RBI HW 630, HW 420, HW 530, HW 735, HW 840 Installation & Operation Manual

CIOM-6

42-9134 Rev. 4

SERIES 8800 & 8900 FINNED COPPER

GAS BOILERS (MODEL HB) &

WATER HEATERS (MODEL HW)

INSTALLATION & OPERATION MANUAL

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,

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 flammable 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 fire department.

Installation and service must be performed by a qualified 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!

1103 kPa

WATER.

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

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 7555 Tranmere Drive
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

Mississauga, Ontario L5S 1L4 Canada

䡲

SERIES 8800 & 8900 INSTALLATION AND OPERATING 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 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.

CONTENTS

Before You Start .................................................page 2

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

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

Combustion Air & Ventilation ..............................page 4

Chimney & Vent Pipe Connections ....................page 8

Common Vent Systems ......................................page 9

General Piping Requirements ..........................page 10

Heating System Piping .....................................page 10

Domestic Water Supply Piping ......................... page 15

Gas Supply Piping............................................ page 20

Electrical Wiring ...............................................page 21

General Operation............................................ page 21

Operating Instructions ......................................page 22

Checking & Adjustments ..................................page 23

Control Description ..........................................page 25

Maintenance..................................................... page 26

Trouble-Shooting ..............................................page 28

Repair Parts, 8900 ...........................................page 30

Repair Parts, 8800 ...........................................page 39

BEFORE YOU START

This manual covers the application, installation,
operation and maintenance of a Series 8800
and 8900 finned copper heating boiler/water heater/pool
heater.

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 Series 8800 and 8900 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, ANSI­Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam and Hot
Water Boilers and CAN1-3.1, Industrial and Commercial
Gas Fired Packaged Boilers. Each unit has been
constructed and hydrostatically tested for a maximum
working pressure of 160 psi,
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 CAN/CGA B149.1 or .2, Installation Code
for Gas Burning Appliances and Equipment.

If installed in the Commonwealth of Massachusetts, you
MUST FOLLOW the additional instructions contained in
RBI's instruction sheet MACODE-3. If you do not have a
copy, call your RBI distributor or contact the RBI Customer
Service Department.

The owner should maintain a record of all service work
performed with the date and a description of the work
done. Include the name of the service organization for
future reference.

1103 kPa

in accordance with

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 3

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 Series 8800
and 8900 boiler/water heater check the rating plate to
ensure that the unit has been sized properly for the job.
The “Net I=B=R Ratings” specify the equivalent amount
of direct cast iron radiation that the unit can supply under
normal conditions. Also ensure that the unit has been
set up for the type of gas available at the installation
site. Other important considerations are the availability
of an adequate electrical supply, fresh air for combustion
and a suitable chimney or vent system.

BOILER/WATER HEATER LOCATION

1. Locate the boiler/water heater in an area that
provides good access to the unit. Servicing may
require the removal of jacket panels.
minimum clearances between adjacent construction
and the boiler/water heater as listed in Table 1 or 1A.

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

Table 1 (8800)

Clearance to Service

Combustibles Clearance

in

To p 24
Back 24
Left Side 24
Right Side 24
Front 48
Flue 6

Table 1A (8900)

Clearance to Service

Combustibles Clearance

in

To p 24
Back 18
Left Side 18
Right Side 18
Front 48
Flue 6

mm
610
610
610
610

1220

152

mm
610
457
457
457

1220

152

Allow the

in
18
18
24
24
48

6

in
18
18
18
18
36

6

mm
457
457
610
610

1220

152

mm
457
457
457
457
914
152

2. An optimum site will be level, central to the piping
system, close to a chimney and have adequate fresh
air for combustion. Ensure that the boiler/water heater
is level from front to back and from side to side. Use
metal shims to level the boiler/water heater. Electrical
and electronic components must also be protected
from exposure to water during operation and
maintenance. DO NOT install this boiler/water heater
in a location that would subject any of the gas ignition
components to direct contact with water or excessive
moisture during operation or servicing.

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

NOTE: Never install a Series 8800 or 8900 boiler/
water heater on a concrete floor that contains wires,
cables, water pipes or hoses. This boiler/water
heater is designed for noncombustible floors only!
Never install this boiler/water heater on combustible
materials or carpeting even if a non-combustible
foundation material is placed over them!

4. Locate the boiler/water heater in an area that will
prevent water damage to adjacent construction
should a leak occur or during routine maintenance.
If such a location doesn’t exist, a suitable drain pan
that’s adequately drained must be installed under
the unit. The
combustion air to the unit.

5.

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

6. NEVER place this boiler/water heater in a location
that would subject it to temperatures at or near
freezing.

WARNING: Never store combustible materials,
gasoline or any product containing 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!

pan must not restrict the flow of

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 4

COMBUSTION AIR & VENTILATION

WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
Section 5.3, Air for Combustion & Ventilation, of
the latest revision of the National Fuel Gas
Code, ANSI Z223.1/ NFPA 54 and all applicable
local building codes. Canadian installations
must comply with CAN/ CGA B149.1 or .2
Installation Code for Gas Burning Appliances
and Equipment, or applicable provisions of the
local building codes. Failure to provide adequate
combustion air for this boiler/water heater can
result in excessive levels of carbon monoxide
which can result in severe personal injury or
death!

To operate properly and safely this boiler/water heater
requires a continuous supply of air for combustion.
NEVER store objects on or around the boiler/water heater!

CAUTION: Combustion air contaminated with
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!

CAUTION: If the boiler/water heater is operated while
the building is under construction it MUST be
protected from wood, concrete, sheet rock and other
types of dust. Failure to properly protect the unit
from construction dust will damage the unit voiding
the warranty!

All Air From Inside The Building

If the boiler/water heater is to be located in a confined
space minimum clearances listed in Table 1 or 1A must
be maintained between the boiler/water heater and any
combustible construction. When installed in a confined
space, Figures 1, 2, 3, 4 and 5, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
sufficient volume to meet the criteria for an unconfined
space. The total air requirements of all gas utilization
equipment, fireplaces, wood stoves or any type of
exhaust fan must be considered when making this
determination. Each opening must have a minimum free
area of 1 in2/1000 Btu/hr,
total input rating of
confined area. Each opening must be no less than

100 in2,

be within 12 in,

76 mm

opening must be within 12 in,
than 3 in,

All Air From Outside The Building

When installed in a confined space two permanent
openings communicating directly with, or by ducts
to, the outdoors or spaces that freely communicate with
the outdoors must be present. The upper opening must
be within 12 in,

76 mm

opening must be within 12 in,
than 3 in,

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,
rating of all of the equipment in the enclosure.

64,516 mm

from, the top of the enclosure. The bottom

76 mm

from, the top of the enclosure. The bottom

76 mm

ALL

305 mm

from, the bottom of the enclosure.

305 mm

from, the bottom of the enclosure.

2200 mm2/kW

gas utilization equipment in the

2

in size. The upper opening must

of, but not less than 3 in,

305 mm

of, but not less than 3 in,

305 mm

550 mm2/kW

based on the

of, but not less

of, but not less

of the total input

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 5

Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr,

1100 mm2/kW

of the total
input rating of all of the equipment in the enclosure.
When ducts are used, they must have the same cross­sectional area as the free area of the opening to which
they connect.

Canadian installations must comply with CSA B149.1
when

air supply

outdoors for
assisted, or power draft-assisted
be a permanent

is provided by natural air flow from the

natural draft

air supply

, partial fan-assisted, fan-

burners

, there shall

opening(s) having a cross-

sectional area of not less than 1 in2 per 7,000 Btuh

(310 mm2 per kW)

plus 1 in2 per 14,000 Btuh

up to and including 1 million Btuh,

(155 mm2 per kW)

in excess

of 1 million Btuh.

When calculating the free area necessary to meet
the make-up air requirements of the enclosure,
consideration must be given to the blockage effects
of louvers, grills and screens. Screens must have
a minimum mesh size of 1/4 in,

6.4 mm

. If the free
area through a louver or grill is not known, ducts
should be sized per Table 2.

Table 2 - Make-up Air Louver Sizing

Required Cross Sectional Area

Input 1/4 in

6.4 mm

75% Free Area 25% Free Area

(MBH) Wire Screen Metal Louvers Wooden Louvers

2

in

420 105
530 133
630 158
735 184
840 210
950 238
1050 263
1160 290
1260 315
1370 343
1470 368
1580 395
1685 421
1790 448
1900 475
2000 500
2400 600
2800 700
3200 800
3600 900
4000 1000

cm

677

858
1019
1187
1355
1535
1697
1871
2032
2213
2374
2548
2716
2890
3065
3226
3871
4516
5161
5806
6452

2

2

in

140
177
210
245
280
317
350
387
420
457
490
527
562
597
633
667
800
933

1067
1200
1333

cm

903
1142
1355
1581
1806
2032
2258
2497
2710
2948
3161
3400
3626
3852
4084
4303
5161
6019
6884
7742
8600

2

2

in

420
530
630
735
840
950

1050
1160
1260
1370
1470
1580

10,194

1685

10,871

1790

11,548

1900

12,258

2000

12,903

2400

15,483

2800

18,064

3200

20,645

3600

23,226

4000

25,806

cm

2710
3419
4064
4742
5419
6129
6774
7484
8129
8839
9484

2

Figure 1 - Vertical Venting Using A Metal Chimney And Inside Air (8900/8800 Series)

2 FT .6 m

10 FT 3.4 m

3 FT 1 m

3 FT 1 m

5 FT 1.52 m

RIOM-40

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 6

Figure 2 - Vertical Venting Using A Masonary Chimney And Inside Air (8900/8800 Series)

10 FT 3.1 m

3 FT 1 m

3 FT 1 m

5 FT 1.52 m

Figure 3 - Dual Flue Outlets And Inside Air (8900/8800 Series)

2 FT .6 m

10 FT 3.4 m

3 FT 1 m

10 FT 3.4 m

5 FT 1.5 m

RIOM-41

RIOM-42

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 7

Figure 4 - Common Vents and Inside Air (8900/8800 Series)

10FT 3.1 m

3FT 1m

5FT 1.52m

3FT 1m

Figure 4A - Common Vents and Inside Air (8800/8900 Series) Dual Flue

10 FT

3.1 m

3 FT

1 m

RIOM-43

3 FT

1 m

5 FT

1.52 m

Figure 5 - Horizontal Venting And Inside Air (8900/8800 Series)

BUILDING OVERHANG

4FT 1.2 M MAX.

PITCH PIPE DOWN TOWARDS TERMINAL
CAP 1/4 IN. PER FOOT 20 MM/M OF RUN TO

3FT .9 m

1.5 FT 0.5m MINIMUM DIST ANCE FROM

EXHAUST TO MAXIMUM SNOW LINE.

ALLOW FOR CONDENSATE DRAINAGE

3FT 1 m

5FT 1.52 m

RIOM-44

RIOM-45

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 8

CHIMNEY & VENT PIPE
CONNECTIONS

WARNING: The vent installation must be in
accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1/NFPA
54-latest revision or applicable provisions of the
local building codes. Canadian installations must
comply with CAN/CGA B149.1 or .2 Installation
Code. Improper venting can result in excessive
levels of carbon monoxide which can result in
severe personal injury or death!

Chimney Inspection & Sizing

A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly
constructed, lined and sized. Exterior masonry chimneys
should not be used unless properly lined to prevent
condensation and draft problems. Table 3A and 3B lists
the equivalent breeching and flue sizes required for the
boiler/water heater.

Table 3A - Equivalent Breeching & Chimney Size

Model Size Model Size

Size in
420 10
530 10
630 12
735 14
840 14
950 14
1050 16
1160 16
1260 16
1370 18
1470 18

Note: These sizes are based on a 20 ft,

mm
254
254
305
356
356
356
406
406
406
457
457

Size in
1580 18
1685 18
1790 20
1900 20
2000 22
2400 24
2800 26
3200 28
3600 30
4000 30

6.1m

chimney height.

mm
457
457
508
508
559
610
660
711
762
762

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 the appliances.

WARNING: 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 the accumulation of
carbon monoxide which can cause severe
personal injury or death!

Vent Connections

Always use a type B or single wall galvanized metal vent
pipe the same diameter as the draft diverter flue collar.
Use the shortest, straightest vent system possible for
the installation. If horizontal runs exceed 6 ft,
must be supported at 6 ft,

1.8 m

intervals with overhead

1.8 m

they

hangers. The vent system should be sloped up toward
the chimney at a minimum rate of 1/4 in/ft,

20 mm/m

and terminate flush with the inside of the chimney flue.
Fasten each connection with at least 3 corrosion
resistant sheet metal screws.

WARNING: Never modify or alter any part of the
boiler’s draft diverter. This includes the removal
or alteration of any baffles. Never install a vent
pipe of a diameter different than that of the
boiler draft hood flue collar. Failure to comply
with this warning can result in severe personal
injury or death.

Always provide a minimum clearance of 6 in,

152 mm

between type C vent pipe and any combustible
materials. Type B1 vent may be used, clearance
between it and any combustible material must be as
listed.

Table 3B - Equivalent Breeching & Chimney Size Dual Flue

Model Size Model Size

Size in
840 10
950 10
1050 12
1160 12
1260 12
1370 14
1470 14
1580 14
1685 14

Note: Minimum vertical rise off top dual flue units: 3 ft,
840-3200), 5 ft,

mm
254
254
305
305
305
355
355
355
355

1.5 m

(sizes 3600-4000).

Size in
1790 16
1900 16
2000 14
2400 16
2800 18
3200 20
3600 22
4000 22

1 m

mm
406
406
356
406
457
508
559
559

(sizes

WARNING: 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!

To determine the appropriate power venter for the boiler/
water heater, see Table 4, Power Venter Sizes. Follow
the power venter manufacturer’s installation instructions.

Table 4 - Power Venter Sizes

8900 Power Venter Max. Pipe Length

Model Size FT

420-530 HS-2 100

630 HS-3 100

735-1160 HS-4 100

1260-1900 HS-5 100

m
31
31
31
31

Models 2000-4000 - Consult Tjernlund

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 9

COMMON VENT SYSTEMS

If an existing boiler/water heater is removed from a
common venting system, the common venting system
may then be too large for the proper venting of the
remaining appliances connected to it. At the time of
removal of an existing boiler/water heater, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining
connected to the common venting system are not in
operation.

Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’évacuation
commun et qui fonctionne alors que d’autres appareils
toujours raccordés au système d’évacuation ne fonction­nent pas: système d’évacuation

a) Seal any unused openings in the common venting

system.

Sceller toutes les ouvertures non utilisées du 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
deficiencies 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 fireplace dampers.

Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l’espace où les appareils toujours
raccordés du système d’évacuation sont installés et
les autres espaces du bâtiment. Mettre en marche
les sécheuses, tous les appareils non raccordés au
système d’évacuation commun et tous les
ventilateurs d’extraction comme les hottes de
cuisinère et les ventilateurs des salles de bain.
S’assurer que ces ventilateurs fonctionnent à la

vitesse maximale. Ne pas faire fonctionner les
ventilateurs d’été. Fermer les registres des
cheminées.

d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.

Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de
façon que l’appareil fonctionne de façon continue.

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

5 minutes of main burner operation. Use the flame
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 flamme d'une
allunette ou d'une chandelle ou la fumée d'une
cigarette, d'un cigare ou d'une pipe.

f) After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their
previous condition of use.

Une fois qu’il a été d éterminé, selon la métode
indiquée ci-dessus, que chaque appareil raccordé
au système d’évacuation est mis à l’air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.

g) Any improper operation of the common venting

system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and or CAN/CGA-B149 Installation
Codes.

Tout mauvais fonctionnement du systéme d'évacu­tion 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 modifié pour respecter les
valeurs minimales des tableaux pertinents de
l'appendice F du National Fuel Gas Code, ANSI
Z223.1/NFPA 54 et (ou) des codes d'installation
CSA-B149.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 10

GENERAL PIPING REQUIREMENTS

CAUTION: Improper piping of this boiler/water heater
will void the manufacturer’s warranty and can cause
boiler failure resulting in flooding and extensive
property damage! Excessive water hardness causing
lime build-up in the copper heat exchanger tubes is

NOT

covered under the manufacturer’s warranty.
Excessive pitting and erosion of the internal surface
of the copper heat exchanger tubes is
under the manufacturer’s warranty if the result
of high water flow rates, see Table 6A and 6B. Return
water temperatures below 110°F, 43°C will result
in heat exchanger damage from excessive
condensation voiding the manufacturer’s warranty,
see Primary/Secondary Piping Figure 7.

NOTE: Shut off valves and unions should be
installed at the inlet and outlet connections of the
boiler/hot water heater to provide for isolation of the
unit should servicing be necessary.

Relief Valve

Pipe the discharge of the pressure relief valve to prevent
scalding in the event of a discharge, see Figure 6. 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 6

1" (25mm) CLEARANCE MUST
BE MAINTAINED BETWEEN HOT
WATER PIPING AND COMBUSTIBLE
CONSTRUCTION.

NOT

covered

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

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualified
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section
IV, and ANSI/ASME CSD-1, Standard for Controls and
Safety Devices for Automatically Fired Boilers. All
applicable local codes and ordinances must also be
followed. A minimum clearance of 1 in,
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,
maintained.

Heating Boiler Piping Connections

The supply and return connections should be sized to
suit the system, see Table 5.

Table 5 - Supply & Return Pipe Sizing

Model Supply Return
8900 21/2" NPT 21/2" NPT
8800 3" Victaulic 3" Victaulic
*Models 420-950 may have 21/2" x 2" reducing fitting
installed.

25 mm

82.7 kPa

must be

must be

DISCHARGE PIPE SIZE TO
EQUAL VALVE OUTLET.

OUTLET

INLET

RIOM-46

DO NOT RESTRICT FLOW.

DISCHARGE SO AS TO AVOID
EXPOSURE OF PERSONS TO
HOT LIQUID OR VAPOR AND
ALLOW COMPLETE DRAINAGE
0F RELIEF VALVE AND PIPING

.

WARNING: Never install any type of valve
between the boiler/water heater and the relief
valve or an explosion causing extensive
property damage, severe personal injury or
death may occur!

Flow Switch

The flow switch supplied with the boiler/water heater
must be wired to the terminal strip in the junction box
to prevent the boiler from firing unless there’s adequate
water flow through the unit. The flow switch must be
installed in the supply piping adjacent to the boiler outlet
connection.

Pump Requirements

This low mass boiler requires a continuous minimum
water flow for proper operation. The system pump must
be sized to overcome the head loss of the boiler and
the heating system in order to achieve the required
temperature rise. Table 6A and 6B provides the heat
exchanger pressure drop and temperature rise figures.
The temperature rise across the boiler must never
exceed 35°F,

19.4°C

. The pump delay turns the pump
on each time the burners fire and runs the pump for up
to 10 minutes after the call for heat is satisfied.

CAUTION: A temperature rise outside of the range
listed in Table 6A and 6B indicates that the flow rate
through the heat exchanger is incorrect which will
damage the heat exchanger voiding the warranty!

The maximum allowable flow rate through an 8900
boiler with copper heat exchanger is 92 GPM,

5.8 L/s

and 185 GPM,

11.7 L/s

on single pass.

The maximum allowable flow rate through an 8800
boiler with copper heat exchanger is 185 GPM,

11.7 L/s

and 370 GPM,

23.3 L/s

on single pass.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 11

Table 6A - Temperature Rise Table — 2 Pass Headers

20°F

Press

Flow

Model

420
530
630
735
840
950
1050
1160
1260
1370
1470
1580
1685
1790
1900
2000
2400
2800
3200
3600
4000

*Flow exceeds recommended maximum use a greater temperature rise or consult manufacturer. Cupro-nickel heat exchanger should be considered.

GPM Ft

34.0

42.9

51.0

59.5

68.0

77.0

85.1

94.0*

164.0

196.8*

Rate

—
—
—
—
—
—
—

—
—
—
—

Drop

0.4

0.7

1.1

1.6

2.4

3.3

4.4

5.8
—
—
—
—
—
—
—

4.1

6.8
—
—
—
—

11.1°C

Press

Flow

Drop

Rate

L/s kPa

1.1

2.1

2.0

2.7

3.2

3.2

4.8

3.8

7.0

4.3

9.8

4.9

12.9

5.4

17.0

5.9
—
—
—
—
—
—
—

12.0

10.3

20.0

12.4
—
—
—
—

—
—
—
—
—
—
—

—
—
—
—

25°F

Flow
Rate

GPM Ft

—

34.3

40.8

47.6

54.4

61.6

68.0

75.2

81.6

88.8

95.3*
—
—
—
—

131.2

157.4

183.7
—
—
—

Press
Drop

—

0.4

0.7

1.1

1.6

2.2

2.9

3.8

4.8

6.1

7.4
—
—
—
—

2.7

4.5

6.9
—
—
—

13.9°C

Press

Flow

Drop

Rate

L/s kPa

—

—

1.3

2.2

2.1

2.6

3.2

3.0

4.6

3.4

6.5

3.9

8.6

4.3

11.2

4.7

14.2

5.2

17.9

5.6

21.8

6.0
—

—

—

—

—

—

—

—

8.0

8.3

13.2

9.9

20.3

11.6
—

—

—

—

—

—

30°F

Flow

Rate

GPM Ft

—
—

34.0

39.7

45.4

51.3

56.7

62.6

68.0

74.0

79.4

85.3

91.0

96.7*
—

109.3

131.2

153.1

174.9

196.8*
—

Press

Drop

—
—

0.5

0.8

1.1

1.6

2.1

2.7

3.4

4.3

5.3

6.5

7.7

9.2
—

1.9

3.2

4.9

7.2

10.0
—

16.7°C

Press

Flow

Drop

Rate

L/s kPa

—
—

2.1

1.5

2.5

2.3

2.9

3.3

3.2

4.6

3.6

6.1

4.0

8.0

4.3

10.1

4.7

12.8

5.0

15.6

5.4

19.0

5.7

22.8

6.1

27.0

—

6.9

5.7

8.3

9.4

9.7

14.5

11.0

21.1

12.4

29.3

—

—
—

—

—

35°F

Flow
Rate

GPM Ft

—
—
—

34.0

38.9

44.0

48.6

53.7

58.3

63.4

68.0

73.1

78.0

82.9

87.9

93.7

112.5

131.2

149.9

168.7

187.4*

Press

Drop

—
—
—

0.6

0.8

1.2

1.6

2.0

2.6

3.3

4.0

4.8

5.8

6.9

8.1

1.4

2.4

3.7

5.4

7.5

10.1

19.4°C

Press

Flow

Drop

Rate

L/s kPa

—
—
—

2.1

1.7

2.5

2.5

2.8

3.5

3.1

4.6

3.4

6.0

3.7

7.6

4.0

9.6

4.3

11.7

4.6

14.3

4.9

17.1

5.2

20.3

5.5

23.9

5.9

4.3

7.1

7.1

8.3

10.9

9.5

15.8

10.6

22.0

11.8

29.6

—
—
—

Table 6B - Temperature Rise Table — Single Pass Headers

25°F

Press

Flow

Drop

Rate
GPM Ft

—
—
—
—
—

61.6

68.0

75.2

81.6

88.8

95.3

102.4

109.2

116.0

123.1

131.2

157.4

183.7

209.9

236.2

262.4

—
—
—
—
—

0.3

0.4

0.5

0.7

0.8

1.0

1.3

1.5

1.8

2.1

0.4

0.6

1.0

1.4

1.9

2.6

Model

420
530
630
735
840
950
1050
1160
1260
1370
1470
1580
1685
1790
1900
2000
2400
2800
3200
3600
4000

20°F

Press

Flow

GPM Ft

68.0

77.0

85.1

94.0

102.1

111.0

119.1

128.0

136.5

145.0

153.9

164.0

196.8

229.6

262.4

295.2

328.0

Rate

—
—
—
—

Drop

—
—
—
—

0.3

0.5

0.6

0.8

1.0

1.3

1.6

1.9

2.3

2.7

3.2

0.6

0.9

1.4

2.1

2.9

3.9

11.1°C

Press

Flow

Drop

Rate

L/s kPa

—
—
—
—

1.0

4.3

1.4

4.9

1.8

5.4

2.4

5.9

3.0

6.4

3.7

7.0

4.6

7.5

5.6

8.1

6.7

8.6

7.9

9.1

9.3

9.7

1.7

10.3

2.8

12.4

4.3

14.5

6.2

16.6

8.6

18.6

11.6

20.7

—
—
—
—

13.9°C

Press

Flow

Drop

Rate

L/s kPa

—

—

—

—

—

—

—

—

—

—

3.9

4.3

4.7

5.2

5.6

6.0

6.5

6.9

7.3

7.8

8.3

9.9

11.6

13.2

14.9

16.6

0.9

1.2

1.6

2.0

2.5

3.0

3.7

4.4

5.2

6.2

1.1

1.8

2.8

4.1

5.7

7.7

30°F

Press

Flow

Drop

Rate

GPM Ft

—
—
—
—
—
—
—

62.6

68.0

74.0

79.4

85.3

91.0

96.7

102.6
—

131.2

153.1

174.9

196.8

218.7

—
—
—
—
—
—
—

0.4

0.5

0.6

0.7

0.9

1.1

1.3

1.5
—

0.4

0.7

1.0

1.4

1.9

16.7°C

Press

Flow

Drop

Rate

L/s kPa

—
—
—
—
—
—
—

4.0

4.3

4.7

5.0

5.4

5.7

6.1

6.5

1.1

1.4

1.8

2.2

2.6

3.2

3.7

4.4

—

8.3

9.7

11.0

12.4

13.8

1.3

2.0

2.9

4.1

5.5

—
—
—
—
—
—
—

—

35°F

Press

Flow
Rate

GPM Ft

—
—
—
—
—
—
—
—
—

63.4

68.0

73.1

78.0

82.9

87.9
—
—

131.2

149.9

168.7

187.4

Drop

—
—
—
—
—
—
—
—
—

0.5

0.6

0.7

0.8

1.0

1.1
—
—

0.5

0.7

1.0

1.4

19.4°C

Press

Flow

Drop

Rate

L/s kPa

—
—
—
—
—
—
—
—
—

4.0

4.3

4.6

4.9

5.2

5.5
—
—

8.3

9.5

10.6

11.8

—
—
—
—
—
—
—
—
—

1.3

1.6

2.0

2.4

2.8

3.3
—
—

1.5

2.2

3.1

4.1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 12

Low Water Cutoff

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

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

Expansion Tank

An expansion tank or other means to control thermal
expansion must be installed in the heating system. An
expansion tank must be installed close to the boiler on
the suction side of the pump.

Primary/Secondary Piping

Boilers connected to heating systems using zone
valves, zone pumps, or systems that have excessive
flow rates or return water temperatures less than 110°F,

43°C

must be isolated from these systems to protect the

boiler.

Variable Water Flows

Figure 7 shows a typical primary/secondary piping
system. A dedicated pump is used to maintain a
constant water flow through the boiler. This secondary
pump is sized to overcome the head loss of the boiler
and secondary piping system while supplying the flow
rate required to maintain the desired temperature rise
across the boiler. The primary pump is sized to provide
the required flow 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 7.

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 8. 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 8.

Multiple Boiler Systems

Systems using multiple boilers can also be installed
using a primary/secondary manifold system, Figure 9.

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

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 13

Figure 7 - Typical Primary/Secondary Piping System

(See Notes)

1

Circuit Setter

Pump

Valve

Check Valve

Backflow-Prevention

Device

Figure 8 - Low Temperature Piping

See Notes and Adjustment Procedures

1

H-1 Rev 2

H-3 Rev 2

Pressure

Relief Valve

Thermometer

Aquastat

Epansion

Tank

Union

Automatic

Air Vent

Pressure
Reducing

Valve

NOTES:

1.Boilercircuitpipingmustbesizedlargeenoughtohandle
maximumflowthroughunit.

2.Boilerpumpsizedtoboilerdesignflow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configurationandvalving.
Checkwithlocalcodesandordinancesforspecificrequirements.

Adjustment Procedure To Maintain Inlet Temperature

Above Dew Point

T1-Temp-Min=110° For Atmospheric

T1-Temp-Min=125° Sealed Combustion

1. Turn heater on and open valves A & B.

2. After steady-state operation, if T1 is less than Temp-Min
slowly close valve B until T1 climbs to desired operating
temperature above Temp-Min.

3. If T1 is greater than desired operating temperature, slowly
close valve A to adjust to lower desired temperature above
Temp-Min.

4. Check after system operating temperature has
stabilized. Make final adjustments.

5. Follow same adjustment procedure for sealed combustion.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 14

Figure 9 - Multiple Boiler Piping

(See Notes)

5

Circuit Setter

1

NOTES:

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

2. Boiler pump sized to boiler design flow requirements.

3. All boilers furnished with factory mounted outlet water
temperature gauge.

4. Boiler pump purging required. Use terminals supplied.

5. Secondary loop pipe diameter must be sized large enough to
handle maximum flow through all units.

Notice: These drawings show suggested piping configuration and valving.
Check with local codes and ordinances for specific requirements.

H-15 Rev 2

Pump

Valve

Check Valve

Backflow-Prevention

Device

Pressure

Relief Valve

Thermometer

Aquastat

Epansion

Tank

Union

Automatic

Air Vent

Pressure
Reducing

Valve

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 15

DOMESTIC WATER SUPPLY PIPING

CAUTION: Proper controls must be used to prevent
water supplied for domestic use from exceeding
130°F,
higher water temperatures are required for
appliances such as a dishwasher, a mixing valve or
some other tempering means must be installed.
Households with small children may require water
temperatures less than 120°F,
must be complied with!

General Piping Requirements

Ensure that the water heater is equipped with bronze
headers. Piping and components connected to the water
heater must be suitable for use with potable water. The
water heater must not be connected to any heating
system piping or components previously used with a
non-potable water heating appliance. Toxic chemicals,
such as those used for boiler treatment, are not to be
introduced into any potable water used for space
heating. If a hot water storage tank is used in the system
it must be equipped with a temperature and pressure
relief valve that complies with ANSI Z21.22 or CAN-4.4
and CAN-4.6.

NOTE: The storage tank must be located as close
to the water heater as possible to prevent excessive
head loss which will reduce flow.

Water Chemistry

The required temperature rise across the water heater
is based on water having a hardness between 8 and
18 grains per gallon with a level of dissolved solids not
exceeding 350 ppm. Water having a hardness less than
8 grains can cause excessive corrosion of the heat
exchanger. Water that has a hardness greater than 18
grains per gallon and/or a level of dissolved solids
exceeding 350 ppm will require a recalculation of the
pump size and temperature rise.

54

°C or a scald injury will occur! When

49

°C. Local codes

CAUTION:
through a water heater with copper heat exchanger
on an 8900 is 92 GPM,
on single pass. The cupro-nickel heat exchanger
allows for 100 GPM,
single pass.

The maximum allowable flow rate through a water
heater with copper heat exchanger on an 8800 is 185
GPM,

11.7 L/s

The cupro-nickel heat exchanger allows for 200 GPM,

12.6 L/s

Tables 6A and 6B.

RBI water heaters are designed to run scale free. Due
to the extreme variables of water conditions world wide
it is necessary to consider pH values and water
hardness in relationship to scaling. It is crucial to
consider these two variables when making heat
exchanger and pump selections. If local water conditions
are extreme, follow the guidelines in the Heat Exchanger
Selection Table (Table 7A) and the Pumping
Performance Table (Table 7B). Scale free operation can
be achieved by using water with a hardness between 8
and 18 and by maintaining the pH between 5 and 9.
Follow the conditions listed under NORMAL in the table.
In some areas of the country additional precautions
must be observed due to unusual characteristics of the
local water supply. Call the nearest RBI representative
for details.

To properly size the pump a grain hardness and pH test
must be taken at the installation site before the order is
placed. Proper pump sizing will improve heater
performance and help ensure heater longevity.

Expansion Tank

An expansion tank or other means to control thermal
expansion must be installed in the water heating system
if back flow prevention devices are installed.

The maximum allowable flow rate

5.8 L/s

and is 185 GPM,

6.3 L/s

and 370 GPM,

and 400 GPM,

and 200 GPM,

23.3 L/s

25.2 L/s

on single pass. See

on single pass.

11.7 L/s

12.6 L/s

on

A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water
conditions are encountered. See Table 7A.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 16

Pump Requirements

This low-mass water heater requires a continuous mini­mum water flow for proper operation. The factory
recommended circulating pump has been sized to
overcome the head loss of the water heater plus a 30
foot piping loop under normal water conditions. Table 7B
provides the heat exchanger pressure drop chart and
temperature rise table. The temperature rise across

the water heater must never exceed 35°F,

19.4°C

.

Cold Water Supply

The cold water supply must be piped to the water
heater’s outlet piping between the water heater and the
hot water storage tank. This will prevent untempered
water from entering the water heater, see the
temperature rise control section below. A typical water
heating system is shown in Figure 10 and 11.

Temperature Rise Control

Water returned to the water heater inlet must not be less
than 110°F, 43°C or excessive condensation of the
products of combustion will damage the water heater
voiding the warranty. The method outlined below can be
employed to prevent this condition from occurring.
A balancing valve should be installed on the outlet side
of the water heater for purposes of adjusting the flow
rate through the heat exchanger. Thermometers are

installed on both the inlet and outlet of the water heater
for determining the temperature rise through the unit.

The proper velocity through the water heater must be
maintained in accordance with Table 7B for efficient
operation and long life. If the temperature rise through
the water heater is lower than recommended the water
velocity is too high. Premature erosion of the heat
exchanger will occur. Conversely, if the temperature rise
is higher than recommended in Table 7B the flow rate
is too low. Scaling and softening of the heat exchanger
will occur.

Thermostatic Mixing Valve - Water Above 140°F, 60°C

Water can be stored at temperatures above 140°F, 60°
provided that a thermo-statically controlled mixing valve
is used to temper the hot water to an acceptable
temperature before it’s supplied for domestic use.

The mixing valve MUST be set to prevent a scald injury
from occurring, see the caution against scalding.

Storage of water for domestic use above 140°F, 60°
will provide an increased quantity of tempered water and
help prevent growth of water born bacteria.

C

C

Table 7A - 8800 and 8900 Heat Exchanger Selection Graph

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 17

Table 7B - 8900 Pumping Performance Requirement Table

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 18

Table 7B - 8800 Pumping Performance Requirement Table

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 19

Figure 10 - Typical Water Heating Piping (HW Models Only)

(See Notes)

Pump

3

8

2

1

4

7

D-1 Rev 5

RBI stock storage tanks do not

incorporate this tapping: See Note 1.

Attention:

Figure 11 - Multiple Water Heating Piping (HW Models Only)

(See Notes)

4

3

6

8

Valve

Globe Valve

Angle Valve

Bufferfly Valve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Valve

Pressure

Reducing Valve

Check Valve

4

Pressure

Relief Valve

1

7

2

NOTES:

1. Optional cold water make up and recirculation line location.

2. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.

3. Thermal expansion tank may be required, check local codes.

4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.

5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.

The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and
Pumping Performance Table before making selection.

6. Common piping must be sized for maximum combined heater flow.

7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.

8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.

Notice: These drawings show suggested piping configuration and valving.

Check with local codes and ordinances for specific requirements.

Flow Switch

Thermometer

7

2

6

D-4 Rev 5

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Attention:

RBI stock storage tanks do not

incorporate this tapping: See Note 1.

Automatic

Air Vent

Temperature &

Pressure

Relief Valve

Vacuum

Relief Valve

Drain Valve

(Typ.)

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 20

GAS SUPPLY PIPING

WARNING: Check the boiler/water heater rating
plate to make sure that the boiler/water heater
is for the type of gas that will be used. If it isn’t,
do not connect the boiler/water heater to the gas
supply. Gas supply piping must be in accordance
with the National Fuel Code, ANSI Z223.1-latest
revision or applicable provisions of the local
building codes. Canadian installations must
comply with CAN/CGA B149.1 or .2 Installation
Code. Failure to comply with this warning can
result in extensive property damage, severe
personal injury or death!

The Series 8800 and 8900 come from the factory ready
to be piped to the gas supply. If for any reason the
boiler/water heater is not for the type of gas available
at the installation site, call the nearest RBI
representative to resolve the problem.

NOTE: A minimum gas supply presssure of 6 in,

152 mm

and maximum 14 in,
propane, must be available at the safety shutoff
valve inlet with the unit(s) operating.

W.C. natural or 11 in,

356 mm

279 mm

W.C. propane

W.C. natural or

A ground joint union should be installed between the
boiler gas controls and the supply piping. Each of these
items are needed to ensure long life and ease of
servicing. Always use a pipe sealant that is suitable for
use with LP gas.

Table 9 - Equivalent Pipe Length Chart

Nominal
Iron Pipe
Size, (in)

1"
1 1/4"
1 1/2"

2"
2 1/2"

3"

4"

Notes: 1. For flow through branch.

2. For flow at full open.

Type of pipe fitting

90°

Elbow

Te e

Equivalent of pipe length (ft)

5.2

2.6

6.9

3.5

8.0

4.0

10.3

5.2

12.3

6.2

15.3

7.7

15.3

7.7

Gate

1

Valve

0.6

0.8

0.9

1.2

1.4

1.8

1.8

Gas

Cock

1.5

1.9

2.3

3.0

3.7

4.5

4.5

2

2

CAUTION: Always use a square jawed wrench on the
gas valve body when making gas connections to it.
Never over-tighten the piping entering the gas valve
body or gas valve failure may result!

Figure 12 - Gas Supply Piping

Table 8 should be used to ensure that the gas supply
piping is sized properly. If more than one appliance is
supplied by the same supply pipe, the piping must be
sized based on the maximum possible demand. Do not
neglect the pressure drop due to pipe fittings. Table 8
should be used in conjunction with Table 9 to ensure
that the gas supply piping has the capacity to meet the
demand.

Figure 12 depicts the proper way to connect the boiler/
water heater to the gas supply piping. The manual shut­off valve MUST be installed in the supply piping. It
should be installed 5 ft,

1.5 m

above the floor where
required by local codes. Provide a sediment trap at the
bottom of the vertical section of the gas supply pipe
upstream of the gas controls.

Table 8 - Gas Pipe Capacity

Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas
at a pressure of 0.5 psig or less and a 0.3" W.C. pressure drop.

Nominal
Iron Pipe
Size, (in)

1"
1 1/4"
1 1/2"

2"
2 1/2"

3"

4"

Note: Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr.

Multiply the propane flow capacity by 2500 Btu/ft3 to determine the propane Btu/hr
capacity for a given pipe size and length.

10

520
1050
1600
3050
4800
8500
17,500

20

350
730
1100
2100
3300
5900
12,000

Pipe length in feet

30

40

50

Maximum gas volume of pipe, (ft3/hr)

285

245

500
760
1450
2300
4100
8300

215

440
670
1270
2000
3600
7400

590
890
1650
2700
4700
9700

60

195

400
610
1150
1850
3250
6800

80

170

350
530
990
1600
2800
5800

100

150
305
460
870
1400
2500
5100

150

120
250
380
710
1130
2000
4100

RIOM-47

When applicable, provisions for vent, bleed and gas
relief lines must be made in accordance with the latest
revision of ANSI Z223.1/NFPA 54.

Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler. All gas connections MUST be leak tested
before putting the boiler into operation.

WARNING: Never use an open flame to test for
gas leaks. Always use an approved leak
detection method. Failure to comply with this
warning can cause extensive property damage,
severe personal injury or death!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 21

Whenever the gas supply piping is pressure tested the
boiler/water heater gas controls must be protected.
If the test pressure is equal to, or less than 1/2 psig,

3.5 kPa

manual shut off valve, see Figure 12. If the test pressure
is greater than, or equal to 1/2 psig,
the boiler/water heater and its individual shut-off valve.

isolate the boiler/water heater by closing it’s

3.5 kPa

, disconnect

ELECTRICAL WIRING

Electrical Power Connections

CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper
operation after servicing!

ATTENTION. Au moment de l’entretien des
commandes, étiquetez tous les fils avant de les
débrancher. Des erreurs de câblage peuvent
entraîner un fonctionnement inadéquat et
dangereux. S’assurer que l’appareil fonctionne
adéquatement une fois l’entretirn terminé.

The electrical connections to this boiler/water heater
must be made in accordance with all applicable local
codes and the latest revision of the National Electrical
Code, ANSI /NFPA-70. Installation should also conform
with CSA C22.1 Canadian Electrical Code Part I if
installed in Canada.

GENERAL OPERATION

WARNING: Before proceeding read and fully
understand the instructions contained in this
manual. Do not attempt to operate this boiler/
water heater if it has not been installed in
accordance with the guidelines set forth in this
manual. Failure to comply with this warning can
result in extensive property damage, severe
personal injury or death!

Should overheating occur or the gas supply fail to shut
off, turn off the manual gas control valve to the
appliance. Do not interrupt water flow through the boiler/
water heater.

En cas de surchauffe ou si l’alimentation en gaz ne
s’arrête pas, fermez manuellement le robinet d’arrêt de
l’admission de gaz.

Hydronic Heating Boilers

Open the make-up water valve and slowly fill the boiler
and all of the radiation with water. Ensure that all bleed
and drain valves are closed.

Adjust the make-up water pressure regulator so a
minimum 12 psig,
maintained at the highest point in the system piping. If
a make-up water pump is used adjust it to maintain a
minimum 12 psig,

82.7kPa

82.7 kPa

system pressure is

system pressure.

Install a separate 120 volt 15 amp circuit for the boiler/
water heater. A shut-off switch should be located at the
boiler/water heater. The boiler/water heater must be
grounded in accordance with the authority having
jurisdiction, or if none, the latest revision of the National
Electrical Code, ANSI/NFPA-70.

Line voltage field wiring of any controls or other devices
must conform to the temperature limitation of type T wire
at 95°F, 35°C above room temperature. Use copper
conductors with a minimum size of #14 awg.

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

Open the system bleed and drain valves, one at a time,
to purge the air trapped in the heating system piping.

With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed
valves. If strainers are used in the system piping, the
make-up water valve should be closed and the strainers
checked and cleaned.

The system expansion tank should be checked to
ensure that the correct water level in the tank is
maintained. The tank should be less than half full
of water with the system full and adjusted to the correct
operating pressure.

Start the boiler as described in the “OPERATING
INSTRUCTIONS” section. Run the boiler for at least an
hour. The system pump(s) and all radiation units must
be operated during this time. Ensure that the make-up
water valve is open.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 22

Shut the boiler off and open the bleed valves to purge
the air trapped in the heating system piping. Close the
make-up water valve and check and clean the strainers
and make-up water pressure reducing valve.

Open the make-up water valve and adjust the system
pressure if necessary. The system should be checked
and bled after three days of operation.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do
the pilot by hand.

Cet appareil est muni d’un dispositif d’allumage qui
allume automatiquement la veilleuse. Ne tentez pas
d’allumer la veilleuse manuellement.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and will
settle on the floor.

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

Propane gas can ignite or explode if an ignition
source is present and result in death, serious
injury and property damage!

FOR YOUR SAFETY

•Have only qualified licensed professionals install,
service and maintain this appliance and your gas
system in accordance with all applicable codes.

•Install a nationally listed combustible gas
detector(s) in your home.

•If you suspect a leak:

1. Have everyone leave the building immediately.

2. Do not attempt to light any appliance.

3. Do not touch any electrical or electronic switches
in the building.

4. Do not use any phone in the building.

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

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

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

not

try to light

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment.

• Appelez immédiatement votre fournisseur de gaz
depuis un voisin. Suives les instructions du
fournisseur.

• Si vous ne pouvez rejoindre le fournisseur, appelez
le service de incendies.

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

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

N’utilisez pas cet appareil s’il a été plongé dans
l’eau, même partiellement. Faites inspecter
l’appareil par un tecnicien qualifié et remplacez
toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.

CAUTION: To prevent being burned, stand clear of
the boiler during ignition and do not touch any hot
metal parts!

OPERATING INSTRUCTIONS

1.

STOP!

Read the safety information above. If, at any
time, the appliance will not operate properly, follow
the instructions “TO TURN OFF GAS TO
APPLIANCE.”

2. Set the operating control or thermostat to off or its
lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do
the pilot by hand.

5. Close the manual main and pilot gas shut-off valves.

6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas,

STOP!

above. If you don’t smell gas go to next step.

7. Connect a manometer having a minimum capacity of
20 in,
gas valve. Make sure that the gas supply piping has
been purged of air and that all gas joints up to the gas
valve have been thoroughly checked for leaks.

8. Open the manual pilot valve.

9. Turn on all electric power to the boiler.

10. Set the operating control or thermostat to the
desired setting.

11. The pilot(s) should automatically light. Do not try to
light the pilot(s) by hand!

12. With the pilot(s) lit, open the main gas shut-off valve.

13. The burners should light with proper boiler
operation.

14. The pilot and manifold pressures should match
those listed in Table 10. To adjust the manifold gas
pressure see the
instructions in the
section.

Follow “B” in the safety information

508 mm

W.C. to the outlet pressure port of the

Gas Pressure Adjustment

“CHECKING AND ADJUSTMENTS”

not

try to light

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 23

Required Gas Pressure

Provide gas supply pressure at inlet to boiler gas train
as follows:

LP Nat
Minimum (in W.C.) 11 6
Maximum (in W.C.) 14 14

Measure pressure when the boiler is firing at full rate.
Low gas pressure could indicate undersized gas line or
insufficient gas supply.

"Static and operating gas pressure required at the gas
valve inlet is between 6" W.C. and 14" W.C. for natural
gas and 11" W.C. and 14" W.C. for propane. If the gas
pressure is above this limit, a lock-up style regulator
suitable for dead end service such as an Equimeter
or Fisher must be installed to prevent increase (creep)
of gas pressure when the units are not operating.
This pressure regulator (supplied by others) may be
installed at the service entrance to each unit or a
"master" regulator sized to handle multiple units may
be utilized. Consult local gas utility or regulator
manufacturer for recommendations to meet specific job
site requirements."

Table 10 - Pilot & Manifold Settings

inches W.C.

Natural 3.5 (± .2)
Propane 10 (± .2)

mm W.C.

89 (± 5)

254 (± 5)

Instructions De Mise En Marche

1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.

2. Réglez le thermostat à la température la plus basse.

3. Coupez l’alimentation électrique de l’appareil.

4. Cet appareil est muni d’un dispositif d’allumage qui
allume automatiquement la veilleuse. Ne tentez pas
d’allumer la veilleuse manuellement.

5.

Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

6. Attendre cinq (5) minutes pour laisser échapper tout
le gaz. Reniflez tout autour de l’appareil, y compris
près du plancher, pour déceler une odeur de gaz.
Si vous sentez une odeur de gaz, ARRÊTEZ!
Passez à l’étape B des instructions de sécurité sur
la portion supérieure de cette étiquette. S’il n’y a pas
d’odeur de gaz, passez à l’étape suivante.

7.

Ouver la vanne manuelle d’arrêt d’alimintation de gaz.

8. Mettez l’appareil sous tension.

9. Réglez le thermostat à la température désirée.

10. Si l’appareil ne se met pas en marche, suivez les
instructions intitulées «Comment couper l’admission
de gaz de l’appareil» et appelez un technicien
qualifié ou le fournisseur de gaz.

To Turn Off Gas To Appliance

1. Set the operating control or thermostat to its lowest
setting.

2. Turn off all electric power to the appliance if service
is to be performed.

3. Close the manual main and pilot gas shut-off valves.

COUPER L’ADMISSION DE GAZ DE L’APAREIL

1. Réglez le thermostat à la température la plus basse.

2. Coupez l’alimentation électrique de l’appareil s’il faut
procéder à l’entretien.

3.

Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

CHECKING & ADJUSTMENTS

1. With the burners in operation, close the manual
shutoff valve in the gas supply line. As soon as the
main burner flames go out, open the manual shutoff
valve. A normal ignition sequence should take place.
If the burners fail to light, the system will make one
more ignition attempt. If the burners have not lit after
the last ignition try, the gas valve will close and the
system will go into lock out on CSD-1 units or
continuous retry. DO NOT attempt to reset the
system until the ignition system has been inspected
and the problem resolved. The pilot and manifold
pressures should match those listed in Table 10.

2. With the burners in operation, interrupt the power
to the control circuit by lowering the operating
control or thermostat. The main burners should go
out. Reset the operating control or thermostat, a
normal ignition sequence should follow.

3. To test the ignition safety shutoff device, close the
manual shutoff valve in the gas supply line. Within
5 seconds of main burner flame extinction, the main
gas valve solenoid should close with an audible
noise.

4. A sparking noise should be heard while the ignition
module tries to relight the pilot. After 15 seconds the
module should lockout and the trial for ignition end.
After 5 minutes a second trial for ignition should
occur. Open the manual shutoff valve in the gas
supply line and reset the ignition control system. A
normal ignition sequence should take place.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 24

Pilot Adjustment

The pilot burner flame should envelope 3/8" to 1/2" of
the flame sensing probe, Figure 13. To adjust the pilot
the following steps must be taken:

1. Remove the pilot gas pressure regulator cap.

2. Turn the pressure regulator adjustment screw clock­wise to increase the flame and counterclockwise to
decrease it.

3. Replace the pressure regulator adjustment screw
cap.

Figure 13 - Pilot Flame Adjustment

SCREWS

BRASS FERULE

1/4" TUBING

Gas Pressure Adjustment

CAUTION: The maximum inlet gas pressure listed on
the rating plate must not be exceeded or damage
to the boiler/water heater may occur voiding the
warranty!

The minimum supply pressure listed on the rating plate
is for input adjustment.

NATURAL GAS: Optimum results are obtained when the
boiler/water heater is operated with the manifold
pressure(s) set per Table 10. The manifold pressure
should not vary outside this range. The gas valve
pressure regulator has been preset at the factory. If
adjustment is necessary the following steps must be
followed:

1. Attach a 20 in,

508 mm

W.C. manometer to the tap

on the manifold.

2. Remove the regulator adjustment screw cap from
the gas regulator. On systems that do not use a
separate gas regulator, remove the adjustment
screw cap from the gas valve body on the valve
closest to the gas supply piping.

3. Rotate the regulator adjustment screw clockwise to
increase the manifold pressure, counterclockwise to
decrease it.

4. Replace the regulator adjustment screw cap and
manifold pressure tap plug.

PROPANE GAS: Optimum results are obtained when
the boiler/water heater is operated with the manifold
pressure(s) set per Table 10. If the manifold pressure is
off by more than 5% adjust it according to steps 1
through 4 above.

Input Rate, Natural Gas

Gas appliances are rated based on sea level operation
with no adjustment required at elevations up to 2000 ft.,

610 m

. At elevations above 2000 ft,

610 m

input ratings

should be reduced by 4% for each additional 1000 ft,

305 m

.

Check the input rate as follows:

1. Turn off all other gas appliances that use the same
gas meter as the boiler/water heater.

2. Call your gas supplier and ask for the heating value
of the gas.

3. Start the boiler/water heater and let it run for 15
minutes.

4. Using the gas meter and a stopwatch, clock the time
that it takes to burn 10 ft3,

0.28m3

of gas and divide

this time by 10.

5. Insert the heating value and the time, in seconds,
into the formula below.

6. Input = (heating value, Btu/hr)(3600)/(time, seconds)

7. If the computed rate deviates by more than 5% from
the rated input value of the unit adjust the manifold
pressure accordingly. DO NOT adjust the manifold
pressure by more than 5%. If a proper rate cannot
be maintained without adjusting the manifold
pressure beyond the 5% limit, the main burner
orifices must be replaced. If the input rate is too low,
go to the next larger size of main burner orifices. If
the input rate is too high, go to the next smaller size.

CAUTION: Never increase the input to the boiler/
water heater above that for which it is rated. Doing
so can cause premature failure of the unit!

CAUTION: Never force the regulator adjustment
screw beyond the stop limits or damage to the
regulator will occur!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 25

CONTROL DESCRIPTION

Boiler Thermostat

If a thermostat is to be used to control the boiler always
follow the instructions included with the thermostat.
Proper location of the thermostat will ensure efficient
trouble-free operation of the boiler. Mount the thermostat
to an inside wall at a height approximately five feet
above the floor.

Avoid placing the thermostat in areas that will not
provide an accurate measurement of the room
temperature. Locating the thermostat behind a door, in
an alcove, close to a source of thermal radiation or in a
drafty area will cause poor or sporadic heating.

For a thermostat that employs an adjustable heat
anticipator, adjust the anticipator to match the current
measured in the thermostat circuit. An increased
anticipator setting may be necessary if the unit cycles
frequently. If the room temperature over-shoots the
thermostat setting, reduce the anticipator setting.

Operating Control

The preferred control setting for potable hot water is
130°F, 54°C. The operating control should be set to the
lowest setting that will satisfy the consumer's needs.

High Limit (Aquastat)

The high limit is located in the top control area of the
boiler/water heater. A remote capillary bulb is run to a
well on the outlet side of the supply header. The high
limit can be reset by depressing the black rubber plug
in the front top jacket panel.

The water heater high limit should be set a minimum of
20°F, 11°C higher than the operating control. Refer to
the HOT WATER SUPPLY section for the proper supply
water temperature.

Flow Switch

A flow switch is provided in the water outlet piping to
prevent the boiler/water heater from firing without
adequate water flow through the heat exchanger.

Low Water Cutoff

If the boiler is to be installed above radiation or if
required by other codes or regulations, install a low
water cutoff in appropriate piping. Wire the switch and
any external controls in series to the "Interlock" contacts
in the junction box (see the attached Connection
Diagrams for details). Ensure that the low water cutoff
device(s) will function properly.

WARNING: Setting the thermostat or operation
control too high can result in scalding resulting
in severe personal injury!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 26

MAINTENANCE

WARNING: Disconnect electrical power and
close the manual gas shut off valve before
performing maintenance or severe personal
injury may result!

WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause
property damage, personal injury, exposure to
hazardous materials or loss of life. Installation
and service must be performed by a qualified
installer, service agency or the gas supplier who
must read and follow the supplied instructions
before installing, servicing or removing this
boiler. This boiler contains crystalline silica
materials that have been identified as
carcinogenic or possibly carcinogenic to
humans when inhaled.

AVERTISSMENT: Une instqallation, un réglage,
une réparation ou un entretien non comforme
aux normes peut entraîner des dommages
matériels, des blessures,exposition à des
matiéres dangereuses ou la mort. L’installation
et l’entretien doivent être effectués par un
installateur ou un service d’entretien qualifié ou
le foumisseur de gaz qui doivent avoir lu les
instructions foumies avant de faire l’installation,
l’entretien ou l’enlèvement de la chaudière et les
respecter, Cette chaudière contient des
matériaux qui ont été identifiés comme étant
cancérogènes ou pouvant l’être.

CAUTION: Servicing, inspection and adjustment
must be done by a trained technician in accordance
with all applicable local and national codes.
Improper servicing or adjustment can damage the
boiler /water heater!

The boiler/water heater should be cleaned and inspected
once a year and before each heating season. Make sure
that the burner and ignition components are free from
dust, soot, dirt, corrosion or other deposits that would
impair the boiler/water heater’s performance. Refer to
page 30 (8900) or page 39 (8800) for component
identification.

Combustion Chamber Inspection

1. Remove the left or right lower jacket end panel, item
5 or 24 (8900) or item 5 or 24 (8800).

2. Remove the upper end refractory brackets and
carefully remove the end refractory panel.

3. Inspect the combustion chamber, heat exchanger
and burner tray components for sign of corrosion
and/or deterioration.

4. Clean or replace components as required.

CAUTION: Improper burner servicing can result in
premature burner failure voiding the warranty.

Burner Drawer & Burner Removal

1. Close the manual shutoff valves in the gas supply
lines and turn off electrical power to the boiler/water
heater.

2. Disconnect the gas train from the gas supply piping
at the ground joint union, Figure 12.

3. Remove the flame roll-out shield, 8900 only.

4. Remove the two bolts that attach the burner drawer
to the base frame.

5. Disconnect the pilot tubing from the solenoid valve
and the ignition lead from the ignition control.

6. Pull the burner drawer out until the burners are fully
exposed.

7. Inspect each burner for damage or signs of
deterioration. Use a brush or compressed air to
remove any debris from the burner ports.

8. DO NOT install damaged or badly corroded burners,
replace them.

9. Install the burners making sure that they are
properly seated in the burner drawer.

10. Replace the burner drawer and flame roll out shield,
8900 only, following the removal steps in reverse
order.

Heat Exchanger Inspection & Cleaning

1. Close the shut off valves in the inlet and outlet
piping. Relieve the system pressure from the boiler
by carefully lifting the relief valve or opening the
drain valve.

2. Disconnect the boiler/water heater from the system
piping.

3. Remove the left and right headers and mounting
studs.

4. Remove the left & right upper and left & right lower
jacket end panels, items 5 & 24 (8900) or items 5
& 24 (8800).

5. Remove the left & right front corner trim panels,

8900.

6. Remove the flue collector front panel.

7. Remove the upper front refractory channel
assembly and front refractory panels.

8. Slide the heat exchanger out and thoroughly
inspect it.

9. The outside surfaces of the copper tubes should be
free of any soot deposits. A slight black smudge is
normal with some types of gases. Black soot
indicates poor combustion. Green deposits indicate
condensation due to low return water temperatures.
In either case the heat exchanger must be cleaned
thoroughly with water and the problem resolved
before the boiler/water heater is returned to service.

10. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 27

Heat Exchanger Replacement

1. Sagging or distorted heat exchanger tubes are an
indication of low water flow through the system.

2. A damaged heat exchanger must be replaced and
the condition that caused the damage resolved
before the boiler/water heater is returned to service.

Vent System

Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage. Immediately replace any
unsound vent system piping.

Controls

Use the “GENERAL OPERATION” and “CHECKING
AND ADJUSTMENTS” sections of this manual for
reference.

1. Check the thermostat or operating controls for
proper operation.

2. A float type low water cutoff device must be flushed
out per the manufacturers’ instructions. The probe
on a probe low water cut off must be removed,
cleaned and inspected at least once a year. Ensure
that the low water cutoff operate properly. If not,
replace them.

3. The flow switch contacts must be open when water
flow is not present.

4. The relief valve should not weep or discharge water
at normal system pressure. If it does contact a
qualified service technician to have it inspected.
NEVER try to clean or repair the relief valve! If the
valve fails to operate properly, have it replaced!

5. The aquastat high limit controls the maximum
water temperature in the boiler and should be 20°F,

11°C

above set point temperature. If the water
temperature reaches the set temperature before
the demand for heat has been met, the aquastat
high limit should shut the boiler off. The water
temperature should never exceed the maximum
set point of 240°F,

116 °C

. The aquastat high limit
cannot be repaired. If it fails to function properly,
replace it.

6. Visually check the pilot and main burner flames to
ensure proper operation, see Figures 13 & 14.

WARNING: A yellow, floating flame indicates a
lack of combustion air. A lifting flame indicates
too much combustion air. Do not operate the
boiler/water heater until the problem is solved
or severe personal injury or death may occur!

Figure 14 - Main Burner Flames

NORMAL

(HARD FLAME)

LIFTING

(TOO MUCH AIR)

YELLOW TIPPING

(MARGINAL)

YELLOW FLAME

(TOO LITTLE AIR)

RIOM-49

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 28

TROUBLE-SHOOTING FLOW CHART FOR HONEYWELL
OR UTC IGNITION MODULE (24V CONTROL SYSTEM)

Proper line voltage

L1 to L2 on heater

terminal strip

24V on secondary

terminals of heater

transformer

24V across 24V and 24V

(GND) terminals of

ignition module

On application of 24V,

control produces audible

spark at pilot

Pilot

Ignites

Adjust the pilot gas

pressure using the

pilot regulator. Pilot

ignition problems

can be caused by

high or low pilot

pressure.

Pilot ignites

Check for tripped breaker or open safety

/ limit switch in supply voltage circuit.

Check for broken or loose

connection to transformer, if none

replace transformer.

Check for open limit in this 24V circuit
operating control, high limit, flow switch,
LWCO, high / low gas pressure switches,

remote operating controls, etc.

Check for loose or broken ignition lead. Check for shorted pilot electrode.

If pilot and ignition lead test good replace module.

During pilot ignition period (audible spark present) check

for 24V between PV and MV/PV terminals of module.

24V at pilot gas

valve leads

A tripped manual reset

high limit may

indicate insufficient

water flow.

Check for loose or

broken wire between

pilot valve and

PV-MV/PV terminals.

Replace
module.

Main Flame

Ignites

Manifold pressure in proper

range (3.5”-4.2” N.G.,

10”-11” L.P.). If no pressure on

manifold, during main flame
trial for ignition period, check
for pressure at tappings of each

main valve. Replace valve

that shows no pressure at

downstream tapping while

powered with pressure at

upstream tapping.

With pilot lit: 24V

between the MV and

MV/PV terminals of

the module

24V at terminals of

all valves in main

gas train

Pilot valve opens.

Confirm that gas is

present at pilot valve

inlet.

Insure pilot line and

pilot orifice are clear

and that the pilot is

undamaged. The pilot

ignites.

Check for loose or

broken wire between

MV-MV/PV terminals.

Replace pilot solenoid

valve.

Replace the pilot

assembly.

Replace
module.

main valves and

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 29

Trouble-Shooting

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Boiler Pounds or Knocks Low or no water flow Ensure that pump is operating

properly - look for voltage through
flow switch.

Ensure that all system valves are
open.

Ensure that all air has been bled
from the system.

Ensure that maximum temperature
rise of 35°F, 19°C has not been
exceeded.

Low or no system pressure Ensure that water makeup valve is

open and functioning.

Heat exchanger blocked Remove return header and inspect

the heat exchanger tubes.

Relief Valve Leaks System pressure too high Ensure relief valve is properly sized

for the system - never exceed
160 psi.

Expansion tank is waterlogged Ensure expansion tank is properly

sized for the system.

Expansion tank is isolated Ensure valve between expansion

tank and system is open.

Sooting of Heat Exchanger Return water temperature to low Adjust balancing valves for a

minimum return water temperature
of 110°F,

Inadequate combustion air Ensure that the make up air supply

is adequate per NFPA 54/ANSI
Z223.

Ensure that the vent system is sized
properly, is not blocked or restricted
and that there is adequate draft

present in the breeching.
Rated input has been exceeded Ensure that the input rate is correct.
Incorrect fuel type Ensure that the fuel type supplied

matches the rating plate.

43 °C.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 30

PARTS LIST (MODELS 420-1900)

36

33

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 31

SERVICE AND REPLACEMENT PARTS LIST (MODELS 420-1900)

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

1 Jacket Lower Front Panel 03-0077 1

2 Jacket Lower Rear Panel 03-0061 1

3, 4, LH Upper Rear Corner Post 03-0107 111111111111111

25, 26 RH Upper Rear Corner Post 03-0108 111111111111111

LH Upper Front Corner Post 03-0109 111111111111111
RH Upper Front Corner Post 03-0110 111111111111111
LH Lower Rear Corner Post 03-0111 111111111111111
RH Lower Rear Corner Post 03-0112 111111111111111
LH Lower Front Corner Post 03-0113 111111111111111
RH Lower Front Corner Post 03-0114 111111111111111

5, 24 Jacket End Panels (Upper/Lower) 72-0016 111111111111111

6 Inlet/Outlet Header, Cast Iron

Inlet/Outlet Header, Bronze
Inlet/Outlet Header, Cast Iron (Mod)
Inlet/Outlet Header, Bronze (Mod)

7 Return Header, Cast Iron

Return Header, Bronze

8 O Ring, Inlet/Outlet & Return Headers 06-0001 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16
NS Stud, Inlet/Outlet & Return Headers 57-0225 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
NS Nut, Inlet/Outlet & Return Headers 57-0491 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

03-0078 1
03-0079 1
03-0080 1
03-0081 1
03-0082 1
03-0083 1
03-0084 1
03-0085 1
03-0086 1
03-0087 1
03-0088 1
03-0089 1
03-0090 1
03-0091 1

03-0062 1
03-0063 1
03-0064 1
03-0065 1
03-0066 1
03-0067 1
03-0068 1
03-0069 1
03-0070 1
03-0071 1
03-0072 1
03-0073 1
03-0074 1
03-0075 1

01-0001S

01-0003S
01-0001M
01-0003M

01-0002S

01-0004S

111111111111111
111111111111111
111111111111111
111111111111111
111111111111111
111111111111111

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 32

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

12 Base Frame Assembly 70-0192 1

NS Heat Shield 70-0482 1

13, 13a Burner Tube 10-0277 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35

Burner Tube w/Bracket 70-0635 1 11111111111111

NS Burner Spacers 70-0363 1

14 Union, 1" 53-0054 1 11111

Union, 1 1/4" 53-0055 1111111
Union, 1 1/2" 53-0056 1 1

15 Firing Valve, 3/4" 11-0461 1* 1* 1* 1*

Firing Valve, 1" 11-0456 1 1 1 1 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2*
Firing Valve, 1 1/4" 11-0457 1111111
Firing Valve, 1 1/2" 11-0458 1 1

NS Main Gas Valve, V88A, 1" 11-0156 1 11111

Main Gas Valve, V88A, 1 1/4" 11-0157 1111111
Main Gas Valve, V88A, 1 1/2" 11-0158 1 1

16 Main Gas Valve, V8944B, 1" 11-0171 1 1 1 1 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2*

Main Gas Valve, V8944B, 1 1/4" 11-0172 1111111
Main Gas Valve, V8944B, 1 1/2" 11-0173 1 1

*4 Stage Only

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

70-0193 1
70-0194 1
70-0195 1
70-0196 1
70-0197 1
70-0198 1
70-0199 1
70-0200 1
70-0201 1
70-0202 1
70-0203 1
70-0204 1
70-0205 1
70-0206 1

70-0483 1
70-0484 1
70-0485 1
70-0486 1
70-0487 1
70-0488 1
70-0489 1
70-0490 1
70-0491 1
70-0492 1
70-0493 1
70-0494 1
70-0495 1
70-0496 1

70-0364 1
70-0365 1
70-0366 1
70-0367 1
70-0368 1
70-0369 1
70-0370 1
70-0371 1
70-0372 1
70-0373 1
70-0374 1
70-0375 1
70-0376 1
70-0377 1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 33

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

NS Valve Body, V5055B, 1" (Mod) 11-0251 1 11111

Valve Body, V5055B, 1 1/4" (Mod) 11-0252 1111111
Valve Body, V5055B, 1 1/2" (Mod) 11-0253 1 1
Valve Actuator, V9055A, (Mod) 11-0303 1 11111111111111

NS Main Gas Valve, V48A, 1", 120V 11-0151 1 11111

Main Gas Valve, V48A, 1 1/4", 120V 11-0152 1111111
Main Gas Valve, V48A, 1 1/2", 120V 11-0153 1 1
Main Gas Valve, V4944B, 1", 120V 11-0166 1 11111
Main Gas Valve, V4944B, 1 1/4", 120V 11-0167 1111111
Main Gas Valve, V4944B, 1 1/2", 120V 11-0168 1 1

17 "A" Valve, 1" 11-0465 1 11111

"A" Valve, 1 1/4" 11-0466 1111111

"A" Valve, 1 1/2" 11-0467 1 1
NS Bracket Refractory Upper End 03-0306 2 22222222222222
NS Bracket Refractory Lower End 03-0307 2 22222222222222

18 End Refractory Panel, Left & Right 05-0001 2 22222222222222
19 Center Refractory Panel 05-0002 2

20 Corner Refractory Panel 05-0005 4

18, 19, 20

Tile Kit

NS Bracket Refractory Front/Rear 03-0308 2 23334455566677

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

05-0003 2
05-0004 2222444666

05-0006 4
05-0007 4
05-0008 4
05-0009 4
05-0010 4
05-0011 4
05-0012 4
05-0013 4
05-0014 4
05-0015 4
05-0016 4

05-0017 4
70-0226K
70-0227K
70-0228K
70-0229K
70-0230K
70-0231K
70-0232K
70-0233K
70-0234K
70-0235K
70-0236K
70-0237K
70-0238K
70-0239K
70-0240K

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 34

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

NS Upper Front Refractory Channel 70-0177 1

NS Upper Rear Refractory Channel 70-0162 1

21 Draft Diverter Top Panel Assembly 70-0030 1

21a

Draft Diverter Top Panel Assembly (Dual Flue)

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

70-0178 1

70-0179 1

70-0180 1

70-0181 1

70-0182 1

70-0183 1

70-0184 1

70-0185 1

70-0186 1

70-0187 1

70-0188 1

70-0189 1

70-0190 1

70-0191 1

70-0163 1

70-0164 1

70-0165 1

70-0166 1

70-0167 1

70-0168 1

70-0169 1

70-0170 1

70-0171 1

70-0172 1

70-0173 1

70-0174 1

70-0175 1

70-0176 1

70-0031 1

70-0032 1

70-0033 1

70-0034 1

70-0035 1

70-0036 1

70-0037 1

70-0038 1

70-0039 1

70-0040 1

70-0041 1

70-0042 1

70-0043 1

70-0044 1

70-0045 1

70-0046 1

70-0047 1

70-0048 1

70-0049 1

70-0050 1

70-0051 1

70-0052 1

70-0053 1

70-0054 1

70-0055 1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 35

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

22 Jacket Upper Front Panel 03-0043 1

27 Jacket Top Panel 03-0001 1

27a Jacket Top Panel (Dual Flue) 03-0016 1

28 Jacket Upper Rear Panel 03-0027 1

29 Burner Drawer Side Rail Assy, Left & Right 70-0362 2 22222222222222

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

03-0044 1

03-0045 1

03-0046 1

03-0047 1

03-0048 1

03-0049 1

03-0050 1

03-0051 1

03-0052 1

03-0053 1

03-0054 1

03-0055 1

03-0056 1

03-0057 1

03-0002 1

03-0003 1

03-0004 1

03-0005 1

03-0006 1

03-0007 1

03-0008 1

03-0009 1

03-0010 1

03-0011 1

03-0012 1

03-0013 1

03-0014 1

03-0015 1

03-0017 1

03-0018 1

03-0019 1

03-0020 1

03-0021 1

03-0022 1

03-0023 1

03-0024 1

03-0025 1

03-0026 1

03-0028 1

03-0029 1

03-0030 1

03-0031 1

03-0032 1

03-0033 1

03-0034 1

03-0035 1

03-0036 1

03-0037 1

03-0038 1

03-0039 1

03-0040 1

03-0041 1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 36

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

NS Heat Exchanger Assembly (Copper) 70-0072 1

NS Heat Exchanger Assembly (Cupronickel) 70-0087 1

NS Heat Exchanger Assembly (Copper) 70-0102 1

NS Heat Exchanger Assembly (Cupronickel) 70-0117 1

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

70-0073 1

70-0074 1

70-0075 1

70-0076 1

70-0077 1

70-0078 1

70-0079 1

70-0080 1

70-0081 1

70-0082 1

70-0083 1

70-0084 1

70-0085 1

70-0086 1

70-0088 1

70-0089 1

70-0090 1

70-0091 1

70-0092 1

70-0093 1

70-0094 1

70-0095 1

70-0096 1

70-0097 1

70-0098 1

70-0099 1

70-0100 1

70-0101 1

70-0103 1

70-0104 1

70-0105 1

70-0106 1

70-0107 1

70-0108 1

70-0109 1

70-0110 1

70-0111 1

70-0112 1

70-0113 1

70-0114 1

70-0115 1

70-0116 1

70-0118 1

70-0119 1

70-0120 1

70-0121 1

70-0122 1

70-0123 1

70-0124 1

70-0125 1

70-0126 1

70-0127 1

70-0128 1

70-0129 1

70-0130 1

70-0131 1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 37

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

30 Tube Bundle (Copper) 70-0132 1

30 Tube Bundle (Cupronickel) 70-0147 1

31 Main Gas Pressure Regulator, RV61, 1" 11-0501 1 11111

Main Gas Pressure Regulator, RV81, 1 1/4" 11-0042 1111111
Main Gas Pressure Regulator, RV81, 1 1/2" 11-0503 1 1

32 Ignitor, PSE-NA29 70-9013 1 11111111111111

Ignitor, PSE-NA185 70-9014 1 11111111111111
Ignitor, PSE-NA29, LP 70-0631 1 11111111111111
Ignitor, PSE-NA185, LP 70-0632 1 11111111111111

33 Solenoid Valve w/Regulator, NG, 24V 11-0373 1 11111111111111

Solenoid Valve w/Regulator, LP, 24V 11-0375 1 11111111111111
Solenoid Valve w/Regulator, NG, 120V 11-0372 1 11111111111111
Solenoid Valve w/Regulator, LP, 120V 11-0374 1 11111111111111

NS Pilot Valve, H91WG, 24V (prior to 0905) 11-0017 1 11111111111111

Pilot Valve, V4046C, 120V (prior to 0905) 11-0016 1 11111111111111

NS Pilot Regulator, RV12LT (prior to 0905) 11-0041 1 11111111111111

35 Manual Pilot "B" Valve 11-0031 1 11111111111111
36 Ignition Module, S8610M 16-0054 1 11111111111111

Ignition Module, UTC 1003 (CSD-1 Only) 16-0058 1 11111111111111

Alarm Board, (CSD-1) 16-0023 1 11111111111111
NS BTC 4 Stage 14-0307 1 11111111111111
NS Ignition Module, RM7890A 16-0001 1 11111111111111
NS Keyboard Display Module, S7800A 16-0010 1 11111111111111
NS Amplifier, R7847A 16-0005 1 11111111111111
NS UV Amplifier, R7849A 16-0006 1 11111111111111
NS Spark Generator, Q652B 16-0008 1 11111111111111
NS Ignition Cable Assembly 120V 16-0201 1 11111111111111

37 Transformer, 40VA 15-0002 1 11111111111111
NS Rocker Switch 48-0001 1 11111111111111
NS Relay, 24V AC 15-0113 1 11111111111111
NS Fan Manager, ST82B 15-0101 1 11111111111111
NS Pump Contactor 1PH 15-0118 1 11111111111111

Pump Contactor 3PH 15-0111 1 11111111111111

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

70-0133 1
70-0134 1
70-0135 1
70-0136 1
70-0137 1
70-0138 1
70-0139 1
70-0140 1
70-0141 1
70-0142 1
70-0143 1
70-0144 1
70-0145 1
70-0146 1

70-0148 1
70-0149 1
70-0150 1
70-0151 1
70-0152 1
70-0153 1
70-0154 1
70-0155 1
70-0156 1
70-0157 1
70-0158 1
70-0159 1
70-0160 1
70-0161 1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 38

8900 8900 Model Size with Item Quantities Below

Ref # Name of Part

NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 11111111111111
NS High Gas Pressure Switch (Manual Reset) 11-0411 1 11111111111111
NS Terminal Block 2P 48-0151 1 11111111111111
NS Terminal Block 6P 48-0157 1 11111111111111

38 High Limit, L4008E, (HB) 14-0112 1 11111111111111

High Limit, L4008E, (HW) 14-0105 1 11111111111111
39 High Limit Well, 3/8 x 3 3/16 13-0105 1 11111111111111
40 Operator, L4008A,(HB), On/Off 14-0102 1 11111111111111

Operator, L6008A, (HW) 14-0106 1 11111111111111

Operator, L6008G, (2 stage) 14-0107 1 11111111111111

Operator, T991E, (HB) 14-0108 1 11111111111111

Operator, T991E, (HW) 14-0110 1 11111111111111

Operator, T6031A, (pool heaters) 14-0003 1 11111111111111
41 Orifice, #29, NG 10-0016 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #30 (2,000' - 3,999'), NG 10-0017 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #31 (4,000' - 5,999'), NG 10-0018 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #32 (6,000' - 7,999'), NG 10-0019 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #47, LP 10-0009 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #49 (2,000' - 3,999'), LP 10-0010 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #51 (4,000' - 5,999'), LP 10-0099 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Orifice, #52 (6,000' - 7,999'), LP 10-0100 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

NS Pressure Relief Valve 50# 30-0360 1 1111111

Pressure Relief Valve 50# 30-0374 11111

Pressure Relief Valve 50# 30-0379 1 1

NS Pressure Relief Valve 125# 30-0364 1 11111111111111
NS Tridicator 13-0308 1 11111111111111
NS Thermometer 13-0302 1 11111111111111

42 Thermometer Well, 3/8 x 2 5/8 13-0103 1 11111111111111

NS Thermometer w/well 13-0320 1 11111111111111
NS Flow Switch 14-0203 1 11111111111111

Flow Switch (Potter) 14-0201 1 11111111111111

NS Rating Plate 82-0054 1 11111111111111
NS Paint 66-0013 1 11111111111111
NS Induced Draft Kit, HS2

Induced Draft Kit, HS3

Induced Draft Kit, HS4

Induced Draft Kit, HS5

NS Vent Termination Hood 6" 09-0112 1 1

Vent Termination Hood 8" 09-0113 111111

Vent Termination Hood 10" 09-0115 1111111

Part # 420 530 630 735 840 950 1050 1160 1260 1370 1470 1580 1685 1790 1900

12-0010EK
12-0001FK
12-0001GK
12-0002DK

11

1

11111

1111111

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 39

PARTS LIST (MODELS 2000-4000)

21

19

18

22

25

7

36

33

42

39

3086

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 40

SERVICE AND REPLACEMENT PARTS LIST (MODELS 2000-4000)

8800 8800 Model Size with Item Quantities Below

Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000

1 Jacket Lower Front Panel 03-1077 1

2 Jacket Lower Rear Panel 03-1071 1

3, 4, LH Upper Rear Corner Post 03-1084 111111

25, 26 RH Upper Rear Corner Post 03-1085 111111

LH Upper Front Corner Post 03-1086 111111

RH Upper Front Corner Post 03-1087 111111

LH Lower Rear Corner Post 03-1088 111111

RH Lower Rear Corner Post 03-1089 111111

LH Upper Rear Corner Post 03-1090 111111

RH Upper Rear Corner Post 03-1091 111111

5, 24 Jacket End Panels (Upper/Lower) 72-0051 111111

6 Inlet/Outlet Header, Bronze

NS Inlet/Outlet Header, Bronze (Mod)

7 Return Header, Bronze

NS Return Header, Bronze (Mod)

8 O Ring, Inlet/Outlet & Return Headers 06-0001 32 32 32 32 32 32
NS Stud, Inlet/Outlet & Return Headers 57-0226 24 24 24 24 24 24
NS Nut, Inlet/Outlet & Return Headers 57-0492 24 24 24 24 24 24
NS Heat Exchanger "V" Baffle 03-1147 15

12 Base Frame Assembly 70-1708 1

NS Heat Shield 70-1733 2

13, 13a Burner Tube, Aluminized Steel 10-0256 19 23 27 30 34 38

Burner Tube, Aluminized w/ Bracket 70-1851 111222
Burner Tube, Stainless Steel 10-0258 19 23 27 30 34 38
Burner Tube, Stainless w/ Bracket 70-1852 111222

14 Union, 1 1/2" 53-0056 1

Union, 2" 53-0057 1 1 1
Union, 2 1/2" 53-0058 1 1

15 Firing Valve, 1 1/4" 11-0457 2* 2

Firing Valve, 1 1/2" 11-0458 1 2* 2* 2 2
Firing Valve, 2" 11-0459 1 1
Firing Valve, 2 1/2" (FM Only) 11-0460 1 1

16 Main Gas Valve, V8944B, 1 1/4" 11-0172 2* 2

Main Gas Valve, V8944B, 1 1/2" 11-0173 1 2* 2* 2 2
Main Gas Valve, V8944B, 2" 11-0174 1 1

NS Main Gas Valve, V4944B, 1 1/2", 120V 11-0168 1

Main Gas Valve, V4944B, 2", 120V 11-0169 1 1

*4 Stage Only

03-1078 1
03-1079 1
03-1080 1
03-1081 1
03-1082 1

03-1072 1
03-1073 1
03-1074 1
03-1075 1
03-1076 1

01-0012S

01-0012M

01-0013S

01-0013M

03-1148 30
03-1149 30
03-1150 30
03-1151 30
03-1152 30

70-1709 1
70-1710 1
70-1711 1
70-1712 1
70-1713 1

70-1734 2
70-1735 2
70-1736 1 1
70-1737 1 1
70-1738 1 1

111111
111111
111111
111111

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 41

8800 8800 Model Size with Item Quantities Below

Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000

NS Main Gas Valve, V88A, 1 1/2" 11-0158 1

Main Gas Valve, V88A, 2" 11-0159 12222

NS Main Gas Valve, V48A, 1 1/2", 120V 11-0153 1

Main Gas Valve, V48A, 2", 120V 11-0154 1 2 1
Main Gas Valve, V48A, 2 1/2", 120V 11-0155 1 1

NS Valve Body, V5055A, 1 1/2" 11-0261 1

Valve Body, V5055A, 2" 11-0262 1 2 2
Valve Body, V5055A, 2 1/2" 11-0263 2 2

NS Valve Body, V5055B, 1 1/2", (Mod) 11-0253 1

Valve Body, V5055B, 2", (Mod) 11-0254 1 1 1
Valve Body, V5055B, 2 1/2", (Mod) 11-0255 1 1

NS Valve Actuator, V4055A 11-0308 111111

Valve Actuator, V4055D 11-0311 111111
Valve Actuator, V4062A, (2 Stage) 11-0304 111111
Valve Actuator, V9055A, (Mod) 11-0303 111111
N.O.V.V., V4295S, 3/4" 11-0361 111111

17 "A" Valve, 1 1/2" 11-0467 1

"A" Valve, 2" 11-0454 11111

"A" Valve, 2 1/2" (FM Only) 11-0455 1 1
18 End Refractory Panel, Left & Right 05-0050 222222
19 Center Refractory Panel 853413 4468810
20 Corner Refractory Panel 05-0052 4

18, 19, 20

22, 28 Jacket Upper Front & Rear Panel 03-1064 2

Tile Kit

NS Bracket Refractory Front/Rear 03-0308 334455
NS Upper Front/Rear Refractory Support 03-1155 2

NS Upper Right/Left Refractory Support 03-1161 222222

21 Draft Diverter Top Panel Assembly 70-1666 1

21a Draft Diverter Top Panel Assembly (Dual Flue) 70-1672 1

27 Jacket Top Panel 03-1051 1

05-0053 4
05-0054 4
05-0055 4
05-0056 4

05-0057 4
70-1739K
70-1740K
70-1741K
70-1742K
70-1743K
70-1744K

03-1156 2

03-1157 2

03-1158 2

03-1159 2

03-1160 2

70-1667 1

70-1668 1

70-1669 1

70-1670 1

70-1671 1

70-1673 1

70-1674 1

70-1675 1

70-1676 1

70-1677 1

03-1065 2

03-1066 2

03-1067 2

03-1068 2

03-1069 2

03-1052 1

03-1053 1

03-1054 1

03-1055 1

03-1056 1

1

1

1

1

1

1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 42

8800 8800 Model Size with Item Quantities Below

Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000

27a Jacket Top Panel (Dual Flue) 03-1057 1

03-1058 1

03-1059 1

03-1060 1

03-1061 1

03-1062 1

NS Jacket Top Channel, Left & Right 03-1063 222222

29 Burner Drawer Side Rail Assy, Left 70-1793 111111

Burner Drawer Side Rail Assy, Right 70-1794 111111

NS Tube Bundle (Copper) 70-1696 1

70-1697 1

70-1698 1

70-1699 1

70-1700 1

70-1701 1

Tube Bundle (Cupronickel) 70-1702 1

70-1703 1

70-1704 1

70-1705 1

70-1706 1

70-1707 1

30 Heat Exchanger (Copper) 70-1684 1

70-1685 1

70-1686 1

70-1687 1

70-1688 1

70-1689 1

Heat Exchanger (Cupronickel) 70-1690 1

70-1691 1

70-1692 1

70-1693 1

70-1694 1

70-1695 1

NS 3" Gruvlok Coupling 53-0100 222222

3" x 4" Gruvlok Nipple 53-0300 222222
3" x 4" Gruvlok Nipple, Brass 53-0600 222222

31 Main Gas Pressure Regulator, RV81, 1 1/2" 11-0503 1

Main Gas Pressure Regulator, RV91, 2" 11-0504 1 1 1
Main Gas Pressure Regulator, RV111, 2 1/2" 11-0505 1 1

32 Ignitor, PSE-NA29, NG, 24V 70-9013 111111

Ignitor, PSE-NA185, NG, 120V 70-9014 111111
Ignitor, PSE-NA29, LP, 24V 70-0631 111111
Ignitor, PSE-NA185, LP, 120V 70-0632 111111

33 Solenoid Valve w/Regulator, NG, 24V 11-0373 111111

Solenoid Valve w/Regulator, LP, 24V 11-0375 111111
Solenoid Valve w/Regulator, NG, 120V 11-0372 111111
Solenoid Valve w/Regulator, LP, 120V 11-0374 111111

NS Pilot Valve, 24V (prior to 0905) 11-0017 111111

Pilot Valve, 120V (prior to 0905) 11-0016 111111

NS Pilot Regulator, RV12LT (prior to 0905) 11-0041 111111

35 Manual Pilot "B" Valve 11-0031 111111
NS Spark Generator, Q652B 16-0008 111111
NS Ignition Cable Assembly 16-0201 111111

36 Ignition Module, S8610M 16-0054 111111

Ignition Module, UTC 1003 (CSD-1 Only) 16-0058 111111
NS Alarm Board (CSD-1) 16-0023 111111
NS Ignition Module, RM7890A 16-0001 111111
NS Keyboard Display Module, S7800A 16-0010 111111
NS Amplifier, R7847A 16-0005 111111
NS UV Amplifier, R7849A 16-0006 111111

37 Transformer, 40 VA 15-0002 111111
NS Rocker Switch 48-0001 111111
NS Relay, 24V AC 15-0113 111111
NS Relay, 120V AC 15-0114 111111

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 43

8800 8800 Model Size with Item Quantities Below

Ref # Name Of Part Part # 2000 2400 2800 3200 3600 4000

NS Pump Contactor 1PH 15-0118 111111

Pump Contactor 3PH 15-0111 111111
NS Low Gas Pressure Switch (Manual Reset) 11-0410 111111
NS High Gas Pressure Switch (Manual Reset) 11-0411 111111
NS Terminal Block 2P 48-0151 111111
NS Terminal Block 4P 48-0152 111111
NS Terminal Block 8P 48-0154 111111

38 High Limit, L4008E, (HB) 14-0112 111111

High Limit, L4008E, (HW) 14-0105 111111

39 High Limit Well, 3/8 x 13/16 13-0105 111111
40 Operator, L4008A, (HB), On/Off 14-0102 111111

Operator, L6008A, (HW), On/Off 14-0106 111111

Operator, L6008G, 2 stage 14-0107 111111

Operator, T991E, (HB), Mod 14-0108 111111

Operator, T991E, (HW) Mod 14-0110 111111

Operator, T6031A (pool heater) 14-0003 111111

41 Orifice, #17, NG 10-0014 20 24 28 32 36 40

Orifice, #19 (2,000' - 3,999'), NG 10-0007 20 24 28 32 36 40

Orifice, #22 (4,000' - 5,999'), NG 10-0095 20 24 28 32 36 40

Orifice, #25 (6,000 - 7,999'), NG 10-0097 20 24 28 32 36 40

Orifice, #34, LP 10-0021 20 24 28 32 36 40

Orifice, #37 (2,000' - 3,999'), LP 10-0024 20 24 28 32 36 40

Orifice, #39 (4,000' - 5,999'), LP 10-0026 20 24 28 32 36 40

Orifice, #41 (6,000' - 7,999'), LP 10-0028 20 24 28 32 36 40
NS Pressure Relief Valve 50# 30-0369 1 1

Pressure Relief Valve 50# 30-0382 1 1 1

Pressure Relief Valve 50# 13-0026 1

Pressure Relief Valve 125# 30-0364 1

Pressure Relief Valve 125# 13-0009 1 1 1

Pressure Relief Valve 125# 13-0003 1

Pressure Relief Valve 125# 13-0053 1
NS Tridicator 13-0305 111111
NS Thermometer (HB) 13-0302 111111

Thermometer (HW) 13-0302 222222

42 Thermometer Well, 3/8 x 2 5/8 13-0103 111111
NS Flow Switch 14-0203 111111
NS Flow Switch (Potter) 14-0201 111111
NS Rating Plate 82-0054 111111
NS Paint 66-0013 111111

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 44

MACODE-3

NOTICE!

Commonwealth of Massachusetts

Installation Requirements

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building

or structure used in whole or in part for residential purposes, including those owned or
operated by the commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade, in the area of the venting, including but not limited to
decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard
wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall
observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed
on each additional level of the dwelling, building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of the property owner to secure the
services of qualified licensed professionals for the installation of hard wired carbon monoxide
detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl

space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up
may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion

of installation, the owner shall have a period of thirty (30) days to comply with the above
requirements; provided, however, that during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in
accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed
and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP

CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

WARNING: Improper venting can result in excessive levels of carbon monoxide which
can cause severe personal injury or death!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 45

MACODE-3

NOTICE!

Commonwealth of Massachusetts

Installation Requirements

In the Commonwealth of Massachusetts, the installation
must be performed by a licensed plumber or gas fitter.

(b) Exemptions

The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most

current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or

structure separate from the dwelling, building or structure used in whole or in part for residential
purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED.

When the manufacturer of Product Approved side wall horizontally vented gas equipment provides
a venting system design or venting system components with the equipment, the instructions
provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system

components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment
does not provide the parts for venting the flue gases, but identifies “special venting systems”, the
following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or

equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that

system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizon-tally vented

gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or
all venting design instructions shall remain with the appliance or equipment at the completion
of the installation.

WARNING: Improper venting can result in excessive levels of carbon monoxide which
can cause severe personal injury or death!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 46

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 47

260 North Elm Street 7555 Tranmere Drive
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

Mississauga, Ontario L5S 1L4 Canada

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