RBI Dominator Series Installation And Operation Instructions Manual
DOM-I0M-11
82-0262
Finned Copper Tube
Gas Boilers (DB) &
Water Heaters (DW)
Boiler Manual
Installation and Operation
Instructions
is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service
technician, and to follow all guidelines in the User’s Information Manual.
03/16 Copyright 2014 Mestek, Inc.
Finned copper tube gas boilers & water heaters – Boiler 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 applianc
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a phone outside
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, service agency or the gas supplier.
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:
• 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 qualifié ou par le
fournisseur de gaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
2
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 21
ELECTRICAL WIRING . . . . . . . . . . . . . . . . PAGE 22
GENERAL OPERATION . . . . . . . . . . . . . . . PAGE 22
BOILER/WATER HEATER OPERATION . . . . . . . PAGE 23
OPERATING INSTRUCTIONS . . . . . . . . . . . . PAGE 27
CHECKING & ADJUSTMENTS. . . . . . . . . . . . PAGE 30
CONTROL DESCRIPTION . . . . . . . . . . . . . . PAGE 31
MAINTENANCE . . . . . . . . . . . . . . . . . . . PAGE 33
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . PAGE 36
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . PAGE 38
START UP FORM . . . . . . . . . . . . . . . . . . . PAGE 45
BEFORE YOU START
This manual covers the application, installation, operation and
maintenance of a Dominator Series finned copper heating boiler/
water heater/(pool heater-Canada only).
To obtain the safe, dependable, efficient operation and long life for
which this heating boiler/water heater was designed, these instructions must be read, understood and followed.
The Dominator Series finned copper heating boiler/water heaters
have been design certified by CSA for use with natural and propane
gas under the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water
Heaters, and ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam
and Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired Pool
Heaters (Canada only) and 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.
Finned copper tube gas boilers & water heaters – Boiler Manual
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, Westfield,
MA 01085 for U.S. or 7555 Tranmere Drive, Mississauga ONT
L5S 1L4 for Canada. Always include the model and serial numbers
from the rating plate of the boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Dominator Series
boiler/water heater check the rating plate to ensure that the unit
has been sized properly for the job. The "Net Ratings" specify
the equivalent amount of direct copper radiation that the unit
can supply under normal conditions. Also ensure that the unit
has been set up for the type of gas available at the installation
site. Other important considerations are the avai lability 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.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1
Clearance to
Combustibles
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
in mm in mm
Service
Clearance
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 floor is structurally sound and will support the
weight of the boiler/water heater.
The Dominator may be installed directly on combus-
tible flooring, but never on carpeting.
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”.
Never store combustible materials, gasoline or any
product containing flammable 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.
Units installed outdoors MUST be protected from ice
and snow accumulation or the unit may be damaged
voiding the warranty!
COMBUSTION AIR & VENTILATION
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!
3
Finned copper tube gas boilers & water heaters – Boiler Manual
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!
Combustion air contaminated with fluorocarbons 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!
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!
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 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 causing severe personal injury or death!
All Air From Inside The Building
If the Dominator 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, Figures 1, 2 & 3, two permanent
openings communicating with an additional room(s) are required.
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 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,
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.
Figure 1 Figure 1 - Vertical Venting with a Metal Chimney System and Inside Air
10 FT
4
Finned copper tube gas boilers & water heaters – Boiler Manual
Figure 2 Vertical Venting using a Masonry Chimney and Inside Air
305 TO 457
12 TO 18
MINIMUM VERTICAL RISE
24
610
Figure 3 Horizontal Venting using Inside Air
1.5 FT 0.5 m
Table 2
VENT PIPE DIAMETER
IN mm IN mm
5 TO 10
127 TO 254
1/4 IN. PER F00T 20 mm/m
OFF THE TOP OF UNIT "A"
12
305
5
Finned copper tube gas boilers & water heaters – Boiler Manual
All Air From Outside The Building
When installed in a confined 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 crosssectional 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
2
75% Free Area
Metal Louvers
2
in
cm
Input
(MBH)
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
1/4 in 6.4 mm
Wire Screen
2
in
cm
Canadian installations must comply with CSA B149.1 when air
supply i s provided by natural air flow from the outdoors for natural
draft, partial fan-assisted, fan-assisted, or power draft-assisted
burners, there shall be a permanent air supply opening(s) having
a cross-sectional 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.
2
25% Free Area
Wooden Louvers
in
2
cm
2
Intake Air Option - General Guidelines
This configuration 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.
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
flexible 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
300 & 400 6 152
600 & 750 8 203
900 & 1050 10 254
1350 - 2100 12 305
Pipe Diameter
in mm
A stack damper interlocked with the unit should be
installed in the intake air pipe when the infiltration 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,
10.8m. 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 inter vals
with overhead hangers. The certified 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 flashed
and sealed.
6
Finned copper tube gas boilers & water heaters – Boiler Manual
Figure 4 Horizontal Combustion Air and Venting for a Single Unit
16 FT 4.9 m
1.5 FT 0.5 m
9
8
Y ,ecnatsiD lacitreV
7
6
5
4
3
2
1
0
0510 15 20
Horizontal Distance, X
1/4 IN. PER FOOT
20 mm/m
1000 BTU'S
2000 & Larger
1201 To 2000
901 To 1200
200 To 900
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 dierences due to prevailing winds. In cold climates, doublewall or insulated inlet pipe recommended to prevent condensation.
Figure 5 Horizontal Combustion Air and Venting for a Multiple Units
2 IN. 5.0 cm
1.5 FT 0.5 m
7
Finned copper tube gas boilers & water heaters – Boiler Manual
Figure 6 Vertical Combustion Air and Venting, Metal Chimney System Shown
10 FT 3.1 m
4 FT
1.2 m
5 FT
1.5 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
Locate exhaust terminal downwind from air intake to reduce potential for ue gas recirculation.
Figure 7 Combination Air Intake and Venting, Masonary Chimney Shown
10 FT 3.1 m
3 FT 1 m
1.5 FT .5m
8
Finned copper tube gas boilers & water heaters – Boiler Manual
GENERAL VENTING GUIDELINES
VENT SYSTEM OPTIONS
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 firestops must be used where required.
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 WC at the flue 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!
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.
Some venting applications may require the stop to
be removed for smooth operation. The barometric
damper should be located after the flue 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 specific
requirements.
In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.
To avoid spillage into the room of dangerous flue gas
containing carbon monoxide, the opening in damper
must never face against the flow of flue gas.
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 flue outlet when venting
vertically. See Fig ures 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 certified 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°
elbow equals 10 equivalent ft). 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 ft. (90° elbow = 10 equivalent ft). If
this is the case, a power venter must also be used.
If horizontal run is less than 35 equivalent ft, 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.
All venting, combusiton air material supplied by
installer. All venting material must be approved for
the application. Consult the vent manufacturer’s
product literature.
9
Finned copper tube gas boilers & water heaters – Boiler Manual
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 flue 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 fire-stops must be used when
combustible construction is penetrated.
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!
Never install a vent pipe having a diameter different than
that of the boiler/water heater flue 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.
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!
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 flue sizes required for the boiler/
water heater. When more than one appliance is connected to the same
chimney flue, the flue must be large enough to safely vent the
combined output of all of the appliances.
Table 5 Equivalent Breeching & Chimney Size (Category I)
Model Size
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 20 ft, 6.1 m chimney height.
Pipe Diameter
in mm
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 flue 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 flush with the inside of the chimney flue, Figure 2. Fasten
each single wall vent connection with at least 3 corrosion resistant
sheet metal screws.
DIRECT VENT, POSITIVE PRESSURE,
CATEGORY III
In this configuration the boiler/water heater blower is used to push
the flue 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
followed! The vent system flue pipe diameter must be sized per Table
5a.
Horizontal Direct Vent Systems - Figures 4 & 5
The vent materials used in horizontal vent systems must be certified
to UL 1738 for installations in the United States, ULS636 for
installations in Canada. The certified 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.
be
10
Finned copper tube gas boilers & water heaters – Boiler Manual
Table 5a Category III Vent Pipe Diameter
Model Size
300 - 400 6 152
600 - 750 8 203
900 - 1050 10 254
1350 12 305
1500 - 2100 14 356
Note: Diameters based on a maximum 35 equivalent feet.
Pipe Diameter
in mm
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 flue 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 fire-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.
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 flue 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
Model Model
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-2 100 ft, 31 m, Max. Pipe Length.
**Choose HS-3 for 100 ft, 31 m, Max. Pipe Length.
Max. Pipe Length
ft mm
HORIZONTAL VENT, NEGATIVE PRESSURE,
CATEGORY I
In this configuration a wall-mounted power venter must be used
to pull the flue 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.
OUTDOOR VENTING
When installed outdoors the Dominator must be fitted 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 deflection 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.
Do not place the boiler/water heater in a location that
would subject it to runo from adjacent buildings or
damage may occur voiding the warranty!
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Finned copper tube gas boilers & water heaters – Boiler Manual
Figure 8 Outdoor Venting
Figure 9 Multiple outdoor Units
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 fonction-nent pas:
système d'évacuation
a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système d'évacuation.
b) Visually inspect the venting system for proper size and horizontal
pitch and determine there is no blockage or restriction, leakage,
corrosion and other deciencies which could cause an unsafe
condition.
Inspecter de façon visuelle le système d'évacu-ation pour
déterminer la grosser et l'inclinaison horizontale qui conv iennent
et s'assurer que le système est exempt d'obstruction, d'étranglement
de fruite, de corrosion et autres défaillances qui pourraient
présenter des risques.
c) Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhaust, so
they will operate at maximum speed. Do not operate a summer
exhaust fan for a boiler installation. Close replace dampers.
Dans la mesure du possible, fermer toutes les portes et les fenêtres
du bâtiment et toutes les portes entre l'espace où les appareils
toujours raccordés du système d'évacuation sont installés et les
autres espaces du bâtiment. Mere en marche les sécheuses, tous
les appareils non raccordés au système d'évacuation commun et
tous les ventilateurs d'extraction comme les hoes 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.
Mere l'appareil inspecté en marche. Suivre les instructions
d'allumage. Régler le thermostat de façon que l'appareil fonctionne
de façon continue.
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Finned copper tube gas boilers & water heaters – Boiler Manual
e) Test for spillage at the dra hood relief opening aer 5 minutes
of main burner operation. Use the ame of a match or candle,
or smoke from a cigaree, cigar or pipe.
Faire fonctionner le brûleur principal pendant 5 min ensuite,
déterminer si le coupe-tirage déborde à l'ouverture de décharge.
Utiliser la amme d'une allunee ou d'une chandelle ou la fumée
d'une cigaree, d'un cigare ou d'une pipe.
f) Aer 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,
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. Remere 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.
Tout mauvais fonctionnement du systéme d'évacu-tion commun
devrait étré corrigé de façor que l'installation soit conforme au
National Fue Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux
codes d'installation CSA-B149. Si la grosseur d'une section
du système d'évacuation doit étré modiée, le système devrait
étré modié pour respecter les valeurs minimales des tableaux
pertinents de l'appendice F du National Fuel Gas Code, ANSI
Z223.1/NFPA 54 et (ou) des codes d'installation CAN/
CGA-B149.
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler/water heater will void
the manufacturer's warranty and can cause boiler failure
resulting in ooding and extensive property damage!
Excessive water hardness causing scaling in the copper
heat exchanger tubes is NOT covered under the
manufacturer's warranty. Excessive piing and erosion
of the internal surface of the copper heat exchanger
tubes is NOT covered under the manufacturer's
warranty if the result of high water ow rates, see Table
7. Return water temperatures below 125°F, 52°C will
result in heat exchanger damage from excessive
condensation voiding the manufacturer's warranty, see
Primary/Secondary Piping Figure 11.
Shut o 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
is boiler/water heater is CSA designed certied 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 ow of water through the boiler/water heater
MUST be maintained! e pump respon-sible for ow through
the boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used. e
pump must be capable of producing a minimum of 15% more
ow 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 o for any reason the
electric, gas and water supplies MUST be shut o and the unit
and its pump completely drained.
Improper outdoor installation of this boiler/water heater
can cause boiler failure voiding the manufacturer's
warranty!
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Finned copper tube gas boilers & water heaters – Boiler Manual
Relief Valve
rise or consult manufacturer. Cupro-nickel heat exchanger should be
Pipe the discharge of the pressure relief valve to prevent scalding in
the event of a discharge, see Figure 10. e 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
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
e ow switch supplied with the boiler/water heater must be wired
to the terminal strip in the control panel to prevent the boiler from
ring unless there’s adequate water ow through the unit. e ow
switch must be installed in the supply piping adjacent to the boiler
outlet connection.
Failure to properly install the ow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
Table 7 Temperature Rise Table
∆T = 15°F ∆T = 8.3°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 33.4 0.21 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
∆T = 20°F ∆T = 11.1°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 25.1 0.12 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 4.1
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
∆T = 25°F ∆T = 13.9°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 20.0 0.08 1.3 0.2
400 27.2 0.19 1.7 0.6
600 40.8 0.51 2.6 1.5
750 51.0 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
∆T = 30°F ∆T = 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
∆T = 35°F ∆T = 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
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Finned copper tube gas boilers & water heaters – Boiler Manual
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualied technician
in accordance with the latest revision of the ANSI/ASME Boiler
and Pressure Vessel Code, Section IV, and, 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.
e 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
e supply and return piping should be sized to suit the system. e
supply and return connection sizes are listed in Table 8.
Table 8 Supply & Return Connection Sizes
Model Size Supply Size Return Size
300 thru 2100 2 1/2” NPT 2 1/2” NPT
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 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 ow through
the boiler. is secondary pump is sized to overcome the head loss
of the boiler and secondary piping system while supplying the ow
rate required to maintain the desired temperature rise across the
boiler. e primary pump is sized to provide the required ow to
the heating system. e secondary piping connections to the primary
system piping must not be more than 6 pipe diameters apart to
ensure zero pressure drop in the primary system, see Figure 11.
Pump Requirements
is low mass boiler requires a continuous minimum water ow
for proper operation. e 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 gures. e temperature rise
across the boiler must never exceed 35°F, 19.4°C.
A temperature rise outside of the range listed in
Table 7 indicates that the ow rate through the
heat exchanger is incorrect which will damage the
heat exchanger voiding the warranty! e maximum
allowable temperature rise is 35°F, 19.4°C.
e maximum allowable ow rate through a Dominator
boiler with copper heat exchanger is 105 GPM, 6.6 L/s.
e 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. e pump delay establishes water ow through the boiler
and heating system before the appliance starts. Consult the staging
controller manual for further details.
Low Water Cuto
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to wiring diagram supplied with the boiler/water heater for
proper wiring connections.
Low Return Water Temperatures
To prevent the problems associated w ith 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 and 12A. e 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. e 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. e primary and secondary
pumps should be sized to provide the required ow through each
system. e secondary piping connections to the primary system
piping must not be more than 6 pipe diameters apart to ensure zero
pressure drop in the primary system, see Figure 12 and 12A.
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
e boiler, when used in connection with a refrigeration system,
must be installed so the chilled medium is piped in parallel with
the boiler. Appropriate valves must be used to prevent the chilled
water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed
to refrigerated air from an air handling device, the piping system
must be equipped with ow-control valves or some other automatic
means of preventing gravity circulation of the boiler water during
the cooling cycle.
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