Vst Vrb-80 User manual

REVOLUTION CONDENSING

HEATING BOILERS

Installation

Manual

Keep this manual near this boiler for future reference

whenever maintance or service is required.

Model

VRB-80 VRB-110 VRB-130

For Your Safety

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result

causing property damage, personal injury or death.

- 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.

This boiler must be installed in accordance with local codes. In the absence of local codes, it must be installed in compliance

with The Federal Manufactured Home Construction and Safety Stand Title 24 CRF, part 3280 or CAN/CSA Z240 MH series,

mobile home. In the absence of such standard, The Standard for mobile Homes (ANSI/NFPA No. 601B-1977).

The installation must conform with local codes or, in the absence of local codes, the National Fuel Gas Code,

ANSIZ223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury (exposure

to hazardous materials)* or loss of life. Refer to the user's information manual provided with this boiler. Installation and

service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied

instructions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as

carcinogenic, or possibly carcinogenic, to humans).

WARNING

2Installation Manual

Safety Information

The following safety symbols are used in this manual for user's safety. Read this manual carefully and follow all instructions to avoid property

damage, fire, explosion, personal injury, or death.

Warning

Caution

Indicates an imminently hazardous situation which, if not avoided, will result in severe injury or death.

Indicates a potentially hazardous situation which, if not avoided, will result in injury or death.

Indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Danger

If you smell gas:

•Do not try to light any appliance.

•Do not touch any electrical switches or use landline phones.

•From a neighbor’s phone, call your gas provider and follow their instructions.

•If you cannot reach your gas provider, call the fire department.

Do not use or store flammable products, such as gasoline, solvents, or adhesives in the same room or area as the boiler.

•Vapors from flammable liquids can explode and/or catch fire causing death or severe burns.

•Keep flammable products far away from the boiler and store them in approved containers. Keep the containers tightly closed and out of the

reach of children.

•The Boiler has a main burner flame that can come on at any time and will ignite flammable vapors.

•Vapors cannot be seen and are heavier than air. They can travel long distances along the ground and can be carried from other rooms to the

boiler’s main burner flame by air current.

Danger

Safety Information

Warning

•Do not store combustibles, such as papers or laundry, near the boiler or venting system.

Failure to do so may result in fire or explosion.

•Do not store or use gasoline or other flammable liquids near this boiler.

Failure to do so may result in fire or explosion.

•Do not store or use compressed gases, such as hair sprays or spray paints, near the boiler or venting system, including the vent

termination.

Failure to do so may result in fire or explosion.

•Do not remove the front cover unless the power to the boiler is turned off or disconnected.

Failure to do so may result in electric shock.

•Do not touch the internal components of the boiler or the power cord with wet hands.

Failure to do so may result in electric shock.

•Do not operate the boiler with the front cover opened.

Failure to do so may result in fire or carbon monoxide (CO) poisoning, which may result in property damage, personal injury, or death.

•Do not operate the boiler without proper venting.

Failure to do so may result in fire or carbon monoxide (CO) poisoning, which may result in property damage, personal injury, or death.

•Shut off the gas supply if the boiler is damaged.

Have your installer or plumber show you the location of the gas shut off valve and demonstrate how to close the valve. If the boiler is

damaged as a result of overheating, fire, flood, or any other reason, close the manual shut off valve and do not operate the boiler again until

it has been inspected by a qualified technician.

•Should overheating occur or if the gas supply fails to shut off, turn off the manual gas shut off valve.

Caution

•Do not use the boiler for anything other than its intended purpose, as described in this manual.

Failure to do so may result in property damage, personal injury, or death.

•Do not turn on the boiler unless the water and gas supplies are fully opened.

Failure to do so may damage the boiler.

•Do not use unapproved replacement or accessory parts.

Failure to do so may result in improper or dangerous operation and will void the manufacturer's warranty.

•When servicing the controls, label all wires prior to disconnecting them.

Failure to do so may result in wiring errors.

•Do not place anything in or around the vent terminals that could obstruct the air flow in or out of the boiler.

Failure to do so may result in fire or carbon monoxide (CO) poisoning, which may result in property damage, personal injury, or death.

•Do not attempt to repair or replace any part of the boiler, unless it is specifically recommended in this manual.

For all other service, contact an authorized technician or licensed professional. Improper adjustments, alterations, service, or maintenance

may lead to property damage, personal injury, or death and will void your warranty.

•Do not operate the boiler if you suspect something might be wrong with it.

Doing so may result in product damage or personal injury.

•Do not allow children to operate or have access to the boiler.

Doing so may result in product damage or personal injury.

•Do not use this appliance if any part has been immersed in water.

Immediately call a qualified service technician to inspect the appliance and replace any part of the control system and/or any gas control

which has been immersed in water.

•This boiler has been approved for use in the USA and Canada only.

Using the boiler in any other country will void the manufacturer's warranty.

4Installation Manual

Important Note for the State of Massachusetts

NOTICE BEFORE INSTALLATION

This appliance must be installed by a licensed plumber or gas fitter in accordance with the Massachusetts Plumbing and Fuel Gas Code 248 CMR

Sections 4.00 and 5.00.

IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.00)

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential

purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet

above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied.

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment,

the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery backup is installed

on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery

operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure

served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of

qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon

monoxide detector with alarm and battery backup may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a

period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery

operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall

comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight

(8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.

The sign shall read, in print size no less than onehalf (1/2) inch in size,“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation

unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248

CMR 5.08(2)(a)1 through 4.

Important Note for the State of Massachusetts

Table of Contents

Safety Information .................................... 2

Important Note for the State of

Massachusetts ........................................... 4

General Information.................................. 6

Included Items ................................................................... 6

Optional Accessories........................................................ 6

Specifications...................................................................... 7

Rating Plate ......................................................................... 8

Dimensions.......................................................................... 9

Components .....................................................................10

Installing the Boiler ................................. 12

Installer Qualifications...................................................12

Compliance Requirements ..........................................12

Location..............................................................................12

Installing the System Piping................... 15

Installing a Space Heating System............................15

Connection the Condensate Drain...........................17

System Filling....................................................................19

Test the Water System ...................................................19

Example of System Applications ...............................20

Connecting the Gas Supply .................... 23

Gas Pipe Sizing Tables....................................................23

Gas Piping..........................................................................24

Inlet Gas Pressure............................................................25

Installing a Vent ....................................... 27

Vent Type............................................................................27

Vent Pipe Materials.........................................................31

Vent Length.......................................................................31

Connecting the Vent Clip .............................................32

Vent Termination.............................................................32

Setting the DIP Switches......................... 35

Connecting the Power Supply ................ 36

Installation Checklist............................... 37

Operating the Boiler................................ 40

Turning the Boiler On or Off........................................40

Setting the Space Heating Temperature ................40

Viewing Basic Information...........................................41

Setting the Heat Load for The Outdoor Reset

Control Mode....................................................................44

Appendix.................................................. 46

Gas Conversion ................................................................46

Wiring Diagram........................................ 50

Component Assembly Diagrams

and Parts Lists.......................................... 51

Case Parts (VRB)...............................................................51

Flue Parts (VRB)................................................................53

Water Parts (VRB Model)...............................................55

Outdoor Temperature Sensor

Installation .............................................. 57

Outdoor Temperature Sensor.....................................57

Outdoor Reset Control

(Available with Outdoor Temperature Sensor).....57

6Installation Manual

General Information

Included Items

The following items are included with the boiler. Check each of the

following items before installation.

Wall mounting bracket Tapping screws & anchors

Installation and

User manual

Quick installation manual

Vent clip Gas conversion kit

Spare parts Outdoor temperature sensor

Pressure Relief Valve 2" Vent termination cap &

Wall flange

Notice

If there is a missing item, please contact Technical Support at 1-800-761-

0053.

Optional Accessories

The following optional accessories are not included with the boiler,

but may be necessary for the installation. Check the need for any of

the following optional accessories before installation.

Cascade communication

cable

Plumb easy valve set

Pipe Cover

General Information

Specifications

The following table shows the specifications for the boiler. Additional specifications about water, gas, electric, and air supplies (venting) appear

in each installation section.

MODEL VRB-80 VRB-110 VRB-130

Heat Capacity (Input) Space Heating 19,900–80,000 BTU/H 19,900–110,000 BTU/H 19,900–130,000 BTU/H

AFUE Natural Gas (propane) 95.0%(95.0%) 95.0%(95.0%) 95.0%(95.0%)

Dimensions (W x D x H) 18.1“ x 27.6” x 11.6“ (460 mm x 700 mm x 295 mm)

Installation Type Indoor wall-hung

Venting Type Forced draft direct vent

Ignition Electronic ignition

Water Pressure 12~30psi

Supply Pressure

Natural Gas 3.5" – 10.5" WC

Propane 8" – 13" WC

Temperature Range Space Heating 82°F – 180°F(27°C – 82°C)

Connection Sizes

Space Heating Supply 1" NPT

Space Heating Return 1" NPT

Gas Inlet 3/4" NPT

Power Supply Main Supply 120V AC, 60 Hz / use less than 5 AMP

Materials

Primary Heat Exchanger

Stainless steel

Secondary Heat Exchanger

Venting

Exhaust/Intake 2" or 3" PVC, CPVC, Polypropylene

2" or 3" Special gas vent type BH (Class II, A/B/C)

Length

2" 60ft(18.3m)

3" 150ft(45.7m)

Vent Clearances 0" to combustibles

Safety Devices Flame rod, APS, Over heat preventer, Low water cut off switch

Exhaust temperature high limit sensor, Power surge fuse

8Installation Manual

Rating Plate

Danger

The gas type and electricity voltage must match the rating plate. Using a diferent gas type and electricity voltage will cause the boiler

to malfunction.

Before the installation, check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type, gas pressure, water

pressure, and electrical supply available in the installation location. If the boiler does not match each of these ratings, do not install the boiler.