RBI FUTERA FUSION HeatNet Installation and Operation Instruction

FTF-IOM-HN-2

82-0312

FUTERA FUSION SERIES FINNED COPPER

GAS BOILERS (MODEL CB)

& WATER HEATERS (MODEL CW)

WITH CONTROL

INSTALLATION & OPERATION MANUAL

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.

WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch. Do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.

• If you cannot reach your gas supplier, call the fi re department.

Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.

WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER HEATER.

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085  Mississauga, Ontario L5S 1L4 Canada
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

www.rbiwaterheaters.com

9/09

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

AVERTISSMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour
réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel,
toute blessure ou la mort

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides infl 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.

• 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
qualifi é ou par le fournisseur de gaz.

CONTENTS

Before Your Start page 2
Ratings & Capacities page 3
Boiler/Water Heater Location page 3
Combustion Air & Ventilation page 3
General Venting Guidelines page 5
Outdoor Venting page 10
General Piping Requirements page 11
Heating System Piping page 11
Domestic Water Supply Piping page 16
Gas Supply Piping page 20
Electrical Wiring page 21
General Operation page 21
Operating Instructions page 22
Sequence of Operation page 24
Checking & Adjustments page 25
HeatNet Field Wiring page 26
Control Description page 28
Diagnostics page 28
Maintenance page 31
Trouble-Shooting page 33
Repair Parts page 34
Startup Sheet page 41
Warranty page 44

BEFORE YOU START

This manual covers the application, installation, operation
and maintenance of a Futera Series fi nned copper heating
boiler/water heater.

To obtain the safe, dependable, effi cient operation and long
life for which this heating boiler/water heater was designed,
these instructions must be read, understood and followed.

The Futera 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 Water Heaters, ANSI-Z21.13/
CSA 4.9, Gas-Fired Low Pressure Steam and Hot Water
Boilers 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.

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 contained in
RBI’s instruction sheet MACODE-3. Which is located in the
back of this manual.

The owner should maintain a record of all service work
performed with the date and a description of the work done.
Include the name of the service organization for future
reference.

Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at: 260 North Elm
Street, Westfi 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.

2

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

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. 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 oudooor
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 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

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 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 12.

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 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!

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.

WARNING: 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!

3

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

All Air From Inside The Building

If the Futera is to be located in a confined space, the
minimum clearances listed in Table 1 must be maintained
between it and any combustible construction. When installed
in a confi ned space without the intake air option, Figures
5 and 6, 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

2

/1000 Btu/hr, 2200 mm2/kW based on

the total input rating of ALL gas utilization equipment in the
confined area. Each opening must be no less than

100 in

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 cross­sectional 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.

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
1999 500 3226 667 4303 2000 12,900

Intake Air Option – General Guidelines
This confi 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.

WARNING: 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!

Single wall galvanized smoke pipe, single wall aluminum
pipe, fl 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

Model For Vertical For Horizontal
Size (Up to 60') (Up To 60')
in mm in mm
500 8 203 6 152
750 8 203 6 152
1000 8 203 6 152
1250 10 254 8 203
1500 10 254 10 254
1750 12 305 12 305
2000 12 305 12 305

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.

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

4

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

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, 3.0 m of pipe, see
Table 3.

An approved, nonrestrictive intake air terminal must be
used. The intake air terminal must terminate as shown in
Figure 3. The penetration point in the roof must be properly
fl ashed and sealed.

Intake Air Option – Horizontal Guidelines

The maximum equivalent length for the horizontal intake
air pipe is 60 ft, 18.3 m. Each 90˚ elbow and the intake air
terminal are equal to 10 linear ft, 3.0 m of pipe. If horizontal
runs exceed 5 ft, 1.5 m they must be supported at 3 ft,

0.9 m intervals with overhead hangers. The certifi ed intake
air terminal from RBI must be used, see Figures 1, 2
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!

VENT SYSTEM OPTIONS

The fl ue products in the vent system may be cooled below
their dew point and form condensate in the flue. The
materials used for a Category IV vent must be resistant to
any corrosive damage from fl ue gas condensate. The fl 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.

The Futera Fusion may be vented the following ways:

1) Direct Vent, Positive Pressure, Category IV 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, Positive Pressure, Category IV 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) Verticle Vent, Positive Pressure, Category IV 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 outdoors or the
space in which the unit is installed.

NOTE: 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.

All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropriate
thimbles and fi re-stops must be used where required.

WARNING: Common vent systems must be
properly engineered and sized, please contact
the factory.

NOTE: Must consult factory when venting single or
multiple unit(s) over 60 equivalent feet. Mechanical
system may be required.

5

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

DIRECT VENT,
POSITIVE PRESSURE, CATEGORY IV

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 Intake Air
Option instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! The vent system
must be sized per Table 4.

Table 4 – Category IV

Model Pipe Diameter (Min.)
Size (Up to 60')
in mm
500 7 178
750 7 178
1000 7 178
1250 8 203
1500 8 203
1750 10 254
2000 10 254

Horizontal Direct Vent Systems – Figures 1 & 2
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, 3.0 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.
Structrual penetrations must be made using approved fi re­stops. For best results, horizontal vent systems should be
as short and straight as possible.

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
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 above adjacent public walkway.
The bottom of the vent terminal(s) shall be located at
least 5 ft, 1.5 m above the air intake terminal(s) unless
there is a 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 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 fi re-stops.

An approved, nonrestrictive vent terminal 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 3.

In addition the vent system must conform to the dimensions
shown in Figure 3. 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.

4 ft, 1.2 m

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 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.

Combination Direct Vent Systems – Figure 4
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 FUSION INSTALLATION AND OPERATION INSTRUCTIONS

Figure 1– Horizontal Air Intake and Venting for a Single Direct Vent System

1/4IN.PERFOOT

20mm/m

16FT 4.9m

1.5FT 0.5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 differences 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

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

Figure 3 - Vertical Air Intake and Venting for Direct Vent System

Note: Locate exhaust terminal downwind to reduce fl ue gas recirculation.

10 FT 3.1 m

4 FT

1.2 m

1.5 FT

0.5 m

5 1/2 FT

1.7 m

Figure 4 – Combination Direct Vent Systems

3 FT. 1 m

5 FT

1.5 m

10 FT. 3.1 m

1.5 FT. .5 m

8

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

SIDE WALL VENT,
POSITIVE PRESSURE, CATEGORY IV

In this confi guration the boiler/water heater blower is used
to push the fl ue products horizontally to the outdoors, see
Figure 5. 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.

WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a fi re causing
extensive property damage, severe personal injury
or death!

NOTE: When using a listed metal chimney system the
chimney system manufacturer’s instructions must 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

(Vent pipe equivalent length up to 60 ft, 18.3 m maximum)

WARNING: Masonry chimneys, when used, must
be lined with a metal liner certifi 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 draft problems.

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.

The vent connector should be sloped up toward the
chimney at a minimum rate of 1/4 in/ft, 21 mm/m. On
masonry chimneys the connector must terminate fl ush with
the inside of the chimney fl ue.

Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials.

WARNING: Failure to maintain minimum clearances
between vent connectors and any combustible
materials can result in a fi re causing extensive
property damage, severe personal injury or death!

9

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

A

OUTDOOR VENTING

When installed outdoors the Futera Fusion must be fi tted
with the factory supplied outdoor hood, air intake adapter
with fi lter and exhaust terminal, see Figure 7A. Multiple
units must be spaced per Figure 7B.

The boiler/heater must be at least 2 ft, .62 m from any
door, window or gravity air inlet into any building and at
least 3 ft, 1 m from any overhang unless local codes dictate
differently.

Avoid locations where wind defl ection off of adjacent walls,
buildings or shrubbery might cause a downdraft. The
unit(s) shouild be located at least 3 ft, 1 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!

Outdoor Installations

WARNING: The Futera Boiler is certified for
outside installations in temperate climates
only.

1. The condensate traps located under the secondary
heat exchanger and the vent pipe must be wrapped
with heat tape to ensure the traps never drop below
32°F.

2. The vent pipe must be insulated to prevent freezing of
condensate in the pipe.

3. The boiler and system must be fi 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.

Figure 7A – Outdoor Venting

Figure 7B – Multiple Outdoor Units

2 FT

(0.62 M)

3 FT

(1 M)

RIOM-60 REV.

10

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

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, see Table

8. 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.

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

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!

Condensate Piping

The condensate trap provided with the boiler must be
attached to the bottom pan and piped to a suitable fl oor
drain or condensate pump. If a condensate neutralization
device is installed, it must be positioned prior to boiler room
drain. Condensate fi ll trap must be maintained with fl uid.

Relief Valve

Pipe the discharge of the pressure relief valve as shown
in Figure 8.

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!

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualifi 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. The 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 8, 9 & 11)
for bleed locations.

Heating Boiler Piping Connections

The supply and return connections should be sized to suit
the system, see Table 6.

Table 6 – 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

This low mass boiler requires a continuous minimum
water fl ow for proper operation. The boiler pump is sized
to overcome the head loss of the boiler and the near
piping in order to achieve the required temperature rise.
The temperature rise across the boiler must never exceed
35˚F, 19.4˚C. The adjustable pump delay turns the pump
on each time the burner fi res and runs the pump for 20 to
600 seconds after the call for heat is satisfi ed.

11

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

Figure 8 – Futera Fusion Secondary Bypass Piping

Pump

Valve

Balance Valve

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

Aquastat Union

Automatic

Air Vent

Temperature &

Pressure

Relief Valve

Vacuum

Relief Valve

Drain Valve

(Typ.)

3-Way

Mixing Valve

12

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

CAUTION: The maximum allowable temperature rise is
35°F, 19.4°C.

The maximum allowable fl 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. The 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.

Low Water Cutoff

If a boiler is installed above any radiation elements it must
be fi tted with a low water cutoff 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 9 shows a typical primary/secondary piping system.
Boilers connected to heating systems using zone valves,
zone pumps, or systems that have excessive fl 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

The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be used
to prevent the chilled water from entering the boiler.

When a boiler is connected to a heating coil that may be
exposed to refrigerated air from an air handling device, the
piping system must be equipped with fl ow-control valves
or some other automatic means of preventing gravity
circulation of the boiler water during the cooling cycle.

13

FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

Figure 9 - Typical Primary/Secondary, Low Temperature Piping System

(See Notes)

Pump

Valve

Balance Valve

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

H-16 REV B

NOTES:

1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit.

2. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is fi lled. Use

purge valves provided. Purge valve may be located on pump fl ange. On multiple boiler installations
the fl ow switch may fail due to trapped air. See manual for procedure.

3. All boilers furnished with factory mounted outlet water temperature gauge.

Notice: These drawings show suggested piping confi guration and valving. Check with local codes and
ordinances for specifi c requirements.

Aquastat Union

Automatic

Air Vent

Temperature &

Pressure

Relief Valve

Vacuum

Relief Valve

Drain Valve

(Typ.)

3-Way

Mixing Valve

14