RBI Series 8800, Series 8900 Installation And Operation Manual

CIOM-3

42-9134 Rev. 4

SERIES 8800 & 8900 FINNED COPPER

GAS BOILERS & WATER HEATERS

INSTALLATION & OPERATION MANUAL

MEA#117-96-E

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI WATER.

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

Do not store or use gasoline or other 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.

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

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 1300 Midway Boulevard
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

Mississauga, Ontario L5T 2G8 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 Your Start ................................................ page 2

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

Location.............................................................. page 3

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

Chimney & Vent Pipe Connections ....................page 4

Common Vent Systems ......................................page 5

Heating System Piping .......................................page 6

Domestic Water Supply Piping .........................page 11

Gas Supply Piping............................................ page 13

Electrical Wiring ...............................................page 14

Operation ......................................................... page 14

Lighting Instructions .........................................page 15

Checking & Adjustment ....................................page 16

Maintenance..................................................... page 17

Repair Parts, 8900 ...........................................page 19

Repair Parts, 8900 ...........................................page 25

BEFORE YOU START

This manual covers the application, installation,
operation and maintenance of a Series 8800
and 8900 finned copper heating boiler/water 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 A.G.A and
CGA for use with natural and propane gas under the
latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water
Heaters, ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure
Steam and Hot Water Boilers and CGA 3.3, Industrial
and Commercial Gas-Designed Atmospherically-Fired
Vertical Flue Boilers & Hot Water Supply Boilers. Each
unit has been constructed and hydrostatically tested for
a maximum working pressure of 160 psi in accordance
with Section IV of the A.S.M.E. Boiler and Pressure
Vessel Code.

All aspects of the boiler/water heater installation must
conform to the requirements of the authority having
jurisdiction, or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1-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.

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

Direct all questions to your RBI Water Heaters distributor
or contact the RBI Customer Service Department, 260
North Elm Street, Westfield, MA 01085. Always include
the model and serial numbers from the rating plate of the
boiler/water heater in question.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 3

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. Allow the
minimum clearances between adjacent construction
and the boiler/water heater as listed in Table 1.
Accessibility clearances must take precedence over
fire protection clearances.

Table 1 - Clearance to Combustibles

8800/8900
Top 24" 610 mm
Back 24" 610 mm
Left Side 24" 610 mm
Right Side 24" 610 mm
Front 48" 1220 mm
Flue 6" 152 mm

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.
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. 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!

WARNING: Never install a Series 8800 or 8900
boiler/water heater on top of combustible
flooring! Failure to comply with this warning may
result in a fire causing extensive property
damage, severe personal injury or death!

DO NOT

install this boiler/water heater

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

that would restrict the introduction of combustion air
into the unit or subject it to a negative pressure.

6.

NEVER

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!

place this boiler/water heater in a location

pan must not restrict the flow of

place this boiler/water heater in a location

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 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

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!

Buildings will require the installation of a fresh air duct
or other means of providing make-up air. Any building
utilizing other gas burning appliances, a fireplace, wood
stove or any type of exhaust fan must be checked for
adequate combustion air when all of these devices are
in operation at one time. Sizing of an outside air duct
must be done to meet the requirements of all such devices.

store objects on or around the boiler!

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 4

WARNING: Never operate the boiler/water heater
in an environment subjected to a negative
pressure. This can result in excessive levels of
carbon monoxide causing severe personal
injury or death!

All Air From Inside The Building

If the boiler/water heater is to be located in a confined
space minimum clearances of 24" (610 mm) must be
maintained between the boiler/water heater and any
combustible construction. When installed in a confined
space 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

2

1 in

/1000 Btu/hr (2200 mm2/kW) based on the total
input rating of
confined area.Each opening must be no less than
100 square inches (64516 mm2) in size. The upper
opening must be within 12 inches (300 mm) of,
but not less than 3 inches (80 mm) from, the top of
the enclosure. The bottom opening must be within
12 inches (300 mm) of, but not less than 3 inches
(80 mm) from, the bottom of the enclosure.

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 inches (300 mm) of, but not less than 3 inches
(80 mm) from, the top of the enclosure. The bottom
opening must be within 12 inches (300 mm) of, but not
less than 3 inches (80 mm) from, the bottom of the
enclosure.

Where directly communicating with the outdoors or
communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 in2/
4000 Btu/hr (550 mm2/kW) of the total input rating of
all of the equipment in the enclosure.

Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr (1100 mm2/kW) of the
total input rating of all of the equipment in the enclosure.

When ducts are used, they must have the same cross­sectional area as the free area of the opening to which
they connect.

ALL

gas utilization equipment in the

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" (6.4mm). If the free area
through a louver or grill is not known ducts should be
sized per Table 2 below.

Table 2 - Make-up Air Duct Sizing

Required Cross Sectional Duct Area in2 (cm2)

Input 1/4" (6.4 mm) Metal Wooden

(MBH) Wire Screen Louvers Louvers

420 105 (677) 140 (903) 420 (2710)
530 133 (858) 177 (1142) 530 (3419)
630 158 (1019) 210 (1355) 630 (4064)
735 184 (1187) 245 (1581) 735 (4742)
840 210 (1355) 280 (1806) 840 (5419)
950 238 (1535) 317 (2032) 950 (6129)
1050 263 (1697) 350 (2258) 1050 (6774)
1160 290 (1871) 387 (2497) 1160 (7484)
1260 315 (2032) 420 (2710) 1260 (8129)
1370 343 (2213) 457 (2948) 1370 (8839)
1470 368 (2374) 490 (3161) 1470 (9484)
1580 395 (2548) 527 (3400) 1580 (10,194)
1685 421 (2716) 562 (3626) 1685 (10,871)
1790 448 (2890) 597 (3852) 1790 (11,548)
1900 475 (3065) 633 (4084) 1900 (12,258)
2000 500 (3226) 667 (4303) 2000 (12,903)
2400 600 (3871) 800 (5161) 2400 (15,483)
2800 700 (4516) 933 (6019) 2800 (18,064)
3200 800 (5161) 1067 (6884) 3200 (20,645)
3600 900 (5806) 1200 (7742) 3600 (23,226)
4000 1000 (6452) 1333 (8600) 4000 (25,806)

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-

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

If this boiler/water heater will be connected to a masonry
chimney, a thorough inspection of the chimney must be
performed. Ensure that the chimney is clean, properly
constructed and properly sized. Table 3 lists the
equivalent breeching and flue sizes required for the
boiler/water heater.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 5

Table 3 - Equivalent Breeching & Chimney Size

Model Size Model Size

Size in (mm) Size in (mm)
420 10 (254) 1580 18 (457)
530 10 (254) 1685 18 (457)

630 12 (305) 1700 20 (508)
735 14 (356) 1900 20 (508)
840 14 (356) 2000 22 (559)
950 14 (356) 2400 24 (610)
1050 16 (406) 2800 26 (660)
1160 16 (406) 3200 28 (711)
1260 16 (406) 3600 30 (762)
1370 18 (457) 4000 30 (762)
1470 18 (457)

Note: These sizes are based on a 20 foot (6.1m) chimney height.

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 feet (1.8 m)
they must be supported at 6 foot (1.8 m) intervals with
overhead hangers. The vent system should be sloped
up toward the chimney at a minimum rate of 1/4 inch/
foot (2 cm/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 inches
(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.

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!

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.

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 6

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. 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

Tout mauvais fonctionnement du systéme
d’évacuation commun devrait étré corrigé de façor
que l’installation soit conforme au National Fue Gas
Code, ANSI Z223.1 et (ou) aux codes d’installation
CAN/CGA-B149. Si la grosseur d’une section du
système d’ évacuation doit étré modifiée, le système
devrait étré modifié pour.

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
manufacturer’s warranty, see Table 5. Excessive
pitting and erosion of the internal surface of the
copper heat exchanger tubes is
the manufacturer’s warranty if the result of high
water flow rates, see Table 5. Return water
temperatures below 115°F will result in heat
exchanger damage from excessive condensation
voiding the manufacturer’s warranty, see Primary/
Secondary Piping below.

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

Install the pressure relief valve in the 3/4" NPT opening
on the outlet side of the inlet/outlet header. On units
where the relief valve is larger than 3/4" NPT, install the
relief valve in the supply piping adjacent to the header.
Pipe the discharge of the pressure relief valve to prevent
scalding in the event of a discharge, see Figure 1. 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.

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!

NOT

covered under the

NOT

covered under

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 7

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.

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" must be maintained
between heating system pipes and all combustible
construction. All heating system piping must be
supported by suitable hangers not the boiler. The
thermal expansion of the system must be considered
when supporting the system. A minimum system
pressure of 12 psig must be maintained.

Heating Boiler Piping Connections

The supply and return connections should be sized to
suit the system, see Table 4.

Table 4 - Supply & Return Pipe Sizing

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

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 5 provides the heat exchanger
pressure drop and temperature rise figures. The

temperature rise across the boiler must never
exceed 30°F (17°C). The pump should be wired to run

continuously unless the optional pump delay is installed.
The pump delay turns the pump on each time the
burners fire and runs the pump for 100 seconds after
the call for heat is satisfied.

CAUTION: A temperature rise outside of the range
listed in Table 5 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
is 100 GPM, 200 GPM for an 8800. If higher flow rates
are required the optional Cupro-Nickel heat
exchanger should be considered.

Low Water Cutoff

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

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 1 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" apart to ensure zero pressure drop
in the primary system, see Figure 1.

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

2. 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"
apart to ensure zero pressure drop in the primary
system, see Figure 2.

Figure 1
Typical
Primary/Secondary
Piping System

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 8

Figure 2
Low
Temperature
Piping

Figure 3
Multiple
Boiler
Piping

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS Page 9

Table 5 - Temperature Rise Table

Heat Exchanger Head Loss & Temperature Rise

20°F

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 rate, use a greater temperature rise or consult factory for applications in
this range

GPM l/s P Ft KPa

34.0

42.9

51.0

59.5

68.0

77.0

85.1

94.0

102.1*

111.0*

119.1*

128.0*
—
—
—

164.0

196.8

229.6*

262.4*
—
—

2.1

2.7

3.2

3.8

4.3

4.9

5.4

5.9

6.4

7.0

7.5

8.1
—
—
—

10.3

12.4

14.5

16.6
—
—

0.6

1.0

1.6

2.5

3.4

4.5

6.1

7.7

9.5

11.7

14.2

17.1
—
—
—

5.9

9.5

14.2

20.0
—
—

1.8

3.0

4.7

7.4

10.1

13.5

18.2

22.9

28.3

35.0

42.4

51.1
—
—
—

17.5

28.3

42.4

59.9
—
—

GPM l/s P Ft KPa GPM l/s P Ft

—

34.3

40.8

47.6

54.4

61.6

68.1

75.2

81.7

88.8

95.2

102.4*

109.2*

116.0*

123.1*

131.2

157.4

183.6

209.9*

236.1*
—

25°F 30°F

—

2.2

2.6

3.0

3.4

3.9

4.3

4.7

5.2

5.6

6.0

6.5

6.9

7.3

7.9

8.3

9.9

11.6

13.2

14.9
—

—

0.6

1.0

1.6

2.2

2.9

3.9

4.9

6.0

7.5

9.1

10.9

13.0

15.3

16.3

3.7

6.0

9.1

12.8

17.6
—

—

1.9

3.0

4.7

6.5

8.6

11.6

14.6

18.1

22.4

27.1

32.7

38.8

45.6

48.7

11.2

18.1

27.1

38.3

52.5
—

—
—

34.0

39.0

45.3

51.3

56.7

62.7

68.1

74.0

79.4

85.3

91.0

96.6

102.6*

109.3

131.2

153.1

174.9

196.8

218.6*

—
—

2.1

2.5

2.9

3.2

3.6

4.0

4.3

4.7

5.0

5.4

5.7

6.1

6.5

6.9

8.3

9.7

11.0

12.4

13.8

—
—

0.7

1.1

1.5

2.0

2.7

3.4

4.2

5.2

6.3

7.6

9.0

10.6

11.3

2.6

4.2

6.3

8.9

12.2

15.1

KPa

—
—

2.1

2.2

4.5

6.0

8.1

10.2

12.6

15.6

18.9

22.8

30.6

32.4

33.9

7.8

12.6

18.8

26.5

36.5

45.1

SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONSPage 10

Multiple Boiler Systems

Systems using multiple boilers can also be installed
using a primary/secondary manifold system, Figure 3.

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, see Figure 4.

Figure 4 - Chilled Medium Piping

FOR HEATING: VALVES “H” OPEN, VALVES “C” CLOSED.

FOR COOLING: VALVES “H” CLOSED, VALVES “C” OPEN.

EXP. TANK

RELIEF

VALVE

NOTE

VENT

PUMP

ROOM

UNIT

H

C

DRAIN

DOMESTIC WATER SUPPLY PIPING

CAUTION: Proper controls must be used to prevent
water supplied for domestic use from exceeding
130°F (54°C) or a scald injury will occur! When
higher water temperatures are required for
appliances such as a dishwasher, a mixing valve or
some other tempering means must be installed.
Households with small children may require water
temperatures less than 120 °F (49°C). Local codes
must be complied with!

General Piping Requirements

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.

FILL

VALVE

C

H

DRAIN

BOILER

CHILLER

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.

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. A Cupro-Nickel heat
exchanger may also be required. The manufacturer
should be consulted when these water conditions are
encountered.