1.7 0.6
600 40.8 0.51 2.6 1.5
750 51.1 0.91 3.2 2.7
900 61.3 1.49 3.9 4.4
1050 71.5 2.42 4.5 7.1
1350 91.9 4.74 5.8 14.0
1500 102.1 6.31 6.4 18.6

ΔT = 30°F ΔT = 16.7°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
600 34.0 0.36 2.1 1.1
750 42.6 0.65 2.7 1.9
900 51.1 1.06 3.2 3.1
1050 59.6 1.73 3.8 5.1
1350 76.6 3.38 4.8 10.0
1500 85.1 4.50 5.4 13.3
1950 110.6* 9.20 7.0 27.1
2100 119.1* 11.27 7.5 33.2

ΔT = 35°F ΔT = 19.4°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
750 36.5 0.49 2.3 1.4
900 43.8 0.80 2.8 2.4
1050 51.1 1.30 3.2 3.8
1350 65.6 2.54 4.1 7.5
1500 72.9 3.38 4.6 10.0
1950 94.8 6.91 6.0 20.4
2100 102.1 8.47 6.4 25.0
*Flow exceeds recommended maximum use a greater temperature
rise or consult manufacturer. Cupro-nickel heat exchanger should be
considered.

4.1

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONS Page 15

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualifi ed
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section
IV, and, when required, 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 piping should be sized to suit the
system. The supply and return connection sizes are
listed in Table 8.

Table 8 - Supply & Return Connection Sizes

Model Size Supply Return
300 thru 2100 2 1/2" NPT 2 1/2" NPT

Pump Requirements

This low mass boiler requires a continuous minimum
water fl 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.

CAUTION: A temperature rise outside of the range
listed in Table 7 indicates that the fl ow rate through the
heat exchanger is incorrect which will damage the
heat exchanger voiding the warranty! The maximum
allowable temperature rise is 35°F, 19.4°C.

The maximum allowable flow rate through a
Dominator boiler with copper heat exchanger is
105 GPM, 6.6 L/s. The cupro-nickel heat exchanger
allows for 120 GPM, 7.6 L/s.

An adjustable pump delay is available as a feature of
the staging controller. The pump delay establishes water
fl ow through the boiler and heating system before the
appliance starts. Consult the staging controller manual
for further details.

Low Water Cutoff

If a boiler is installed above any radiation elements it
must be fi tted with a low water cutoff device.

Refer to wiring diagram supplied with the boiler/water
heater for proper wiring connections.

Expansion Tank & Air Separator

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.

Primary/Secondary Piping

Boilers connected to heating systems using zone valves,
zone pumps, or systems that have excessive fl ow rates
or return water temperatures less than 125°F, 52°C
must be isolated from these systems to protect the boiler.

Variable Water Flows

Figure 11 shows a typical primary/secondary piping
system. A dedicated pump is used to maintain a
constant water fl ow through the boiler. This secondary
pump is sized to overcome the head loss of the boiler
and secondary piping system while supplying the fl ow
rate required to maintain the desired temperature rise
across the boiler. The primary pump is sized to provide
the required fl ow to the heating system. The secondary
piping connections to the primary system piping must
not be more than 12 in, 305 mm apart to ensure zero
pressure drop in the primary system, see Figure 11.

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

12. 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 flow through each system. The secondary
piping connections to the primary system piping must
not be more than 12 in, 305 mm apart to ensure zero
pressure drop in the primary system, see Figure 12.

Multiple Boiler Systems

Systems using multiple boilers can also be installed
using a primary/secondary manifold system, Figure 13.

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 fl ow­control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.

DOMINATOR INSTALLATION AND OPERATION INSTRUCTIONSPage 16

Figure 11 - Typical Primary/Secondary Piping System

(See Notes)

NOTES:

1. Boiler circuit piping must be sized
large enough to handle maximum fl ow
through unit.

2. Boiler pump sized to boiler design fl 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 confi guration and valving.
Check with local codes and ordinances
for specifi c requirements.

H-1 Rev 3

Pump

Gate Valve

Globe Valve

Angle Valve

Bufferfly Valve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Val ve

Figure 12 - Low Temperature Piping

(See Notes and Adjustment Procedures)

H-18 Rev 2

NOTES:

1. For pump selection consult factory.

2. Boiler pump sized to boiler and thermostatic 3-way valve design fl ow
requirements.

3. Boiler circuit piping must be sized large enough to handle maximum fl 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 confi guration and valving.
Check with local codes and ordinances for specifi c requirements.

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Automatic

Air Vent

Backflow-

Prevention

Adjustment Procedure To Maintain Inlet Temperature

Above Dew Point

T1-Temp-Min+110° For Atmospheric

T1-Temp-Min=125° 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 stabiized.
Make fi nal adjustments.

5. Follow same adjustment procedure for sealed combustion.

Device