RBI SPECTRUM Series User manual

02/14 Copyright Mestek, Inc.
SPMI0M-10
82-0255
Boiler Manual
Installation and Operation
Instructions
is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service
technician, and to follow all guidelines in the User’s Information Manual.
Finned Copper Tube
Gas Boilers (SB) &
Water Heaters (SW)

Finned copper tube gas boilers & water heaters – Boiler Manual
2
If the information in this manual is not followed
exactly, a fire or explosion may result causing property,
personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other applianc
WHAT TO DO IF YOU SMELL GAS:
• Donottrytolightanyappliance.
• Do not touch any electrical switch. Do not use any
phoneinyourbuilding.
• Immediatelycallyourgassupplierfromaphoneoutside
thebuilding.Followthegassupplier’sinstructions.
• If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer,serviceagencyorthegassupplier.
Assurez-vous de bien suivre les instructions données
dans cette notice pour réduire au minimum le risque
d’incendieoud’explosionoupourévitertoutdommoge
matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides inflammables à proximité de cet
appareiloudetoutautreappareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Nepastenterd’allumerd’appareil.
• Netouchezàaucuninterrupteur;nepasvousservir
destéléphonessetrouvantdanslebâtiment.
• Appelezimmédiatementvotrefournisseurdegasdepuis
unvoisin.Suivezlesintructionsdufournisseur.
• Sivousnepurvezrejoindrelefournisseur,appelezle
servicedesincendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualifié ou par le
fournisseurdegaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNEDANDTESTEDACCORDINGTOA.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING
PRESSUREOF160PSI,1103 kPaWATER.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED
ADJACENT TO THE HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE PURPOSES.
BEFORE YOUR START . . . . . . . . . . . . . . . . PAGE 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . PAGE 3
BOILER/WATER HEATER LOCATION . . . . . . . . .PAGE 3
COMBUSTION AIR & VENTILATION . . . . . . . . . . PAGE 3
CHIMNEY & VENT PIPE CONNECTIONS . . . . . . PAGE 10
COMMON VENT SYSTEMS . . . . . . . . . . . . . PAGE 12
OUTDOOR VENTING . . . . . . . . . . . . . . . . . PAGE 13
GENERAL PIPING REQUIREMENTS . . . . . . . . PAGE 13
HEATING SYSTEM PIPING . . . . . . . . . . . . . PAGE 15
DOMESTIC WATER SUPPLY PIPING . . . . . . . . PAGE 18
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . PAGE 21
ELECTRICAL WIRING . . . . . . . . . . . . . . . . PAGE 22
GENERAL OPERATION . . . . . . . . . . . . . . . PAGE 22
OPERATING INSTRUCTIONS . . . . . . . . . . . . PAGE 27
CHECKING & ADJUSTMENTS. . . . . . . . . . . . PAGE 29
CONTROL DESCRIPTION . . . . . . . . . . . . . . PAGE 30
MAINTENANCE . . . . . . . . . . . . . . . . . . . PAGE 32
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . PAGE 37
BEFORE YOU START
is manual covers the application, installation, operation and
maintenance of a Spectrum nned copper heating boiler/water
heater/pool heater (Canada Only).
To obtain the safe, dependable, ecient operation and long life for
which this heating boiler/water heater was designed, these
instructions must be read, understood and followed.
eSpectrum nnedcopperheatingboiler/water heatershavebeen
design certied by CSA 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 CAN-1-3.1, Industrial and Commercial Gas
Fired Boilers. Each unit has been constructed and hydrostatically
tested for a maximum working pressure of 160 psi,1103 KPa in
accordance with Section IV of the A.S.M.E. Boiler and Pressure
Vessel Code.
All aspects of the boiler/water heater installation must conform to
the requirements of the authority having jurisdiction, or, in the
absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA54-latest revision.
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.

Finned copper tube gas boilers & water heaters – Boiler Manual
3
If installed in the Commonwealth of Massachuses, you MUST
FOLLOWtheadditionalinstructionscontainedinRBI'sinstruction
sheetMACODE-3.Ifyoudonothaveacopy,callyourRBIdistributor
or contact the RBI Customer Service Department.
e owner should maintain a record of all service work performed
with the date and a description of the work done. Include the name
of the service organization for future reference.
Direct all questions to your RBI distributor or contact the RBI
Customer Service Department, 260 North Elm Street, Westeld,
MA 01085 for U.S. or 7555 Tranmere Drive, Mississauga ONT
L5S 1L4 for Canada. Always include the model and serial numbers
from the rating plate of the boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Spectrum boiler/water
heater check the rating plate to ensure that the unit has been sized
properly for the job. e "Net AHRI 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
importantconsiderationsaretheavailabilityofan adequateelectrical
supply, fresh air for combustion and a suitable chimney or vent
system.
BOILER/WATER HEATER LOCATION
1. is boiler/water heater is suitable for indoor and outdoor
installations. Locate the boiler/water heater in an area that
provides good access to the unit. Servicing may require the
removalofjacketpanels.Allowtheminimumclearancesbetween
adjacent construction and the boiler/water heater as listed in
Table 1.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it
be required.
Table 1
Clearance to
Combustibles
Service
Clearance
in mm in mm
Top 14 356 18 457
Back 6152 18 457
Left Side 6152 24 609
Right Side 6152 24 609
Front 6152 24 609
Flue 6152 6152
2. An optimum site will be level, central to the piping system, close
toa chimneyandhaveadequatefreshairfor 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 oor is structurally sound and will support the
weight of the boiler/water heater.
eSpectrum maybeinstalleddirectlyoncombustible
ooring, only if RBI supplied special oor pan is used
but never on carpeting, see Table 2.
Table 2 Special Base for Combustion Floors
Model Number Part Number
100 70-1248
150 70- 1249
200 70- 1250
250 70-1251
300 70-1252
350 70-1253
400 70-1254
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. e pan must not restrict the ow of 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 “GENEL VENTING
GUIDELINES”.
6. NEVER place this boiler/water heater in a location that would
subject it to temperatures at or near freezing. See the “Freeze
Protection” section on page 8.
Never store combustible materials, gasoline or any
product containing ammable vapors or liquids in the
vicinity of the boiler/water heater. Failure to comply
with this warning can result in an explosion or fire
causing extensive property damage, severe
personalinjuryordeath!
Units installed outdoors MUST be protected from ice
and snow accumulation or the unit will be damaged
voiding the warranty!

Finned copper tube gas boilers & water heaters – Boiler Manual
4
COMBUSTION AIR & VENTILATION
is boiler/water heater must be supplied with
combustion air in accordance with Section 5.3, Air
for Combustion & Ventilation, of the latest revision
of the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and all applicable local building codes. Canadian
installations must comply with CSA B149.1 or .2
Installation Code for Gas Burning Appliances and
Equipment, or applicable provisions of the local
buildingcodes.Failuretoprovideadequatecombustion
air for this boiler/water heater can result in excessive
levels of carbon monoxide that 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!
Combustion air contaminated with uorocarbons or
other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. ese acids will
cause premature failure of the boiler/water heater
voiding the warranty!
Iftheboiler/waterheaterisoperated while thebuilding
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 conned space,
minimum clearances listed in Table 1 must be maintained between
the boiler/water heater and any combustible construction. When
installed in a conned space, Figures 1 and 2, two permanent
openings communicating with an additional room(s) are required.
e combined volume of these spaces must have sucient volume
to meet the criteria for an unconned space. e total air
requirements of all gas utilization equipment, replaces, wood stoves
or any type of exhaust fan must be considered when making this
determination. Each opening must have a minimum free area of
1 in2/1000 Btu/hr, 2200 mm2/kW based on the total input rating
of ALL gas utilization equipment in the conned area. Each opening
must be no less than 100 in2, 64,516 mm2in size. e upper
opening must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. e boom opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the
boom of the enclosure.
All Air From Outside The Building
When installed in a conned space two permanent openings
communicating directly with, or by ducts to, the outdoors or spaces
that freely communicate with the outdoors must be present. e
upper opening must be within 12 in, 305 mm of, but not less than
3 in, 76 mm from, the top of the enclosure. e boom opening
must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the boom of the enclosure.
Wheredirectlycommunicatingwiththeoutdoorsorcommunicating
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.
Wherecommunicatingwiththe outdoorsthroughhorizontalducts,
eachopeningshallhavea minimumfreeareaof1 in2/2000Btu/hr,
1100 mm2/kW of thetotalinput ratingofallofthe equipmentin the
enclosure.
When louvers and screens are used, they must have the same cross-
sectional area as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure, consideration must be given to the
blockage eects of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 in, 6.4mm. If the free area through a
louver or grill is not known, ducts should be sized per Table 3.
Canadian installations must comply with CSA B149.1 when air
supply is provided bynaturalairow fromthe outdoorsfor natural
dra, partial fan-assisted, fan-assisted, or power dra-assisted
burners, there shall be a permanent air supply opening(s) having
a cross-sectional area of not less than 1 in2per 7,000 Btuh
(310 mm2per kW) up to and including 1 million Btuh, plus
1in2per14,000Btuh(155 mm2per kW)in excess of 1million
Btuh.
Table 3 Make-up Air Louver Sizing
Required Cross Sectional Area
Input
(MBH)
1/4 in 6.4 mm
Wire Screen
75% Free Area
Metal Louvers
25% Free Area
Wooden Louvers
in2cm2in2cm2in2cm2
100 25 161 33 213 100 645
150 37 858 50 322 150 967
200 50 322 67 432 200 1290
250 62 400 83 535 250 1612
300 75 484 100 645 300 1934
350 87 561 117 754 350 2257
400 100 645 133 858 400 2579

Finned copper tube gas boilers & water heaters – Boiler Manual
5
CHIMNEY & VENT PIPE CONNECTIONS
e vent installation must be in accordance with Part
7, Venting of Equipment, of the latest revision of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 or
applicable provisions of the local building codes.
Canadian installations must comply with CSA B149.1
or .2 Installation Code. Improper venting can result
inexcessivelevelsof carbonmonoxidewhichcanresult
in severe personal injury or death!
Chimney Inspection & Sizing
A thorough inspection of the masonry chimney must be
performed toensurethatthechimney isclean,properlyconstructed,
lined and sized. Exterior masonry chimneys should not be used
unless properly lined to prevent condensation and dra problems.
Table 4 lists the equivalent breeching and ue sizes required for
the boiler/water heater.
Table 4 Equivalent Breeching and Chimney Size
Model
Size
Size
in
Size
mm
100 5 127
150 6 152
200 7 178
250 8 203
300 8 203
350 9 229
400 10 254
Note: These sizes are based on a 20 ft,6.1 m chimney height.
When more than one appliance is connected to the same chimney
ue, the ue must be large enough to safely vent the combined
output of all the appliances.
If an appliance using any type of a mechanical dra
system operating under positivepressure is connected
to a chimney ue, never connect any other appliances
to this ue. 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 dra hood ue collar, Table 4. Use
the shortest, straightest vent system possible for the installation. If
horizontal runs exceed 6 , 1.8 m they must be supported at 6 ,
1.8 m intervals with overhead hangers. e vent system should be
sloped up toward the chimney at a minimum rate of 1/4 in/,
20 mm/m and terminate ush with the inside of the chimney ue.
Fasten each connection with at least 3 corrosion resistant sheet
metal screws.
Never modify or alter any part of the boiler’s dra
hood. is includes the removal or alteration of any
baes. Never install a vent pipe of a diameter dierent
than that of the boiler dra hood ue 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.
Failuretomaintainminimumclearancesbetweenvent
connectors and any combustible material can result
in a re causing extensive property damage, severe
personal injury or death!
To determine the appropriate power venter for the boiler/water
heater, see Table 5, Power Venter Sizes. Follow the power venter
manufacturer’s installation instructions.
Table 5 Power Venter Sizes
Spectrum Power Venter Max. Pipe Length
Model Model ft mm
100-250 HS-1 100 31
300-400 HS-2 100 31
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.
Aumomentduretraitd’unechaudièreexistante,lesmesuressuivantes
doiventêtreprisespourchaqueappareiltoujoursraccordéausystème
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.
Scellertouteslesouverturesnonutiliséesdusys-tèmed’évacuation.
b) Visuallyinspecttheventingsystemfor propersize andhorizontal
pitch and determine there is no blockage or restriction, leakage,
corrosion and other deciencies which could cause an unsafe
condition.
Inspecter de façon visuelle le système d’évacuation pour
déterminerlagrosseretl’inclinaisonhorizontalequiconviennent
et s’assurer que le système est ex-empt d’obstruction,
d’étranglement de fruite, de corrosion et autres défaillances qui
pourraient présenter des risques.

Finned copper tube gas boilers & water heaters – Boiler Manual
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 bath-room exhaust, so
they will operate at maximum speed. Do not operate a summer
exhaust fan for a boiler installation. Close replace dampers.
Danslamesuredupossible,fermertouteslesportesetlesfenêtres
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. Mere en marche les sécheuses,
touslesappareilsnonraccordésausystèmed’évacuationcommun
ettousles ventilateursd’extractioncomme leshoesde cuisinère
etlesventilateursdessalles debain. S’assurerque cesventilateurs
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
lightinginstructions.Adjustthermostatsoappliancewilloperate
continuously.
Mere l’appareil inspecté en marche. Suivre les instructions
d’allumage.Réglerlethermostatdefaçonquel’appareilfonctionne
de façon continue.
e) Test for spillage at the dra hood relief opening aer 5 minutes
of main burner operation. Use the ame of a match or candle,
or smoke from a cigaree, cigar or pipe.
Faire fonctionner le brûleur principal pendant 5 min ensuite,
déterminer si le coupe-tirage déborde à l'ouverture de décharge.
Utiliserlaammed'unealluneeoud'unechandelleoula fumée
d'une ciga-ree, d'un cigare ou d'une pipe.
f) Aer it has been determined that each appliance remaining
connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
replace dampers and any other gas-burning appliance to their
previous condition of use.
Une fois qu’il a été déterminé, selon la métode indiquée ci-
dessus, que chaque appareil raccordé au système d’évacuation
est mis à l’air libre de façor adéquate. Remere 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.
Toutmauvaisfonctionnementdusystémed’évacuationcommun
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 CAN/CGA-B149. Si la grosseur d’une
section du système d’ évacuation doit étré modiée, le système
devrait étré modié pour.

Finned copper tube gas boilers & water heaters – Boiler Manual
7
Figure 1 Vertical Venting with a Metal Chimney System and Inside Air
Figure 2 Vertical Venting using a Metal Chimney and Inside Air
10 FT3.1m
RIOM-51

Finned copper tube gas boilers & water heaters – Boiler Manual
8
OUTDOOR VENTING
When installed outdoors the Spectrum must be ed with the
factory supplied outdoor hood assembly, see Figure 3. Multiple
units must be spaced per Figure 3A.
e boiler/water heater must be at least 10 , 3.1 m from any
door, window or gravity air inlet into any building and at least
3 , 0.9 m from any overhang unless local codes dictate dierently.
Avoidlocationswherewinddeectionoofadjacentwalls,buildings
orshrubbery mightcauseadowndra.eunit(s)shouldbelocated
at least 3 , 0.9 m from structures. Outdoor installations are not
recommended in areas where the danger of snow blockage exists.
Do not place the boiler/water heater in a location that
would subject it to runo from adjacent buildings or
damage may occur voiding the warranty!
Figure 3 Outdoor Venting
Figure 3A Multiple Outdoor Units
GENERAL PIPING REQUIREMENTS
Improperpipingofthisboiler/waterheaterwillvoidthe
manufacturer’s warranty and can cause boiler failure
resulting in ooding and extensive property damage!
Excessive water hardness causing lime build-up in
thecopperheatexchangertubes isNOTcoveredunder
the manufacturer’s warranty. Excessive piing and
erosion of the internal surface of the copper heat
exchanger tubes is NOT covered under the
manufacturer’s warranty if the result of high water
owrates,seeTable7 or8. Return watertemperatures
below 110°F, 43°C will result in heat exchanger
damage from excessive condensation voiding the
manufacturer’s warranty, see Primary/Secondary
PipingFigure5.
Shut o valves and unions should be installed at the
inlet and outlet connections of the boiler water heater
to provide for isolation of the unit should servicing
be necessary.
Freeze Protection
is boiler/water heater is CSA designed certied for outdoor
installation. Outdoor installations in areas where the danger of
freezingexistsarenotrecommendedunlessproperfreezeprotection
is provided. If the unit is to be installed in such an area the following
precautions MUST be observed:
1. A continuous ow of water through the boiler/water heater
MUST be maintained! e pump responsible for ow through
the boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used. e
pump must be capable of producing 15% more ow and
overcominga 20% increaseinheadloss.Domesticwatersystems
must be isolated from the water heater by the use of a
heat exchanger or other approved method.
3. If the boiler/water heater must be shut o for any reason the
electric, gas and water supplies MUST be shut o and the unit
and its pump completely drained.
Improperoutdoorinstallationofthisboiler/waterheater
can cause boiler failure voiding the manufacturer's
warranty!
SPECTRUM
HEADER
HOOD
SUPPLY/RETURN
HEADER HOOD
EXHAUST
HOOD
COMBUSTION
AIR HOOD
3'
0.9 m
4'
1.2 m
RIOM-53
RIOM-54
RIOM-52

Finned copper tube gas boilers & water heaters – Boiler Manual
9
Relief Valve
Pipe the discharge of the pressure relief valve to prevent scalding in
the event of a discharge, see Figure 4. e discharge piping must be
sizedthesameasthe pressurereliefvalveoutletand installedtoallow
complete drainage of both the relief valve and the discharge piping.
Figure 4
Neverinstallanytype ofvalvebetweentheboiler/water
heater and the relief valve or an explosion causing
extensive property damage, severe personal injury or
deathmayoccur!
Flow Switch
e ow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to prevent the
boiler from ring unless there’s adequate water ow through the
unit. e ow switch must be installed in the supply piping adjacent
to the boiler outlet connection.
Failure to properly install the ow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualied 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, 25 mm must be maintained
between heating system pipes and all combustible construction. All
heating system piping must be supported by suitable hangers not the
boiler.
1", 25 mm
e thermal expansion of the system must be considered when
supporting the system. A minimum system pressure of 12 psig,
82.7 kPa must be maintained.
Heating Boiler Piping Connections
e supply and return connections should be sized to suit the
system, see Table 6.
Table 6 Supply and Return Pipe Sizing
Model Size Supply Size Return Size
100 thru 400 1 1/2” NPT 1 1/2” NPT
Pump Requirements
is low mass boiler requires a continuous minimum water ow
for proper operation. e boiler pump must be sized to overcome
the head loss of the boiler and the near piping in order to achieve
the required temperature rise. Table 7 and 8 provides the heat
exchanger pressure drop and temperature rise gures.
e temperature rise across the boiler must never exceed 30°F,
16.7°C. A pump delay is installed, the pump delay turns the pump
on each time the burners re and runs the pump up to 10 minutes
aer the call for heat is satised.
A temperature rise outside of the range listed in Tables
7 or 8 indicates that the ow rate through the heat
exchanger is incorrect which will damage the heat
exchanger voiding the warranty!
emaximumallowableowratethrougha Spectrum
boiler with copper heat exchanger is 92 GPM,
5.8 L/s (2-pass heat exchanger) and 46 GPM,
2.9 L/s (4-pass heat exchanger).
Low Water Cuto
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to wiring diagram supplied with the boiler/water heater for
proper wiring connections.
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 system
pump.
Primary/Secondary Piping
Boilers connected to heating systems using zone valves, zone pumps,
or systems that have excessive ow rates or return water temperatures
less than 110°F, 43°C must be isolated from these systems to protect
the boiler.
RIOM-57

Finned copper tube gas boilers & water heaters – Boiler Manual
10
Table 7 Temperature Rise Table – 2 Pass Headers
Table 8 Temperature Rise Table – 4 Pass Headers
∆T = 10°F ∆T = 5.5°C ∆T = 20°F ∆T = 11.1°C ∆T = 30°F ∆T = 16.7°C
Model
Number
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
GPM Ft L/s kPa GPM Ft L/s kPa GPM Ft L/s kPa
100 16.4 0.34 1.0 1.0 ——————— —
150 24.6 0.94 1.6 2.8 ——————— —
200 32.4 1.92 2.0 5.7 16.2 0.53 1.0 1.6 ——— —
250 40.5 3.46 2.6 10.2 20.3 0.96 1.3 2.8 ——— —
300 49.8* 5.89 3.1 17.3 24.9 1.63 1.6 4.8 16.6 0.80 1.0 2.3
350 See Note 29.1 2.47 1.8 7.3 19.4 1.20 1.2 3.4
400 33.2 3.54 2.1 10.4 22.1 1.70 1.4 4.9
Note: Unit equipped with 2-pass headers, see Table 7.
*Flow exceeds recommended maximum use a greater temperature rise or consult manufacturer. Cupro-nickel heat exchanger
should be considered.
∆T = 10°F ∆T = 5.5°C ∆T = 20°F ∆T = 11.1°C ∆T = 30°F ∆T = 16.7°C
Model
Number
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
Flow
Rate
Pres.
Drop
GPM Ft L/s kPa GPM Ft L/s kPa GPM Ft L/s kPa
100 16.4 0.05 1.0 0.1 ——————— —
150 24.6 0.13 1.6 0.4 ——————— —
200 32.4 0.27 2.0 0.8 16.2 0.07 1.0 0.2 ——— —
250 40.5 0.48 2.6 1.4 20.3 0.13 1.3 0.4 ——— —
300 49.8 0.82 3.1 2.4 24.9 0.23 1.6 0.7 16.6 0.10 1.0 0.3
350 58.1 1.23 3.7 3.6 29.1 0.34 1.8 1.0 19.4 0.20 1.2 0.5
400 66.4 1.77 4.2 5.2 33.2 0.49 2.1 1.4 22.1 0.20 1.4 0.7
Note: Unit equipped with 4-pass headers, see Table 8.

Finned copper tube gas boilers & water heaters – Boiler Manual
11
Figure 5 Typical Primary/Secondary Piping System
(See Notes)
Figure 6 Low Temperature Piping with Thermostatic Valve
(See Notes)
H-1 Rev 4
H-18 Rev 3
NOTES:
1. For pump selection consult factory.
2. Boiler pump sized to boiler and thermostatic 3-way valve design ow requirements.
3. Boiler circuit piping must be sized large enough to handle maximum ow through unit.
4. All boilers furnished with factory mounted outlet water temperature gauge.
5. Boiler pump purging required. Use terminals supplied.
6. Valve is precalibrated for 140°F return temperature.
Notice: These drawings show suggested piping conguration and valving.
Check with local codes and ordinances for specic requirements.
NOTES:
1. Boiler circuit piping must be sized
large enough to handle maximum
ow through unit.
2. Boiler pump sized to boiler design
ow requirements.
3. All boilers furnished with factory
mounted outlet water temperature
gauge.
4. Boiler pump purging required. Use
terminals supplied.
Notice: These drawings show suggested
piping conguration and valving.
Check with local codes and ordinances for
specic requirements. Operated Valve
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Va lve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Gate Valve
Globe Valve
Balance Valve
Backflow-
Prevention
Device
3-Way Valve
Expansion
Tank

Finned copper tube gas boilers & water heaters – Boiler Manual
12
Figure 6 Low Temperature Piping
(See Notes and Adjustment Procedures)
Figure 6A Multiple Boiler Piping
(See Notes)
H-15 Rev 5
NOTES:
1. Boiler circuit piping must be large enough to handle maximum ow through unit.
2. Boiler pump sized to boiler design ow 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 ow through all units.
Notice: These drawings show suggested piping conguration and valving.
Check with local codes and ordinances for specic requirements.
Adjustment Procedure
To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min=110°F For Atmospheric
T1-Temp-Min=125°F Sealed Combusion
1. Turn heater on and open valves A & B.
2. After steady-state operation, if T1 is less
than Temp-Min slowly close valve B until
T1 climbs to desired operating temperature
above Temp-Min.
3. If T1 is greater than desired operating
temperature, slowly close valve A to adjust to
lower desired temperature above Temp-Min.
4. Check after system operating temperature
has stabilized. Make nal adjustments.
5. Follow same adjustment procedure for
sealed combustion.
H-3 Rev 6
NOTES:
1. Boiler circuit piping must be
sized large enough to handle
maximum ow through unit.
2. Boiler pump sized to boiler
design ow requirements.
3. All boilers furnished with
factory mounted outlet
water temperature gauge.
4. Boiler pump purging required.
Use terminals supplied.
Notice: These drawings show
suggested piping conguration
and valving.Check with local
codes and ordinances for
specic requirements.
Operated Valve
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Va lve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Gate Valve
Globe Valve
Balance Valve
Backflow-
Prevention
Device
Expansion
Tank

Finned copper tube gas boilers & water heaters – Boiler Manual
13
Variable Water Flows
Figure 5 shows a typical primary/secondary piping system. A
dedicated pump is used to maintain a constant water ow through
the boiler. is boiler pump is sized to overcome the head loss of
the boiler and near piping while supplying the ow rate required
to maintain the desired temperature rise across the boiler heat
exchanger. e system pump is sized to provide the required ow
to the heating system.
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 Figures 6 and 6A. e bypass and bypass
valve must be sized the same as the secondary piping. A balancing
valve must also be installed in the supply side of the secondary
piping downstream of the bypass. e balancing valve should be
adjusted to divert some of the heated discharge water into the return
water until the required inlet water temperature is achieved. e
primaryandsecondarypumpsshouldbesizedtoprovidetherequired
ow through each system.
Multiple Boiler Systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 7.
Piping For Use With Cooling Units
e boiler, when used in connection with a refrigeration system,
must be installed so the chilled medium is piped in parallel with
the boiler. Appropriate valves must be used to prevent the chilled
water from entering the boiler.
When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling device, the piping
system must be equipped with ow-control valves or some other
automaticmeansofpreventinggravity circulationof the boiler water
during the cooling cycle.
DOMESTIC WATER SUPPLY PIPING
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
than120°F,49°C.Localcodesmustbe 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. e water heater must not be connected to
any heating system piping or components previously used with a
non-potable water heating appliance. No toxic chemicals, such as
those used for boiler treatment, are 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.
e storage tank must be located as close to the water
heater as possible to prevent excessive head loss which
will reduce ow.
Water Chemistry
e required temperature rise across the water heater is based on
water having a hardness between 5 and 25 grains per gallon with
a level of dissolved solids not exceeding 350 ppm. Water having a
hardness less than 5 grains can cause excessive corrosion of the
heat exchanger. Water that has a hardness greater than 25
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. e
manufacturer should be consulted when these water conditions
areencountered. See Table9A.
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 9A) and
the Pumping Performance Table (Table 9B). 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
thecountryadditionalprecautionsmustbeobserveddue tounusual
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 ow prevention
devices are installed.

Finned copper tube gas boilers & water heaters – Boiler Manual
14
Pump Requirements
is low-mass water heater requires a continuous mini-
mum water ow for proper operation. e factory recommended
circulating pump has been sized to overcome the head loss of the
waterheaterplusa30footpipingloopundernormalwaterconditions.
Table 9B provides the heat exchanger pressure drop chart and
temperature rise table. etemperatureriseacrossthewater
heatermustneverexceed30°F,16.7°C.
emaximumallowableowrate througha Spectrum
waterheateris92GPM,5.8L/s(2-passheatexchanger)
and 46 GPM, 2.9 L/s (4-pass heat exchanger). e
cupro-nickel heat exchanger allows for 100 GPM, 6.3
L/s (2-pass heat exchanger) and 50 GPM, 3.2 L/s
(4-pass heat exchanger). See Table 9B.
Cold Water Supply
e cold water supply must be piped to the storage tank on the
water heater’s outlet piping between the water heater and the hot
waterstoragetank.iswill preventuntemperedwaterfromentering
thewaterheater, see theTemperatureRiseControlsection.A typical
water heating system is shown in Figures 8 and 9.
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. e
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 ow rate through the heat
exchanger. ermometers are installed on both the inlet and outlet
of the water heater for determining the temperature rise through
the unit.
e proper velocity through the water heater must be maintained
in accordance with Table 9B for ecient 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 9B the ow rate is too low.
Scaling and soening 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°C provided
that a thermostatically controlled mixing valve is used to temper
the hot water to an acceptable temperature before it’s supplied for
domestic use.
e 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°C will provide
anincreasedquantityoftemperedwaterandhelppreventthe growth
of water born bacteria.

Finned copper tube gas boilers & water heaters – Boiler Manual
15
Table 9A Spectrum Heat Exchanger Selection Graph
Table 9B Spectrum Pumping Performance Requirement Table

Finned copper tube gas boilers & water heaters – Boiler Manual
16
Figure 8 Typical Water Heating Piping (MW Models Only)
(See Notes)
Figure 9 Multiple Water Heating Piping (MW Models Only)
(See Notes)
D-4 Rev 6
D-1 Rev 6
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 ft 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 ow.
7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
8. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.
Notice: These drawings show suggested piping conguration and valving.
Check with local codes and ordinances for specic requirements.
Operated Valve
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Valve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Valve
Globe Valve
Balance Valve
Vacuum
Relief Valve
Temperature &
Pressure
Relief Valve
Drain Valve
(Typ.)
2
3
1
4
7
8
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
SELF BALANCING DOUBLE REVERSE
RETURN MAKE-UP & SUPPLY, CIRCULATION
1
2
3
2
7
7
6
68
4
4
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.

Finned copper tube gas boilers & water heaters – Boiler Manual
17
GAS SUPPLY PIPING
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.
CanadianInstallationsmust complywith 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!
e Spectrum boiler/water heaters 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.
Aminimum gassupplypressure of 5 in,127 mm WC
naturalor12 in, 305mmWC propaneandmaximum
gas supply pressure of 14 in, 356 mm WC natual or
propane, must be available at the safety shuto valve
inletwiththeunit(s)operating.
Table 10 should be used to ensure that the gas supply piping is
sized properly. If more than one appliance is supplied by the same
supplypipe,thepipingmustbesizedbasedonthemaximumpossible
demand. Do not neglect the pressure drop due to pipe ings. Table
10 should be used in conjunction with Table 11 to ensure that the
gas supply piping has the capacity to meet the demand.
Table 10 Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specic gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Iron Pipe
Size
Pipe length in feet
10 20 30 40 50 60 80 100 150
Maximum gas volume of pipe, (ft3/hr)
3/4" 278 190 152 130 115 105 90 79 64
1" 520 350 285 245 215 195 170 150 120
1 1/4" 1050 730 590 500 440 400 350 305 250
1 1/2" 1600 1100 890 760 670 610 530 460 380
2" 3050 2100 1650 1450 1270 1150 990 870 710
2 1/2" 4800 3300 2700 2300 2000 1850 1600 1400 1130
3" 8500 5900 4700 4100 3600 3250 2800 2500 2000
4" 17,500 12,000 9700 8300 7400 6800 5800 5100 4100
Note: Multiply the gas volume by 0.62 for propane ow capacity in ft3/hr.
Multiply the propane ow capacity by 2500 Btu/ft3to determine
the propane Btu/hr capacity for a given pipe size and length.
Table 11 Equivalent Pipe Length
Nominal
Iron Pipe
Size
Type of pipe tting
90˚ Elbow Tee1Gate Valve2Gas Cock2
Equivalent pipe length, (ft)
1" 2.6 5.2 0.6 1.5
1 1/4" 3.5 6.9 0.8 1.9
1 1/2" 4.0 8.0 0.9 2.3
2" 5.2 10.3 1.2 3.0
2 1/2" 6.2 12.3 1.4 3.7
3" 7.7 15.3 1.8 4.5
4" 7.7 15.3 1.8 4.5
Notes: 1. For ow through branch.
2. For ow at full open.
Figure 10 depicts the proper way to connect the boiler/water heater
tothegassupplypiping. emanualshut-ovalveMUSTbeinstalled
in the supply piping. It should be installed 5 , 1.5 m above the
oor where required by local codes. Provide a sediment trap at the
boom of the vertical section of the gas supply pipe upstream of
the gas controls.
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.
Figure 10 Gas Supply Piping
Always use a 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!
RIOM-47

Finned copper tube gas boilers & water heaters – Boiler Manual
18
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 puing the boiler into
operation.
Never use an open ame to test for gas leaks. Always
use an approved leak detection method. Failure to
complywiththiswarningcancauseextensiveproperty
damage, severe personal injury or death!
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 isolate the boiler/water heater
by closing it’s manual shut o valve, see Figure 10. If the test pressure
is greaterthan, orequal to1/2 psig, 3.5 kPa,disconnect theboiler/
water heater and its individual shut-o valve.
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
LP Nat
Minimum (in WC) 12 5
Maximum (in WC) 14 14
Measure pressure when boiler is ring at full rate. Low gas pressure
could indicate undersized gas line or insucient gas supply.
"Static and operating gas pressure required at the gas valve inlet is
between 5 in WC and 14 in WC for natural gas and 12 in WC
and 14 in WC 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. is pressure
regulator(suppliedbyothers)maybeinstalledattheserviceentrance
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 specic job site requirements."
ELECTRICAL WIRING
Electrical Power Connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation! Verify proper operation aer
servicing!
AENTION. Au moment de l’entretien des
commandes, étiquetez tous les ls 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.
e electrical connections to this boiler/water heater must be made
in accordance with all applicable local codes and the latest revision
oftheNationalElectricalCode,ANSI/NFPA-70.Installationshould
also conform with CSA C22.1 Canadian Electrical Code Part I if
installed in Canada.
Install a separate 120 volt 15 amp circuit for the boiler/water heater
and circulator pump. A shut-o switch should be located at the
boiler/water heater. e 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 eld 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.

Finned copper tube gas boilers & water heaters – Boiler Manual
19
GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not aempt
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 o, turn
o the manual gas control valve to the appliance. Do not interrupt
water ow through the boiler/water heater.
Encasdesurchaueousi l’alimentationen gaznes’arrêtepas,fermez
manuellement le robinet d’arrêt de l’admission de gaz.
Hydronic Heating Boilers
Open the make-up water valve and slowly ll 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, 82.7 kPa system pressure is maintained at the highest point
in the system piping. If a make-up water pump is used adjust to
maintain a minimum 12 psig, 82.7 kPa system pressure.
Open the system bleed and drain valves, one at a time, to purge
the air trapped in the heating system piping.
With the boiler o, 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.
e system expansion tank should be checked to ensure that the
correct water level in the tank is maintained. e tank should be
less than half full of water with the system full and adjusted to the
correct operating pressure.
Startthe boilerasdescribedinthe“LIGHTINGANDOPETING
INSTRUCTIONS” on the next page. Run the boiler for at least an
hour. e system pump(s) and all radiation units must be operated
during this time. Ensure that the make-up water valve is open.
Shutthe boiler o andopen the bleed valvestopurge theair 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. e system should be checked and bled aer three days
of operation.

Finned copper tube gas boilers & water heaters – Boiler Manual
20
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
FOR YOUR SAFETY READ BEFORE OPERATING
A. If this appliance is equipped with an electronic
ignition device, this automatically lights the burner. Do
not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the oor.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will not push
in or turn by hand, don't try to repair it, call a qualied
service technician. Force or attempted repair may re-
sult in a re or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualied service technician to
inspect the appliance and to replace any part of the
control system and any gas control that has been under
water.
OPERATING INSTRUCTIONS
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is
to be performed.
3. Remove control access panel.
1. STOP! Read the safety information above.
2. Set the thermostat to 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 not try to light the pilot
by hand!
5. Remove control access panel.
6. Push in gas control knob slightly and turn clockwise
to “OFF”.
7.
Wait ve (5) minutes to clear out any gas. Then smell for
gas, including near the oor. If you smell gas, STOP!
Follow “B” in the safety information above (to the left)
on this label. If you do not smell gas, go to the next step.
8. Turn the gas control knob counterclockwise to
“ON”.
9. Replace control access panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your
service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
4. Push in gas control knob slightly and turn
clockwise to “OFF”. Do not force.
5. Replace control access panel.
OFF
ON
GAS CONTROL KNOB
PRESSURE REGULATOR
ADJUSTMENT (UNDER
CAP SCREW)
OUTLET PRESS. TAP
GAS INLET
GAS OUTLET
GROUND
TERMINALS (2)
INTERMITTENT PILOT - HONEYWELL VR8304A
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 qualied 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 re
department.