RBI FB-750, FB-1000, FB-1250, FB-1500, FB-1750 Installation And Operation Instructions Manual
...
FTII-IOM-8
Finned copper tube
Gas boilers (FB) &
Water heaters (FW)
82-0253
Boiler manual
Installation and
operation instructions
is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with a dustfree 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/water heater. 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.
260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085 Mississauga, ONT. L5S IL4 Canada
Tel: (413) 568-9571 Tel: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
Copyright 2010 Mestek, Inc.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
CONTENTS
BEFORE YOUR START . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOILER/WATER HEATER LOCATION . . . . . . . . . . . . . . . 3
COMBUSTION AIR & VENTILATION . . . . . . . . . . . . . . . . . 3
GENERAL VENTING GUIDELINES . . . . . . . . . . . . . . . . . 5
OUTDOOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COMMON VENT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . . . 14
HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . . 16
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . . . . 20
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 25
CHECKING & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . 27
CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSTICSPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
START UP SHEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MASS CODE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BEFORE Y OU START
This manual covers the application, installation, operation
and maintenance of a Futera II Series finned copper
heating boiler/water heater/pool heater.
To obtain the saf e, dependable, effi cient operation and long
life for which this heating boiler/w ater heater was designed,
these instructions must be read, understood and followed.
The Futera II Series finned copper heating boiler/water
heaters have been design certified by CSA for use with
natural and propane gas under the latest revision of
ANSI-Z21.10.3/CSA 4.3, Gas W ater 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 b y the authority having jurisdiction,
the installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.
In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for
Gas Burning Appliances and Equipment.
If installed in the Commonwealth of Massachusetts, you
MUST FOLLOW the additional instructions located in the
back of this manual (MACODE-3).
The owner should maintain a record of all service work
performed with the date and a description of the work done.
Include the name of the service organization for future
reference.
Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at:
U.S. —
260 North Elm Street
Westfi eld, MA 01085
Canada —
7555 Tranmere Drive
Mississauga ONT L5S 1L4
Always include the model and serial numbers from the
rating plate of the boiler/water heater in question.
2
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
RATINGS & CAPACITIES
Before undertaking the installation of the Futera II Series
boiler/water heater check the rating plate to ensure that the
unit has been sized properly for the job. The “Net I=B=R
Ratings” specify the equivalent amount of direct 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. This 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.
NOTE: Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1
Clearance to Service
Combustibles Clearance
in mm in mm
Top 24 610 30 762
Back 14 356 24 610
Left Side 6 153 12 306
Right Side 6 153 12 306
Front 8 203 30 762
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 fl oor is structurally sound and will
support the weight of the boiler/water heater.
NOTE: The Futera II may be installed directly on
combustible fl 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
“GENERAL 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 15.
CAUTION: Units installed outdoors MUST be protected
from ice and snow accumulation or the unit will be
damaged voiding the warranty!
WARNING: Never store combustible materials,
gasoline or any product containing flammable
vapors or liquids in the vicinity of the boiler/water
heater. Failure to comply with this warning can
result in an explosion or fire causing extensive
property damage, severe personal injury or death!
COMBUSTION AIR & VENTILATION
WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
Section 5.3, Air for Comb ustion & 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!
CAUTION: Combustion air contaminated with
fl uorocarbons or other halogenated compounds such
as cleaning solvents and refrigerants will result in the
formation of acids in the combustion chamber. These
acids will cause premature failure of the boiler/water
heater voiding the warranty!
CAUTION: 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 fi 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.
3
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Never operate the Futera II 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!
All Air From Inside The Building
If the Futera II is to be located in a confi ned space, the
minimum clearances listed in Table 1 must be maintained
between it and any combustible construction. When
installed in a confined space without the intake air
option, Figures 7, 8 and 9, two permanent openings
communicating with an additional room(s) are required. The
combined volume of these spaces must have suffi cient
volume to meet the criteria for an unconfi ned space. The
total air requirements of all gas utilization equipment,
fi 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 in
hr, 2200 mm
gas utilization equipment in the confined area. Each
opening must be no less than 100 in
2
/kW based on the total input rating of ALL
2
, 64,516 mm2 in size.
The upper opening must be within 12 in, 305 mm of, but
not less than 3 in, 76 mm from, the top of the enclosure.
The bottom opening must be within 12 in, 305 mm of, but
not less than 3 in, 76 mm from, the bottom of the
enclosure.
All Air From Outside The Building
When installed in a confi 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. The
upper opening must be within 12 in, 305 mm of, but not
less than 3 in, 76 mm from, the top of the enclosure. The
bottom opening must be within 12 in, 305 mm of, but not
less than 3 in, 76 mm from, the bottom of the enclosure.
Where directly communicating with the outdoors
or communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of
2
/4000 Btu/hr, 550 mm2/kW of the total input rating
1 in
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
2
/2000 Btu/hr, 1100 mm2/kW of the total input rating
1 in
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 effects of louvers, grills and
screens. Screens must have a minimum mesh size of
1/4 in, 6.4 mm. If the free area through a louver or grill is
not known, ducts should be sized per Table 2.
2
/1000 Btu/
Table 2 – Make-up Air Louver Sizing
Required Cross Sectional Area
Input 1/4 in 6.4 mm
(MBH) Wire Screen Metal Louvers Wooden Louvers
in
2
cm
75% Free Area 25% Free Area
2
in
2
cm
2
in
2
cm
2
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
1950 486 3135 649 4187 1950 12,580
Canadian installations must comply with CSA B149.1 when
air supply is provided by natural air fl ow from the outdoors
for natural draft, partial fan-assisted, fan-assisted, or
power draft-assisted burners, there shall be a permanent
air supply opening(s) having a cross-sectional area of not
less than 1 in
and including 1 million Btuh, plus 1 in
(155 mm
2
per 7,000 Btuh (310 mm2 per kW) up to
2
per kW) in excess of 1 million Btuh.
2
per 14,000 Btuh
Intake Air Option – General Guidelines
This confi guration provides combustion air directly to the
boiler/water heater’s air intake using a dedicated pipe when
using the direct vent option. The RBI air intake adapter
must be fi tted to the blower inlet. Combustion air can be
drawn in horizontally through the same outside wall which
terminates the exhaust gases or vertically through the roof,
see Figures 2, 3, 4, 5 & 6.
WARNING: Common intake air systems may be
used provided the common duct is sized properly
and an intake combustion air damper is installed
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!
All joints in metal intake air systems must be secured using
corrosion resistant fasteners and sealed using a suitable
Silicone caulk. If PVC or CPVC is used, the joints must be
cleaned with a suitable solvent and connected using a
solvent based PVC cement. The combustion air system
MUST be supported by the building structure not the
boiler/water heater.
CAUTION: A combustion air damper interlocked with
the unit should be installed in the intake air pipe when
the infi ltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake Air Option – Vertical Guidelines
The maximum equivalent length for the vertical intake air
pipe is 60 ft, 18.3 m. Each 90˚ elbow and the intake air
terminal are equal to 10 linear ft, 3.1 m of pipe.
An approved, nonrestrictive intake air terminal must be
used. The intake air terminal must terminate as shown in
Figure 5. The penetration point in the roof must be properly
fl ashed and sealed.
4
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
Intake Air Option – Horizontal Guidelines
The maximum equivalent length for the horizontal
combustion air pipe on installations that used the Direct
V ent option is 60 ft, 18.3 m. The maximum equivalent length
for the horizontal combustion air pipe on installations that
use the Horizontal Pow er V ent option is 100 ft, 30.5 m. Each
90° elbow and the combustion air terminal are equal to 10
linear ft, 3.1 m of pipe. If horizontal runs exceed 5 ft, 1.5 m
they must be supported at 3 ft, 0.9 m intervals with ov erhead
hangers. The certifi ed combustion air terminal from RBI must
be used and installed as shown in Figures 3 and 4.
GENERAL VENTING GUIDELINES
WARNING: The vent installation must be in
accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54latest 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!
All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropr iate
thimbles and fi re-stops must be used where required.
VENT SYSTEM OPTIONS
The Futera II may be vented the following ways:
1) Direct Vent, Positive Pressure, Category III uses a
vent system certifi 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, P ositive Pressure, Category III uses
a vent system certifi 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) Horizontal Vent, Negative Pressure, Category I
for horizontal vent runs equivalent to more than 60
ft, 18.3 m (90 degree elbow = 10 equivalent feet), a
dedicated wall mounted power venter must be used.
The vent system can be single wall galvaniz ed steel or
type B vent pipe. Combustion air is obtained from the
space in which the unit is installed or from the outdoors.
A barometric damper must be installed when the
horzontal run is longer than 60 equivalent feet (90
degree elbow = 10 equivalent f eet). If this is the case, a
power venter must also be used.
WARNING: Common vent systems must be
properly engineered and sized to provide a
negative draft of 0.01 to 0.08 in, 0.25 to 2.0 mm W .C.
at the fl ue outlet. Common positive pressure vent
systems are not to be used. Improper installation
can result in excessive levels of carbon monoxide,
which can cause severe personal injury or death!
NOTE: A single acting barometric damper must be
installed directly to the boiler/water heater fl ue outlet, if
required. This does not apply to outdoor units or direct
vent positive pressure units.
NOTE: Some venting applications may require the stop
to be removed for smooth operation. The barometric
damper should be located after the fl ue collector, refer
to Figures 2, 7A and 8 for proper location. Be sure that
the damper is mounted horizontally (never vertically).
Carefully follow the instructions provided with the
barometric damper.
In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.
WARNING: To avoid spillage into the room of
dangerous fl ue gas containing carbon monoxide,
the opening in damper must never face against the
fl ow of fl ue gas.
If horizontal run is less than 60 equivalent feet, do not
use a barometric damper. Follow applicab le instructions
under the “DIRECT VENT, POSITIVE PRESSURE”
section, page 6.
4) Vertical/Chimney Vent, Negative Pressure,
Category I uses an approved metal chimney system
or masonry chimney. Combustion air is obtained from
the space in which the unit is installed. A barometric
damper must be installed near the fl ue outlet when
venting vertically.
5) Outdoor Installation uses the outdoor option kit.
Barometric damper is not required.
NOTE: All venting, combustion air material supplied by
installer.
5
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
DIRECT VENT ,
POSITIVE PRESSURE, CATEGORY III
In this confi guration the boiler/water heater blower is used
to push the fl ue products to the outdoors while drawing
combustion air from the outdoors. The equivalent length
of the vent system must not exceed 60 ft., 18.3 m. The
Intake Air Option instructions under the “COMBUSTION
AIR & VENTILATION” section must be followed! The vent
system must be sized per Figure 2, Outlet Sizes.
Horizontal Direct Vent Systems – Figures 3 & 4
The vent materials used in horizontal vent systems must
be certifi ed to UL 1738 for installations in the United States,
ULC S636 for installations in Canada. The certifi ed vent
terminal from RBI must also be used.
The maximum equivalent length for the horizontal vent
pipe is 60 ft, 18.3 m. Each 90˚ elbow and the vent terminal
are equal to 10 linear ft, 3.1 m of pipe. 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 m ust be made using
approved fire-stops. For best results, horizontal vent
systems should be as short and straight as possible.
The 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 ft, 1.5 m they must be
supported at 3 ft, 0.9 m intervals with overhead hangers.
The vent system must be pitched down, toward the vent
terminal, 1/4 in/ft, 20 mm/m. If an y 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 ft,
1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,
0.30 m above any door, window or gravity air inlet into
any building. It must not terminate less than 4 ft, 1.2 m
horizontally from, and in no case above or below, unless
a 4 ft, 1.2 m horizontal distance is maintained, from electric
meters, gas meters, regulators and relief equipment and
not less than 7 ft, 2.1 m from any adjacent public walkway.
The bottom of the vent terminal(s) shall be located at
least 5 ft, 1.5 m above the air intake terminal(s) unless
there is a minimum 5 ft, 1.5 m horizontal separation
between them. Avoid terminal locations likely to be affected
by winds, snowdrifts, people and pets. Protect building
materials and vegetation from degradation caused by the
fl ue gases.
Vertical Direct Vent Systems – Figure 5
The maximum equivalent length for the vertical pipe is
60 ft, 18.3 m. Each 90˚ elbow and the vent terminal are
equal to 10 linear ft, 3.1 m of pipe. 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 fi restops.
An approved nonrestrictive intake air teminal must be
used. The top of a vertical vent system must extend at least
1
/2 ft, 1.7 m above the roof surface and maximum snow
5
line that it passes through, 4 ft, 1.2 m above the intake air
terminal, see Figure 5.
In addition the vent system must conform to the dimensions
shown in Figure 5. The penetration point in the roof must
be properly fl ashed and sealed.
The vent system must be gas tight. All seams and joints
in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
Combination Direct Vent Systems – Figure 6
The 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
“GENERAL VENTING GUIDELINES” sections.
6
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
Figure 1 - Air Intake Vertical or Thru Wall
Figure 2 - Venting Thru Wall/Vertical
7
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
Figure 3 – Horizontal Air Intake and Venting for a Single Direct Vent System
WARNING: When running horizontal
combustion air and venting for single or
multiple units, exhaust and combustion air
terminals must be installed on the same
plane (outside wall) in order to prevent
pressure differences due to prevailing
winds. In cold climates, double-wall or
insulated inlet pipe recommended to
prevent condensation.
Figure 4 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems
8
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
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 5 - Vertical Air Intake and Venting for Direct Vent System
Figure 6 – Combination Direct Vent Systems
3 FT. 1 m
1.5 FT. .5 m
10 FT. 3.1 m
9
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
SIDE W ALL VENT ,
POSITIVE PRESSURE, CATEGORY III
In this confi guration the boiler/water heater blower is used
to push the fl ue products horizontally to the outdoors, see
Figure 7. The air for combustion is taken from the space
in which the unit is installed. The applicable instructions
under the “COMBUSTION AIR & VENTILATION” section
must be followed! The vent guidelines under the Horizontal
Direct Vent Systems section must also be followed.
HORIZONT AL VENT ,
NEGATIVE PRESSURE, CATEGORY I
In this confi guration a wall-mounted power venter must be
used to pull the fl ue products horizontally from the unit and
vent them to the outdoors, see Figures 3, 4 & 7A. The air
for combustion is taken from the space in which the unit is
installed, or from the outdoors. The applicable instructions
under the “COMBUSTION AIR & VENTILATION” section
must be followed!
To maximize the performance of single wall sheet metal
vent systems locate 90˚ elbows as far from the boiler as
possible and from one another. For best results, horizontal
vent systems should be as short and straight as possible.
When horizontal vent runs exceed 5 ft, 1.5 m they
must be supported at 3 ft, 0.9 m inter vals with overhead
hangers. The vent system must be pitched down, toward
the vent terminal, 1/4 in/ft, 21 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 ft,
1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,
0.30 m above any door, window or gravity air inlet
into any building. It must not terminate less than
4 ft, 1.2 m horizontally from, and in no case above
or below, unless a 4 ft, 1.2 m horizontal distance
is maintained, from electric meters, gas meters, regulators
and relief equipment and not less than 7 ft, 2.1 m from
any adjacent public walkway.The bottom of the vent
terminal(s) shall be located at least 5 ft, 1.5 m above
the air intake terminal(s) unless there is a minimum 5 ft,
1.5 m horizontal separation between them. Avoid terminal
locations likely to be affected by winds, snowdrifts, people
and pets. Protect building materials and vegetation from
degradation caused by the fl ue gases.
To determine the appropriate power venter for the
boiler/water heater, see Table 3. Follow the power venter
manufacturer’s installation instructions.
Table 3 - Power Venter Sizes
Futera II Power Venter Max. Pipe Length
Model Model FT m
500 - 750 HS-3 100 31
1000-1250 HS-4 100 31
1500-1950 HS-5 100 31
VERTICAL/CHIMNEY VENT ,
NEGATIVE PRESSURE, CATEGORY I
The Futera II is listed as a Category I appliance when
vented vertically into a listed metal chimney system or
properly sized masonry chimney, Figures 8 & 9. The
chimney must provide a negative pressure of 0.01 to 0.08
in, 0.25 to 2.0 mm W.C . at the boiler/water heater fl ue collar
with the unit running. A barometric damper must be
attached directly to the fl ue collar increaser as shown.
Multiple Futera II’s can be vented into a single vertical
chimney provided that the breeching and chimney are
properly sized per the latest revision of the National Fuel
Gas Code, ANSI Z223.1.
When more than one appliance is connected to the same
chimney fl ue, the fl ue must be large enough to safely vent
the combined output of all of the appliances.
WARNING: If an appliance using any type of a
mechanical draft system operating under positive
pressure is connected to a chimney fl ue, never
connect any other appliances to this fl ue. Doing
so can result in excessive levels of carbon
monoxide which can cause severe personal injury
or death!
Chimney Inspection & Sizing
A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly
constructed and properly sized. Exterior masonry chimneys
should not be used unless properly lined to prevent
condensation and draft problems. Table 3A lists the
equivalent breeching and fl ue sizes required for the boiler/
water heater.
Table 3A - Equivalent Breeching & Chimney Size,
Negative Pressure
Model Size Pipe Diameter
in mm
500 8 203
750, 1000 10 254
1250, 1500 12 305
1750, 1950 14 356
Note: These sizes are based on a 20 ft, 6.1m chimney height.
Vent Connections
Locate the boiler/water heater as close to the chimney as
possible. Use the shortest, straightest vent connector
possible for the installation. If horizontal runs exceed 5 ft,
1.5 m they must be supported at 3 ft, 0.9 m intervals with
overhead hangers. Use a type B, single wall stainless or
single wall galvanized steel vent pipe the same diameter
as the fl ue collar to connect the boiler/water heater to a
masonry chimney, see Figure 2. When using a listed metal
chimney system use the appropriate vent connector.
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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
The vent connector should be sloped up toward the
chimney at a minimum rate of 1/4 in/ft, 21 mm/m. O n
masonry chimneys the connector must terminate fl ush with
the inside of the chimney fl ue, Figure 9. Fasten each single
wall vent connection with at least 3 corrosion resistant
sheet metal screws.
Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials. Type B1 vent may be used, clearance between
it and any combustible material must be as listed.
Figure 7 – Side Wall Venting, Positive Pressure
4 FT
1.2 m
3 FT
0.9 m
WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a fi re causing
extensive property damage, severe per sonal injury
or death!
1/4 IN. PER F00T 20 mm/m
24"
0.6 m
1.5 FT 0.5 m
Figure 7A – Power Venting, Negative Pressure
1.5 FT 0.5 m
4 FT
1.2 m
3 FT
0.9 m
7 FT
2.1 m
0.6 m
1/4 IN. PER F00T 20 mm/m
24"
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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
Figure 8 – Vertical Venting with a Metal Chimney System
12
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
24"
.6 m
Figure 9 – Vertical Venting using a Masonry Chimney
OUTDOOR VENTING
When installed outdoors the Futera II must be fi tted with
the factory supplied outdoor hood, air intake adapter with
fi lter. Horizontal discharge tee supplied by others, see
Figure 10. Multiple units must be spaced per Figure 11 to
prevent fl ue gases from being ingested by adjacent units.
The boiler/water heater must be at least 10 ft, 3.1 m from
any door, window or gravity air inlet into any building and
at least 3 ft, 0.9 m from any overhang unless local codes
dictate differently.
Figure 10 – Outdoor Venting
Avoid locations where wind deflection off of adjacent
walls, buildings or shrubbery might cause a downdraft.
The unit(s) should be located at least 3 ft, 0.9 m from
structures. Outdoor installations are not recommended in
areas where the danger of snow blockage exists.
CAUTION: Do not place the boiler/water heater in a
location that would subject it to runoff from adjacent
buildings or damage may occur voiding the warranty!
Figure 11 – Multiple Outdoor Units
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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
COMMON VENT SYSTEMS
If an existing boiler/water heater is removed from a
common venting system, the common venting system may
then be too large for the proper venting of the remaining
appliances connected to it. At the time of removal of an
existing boiler/water heater, the following steps shall be
followed with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.
Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’évacuation
commun et qui fonctionne alors que d’autres appareils
toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation
Seal any unused openings in the common venting system
a)
Sceller toutes les ouvertures non utilisées du sys-
tème d’évacuation.
b) Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.
Inspecter de façon visuelle le système d’évacu-ation
pour déterminer la grosser et l’inclinaison horizontale
qui conviennent et s’assurer que le système est exempt
d’obstruction, d’étranglement de fruite, de corrosion et
autres défaillances qui pourraient présenter des risques.
c) Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building. Turn
on clothes dryers and any appliance not connected to the
common venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhaust, so they will operate
at maximum speed. Do not operate a summer exhaust
fan for a boiler installation. Close fi replace dampers.
Dans la mesure du possible, fermer toutes les portes
et les fenêtres du bâtiment et toutes les portes entre
l’espace où les appareils toujours raccordés du système
d’évacuation sont installés et les autres espaces du
bâtiment. Mettre en marche les sécheuses, tous les
appareils non raccordés au système d’évacuation
commun et tous les ventilateurs d’extr action comme les
hottes de cuisinère et les ventilateurs des salles de bain.
S’assurer queces ventilateurs fonctionnent à la vitesse
maximale. Ne pas faire fonctionner les ventilateurs
d’été. Fermer les registres des cheminées.
d) Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de façon
que l’appareil fonctionne de façon continue.
e) Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the fl ame of a
match or candle, or smoke from a cigarette, cigar or
pipe.
Faire fonctionner le brûleur principal pendant 5 min
ensuite, déterminer si le coupe-tirage déborde à
l’ouverture de décharge. Utiliser la flamme d’une
allunette ou d’une chandelle ou la fumée d’une
cigarette, d’un cigare ou d’une pipe.
h) After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers and
any other gas-burning appliance to their previous
condition of use.
Une fois qu’il a été d éterminé, selon la métode
.
indiquée ci-dessus, que chaque appareil raccordé au
système d’évacuation est mis à l’air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les appareils
au gaz à leur position originale.
g) Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When resizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Appendix F in the National Fuel
Gas Code, ANSI Z223.1/ NFPA 54 and or CAN/CGA
B149 Installation Codes.
Tout mauvais fonctionnement du systéme d’évacu-tion
commun devrait étré corrigé de façor que l’installation
soit conforme au National Fue Gas Code, ANSI
Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/
CGA-B149. Si la grosseur d’une section du système
d’ évacuation doit étré modifi ée, le système devrait étré
modifié pour respecter les valeurs minimales des
tableaux pertinents de l’appendice F du National Fuel
Gas Code, ANSI Z223.1/ NFPA 54 et (ou) des codes
d’installation CAN/CGA-B149.
GENERAL PIPING REQUIREMENTS
CAUTION: Improper piping of this boiler/water heater
will void the manufacturer’s warranty and can cause
boiler failure resulting in flooding and extensive
property damage! Excessive water hardness causing
scaling in the copper heat exchanger tubes is NOT
covered under the manufacturer’ s warranty. Excessive
pitting 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 fl ow
rates, see Table 5. Return water temperatures below
125˚F, 52°C will result in heat exchanger damage from
excessive condensation voiding the manufacturer’s
warranty , see Primary / Secondary Piping, Figure 13.
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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
NOTE: Shut off valves and unions should be installed
at the inlet and outlet connections of the boiler/hot
water heater to provide for isolation of the unit should
servicing be necessary.
Freeze Protection
This boiler/water heater is CSA designed certifi ed for outdoor installation. Outdoor installations in areas where the
danger of freezing exists are not recommended unless
proper freeze protection is provided. The following
precautions MUST be observed:
1. A continuous fl ow of water through the unit MUST be
maintained! The pump responsible for fl 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. The pump must be capable of producing
a minimum of 15% more fl 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 off for any reason the electric,
gas and water supplies MUST be shut off and the unit
and its pump completely drained.
CAUTION: Improper outdoor installation of this unit
can cause boiler failure voiding the manufacturer’s
warranty!
Relief Valve
Pipe the discharge of the pressure relief valve as shown
in Figure 12.
WARNING: Never install any type of valve between
the boiler/water heater and the relief valve or an
explosion causing extensive property damage,
severe personal injury or death may occur!
Flow Switch
The fl ow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to prevent
the boiler from fi ring unless there’s adequate water fl ow
through the unit. The fl ow switch must be installed in the
supply piping adjacent to the boiler outlet connection.
CAUTION: Failure to properly install the fl ow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!
Figure 12 – Futera II Piping
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