Mestek TRS-IOM-5 Boiler and Water Heater Instruction Manual
- June 14, 2024
- MESTEK
Table of Contents
TRS-IOM-5 Boiler and Water Heater
Product Information
Product Name: Stainless Steel Water Tube Gas
Boilers (WB) & Water Heaters (WW)
Models: 1250, 1500, 2000, 2500, 3000 &
4000
Manufacturer: Mestek, Inc.
Copyright: 2019
Certifications: Designed and tested according
to A.S.M.E Boiler and Pressure Vessel Code, CSA certified for use
with natural gas under ANSI-Z21.10.3/CSA 4.3 and ANSI-Z21.13/CSA
4.9 standards
Product Usage Instructions
1. Safety Precautions:
-
Do not store or use gasoline or other flammable vapors and
liquids near the appliance. -
If you smell gas, follow the instructions below:
-
Installation and service must be performed by a qualified
installer, service agency, or the gas supplier. -
If vous sentez une odeur de gaz, suivez les instructions du
fournisseur.
-
-
Failure to properly vent this unit can cause carbon monoxide
buildup, leading to severe personal injury or death. -
Avoid using automotive anti-freeze in the boiler waterways. If
anti-freeze is necessary, use an anti-freeze specifically
formulated for hydronic heating systems to prevent damage to the
boiler.
2. Installation and Operation:
-
This manual covers the application, installation, operation,
and maintenance of the Torus series boiler/water heater. -
Read, understand, and follow these instructions to ensure safe,
dependable, efficient operation, and long product life. -
Ensure compliance with the authority having jurisdiction’s
requirements or the National Fuel Gas Code (ANSI Z223.1/NFPA
54-latest revision). -
If applicable, follow the additional instructions contained in
RBI’s instruction sheet MACODE-3 for installation in the
Commonwealth of Massachusetts.
3. Maintenance and Service:
-
Maintain a record of all service work performed, including the
date and description of the work done. Include the name of the
service organization for future reference. -
For sales and technical assistance, contact the RBI
Manufacturer’s Representative at 877-316-5074.
4. Important Note:
Retain these instructions for future reference purposes.
TRS-IOM-5 82-0954-001
Boiler & Water Heater Manual
Installation and Operation Instructions
Stainless Steel Water Tube Gas Boilers (WB) & Water Heaters (WW) Models 1250,
1500, 2000, 2500, 3000 & 4000 Also read and follow:
HeatNet Control Manual
This manual is intended only for use by a qualified 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/water heater 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. The 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. Affix these instructions near to the
boiler/water heater. Instruct the building owner to retain the instructions
for future use by a qualified service technician, and to follow all guidelines
in the User’s Information Manual.
5/2023 Copyright 2019 Mestek, Inc.
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
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 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 phone outside of 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’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.
CONTENTS
Before Your Start ………………………………………… page 2 Ratings & Capacities ……………………………………
page 3 Location …………………………………………………….. page 3 Combustion Air & Ventilation
………………………… page 3 Venting Guidelines………………………………………. page 5 Common Vent
Systems …………………………….. page 15 General Piping Requirements …………………….. page 20
Heating System Piping ………………………………. page 21 Domestic Water Supply Piping
……………………. page 24 Condensate Piping ……………………………………. page 26 Gas Supply Piping
…………………………………….. page 26 Electrical Wiring………………………………………… page 27 Boiler
Operation………………………………………… page 28 Operating Instructions ……………………………….. page
28 Sequence of Operation………………………………. page 31 Checking & Adjustment
……………………………… page 31 Ignition Troubleshooting …………………………….. page 33
Diagnostics ………………………………………………. page 34 Maintenance …………………………………………….. page
35 Pressure Switches…………………………………….. page 36 Wiring ……………………………………………………… page
37 Repair Parts……………………………………………… page 38 Start-Up …………………………………………………… page
46 Mass Code ………………………………………………. page 48 Warranty ………………………………………………….. page
49
BEFORE YOU START
This manual covers the application, installation, operation and maintenance of
a Torus series boiler/ water heater.
· Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se
trouvant dans le bâtiment.
· Appelez immédiatement votre fournisseur de gas
To obtain the safe, dependable, efficient operation and long life for which this boiler was designed, these instructions must be read, understood and followed.
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!
Do not use automotive anti-freeze in the boiler waterways. If the use of anti-
freeze is necessary an anti-freeze specifically formulated for hydronic
heating systems must be used or damage to the boiler may occur voiding the
warranty!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
The Torus series boiler/water heater series has been design certified by CSA
for use with natural 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. 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/NFPA 54-latest
revision. Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
In Canada, the installation must be in accordance with the requirements of CSA B149.1 or .2, Installation Code for Gas Burning Appliances and Equipment.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER
HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
If installed in the Commonwealth of Massachusetts, you MUST FOLLOW the additional instructions contained in RBI’s instruction sheet MACODE-3. Which is located in the back of this manual.
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
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.
For sales and technical assistance please call the RBI Manufacturer’s
Representative at 877-316-5074.
Please have the model and serial number from the equipment available.
RATINGS & CAPACITIES
Before installing the Torus series boiler check the rating plate to ensure
that the unit has been sized properly for the job. 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 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 as listed in Table 1.
Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.
Table 1 – Clearances
Top Back Left Side Right Side Front Flue
Clearance to Combustibles
in
mm
6
153
6
153
6
153
6
153
6
153
6
153
Service Clearance
in
mm
30
762
24
610
24
610
24
610
36
914
2. An optimum site will be level, central to the piping system, close to a
chimney or outside wall and have
adequate fresh air for combustion. Ensure that the unit is level from front to
back and from side to side. Use metal shims if leveling is required.
Electrical and electronic components must 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 and other electronic 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.
The Torus may be installed directly on combustible flooring, but never on
carpeting.
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.
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 the “COMBUSTION AIR & VENTILATION” and “GENERAL VENTING
GUIDLINES”.
6. NEVER place this boiler/water heater in a location that would subject it
to temperatures at or near freezing.
Never store combustible materials, gasoline or any product containing
flammable vapors or liquids in the vicinity of the boiler. Failure to comply
with this warning can result in an explosion or fire causing extensive
property damage, severe personal injury or death!
COMBUSTION AIR & VENTILATION
This boiler/water heater must be supplied with combustion air in accordance
with Section 9.3, 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 building codes. Failure to provide adequate combustion
air for this boiler/water heater can result in excessive levels of carbon
monoxide which can result in severe personal injury or death!
To operate properly and safely this boiler/water heater requires a continuous
supply of air for combustion. NEVER store objects on or around the boiler!
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 voiding the warranty!
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
If the boiler/water heater is operated while the building is under
construction it must be protected from wood, concrete, sheet rock and other
types of dust. Failure to properly protect the unit from construction dust
will damage the unit voiding the warranty!
Buildings will require the installation of a fresh air duct or other means of
providing make-up air if the intake air option isn’t used. 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.
Never operate the Torus in an environment subjected to a negative pressure.
Failure to comply with this warning 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 the minimum
clearances listed in Table 1 must be maintained between it and any combustible
construction. When installed in a confined space without the intake air option
two permanent openings communicating with an additional room(s) are required.
The combined volume of these spaces must have sufficient volume to meet the
criteria for an unconfined space. The total air requirements of all gas
utilization equipment, fireplaces, wood stoves or any type of exhaust fan must
be considered when making this determination. Each opening must have a minimum
free area of 1 in2/1000 Btu/hr, 2200 mm2/kW based on the
total input rating of ALL gas utilization equipment in the confined area. Each
opening must be no less than 100 in2, 64,516 mm2 in size. The upper opening
must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the top
of the enclosure. The bottom opening must be within 12 in, 300 mm of, but not
less than 3 in, 80 mm from, the bottom
of the enclosure.
All Air From Outside The Building
When installed in a confined space without the intake air option two permanent
openings communicating directly with, or by ducts to, the outdoors or spaces
that freely communicate with the outdoors must be present. The upper opening
must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the top
of the enclosure. The bottom opening must be within 12 in, 300 mm of, but not
less than 3 in, 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 1in2/ 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 cross-
sectional area as the free area of the opening to which they connect.
Table 2 – Make-up Air Duct Sizing
Required Cross Sectional Duct Area
Input (MBH)
1250 1500 2000 2500 3000 4000
1/4 in, 6.4 mm Wire Screen
in2 313 375 500 635 750 1000
cm2 2019 2419 3226 4031 4838 6452
Metal Louvers
in2 416 500 667 833 1000 1334
cm2 2684 3226 4303 5382 6452 8592
Wooden Louvers
in2 1250 1500 2000 2500 3000 4000
cm2 8065 9677 12903 16127 19354 25808
When calculating the free area necessary to meet the make-up air requirements of the enclosure, consideration must be given to the blockage effects of louvers, grills and screens.
Screens must have a minimum mesh size of 1/4 in,
6.4 mm. If the free area through a louver or grill is not known ducts should
be sized per Table 2.
Direct Intake Air Option – General
This configuration provides combustion air directly to the boiler/water heater
air intake using a dedicated pipe when using the direct vent option.
Combustion air can be drawn in horizontally through an outside wall or
vertically through the roof, see Figures 2, 3, 4 & 5. It must be sized per
Table 3.
Single wall galvanized smoke pipe, single wall aluminum pipe, flexible aluminum pipe, PVC or CPVC pipe can be used for the intake air pipe.
Table 3 – Intake Air Pipe Sizing
Model Size
1250
1500
2000 2500 3000 4000
Pipe Diameter
in
Length
6
80′
8
160′
6
80′
8
160′
8
160′
10
160′
10
160′
12
160′
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
All joints in metal intake air systems must be secured using corrosion
resistant fasteners and sealed using a suitable Silicone caulk. If PVC or CPVC
is used, the joints must be cleaned with a suitable solvent and connected
using a solvent based PVC cement. The intake air system MUST be supported by
the building structure not the boiler.
Direct Intake Air Option – Vertical
The maximum equivalent length for the vertical intake air pipe is based on
Table 4. Each 90° mitered elbow and the intake air cap are equal to 10 ft, 3.3
m of straight pipe. If 90° long sweep elbows are installed use the
manufacturers recommended equivalent length.
A listed, nonrestrictive intake air cap must be used. The intake air cap must
terminate as shown in Figure 4. The penetration point in the roof must be
properly flashed and sealed.
For Category II and IV appliances the vent shall not terminate:
- over public walkways; or 2) near soffit vents or crawl spaces or other
areas where condensate or vapor could create a nuisance or hazard or cause
property damage; or 3) where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.
A barometric damper or blast gate as required, must be installed if a Category II vertical vent system produces a negative draft in excess of 0.10 in, 2.5 mm WC at the
flue outlet. Size the vent system per local codes and the vent pipe manufactures requirements, using generally accepted engineering practices.
Direct Intake Air Option – Horizontal
The maximum equivalent length for the horizontal intake air pipe is based on
Table 4. Each 90° mitered elbow and the intake air terminal are equal to 10
ft, 3.3
m of straight pipe. If 90° long sweep elbows are installed use the
manufacturers recommended equivalent length.
For instructions utilizing the non-metallic vent option, see Addendum (TR-PVS-
IOM) for PVC/CPVC and (TR-CVS-IOM/TR-DVSIOM) for Polypropylene.
VENT SYSTEM OPTIONS
Horizontal runs that exceed 5 ft, 1.5 m must be supported at 3 ft, 0.98 m
intervals with overhead hangers. The intake air terminal must terminate as
shown in Figures 2, 3 or 5.
GENERAL VENTING GUIDELINES
The vent installation must be in accordance with Part 7, Venting of Equipment,
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision or
applicable provisions of the local building codes. Canadian installations must
comply with CSA B149.1 or .2 Installation Code. See Figure A for added
clarity. Improper venting can result in excessive levels of carbon monoxide
which can result in severe personal injury or death! Boiler/Water Heater shall
not be connected to a chimney flue serving a separate appliance, designed to
burn solid fuel.
All vent systems must be fully supported by the building structure and not by
the boiler. Appropriate thimbles and fire-stops must be used where required.
Improper installation of common positive pressure vent systems can result in
excessive levels of carbon monoxide which can cause severe personal injury or
death!
The Torus may be vented the following ways: 1) Direct Vent (individual venting
only) (page 11
& 12) – Positive Pressure, Category IV uses a stainless steel vent system
certified to UL 1738 for installations in the United States, and a stainless
steel vent system certified to ULC S636 for installations in Canada.
Combustion air is piped from the outdoors to the blower inlet.
2) Side Wall Vent (individual venting only) (page 13) – Positive Pressure,
Category IV uses a stainless steel vent system certified to UL 1738 for
installations in the United States, and a stainless steel vent system
certified to ULC S636 for installations in Canada. Combustion air is obtained
from the space in which the unit is installed.
To ensure proper operation, boilers/water heaters that are sidewall vented and
use room air must not be fired less than 33% input.
3) Vertical Vent (individual venting only) (page 13) – Positive Pressure,
Category IV uses a stainless steel vent system certified to UL 1738 for
installations in the United States, and a stainless steel vent system
certified to ULC S636 for installations in Canada. Combustion air is obtained
from the space in which the unit is installed.
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
-
Vertical Vent (individual venting only) (page 14) – Negative Pressure, Category II uses stainless steel vent system certified to UL 1738 for installations in the United States, and a stainless
steel vent system certified to ULC S636 for installation in Canada. Combustion air is obtained from the space in which the unit is installed. -
Common Vent (page 10) – Negative Pressure, Category II uses a stainless steel vent system certified to UL 1738 for installations in the United States, and a stainless steel vent system certified to ULC S636 for installations in Canada.
Abnormal wind patterns may effect overall performance.
Use (Table 4) for the maximum Category (IV) equivalent vent length and the equivalent length per fitting. Table 4 – “Category IV Equivalent Length per Fitting” chart is meant as a guideline for preliminary sizing. If vent length approaches 75% of maximum length listed, an engineered vent system calculation must be performed. Consult factory.
Table 4 – Category IV Maximum Equivalent Vent Length & Equivalent Length per Fitting
Model/Outlet Diameter
K* Maximum Equivalent Length (Catagory IV)
1250
6″
8″
80′
160′
1500
6″
8″
80′
160′
2000 8″
160′
2500 10″
160′
Standard Tee
1.25 25 ft
30 ft
25 ft
30 ft
35 ft
40 ft
Boot Tee
0.65 15 ft
15 ft
15 ft
15 ft
15 ft
20 ft
Cap – Low Res (UL) 0.50 10 ft
15 ft
10 ft
15 ft
15 ft
15 ft
45° w/Bird Screen
0.40 10 ft
10 ft
10 ft
10 ft
10 ft
15 ft
Elbow – 90°
0.38 10 ft
10 ft
10 ft
10 ft
10 ft
15 ft
Elbow – 45°
0.15 5 ft
5 ft
5 ft
5 ft
5 ft
7 ft
*Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings.
3000 10″
160′
40 ft 20 ft 15 ft 15 ft 15 ft 7 ft
4000 12″
160′
45 ft 25 ft 20 ft 15 ft 15 ft 7 ft
The RBI Torus is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers. Use only listed manufacturers (Table X), terminations (Table Y), and transition adapters (Table Z). The chimney systems manufacturer’s installation instructions must be followed.
DIRECT VENT
POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler/water heater blower is used to push the flue
products to the outdoors while drawing combustion air from the outdoors. The
INTAKE AIR OPTION instructions under the COMBUSTION AIR
& VENTILATION SECTION must be followed!
When horizontal vent runs exceed 5 ft, 1.5m they must
be supported at 3 ft, 0.98 m intervals with overhead hangers. If any part of a
single wall metal vent system passes through an unheated space it must be
insulated with insulation rated for 400°F, 212°C.
Horizontal Direct Vent Systems – Figures 2 & 3 The vent materials used in
positive pressure vent systems must be certified to UL 1738 for installations
in the United States, ULC S636 for installations in Canada.
To maximize the performance of single wall sheet metal vent systems locate 90°
elbows as far from the boiler as possible and from one another. For best
results, horizontal vent systems should be as short and straight as possible.
The vent system must be both gas and water tight. All seams and joints in
metal pipes must be joined and sealed in accordance with the vent system
manufacturer’s instructions.
Horizontal vent systems shall terminate at least 4 ft,
1.3 m below, 4 ft, 1.3 m horizontally from or 1 ft,
0.23 m above any door, window or gravity air inlet into any building. It must
not terminate less than 4 ft, 1.3 m horizontally from, and in no case above or
below, unless
a 4 ft, 1.3 m horizontal distance is maintained, from electric
meters, gas meters, regulators and relief equipment and not less than 7 ft,
2.3 m above adjacent public walkway. The bottom of the vent terminal(s) shall
be located at least
5 ft, 1.5 m above the air intake terminal(s) unless there is
a 5 ft, 1.5 m distance between them.
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Avoid terminal locations likely to be affected by winds, snowdrifts, people
and pets. Protect building materials and vegetation from degradation caused by
the flue gases.
When running horizontal combustion air and venting for single or multiple
units, exhaust and combustion air terminals must be installed on the same
plane (outside wall) in order to prevent pressure differences due to
prevailing winds. In cold climates, double-wall or insulated inlet pipe
recommended to prevent condensation.
Vertical Direct Vent Systems – see Figure 4 The vent materials used in
positive pressure vent systems must be certified to UL 1738 for installations
in the United States, ULC S636 for installations in Canada.
If any part of a single wall metal vent system passes through an unheated
space it must be insulated with insulation rated for 400°F, 204°C. Structural
penetrations must be made using approved fire-stops.
The top of a vertical vent system must extend at least 51/2 ft, 1.8 m above
the roof surface that it passes through, 4 ft, 1.3 m above the intake air cap,
see Figure 4. In addition the vent system must conform to the dimensions shown
in Figure 4. The penetration point in the roof must be properly flashed and
sealed.
The vent system must be gas tight. All seams and joints in metal pipes must be
joined and sealed in accordance with the vent system manufacturer’s
instructions.
Combination Direct Vent Systems – see Figure 5 The boiler can be vented
vertically with the intake air piped horizontally through an outside wall.
Follow the instructions in the INTAKE AIR OPTION – HORIZONTAL GUIDELINES on
page 5. Also follow the general instructions in the COMBUSTION AIR &
VENTILATION and GENERAL VENTING GUIDELINES sections.
Table X- Approved Stainless Steel Vent Manufacturers (CAT II/IV)
Make
Model
DuraVent
FasNSeal Vent
M&G DuraVent
DuraSeal Vent
Heatfab
Saf-T Vent
Metal-Fab
CORR/GUARD
Security Chimneys
Secure Seal
Schebler Chimney Systems e Vent
VAN-PACKER
CS
Z-Flex
Z-Vent
Jeremias
DWGV/SWGV
ICC
VIC
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Table Y- Approved Intake/Exhaust Terminations (CAT IV – Sidewall/Horizontal Direct Vent)
Exhaust Termination
Hood
Exhaust 90 deg
Exhaust Tee
Exhaust 45 deg
Exhaust Straight
*with bird screen
Table Z – Approved Manufacturers Stainless Steel Boiler Transition Adapters (CAT II/IV)
Model Size
1250/1500/2000 2500/3000
4000
M&G DuraVent (DuraSeal)
Transition Adapter
Flue
DS8FFNSAU
DS10FFNSAU
DS
DSD DS12FFNSAU
DSD12FFNSAUK
ICC
Transition Adapter
HM-8AC HM-10AC HM-10AC HM-12AC HM-12DSDA
Flue
VIC-SW VIC-DW
Metal-Fab
Transition Adapter
8FCSLCA 10FCSPKA2
12FCSLCA
Flue
Corr/Guard
Model Size
1250/1500/2000 2500/3000 4000
Heatfab (Saf-T Vent)
Transition Adapter
Flue
9801MAD
91001MAD
EZ/GC Cl Plus
91201MAD
Security Chimneys (Secure Seal)
Transition Adapter
Flue
SS8FFNSAU SSD8FFNSAUK
SS10FFNSAU
SS
SSD10FFNSAUK
SSD
SS12FFNSAU SSD12FFNSAUK
Jeremias
Transition Adapter
Flue
SWGV8-RCIS SWGV10-RCIS SWGV12-RCIS
DWGV SWGV
RBI Exhaust Termination
09-0113
09-0115
09-0116
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Model Size
VAN-PACKER
Transition Adapter
Flue
Z-Flex
Transition Adapter
Flue
Schebler Chimney Systems (e-Vent)
Transition Adapter
Flue
1250/1500/2000 2500/3000 4000
C08VLSL/M C10VLSL/M C12VLSL/M
2SVSAFNS08
ESW-UNAK-08R EVD-UNAK-08R
CS
2SVSAFNS10
Z-Flex
ESW-UNAK-10R EVD-UNAK-10R
ESW EVD
2SVSAFNS12
ESW-UNAK-12R EVD-UNAK-12R
*Factory Installed
The RBI Torus is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers. Use only listed manufacturers (Table X), terminations (Table Y), and transition adapters (Table Z). The chimney systems manufacturer’s installation instructions must be followed.
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Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual Figure 1 – Multiple Boiler Common Venting
DOUBLE ACTING BAROMETRIC DAMPER
THERMAL SPILL SWITCH
“B” “D”
“F”
“C”
VENT PIPE & CAP
BOILER #4 (IF REQUIRED)
BOILER #3 (IF REQUIRED)
BOILER #2 (IF REQUIRED)
BOILER #1
RIOM-0301_A
VERTICAL CHIMNEY VENTING – Vertical venting multiple boiler/water heater
installations:
It is recommended that the boiler/water heater
nearest the vertical chimney be fired first when the horizontal distance
exceeds 50% of the vertical distance. Refer to the HeatNet manual on how to
select the lead boiler.
When sized for a (CAT II) configuration, a negative pressure of 0.02 to 0.10
inches WC is required in each boiler/water heater riser when all boilers/water
heaters
are operating at full input. A barometer damper must be installed as
illustrated. [Exception: if the vent system is designed using accepted
engineering practices, and the design calculations prove there is no need for
barometric dampers, the barometric dampers may be omitted.] When required by
applicable codes, install a thermal spill switch on each barometric damper.
1. Connect each boiler/water heater riser to the common vent with a Y
connection or Boot T only.
2. Install an approved vent cap at each vent termination.
3. Dimensions: B = breeching length C = chimney height D = breeching diameter
F = riser diameter
(No smaller than the dimension given in Table 4, page 6.)
4. Multi-story, common venting systems shall be in accordance with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or the CSA B149.1, Natural
Gas and Propane Installation Code (Current Editions), local codes and vent
manufacturer’s installation instructions. Size the chimney and breeching using
generally accepted engineering practices. (Consult factory for vertical
heights beyond 60 ft.)
10
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure 2 – Horizontal Air Intake and Venting for a Single Direct Vent System
PITCH PIPE DOWN TOWARDS BOILER 1/4 INCH PER FOOT
PITCH PIPE DOWN TOWARDS TERMINAL 1/4 INCH PER FOOT
10 FT MINIMUM
TO ADJACENT BUILDING
REFER TO TABLE “Y” FOR APPROVED VENT TERMINATION AND DIMENTIONAL DATA
EXHAUST
“Y” MINIMUM BETWEEN TERMINALS
COMBUSTION AIR
1.5 FT MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE.
WARNING: When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall) in order to prevent pressure differences due to prevailing winds. In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.
“X” BETWEEN TERMINALS
RIOM-0093_A
Figure 3 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems
11
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure 4 – Vertical Air Intake and Venting for Direct Vent System
10 FT 3.1 m
4 FT 1.2 m
1.5 FT 0.5 m
5 1/2 FT 1.7 m
5 FT 1.5 m
Figure 5 – Combination Direct Vent Systems
(.5 m)
(3.1 m)
(.5 m)
12
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
SIDE WALL VENT POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler/water heater blower is used to push the flue
products horizontally to the outdoors, see Figure 6.
To ensure proper operation, boilers/water heaters that are vented sidewall and
use room air must not exceed a 6:1 turndown.
The air for combustion is taken from the space in which the unit is installed. The applicable instructions under the COMBUSTION AIR & VENTILATION SECTION must be followed! The vent guidelines under the HORIZONTAL DIRECT VENT SYSTEMS section must also be followed.
Figure 6 – Side Wall Venting
1/4 IN/FT 20 mm/m
1.5 FT .5 m
VERTICAL VENT (Recommended)
POSITIVE PRESSURE – CATEGORY IV
In this configuration the boiler/water heater blower is used to push the flue
products vertically to the outdoors, see Figure 7. The air for combustion is
taken from the space in which the unit is installed. The applicable
instructions under the COMBUSTION AIR & VENTILATION SECTION must be followed!
The vent guidelines under the VERTICAL DIRECT VENT SYSTEMS section must also
be followed.
Figure 7 – Vertical Positive Pressure Venting
10 FT 3.1 m
1.5 FT (0.5m) (30 cm)
(30cm)
2.0 FT (.6m)
13
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
VERTICAL VENT (Optional)
NEGATIVE PRESSURE – CATEGORY II
The Torus is listed as a Category II appliance when vented vertically into a
listed metal AL294C S.S. chimney system, Figure 8. The chimney system must
provide a negative pressure of 0.02 to 0.10 in, 0.51 to 2.5 mm WC at the
boiler/water heater flue collar with the unit running.
When using a listed metal chimney system the chimney system manufacturer’s instructions must be followed.
Multiple boiler/water heater vent systems must be designed and verified by a qualified professional and stack manufacturer. The vent system must prevent backflow of exhaust gas through idle boilers.
When more than one appliance is connected to the same chimney system the system must be large enough to safely vent the combined output of all of the appliances.
Table 5 lists the minimum riser sizes required for the Torus boiler/water heater.
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 excessive levels of carbon
monoxide which can cause
severe personal injury or death!
Table 5 – Minimum Riser Connection, Negative Pressure
Model Size
1250 1500 2000 2500 3000 4000
Breech & Flue Diameter
in
mm
10
254
10
254
10
254
12
305
12
305
14
356
Vent system must be sized per an engineered system.
Vent Connections Locate the boiler/water heater as close to the chimney system
as possible. Use the shortest, straightest vent connector possible for the
installation. If horizontal runs exceed 5 ft, 1.5 m they must be supported at
3 ft, 0.9 m intervals with overhead hangers. Use the appropriate vent
connector of the same diameter as the flue collar to connect the boiler/water
heater to a listed metal chimney system. Follow the chimney system
manufacturer’s instructions for proper assembly.
The vent system should be sloped up toward the chimney at a minimum rate of
1/4 in/ft, 2 cm/m.
Always provide a minimum clearance of 6 in, 152 mm between single wall vent
pipe and any combustible materials.
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!
Exit cones are favorable when used
to increase the velocity of the flue
gas exiting the stack and, may also help, in cold climates, to reduce ice
build-up. Exit cone terminations must be supplied by others, installed per
manufacturer’s instructions, and meet local and federal code.
generic exit cone
Figure 8 – Vertical Venting with a Metal Chimney System
2 FT .6 m
10 FT 3.1 m
Note:
- All building structural
modifications by others. 2) Firestopping per local building codes.
14
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
EXISTING COMMON VENT SYSTEMS
If an existing boiler/water heater is removed from a common venting system,
the common venting system may then be too large for the proper venting of the
remaining appliances connected to it. At the time of removal of an existing
boiler/water heater, the following steps shall be followed with each appliance
remaining connected to the common venting system placed in operation, while
the other appliances remaining connected to the common venting system are not
in operation.
Au moment du retrait d’une chaudière existante, les mesures suivantes doivent
être prises pour chaque appareil toujours raccordé au système d’évacuation
commun et qui fonctionne alors que d’autres appareils toujours raccordés au
système d’évacuation ne fonctionnent pas: système d’évacuation
a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système d’évacuation.
b) Visually inspect the venting system for proper size and horizontal pitch
and determine there is no blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe condition.
Inspecter de façon visuelle le système d’évacu-ation pour déterminer la
grosser et l’inclinaison horizontale qui conviennent et s’assurer que le
système est exempt d’obstruction, d’étranglement de fruite, de corrosion et
autres défaillances qui pourraient présenter des risques.
c) Insofar as is practical, close all building doors and windows and all doors
between the space in which the appliances remaining connected to the common
venting system are located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom exhaust, so they will
operate at maximum speed. Do not operate a summer exhaust fan for a boiler
installation. Close fireplace dampers.
Dans la mesure du possible, fermer toutes les portes et les fenêtres du
bâtiment et toutes les portes entre l’espace où les appareils toujours
raccordés du système d’évacuation sont installés et les autres
espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non
raccordés au système d’évacuation commun et tous les
ventilateurs d’extraction comme les hottes de
cuisinère et les ventilateurs des salles de bain. S’assurer que ces
ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les
registres des cheminées.
d) Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust thermostat so appliance will operate continuously.
Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage.
Régler le thermostat de façon que l’appareil fonctionne de façon continue.
e) 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.
f) 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 Appendix F in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and
or CSA B149 Installation Codes.
Tout mauvais fonctionnement du systéme d’évacu-
tion commun devrait étré corrigé de façor que l’installation soit conforme au
National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation
CSA-B149. Si la grosseur d’une section du système d’ évacuation doit étré
modifiée, le
système devrait étré modifié pour respecter les valeurs minimales des tableaux
pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et
(ou) des codes d’installation CSA-B149.
15
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure A – Direct Vent Terminal Clearances
Canadian Installations¹
US Installations²
A =
Clearance above grade, veranda, porch, deck, or balcony
12 in (30 cm)
12 in (30 cm)
B =
Clearance to window or door that may be opened
6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 12 in (30 cm) for appliances
10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW); 36 in (91 cm) for appliances 100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 9 in (23 cm) for appliances
10,000 Btuh (3 kW) and < 50,000 Btuh (15 kW); 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)
C =
Clearance to permanently closed window
Vertical clearance to ventilated soffit
D =
located above the terminal within a horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
E = Clearance to unventilated soffit
Per local installation codes
F = Clearance to outside corner
G = Clearance to inside corner
Clearance to each side of center line H = extended above meter / regulator
assembly
3 ft (91 cm) within a height of 15 ft (4.6m)
I =
Clearance to service regulator vent outlet
3 ft (91 cm)
Clearance to nonmechanical air supply J = inlet to building or the combustion
air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000 Btuh (3kW); 12 in (30 cm) for appliances
10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW); 36 in (91 cm) for appliances 100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh (3kW); 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and < 50,000 Btuh (15 kW); 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)
16
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure A – Direct Vent Terminal Clearances – Concluded
K =
Clearance to a mechanical air supply inlet
Clearance above paved sidewalk
L =
or paved driveway located on
public property
M =
Clearance under veranda, porch, deck, or balcony
6 ft (1.83 m) 7 ft (2.13 m) 12 in (30 cm)
3 ft (91 cm) above if within 10 ft (3 m) horizontally
Vents for Category II and IV appliances cannot be located above public
walkways or other areas where condensate or vapor can cause a nuisance or
hazard
Per local installation codes
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.
Figure A – Other Than Direct Vent Terminal Clearances
Canadian Installations¹ US Installations²
A =
Clearance above grade, veranda, porch, deck, or balcony
12 in (30 cm)
12 in (30 cm)
B =
Clearance to window or door that may be opened
6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 12 in (30 cm) for appliances
10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW); 36 in (91 cm) for appliances 100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening; 1 ft (300 mm) above opening
C =
Clearance to permanently closed window
Vertical clearance to ventilated soffit
D =
located above the terminal within a horizontal distance of 2 ft (61 cm)
from the center line of the terminal
E = Clearance to unventilated soffit F = Clearance to outside corner
Per local installation codes
G = Clearance to inside corner
Clearance to each side of center line H = extended above meter/regulator
assembly
3 ft (91 cm) within a height of 15 ft (4.6m)
I =
Clearance to service regulator vent outlet
3 ft (91 cm)
6 in (15 cm) for appliances < 10,000
4 ft (1.2 m) below or to side of opening;
Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances 1 ft (300 mm) above opening
J = inlet to building or the combustion air
10,000 Btuh (3 kW) and < 100,000
inlet to any other appliance
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
17
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure A – Other Than Direct Vent Terminal Clearances – Concluded
K =
Clearance to a mechanical air supply inlet
Clearance above paved sidewalk or L = paved driveway located on public
property
6 ft (1.83 m) 7 ft (2.13 m)
M =
Clearance under veranda, porch, deck, or balcony
12 in (30 cm)
3 ft (91 cm) above if within 10 ft (3 m) horizontally
Vents for Category II and IV appliances cannot be located above public
walkways or other areas where condensate or vapor can cause a nuisance or
hazard
Per local installation codes
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.
18
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
OUTDOOR VENTING
When installed outdoors the Torus Line must be fitted with the factory
supplied outdoor hood, air intake adapter with filter and exhaust terminal,
see Figure 7. Multiple units must be spaced per Figure 8.
The boiler/heater must be at least 2 ft, .62 m from any door, window or
gravity air inlet into any building and at least 3 ft, 1 m from any overhang
unless local codes dictate differently.
Avoid locations where wind deflection off of adjacent walls, buildings or
shrubbery might cause a downdraft. The unit(s) should be located at least 3
ft, 1 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
runoff from adjacent buildings or damage may occur voiding the warranty!
Outdoor Installations
The Torus Boiler/Water Heater is certified for outside installations in a
temperate climate not subject to freezing temperatures. 1. The condensate
traps located under the secondary heat exchanger and the vent pipe must be
wrapped with heat tape to ensure the traps never drop below 32°F. 2. The vent
pipe must be insulated to prevent freezing of condensate in the pipe. 3. The
boiler and system must be filled with a propylene glycol/water antifreeze
mixture not to exceed 50% glycol by volume. 4. All water piping exposed to low
temperatures must be insulated.
Figure 7 – Outdoor Venting
Figure 8 – Multiple Outdoor Units
3 FT (1 M)
2 FT (0.62 M)
19
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler/water heater will void the manufacturer’s
warranty and can cause boiler/water heater failure resulting in flooding and
extensive property damage!
Shut off 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.
Relief Valve Pipe the discharge of the pressure relief valve as shown in
Figure 9. Mount on rear section or vertically on supply nipple.
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!
Figure 9 – Torus Water Tube Piping
AIR VENT FLOW SENSOR PRESSURE RELIEF VALVE PIPE DISCHARGE PER ASME SECTION IV
– SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR AND ALLOW COMPLETE
DRAINAGE OF RELIEF VALVE AND PIPING
BOILER OUTLET
BOILER DRAIN FLUE OUTLET GAS CONNECTION
CONDENSATE DRAIN
AIR INLET
FILTER BOX COVER
LOW WATER CUT OFF PROBE
RIOM-0304_A
BOILER INLET
FILTER BOX
Freeze Protection
Installations in areas where the danger of freezing exists are not recommended
unless proper freeze protection is provided. The following precautions MUST be
observed: 1. A continuous flow of water through the unit MUST
be maintained! The pump responsible for flow through the boiler must run
continuously! 2. A propylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used. The pump must be
capable of producing a minimum of 15% more flow and overcoming a 20% increase
in head loss. Domestic water systems must be isolated from the boiler by
the use of a heat exchanger or other approved method. 3. If the unit must be
shut off for any reason the electric, gas and water supplies MUST be shut off
and the unit and its pump completely drained.
Flow Sensor
The factory mounted SIKA flow sensor, as shown in Figure 9, is wired to
prevent the boiler/water heater from firing unless there’s adequate water
flow, Table 6, through the unit.
The SIKA flow sensor sends information to the HeatNet control and displays the
water flow information in (gpm). The minimum flow settings are fully
adjustable. The boiler will not operate if the (gpm) falls below the minimum
value. If the system is using Glycol the % of glycol mixture must be entered.
The SIKA Flow sensor is limited to 194°F, 90°C water temperature, 145 psi
operating pressure and a 50% glycol mixture. If the return water temperature
rises above 194°F, 90°C the boiler will shut down. For applications outside
these requirements, please consult Manufacturer. Reference the HeatNet IOM for
menu instructions.
Air Vent
The factory mounted air vent, as shown in Figure 9, is installed to
automatically purge unwanted air from the boiler allowing the system to run
more effectively.
Please note that after installing in a new system or retrofitting an old,
close the isolation valve installed upstream of the Air Vent prior to filling
the system with water. Once the system has been properly filled open the Air
Vent isolation valve for automatic operation. If this is not done, it is
entirely possible that the internal float mechanism will become
clogged open, causing the air vent to leak.
RIOM-0304_A
20
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Table 6 – Temperature Rise Table
Model Size
Water Flow Rates (GPM)
Full/Min Input
Full Input
Min (gpm)
Max (gpm)
1250
40.2
160.9
1500
48.3
193.1
2000
64.3
257.3
2500
81.3
325.1
3000
97.5
390.2
4000
130.1
520.2
Verify system pipe sizing allows for flow velocity requirements.
Table 6a – Temperature Rise Table
15 Deg f (Delta t)
20 Deg f (Delta t)*
Model
(gpm)
Drop (ft)
(gpm)
Drop (ft)
GPM L/s Ft kPa GPM L/s Ft kPa 1250 160.9 10.2 27.3 81.7 120.7 7.6 15.4 45.9 1500 193.1 12.2 27.5 82.1 144.8 9.1 16.4 49.0 2000 257.3 16.2 33.6 100.3 193.0 12.2 20.1 60.1 2500 325.1 20.5 24.5 73.2 243.8 15.4 16.2 48.3
3000 390.2 24.6 32.1 95.9 292.6 18.5 21.0 62.7 4000 520.2 32.8 33.1 99.0 390.2 24.6 19.9 59.6
30 Deg f (Delta t)*
40 Deg f (Delta t)*
Model
(gpm)
Drop (ft)
(gpm)
Drop (ft)
GPM L/s Ft kPa GPM L/s Ft kPa 1250 80.4 5.1 7.3 21.7 60.3 3.8 4.7 13.9
1500 96.5 6.1 8.1 24.2 72.4 4.6 5.0 14.9 2000 128.7 8.1 9.9 29.7 96.5 6.1 6.1 18.2 2500 162.6 10.3 9.2 27.4 121.9 7.7 6.2 18.4 3000 195.1 12.3 11.8 35.3 146.3 9.2 7.9 23.7 4000 260.1 16.4 10.1 30.2 195.1 12.3 6.5 19.3
50 Deg f (Delta t)
60 Deg f (Delta t)
Model
(gpm)
Drop (ft)
(gpm)
Drop (ft)
GPM L/s Ft kPa GPM L/s Ft kPa
1250 48.3 3.0 1500 57.9 3.7 2000 77.2 4.9 2500 97.5 6.2 3000 117.0 7.4
3.6 10.7 40.2 2.5 3.5 10.4 48.3 3.0 4.2 12.5 64.3 4.1 4.5 13.5 81.3 5.1 5.8 17.4 97.5 6.2
3.0 9.1 2.6 7.8 3.1 9.2 3.5 10.4 4.5 13.5
4000 156.1 9.8 4.7 14.0 130.1 8.2 3.7 10.9
Verify system pipe sizing allows for flow velocity requirements. *Recommended (Delta T) temperature rise.
In order to maintain boiler capacity, increase flow rates approximately (10%) and pump head (25%) for mixtures up to 50% glycol.
Use the following equation to determine the boiler derate capacity when adjustments aren’t made. (2012 ASHRAE Systems Handbook)
qw = 500Q(p/pw)CpT
Where
qw = Total heat transfer rate, BTU/h p = fluid density. lb/ft³ Cp = specific
heat of fluid, Btu/lb °F
Q = flow rate, gpm pw = density of water at 60°F, lb/ft³ T = temperature difference, °F
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.
Where required, the piping must comply with 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 1in, 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. The thermal expansion of the system must be
considered when supporting the system. A minimum system pressure of 20 psig,
138 kPa must be maintained at boiler operating conditions. For glycol systems,
a minimum system pressure of 30 psig, 207 kPa must be maintained at boiler
operating conditions.
When equipped with a boiler pressure transducer, pressure will be monitored
closely for increased protection. A warning and/or alarm will be detected when
conditions fall below the following parameters:
Warning (boiler water) – pressure < 18 psi Warning (boiler water/glycol mix) – pressure < 28 psi Alarm – pressure < 15 psi
Boiler /Water Heater Piping Connections
The supply and return connections should be sized to suit the system, see
Table 7.
Table 7 – Supply & Return Pipe Connection
Model Size 1250 1500 2000 2500 3000 4000
Supply Size 2 1/2″ NPT 2 1/2″ NPT 2 1/2″ NPT
4″ NPT 4″ NPT 4″ NPT
Return Size 2 1/2″ NPT 2 1/2″ NPT 2 1/2″ NPT
4″ NPT 4″ NPT 4″ NPT
System Cleaning & Flushing: Prior to
commissioning the boiler(s), the piping/ system must be cleaned and flushed to
prevent contaminants from settling back into the boiler and fouling the heat
exchanger.
Isolate the boiler from the system prior to the cleaning process. Fill the system with water, add the cleaning solution and follow the solution manufacturer’s instructions. Once clean, refill the system with clean water as specified in the Water Treatment section.
21
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Water Treatment This boiler was designed to operate in a closed loop heating
system. System fill water must not contain more than 500 ppm Total Dissolved
Solids, less than 150 ppm chloride concentration and no greater than 200 ppm
Water Hardness. Suspended solids such as Magnetite, Iron Oxides must be
flushed from the system prior to commissioning the boiler(s). The PH level
must be within the 6.5-8.5 range. Where required, the system must be protected
by the addition of a corrosion inhibitor per the chemical supplier’s
instructions.
For systems requiring glycol for freeze protection use a glycol/ water mix
that prevents foaming. Air entrapped within foam significantly decreases heat
transfer and can result in damage to the heat exchanger. Products such as
DOWFROST, DOWTHERM, UCARTHERM or an equivalent product must be used to ensure
proper protection to the boiler.
The water used for dilution of concentrated heat transfer fluids must be
distilled, de-ionized, or equivalently clean as stated above. De-ionized water
by itself can be aggressive torwards many metals, but is perfectly safe when
used for dilution of DOWFROST, DOWTHERM or UCARTHERM as specified by the
manufacturer.
FAILURE TO ENSURE PROPER WATER QUALITY CAN RESULT IN DAMAGE TO THE BOILER(S)
VOIDING THE WARRANTY.
Water Meter Make-up water introduced into a closed system due to system leaks
can negatively affect the long term reliability of the heating sytem resulting
in abnormal boiler water quality. It is recommended that a water meter be
installed in the system make-up line. If makeup is recorded, the leaks must be
found and repaired.
Pump Requirements This boiler requires a continuous minimum water flow for
proper operation. The system pump must be sized to overcome the head loss of
the boiler and the heating system in order to achieve the required temperature
rise. Table 6a provides the heat exchanger pressure drop and temperature rise
figures. If the system contains hydronic antifreeze this must be considered
when sizing the pump. The temperature rise across the boiler must never exceed
60°F, 15.5°C.
Low Water Cutoff Each boiler comes equipped with a factory installed low water
cutoff.
Expansion Tank & Air Separator An expansion tank or other means to control
thermal expansion must be installed in the heating system. It is recommended
the expansion tank is installed close to the suction side of the pump.
Coalescing style air separators are strongly recommended in Variable Speed 22
Systems where velocities can vary and maybe too slow for conventional type air
separators. Failure to follow these guidelines will result in poor system
performance with minimal air removal and may void the factory warranty.
Reverse Return Piping Consideration of system thermal mass, minimum system
load & system flow must be based on the relationship between the boiler
minimum output and the system’s ability to absorb the energy. Insure at least
a ten (10) minute boiler run cycle at minimum system load. Systems using
multiple boilers can also be installed using a reverse return system, Figure
11.
Primary/Secondary Piping Although acceptable, the system is not as cost
effective as reverse return piping. Figure 12 shows a typical primary/
secondary piping system. A dedicated pump is used to maintain a constant water
flow through the boiler. Flow must be properly accounted for in the design of
primary/secondary systems. In order to prevent boiler(s) short cycling the
system flow must be equal to or higher than the boiler(s) local flow. Systems
using multiple boilers can be installed using a primary/secondary manifold
system, Figure 13.
Piping For Use With Cooling Units The boiler, when used in connection with a
refrigeration system, must be installed so the chilled medium is piped in
parallel with the boiler. Appropriate valves must be used to prevent the
chilled water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed to
refrigerated air from an air handling device, the piping system must be
equipped with flow-control valves or some other automatic means of preventing
gravity circulation of the boiler water during the cooling cycle.
It is essential that following boiler shut off, the boiler pump continue to
operate for approximately (5) minutes to dissipate the heat away from the heat
exchanger.
Figure 10 – Typical Single Boiler Piping (Circulator pump must be sized for
minimum water flow rate of boiler, including system pressure drop)
SYSTEM RETURN
WM
SYSTEM SUPPLY
COLD WATER MAKE-UP
WM
RIOM-305_A
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure 11 – Typical Multiple Boiler Reverse Return Piping
(Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local
manufactures representative for assistance.)
AIR SEPARATOR ALTERNATE LOCATION
AIR SEPARATOR TYPICAL LOCATION
SYSTEM RETURN
M
Motorized Valve
M M M M
WM
SYSTEM SUPPLY
COLD WATER MAKE-UP
NOTE: Not all system valves may be shown. Consult local codes for additional
system components which may be necessary. For HeatNet operation, a sensor is
required and installed at a minimum of 12″ from primary loop tee.
Figure 12 – Typical Single Boiler Primary/Secondary Piping
MINIMUM 3X PIPE DIAMETERS MAXIMUM 10X PIPE DIAMETERS
BETWEEN CENTERS
SYSTEM RETURN
AIR SEPARATOR ALTERNATE LOCATION
SYSTEM SUPPLY
AIR SEPARATOR TYPICAL LOCATION
WM
COLD WATER MAKE-UP
NOTE: Not all system valves may be shown. Consult local codes for additional
system components which may be necessary. For HeatNet operation, a sensor is
required and installed at a minimum of 12″ from primary loop tee.
Figure 13 – Typical Multiple Boiler Primary/Secondary Piping
SYSTEM RETURN AIR SEPARATOR ALTERNATE LOCATION
MINIMUM 3X PIPE DIAMETERS MAXIMUM 10X PIPE DIAMETERS BETWEEN CENTERS
AIR SEPARATOR TYPICAL LOCATION
WM
SYSTEM SUPPLY
COLD WATER MAKE-UP
NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12″ from primary loop tee.
Heat Net Sensor For Heat-net Operation, A Sensor Is Required And Installed At
A Minimum Of 12″ From Primary Loop Tee.
WM
Water Meter
23
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
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 than 120°F, 49°C. Local codes must be complied with!
General Piping Requirements
The 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. No toxic chemicals, such as those used for boiler treatment, are to
be
introduced into the potable water used for space heating.
Potable Water 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. The storage tank must be located as close to the boiler
as possible to prevent excessive head loss which will reduce flow. Two typical
water heating systems are shown in Figures 14 & 15.
Thermostatic Mixing Valve- Water Above 140°F, 60°C
Water can be stored a 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. The mixing valve
MUST be set to prevent a scald injury from occurring, see the caution against
scalding above. Storage of water for domestic use above 140°F, 60°C will
provide an increased quantity of tempered water and help prevent the growth of
water born bacteria.
Potable Water & Space Heating
The following must comply when this water heater is used for both potable
water and space heating applications.
1. Follow the “General Piping Requirements” Section of this page.
2. The water heater must not be used in space heating applications only.
3. When the system requires water for space heating at temperatures greater
than 140°F, 60°C a means such as a mixing valve shall be installed to temper
the water in order to reduce scalding.
Water Chemistry
The required temperature rise across the primary heat exchanger is based on
water having a hardness between 4 and 12 grains per gallon with a level of
dissolved solids not exceeding 350 ppm. Water having a hardness less than 4
grains can cause excessive corrosion of the heat exchanger. Water that has a
hardness greater than 12 grains per gallon and/or a level of dissolved solids
exceeding 350 ppm will require a larger circulating pump and temperature rise.
Water hardness greater than 15 grains per gallon will require a water softner
system.
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 pump
selections. Scale free operation can be achieved when properly following the
guidelines in (Table 8). In some areas of the country additional precautions
must be observed due to unusual characteristics of the local water supply.
Call the nearest RBI representative for details.
Table 8
pH Level
Water Hardness
Model 1250 1500 2000 2500 3000 4000
Water Heater Min Flow Rates
6.5-8.5
Normal (4 to 12) gpg
Hard (12-15) gpg
GPM 99 110 138 214 214 280
Delta-t 24.5 26.5 28.1 22.7 27.5 28.0
Drop (ft) 10.5 10.1 11.2 13.4 13.4 11.4
GPM 132 147 183 285 285 372
Delta-t 18.4 19.8 21.2 17 20.6 21.1
Drop (ft) 18.3 16.8 18.3 20.2 20.2 18.4
Expansion Tank
An expansion tank or other means to control thermal expansion must be
installed in the water heating system if back flow prevention devices are
installed.
Pump Requirements
This low-mass water heater requires a continuous
minimum water flow for proper operation. When making pump selections, proper
velocity through the water heater must be maintained for efficient operation
and long life. If the temperature rise is too high, the flow rate is too low.
Scaling and softening of the primary heat exchanger will occur. The
temperature rise across the primary heat exchanger must never exceed the flow
rates listed in Table 8.
24
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual Figure 14 – Typical Single Boiler with Direct Storage Tank Piping
SUPPLY
4 1
FLOW FLOW
BRONZE
2
PUMP
CIRCULATOR RETURN 5
COLD WATER MAKE-UP
RIOM-0309_A
NOTES:
1. LOCATE HEATNET SENSOR WITH WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH
HEAT SENSING COMPOUND.
2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
3. CAUTION: MEASURE WATER HARDNESS AND PH AT JOB SITE. THIS MUST BE MEASURED
BEFORE SELECTING PUMP.
4. HOT WATER TANKS SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE &
PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP.
REFER TO LOCAL CODES.
5. MA CODE REQUIRES A 1/8 IN HOLE IN CHECK VALVE TO COMPENSATE FOR THERMAL
EXPANSION.
6. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR THE
REQUIREMENTS OF AN ACID NEUTRALIZATION KIT.
7. A THERMOSTATIC MIXING VALVE MAY BE REQUIRED AT THE OUTLET OF THE TANK IN
ORDER TO LIMIT THE MIXED WATER TO A DESIRABLE TEMPERATURE HELPING TO PREVENT
SCALDING AND INJURY. CONSULT LOCAL CODES.
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
PUMP
GATE VALVE CHECK VALVE
BACKFLOW PREVENTION DEVICE
TEMPERATURE & PRESSURE
RELIEF VALVE
VACUUM RELIEF VALVE
THERMOMETER
EXPANSION TANK
HEATNET SENSOR
Figure 15 – Typical Multiple Boiler with Direct Storage Tank Piping
FLOW
5 6
FLOW
1
COLD WATER
MAKE-UP
7
3
FLOW
2
CIRCULATOR
6
RETURN
BRONZE PUMP
2
FLOW
NOTES:
SUPPLY
1. OPTIONAL COLD WATER MAKE UP AND RECIRCULATION LINE LOCATION.
2. LOCATE HEATNET SENSOR WITH WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND. FOR MULTIPLE TANKS, SELF-BALANCING REVERSE-RETURN SYSTEMS, A SINGLE HEATNET SENSOR IS APPLIED.
3. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES.
4. CAUTION: TEST WATER HARDNESS AND PH AT JOB SITE. THIS MUST BE MEASURED BEFORE SELECTING PUMP.
5. COMMON PIPING MUST BE SIZED FOR MAXIMUM COMBINED HEATER FLOW.
6. HOT WATER TANKS SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE & PRESSURE RELIEF VALVE. VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP. REFER TO LOCAL CODES.
5
7. MA CODE REQUIRES A 1/8 IN HOLE IN CHECK VALVE TO COMPENSATE FOR THERMAL
EXPANSION. 8. CONTRACTOR SHALL VERIFY, WITH AUTHORITY HAVING JURISDICTION, FOR
THE REQUIREMENTS OF AN ACID NEUTRALIZATION KIT. 9. A THERMOSTATIC MIXING VALVE
MAY BE REQUIRED AT THE OUTLET OF THE TANK IN ORDER TO LIMIT THE MIXED WATER TO
A DESIRABLE TEMPERATURE HELPING TO PREVENT SCALDING AND INJURY. CONSULT LOCAL
CODES.
NOTICE: THESE DRAWINGS SHOW SUGGESTED PIPING CONFIGURATION, VALVING AND ARE
DIAGRAMMATIC. CHECK WITH LOCAL CODES AND ORDINANCES FOR SPECIFIC REQUIREMENTS.
PUMP
GATE VALVE CHECK VALVE
BACKFLOW PREVENTION DEVICE
TEMPERATURE & PRESURE
RELIEF VALVE
VACUUM RELIEF THERMOMETER VALVE
EXPANSION TANK
HEATNET SENSOR
RIOM-0310_A
25
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
CONDENSATE PIPING
The condensate trap provided with the boiler/water heater must be attached to
the bottom pan and piped to a suitable floor drain (consult local code) or
condensate pump. If a condensate neutralization device is required by local
code, it must be positioned prior to boiler room drain. Fill the condensate
trap with water, check and maintain water level in trap during operation prior
to start-up.
GAS SUPPLY PIPING
Check the boiler/water heater rating plate to make sure that the boiler is for
the type of gas that will be used. If it isn’t, do not connect the boiler to
the gas supply. Failure to comply with this warning can result in extensive
property damage, severe personal injury or death!
The Torus comes 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 your RBI representative to resolve the problem.
Do not size the gas supply line nominal iron pipe size based only on the
boiler gas inlet connection size. The gas supply line (feed) to the boiler gas
inlet connection must be designed per an engineered method and utilizing
(Table 9) to ensure that the gas supply piping is sized properly. Do not
neglect the pressure drop due to pipe fittings. (Table 9) should be used in
conjunction with (Table 10) to ensure that the gas supply piping has the
capacity to meet the demand. If more than one appliance is supplied by the
same supply pipe, the piping must be sized based on the maximum possible
demand.
Figure 16 – Torus Series Condensate Drain
Figure 17 depicts the proper way to connect the boiler to the gas supply piping. The manual shut-off valve MUST be installed in the supply piping. It should be installed 5 ft, 1 m above the floor where required by local codes. Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls.
A ground joint union should be installed between the boiler/ water heater 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 with the type of gas (NG/LP) being used.
Table 9 – Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas at a pressure of 0.5 psig or less and a 0.3″ WC pressure drop.
Nominal Iron Pipe 10
Size
Pipe length in feet 20 30 40 50 60 80 100 150
Maximum gas volume of pipe (ft3/hr)
11/2″ 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
5″ 31,700 21,800 17,500 15,000 31,300 12,000 10,300 9110 7320
6″ 51,300 35,300 28,300 24,200 21,500 19,500 16,700 14,800 11,900
Note: Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr. Multiply the propane flow capacity by 2500 Btu/ft3 to determine the propane Btu/hr capacity for a given pipe size and length.
Table 10 – Equivalent Pipe Length Chart
Nominal Iron Pipe
90° Elbow
Type of pipe fitting
Tee1
Gas Valve2
Size
Equivalent pipe length, (ft)
11/2″
4.0
8.0
0.9
2″
5.2
10.3
1.2
21/2″
6.2
12.3
1.4
3″
7.7
15.3
1.8
4″
10.1
20.2
2.4
5″
12.6
25.2
2.9
6″
15.2
30.4
3.5
Notes: 1. For flow through branch.
2. For flow at full open.
Gas Cock2 2.3 3.0 3.5 4.5 6.0 7.3 13.4
CONDENSATE DRAIN OUTLET
RIOM-0311_A
CONDENSATE DRAIN ASSEMBLY
A lockup style regulator, supplied by others, must be installed, see Figure
17, if gas pressure exceeds (14 in WC). The regulator, when installed as
shown, must be installed
at a distance of at least 10 pipe diameters from the boiler main gas valve.
All boilers are calibrated and factory test fired at
(7 in ± 1.0) WC.
26
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
A minimum of (3 in WC) and maximum of (14 in WC) must be maintained to the inlet of the boiler/water heater gas train not to exceed a maximum of (1 in WC) drop when firing from minimum input to full load of the gas supply line and all the appliances running.
Whenever the gas supply piping is pressure tested the boiler gas controls must
be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa
isolate the boiler
by closing its’ manual shut off valve, see Figure 17. If the test pressure is
greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler and its
individual shut-off valve.
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!
Safe lighting and other performance criteria were met with the gas manifold
and control assembly provided on the boiler/water heater. All gas connections
MUST be leak tested before putting the boiler into operation.
Never use an open flame to test for gas leaks. Always use an approved leak
detection method. Failure to comply with this warning can cause extensive
property damage, severe personal injury or death!
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 after
servicing.
ATTENTION. Au moment de l’entretien des com-mandes, étiquetez tous les fils
avant de les débrancher. Des erreurs de câblage peuvent entraîner un
fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne
adéquatement une fois l’entretirn terminé.
Gas train must be isolated when purging the gas line prior to commissioning
the boiler.
Corruption of the gas train components with debris and cutting oils can reduce
reliable operation which can have a negative effect on the operation &
manufacturers warranty of the Dungs gas valve. The factory supplied Dungs MBC
modulation gas valve, see Figure 17, incorporates an internal filter that must
be inspected and changed at required intervals. Reference the Dungs MBC
Installation Instructions – 264541 for detailed instructions. Combined with
clean gas pipes and good plumbing practices (such as installing a drip leg),
should adequately protect the MBC valve seat, regulator and internal orifices
from clogging or damage. However, site conditions might warrant an additional
filter. This should be installed upstream of the appliance gas regulator to
the unit.
The electrical connections to this boiler/water heater
must be made in accordance with all applicable local codes and the latest
revision of the National Electrical
Code, ANSI /NFPA-70. Installation should also conform with CSA C22.1 Canadian
Electrical Code Part I if installed in Canada. A separate circuit breaker must
be installed per boiler – (if required, the optional local pump FLA must be
incorporated and sized accordingly). A properly rated shut-off switch should
be located at the boiler. The boiler must be grounded in accordance with the
authority having jurisdiction, or if none, the latest revision of the National
Electrical Code, ANSI/NFPA-70.
Refer to the wiring diagram supplied with the boiler for proper wiring
connections and boiler full load amperage (FLA).
Figure 17 – Gas Supply Piping
FROM GAS SUPPLY
MAIN GAS VALVE
LOW GAS PRESSURE SWITCH (ON APPLICABLE MODELS)
DUNGS VALVE
GROUND UNION
HIGH GAS PRESSURE SWITCH (ON APPLICABLE MODELS)
CSD-1 TEST PORTS
FIRING VALVE
SUPPLIED BY OTHERS
PRESSURE REGULATOR
SEDIMENT TRAP AND DRIP LEG
HIGH FIRE GAS PRESSURE ADJUSTMENT
LOW FIRE GAS PRESSURE ADJUSTMENT MANUAL SHUT-OFF VALVE
SUPPLY PRESSURE TEST PORT
RIOM-0312_A
27
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
BOILER/WATER HEATER OPERATION
Before proceeding read and fully understand the instructions contained in this
manual. Do not attempt to operate this boiler if it has not been installed in
accordance with the guidelines set forth in this manual. Failure to comply
with this warning can result in extensive property damage, severe personal
injury or death! Should overheating occur or the gas supply fail to shut off,
turn off the manual gas control valve to the appliance. Do Not interrupt water
flow through the boiler/water heater. En cas de surchauffe ou si
l’alimentation en gaz ne s’arrête pas, fermez manuellement le robinet d’arrêt
de l’admission de gaz. Hydronic Heating Boilers (Fill System) Open the make-up
water valve and slowly fill the boiler and all of the radiation with water.
Ensure that all bleed and drain valves are closed. Adjust the make-up water
pressure regulator so a minimum 5 psig, 82.7 kPa system pressure is maintained
at the highest point in the system piping. A minimum system pressure of 20
psig, 138 kPa must be maintained at boiler operating conditions. A minimum
system pressure of 30 psig, 207 kPa fill pressure is required, at boiler
operating conditions, on glycol mixtures within a closed loop. Open the system
bleed and drain valves, one at a time, to purge the air trapped in the heating
system piping. With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed valves. If strainers are
used in the system piping the make-up water valve should be closed and the
strainers checked and cleaned. The system expansion tank should be checked to
ensure that tank air pressure equals cold static fill pressure. Start the
boiler as described in the OPERATING INSTRUCTIONS below. Run the boiler for at
least an hour. The system pump(s) and all radiation units must be operated
during this time. Ensure that the make-up water valve is open. Shut the boiler
off and open the bleed valves to purge the air trapped in the heating system
piping. Close the make-up water valve and check and clean the strainers and
make-up water pressure reducing valve. Open the make-up water valve and adjust
the system pressure if necessary.
The system should be checked and bled after three days of operation.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING. ONLY QUALIFIED LICENSED SERVICE
TECHNICIANS SHALL START, TROUBLESHOOT, AND SERVICE THIS APPLIANCE WITH
APPROVED COMBUSTION ANALYZER. POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN
MARCHE
A. This appliance is equipped with an ignition device which automatically
lights the burner. Do not try to light the burner by hand.
Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la
veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to
smell next to the floor because some gas is heavier than air and will settle
on the floor.
WHAT TO DO IF YOU SMELL GAS · Do not try to light any appliance. · Do not
tough any electric switch; do not use any phone
in your building. · Immediately call your gas supplier from a phone outside
of the building. Follow the gas suppliers instructions. · If you cannot reach
your gas supplier, call the fire
department.
AVANT DE FAIRE FONCTIONNER, reniflez tout autour de l’appareil pour déceler
une odeur de gaz. Reniflez près du plancher, car certains gaz sont plus lourds
que l’air et peuvent s’accumuler au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: · Ne pas tenter d’allumer
d’appareil. · Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment. · Appelez immédiatement votre
fournisseur de gaz
depuis un voisin. Suives les instructions du fournisseur. · Si vous ne pouvez
rejoindre le fournisseur, appelez le service de incendies.
C. Do not use this appliance if any part has been under water. Immediately
call a qualified service technician to inspect the appliance and to replace
any part of the control system and any gas control that has been under water.
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement.
Faites inspecter l’appareil par un tecnicien qualifié et remplacez toute
partie du système de contrôle et toute commande qui ont été plongés dans
l’eau.
28
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Operating Instructions 1. STOP! Read the safety information above. If, at any
time, the appliance will not operate properly, follow the instructions “TO
TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.
2. Set the operating control to off and disable any outside (BMS) call for
heat.
3. Turn off all electric power to the appliance.
4. Remove the front cover.
5. Close manual main shut-off valves 1 and 2, Figure 17.
6. Purge the gas piping up to the manual valve ahead of the main gas control
of air. When the bleeding is complete, check all gas joints up to the gas
valve for leaks.
7. Wait five (5) minutes to clear out any gas.
8. Install a fitting at the supply test port and connect a manometer having a
minimum range of 20 in, 508 mm WC to it, Figure 17. Connect both sides of a
manometer or pressure gauge to the manometer pressure taps (differential
pressure barbed connections) on the pressure test manifold located inside the
upper control panel, Figure 18.
9. See the “Gas Supply Piping” section for the required static and run gas
pressure.
10. Open the manual main shut-off valves 1 and 2, Figure 17. Follow the same
procedure for multiple gas train configurations (Dual Fuel).
11. Place the “Remote/Local” switch to Remote.
12. Turn the power switch on the front of the boiler to “on”. It will light
up when the power is on. If all interlocks are properly closed, the display
will say “Standby”, Figure 18.
13. Slide the HeatNet controls low fire switch (on the HeatNet control board)
to the low fire position.
14. The boiler will begin the start sequence.
15. When the main display reads “MAIN IGNITION”, the burner will light at the
“Ignition (%)” shown on the display. In the event the boiler doesn’t light the
burner will recycle 3 times prior to an ignition lockout. For CSD-1 models,
the burner will lockout after one failed ignition try. Non CSD-1 models will
require a power cycle to reset the Fenwal control. CSD-1 models utilize a
ignition lockout reset switch, Figure 18.
16. To adjust the IGNITION value as shown in the display, place the S2′ Calibration switch located on the 3.0 HeatNet board to theCAL’ position. A
reload message will be displayed then the calibrate screen. Press the `Adjust’
button under the Ignition (%) setting. The percentage value will turn green
and the boiler will ramp to the ignition setting. Set the Blower speed, using
the arrow keys, to provide the desired rate for ignition. When the adjustment
is satisfactory, press the check key to save the setting.
The Calibration (Min % & Max %) represents the mapped signal sent to the
blower and doesn’t reflect the (modulation %) as indicated on the HeatNet
Screen.
17. Setting the Min % and Low Fire Combustion values: The boiler will cycle
and achieve low fire status. Allow low fire to settle out for a few minutes
and observe the combustion reading.
29
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure 18 – Control Panel Components
TOUCH SCREEEN USB
POWER SWITCH
BLOWER PROVE PRESSURE TAPS
AUTO HIGH LIMIT ON APPLICABLE MODELS MANUAL RESET HIGH LIMIT
BLOWER RELAY 12V POWER SUPPLY
CABINET LIGHT
LOCAL / REMOTE SWITCH
LOW WATER CUTOFF RESET
BLOCKED VENT
HEATNET CONTROL BOARD
SPARK GENERATOR
RIOM-0313_B
a. Verify the S2′ – Calibration switch located on the 3.0 HeatNet board is in theCAL’ position.
RIOM-0313 _B
a. Verify the S2′- Calibration switch located on the 3.0 HeatNet board is in theCAL’ position. While in Standby (no call for heat on inputs), the Max %
percentage may be preset, before firing the boiler. Press the ‘Adjust’ button
under the Maximum (%) setting and set this value to a lower input value (50%).
This will allow for manual input control during the high fire set up process
(18b.). When the adjustment is satisfactory press the check key to save the
setting.
b. Press the `Adjust’ button under the Minimum (%) setting. The percentage
value will turn green. Adjust the minimum value (%), using the arrow keys, to
achieve the required combustion – C02/02, (Table 11), and pressure delta p,
(Table 12), at low fire based on the desired turn down.
c. Adjust low fire 02-C02 by opening the low fire adjustment door located on
the forward facing side of the main gas valve, (Figure 17). Inserting an allen
wrench and rotating the allen screw clock-wise will increase the C02 and lower
the 02; rotating counter clock-wise will decrease the C02 and increase the 02.
d. When the adjustment is satisfactory, press the check key to save the
setting.
18. Setting the Max VFD and High Fire Combustion values: Remove the demand
from the Fenwel control by disabling the low fire switch allowing the boiler
to stop.
30
b. Using the low fire switch on the HeatNet board create a minimum input
demand. The boiler will cycle to low fire position. Press the `Adjust’ button
under the Maximum (%) setting. Boiler input will modulate to the previously
set (50%) input. The percentage value will turn green indicating that it can
be changed. Adjust the maximum value (%), using the arrow keys, to achieve the
required combustion CO2/O2 (Table 11), and pressure delta p, (Table 12).
c. The high fire trim adjustment is located on the outlet flange, (Figure 17),
of the gas valve.
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
d. When the adjustment is satisfactory press the check key to save the
setting. When complete, place the S2′ switch back to theNORM’ position.
e. Allow the boiler to settle into min input and observe combustion and
pressure-delta p readings to ensure the boiler is operating correctly. Make
any required adjustments. When complete disable the low fire hold switch.
f. Follow the instructions in the HeatNet Control manual to allow adjustments
required for high altitude installations.
Measure flame current 1. With the boiler operating at low fire, measure the
flame
current. 2. Attach microammeter leads to the flame current test
pins of the Fenwal ignition module as in Figure 19. 3. The flame current
should be approximately 6
microamps, and never less than 1 microamp. 4. If flame current is too low,
check the ignition electrode/
flame rod assembly following the instructions in the Checking, Adjustment &
Operation section of this manual.
Figure 19 – Fenwal Ingnition Module
SEQUENCE OF OPERATION
NO DEMAND Standby 1. The boiler is idle with no interlocks in the fault condition.
DEMAND
Pre-Purge
1. The blower operates at purge RPM. The water flow interlock must `make’
within 15 seconds after the demand signal is initiated.
2. The HeatNet Control starts a 10 second purge delay once the air prove switch contacts close.
Main Run % Input 1. The main gas valve opens.
2. The ignition transformer is de-energized after 6 seconds of ignition.
3. The blower stays at the minimum input setting for 3 seconds then operates
at demand % input. See the calibration section in the “Torus Series
ControlIOM” to enter the calibration menus.
Figure 19a – Spark Gap
NO DEMAND
Post-Purge
.125
1. The main gas valve closes.
2. The blower operates at purge RPM for 10 seconds.
3. The boiler is idle with no interlocks in the fault condition.
TOP
CHECKING, ADJUSTMENT & OPERATION
Spark Gap
The gap has to be measured and adjusted with the igniter removed from the
boiler. Observe the trial for ignition to confirm that the spark is strong and
continuous. If not, allow the electrodes to cool. Check and adjust the spark
gap as shown in Figure 19a. Electrode tips should face slightly downward.
171° BOTTOM
RIOM-0314_A
31
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Table 11 – Combustion Settings
Torus Series Whirlwind BlueJet Burner
w/Gas Orifice Slide Trim**
Inlet Air Temp.
-40°F -30°F -20°F -10°F
0°F 10°F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F
CO2 % NG
Low
High
Low
Fire
Fire
Fire
7.2
8.0
8.4
7.3
8.1
8.5
7.4
8.2
8.7
7.5
8.3
8.8
7.6
8.4
8.9
7.7
8.5
9.0
7.8
8.6
9.2
7.9
8.7
9.3
8.0
8.8
9.4
8.1
8.9
9.5
8.2
9.0
9.6
8.3
9.1
9.7
8.4
9.2
9.8
8.5
9.3
9.9
8.6
9.4
10.1
**Located on outlet flange of gas valve. (Figure 17)
LPG
High Fire
9.4 9.5 9.6 9.7 9.8 9.9 10.1 10.2 10.3 10.5 10.6 10.7 10.8 10.9 11.0
O2 %
Low
High
Fire
Fire
8.3
6.9
8.1
6.7
7.9
6.5
7.8
6.4
7.6
6.2
7.4
6.1
7.2
5.9
7.1
5.7
6.9
5.5
6.7
5.3
6.5
5.2
6.4
5.0
6.2
4.8
6.1
4.7
5.9
4.5
Due to job conditions, deviation from specified may be required allow ± (0.2)% range adjustment.
Note: When units are installed with direct sealed combustion air, during periods of time with low outdoor temperature, it is possible for the room air to condense and possibly form frost on the air handling components of the boiler. Refer to: (2015 ASHRAE Cold-Climate Buildings Design Guide).
Table 12 – Input Parameters *High Fire – Pressure Signal (P)
Firing Rate
Fuel 100%
1250
(Delta P – W.C.)
NG
LP
8.20 8.10
1500
(Delta P – W.C.)
NG
LP
6.90 6.90
2000
(Delta P – W.C.)
NG
LP
9.10 9.10
2500
(Delta P – W.C.)
NG
LP
4.80 4.80
3000
(Delta P – W.C.)
NG
LP
6.30 6.30
4000
(Delta P – W.C.)
NG
LP
6.80 6.10
*Low Fire – Pressure Signal (P)
Firing Rate
1250
(Delta P – W.C.)
1500
(Delta P – W.C.)
2000
(Delta P – W.C.)
2500
(Delta P – W.C.)
Fuel NG
LP
NG
LP
NG
LP
NG
LP
6:1 0.50 0.50 0.50 0.50 0.65 0.70 0.50 0.50
8:1 0.40 0.40 0.40 0.40 0.50 0.40 0.30 0.40
10:1 0.30 N/A 0.30 N/A 0.35 N/A N/A N/A
To determine signal in mm WC, multiply signal pressure by 25.4. *See Factory Combustion label for Dual Fuel signal pressure.
32
3000
(Delta P – W.C.)
NG
LP
0.50 0.50
0.40 0.40
0.30 N/A
4000
(Delta P – W.C.)
NG
LP
0.50 0.60
0.40 0.40
N/A N/A
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Torus Series “HeatNet Control” Troubleshooting (Firing the Torus Boiler/Water Heater)
Ametek Blower
Operate Blower Motor @ 0%
FireTube Control Functions Ignition Sequence
DISPLAY: STANDBY
CALL FOR HEAT?
YES
INPUTS: 1. MODBUS 2. AA 3.Heat Demand 4. 4-20ma 5. T1-T4
Start Circulator
J13 “CIRC”
Hand Shake
Ignition Control (Fenwal)
Interlocks OK?
NO YES
J5, J11A,J11B
Are we below the Temp Band?
NO
Setpoint – 1/2 Heat Band
YES, fire the boiler.
DISPLAY: HEATING:
Close the Last limit in the Limit String to Ignition
Control
J5 Pin 10 “LIMITS”
LIMITS
Operate Blower Motor @ 0%
Operate Blower Motor @ ~55%
Operate Blower Motor @ ~32%
J5 Pin 3
J4 Pins 4 & 8
NO
Have We received the
“BLOWER”
“BLOWER”
signal?
If Yes, do
not operate blower.
YES
YES
“MAIN VALVE” greater than 7 VAC
J4 Pins 4 & 8
DISPLAY: PRE PURGE
NO
PRE_PURGE
NO Ignition Control?
J5 Pin 7 “Ignition Control”
J4 Pins 4 & 8
DISPLAY: Ignition:
YES Ignition
NO MAIN signal?
J5 Pin 1 “MAIN”
Operate Blower Motor @ Min Fire, then Modulate to
maintain temp
J4 Pins 4 & 8
DISPLAY: RUN % 25
YES
1. Minimum fire rate 2. Hold for (x) secs. 3. Modulate to temp
BLOWER IGNITION MAIN
NO
Limits OK?
TERM 6
“LIMITS”
YES
Send 120 VAC BLOWER signal
TERM 4 “MOTOR”
TERM 7
“Ignition”
After 10 Seconds send Ignition Control signal
Ignition Control Signal?
YES
TERM 9 “MAIN”
4 Second Spark Period send MAIN VALVE signal
33
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Ignition Safety To test the ignition safety shutoff device, close the manual
shutoff valve 1 (Figure 17) in the gas supply line. Within 5 seconds of main
burner flame extinction, the main gas valve solenoid should close. The control
board will lockout and display “LOW GAS PRESSURE”. Open the manual shutoff
valve in the gas supply line and reset the control board by toggling the power
switch.
To confirm the input of the unit follow the instructions in the INPUT RATE
section below.
Input Rate, Natural Gas 1. Turn off all other gas appliances that use the same
gas meter as the boiler.
2. Call your gas supplier and ask for the heating value of the gas (Btu per
cu/ft).
3. Start the boiler and let it run for 15 minutes.
4. With the boiler operation clock the time that it takes to burn 10 cu/ft of
gas at full fire.
5. Insert the heating value and the time, in seconds, into the formula below.
6. Input = 10 / seconds (Btu per cu/ft)(3600).
7. If the computed rate exceeds the desired input follow section “operating
instructions” to make the appropriate adjustments.
Never increase the input to the boiler above that for which it is rated. Doing
so can cause premature failure of the boiler!
Low Water Cutoff Ensure that the low water cutoff device(s) function properly.
Test in accordance with the manufacturer’s instructions included with the
device(s).
DIAGNOSTICS
The Torus has a display that indicates the sequence of operation, Figure 18.
The display will also list faults should the unit fail to operate. An
explanation of each fault is listed below.
STANDBY: Indicates that power is being supplied to the unit and there is no
call for heat.
STANDBY OPERATING LIMIT: Indicates that the operating limit if used is open.
Fenwal “flashing”: Indicates that there is a call for heat and the Fenwal is
locked out.
STANDBY START DEMAND: Indicates that there is a call for heat and the Fenwal
is not functioning or is locked out.
STANDBY WATER LIMIT: Indicates that either the high limit, low water cut off,
or both are open without a call for heat.
LOCKOUT WATER LIMIT: Indicates that either the high limit, low water cut off,
or both are open with a call for heat.
STANDBY GAS PRESSURE: Indicates that the low gas pressure switch or the high
gas pressure switch if used is open without a call for heat.
LOCKOUT GAS PRESSURE: Indicates that the low gas pressure switch or the high
gas pressure switch if used is open with a call for heat.
WAITING FOR FLOW: Indicates that minimum flow hasn’t been achieved.
FAULT INSUFFICIENT FLOW: Indicates that inadequate flow is present.
LWCO LOCKOUT: Indicates low or no water in the boiler.
34
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
MAINTENANCE
Disconnect electrical power and close the manual gas shut off valve before
performing maintenance or severe personal injury may result!
Servicing, inspection and adjustment must be done by a trained technician in
accordance with all applicable local and national codes. Improper servicing or
adjustment can damage the boiler!
The boiler/water heater must be inspected at least once a year and before each
heating season. Make sure that combustion readings and air box pressures are
taken on each boiler/water heater and match the desired emissions outlined
under the specification in the Installation Manual — adjust as necessary.
Accessing the burner compartment isn’t necessary during normal maintenance
unless combustion values or air box pressures don’t meet specification.
Improper burner servicing can result in premature burner failure voiding the
warranty!
Burner Removal & Inspection
Wear a tightly fitted dust mask when servicing the burner and gently handle
the burner and its gasket to prevent inhalation of airborne fibers.
Do not attempt to remove the burner without having a burner gasket kit on
hand.
Heat Exchanger Cleaning In the unlikely event that the heat exchanger becomes
blocked consult the factory for the proper cleaning procedure.
Air Intake & Vent System Thoroughly inspect the air intake and vent systems
for any signs of blockage, corrosion or leakage and periodically clean screen
in the vent terminal (where applicable). Immediately replace any unsound vent
system piping. Inspect the air filter and replace when required.
Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this
manual for reference.
1. Check the operating controls for proper operation.
2. The probe on a probe low water cut off must be removed, cleaned and
inspected at least once a year. Ensure that the low water cutoffs operate
properly. If not, replace them.
3. The flow sensor isolation valves must be open in order for proper
operation.
In the unlikely event that the SIKA flow sensor requires cleaning, in order to
flush the flow sensor, close the ball valve installed upstream of the flow
sensor, connect a hose to the drain fitting provided and open the drain valve.
Drain approximately a gallon of water to properly flush the flow sensor. The
drain is then closed and the upstream valve reopened.
4. The relief valve should not weep or discharge water at normal system
pressure this may be due to thermal expansion in a closed water supply
system. If it does contact a qualified service technician to have it
inspected. NEVER plug or try to clean or repair the relief valve! If the valve
fails to operate properly, have it replaced!
5. The aquastat high limit controls the maximum water temperature in the
boiler/water heater. It is adjustable from 100°F, 38°C to 210°F, 99°C. If the
water temperature reaches the set temperature before the demand for heat has
been met, the aquastat high limit should shut the boiler/water heater off. The
water temperature should never exceed the maximum set point of 210°F, 99°C.
The aquastat high limit cannot be repaired. If it fails to function properly
replace it.
6. Visually check the main burner flames to ensure proper operation, see
Figure 20.
Visual flame appearance with proper combustion will have a red and blue
striped appearance at low fire and flecked areas of red with a majority of
blue across the metal mesh burner at high fire. Areas of deep red indicate an
infrared condition requiring a combustion adjustment to reduce CO2 levels.
Figure 20 – Main Burner Flame
35
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual Figure 21 – Pressure Switches
L.P. GAS VALVE
N.G. GAS VALVE
TO FILTER BOX
PS1 BLOWER PROVE SWITCH
TO FLUE COLLAR TAP
TO FILTER BOX
ELECTRICAL PANEL
PS2 BLOCKED
VENT SWITCH
FILTER BOX
1250 ADAPTER PLATE
1500-4000 BLOWER HOUSING
36
RIOM-0318_B
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual Figure 23 – Relays, Interlocks and Boiler Status
The Highest priority
Low Voltage Interlocks, 24VAC
SYSTEM FLOW PROVE ———
1
Low Water Cutoff——————-
2
Variable Frequency Drive ——–
3
Gas Pressure (High & Low) —–
4
Spare for user or Factory ——
5
Operator——————————
6
Water Flow Switch—————–
7
Factory ——————————
8
Remote 120 VAC Operator
JUMPER WIRE if not used
Stage Control
Damper Control Local Pump or
Power Open/ Power Close Valve
Alarm
DHW Pump or Power Open/ Power Close Valve
USB and Flashdrive Ports: Used by HeatNet Pro and updating firmware.
Low Fire Hold: Fires the boiler at the minimum rate while in Calibrate. This
functions exactly as the T1 input Calibrate: Allows adjustment of the Minimum
Fire, Maximum Fire, and Pilot Ignition settings.
Combustion proving switch from Combustion Air Damper.
37
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Figure 24 – Exploded View and Replacement Parts
36 37 35 34
33 32
39 40 38
29 41 26 28 27
42 32 31 30
52 62 45 54
69 65 56
55
49
75
64
47
50
68
58 44
67 59
43 57
46 71
53
61
63
70
51
73 72
66 60 74 48
RIOM-0319_B
38
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
RIOM-0319_B
24 25
21
2 1 3 4 5 89 88 86
15 20
17 18 19
16
14 13 15 10 9
15
8
7
23 22 12 11 15 6 15
81 80
77
78
76 79
87
85
83
84 82 95 94 93
92 90 91
RIOM-0319_B
39
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
100 99
98
101
102
97 96
103
MBC 1000 VALVE GAS TRAIN
100 99 98
97
96
101
102
103
98 97 96
100
99
101 102
MBC 2500 VALVE GAS TRAIN
103 MBC 4000 VALVE GAS TRAIN
105 104
107 106
SUPPLY HEADER 1250-2000 COMPONENT PLACEMENT 105
104
106 107
107 106
104 105
VERTICAL SUPPLY HEADER 1250-4000 COMPONENT PLACEMENT
40
SUPPLY HEADER 3000-4000 COMPONENT PLACEMENT
RIOM-0319_B
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
110 111 108
110 111 108
1250 FILTER BOX COMPONENTS
113
112 116 117 114 1500 FILTER BOX COMPONENTS
113 112 116
110 111 108
110 111 108
112 115 112
116
112 115 112
116
3000 FILTER BOX COMPONENTS
4000 FILTER BOX COMPONENTS 110
111 108
113
112 116
2000 FILTER BOX COMPONENTS
RIOM-0319_B
41
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
119
118 121 135
129 137
128 136
120
127 125 126 124 122 123
130
133 132 131 134
140
42
138 141
139 142
RIOM-0319_B
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Torus Parts List
Ref # Name of Part 1 Weldment, Base Frame
2 Assembly, Heat Exchanger, WB(Burner included)
Assembly, Heat Exchanger, WW(Burner included)
3 Hex Head Cap Screw, 1/2-13 X 1-1/4″ 4 Flat Washer, 1/2″ 5 Hex Nut, 1/2-13 6
Burner
7 Gasket, Burner 8 Pin, Burner 9 Electrode, Ignition 10 Gasket, Ignition
Electrode 11 Electrode, Ionisation 12 Gasket, Ionisation Electrode 13 Sight
Glass 14 Gasket, Sight Glass 15 Socket Head Screw, M4X0.7mm X 8mm 16
Insulation, Burner Door 17 Insulation, Deflector 18 O-Ring Gasket, Burner Door
19 Gasket, Fiber Glass Braid 20 Clip, Burner Door Insulation 21 Pin, Trolley
22 Socket Head Screw, M14X2 X 35mm 23 Flat Washer, M14 24 Gasket, Flue Exit,
8″
Gasket, Flue Exit, 10″ Gasket, Flue Exit, 12″ 25 Clamp, Flue Exit, 8″ Clamp,
Flue Exit, 10″ Clamp, Flue Exit, 12″ 26 Pressure Relief Valve, 50# (WB)
Pressure Relief Valve, 125# (WW) 27 T&P Gauge Duplex 0-230PSI (WB/WW) T&P
Gauge Duplex 0-100PSI (WB) 28 Weldment, Supply Header, WB
Weldment, Vertical Supply Header,WB Weldment, Supply Header,WW
Weldment, Vertical Supply Header,WW 29 Weldment, Return Header, WB
Weldment, Vertical Return Header, WB Weldment, Return Header, WW Weldment,
Vertical Return Header, WW 30 Assembly, Lower Front Jacket Panel, WB & WW 31
Assembly, Front Door, WB & WW 32 Assembly, Lower LH & RH Jacket Panel
33 Panel, Electrical Jacket 34 Assembly, Upper LH Jacket Panel
35 Assembly, Filter Access Jacket Panel 36 Panel, Air Intake Jacket
37 Collar Extension, 8″ Collar Extension, 10″ Collar Extension, 12″
38 Assembly, Top RH Jacket Panel
Assembly, Top RH Jacket Panel (Vertical Option)
Model Size with Quantities Below
Part No.
1250 1500 2000 2500 3000 4000
74-1013-001
1
74-1013-002
1
74-1013-003
1
74-1013-004
1
1
74-1013-005
1
74-1003-001
1
74-1003-002
1
74-1003-003
1
74-1003-004
1
1
74-1003-005
1
74-1004-001
1
74-1004-002
1
74-1004-003
1
74-1004-004
1
1
74-1004-005
1
57-0133-011
57-0573-015
57-0498
22-0016-001
1
22-0016-002
1
22-0016-003
1
22-0016-004
1
1
22-0016-005
1
22-0015-001
1
1
1
22-0015-002
1
1
1
22-0002-001
22-0009-001
1
1
1
1
1
1
22-0011-001
1
1
1
1
1
1
22-0010-001
1
1
1
1
1
1
22-0012-001
1
1
1
1
1
1
22-0007-001
1
1
1
1
1
1
22-0008-001
2
2
2
2
2
2
57-1455-006
18
18
18
18
18
18
22-0006-001
1
1
1
22-0006-002
1
1
1
22-0005-001
1
1
1
22-0005-002
1
1
1
22-0013-001
1
1
1
22-0013-002
1
1
1
22-0014-001
1
1
1
22-0014-002
1
1
1
22-0001-001
4
4
4
4
4
4
22-0003-001
57-1479-017
8
8
8
8
8
8
57-1101-012
8
8
8
8
8
8
22-0004-001
1
1
1
22-0004-002
1
1
22-0004-003
1
22-0017-001
1
1
1
22-0017-002
1
1
22-0017-003
1
13-0002
1
1
1
13-0026
1
1
1
13-0080
1
1
13-0091
1
13-0076
1
1
1
13-0305
1
1
1
1
1
1
13-0308
1
1
1
1
1
1
74-1008-001
1
74-1008-002
1
74-1008-003
1
74-1008-004
1
1
74-1008-005
1
74-1010-001
1
1
1
74-1010-002
1
1
1
74-1018-001
1
74-1018-002
1
74-1018-003
1
74-1018-004
1
1
74-1018-005
1
74-1020-001
1
1
1
74-1020-002
1
1
1
74-1009-001
1
1
1
74-1009-002
1
1
1
74-1011-001
1
1
1
74-1011-002
1
1
1
74-1019-001
1
1
1
74-1019-002
1
1
1
74-1021-001
1
1
1
74-1021-002
1
1
1
75-0559-001
1
1
1
75-0559-002
1
1
1
75-0557-001
1
1
1
75-0557-002
1
1
1
75-0561-001
1
75-0561-002
1
75-0561-003
1
75-0561-004
1
1
75-0561-005
1
03-4743-016
1
1
1
03-4743-017
1
1
1
75-0561-006
1
75-0561-007
1
75-0561-008
1
75-0561-009
1
1
75-0561-010
1
75-0502-006
1
1
1
75-0502-007
1
1
1
03-4740-001
1
03-4740-004
1
03-4740-007
1
03-4740-010
1
1
03-4740-013
1
03-4734-001
1
1
1
03-4734-002
1
1
03-4734-003
1
75-0502-001
1
75-0502-002
1
75-0502-003
1
75-0502-004
1
1
75-0502-005
1
1
1
1
1
1
1
43
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Ref # Name of Part 39 Assembly, Rear Supply & Return Jacket Panel Assembly,
Upper Rear Jacket Panel (Vertical Option) 40 Assembly, Center Rear Jacket
Panel 41 Panel, Lower Rear Jacket 42 Assembly, Upper RH Jacket Panel
43 Bracket, Front Filter Box 44 Bracket, Rear Filter Box 45 Bracket, LH Filter
Box
46 Bracket, RH Filter Box
47 Profile, Corner, P130-25 x 4-15/16″ Profile, Corner, P130-25 x 6-3/16″
48 Profile, Corner, P130-25 x 7-11/16″ 49 Profile, Corner, P130-25 x 15-1/32″
Profile, Corner, P130-25 x 16-5/8″ 50 Profile, Corner, P130-25 x 22-23/32″
Profile, Corner, P130-25 x 25-9/16″ 51 Profile, Corner, P130-25 x 28-1/16″
Profile, Corner, P130-25 x 39-9/16″ 52 Profile, Corner, P130-25 x 40-11/16″
Profile, Corner, P130-25 x 45-7/16″ Profile, Corner, P130-25 x 53-9/16″
Profile, Corner, P130-25 x 64″ Profile, Corner, P130-25 x 80-1/4″ 53 Profile,
Omega, P230-25 x 28-1/16″ Profile, Omega, P230-25 x 39-9/16″ 54 Profile,
Omega, P230-25 x 40-11/16″ Profile, Omega, P230-25 x 45-7/16″ Profile, Omega,
P230-25 x 53-9/16″ Profile, Omega, P230-25 x 64″ Profile, Omega, P230-25 x
80-1/4″ 55 Profile, Omega, P230-25 x 28-1/16″, modified-001 Profile, Omega,
P230-25 x 39-9/16″, modified-003 56 Profile, Omega, P230-25 x 28-1/16″,
modified-002 Profile, Omega, P230-25 x 39-9/16″, modified-004 57 Profile,
Omega, P230-25 x 40-11/16″, modified-005 Profile, Omega, P230-25 x 45-7/16″,
modified-007 Profile, Omega, P230-25 x 53-9/16″, modified-009 Profile, Omega,
P230-25 x 64″, modified-011 Profile, Omega, P230-25 x 80-1/4″, modified-013 58
Profile, Omega, P230-25 x 40-11/16″, modified-006 Profile, Omega, P230-25 x
45-7/16″, modified-008 Profile, Omega, P230-25 x 53-9/16″, modified-010
Profile, Omega, P230-25 x 64″, modified-012 Profile, Omega, P230-25 x 80-1/4″,
modified-014 59 Profile, Corner, P130-25 x 27-25/32″, modified-001 Profile,
Corner, P130-25 x 40-1/4″, modified-013 60 Profile, Corner, P130-25 x
27-25/32″, modified-002 Profile, Corner, P130-25 x 40-1/4″, modified-014 61
Profile, Corner, P130-25 x 27-25/32″, modified-003 Profile, Corner, P130-25 x
40-1/4″, modified-015 62 Profile, Corner, P130-25 x 27-25/32″, modified-004
Profile, Corner, P130-25 x 40-1/4″, modified-016 63 Profile, Corner, P130-25 x
28-1/16″, modified-005 Profile, Corner, P130-25 x 39-9/16″, modified-010 64
Profile, Corner, P130-25 x 28-1/16″, modified-006 Profile, Corner, P130-25 x
39-9/16″, modified-011 65 Profile, Corner, P130-25 x 28-1/16″, modified-007
Profile, Corner, P130-25 x 39-9/16″, modified-012 66 Profile, Corner, P130-25
x 30-1/4″, modified-008 Profile, Corner, P130-25 x 35″, modified-009 Profile,
Corner, P130-25 x 43-1/8″, modified-017 Profile, Corner, P130-25 x 53-9/16″,
modified-018 Profile, Corner, P130-25 x 69-13/16″, modified-019 67 Corner, 3
Branch 68 Corner, 4 Branch 69 Omega Joint 70 Corner, 2 Branch Modified 71
Corner, 3 Branch Modified 72 Corner, 3 Branch Modified 73 Corner, 3 Branch
Modified 74 Corner, 4 Branch Modified 75 Corner, 4 Branch Modified NS 3/4″ PVC
Foam Gasket (per ft / per roll 50′) 76 Casting, Blower to HX Door Adapter 77
Coupling, 2 1/2″ Coupling, 4″ 78 Assembly, Drain 79 Assembly, Condensate
Piping 80 10K Temperature Sensor 81 High Limit Well, 3/8″ NPT x 3″ Long 82 USB
Socket 83 USB Cable 84 USB Socket Cap 85 Latch, 1/4 Turn 86 Cam, 1/4 Turn
Latch 87 Pull Handle 88 Weldment, Front Door Panel Weldment, RH Front Door
Panel 89 Panel, LH Front Door 90 LWCO Board 91 Touch Screen Display 92
Bracket, Touch screen Display 93 Overlay for Touch Screen Display
44
Part No. 75-0563-001 75-0563-002 75-0563-003 75-0563-004 03-4744-004
03-4744-009 03-4744-001 03-4744-005 03-4744-006 75-0561-011 75-0561-012
75-0561-013 75-0561-014 75-0561-015 03-4713-001 03-4713-002 03-4713-003
03-4713-004 03-4713-005 03-4713-007 03-4713-009 03-4713-011 03-4713-013
03-4713-006 03-4713-008 03-4713-010 03-4713-012 03-4713-014 61-0330-0493
61-0330-0618 61-0330-0769 61-0330-1504 61-0330-1664 61-0330-2273 61-0330-2558
61-0330-2806 61-0330-3956 61-0330-4069 61-0330-4544 61-0330-5357 61-0330-6399
61-0330-8024 61-0331-2806 61-0331-3956 61-0331-4069 61-0331-4544 61-0331-5357
61-0331-6399 61-0331-8024 04-0758-001 04-0758-003 04-0758-002 04-0758-004
04-0758-005 04-0758-007 04-0758-009 04-0758-011 04-0758-013 04-0758-006
04-0758-008 04-0758-010 04-0758-012 04-0758-014 04-0759-001 04-0759-013
04-0759-002 04-0759-014 04-0759-003 04-0759-015 04-0759-004 04-0759-016
04-0759-005 04-0759-010 04-0759-006 04-0759-011 04-0759-007 04-0759-012
04-0759-008 04-0759-009 04-0759-017 04-0759-018 04-0759-019
20-0053 20-0054 20-0069 04-0756-001 04-0756-002 04-0756-003 04-0756-004
04-0757-001 04-0757-002 06-0151 01-0214-001 01-0214-002 53-6404-005
53-6404-007 75-0539-001 75-0546-001 75-0546-002 14-0325 13-0104 44-0064
44-0065 44-0066 20-0042 20-0043 20-0044 74-1022-001 74-1022-002 03-4741-003
14-0258 40-0091-002 03-4719-001 82-0756-001
1250 1 1 1 1 1
1 1 1
1
2 2 2 2 2 2
1 1
1 1 1
1
1 1 1 1 1 1 1 2
4 2 4 2 2 1 1 2 2 50 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 2 1
Model Size with Quantities Below
1500 2000 2500 3000
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
4
4
4
2
2
2
2
4
4
4
4
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
50
50
50
50
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
4000 1 1 1 1
1 1 1
1
1 2 2 2 2 2
2 1
1 1 1
1
1 1 1 1 1 1 1 1
2 4 2 4 2 2 1 1 2 2 50 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Ref # Name of Part 94 Rocker Switch, Red 95 Rocker Switch, Green 96 “A” Valve,
1 1/2″ “A” Valve, 2″ 97 Low Gas Pressure Switch 98 Gas Valve Connector 99
Valve Proving System 100 Gas Valve MBC-SE 1000 Gas Valve MBC-SE 2500 Gas Valve
MBC 4000 101 High Gas Pressure Switch 102 Firing Valve, 1 1/2″ Firing Valve,
2″ 103 Flange, Adjustable Shutter, 1″ NPT Flange, Adjustable Shutter, 1 1/2″
NPT 104 High Limit Well, 3/8″ NPT x 3″ Long 105 LWCO Probe 106 Air Vent 107
Ball Valve, T-Handle, 3/4″ NPT 108 Weldment, Filter Box
110 Panel, Filter Box Cover 111 Assembly, HT Air & Gas Mixing Box, NG
NS Panel, HT Air & Gas Mixing Box, NG
NS Gasket, Air & Gas Mixing Box NS Kit, Swirl Plate
112 Gasket, Blower Inlet 113 Gasket, Air & Gas Mixing Box 114 Assembly, Blower
Adapter 115 Spacer, Blower 116 Blower, 120V 1ph
Blower, 120V 1ph Blower, 208-240V 1ph Blower, 208-240V 3ph Blower, 208-240V
3ph Blower, 460-575V 3ph 117 Gasket, Blower Outlet NS Gasket, Blower Outlet NS
Combustion Air Filter NS Grommet Plate, NG NS Gasket, Grommet Plate NS
Grommet, NG 118 Terminal Block Cover, 10P 119 Solid State Relay, 20A, 1PH
Solid State Relay, 25A, 3PH 120 Power Supply, 120VAC Primary, 12VDC Secondary
121 Terminal Block 300V, 30A 122 Ignition Control Module, Fenwal 123 Bracket,
Ignition Module 124 Pressure control, 4.00″ WC 125 Pressure control, 0.30″ WC
126 Bracket, Pressure Switch 127 Fitting, Thru Wall, 3/16″ Hose 128 Ground
Bar, 600V, 6P 129 Distribution Block, 600 VAC, 115A, 4P NS Cover, Distribution
Block 130 High Limit, Manual Reset NS High Limit, Auto Reset NS High Limit,
350F, THERM-O-DISC 131 Terminal Block, Screwless Feed, 600V, 30A 132 Cover,
Screwless Feed Terminal Block NS End Bracket, Screwless Feed Terminal Block NS
Jumper, Screwless Feed Terminal Block 133 Din Rail 134 HeatNet Board, V3.0,
Full, SATA 135 LED Light, 12V NS Circuit Breaker(CSD-1 only) 136 Weldment,
Electrical Panel 137 Shield, Electrical Panel NS Wire Harness, Display NS Wire
Harness, Blower Motor & Flow Sensor NS Wire Harness, Ignition Control Module
NS Wire Harness, 120 & 24VAC to J14 NS Wire Harness, SSR to Blower Motor Power
NS Wire Harness, Operator to Electrical Panel NS Wire Harness, J4 to J1 Flow
Sensor NS Wire Harness, Gas Valve to Ignition Control NS Wire Harness, Ign
Control H.V. Out to Spark Electrode NS Wire Harness, Ign Control B.GND to
Ground Electrode NS Wire Harness, Ign Control S1 to Flame Sense Electrode 138
Flow Sensor 139 Ball Valve, T-Handle, 1″ NPT 140 Ball Valve, 1″ NPT, w/ Hose
Drain 141 Plate, Flow Sensor 142 U-Bolt, 1/4-20 X 1/2″ Pipe
Part No. 48-0013 48-0016 11-0467 11-0454 11-0422 11-0220 11-0412 11-0230 11-0227 11-0218 11-0421 11-0458 11-0459 11-0228 11-0229 13-0104 14-0275 13-0352-001 11-0471-002 74-1006-001 74-1006-002 74-1006-003 03-4706-001 03-4706-002 75-0514-001 75-0514-002 75-0514-003 75-0514-004 03-4737-001 03-4737-002 03-4737-003 03-4737-004 06-0214-001 11-0658-001 11-0659-001 11-0659-002 11-0659-003 06-0210-001 06-0210-002 06-0214-001 75-0515-001 04-0762-001 12-0032-001 12-0034-001 12-0033-001 12-0026-001 12-0029-001 12-0030-001 06-0213-001 06-0209 09-0495-001 09-0495-002 03-4712-001 03-4712-002 06-0219-001 06-0072 06-0073 42-0192-009 15-0137 15-0142-001 15-0352 48-0156 16-0063-001 03-4750-001 14-0070 14-0071 03-4571-001 55-0152 48-0446 48-0177-004 48-0184-004 14-0127 14-0115 14-0129-001 48-0178-002 48-0182-001 48-0185-001 48-0181-002 48-0356-1363 40-0092 48-0458 15-0401-001 74-1005-001 03-4717-001 40-0115-001 40-0401-001 40-0403-003 40-0405-005 40-0406-003 40-0408-003 40-0415-003 40-0418-001 40-0419-001 40-0419-002 40-0419-003 40-0419-004 40-0419-005 40-0419-006 14-0330-002 11-0471-003 13-0252-009 03-4725-001 57-2102-005
1250 1 2 1 1 1 1 1
1 1 1 2 1 1 1 1
1 1
1
1 1
1 1 1 1
1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 4 1 1 1 1 1 18 5 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 2
Model Size with Quantities Below
1500 2000 2500 3000
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
18
18
18
18
5
5
5
5
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4000 1 2 1 1 1 1
1 1 1 1 2 1 1 1
1 1
1
1 1
1 2
1
1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 4 1 1 1 1 1 1 18 5 2 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 2
45
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
START-UP REPORT
DATE: TECHNICIAN: COMPANY: PHONE NUMBER:
JOB NAME: LOCATION: MODEL: SERIAL #:
PRE-STARTUP CHECK LIST
NO VISIBLE DAMAGE TO UNIT PIPING PROPERLY CONNECTED BOILER CIRCULATOR WIRED VENT/STACK CONNECTED
INLET AIR FILTER INSTALLED AND CLEAN PROPER SERVICE CLEARANCES PROVIDED PUMP RUNNING, HEAT EXCHANGER FULL GAS LINES PURGED, NO LEAKS, NO MISSING TEST PLUGS
BOILER START UP SEQUENCE
Note: Locate the S2 Calibration Switch and low fire hold switch in the bottom-
right of the electrical panel on the main HeatNet board. Also locate the
manometer pressure taps (Figures 17 &18). 1. Check spark gap and flame rod
position: (follow section “Checking, Adjustment & Operation”). 2. Perform pre-
start up checks and set up: (follow section “Operating Instructions”; Steps
1-10). 3. Disable any external call for heat and toggle the remote/local
switch to REMOTE. 4. Ignition and low fire adjustment: Toggle the LOW FIRE
switch to cycle the boiler to low fire ignition
(follow section “Operating Instructions”; Steps 11-16). 5. Check flame
current: (follow section “Measure Flame Current”). 6. Set min % and low fire
combustion values: (follow section “Operating Instructions”; Step 17). 7.
Record combustion and Delta P at low fire. 8. Set max % and high fire
combustion values; (follow section “Operating Instructions”; Step 18). 9.
Record combustion and Delta P at high firing rate. 10. Check all combustion
results using a calibrated flue gas analyzer. 11. Release the LOW FIRE switch
to place boiler in standby.
In addition to completing the Torus Series start-up report, complete the control set-up information in the rear of the HeatNet manual.
46
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
COMBUSTION ANALYSIS
GAS INLET PRESSURE (WC) CO2 O2 CO (PPM) NET STACK TEMPERATURE AIR BOX
DIFFERENTIAL (DELTA P – WC)
MINIMUM FIRING RATE
INCHES WC % %
PPM oF
INCHES WC
100% FIRING RATE
INCHES WC % %
PPM oF
INCHES WC
SAFETY TEST CHECKLIST
FLOW SWITCHES (By Others) LOW WATER CUT-OFF
AIR SWITCH HIGH LIMITS
FLAME SAFEGUARD
COMMISSIONING THE BOILER
UNIT CYCLED MINIMUM OF 15 TIMES CUSTOMER INSTRUCTED ALL COVERS REPLACED CUSTOMER GIVEN MANUAL TARGET TEMPERATURE SET PER CUSTOMER
THE DELTA T BETWEEN THE HEATER INLET AND OUTLET IS CRITICAL TO PROPER FLOW. BEFORE YOU LEAVE THE JOBSITE, YOU MUST RECORD THE DELTA T. THIS READING SHOULD NOT EXCEED 100 oF, 55 oC, NOR BE LOWER THAN 20oF, 11.1oC.
COMMISSIONED BY: __ (SIGNATURE)
DATE: ____
DELTA T =
ADDITIONAL NOTES AND COMMENTS
47
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
NOTICE!
MACODE-3
Commonwealth of Massachusetts Installation Requirements
(a) For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet above finished
grade, in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of
the side wall horizontal vented gas fueled equipment, the installing plumber
or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or gasfitter
shall observe that a battery operated or hard wired carbon monoxide detector
with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure the services of
qualified licensed professionals for the installation of hard wired carbon
monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is
installed in a crawl space or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be installed on the next adjacent
floor level.
b. In the event that the requirements of this subdivision can not be met at
the time of completion of installation, the owner shall have a period of
thirty (30) days to comply with the above requirements; provided, however,
that during said thirty (30) day period, a battery operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720
and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally
vented gas fueled equipment shall not approve the installation unless, upon
inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
Improper venting can result in excessive levels of carbon monoxide which can
cause severe personal injury or death!
In the Commonwealth of Massachusetts, the installation must be performed by a
licensed plumber or gas fitter.
(b) Exemptions
The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be
Vented” in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment
installed in a room or structure separate from the dwelling, building or
structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall horizontally vented gas
equipment provides a venting system design or venting system components with
the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or
the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but
identifies “special venting systems”, the following requirements shall be
satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included
with the appliance or equipment installation instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and
the instructions for that system shall include a parts list and detailed
installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instructions, all parts
lists for venting instructions, and/or all venting design instructions shall
remain with the appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of carbon monoxide which can
cause severe personal injury or death!
48
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual
Torus Series Boilers/Water Heaters
Limited Warranty
The “Manufacturer” warrants to the original owner at the original installation
site that the heat exchanger of the Industrial, Commercial, and other Non-
Residential Use Boiler (the “Product”) will be free from defects in material
or workmanship for ten (10) years from the date of installation. Additional
twenty one (21) year thermal shock warranty on heat exchanger. If upon
examination by the Manufacturer the Product is shown to have a defect in
material or workmanship during the warranty period, the Manufacturer will
repair or replace, at its option, that part of the Product which is shown to
be defective. All other RBI supplied Boiler parts and replacement heat
exchangers are warranted against defects in material and workmanship for one
(1) year from date of installation or 18 months from date of shipment from
RBI. This boiler is designed to operate in a closed loop heating system.
System fill water must not contain more than 500 ppm Dissolved Solids, less
than 150 ppm Chloride concentration and no greater than 200 ppm Water
Hardness. Suspended solids such as Magnetite, Iron Oxides must be flushed from
the system prior to commissioning the boiler(s). The PH level must be within
the 6.5-8.5 range. Where required, the system must be protected by the
addition of a corrosion inhibitor per the chemical supplier’s instructions.
The “Manufacturer” warrants to the original owner at the original installation
site that the heat exchanger of the Industrial, Commercial, and other Non-
Residential Use Water Heater (the “Product”) will be free from defects in
material or workmanship for five (5) years from the date of installation.
Additional twenty one (21) year thermal warranty on heat exchanger. If upon
examination by the Manufacturer the Product is shown to have a defect in
material or workmanship during the warranty period, the Manufacturer will
repair or replace, at its option, that part of the Product which is shown to
be defective. All other RBI supplied Water Heater parts are warranted against
defects in material and workmanship for one (1) year from date of installation
or 18 months from date of shipment from RBI. This Water Heater is designed to
operate scale free maintaining a water hardness between 4 and 12 grains per
gallon with a level of dissolved solids not exceeding 350 ppm. Water having a
hardness less than 4 grains can cause excessive corrosion of the heat
exchanger. Water that has a hardness greater than 12 grains per gallon and/or
a level of dissolved solids exceeding 350 ppm will require a larger
circulating pump and temperature rise. Water hardness greater than 15 grains
per gallon will require a water softener system. (See Installation
Instructions for proper pump performance.) Excessive water hardness causing a
lime build-up in the heat exchanger tubes is not a fault of the equipment and
is not covered under the manufacturer’s warranty. This limited warranty does
not apply: (a) if the Product has been subjected to misuse or neglect, has
been accidentally or intentionally damaged, has not been
installed, maintained or operated in accordance with the furnished written
instructions, or has been altered or modified in any way. These include but
not limited to: · Chemical corrosion, no corrosive chemical (freon, dry
cleaning chemicals, degreasing liquids, chlorine or any
chemicals that produce hydrochloric acid) can be present in the boiler room as
it rapidly destroys the heating equipment and voids the warranty. (b) to any
expenses, including labor or material, incurred during removal or
reinstallation of the Product or parts thereof. (c) to damage as a result of
settlement, distortion, collapse, or cracking of any foundation area, beams or
pipes surrounding the Product. (d) to any workmanship of any installer of the
Product; or to Products installed outside the continental United States or
Canada. This limited warranty is conditional upon: (a) shipment, to the
Manufacturer, of that part of the Product thought to be defective. Goods can
only be returned with prior written approval from the Manufacturer. All
returns must be freight prepaid. (b) determination in the reasonable opinion
of the Manufacturer that there exists a defect in material or workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend
the duration of the warranty with respect to such repaired or replaced part
beyond the stated warranty period. THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES,
INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED
WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY
CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR
ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF
FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE
PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY
BY EACH JURISDICTION.
49
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual 50
Torus Stainless Steel Condensing Boilers & Water Heaters Installation Manual 51
260 North Elm Street
7555 Tranmere Drive
Westfield, MA 01085
Mississauga, Ontario L5S 1L4 Canada
Phone: 833-265-5371
Phone: 905-670-5888
www.rbiwaterheaters.com