RBI INFINITE ENERGY Installation and Operation Instruction
High Effi ciency
Condensing
Stainless Steel
Gas Hot Water
Supply Boiler
IE8000-R1
Models IEW-199, IEW-399
Boiler manual
Installation and
operation instructions
CONTROLS
260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085 Mississauga, ONT. L5S IL4 Canada
Tel: (413) 568-9571 Tel: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
Copyright 2010 Mestek, Inc.
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3
D. COMBUSTION & VENTILATION AIR . . . . . . . .3
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
2. BOILER SET-UP 7
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. FLOOR STANDING INSTALLATION . . . . . . . . .7
3. VENTING & AIR INLET PIPING 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .8
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .8
D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .12
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .12
F. EXHAUST TAPPING FOR VENT SAMPLE . .13
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .13
4. WATER PIPING AND CONTROLS 14
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
B. OPERATING PARAMETERS . . . . . . . . . . . . . .14
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .14
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .16
5. FUEL PIPING 22
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .22
C. GAS SUPPLY PIPING – INSTALLATION . . . .22
D. GAS SUPPLY PIPING – OPERATION . . . . . . .23
E. MAIN GAS VALVE – OPERATION . . . . . . . . .23
6. CONDENSATE DRAIN PIPING 24
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .24
C. CONDENSATE DRAIN PIPE MATERIAL . . . .25
D. CONDENSATE DRAIN PIPE SIZING . . . . . . .25
E. CONDENSATE DRAIN PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .25
7. ELECTRICAL CONNECTIONS 26
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .26
C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .26
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 29
A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .29
B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .30
C. BOILER CONTROL . . . . . . . . . . . . . . . . . . . . .32
D. SERVICE NOTIFICATION . . . . . . . . . . . . . . . .33
E. SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . .33
F. STATUS & FAULT HISTORY . . . . . . . . . . . . . .34
G. SENSOR RESISTANCE . . . . . . . . . . . . . . . . .34
H. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . .35
I. DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9. START-UP PROCEDURE 37
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .37
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .37
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .37
E. LIGHTING & OPERATING PROCEDURES . . .39
10. TROUBLESHOOTING 40
A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .40
B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .40
C. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .44
11. MAINTENANCE 45
A. GENERAL (WITH BOILER IN USE) . . . . . . . .46
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .46
C. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .46
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .47
12. BOILER DIMENSIONS & RATINGS 48
13. REPAIR PARTS 50
APPENDIX A. STATUS SCREENS 54
APPENDIX B. USER MENU 57
APPENDIX C. INSTALLER MENU 59
APPENDIX D. COMBUSTION TEST
RECORD 63
WARRANTY 65
TABLE OF CONTENTS
TABLE OF CONTENTS
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this manual
in the order shown. The order of these instructions has
been set in order to provide the installer with a logical
sequence of steps that will minimize potential
interferences and maximize safety during boiler
installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of RBI, Inc.
are as follows:
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
1
USING THIS MANUAL
A. GENERAL
1. Infinite Energy boilers are supplied completely
assembled as packaged boilers. The package should
be inspected for damage upon receipt and any
damage to the unit should be reported to the shipping
company and wholesaler. This boiler should be stored
in a clean, dry area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your RBI
Representative for help in answering questions.
3. This boiler must be installed by a qualified contractor.
The boiler warranty may be voided if the boiler is not
installed correctly.
B. CODES & REGULATIONS
1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.
2. In the absence of local requirements the following
should be followed:
a. ASME Boiler and Pressure Vessel Code, Section
IV - “Heating Boilers”
b. ASME Boiler and Pressure Vessel Code, Section
VI - “Recommended Rules for the Care and
Operation of Heating Boilers”
c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”
d. ANSI/NFPA 70 - “National Electrical Code”
e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents
and Solid Fuel Burning Appliances”
3. 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.
**Please read if installing in Massachusetts**
Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:
·
A hard wired carbon monoxide detector with an
alarm and battery back-up must be installed on
the floor level where the gas equipment is to be
installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.
·
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.
·
Detector(s) must be installed by qualified licensed
professionals.
·
APPROVED CARBON MONOXIDE
DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
·
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”.
·
EXEMPTIONS to the requirements listed above:
°
The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.
°
The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.
·
This boiler installation manual shall remain with
the boiler at the completion of the installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbiage and also for additional (non-vent
related) requirements (248 CMR is available online).
If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
1. PREINSTALLATION
Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.
WARNING
2
PREINSTALLATION
C. ACCESSIBILITY CLEARANCES
1. The Infinite Energy boiler is certified for closet
installations with zero clearance to combustible
construction. In addition, it is design certified for use
on combustible floors.
2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
Models IEW-199 and IEW-399. However, local codes
or special conditions may require greater
clearances.
E. D. COMBUSTION AND
VENTILATION AIR
D. COMBUSTION AND VENTILATION AIR
1. The Infinite Energy boiler is designed for operation
with combustion air piped directly to the boiler from
outside the building (sealed combustion). If the boiler
is vented vertically, the combustion air can be
supplied from within the building only if adequate
combustion air and ventilation air is provided in
accordance with the section of the National Fuel Gas
Code entitled, "Air for Combustion and Ventilation" or
applicable provisions of the local building code.
Subsections 3 through 10 as follows are based on the
National Fuel Gas Code requirements.
2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow the
National Fuel Gas Code recommendations
summarized in subsections 3 through 10.
3. Required Combustion Air Volume: The total required
volume of indoor air is to be the sum of the required
volumes for all appliances located within the space.
Rooms communicating directly with the space in
which the appliances are installed and through
combustion air openings sized as indicated in
Subsection 3 are considered part of the required
volume. The required volume of indoor air is to be
determined by one of two methods.
a. Standard Method
: The minimum required volume
of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/kW). This method is to
be used if the air infiltration rate is unknown or if
the rate of air infiltration is known to be greater
than 0.6 air changes per hour. As an option, this
method may be used if the air infiltration rate is
known to be between 0.6 and 0.4 air changes per
hour. If the air infiltration rate is known to be
below 0.4 then the Known Air Infiltration Rate
Method must be used. If the building in which this
appliance is to be installed is unusually tight, RBI
recommends that the air infiltration rate be
determined.
b. Known Air Infiltration Rate Method
:
where:
I
fan
= Input of the fan assisted appliances
assisted in Btu/hr
ACH = air change per hour (percent of the
volume of the space exchanged per
hour, expressed as a decimal)
Note: These calculations are not to be used for
infiltration rates greater than 0.60 ACH.
Figure 1.1: Minimum Accessibility Clearances – IEW-199 & IEW-399
3
PREINSTALLATION
15 ft
3
I
fan
ACH 1000
Btu
/
hr
Required Volume
fan
=
⎛
⎜
⎝
⎛
⎜
⎝
4. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located as
follows:
a. Combining Spaces on the Same Floor
: Provide
two permanent openings communicating with
additional spaces that have a minimum free area
of 1 in
2
per 1000 Btu/hr (22 cm2per 1000 W) of
the total input rating of all gas fired equipment but
not less than 100 in
2
(645 cm2). One opening is to
begin within 12 inches (305 mm) from the top of
the space and the other is to begin within 12
inches (305 mm) from the floor. The minimum
dimension of either of these openings shall be 3
inches (76 mm), see Figure 1.2 for an illustration
of this arrangement.
b. Combining Spaces on Different Floors
: Provide
one or more permanent openings communicating
with additional spaces that have a total minimum
free area of 2 in
2
per 1000 Btu/hr (44 cm2per
1000 W) of total input rating of all equipment, see
Figure 1.3 for an illustration of this arrangement.
5. Outdoor Combustion Air: Outdoor combustion air is
to be provided through one or two permanent
openings. The minimum dimension of these air
openings is 3 inches (76 mm).
a. Two Permanent Opening Method
: Provide two
permanent openings. One opening is to begin
within 12 inches (305 mm) of the top of the space
and the other is to begin within 12 inches (305
mm) of the floor. The openings are to
communicate directly or by ducts with the
outdoors or with spaces that freely communicate
with the outdoors. The size of the openings shall
be determined as follows:
i. Where communicating directly or through
vertical ducts with the outdoors each opening
shall have a minimum free area of 1 in2 per
4000 Btu/hr (22 cm
2
per 4000 W) of total
input rating for all equipment in the space, see
Figure 1.4 for openings directly
communicating with the outdoors or Figure
1.5 for openings connected by ducts to the
outdoors.
Figure 1.2: Air Openings – All Air from Indoors
on the Same Floor
Figure 1.3: Air Openings – All Air from Indoors
on Different Floors
Figure 1.4: Air Openings – All Air Directly from
Outdoors
Figure 1.5: Air Openings – All Air from Outdoors
through Vertical Ducts
4
PREINSTALLATION
ii. Where communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 in
2
per 2000 Btu/hr (22
cm2per 2000 W) of total rated input for all
appliances in the space, see Figure 1.6.
b. One Permanent Opening Method
: Provide one
permanent opening beginning within 12 inches
(305 mm) of the top of the space. The opening
shall communicate directly with the outdoors,
communicate through a vertical or horizontal duct,
or communicate with a space that freely
communicates with the outdoors. The opening
shall have a minimum free area of 1 in
2
per 3000
Btu/hr of total rated input for all appliances in the
space and not less than the sum of the crosssectional areas of all vent connectors in the space.
The gas-fired equipment shall have clearances of
at least 1 inch (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the
appliance, see Figure 1.7 for this arrangement.
6. Combination Indoor and Outdoor Combustion Air: If
the required volume of indoor air exceeds the
available indoor air volume, outdoor air openings or
ducts may be used to supplement the available indoor
air provided:
a. The size and location of the indoor openings
comply with Subsection 3.
b. The outdoor openings are to be located in
accordance with Subsection 4.
c. The size of the outdoor openings are to be sized
as follows:
where:
A
req
= minimum area of outdoor openings.
A
full
= full size of outdoor openings calculated
in accordance with Subsection 4.
V
avail
= available indoor air volume
V
req
= required indoor air volume
7. Engineered Installations: Engineered combustion air
installations shall provide an adequate supply of
combustion, ventilation, and dilution air and shall be
approved by the authority having jurisdiction.
8. Mechanical Combustion Air Supply:
a. In installations where all combustion air is
provided by a mechanical air supply system, the
combustion air shall be supplied from the
outdoors at the minimum rate of 0.35 ft
3
/min per
1000 Btu/hr (0.034 m
3
/min per 1000 W) of the
total rated input of all appliances in the space.
b. In installations where exhaust fans are installed,
additional air shall be provided to replace the
exhaust air.
c. Each of the appliances served shall be interlocked
to the mechanical air supply to prevent main
burner operation when the mechanical air supply
system is not in operation.
d. In buildings where the combustion air is provided
by the mechanical ventilation system, the system
shall provide the specified combustion air rate in
addition to the required ventilation air.
9. Louvers & Grills:
a. The required size of openings for combustion,
ventilation, and dilution air shall be based on the
net free area of each opening.
i. Where the free area through a louver or grille
is known, it shall be used in calculating the
opening size required to provide the free area
specified.
ii. Where the free area through a louver or grille
is not known, it shall be assumed that wooden
louvers will have 25% free area and metal
louvers and grilles will have 75% free area.
iii. Non-motorized dampers shall be fixed in the
open position.
b. Motorized dampers shall be interlocked with the
equipment so that they are proven in the full open
position prior to ignition and during operation of
the main burner.
Figure 1.6: Air Openings – All Air from Outdoors
through Horizontal Ducts
Figure 1.7: Air Openings – All Air from Outdoors
through One Opening
5
PREINSTALLATION
i. The interlock shall prevent the main burner
from igniting if the damper fails to open during
burner startup.
ii. The interlock shall shut down the burner if the
damper closes during burner operation.
10. Combustion Air Ducts:
a. Ducts shall be constructed of galvanized steel or
an equivalent corrosion-resistant material.
b. Ducts shall terminate in an unobstructed space,
allowing free movement of combustion air to the
appliances.
c. Ducts shall serve a single space.
d. Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between ducts
serving upper and lower combustion air openings
shall be maintained to the source of combustion
air.
e. Ducts shall not be screened where terminating in
an attic space.
f. Horizontal upper combustion air ducts shall not
slope downward toward the source of the
combustion air.
g. The remaining space surrounding a chimney liner,
gas vent, special gas vent, or plastic piping
installed within a masonry, metal, or factory built
chimney shall not be used to supply combustion
air unless it is directly piped to the air inlet as
shown in Figure 3.9.
h. Combustion air intake openings located on the
exterior of buildings shall have the lowest side of
the combustion air intake opening at least 12
inches (305 mm) above grade.
11. Refer to Section 3 of this manual, Venting & Air Inlet
Piping, for specific instructions for piping the exhaust
and combustion air.
E. PLANNING THE LAYOUT
1. Prepare sketches and notes showing the layout of the
boiler installation to minimize the possibility of
interferences with new or existing equipment, piping,
venting and wiring.
2. The following sections of this manual should be
reviewed for consideration of limitations with
respect to:
a. Venting and Air Inlet Piping: Section 3
b. Water Piping: Section 4
c. Fuel Piping: Section 5
d. Condensate Removal: Section 6
e. Electrical Connections: Section 7
f. Boiler Control: Section 8
g. Boiler Dimensions and Ratings: Section 12
6
PREINSTALLATION
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
WARNING
This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate where it will be
exposed to freezing temperatures.
WARNING
Do not install this boiler in the attic.
WARNING
7
BOILER SET-UP
A. GENERAL
1. Infinite Energy boilers are intended for installation in
an area with a floor drain or in a suitable drain pan.
Do not install any boiler where leaks or relief valve
discharge will cause property damage.
2. The Infinite Energy boiler is not intended to support
external piping. All venting and other piping should
be supported independently of the boiler.
3. Install the boiler level to prevent condensate from
backing up inside the boiler.
B. FLOOR STANDING INSTALLATION
1. For floor standing installations, use the leveling feet to
assure that the boiler is completely level. This will
prevent condensate from backing up in the boiler.
2. Be sure to leave adequate space for condensate
piping or a pump if required.
2. BOILER SET-UP
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
A. GENERAL
1. Install the Infinite Energy boiler venting system in
accordance with these instructions and with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54,
CAN/CGA B149, and/or applicable provisions of local
building codes.
2. The Infinite Energy boiler is a direct vent appliance
and is ETL Listed as a Category IV appliance with
Intertek Testing Laboratories, Inc.
B. APPROVED MATERIALS
1. Table 3.1 lists approved materials for vent pipe (and
adhesives where applicable). Use only these materials
for exhaust vent piping.
2. PVC pipe and fittings are not to be used for venting in
confined spaces such as closet installations. Use only
CPVC vent pipe under these conditions.
3. Cellular core piping is approved for inlet air piping only.
* PVC pipe fittings are not to be used for venting within confined spaces.
Notice: Installations in Canada require compliance with
ULC S636 – Standard for Type BH Gas Venting Systems.
C. EXHAUST VENT/AIR INTAKE PIPE
LOCATION
1. Install vent piping before installing water, fuel, or
condensate piping. Working from largest to smallest
diameter reduces the complexity of piping
interferences.
2. Vent and air intake piping is to be installed so that
there is sufficient access for routine inspection as
required in Section 11 of this manual.
3. The vent piping for this boiler is approved for zero
clearance to combustible construction. However, a fire
stop must be used where the vent pipe penetrates
walls or ceilings.
4. The Infinite Energy boiler, like all high efficiency, gasfired appliances, is likely to produce a vapor plume
due to condensation. Surfaces near the vent
termination will likely become coated with
condensation.
5. The maximum combined vent and air inlet vent
length for the Infinite Energy boiler is about 200
equivalent feet (60 m). Be sure that the boiler is
located such that the maximum vent length is not
exceeded.
6. Air Intake Pipe Location – Sidewall Venting:
a. Provide 1 foot (30 cm) clearance from the bottom
of the air intake pipe to the level of maximum
snow accumulation. Snow removal may be
necessary to maintain clearances.
b. Do not locate air intake pipe in a parking area
where machinery may damage the pipe.
c. The maximum distance between the air intake
and exhaust is 6 feet (1.8 m).
3. VENTING & AIR INLET PIPING
The venting system for this product is to be installed in
strict accordance with these venting instructions.
Failure to install the vent system properly may result in
severe personal injury, death or major property damage.
WARNING
This vent system operates under positive pressure.
Vent connectors serving appliances vented by
natural draft shall not be connected into any portion
of this venting system. Failure to comply may result
in serious injury, death or major property damage.
WARNING
Only the materials listed below are approved for use
with the Infinite Energy boiler. Use only these
components in accordance with these instructions.
Failure to use the correct material may result in
serious injury, death, or major property damage.
WARNING
Use of cellular core pipe for any exhaust vent
component is prohibited. Use of cellular core pipe
may result in severe personal injury, death, or major
property damage.
WARNING
If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.
NOTICE
Locating air intake and exhaust pipes on different
sides of a building can cause erratic operation due to
wind gusts. When using the sidewall venting
configuration always locate both terminations on the
same outside wall.
NOTICE
8
VENTING & AIR INLET PIPING
Table 3.1: Approved Materials for Exhaust Vent Pipe
Description Material
Conforming to
Standard
Vent Piping &
Fittings
PVC (Sch 40 or 80)*
ANSI/ASTM D1785
CPVC (Sch 40 or 80) ANSI/ASTM D1785
PVC-DWV*
ANSI/ASTM D2665
MUGRO™ PP(s) ULC-S636
InnoFlue®PP ULC-S636
Pipe Cement
(PVC & CPVC Only)
PVC/CPVC Cement ANSI/ASTM D2564
9
VENTING & AIR INLET PIPING
d. If the vent pipe and air inlet pipe terminations
penetrate the wall at the same level the minimum
distance between them is 8" center-to-center.
e. For multiple boiler installations, the minimum
horizontal distance between the inlet of one boiler
to the exhaust of an adjacent boiler is 8" center-tocenter. In addition, the minimum vertical distance
between the exhaust and air inlet is 6", see Figure
3.1 for an illustration.
f. The exhaust outlet of the vent pipe should not be
angled any more than 5º from horizontal.
g. Precautions should be taken to prevent
recirculation of flue gases to the air inlet pipe of
the boiler or other adjacent appliances.
7. Sidewall Venting Configuration:
a. See Figure 3.2 for an illustration of clearances for
location of exit terminals of direct-vent venting
systems.
• This boiler vent system shall terminate at least
3 feet (0.9 m) above any forced air inlet
located within 10 ft (3 m). Note: This does not
apply to the combustion air intake of a directvent appliance.
• Provide a minimum of 1 foot (30 cm) distance
from any door, operable window, or gravity
intake into any building.
• Provide a minimum of 1 foot (30 cm) clearance
from the bottom of the exit terminal above the
expected snow accumulation level. Snow
removal may be required to maintain clearance.
• Provide a minimum of 4 feet (1.22 m)
horizontal clearance from electrical meters, gas
meters, gas regulators, and relief equipment. In
no case shall the exit terminal be above or
below the aforementioned equipment unless
the 4 foot horizontal distance is maintained.
• Do not locate the exhaust exit terminal over
public walkways where condensate could drip
and create a hazard or nuisance.
• When adjacent to public walkways, locate the
exit terminal at least 7 feet above grade.
• Do not locate the exhaust termination directly
under roof overhangs to prevent icicles from
forming or recirculation of exhaust gases from
occurring.
• Provide 3 feet clearance from the inside corner
of adjacent walls.
b. Figure 3.3 and 3.4 show approved sidewall venting
configurations using the standard fittings supplied.
c. Figure 3.4 is only approved for locations in which
the outdoor temperature is above -5°F (-21°C) in
accordance with ASHRAE 90A-1980
recommendations.
d. Figures 3.5 and 3.6 show approved sidewall vent
configurations using optional vent termination kits.
Figure 3.1: Vent Pipe Spacing for Multiple Infinite
Energy Boilers
Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems
Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.
CAUTION
Figure 3.3: Standard Exhaust and Air Inlet Pipe
Penetrations
Figure 3.4: Offset Exhaust and Air Inlet
Terminations
Figure 3.5: Optional Stainless Steel Vent Kit
Installation
Figure 3.6: Optional Concentric PVC Vent Kit
Installation
10
VENTING & AIR INLET PIPING
11
VENTING & AIR INLET PIPING
8. Vertical Venting Configuration:
a. Figure 3.7 shows the approved venting
configuration for vertical venting using the
standard fittings supplied.
b. Locate the air intake pipe inlet 12" above the
expected snow accumulation on the roof surface
or 24" above the roof surface, whichever is greater.
c. Locate the end of the exhaust vent pipe a minimum
of 12" above the inlet to the air intake pipe.
d. Figure 3.8 shows an approved vertical vent
configuration using the optional concentric vent
termination kit.
e. Figure 3.9 shows an option for routing the exhaust
through an unused chimney while bringing
combustion air from the space surrounding the
vent pipe.
f. Figure 3.9 shows an option for routing the exhaust
through an unused chimney with the combustion
air supplied from inside the building. Be sure to
note the requirements for combustion air as listed
under Section 1.D. "Combustion and Ventilation
Air". These requirements are in accordance with
the National Fuel Gas Code.
Figure 3.7: Standard Vertical Vent Installation
Figure 3.8: Concentric PVC Vertical Vent Installation
Figure 3.9
D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. Infinite Energy boiler model IEW-199 to be installed
using 3" Schedule 40 or 80 PVC or CPVC piping
using the provided vent adapter. Infinite Energy model
IEW-399 boilers are to be installed using 4" Schedule
40 or 80 PVC or CPVC piping using the vent adapter
provided.
2. Concentric polypropylene venting systems can be
installed using optional vent adapters. Table 3.2 shows
the appropriate Stock Codes.
Contact your RBI Representative for more information
on this option.
3. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. The equivalent length of elbows, tees and other
fittings are listed in Table 3.3.
b. The equivalent length can be calculated as follows.
This is well below the 200 feet maximum
equivalent length. If the total is above 200
equivalent feet, alternate boiler locations or
exhaust penetration location should be considered.
E. EXHAUST VENT/AIR INTAKE
INSTALLATION
1. Figure 12.1 shows the exhaust connection on top of
the boiler, near the rear in the center.
a. The exhaust connections for the IEW-199 (3") and
IEW-399 (4") are male CPVC pipe.
b. These connections are to be joined with suitable
PVC/CPVC adhesives in accordance with
manufacturers’ instructions.
2. The Air Intake connection is to the right of the exhaust.
3. Both connections are clearly marked.
4. Remove all burrs and debris from the joints and fittings.
5. Horizontal lengths of exhaust vent must be installed with
a slope of not less than 1/4" per foot (21 mm per meter)
toward the boiler to allow condensate to drain from the
vent pipe. If the vent pipe must be piped around an
obstacle that causes a low point in the piping, a drain
with an appropriate trap must be installed.
6. All piping must be fully supported. Use pipe hangers
at a minimum of 4 foot (1.22 meter) intervals to
prevent sagging of the pipe.
12
This appliance uses a positive pressure venting
system. All joints must be sealed completely to
prevent leakage of flue products into living spaces.
Failure to do this may result in severe personal injury,
death or major property damage.
WARNING
VENTING & AIR INLET PIPING
Exhaust Air Inlet Total
Straight Length of Pipe 50' 50' 100'
90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15'
45° Elbows, SR 2 x 3' = 6' 6'
Conc. Vent Termination 1 x 3' = 3' 3'
Total 124'
Table 3.4: Sample Equivalent Length Calculation
Figure 3.10
Boiler Model Stock Code
IEW-199 3354236
IEW-399 3354237
Table 3.2: Stock Codes
Fitting Description Equivalent Length
Elbow, 90° Short Radius 5 feet
Elbow, 90° Long Radius 4 feet
Elbow, 45° Short Radius 3 feet
Coupling 0 feet
Air Intake Tee 0 feet
Stainless Steel Vent Kit 1 foot
Concentric Vent Kit 3 feet
Table 3.3: Equivalent Length of Fittings
13
VENTING & AIR INLET PIPING
7. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
8. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
9. PVC & CPVC Piping:
a. Use only solid PVC or CPVC Schedule 40 or 80
pipe for exhaust venting. Cellular core PVC or
CPVC is not approved for exhaust vent.
b. All joints in vent pipe, fittings, attachment to the
boiler stub, and all vent termination joints must be
properly cleaned, primed and cemented. Use only
cement and primer approved for use with PVC or
CPVC pipe that conforms to ANSI/ASTM D2564.
c. A straight coupling is provided with the boiler to
be used as an outside vent termination. One of
the two screens is to be installed to prevent birds
or rodents from entering.
d. An air intake tee is provided with the boiler to be
used as an outside air intake termination. A screen
is to be installed to prevent birds or rodents from
entering.
e. The following are optional combination air
intake/exhaust terminations that are available
separately from your RBI distributor for use with
Infinite Energy boilers.
f. Refer to Figures 3.3 to 3.6 for sidewall venting
options using PVC or CPVC pipe.
g. Refer to Figures 3.7 & 3.8 for vertical venting
options using PVC or CPVC pipe.
F. EXHAUST TAPPING FOR VENT SAMPLE
To properly install the boiler, carbon dioxide (CO2) and
carbon monoxide (CO) readings are to be determined
from a sample of combustion gases from the vent pipe.
To do this, a hole must be drilled in the vent pipe.
a. Drill a 21/64" diameter hole in the exhaust vent
pipe at a point between 6" and 12" from the
boiler connection.
b. Tap the hole with a 1/8" NPT pipe tap.
c. Use a 1/8" NPT, PVC or Teflon Pipe Plug to seal
the hole.
See Section 9.D.7 for instructions on taking combustion
readings.
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
If removing an existing boiler from a common vent
system the following steps must be carried out for each
appliance that remains connected. These steps are to be
completed for each appliance while the other appliances
that remain connected are not in operation.
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper size
and horizontal pitch. Verify that there is no
blockage or restriction, leakage, corrosion, and
other deficiencies which could cause an unsafe
condition.
c. Where practical, close all building doors and
windows. This includes interior doors between the
space in which the appliances remaining
connected to the common venting system are
located and other interior spaces in the building.
d. Turn on clothes dryers and any other appliance
not connected to the common venting system.
Exhaust fans such as range hoods or bathroom
exhaust fans are to be operated at their maximum
speed (do not operate a summer exhaust fan).
e. Close fireplace dampers.
f. Place the appliance that is being inspected in
operation. Follow the lighting instructions and
adjust the thermostat so that the appliance will
operate continuously.
g. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame from a match or candle, or smoke from a
cigarette, cigar, or pipe.
h. After each appliance remaining connected to the
common vent system has been determined to vent
properly as outlined above, doors, windows,
exhaust fans, fireplace dampers and any other gas
burning appliance are to be returned to their
previous condition of use.
i. Any improper operation of the common venting
system should be corrected at once so that the
installation conforms with the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA
B149 Natural Gas and Propane Installation Code.
j. When resizing any portion of the common venting
system, the system should be resized to approach
the minimum size as determined using the
appropriate tables in Part 11 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and or
CAN/CSA B149.1, Natural Gas and Propane
Installation Code.
Description Stock Code
3" PVC Concentric Vent Termination Kit 3391403
3" Stainless Steel Vent Termination Kit 3354161
Table 3.5: Vent Termination Kits
A. GENERAL
1. Size water supply and return piping in accordance
with system requirements. Do not use smaller
diameter piping than the boiler connections.
2. If the Infinite Energy boiler is used to replace an existing
boiler, make sure that the system piping is thoroughly
cleaned and free from debris before installation.
3. In systems where sediment may exist, install a strainer
in the boiler return piping to prevent large particles
and pipe scale from entering the boiler heat
exchanger. Use a large mesh screen in the strainer.
4. Install this boiler so that the gas ignition system
components are protected from water (dripping, spraying,
etc.) during operation and service (pump replacement,
condensate trap cleaning, sensor replacement, etc.).
5. The Infinite Energy boiler is supplied with a default
tank temperature setpoint of 120°F (49°C). However,
the setpoint can be set as high as 158°F (70°C) which
can potentially cause scald injury. If the tank
temperature is set to above 120°F (49°C), RBI
recommends the use of a mixing valve to provide
lower temperature water to faucets and shower heads.
B. OPERATING PARAMETERS
1. The Infinite Energy boiler is designed to operate in an
open loop domestic water heating system under
forced circulation with a water storage tank. The
system must be completely filled with water at all
times and water must be circulating through the boiler
while the unit is firing for it to operate effectively.
2. The minimum system pressure is 14.5 PSI (69 kPa).
3. Table 4.1 lists the minimum flow rates for each Infinite
Energy model.
4. Table 4.2 provides the water volume of the heat
exchanger including the supply and return pipes that
are attached at the factory.
5. The required temperature rise and the standard
circulating pump are sized based on the heating of
potable water with a hardness of 5 to 25 grains per
gallon and a total dissolved solids not exceeding 350
ppm. Consult the manufacturer when heating potable
water exceeding these specifications.
Heating of high hardness and/or high total dissolved
solids water may require a larger circulating pump,
and a revised temperature rise specification based on
the water chemistry of the water to be heated.
Water with a hardness of less than 5 grains per gallon
will usually have a pH which can be aggressive and
corrosive causing non-warrantable damage to the
pump, and associated piping. Corrosion due to water
chemistry generally shows up first in the hot water
system because heated water increases the rate of
corrosive chemical reactions.
C. SYSTEM COMPONENTS
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
boiler to be mounted in the piping from the boiler
supply to the system as shown in Figure 4.1. Most
local codes require this gauge.
2. Potable Water Expansion Tank: An expansion tank is
required to provide room for expansion of the heating
medium (water or glycol solution). Consult the expansion
tank manufacturer's instructions for specific information
regarding installation. The expansion tank is to be sized
for the required system volume and capacity. In addition,
be sure that the expansion tank is sized based on the
proper heating medium. Glycol solutions may expand
more than water for a similar temperature rise.
3. Y-Type Strainer or Filter Ball
®
Valve: RBI recommends
the use of a strainer device in the system to prevent
dirt or sediment from clogging the heat exchanger. A
20 mesh stainless steel screen is adequate to protect
the heat exchanger. The strainer should be cleaned
often in the first several months of operation. The Filter
Ball
®
Valve from Jomar International incorporates a
strainer into a ball valve which allows the technician to
isolate the water circuit while cleaning the strainer.
4. WATER PIPING & CONTROLS
Table 4.1: Minimum Flow Rate
Water temperatures over 125°F
(52°C) can cause severe burns
instantly, or death from scalds.
Children, disabled, and elderly
are at the highest risk of being
scalded.
See instruction manual before
setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available, see
manual.
DANGER
!
Table 4.2: Heat Exchanger Water Capacity
WATER PIPING AND CONTROLS
Water temperature rise and maximum flow data is
based on heating potable water with a hardness of 5
to 25 grains per gallon and total dissolved solids not
exceeding 350 ppm.
NOTICE
Infinite Energy
Model
Total Water Capacity
Gallons (Liters)
IEW-199 1.19 (4.50)
IEW-399 2.60 (9.84)
14
Infinite Energy
Model
Minimum Flow Rate
Water GPM (LPM)
IEW-199 5.5 (20.8)
IEW-399 13.2 (50.0)
15
WATER PIPING AND CONTROLS
4. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the system from backing up into the city water supply.
5. Pressure Relief Valve: The boiler pressure relief valve
is shipped separately for field installation. It is
extremely important that this is installed on the boiler
return pipe (at the rear of the boiler).
The valve is to be installed as shown in Figure 4.1
Pipe the discharge of the relief valve to within 12"
(305 mm) of the floor and close to a floor drain.
Provide piping that is the same size or larger than the
relief valve outlet.
6. Pump: The boiler pump is to be sized to overcome the
pressure drop of the system while providing the flow
required by the boiler.
a. The pump should be sized based on gross output of
the boiler. Table 4.3 shows the Boiler Output as
reported to the Hydronics Institute Section of AHRI.
b. The required flow is calculated based on the design
temperature difference from the return to the supply of
the boiler. For a IEW-199 with a design temperature
difference of 20°F the calculation is as follows.
Output 182,000
Required Flow =
________=_________
= 18.2 GPM
D
T x 500 20 x 500
c. The boiler pressure drop for various flow rates can
be determined using Figure 4.2, the Infinite
Energy Boiler Pump Sizing Graph.
Figure 4.1: Relief Valve Installation
Infinite Energy
Model
Boiler Input
Btu/hr (kW)
Gross Output
Btu/hr (kW)
IEW-199 199,000 (58.3) 182,000 (53.3)
IEW-399 399,000 (116.9) 373,000 (109.3)
Table 4.3: Boiler Inputs and Outputs
Pipe the discharge of the relief valve as close as
possible to the floor and away from high traffic areas.
Pipe the discharge to a floor drain. Failure to do so
may result in personal injury and/or property damage.
CAUTION
Figure 4.2: Infinite Energy Pump Sizing Graph (General Pump – Primary/Secondary)
Do not operate this appliance without installing the
pressure relief valve supplied with the boiler or one
with sufficient relieving capacity in accordance with
the ASME Rating Plate on the boiler heat exchanger.
WARNING
16
WATER PIPING AND CONTROLS
d. Table 4.4 provides the flow rate and pressure drop
information that corresponds to various system
temperature rise values (DT). The pressure drop
shown is for the boiler only. If there is significant
system pressure drop in the system, this should be
included when specifying pumps.
e. Table 4.5 provides a list of recommended pumps
for hot water supply boilers.
* An isolation relay must be used for these circulators and any circulator
with a FLA rating above 4.5 Amps.
D. SYSTEM PIPING
1. Figure 4.3 shows piping for a single boiler with a
single storage tank. When using the factory specified
pump, the maximum total pipe length is 30 feet (10
meters) with 6 90° elbows all at the full pipe diameter
of the pump connections.
2. In Figure 4.4, a single boiler is used with multiple
water storage tanks. The pumps are piped in parallel
with reverse return piping.
3. Figure 4.5 shows two boilers piped into a single
storage tank.
4. Figure 4.6 shows piping for two boilers and two water
storage tanks.
5. In Figure 4.7, we show a single boiler with a single
tank using a patented anti-scale principle. In this
configuration, the boiler control switches the 3-way
valve to bypass when the call for heat ends. The
pump is then operated to draw cool water from the
anti-scale buffer tank until the supply and return
temperatures equalize.
Table 4.5: Pump Selection Chart (General Pump –
Primary/Secondary)
Pump
Manufacturer
Temperature
Difference
IEW-199 IEW-399
Taco
20°F
1400-20* 1400-50*
Bell & Gossett PL-36* PL-55*
Table 4.4: Flow Rate and Pressure Drop for Various
System Temperature Rise Values
Temperature Rise / Pressure Drop
DT
IEW-199 IEW-399
(°F) (°C) GPM LPM Ft m GPM LPM Ft m
20
11
18.2 68.9 17.12 5.22 37.3 141.2 18.08 5.51
17
WATER PIPING AND CONTROLS
Figure 4.3: Piping – One Boiler with a Single Storage Tank
18
WATER PIPING AND CONTROLS
Figure 4.4: Piping – One Boiler with Multiple Storage Tanks
Figure 4.5: Piping – Two Boilers with a Single Storage Tank
19
WATER PIPING AND CONTROLS
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