RBI CB500, CB750, CB1000, CB1250, CB1500 Installation And Operation Instructions Manual
...
FTF-I0M-HN-4
82-0312
Finned copper tube
Gas boilers (CB), &
Water heaters (CW) &
Pool heaters (CP)
Boiler manual
Installation and operation
instructions
Also read and follow:
HeatNet control manual
is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
A x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a quali ed service
technician, and to follow all guidelines in the User’s Information Manual.
10/12 Copyright 2012 Mestek, Inc.
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
If the information in this manual is not followed
exactly, a re or explosion may result causing property,
personal injury or loss of life.
Do not store or use gasoline or other ammable vapors
and liquids in the vicinity of this or any other applianc
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the re
department.
Installation and service must be performed by a quali ed
installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données
dans ce e 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 in ammables à proximité de cet
appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment.
BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 3
BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 3
COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . 3
GENERAL VENTING GUIDELINES. . . . . . . . . . . . . . 5
OUTDOOR VENTING. . . . . . . . . . . . . . . . . . . . .10
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . 11
HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . .12
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . .16
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . .20
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . 21
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . 22
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 24
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . .25
CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . .26
HEATNET FIELD WIRING . . . . . . . . . . . . . . . . . .28
CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . .28
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 31
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .33
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . .33
REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . 34
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . .40
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . 43
• Appelez immédiatement votre fournisseur de gas depuis
un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le
service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien quali é ou par le
fournisseur de gaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
2
BEFORE YOU START
is manual covers the application, installation, operation and
maintenance of a Futera Series nned copper heating boiler/water
heater/pool heater.
To obtain the safe, dependable, e cient operation and long life
for which this heating boiler/water heater was designed, these
instructions must be read, understood and followed.
e Futera Series nned copper heating boiler/water heaters have
been design certi ed by CSA for use with natural and propane gas
under the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water
Heaters, ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam
and Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired Pool
Heaters and CAN1-3.1, Industrial and Commercial Gas Fired
Packaged 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.
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
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.
If installed in the Commonwealth of Massachuse s, you MUST
FOLLOW the additional instructions contained in RBI’s instruction
sheet MACODE-3. Which is located in the back of this manual.
e owner should maintain a record of all service work performed
with the date and a description of the work done. Include the name
of the service organization for future reference.
Direct all questions to your RBI distributor or contact the RBI
Customer Service Department at: 260 North Elm Street, West eld,
MA 01085 for US or 7555 Tranmere Drive, Mississauga ONT L5S
1L4 for Canada. Always include the model and serial numbers from
the rating plate of the boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Futera Series boiler/water
heater check the rating plate to ensure that the unit has been sized
properly for the job. e “Net AHRI Ratings” specify the equivalent
amount of direct copper radiation that the unit can supply under
normal conditions. Also ensure that the unit has been set up for
the type of gas available at the installation site. Other important
considerations are the availability of an adequate electrical supply,
fresh air for combustion and a suitable chimney or vent system.
BOILER/WATER HEATER LOCATION
1. is boiler/water heater is suitable for indoor and outdoor
installations. Locate the boiler/water heater in an area that
provides good access to the unit. Servicing may require
the removal of jacket panels. Allow the minimum clearances
between adjacent construction and the boiler/water heater as
listed in Table 1.
Service clearances are not mandatory, but are recom-
mended to ensure ease of service should it be required.
Table 1
Clearance to
Combustibles
To p 6 153 30 762
Back 6 153 24 610
Left Side 6 153 24 610
Right Side 6 153 24 610
Front 6 153 30 762
in mm in mm
Service
Clearance
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 boiler/water heater is level from
front to back and from side to side. Use metal shims to level
the boiler/water heater. Electrical and electronic components
must also be protected from exposure to water during operation
and maintenance. DO NOT install this boiler/water heater in
a location that would subject any of the gas ignition components
to direct contact with water or excessive moisture during
operation or servicing.
3. Ensure that the oor is structurally sound and will support
the weight of the boiler/water heater.
e Futera may be installed directly on combustible
ooring, 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. If such a location doesn’t exist,
a suitable drain pan that’s adequately drained must be installed
under the unit.
5. DO NOT place this boiler/water heater in a location that
would restrict the introduction of combustion air into the unit
or subject it to a negative pressure, see “GENE L VENTING
GUIDELINES”.
6. NEVER place this boiler/water heater in a location that
would subject it to temperatures at or near freezing, see the
“FREEZE PROTECTION” section on page 11.
Never store combustible materials, gasoline or any
product containing ammable vapors or liquids in
the vicinity of the boiler/water heater. Failure to
comply with this warning can result in an explosion
or re causing extensive property damage, severe
personal injury or death!
COMBUSTION AIR & VENTILATION
is boiler/water heater must be supplied with
combustion air in accordance with Section 5.3,
Air for Combustion & Ventilation, of the latest
revision of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and all applicable local building
codes. Canadian installations must comply with
CAN/CGA B149.1 or .2 Installation Code for Gas
Burning Appliances and Equipment, or applicable
provisions of the local building codes. Failure to
provide adequate combustion air for this boiler/
water heater can result in excessive levels of carbon
monoxide which can result in severe personal injury
or death!
To operate properly and safely this boiler/water heater requires
a continuous supply of air for combustion. NEVER store objects
on or around the boiler/water heater!
3
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Combustion air contaminated with uorocarbons
or other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. ese acids will
cause premature failure of the boiler/water heater
voiding the warranty!
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 replace, 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 Futera in an environment subjected
to a negative pressure unless it is Direct Vented. Failure
to comply with this warning can result in excessive
levels of carbon monoxide causing severe personal
injury or death!
Where directly communicating with the outdoors or communi-
cating with the outdoors through vertical ducts, each opening shall
have a minimum free area of 1 in
2
/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 in
2
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.
When calculating the free area necessary to meet the make-up
air requirements of the enclosure, consideration must be given
to the blockage e ects of louvers, grills and screens. Screens must
have a minimum mesh size of 1/4 in, 6.4 mm. If the free area
through a louver or grill is not known, ducts should be sized per
Table 2.
Canadian installations must comply with CSA B149.1 when
air supply is provided by natural air ow from the outdoors for
natural dra , partial fan-assisted, fan-assisted, or power dra -
assisted burners, there shall be a permanent air supply opening(s)
having a cross-sectional area of not less than 1 in
2
per 7,000
Btuh (310 mm2 per kW) up to and including 1 million Btuh,
plus 1 in2 per 14,000 Btuh (155 mm2 per kW) in excess of
1 million Btuh.
/
All Air From Inside The Building
If the Futera is to be located in a con ned space, the minimum
clearances listed in Table 1 must be maintained between it and any
combustible construction. When installed in a con ned space
without the intake air option, Figures 5 and 6, two permanent
openings communicating with an additional room(s) are required.
e combined volume of these spaces must have su cient volume
to meet the criteria for an uncon ned space. e total air
requirements of all gas utilization equipment, replaces, wood stoves
or any type of exhaust fan must be considered when making this
determination. Each opening must have a minimum free area of
1 in2/1000 Btu/hr, 2200 mm2/kW based on the total input rating
of ALL gas utilization equipment in the con ned area. Each opening
must be no less than 100 in2, 64,516 mm2 in size. e upper
opening must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. e bo om opening must
be within 12 in, 305 mm of, but not less than 3 in, 76 mm from,
the bo om of the enclosure.
All Air From Outside The Building
When installed in a con ned space without utilizing 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. e upper opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the
top of the enclosure. e bo om opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the bo om of
the enclosure.
Table 2 Make-up Air Louver Sizing
Required Cross Sectional Area
2
75% Free Area
Metal Louvers
2
in
cm
1/4 in 6.4 mm
Input
(MBH)
500 125 806 167 1077 500 3226
750 187 1206 250 1613 750 4839
1000 250 1613 333 2148 1000 6452
1250 313 2019 416 2684 1250 8065
1500 375 2419 500 3226 1500 9677
1750 437 2819 583 3761 1750 11,290
1999 500 3226 667 4303 2000 12,900
Wire Screen
2
cm
in
2
25% Free Area
Wooden Louvers
in
2
cm
2
Intake Air Option – General Guidelines
is con guration provides combustion air directly to the boiler/
water heater’s air intake adapter using a dedicated pipe when using
the direct vent option. Combustion air can be drawn in horizontally
through the same outside wall which terminates the exhaust gases
or vertically through the roof, see Figures 1, 2, 3 & 4.
Common intake air systems may be used provided
the common duct is sized properly. An intake
combustion air damper should be installed if the
common vent option is used in the intake air pipe of
each heater. Improper installation can result in excessive
levels of carbon monoxide which can cause severe
personal injury or death!
4
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Single wall galvanized smoke pipe, single wall aluminum pipe,
exible aluminum pipe, PVC or CPVC pipe can be used for the
intake air pipe. It must be sized per Table 3.
Table 3 Intake Air Pipe Sizing (Up to 60 ft)
Model
Size
500 8 203
750 8 203
1000 8 203
1250 10 254
1500 10 254
1750 12 305
2000 12 305
Note: Max horizontal/vertical intake pipe 60 ft equivalent.
in mm
All joints in metal intake air systems must be secured using corro-
sion 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. e
combustion air system MUST be supported by the building
structure not the boiler/water heater.
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
in ltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
All vent systems must be fully supported by the building structure
and not by the boiler/water heater. Appropriate thimbles and restops must be used where required.
Common vent systems must be properly engineered
and sized, please contact the factory.
A UL listed stainless steel vent system must be used
unless this unit is ed with an RBI supplied non
metallic vent kit. Failure to comply with this warning
can cause excessive levels of carbon monoxide resulting
in severe illness and death!!
For instructions utilizing the non-metallic vent option,
see Addendum (FTF-PVCVO) for PVC and (FTF-
PPVO) for Polypropylene.
VENT SYSTEM OPTIONS
e ue products in the vent system may be cooled below their
dew point and form condensate in the ue. e materials used for
a Category IV vent must be resistant to any corrosive damage
from ue gas condensate. e ue from a Category IV vent system
must have a condensate drain with provisions to properly collect
and dispose of any condensate that may occur in the venting system.
e Futera Fusion may be vented the following ways:
Intake Air Option – Vertical Guidelines
e maximum equivalent length for the vertical intake air pipe is
60 , 18.3 m. Each 90° elbow and the intake air terminal are equal
to 10 linear , 3.0 m of pipe, see Table 3.
An approved, nonrestrictive intake air terminal must be used. e
intake air terminal must terminate as shown in Figure 3. e
penetration point in the roof must be properly ashed and sealed.
Intake Air Option – Horizontal Guidelines
e maximum equivalent length for the horizontal intake air pipe
is 60 , 18.3 m. Each 90° elbow and the intake air terminal
are equal to 10 linear , 3.0 m of pipe. If horizontal runs exceed
5 , 1.5 m they must be supported at 3 , 0.9 m intervals with
overhead hangers. e certi ed intake air terminal from RBI must
be used, see Figures 1, 2 and 4.
GENERAL VENTING GUIDELINES
e 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 CAN/CGA B149.1
or .2 Installation Code. Improper venting can result
in excessive levels of carbon monoxide which can
result in severe personal injury or death!
1) Direct Vent, Positive Pressure, Category IV uses a vent
system certi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air
is piped from the outdoors to the blower inlet.
2) Side Wall Vent, Positive Pressure, Category IV uses
a vent system certi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
3) Vertical Vent, Positive Pressure, Category IV uses a
vent system certi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air
is obtained from the outdoors or the space in which the unit
is installed.
4) Vertical Vent, Negative Pressure, Category II (common
venting) requires negative pressure in vent (natural dra ).
Requires a metal chimney system approved for Category II
venting. is method is required if common venting multiple
Fusion boilers.
All venting and combustion air material supplied by
installer. All venting materials must be approved for
the application. Consult the vent manufacturer’s
product literature.
e maximum equivalent length for the ue outlet vent
system for Category IV conditions is 60 , 18.3 m.
Use Table 4 for the equivalent lengths per ing. Table
4 - “Category IV Equivalent Length per Fi ing” 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.
5
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Table 4 Category IV Equivalent Length Per Fitting
Model/Outlet
Diameter
Standard Tee 1.25 25 ft 25 ft 30 ft 30 ft 35 ft 40 ft 40 ft
Boot Tee 0.65 15 ft 15 ft 15 ft 15 ft 15 ft 20 ft 20 ft
Cap - Low Res (UL) 0.50 10 ft 10 ft 10 ft 10 ft 10 ft 15 ft 15 ft
45° w/Bird Screen 0.40 10 ft 10 ft 10 ft 10 ft 10 ft 10 ft 10 ft
Elbow - 90° 0.38 10 ft 10 ft 10 ft 10 ft 10 ft 15 ft 15 ft
Elbow - 45° 0.15 5 ft 5 ft 5 ft 5 ft 5 ft 5 ft 40 ft
*Equivalent lengths based on listed K-factors and (5x) pipe diameters straight length between ttings.
*K
CB5007"CB7507"CB10007"CB12508"CB15008"CB1750
Must consult factory when venting single or multiple unit(s)
over 60 equivalent feet. Mechanical system may be required.
Equivalent Feet of Straight Pipe
10"
CB2000
10"
Horizontal Direct Vent Systems
Figures 1 & 2
e vent materials used in horizontal vent systems must be certi ed
to UL 1738 for installations in the United States, ULC S636 for
installations in Canada. e certi ed vent terminal from RBI must
also be used.
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 re-
stops. For best results, horizontal vent systems should be as short
and straight as possible.
e vent system must be both gas tight and watertight. All seams
and joints in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
When horizontal vent runs exceed 5 , 1.5 m they must be supported
at 3 , 0.9 m intervals with overhead hangers. e vent system must
be pitched down, toward the vent terminal, 1/4 in/ , 20 mm/m. 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.
Horizontal vent systems shall terminate at least 4 , 1.2 m below,
4 , 1.2 m horizontally from or 1 , 0.30 m above any door, window
or gravity air inlet into any building. It must not terminate less than
4 , 1.2 m horizontally from, and in no case above or below, unless
a 4 , 1.2 m horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment and not less than 7 ,
2.1 m above adjacent public walkway. e bo om of the vent
terminal(s) shall be located at least 5 , 1.5 m above the air intake
terminal(s) unless there is a minimum 5 , 1.5 m horizontal
separation between them. Avoid terminal locations likely to be
a ected by winds, snowdri s, people and pets. Protect building
materials and vegetation from degradation caused by the ue gases.
DIRECT VENT, POSITIVE PRESSURE,
CATEGORY IV
In this con guration the boiler/water heater blower is used to push
the ue products to the outdoors while drawing combustion air
from the outdoors. e Intake Air Option instructions under the
“COMBUSTION AIR & VENTILATION” section must be
followed! e vent system must be sized per Table 5.
Table 5 Category IV
Model
Size
500 7 178
750 7 178
1000 7 178
1250 8 203
1500 8 203
1750 10 254
2000 10 254
Pipe Diameter (Min.)
(Up to 60 ft)
in mm
6
Vertical Direct Vent Systems – Figure 3
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 re-stops.
An approved, nonrestrictive vent terminal must be used. e top
of a vertical vent system must extend at least 51/2 , 1.7 m above
the roof surface and maximum snow line that it passes through,
4 , 1.2 m above the intake air terminal, see Figure 3.
In addition the vent system must conform to the dimensions shown
in Figure 3. e penetration point in the roof must be properly
ashed and sealed.
e 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 – Figure 4
e boiler/water heater 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 “GENE L VENTING GUIDE
LINES” sections.
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 1 Horizontal Air Intake and Venting for a Single Direct Vent System
16 FT 4.9 m
1.5 FT 0.5 m
1/4 IN. PER FOOT
20 mm/m
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 di erences due to prevailing
winds. In cold climates, double-wall or insulated inlet pipe
recommended to prevent condensation.
Figure 2 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
MBH
500 TO 1000
1001 TO 2000
2001 TO 4000
4001 & LARGER
kW
146 TO 293
293 TO 586
586 TO 1172
1172 & LARGER
FT m
5 1.5
10 3.1
15 4.6
20 6.1
5 FT 1.5 m
1.5 FT 0.5 m
1000 BTU’S
2 IN. 5.0 cm
7
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
10 FT 3.1 m
4 FT
1.2 m
5 FT
1.5 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
Figure 3 Vertical Air Intake and Venting for a Direct Vent System
Locate exhaust terminal downwind to reduce ue gas recirculation.
Figure 4 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
3 FT. 1 m
1.5 FT. .5 m
10 FT. 3.1 m
8
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
SIDE WALL VENT, POSITIVE PRESSURE,
CATEGORY IV – Figure 5
In this con guration the boiler/water heater blower is used to push the ue
products horizontally to the outdoors, see Figure 5. e air for combustion
is taken from the space in which the unit is installed. e applicable instructions
under the “COMBUSTION AIR & VENTILATION” section must be
followed! e vent guidelines under the Horizontal Direct Vent Systems
section must also be followed.
Figure 5 Side Wall Venting
1/4 IN. PER F00T
20 mm/m
Figure 6 Vertical Venting with a Metal Chimney System
10 FT. 3.1 m
1.5 FT 0.5 m
VERTICAL VENT, POSITIVE PRESSURE,
CATEGORY IV – Figure 6
(Vent pipe equivalent length up to 60 , 18.3 m maximum)
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
A through inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed lined, and
sized. Exterior masonry chimneys should not be used unless
properly lined to prevent condensation and dra problems.
VERTICAL CHIMNEY VENTING NEGATIVE
PRESSURE — CATEGORY II
Category II venting is required for multiple Fusion
boilers connected to a common vent. Common vent
systems cannot be pressurized.
e Fusion is listed as a CategoryII appliance when vented vertically
into a listed metal chimney system. e chimney must provide a
negative pressure not greater than 0.10inch, 2.5 mm WC at the
boiler/water heater ue collar with the unit running.
When using a listed metal chimney system the chimney
system manufacturer’s instructions must be followed.
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
(Common Venting)
9
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
g
e vent piping must be large enough to safely vent the
combined output of all of the appliances connected
to the system.
If an appliance using any type of a mechanical dra
system operating under positive pressure is connected
to a chimney ue, never connect any other appliances
to this ue. Doing so can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
CATEGORY II CHIMNEY INSPECTION
& SIZING
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
A thorough inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed, lined
and sized. Exterior masonry chimneys should not be used unless
properly lined to prevent condensation and dra problems.
Table6 lists the minimum riser sizes required for the Fusion boiler/
water heater.
Vent Connections
Locate the boiler/water heater as close to the chimney as possible.
Use the shortest, straightest vent connector possible for the instal-
lation. If horizontal runs exceed 5 , 1.5 m they must be supported
at 3 , 0.9 m intervals with overhead hangers.
e vent connector should be sloped up toward the chimney at a
minimum rate of 1/4 in/ , 21 mm/m. On masonry chimneys the
connector must terminate ush with the inside of the chimney ue.
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 re causing extensive property damage, severe
personal injury or death!
Exit cones are favorable when used to increase
the velocity of the ue gas exiting the stack and,
may also help, in cold climates, to reduce ice buildup. Exit cone terminations must be supplied by
others, installed per manufacturer’s instructions,
and meet local and federal code.
eneric exit cone
Table 6 Equivalent Breeching & Chimney Size, Negative Pressure
Model
Size
500 7 178
750 7 178
1000 8 203
1250 8 203
1500 8 203
1750 10 254
2000 10 254
Note: These sizes are based on a 20 ft, 6.1 m chimney height.
Pipe Diameter
in mm
CATEGORY II VENT CONNECTIONS
Locate the boiler/water heater as close to the chimney as possible.
Use the shortest, straightest vent connector possi ble for the installation.
If horizontal runs exceed 5 , 1.5 m they must be supported at 3 ,
0.9 m intervals with overhead hangers.
e boiler vent connectors should be sloped up toward the breeching
at a minimum rate of 1/4 in per , 21mm per m.
Always provide a minimum clearance of 6 in, 152 mm
single wall vent pipe and any combustible materials.
Failure to maintain minimum clearances between
vent connectors and any combustible material can
result in a re causing extensive property damage,
severe personal injury or death!
between
OUTDOOR VENTING
When installed outdoors the Futera Fusion must be ed with the
factory supplied outdoor hood, air intake adapter with lter and
exhaust terminal, see Figure 7. Multiple units must be spaced per
Figure 8.
e boiler/heater must be at least 2 , .62 m from any door, window
or gravity air inlet into any building and at least 3 , 1 m from any
overhang unless local codes dictate di erently.
Avoid locations where wind de ection o of adjacent walls,
buildings or shrubbery might cause a downdra . e unit(s) should
be located at least 3 , 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 runo from adjacent buildings or
damage may occur voiding the warranty!
Outdoor Installations
e Futera Boiler is certi ed for outside installations
in temperate climates only.
1. e 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. e vent pipe must be insulated to prevent freezing of condensate
in the pipe.
3. e boiler and system must be lled with an ethylene glycol/
water antifreeze mixture not to exceed 50% glycol by volume.
4. All water piping exposed to low temperatures must be insulated.
10
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
A
Figure 7 Outdoor Venting
Figure 8 Multiple Outdoor Units
2 FT
(0.62 M)
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler/water heater will void
the manufacturer’s warranty and can cause boiler
failure resulting in ooding and extensive property
damage! Excessive water hardness causing scaling
in the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty, see Table 8.
Excessive pi ing and erosion of the internal surface of
the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result of high
water ow rates.
Shut o valves and unions should be installed at the
inlet and outlet connections of the boiler/hot water
heater to provide for isolation of the unit should
servicing be necessary.
Freeze Protection
Installations in areas where the danger of freezing exists are not
recommended unless proper freeze protection is provided. e
following precautions MUST be observed:
A continuous ow of water through the unit MUST be maintained!
1.
e pump responsible for ow through the boiler/water heater
must run continuously!
2. An ethylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used.
e pump must be capable of producing a minimum of 15%
more ow and overcoming a 20% increase in head loss.
Domestic water systems must be isolated from the water heater
by the use of a heat exchanger or other approved method.
3. If the unit must be shut o for any reason the electric, gas and
water supplies MUST be shut o and the unit and its pump
completely drained.
3 FT
(1 M)
RIOM-60 REV.
Improper outdoor installation of this unit can cause
boiler failure voiding the manufacturer’s warranty!
Condensate Piping
e condensate trap provided with the boiler must be a ached to
the bo om pan and piped to a suitable oor drain or condensate
pump. If a condensate neutralization device is installed, it must be
positioned prior to boiler room drain. Condensate ll trap must
be maintained with uid.
Relief Valve
Pipe the discharge of the pressure relief valve as shown in Figure 9.
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!
11
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Flow Switch
e ow switch supplied with the boiler/water heater must be
wired to the terminal strip in the control panel to prevent the boiler
from ring unless there’s adequate water ow through the unit. e
ow switch must be installed in the supply piping adjacent to the
boiler outlet connection.
Failure to properly install the ow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a quali ed technician
in accordance with the latest revision of the ANSI/ASME Boiler and
Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1,
Standard for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must also be
followed. A minimum clearance of 1 in, 25 mm must be maintained
between heating system pipes and all combustible construction.
All heating system piping must be supported by suitable hangers
not the boiler. e thermal expansion of the system must be
considered when supporting the system. A minimum system
pressure of 12 psig, 82.7 kPa must be maintained.
Bleed Air From Boiler
Open the water heater piping bleed valves one at a time, to purge
the air trapped in the primary and secondary heat exchangers. Refer
to piping drawings (Figures 9, 10 & 11) for bleed locations.
Heating Boiler Piping Connections
e supply and return connections should be sized to suit the system,
see Table 7.
Table 7 Supply & Return Pipe Sizing
Model Size Supply Size Return Size
500 thru 1000 2” NPT 2” NPT
1250 thru 2000 2 1/2” NPT 2 1/2” NPT
Pump Requirements
is low mass boiler requires a continuous minimum water ow
for proper operation. e boiler pump is sized to overcome the
head loss of the boiler and the near piping in order to achieve the
required temperature rise. e temperature rise across the boiler
must never exceed 35°F, 19.4°C. e adjustable pump delay turns
the pump on each time the burner res and runs the pump for 20
to 600 seconds a er the call for heat is satis ed.
e maximum allowable primary heat exchanger
temperature rise is 35°F, 19.4°C.
e maximum allowable ow rate through a Futera Fusion boiler
is 97 GPM, 6.1 L/s on 500 through 1000 models and 136 GPM,
8.6 L/s for 1250 through 2000 models. e Cupro-Nickel heat
exchanger allows for 108 GPM, 6.8 L/s on 500 through 1000 models
and 151 GPM, 9.5 L/s on 1250 through 2000 models.
Factory Supplied - On Board - Circulating Pump
e factory installed - on board - pump is sized to work the total
boiler head loss plus an additional (30 ) of pipe and (6 elbows)
- (min pipe diameter of inlet/outlet boiler water connections - see
Table 7). Please consult factory for systems outside these parameters.
Low Water Cuto
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to the wiring diagram supplied with the boiler/water heater
for proper wiring connections.
Expansion Tank & Air Separator
An expansion tank or other means to control thermal expansion
must be installed in the heating system. An expansion tank must
be installed close to the boiler on the suction side of the pump. An
air scoop and automatic air vent must also be installed to eliminate
air trapped in the system.
Primary/Secondary Piping
Figure 10 shows a typical primar y/secondary piping system. Boilers
connected to heating systems using zone valves, zone pumps, or
systems that have excessive ow rates must be isolated from these
systems to protect the boiler.
Multiple Boiler Systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 11.
Piping For Use With Cooling Units
e boiler, when used in connection with a refrigeration system,
must be installed so the chilled medium is piped in parallel with
the boiler. Appropriate valves must be used to prevent the chilled
water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed
to refrigerated air from an air handling device, the piping system
must be equipped with ow-control valves or some other automatic
means of preventing gravity circulation of the boiler water during
the cooling cycle.
12
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 9 Futera Fusion Secondary Bypass Piping
Discharge Pipe:
Do not restrict ow.
Pipe size equal to valve outlet.
Pump
Valve
Balance Valve
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Discharge so as to avoid exposure
of persons to hot liquid or vapor
and to allow complete drainage
of relief valve and piping.
NOTES:
1. Fill condensate drain trap with water or approved
anti-freeze solution prior to start-up.
2. Air purging valve may be located on pump or ange.
Item
Number Description
1
2
3
4
5
6
7
8
3-Way Valve
Air Purging Valves
Flow Switch
Circulator
Pressure Relief Valve
T & P Gauge
Primary Heat Exchanger Drain Valves
Condensate Drain Trap
Thermometer
Aquastat Union
Automatic
Air Vent
Temperature &
Pressure
Relief Valve
Vacuum
Relief Valve
Drain Valve
(Typ.)
3-Way
Mixing Valve
13
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Figure 10 Typical Primary/Secondary, Low Temperature Piping System (See Notes)
H-16 REV C
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum ow through unit.
2. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual for procedure.
3. All boilers furnished with factory mounted outlet water temperature gauge.
4. For HeatNet operation, a sensor is required and installation at a minimum of 12" from the primary tee.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
H-16 REV C
14
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 11 Multiple Boiler Piping (See Notes)
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum ow through each unit.
2. System loop pipe diameter must be sized large enough to handle maximum ow through all units.
3. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual for procedure.
4. All boilers furnished with factory mounted outlet water temperature gauge.
5. Condensate lines on each unit should be connected to a oor drain.
6. For HeatNet operation, a sensor is required and installed at a minimum of 12" from primary loop tee.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
H-17 REV C
15
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
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 wi ll 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 temperature less than 120°F, 49°C. Local codes
must be complied with!
General Piping Requirements
Ensure that the water heater is equipped with bronze
headers. Piping and components connected to the water heater
must be suitable for use with potable water. e water heater must
not be connected to any heating system piping or components
previously used with a non-potable water heating appliance. No toxic
chemicals, such as those used for boiler treatment, are to be
introduced into the potable water used for space heating. If a hot
water storage tank is used in the system it must be equipped with a
temperature and pressure relief valve that complies with ANSI
Z21.22 or CAN-4.4 and CAN-4.6.
e storage tank must be located as close to the water
heater as possible to prevent excessive head loss which
will reduce ow.
Bleed Air From Water Heater
Open the water heater piping bleed valves one at a time, to purge
the air trapped in the primary and secondary heat exchangers. Refer
to piping drawings (Figures 12 & 13) for bleed locations.
RBI water heaters are designed to run scale free. Due to the extreme
variables of water conditions world wide it is necessary to consider
pH values and water hardness in relationship to scaling. It is crucial
to consider these two variables when making heat exchanger and
pump selections. If local water conditions are extreme, follow the
guidelines in the Heat Exchanger Selection Table 9. Scale free
operation can be achieved by using water with a hardness between
8 and 18 and by maintaining the pH between 5 and 9. Follow
the conditions listed under NORMAL in the table. In some areas
of the country additional precautions must be observed due to
unusual characteristics of the local water supply. Call the nearest RBI
representative for details.
Expansion Tank
An expansion tank or other means to control thermal expansion
must be installed in the water heating system if back ow prevention
devices are installed.
Pump Requirements
is low-mass water heater requires a continuous minimum water
ow for proper operation. e proper velocity through the water
heater must be maintained for e cient operation and long life. If the
temperature rise through the water heater is lower than recommended
the water velocity is too high. Premature erosion of the heat exchanger
will occur. Conversely, if the temperature rise is too high, the ow rate
is too low. Scaling and so ening of the heat exchanger will occur. e
temperature rise across the primary heat exchanger must
never exceed 35°F, 19.4°C.
e factory mounted circulatory pump is sized to work
the total boiler pressure drop and an additional 30' of
pipe and 6-90° elbows.
Water Chemistry
e required temperature rise across the water heater is based on
water having a hardness between 8 and 18 grains per gallon with a
level of dissolved solids not exceeding 350 ppm. Water having a
hardness less than 8 grains can cause excessive corrosion of the heat
exchanger. Water that has a hardness greater than 18 grains per gallon
and/or a level of dissolved solids exceeding 350 ppm will require a
recalculation of the pump size and temperature rise.
A cupro-nickel heat exchanger may also be required. e manufacturer
should be consulted when these water conditions are encountered.
See Table 8.
16
Storage Tank Thermostatic Mixing Valve
Water can be stored at temperatures above 140°F, 60°C provided
that a thermostatically controlled mixing valve is used to temper
the hot water to an acceptable temperature before it’s supplied for
domestic use.
e mixing valve MUST be set to prevent a scald injury from
occurring, see the caution against scalding.
Storage of water for domestic use above 140°F, 60°C will provide
an increased quantity of tempered water and help prevent the
growth of water born bacteria.
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Table 8 Futera Fusion Primary Heat Exchanger Selection Graph
T o properly size the pump a grain hardness and pH test m ust be taken at the installation site before the order is placed. Proper
pump sizing will improve heater performance and help ensure heater longe vity .
For hard/soft water pump selection, must consult factory.
Table 9 Delta T/Boiler Recovery Table - Fahrenheit
Model
500 750 1000 1250 1500 1750 2000
Inlet
Temp
(deg f)
60 614 96 833 106 1050 112 1460 101 1664 106 1859 111 2118 111
80 753 76 998 86 1245 92 1768 81 2000 86 2205 91 2520 91
100 999 56 1268 66 1546 72 2293 61 2530 66 2758 71 3136 71
120 1513 36 1770 46 2083 52 3320 41 3532 46 3737 51 4247 51
140 3336 16 3072 26 3321 32 6354 21 6130 26 6026 31 6855 31
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Flow
Rate
(gph)Δt(deg f)
Table 10 Delta T/Boiler Recovery Table - Centigrade
Model
500 750 1000 1250 1500 1750 2000
Inlet
Temp
(deg C)
16 2322 53 3148 59 3968 62 5517 56 6289 59 7028 62 8007 62
27 2846 42 3773 48 4707 51 6683 45 7561 48 8336 51 9527 51
38 3777 31 4792 37 5844 40 8669 34 9563 37 10,427 39 11,852 39
49 5718 20 6690 26 7873 29 12,551 23 13,350 26 14,126 28 16,054 28
60 12,609 9 11,612 14 12,552 18 24,016 12 23,172 14 22,777 17 25,913 17
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
Flow
Rate
(l/h)Δt(deg C)
17
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Figure 12 Typical Water Heating Piping (CW Models Only) (See Notes)
Pump
Val ve
Balance Valve
Pressure
Reducing Valve
7
Check Valve
7
5
1
D-17 REV A
2
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Automatic
Air Vent
Temperature &
Pressure
Relief Valve
6
Va cuu m
Relief Valve
Drain Valve
(Typ.)
NOTES:
1. When using intermittent pump and pump delay, 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.
Be sure to specify when ordering the pH and water hardness. This must be measured before selecting heat
exchanger and pump. Consult the Heat Exchanger Graph before making selection.
4. Common piping must be sized for maximum combined heater ow.
5. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
6. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.
7. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual procedure.
Notice: These drawings show suggested piping con guration and valving. Check with local codes and ordinances for
speci c requirements.
18
3-Way
Mixing Valve
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 13 Multiple Water Heating Piping (CW Models Only) (See Notes)
Pump
Valve
Balance Valve
7
Pressure
7
Reducing Valve
1
7
4
2
7
6
Check Valve
Pressure
Relief Valve
5
Flow Switch
2
5
Thermometer
1
Aquastat Union
4
Automatic
Air Vent
D-18 REV.B
Temperature &
Pressure
Relief Valve
Vacuum
Relief Valve
NOTES:
1. When using intermittent pump and pump delay, 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: TEST WATER HARDNESS AND pH AT JOB SITE.
Be sure to specify when ordering the pH and water hardness. This must be measured before selecting heat
exchanger and pump. Consult the Heat Exchanger Graph before making selection.
4. Common piping must be sized for maximum combined heater ow.
5. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
6. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.
7. Boiler and pump purging required. Air must be purged from 3-way valve after boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual procedure.
Notice: These drawings show suggested piping con guration and valving. Check with local codes and ordinances for
speci c requirements.
Drain Valve
(Typ.)
3-Way
Mixing Valve
19
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
GAS SUPPLY PIPING
Check the boiler/water heater rating plate to make sure
that the boiler/water heater is for the type of gas that
will be used. If it isn’t, do not connect the boiler/water
heater to the gas supply. Gas supply piping must be in
accordance with the National Fuel Code, ANSI Z223.1latest revision or applicable provisions of the local
building codes. Canadian installations must comply
with CAN/CGA B149.1 or .2 Installation Code. Failure
to comply with this warning can result in extensive
property damage, severe personal injury or death!
e Futera Fusion 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.
A minimum gas supply pressure of 2 in, 51 mm, WC
natural or propane and maximum 14 in, 356 mm
WC natural or propane, must be available at the safety
shuto valve inlet with the unit(s) operating, and not
to exceed a maximum of a (1.0 in WC) drop when
ring from minimum input to full load of the supply
line and all appliances running.
Table 11 should be used to ensure that the gas supply piping is sized
properly. If more than one appliance is supplied by the same supply
pipe, the piping must be sized based on the maximum possible
demand. Do not neglect the pressure drop due to pipe ings. Table
10 should be used in conjunction with Table 11 to ensure that the
gas supply piping has the capacity to meet the demand.
Figure 14 depicts the proper way to connect the boiler/water
heater to the gas supply piping. e manual shut-o valve MUST
be installed in the supply piping. It should be installed 5 , 1.5 m
above the oor where required by local codes. Provide a sediment
trap at the bo om of the vertical section of the gas supply pipe
upstream of the gas controls.
A ground joint union should be installed between the boiler gas
controls and the supply piping. Each of these items are needed to
ensure long life and ease of servicing. Always use a pipe sealant
that is suitable for use with LP gas.
Table 11 Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specifi c gravity gas
at a pressure of 0.5 psig or less and a 0.3 in WC pressure drop.
Nominal
Iron Pipe
Size
1" 520 350 285 245 215 195 170 150 120
1 1/4" 1050 730 590 500 440 400 350 305 250
1 1/2" 1600 1100 890 760 670 610 530 460 380
2" 3050 2100 1650 1270 1270 1150 990 870 710
Note: Multiply the gas volume by 0.62 for propane fl ow capacity in ft
Multiply the propane fl ow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
Table 12 Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size
1" 2.6 5.2 0.6 1.5
1 1/4" 3.5 6.9 0.8 1.9
1 1/2" 4.0 8.0 0.9 2.3
2" 5.2 10.3 1.2 3.0
Notes: 1. For fl ow through branch.
2. For fl ow at full open.
10 20 30 40 50 60 80 100 150
Maximum gas volume of pipe, (ft
90° Elbow Tee
Pipe length in feet
Type of pipe fi tting
1
Gate Valv e2Gas Cock
Equivalent pipe length, (ft)
3
/hr)
3
/hr.
2
Figure 14 Gas Supply Piping
20
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
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!
When applicable, provisions for vent, bleed and gas relief lines must
be made in accordance with the latest revision of ANSI Z223.1/
NFPA 54. e main Dungs gas valve supplied with boiler/water
heater does not require external venting.
Safe lighting and other performance criteria were met with the
gas manifold and control assembly provided on the boiler. All gas
connections MUST be leak tested before pu ing the boiler into
operation.
Never use an open ame to test for gas leaks. Always use
an approved leak detection method. Failure to comply
with this warning can cause extensive property damage,
severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler/water
heater gas controls must be protected. If the test pressure is equal
to, or less than 1/2 ps ig , 3.5 kPa isolate the boiler/water heater
by closing it’s manual shut o valve, see Figure 14. If the test pressure
is greater than, or equal to 1/2 psi g, 3.5 kPa, disconnect the boiler/
water heater and its individual shut-o valve.
ELECTRICAL WIRING
Refer to the wiring diagram supplied with the boiler/water heater
for proper wiring connections and boiler full load amperage (FLA).
GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not a empt
to operate this boiler/water heater if it has not been
installed in accordance with the guidelines set forth in
this manual. Failure to comply with this warning can
result in extensive property damage, severe personal
injury or death!
Should overheating occur or the gas supply fail to shut o , turn
o the manual gas control valve to the appliance. Do not interrupt
water ow through the boiler/water heater.
En cas de surchau e 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 ll the boiler and all of the
radiation with water. Ensure that all bleed and drain valves are closed.
Adjust the make-up water pressure regulator so a minimum 5 psig,
34.4 kPa system pressure is maintained at the highest point in the
system piping. If a make-up water pump is used adjust it to maintain
a minimum 12 psig, 82.7 kPa pressure at boiler under operating
conditions.
Electrical Power Connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation! Verify proper operation a er
servicing.
Au moment de l’entretien des commandes, 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.
e 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 properly rated shut-o switch should be located at the boiler/water
heater. e boiler/water heater must be grounded in accordance with
the authority having jurisdiction, or if none, the latest revision of the
National Electrical Code, ANSI/NFPA-70.
Line voltage eld wiring of any controls or other devices must
conform to the temperature limitation of type TEW wire at 95°F,
35°C above room temperature. Use copper conductors with a
minimum size of #14 awg. Use appropriate wiring materials for
units installed outdoors. e wire size must be compatible with
the total amp draw of the circuit.
Glycol systems require a minimum of 20 psig, 137.8 kPa
at boiler operating conditions.
Open the boiler piping bleed valves one at a time, to purge
the air trapped in the primary and secondary heat
exchanger. Refer to piping drawings (Figures 10 & 11) for
bleed locations.
With the boiler o , run the system pump for at least 30 minutes
and bleed the system piping using the bleed valves. If strainers are
used in the system piping, the make- up water valve should be closed
and the strainers checked and cleaned.
e system expansion tank should be checked to ensure that the
correct water level in the tank is maintained. e tank should be
less than half full of water with the system full and adjusted
to the correct operating pressure.
Start the boiler as described in the “OPE TING INSTRUC
TIONS” section. Run the boiler for at least an hour. e system
pump(s) and all radiation units must be operated during this time.
Ensure that the make-up water valve is open.
Shut the boiler o 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. e system should be checked and bled a er three days
of operation.
21
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE
A. is appliance is equipped with an ignition device which auto-
matically lights the pilot. Do not try to light the pilot 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 OPE TING smell all around the appliance area
for gas. Be sure to smell next to the oor because some gas is
heavier than air and will se le on the oor.
Propane gas may not always be detected by smell.
Propane gas is heavier than air and can collect in low
areas.
Propane gas can ignite or explode if an ignition source
is present and result in death, serious injury and
property damage!
FOR YOUR SAFETY
• Have only quali ed licensed professionals install, service and
maintain this appliance and your gas system in accordance with
all applicable codes.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not a empt to light any appliance.
3. Do not touch any electrical or electronic switches in the
building.
4. Do not use any phone in the building.
5. Call your gas supplier from a phone outside of the building.
6. If you cannot reach your gas supplier call the re department.
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 quali ed service technician to inspect the
appliance and to replace any part of the control system and any
gas control that has been under water.
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
partiellement. Faites inspecter l’appareil par un tecnicien quali é
et remplacez toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
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 o and disable any outside (BMS)
call for heat.
3. Turn o all electric power to the appliance.
4. Close main isolation gas valve ( eld supplied), Figure 14.
5. 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.
6. Wait ve (5) minutes to clear out any gas.
7. Install a ing at the supply test port and connect a manometer
having a minimum range of 20 in, 508 mm WC to it, Figure
14.
8. Remove the 1/8 in pipe plug from the pilot test port located
on the CV100 pilot/reg combination gas valve and connect a
manometer having a minimum range of 6 in, 154 mm WC to
it, Figure 15.
9. Open the main isolation gas valve ( eld supplied), Figure 14
10. Place the “Remote/Local” switch to Remote inside control
cabinet, Figure 16.
11. 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 16.
12. Slide the Low Fire Hold Switch (on HeatNet control board)
to Low Fire position.
13. e boiler will begin the start sequence.
14. When the main display reads “PILOT RUNNING” and the
ame current is 5 VDC, switch the Honeywell 7800 to the “test”
position, Figure 16. is will hold the Honeywell 7800 in its
ignition state..
15. Adjust the pilot pressure per the CHECKING, ADJUSTMENT
& OPE TION section.
16. Remove the demand from the 7800 control by disabling the
Low Fire switch, allowing the boiler to stop.
22
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 15
Figure 16 HeatNet Control Panel
TRANSFORMER
MANUAL RESET
PUMP MOTOR
RELAY
LOCAL REMOTE
DISPLAY
WINDOW
BACK
BUTTON
SWITCH
TEST RUN
SWITCH
HEAT NET
CONTROL
BOARD
FLAME
SAFEGUARD
MODULE
PROTOCESSOR
MODULE
(OPTIONAL)
IGNITION STATUS
WINDOW
UP BUTTON
DOWN BUTTON
POWER SWITCH
19. Switch the Honeywell 7800 back to “run”.
20. Create a min input demand as before (enable Low Fire Hold
switch). e boiler will begin the start sequence.
21. Monitor the ame current on the 7800. No ame current should
be detected and the 7800 should lock out. If ame current is
detected at any time up to the 7800 locking out, the 120V wiring
on the ignition transformer must be reversed and the test run
again to insure that no ame is detected.
Improper wiring of the ignition transformer can result
in an explosion causing extensive property damage,
severe personal injury or death!
22. Open main isolation gas valve ( eld supplied).
23. Reset the Honeywell 7800. e boiler will start and will run at
minimum input rate.
24. Se ing the low re: Allow the low re to se le out for a
few minutes and observe the combustion reading. Refer to
“Combustion Reading” table for proper combustion readings
and elbow pressure, Table 13.
e low re O2-CO2 can be adjusted in the eld by opening
the low re adjustment door located on the forward facing side
of the main gas valve, see Figure 15. Inserting an allen wrench
and rotating the allen screw clock-wise will increase the CO
and lower the O2, rotating counter clock-wise will decrease the
and increase the O2. DO NOT LEAVE THE BURNER
CO
2
IN AN INF RED STATE. A few random speckles of red
are ne, but large concentrations of spots or large areas of red
are not. If large amounts of red concentrations are observed,
verify combustion readings.
25. Jumper the “AA” terminals located on the HeatNet control board.
e boiler input will rise to its maximum input, “Run 100%”,
see Figure 19.
26. Allow the boiler to reach steady state and verify supply gas
pressure and check input rates as explained in the “Gas Supply
Piping” section. Also, refer to “Combustion Reading” table for
proper combustion readings and elbow pressure, Table 13.
e high re trim is located on the outlet ange of the gas valve,
see Figure 15. O
and rotating clock-wise to increase the CO
Rotating counter clock-wise will decrease the CO
.
the O
2
-CO2 can be adjusted by inserting a screwdriver
2
and lower the O2.
2
and increase
2
27. Remove jumper “AA” and allow boiler to se le into minimum
input. Observe the combustion readings and make any nal
adjustments. When nished disable the Low Fire Hold switch
and replace test ports to normal state.
28. Boiler allows for many modes of operation and control methods.
Reference the “HeatNet Control” manual.
2
SELECT BUTTON
17. Close main isolation gas valve ( eld supplied), Figure 14.
18. Remove the manometer ing from the pilot test port and
replace the plug. Place monitor tube on to the test port tee
located along the 1/8 in hose piped directly o of the manifold
test port, Figure 15.
Table 13 Combustion Readings
Natural Fuel Propane Fuel
CO
O
%
2
%
2
8.0 - 8.5 (min.) 9.4 - 9.9 (min.)
8.8 - 9.8 (100%) 10.3 - 11.5 (100%)
6.6 - 5.8 (min.) 6.6 - 5.8 (min.)
5.2 - 3.5 (100%) 5.2 - 3.5 (100%)
*For factory set gas manifold (elbow) pressures see label on
inner cabinet door.
23
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
INSTRUCTIONS DE MISE EN MARCHE
1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion
supérieure de ce e étique e.
2. Réglez le thermostat à la température la plus basse.
3. Coupez l’alimentation électrique de l’appareil.
4. Cet appareil est muni d’un dispositif d’allumage qui allume
automatiquement la veilleuse. Ne tentez pas d’allumer la veil leuse
manuellement.
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
6. A endre cinq (5) minutes pour laisser échapper tout le gaz.
Reni ez tout autour de l’appareil, y compris près du plancher,
pour déceler une odeur de gaz. Si vous sentez une odeur de
gaz, ARRÊTEZ! Passez à l’étape B des instructions de sécurité
sur la portion supérieure de ce e étique e. S’il n’y a pas d’odeur
de gaz, passez à l’étape suivante.
7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.
8. Me ez l’appareil sous tension.
9. Réglez le thermostat à la température désirée.
10. Si l’appareil ne se met pas en marche, suivez les instructions
intitulées couper l’admission de gaz de l’appareil et appelez un
technicien quali é ou le fournisseur de gaz.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest se ing.
2. Turn o all electric power to the boiler if service is to be performed.
3. Close the manual main and pilot gas shut-o valves.
COMMENT COUPER L’ADMISSION DE GAZ DE
L’APAREIL
1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut procéder
à l’entretien.
3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. e boiler is idle with no interlocks in the fault condition.
DEMAND
Pre-Purge
1. e blower operates at purge RPM. e water ow interlock
must ‘make’ within 15 seconds a er the demand signal is initiated.
2. e Honeywell 7800 starts a 10 second purge delay once the
air prove switch contacts close.
Pilot Run - %Input
1. e blower operates at minimum ignition se ing. See the
calibration section in the “HeatNet Control-IOM” to enter the
calibration menus.
2. e ignition transformer is energized. e pilot solenoid valve
opens for the 10 second pilot ignition trial.
Main Run - %Input
1. e main gas valve opens.
2. e ignition transformer is de-energized.
3. e pilot solenoid valve closes.
4. e blower stays at the minimum input se ing for 3 seconds
then operates at demand % input. See the calibration section
in the “HeatNet Control-IOM” to enter the calibration menus.
NO DEMAND
Post-Purge
1. e main gas valve closes.
2. e blower operates at purge RPM for 10 seconds.
3. e boiler is idle with no interlocks in the fault condition.
24
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
CHECKING & ADJUSTMENTS
Spark Gap
With the main and pilot gas manual valves in the closed position
energize the unit. Observe the trial for ignition to con rm that the
spark is strong and continuous. If not check and adjust the spark
gap as shown in Figure 17.
Figure 17 Spark Gap
e air damper adjustments must only be made by
a trained technician using a combustion analyzer!
Improper adjustment can result in excessive levels of
carbon monoxide or an explosion resulting in severe
personal injury or death!
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
LP Nat
Minimum (in WC) 2 2
Maximum (in WC) 14 14
Measure pressure when the boiler is ring at full rate. Low gas
pressure could indicate undersized gas line or insu cient gas supply.
“Static and operating gas pressure required at the gas valve inlet
is between 2 in WC and 14 in WC for natural gas and 2 in WC and
14 in WC propane. If the gas pressure is above this limit, a lock-up
style regulator suitable for dead end service such as an Equimeter
or Fisher must be installed to prevent increase (creep) of gas pressure
when the units are not operating and not to exceed a maximum of
(10 in WC) drop when ring from minimum input to supply line
and all the appliances running. is pressure regulator (supplied by
others) may be installed at the service entrance to each unit or
a “master” regulator sized to handle multiple units with adequate
turndown capability may be utilized. Consult local gas utility or
regulator manufacturer for recommendations to meet speci c job
site requirements.”
Pilot Adjustment
e pilot pressure has been factory set at 3 in for natural and LP
gas and shouldn’t need adjustment. To check the pilot pressure
close the manual main shut-o valve 2 and the pilot gas shut-o
valve, Figure 14. Remove the 1/8 in p ip e pl ug fr om the pilot tee
and connect a manometer having a minimum range of 6 in,
152 mm WC to it. Open the pilot gas shut-o valve. With the unit
powered, generate a call for heat. When the prepurge is complete
the ignition/pilot trial will begin. At this point put the Honeywell
RM7800 test switch in the test position. e control will hold in
the ignition/pilot sequence allowing you to check the pressure.
To adjust the pilot the following steps must be taken:
1. Remove the pilot gas pressure regulator cap.
2. Turn the pressure regulator adjustment screw clock-wise to
increase the pressure and counterclockwise to decrease it.
3. Replace the pressure regulator adjustment screw cap.
Never force the regulator adjustment screw beyond the stop
limits or damage to the regulator will occur!
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 , 610 m. At elevations
above 2000 , 610 m input ratings should be reduced by 4% for
each 1000 , 305 m.
Check the input rate as follows:
1. Turn o all other gas appliances that use the same gas meter
as the boiler/water heater.
2. Call your gas supplier and ask for the heating value of the gas.
3. Start the boiler/water heater and let it run for 15 minutes.
4. Using the gas meter and a stopwatch, clock the time that it
takes to burn 10
5. Insert the heating value and the time, in seconds, into the formula
below.
6. Input = (heating value, Btu/hr)(3600)/(time, seconds)
7. If the computed rate deviates by more than 5% from the rated
input value of the unit, consult factory.
Never increase the input to the boiler/water heater above that
for which it is rated. Doing so can cause premature failure of
the boiler!
3
, 0.28 m3 of gas and divide this time by 10.
25
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Figure 18 RBI HeatNet Field Wiring to Terminal Block (BoardRevision 2.0 and Greater)
NOTES:
1. Remove jumper “A” when using a low water
cuto interlock.
2. For multiple boilers utilizing a system air damper
when in a master/member con guration consult
the factory or reference wiring diagram 42-0505
sheet 2 for wiring connections.
3. For single boilers or multiple boilers with
individual dampers connect the end proving
switch to terminal block 15 and 16. Terminals
17 and 18 provide 120V power to the damper
motor.
4. There are (2) methods in which a 4-20mA signal
can be used to control HeatNet equipped
boilers.
Method 1
A 4-20mA signal can be used to directly
modulate each boiler from a remote panel or
building management system. On multiple
boiler installations, there is no communication
between boilers, no HeatNet system sensor;
therefore no master/member relationship exists.
(Use Menu: Setup: Setpoints: Setpoint Source:
Auto)
Method 2
A 4-20mA signal can be used to change
the setpoint temperature the HeatNet is
maintaining. This can be used on single
or multiple boilers with a master/member
relationship.
(Use Menu: Setup: Setpoints: Setpoint
Source: 4-20, then set the parameters for the
temperature and boiler start point.)
26
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Figure 19 RBI Field Wiring to HeatNet Board (BoardRevision 2.0 and Greater)
RIOM 86
27
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
CONTROL DESCRIPTION
Low Water Cuto
If the boiler is to be installed above radiation or if required by other
codes or regulations, install a low water cuto in appropriate piping.
Wire the switch to the “Interlock” contacts as illustrated on “Field
Wiring” schematic. Ensure that the low water cuto device(s) will
function properly.
Operating Control
e preferred control se ing for potable hot water is 130°F, 54°C.
e operating control should be set to the lowest se ing that will
satisfy the consumer’s needs.
Se ing the thermostat or operation control too high
can result in scalding resulting in severe personal
injury!
High Limit (Aquastat)
e high limit is located in the top control area of the boiler/water
heater. A remote capillary bulb is run to a well on the outlet side
of the supply header. e high limit can be reset by depressing the
red bu on.
e water heater high limit should be set a minimum of 20°F, 11°C
higher than the operating control. Refer to the HOT WATER
SUPPLY section for the proper supply water temperature.
HIGH LIMIT: When the high limit aquastat trips the following
message is displayed:
FAULT
SYSTEM SET
HIGH LIMIT
160˚F
FAULT
10/27 9:16
SYSTEM SET
160˚F
e high limit interlock breaks power to the ignition control
(sh u ing it o ) and e ectively removes any chance of the gas valve
receiving power. e Futera Fusion series control will remain
powered to display the fault, latch the alarm relay/audible beeper,
and to access the log. e interlock is located on J5, HIGH LIMIT.
INTERLOCK SPARE 3: is is a reserved interlock input that
is normally jumpered at the factory, but can have a remote interlock connected as a eld install. e interlock is located on J11A,
SPARE 3.
Flow Switch
A ow switch is provided in the water outlet piping to prevent
the boiler/water heater from ring without adequate water ow
through the heat exchanger.
DIAGNOSTICS
e Futera Fusion has a display that indicates the sequence of
operation. e display will also list faults should the unit fail to
operate. An explanation of each status message and fault can be
located in HeatNet Control Manual under status screen fault display
section.
STATUS SCREEN FAULT DISPLAY
ere are numerous interlock switches and so ware limits that
are detected. Each of these, when tripped will produce a display
message, an audible beeping, and an alarm relay closure. e fault
is displayed rst, then a er a second, the time the fault occurred
is displayed. is cycle will keep occurring until the fault is cleared.
ese faults are:
FAULT
SYSTEM SET
INTERLOCK SPARE 3
160˚F
LOW WATER CUTOFF: If there is a low water condition reported
by the low water cuto switch this fault is displayed. Check that
there is water ow and water in the boiler. ere is a reset switch
located on the LWCO box. e interlock connection is located on
J11A, LWCO.
FAULT
SYSTEM SET
LOW WATER CUTOFF
160˚F
28
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
VAR FREQ DRIVE: e variable frequency drive, which controls
the blower, reports this fault in the event of over current or other
conditions that would cause it to shut down. If this is the case,
check the fault indicators on the VFD. e interlock is located on
J11A, VFD.
FAULT
VAR FREQ DRIVE
SYSTEM SET
160˚F
GAS PRESSURE: e optional gas pressure switches (high pressure
and low pressure) are connected in series, so if either trip, a fault
will be reported here. A reset switch is located on the gas pressure
switches. e interlock is located on J11A, GAS PR.
FAULT
GAS PRESSURE
SYSTEM SET
160˚F
FLOW SWITCH ERROR: Once the Futera Fusion series boiler
receives a call for heat, it closes the circulator pump relay. It then
waits 10 seconds to prove ow. If there is no ow, the ow switch
alarm will be set. Every 10 seconds the circulator pump relay will
cycle ON for 10 seconds and then OFF for 10 seconds to try and
establish ow. e interlock connection is located on J11B, WTR
FLW.
FAULT
WATER FLOW SWITCH
SYSTEM SET
160˚F
IGNITION CTRL ALARM: e ignition control alarm is displayed
if the ignition control detects a fault. is could be a ame failure,
air proving switch, or other fault associated with the ignition control.
When this fault occurs, you will need to refer to the ignition control
for the reason.
FAULT
IGNITION CTRL ALARM
SYSTEM SET
INTERLOCK SPARE 4: is is also a spare interlock (similar to
INTERLOCK SPARE 3) for future expansion or use as a eld
interlock. e interlock is located on J11B, SPARE 4.
FAULT
INTERLOCK SPARE 4
SYSTEM SET
160˚F
160˚F
IRI ALARM: e optional IRI alarm is the alarm from the gas
valve. If this alarm is set check the gas valve.
FAULT
IRI ALARM
SYSTEM SET
160˚F
29
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
COMBUST AIR DAMPER: If the combustion air damper has
been selected for use (MASTER BOILER, AUX FUNCTIONS),
and the proof switch does not make, this fault will be displayed.
When the combustion air damper is used, the master’s BOILER3/
DAMPER relay contacts at J13 are closed. ese should be wired
to the combustion air damper or preferably an isolation relay.
e prove switch on the combustion air damper must be wired to
J10B, SPARE 1.
FAULT
SYSTEM SET
COMBUSTION AIR DAMPER
160˚F
When the master boiler receives a call for heat and needs to start a
boiler, the BOILER3/DAMPER relay K5 closes. At the same time,
the boiler is started, res, and continues to re. If the combustion air
damper does not prove within the proof time speci ed in the
combustion air damper menu, the boiler will shut down and display
the fault. e fault on the Master boiler can be cleared by removing
the call for heat on the master boiler and xing the combustion air
damper problem. A combustion damper fault on a Member boiler
can only be cleared by power cycling.
SHORTED ***** SENSOR: If the shorted sensor fault is displayed,
the sensor in the position reported was originally detected, but
has since shorted. e boiler will shut down on any SHORTED
sensor.
FAULT
SYSTEM SET
SHORTED OUTSIDE SENSOR
160˚F
DELTA TEMP > 40°F: If the temperature across the heat exchanger
rises above the maximum designated temperature for the Futera
Fusion model boiler, a warning or fault will be displayed. is
protection is required to prevent damage to the heat exchanger in the
event high di erential temperatures are encountered. e fault or
warning condition may be changed in the AUX FUNCTIONS
menu under ALARM TYPE. e default condition is WARNING
with LIM->HALF TE = YES.
When this condition exists and the ALARM TYPE is set to
WARNING and LIM-> HALF TE, the boiler is limited to 1/2
it’s input rate. So, if the boiler is trying to re at 80%, the rate is
limited to 40% until the temperature across the heat exchanger
falls at least 10°F below the maximum designated temperature
for the Futera Fusion boiler model. In this case: 40°F - 10°F = 30°F.
e Master boiler controls a system damper and Member boilers
control their own respective dampers. When the call for heat is
removed, the damper will remain open for 30 seconds before closing.
is allows for post purge cycles to complete.
OPEN ***** SENSOR: If the open sensor fault is displayed, the
sensor in the position reported was originally detected, but has
since opened. e boiler will shut down on any OPEN sensor.
FAULT
SYSTEM SET
OPEN OUTSIDE SENSOR
160˚F
If the ALARM TYPE is set to FAULT, the boiler will display the
FAULT message and this condition will be treated as an interlock,
thus shu ing down the boiler until the Delta Temp drops 10°F
below the maximum designated temperature.
1/2 INPUT
LOCAL SET
DELTA TEMP > 40°F
41˚F
RETURN TEMP < 130°F: If the Return Inlet temperature is less
than 130°F this warning will be displayed. is warning does not
a ect operation and does not set the alarm relay. A log entry is
made to aide in diagnosing why this may be occurring. Condensing
will occur with return temperatures below 130°F and a shortened
heat exchanger life will occur.
PREPURGE
LOCAL SET
RETURN TEMP < 130°F
41˚F
30
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
MAINTENANCE
Disconnect electrical power and close the manual gas
shut o 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/water heater!
e boiler/water heater must be cleaned and inspected at least once
a year and before each heating season. Make sure that the burner and
ignition components are free from dust, soot, dirt, corrosion or other
deposits that would impair the boiler/water heater‘s performance.
Refer to Figure 21 for component identi cation.
Improper burner servicing can result in premature
burner failure voiding the warranty!
Burner Removal
1. Close the manual shuto valves in the gas supply line and turn
o electrical power to the boiler/water heater.
2. Remove the jacket top panel.
3. Disconnect the wires to the fan and remove the four bolts that
secure the fan to the transition piece.
4. Remove wires from the spark rods and remove the UV sense
from the transition piece.
5. Disconnect the compression nut at the back of the transition
piece to remove pilot gas tubing.
6. Remove the four nuts holding the transition piece to the heat
exchanger.
7. Li and remove the transition piece and burner together from
the boiler/water heater, taking care not to damage the spark
rods and or their alignment.
8. Disconnect the compression nut from the inside of the transition piece.
9. Remove the transition piece, taking care not to damage the spark
rods and or their alignment.
Heat Exchanger Inspection
1. Close the manual shuto valves in the gas supply lines and turn
o electrical power to the boiler/water heater.
2. Remove burner following the instructions in the Burner
Removal section.
3. Remove the front jacket panel and combustion chamber door.
4. Inspect the inside and outside of the heat exchanger for signs
of damage, sooting or corrosion.
5. e outside surfaces of the copper tubes should be free of any
soot deposits. A slight black smudge is normal with some types
of gases. Black soot indicates poor combustion. Green deposits
indicate condensation due to low return water temperatures. In
either case the heat exchanger must be cleaned thoroughly and
the problem resolved before the boiler/water heater is returned
to service.
6. If there are no signs of damage, sooting or corrosion, reassemble
the unit following the previous steps in reverse order.
7. A badly corroded or damaged heat exchanger must be replaced,
see the Heat Exchanger Repair & Replacement section.
Heat Exchanger Cleaning
1. Close the shut o valves in the inlet and outlet piping. On heating
systems close the system ll valve and relieve the system pressure
from the boiler by carefully li ing the relief valve or opening
the drain valve.
2. Disconnect the boiler/water heater from the system piping.
3. Remove the eight bolts on the rear pipe enclosure panel.
4. Remove the front jacket panel and combustion chamber door.
5. Slide the heat exchanger out of the unit.
6. Remove the “V” ba e straps and “V” ba es.
7. oroughly clean the heat exchanger with water from a highpressure hose. Use a so bristle brush if necessary.
8. Replace the cleaned heat exchanger and other components in
the reverse order of their removal.
Heat Exchanger Repair & Replacement
1. A leaking or otherwise damaged tube(s) can be replaced as
outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler/water heater as
outlined in the Heat Exchanger Cleaning section.
3. Remove the pipe plugs from the inlet/outlet and return headers
opposite from the ends of the tube(s) being replaced.
4. Carefully cut the damaged tube(s) in half, taking care not to
damage the adjacent tubes and remove.
5. Install and swage/expand in place the new tube(s).
6. Replace the pipe plugs using a suitable thread sealant on each
one.
7. Sagging or distorted heat exchanger tubes are an indication of
low water ow through the system. A damaged heat exchanger
must be replaced and the condition that caused the damage
resolved before the boiler/water heater is returned to service.
8. Replace the heat exchanger and other components in the reverse
order of their removal.
Air Intake & Vent System
oroughly inspect the air intake and vent systems for any signs of
blockage, corrosion or leakage. Immediately replace any unsound
vent system piping. Inspect the air lter and wash with warm water
and soap if dirty.
31
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
Controls
Use the “GENERAL OPERATION” and “CHECKING AND
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A oat type low water cuto device must be ushed out per
the manufacturers’ instructions. e probe on a probe low water
cut o must be removed, cleaned and inspected at least once
a year. Ensure that the low water cuto s operate properly. If not,
replace them.
3. e ow switch contacts must be open when water ow is not
present.
4. e relief valve should not weep or discharge water at normal
system pressure. If it does, contact a quali ed service technician
to have it inspected. NEVER try to clean or repair the relief
valve! If the valve fails to operate properly, have it replaced!
5. e aquastat high limit controls the maximum water temperature
in the boiler. If the water temperature reaches the set temperature
before the demand for heat has been met, the aquastat high limit
should shut the boiler o . e water temperature should never
exceed the maximum set point of 250°F, 121°C, for boilers and
210°F, 99°C for water heaters. e aquastat high limit cannot be
repaired. If it fails to function properly, replace it.
6. Visually check the pilot and main burner ames to ensure proper
operation.
A yellow, oating ame indicates a lack of combution
air. Do not operate the boiler/water heater until the
problem is solved or severe personal injury or death
may occur!
Figure 20 Main Burner Flame
32
32
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
T rouble s hoo t ing A S t ar t u p
A c t i o n C he c k I den t i f y S ou r c e S y m p t o m
A n I n t e r l o ck i s t r i pped .
1 .
1 . I s i t a 24 V A C I n t e r l o ck ?
2 . I s i t a 120 V A C I n t e r l o ck /
A l a r m ?
3 . I n t e r na l A l a r m s
1 . A ll 24 V A C I n t e r l o cks a r e
l o c a t ed on J 1 1 A and J 1 1 B .
E x a m p l e s o f 24 V A C I n t e r l o cks :
1 .S P A R E 3
2 . V a r i ab l e F r equen c y Dr i v e ( V F D )
3 . Lo w W a t e r C
4 . G a s P r e ss u r e
5 . S pa r e 4
6 . O pe r a t o r O P L I M
7 . W a t e r Fl o w
8 . A i r P r e ss u r e f r o m U V S en s o r .
2 . A ll 120 V A C i n t e r l o cks /A l a r m s
a r e
l o c a t ed on J 5 . T he s e i n c l ude :
1 . F L A M E SA F E A L A R M ( I gn i t i o n
CTRL ALARM)
2 . V alve Alarm (IRI ALARM)
3 . XS_FACTORY (Reserved)
4 . H I G H L I M I T
1 . O PE N SE N S OR
2 . S H O R T E D SE N S OR
3 . C O M B U S T I O N AI R D A M PE R
u t o f f ( L W C O ) ,
1 . U s e a m u l t i m e t e r and c he c k
f o r 24 V A C on J 1 1 A, J 1 1 B t o
i den t i f y w h i c h i n t e r l o ck ha s
t r i pped . R e s e t t he I n t e r l o ck o r
c he ck f o r d i sc onne c t ed
o r s ho r t s .
T he A i r P r e ss u r e f r o m U V
S en s o r i n t e r l o ck i f d i s p l a y e d
w ill a ll o w t he bo il e r t o
f un c t i on , bu t i t need s t o b e
f un c t i ona
l w h il e t he bo il e r i s
r unn i ng f o r i t t o c l ea r .
1 . U s e a m u l t i m e t e r on J 5 t o
t o c he ck f o r 120 V A C o n
t he s e i n t e r l o cks ( e x c ep t t h e
H I G H
L I M I T ) . T he H i gh L i m i t
I n t e r l o ck i s d i s p l a y ed w he n
t he r e i s no 120 V A C , s i n c e
t he H I G H L I M I T b r ea ks t h e
120 V A C t o t he I gn i t i o n
C on t r
o l .
N O T E: St r a y V o l t age s
G r ea t e r t han 8 V A C and l e s s
t han 18 V A C on t he s e
i n t e r l o cks c an c au s e
i n t e r m i tt an t ope r a t i on . If t h i s
i s t he c a s e , c he ck f o r ba c
f ed v o l t age s f r o m f i e l d w i r i ng .
C he ck s en s o r v o l t age s a t
J 10 A and J 10 B. T h e
T e m pe r a t u r e s en s o r i npu t s
s hou l d be be t w een 0 V D C
and 5 V DC m ea s u r ed
t he s en s o r . E x a m p l e : At 77 °F,
t he v o l t age w ou l d r ead 2 . 5
V DC .
w i r i n g
k
a c r o s s
2 .
P r o c eed t o HeatNet
m o r e de t a il s an d
p r ob l e m r e s o l u t i on .
f o r
M anua l Control
T he c o m bu s t i on a i r da m pe r
p r o v e s w i t c h m u s t be w i r e d
a c r o ss S P A R E 1 and
a " DR Y " c on t a c t. D o no t
app l y a v o l t age t o t h i s i npu t ,
t he i npu t s upp li e s i t ' s o w n
v o l t age / c u rr en t .
m u s t b e
33
Fi
l
F
F
REPAIR PARTS
Figure 21 Repair Parts
nned copper tube gas boilers & water heaters – Boiler Manua
34
34
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
REPAIR PARTS (CONTINUED)
35
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
15 Burner for Turbo Pilot
15a Transition Gasket
15b Burner Gasket
18 Gas Valve
Test Port (CSD-1) 11-0354 1111111
19 Flange 1" (Outlet) 11-0228 1111
17 Flange 1" (Inlet) 11-0231 1111
17 Flange 1-1/4" 11-0213 2
17 Flange 1-1/2" (Inlet) 11-0214 2 2
19 Flange 1-1/2" (Outlet) 11-0229 1 1 1
NS Ori ce Gasket 06-0022 1111111
Gas Injectors NG 10-1009 1111
NS
Gas Injectors NG 10-1002 1 1 1
Gas Injectors LP 10-1010 1111111
Firing Valve, 1" 11-0456 1 1
21
Firing Valve, 1-1/4" 11-0457 1 1
Firing Valve, 1-1/2" 11-0458 1 1 1
Blower, Fasco 7043 12-0016-1 1 1 1
23
Blower, Fasco 7035 12-0017 1111
Flow Switch 14-0203 1111111
25
Flow Switch (Outdoor) 14-0205 1111111
Flow Switch (Potter) 14-0201 1111111
Flow Switch (Outdoor Potter) 14-0202 1111111
26 Frequency Drive 15-0231 1111111
27 Jacket Top Panel
36 Combustion Chamber Top Panel
Manning Glass Insulation (per square foot) 05-0104 4445555
Pressure Relief Valve 50# 30-0360 1 1 1
39
Pressure Relief Valve 50# 30-0374 1
Pressure Relief Valve 50# 30-0379 1 1 1
Pressure Relief Valve 125# 30-0364 1111111
40 Latch 20-0046 2222222
70-2529.1 1
70-2530.1 1
70-2531.1 1
70-2532.1 1
70-2533.1 1
70-2534.1 1
70-2535.1 1
06-0026 1 1 1
06-0027 1111
06-0041 1 1 1
06-0042 1111
11-0230 1111
11-0227 1 1 1
70-2412 1 1 1
70-2413 1 1 1 1
70-2356 1 1 1
70-2357 1111
36
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
42 Air Filter (prior to 0110)
NS Air Filter Upgrade Kit
Air Filter
Tridicator 0-100 psi (PRV 30-60 psi) 13-0308 1111111
45
Tridicator 0-230 psi (PRV 75-160 psi) 13-0305 1111111
46 Heat Exchanger Assembly (Copper)
Cast Iron (prior to 0209 must replace
combustion chamber top panel #36)
Heat Exchanger Assembly (Copper)
Bronze
Heat Exchanger Assembly (Cupronickel)
Cast Iron (prior to 0209 must replace
combustion chamber top panel #36)
Heat Exchanger Assembly (Cupronickel)
Bronze
NS Inlet Adapters (Flanged)
Outlet Adapters (Flanged)
Inlet/Outlet Header Gasket
09-0489 1 1 1
09-0498 1 1
09-0499 1 1
21-2005 1 1 1
21-2006 1111
09-0483 1 1 1
09-0484 1111
70-2515.1R
70-2516.1R
70-2517.1R
70-2518.1R
70-2519.1R
70-2520.1R
70-2521.1R
70-2186.1R
70-2187.1R
70-2188.1R
70-2189.1R
70-2190.1R
70-2191.1R
70-2192.1R
70-2522.1R
70-2523.1R
70-2524.1R
70-2525.1R
70-2526.1R
70-2527.1R
70-2528.1R
70-2193.1R
70-2194.1R
70-2195.1R
70-2196.1R
70-2197.1R
70-2198.1R
70-2199.1R
01-0044GL
01-0045GL
01-0046GL
01-0047GL
06-0202 4 4 4
06-0201 4444
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
111
1111
111
1111
1
1
1
1
37
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
NS Heat Exchanger "V" Ba e
Strap “V” Ba e
High Limit, Jumo, (CB) 14-0013 1111111
48
High Limit, Jumo, (CW) 14-0014 1111111
NS Operator, T6031A (pool heater) 14-0003 1111111
NS High Limit Well, 3/8 x 3 13-0104 2222222
NS 10K Temperature Sensor 14-0325 3333333
50 Transformer, 50 VA 15-0007 1111111
51 Purge Timer, ST7800 16-0007 1111111
52 Spark Generator 16-0036 1111111
53 Flame Safeguard, RM7895C 16-0024R 1111111
NS UV Ampli er, R7849A 16-0006 1111111
NS Keyboard Display Module, S7800A 16-0010 1111111
54 Main Board (HeatNet) (green) 16-0038 1111111
55 Display Board (HeatNet) 40-0088 1111111
NS Ribbon Cable 40-0115 1111111
NS Power Switch 48-0013 1111111
NS Toggle Switch Remote / Local 48-0014 1111111
56 Air Pressure Switch 11-0416 1111111
NS Low Gas Pressure Switch (Manual Reset) 11-0422 1111111
NS High Gas Pressure Switch (Manual Reset) 11-0411 1111111
NS High Gas Pressure Switch Base 11-0423 1111111
NS Ignition Cable 44-0063 1111111
60 Transition Assembly
60a Gasket
Pump Contactor Relay (20 AMP) 15-0137 1 1 1
61
Pump Contactor Relay (9 AMP) 15-0210 1 1 1
Pump Contactor Relay (12 AMP) 15-0211 1
Overload Relays
Thermostatic Valve (CB) 2" Cast Iron 13-0201 1 1 1
68
Thermostatic Valve (CB) 2-1/2" Cast Iron 13-0202 1111
Thermostatic Valve (CW) 2" Bronze 13-0203 1 1 1
Thermostatic Valve (CW) 2-1/2" Bronze 13-0204 1111
NS Drain Valve Gaskets
03-1612 20
03-1613 20
03-1614 20
03-1615 28
03-1616 28
03-1617 28
03-1618 28
03-1619 2 2 2
03-1620 2222
70-2305 1 1 1
70-2306 1111
06-0043 1 1 1
06-0044 1111
15-0217 1
15-0214 1 1
15-0215 1
06-0083 1111111
06-0084 1111111
38
Finned copper tube gas boilers & water heaters – Boiler Manual
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
NS Rating Plate 82-0054 1111111
NS Futera Fusion Overlay (HeatNet) 82-0313 1111111
77 Keypad Overlay 82-0189 1111111
78 Mini Fan 12-0021 1111111
79 Air Shuto Valve 11-0376 1111111
80 Pilot Tube 3/8 62-0102 2222222
Pilot Ori ce, NG 10-0140 1111111
81
Pilot Ori ce, LP 10-0139 1111111
82 Mini Peeper C7027A 16-0009 1111111
85 Turbo Pilot Torch 70-2559 1111111
86 1/2" Aluminum Tubing 62-0103 1111111
NS Spark Rod Assembly
83 Spark Plate Gasket
84 Electrode 16-0335 1111111
NS Spark Rod O'ring 06-0008 1111111
NS Silicone 66-0151 1111111
NS Silicone Tubing 06-0051 2222222
Vent Termination Hood 7" 09-0140 1111
NS
Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1 1
Air Intake Hood 6" 09-0102 1 1 1
NS
Air Intake Hood 8" 09-0103 1
Air Intake Hood 10" 09-0104 1
Air Intake Hood 12" 09-0105 1 1
70-2566 1 1 1
70-2567 1111
06-0102 1 1 1
06-0037 1111
39
Fi
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
F
:
T
:
:
:
:
ST
T
N
D
D
D
L
V
D
S
R
f
.
.
T
f
.
.
.
.
.
.
J
.
.
.
0.
.
.
dby.
.
START-UP REPORT
DATE
E C HNI C IAN:
MPANY
PH O NE N U MBER
PRE
NO VISIBLE DAMAGE TO UNI
IPING PROPERLY CONNECTE
B O ILER CIRC U LAT O R WIRE
ENT / STACK C O NNECTE
LE
Note: Locate the AA terminals and minimum hold switch in the bottom-right of the electrical panel on the main
HeatNet board. Also locate the manometer test mani
Disable an y external call f or heat and toggle the remote/local switch to REMOTE
.
oggle the LOW FIRE switch to c y cle the boiler then hold at trial
2
et pressure to 3–3.5" WC (ame signal should read 5.0 VDC)
3.
Release boiler to main ame trial for ignition
4
heck for stable ame
.
ecord combustion and manifold pressure at minimum ring rate.
um p er the AA terminals to
ecord combustion and manifold pressure.
emove the AA j umper to place the boiler at minimum rate
9
ake any nal adjustments on low re. 1
heck all combustion results using a calibrated ue gas anal y zer
11
e l ease t h e LOW FIRE switc h to p l ace b oi l er in stan
12
T
HE CK LI
T
E
U
N C E
force 100% input
JOB NAME:
OCA TION:
DEL
ERIAL #
INLET AIR FILTER IN S TALLED AND C LEA
PROPER SERVICE CLEARANCES PROVIDE
UMP RUNNING, HEAT EX C HANGER FUL
GAS LINES PURGED, N O LEAKS, N O MISSING TEST
L U G
old in the bottom o f the electrical panel
or pilot ignition
In addition to completing the Fusion start-up report, complete the control set-up information in the rear of
the HeatNet manual.
40
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
A
YSIS
TE
00%
TE
O
)
E
ST
S
CH
D
S
B
R
R
H
S
T
-
-
-
.
T
1
D
D
L
T
R
______________________________________
)
_
DD
S
M
STI O N
GAS PRESSURE AT SUPPLY TEST PORT INCHES WC I NCHES WC
C
F I N
1
F IN
CO ( PPM
NET S TA C K TEMPERAT U R
MANIFOLD PRESSURE (WC) IN C HE S WC I N C HE S WC
AF TY
L O W SWITCHE
OW WATER CUT-OFF
C O MMISSIONIN
NIT CYCLED MINIMUM O F 15 TIME
CUSTOMER INSTRUCTE
ALL COVERS REPLACE
UST O MER GIVEN MANUA
ARGET TEMPERAT U RE SET PER C U ST O ME
E S T
Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140°F,60°C. Operating
at lower return temperatures is likely to cause condensation in the primary heat exchanger, resulting in corrosion and possible
failure of the heat exchanger.
HE CK LI
IR S WIT
IGH LIMIT
I
E
E
M
FLAME SAFEGUAR
HE D ELTA T B ETWEEN THE HEATE R IN
LET AND OU TLET IS CRITICAL T O PR O P
ER FL O W . BEF O RE Y OU LEAVE THE JO B
ITE, Y O U MUST REC O RD THE DELT AT
HIS READING SH O ULD N O T EXCEED
, 19.4
5
.
C, N O R BE L O WER THAN 2 0 ,
COMMISSIONED BY:
DATE: ___________________________
A
TI ON
N O TE
SIGNATURE
ELTA T =
C O MMENTS
41
nned copper tube gas boilers & water heaters – Boiler Manua
l
F
Commonwealth of Massachusetts
NOTICE!
Installation Requirements MACODE-3
In the Commonwealth of Massachusetts, the installation
must be performed by a licensed plumber or gas tter.
1. 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 nished grade,
in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satis ed:
d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the
time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gas tter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the oor level
where the gas equipment is to be installed. In addition, the
installing plumber or gas tter 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 quali ed
licensed professionals for the installation of hard wired
carbon monoxide detectors.
i. 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
oor level.
ii. 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.
e. 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 certi ed.
f. 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”.
g. 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!
2. Exemptions — The following equipment is exempt from
248 CMR 5.08(2)(a) 1 through 4:
a. 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
b. 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.
3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED.
a. 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:
i. Detailed instructions for the installation of the venting
system design or the venting system components; and
ii. A complete parts list for the venting system design or
venting system.
4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
a. When the manufacturer of a Product Approved side wall
horizontally vented gas fueled equipment does not provide
the parts for venting the ue gases, but identi es “special
venting systems”, the following requirements shall be
satis ed by the manufacturer:
i. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
ii. 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.
5. 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!
42
LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
e “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/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.
e “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 Boiler/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.
is 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 wri en instructions, or has been altered or modi ed in any way.
ese include but not limited to:
• 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.
• Excessive pi ing and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and
is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• 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.
• All copper n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan
assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation (bypass and valve
arrangement included on Futera Fusion Series). e manufacturer’s warranty does not cover damage done by condensation.
(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 se lement, 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.
is 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 wri en
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.
260 North Elm Street 7555 Tranmere Drive
West eld, MA 01085 䡲 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
43
260 North Elm Street 7555 Tranmere Drive
West eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
44
Copyright 2012 Mestek, Inc.
Loading...