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: (413) 568-9571Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
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 615330762
Back 615324610
Left Side 615324610
Right Side 615324610
Front 615330762
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
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 82036 152
750 82036 152
1000 8 2036 152
1250 10 2548 203
1500 10 25410 254
1750 12 30512 305
2000 12 30512 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 inand including1 million Btuh, plus 1 in
(155 mm
2
per 7,000 Btuh (310 mm2 per kW) up to
2
per kW) in excess of1 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 2031500 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
1/4IN.PERFOOT
20mm/m
16FT 4.9m
1.5FT 0.5m
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
1000BTU'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.
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
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Figure 11 - Multiple Boiler Piping (See notes)
Pump
Valve
Balance Valve
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
H-17 REV B
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum fl ow through each unit.
2. System loop pipe diameter must be sized large enough to handle maximum fl ow through all units.
3. 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.
4. All boilers furnished with factory mounted outlet water temperature gauge.
5. Condensate lines on each unit should be connected for a fl oor drain.
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
15
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
DOMESTIC WATER SUPPLY PIPING
CAUTION: Proper controls must be used to prevent
water supplied for domestic use from exceeding 130˚F,
54˚C or a scald injury will occur! When higher water
temperatures are required for appliances such as a
dishwasher, a mixing valve or some other tempering
means must be installed. Households with small
children may require water temperatures less than
120˚F, 49˚C. Local codes must be complied with!
General Piping Requirements
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. The
water heater must not be connected to any heating system
piping or components previously used with a non-potable
water heating appliance. No toxic chemicals, such as those
used for boiler treatment, are to be introduced into the
potable water used for space heating. 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.
NOTE: The storage tank must be located as close to
the water heater as possible to prevent excessive head
loss which will reduce fl 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.
Water Chemistry
The 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.
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 (Table
8). 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 fl ow prevention devices are installed.
Pump Requirements
This low-mass water heater requires a continuous minimum water fl ow for proper operation. The proper velocity
through the water heater must be maintained for effi 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
fl ow rate is too low. Scaling and softening of the heat
exchanger will occur. The temperature rise across the
water heater must never exceed 35°F, 19.4°C.
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.
The 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.
A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water
conditions are encountered. See Table 8.
CAUTION:
a Futera Fusion water heater is 97 GPM, 6.1 L/s on 500
through 1000 models and 136 GPM, 8.9 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.
The maximum allowable flow rate through
16
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed. Proper
pump sizing will improve heater performance and help ensure heater longevity.
For hard/soft water pump selection, must consult factory.
17
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Figure 12 - Typical Water Heating Piping (CW Models Only)
(See Notes)
Pump
Val ve
Balance Valve
Pressure
Reducing Valve
7
Check Valve
Pressure
7
Relief Valve
Flow Switch
5
1
D-17 REV A
2
6
NOTES:
1. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install
aquastat 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 fl ow.
5. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
6. MA Code requires an 1/8" 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 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 procedure.
Thermometer
Aquastat Union
Automatic
Air Vent
Temperature &
Pressure
Relief Valve
Va cuu m
Relief Valve
Drain Valve
(Typ.)
3-Way
Mixing Valve
Notice: These drawings show suggested piping confi guration and valving. Check with local codes and
ordinances for specifi c requirements.
18
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
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 remote aquastat well in lower 1/3 of tank. Install
aquastat 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 fl ow.
5. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
6. MA Code requires an 1/8" 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 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 procedure.
Notice: These drawings show suggested piping confi guration and valving. Check with local codes and
ordinances for specifi c requirements.
19
Drain Valve
(Typ.)
3-Way
Mixing Va lve
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
GAS SUPPLY PIPING
WARNING: 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 Z223.1-latest
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!
The 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.
NOTE: A minimum gas supply pressure of 2 in, 51 mm,
W.C. natural or propane and maximum 14 in, 356 mm
W.C.. natural or propane, must be available at the safety
shutoff valve inlet with the unit(s) operating.
Table 9 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 fi ttings. Table 9 should be used
in conjunction with Table 10 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. The manual shut-off valve
MUST be installed in the supply piping. It should be installed
5 ft, 1.5 m above the fl oor where required by local codes.
Provide a sediment trap at the bottom of the vertical section
of the gas supply pipe upstream of the gas controls.
Table 9 – Gas Pipe Capacity
3
Maximum pipe capacity in ft
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Iron Pipe
Size, (in)
1"
1 1/4"
1 1/2"
2"
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.
10
520
1050
1600
3050
350
730
1100
2100
/hr based on 0.60 specifi c gravity gas
Pipe length in feet
30
40
50
215
440
670
1270
60
195
400
610
1150
20
Maximum gas volume of pipe, (ft
285
245
590
500
890
760
1650
1270
80
170
350
530
990
3
/hr)
100
150
305
460
870
150
120
250
380
710
3
/hr.
Table 10 – Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size, (in)
1"
1 1/4"
1 1/2"
2"
Notes: 1. For fl ow through branch.
2. For fl ow at full open.
90˚ Elbow
2.6
3.5
4.0
5.2
Type of pipe fi tting
1
Te e
Equivalent pipe length, (ft)
5.2
6.9
8.0
10.3
Gate Valve
0.6
0.8
0.9
1.2
2
Gas Cock
2
1.5
1.9
2.3
3.0
CAUTION: 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. The 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
putting the boiler into operation.
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.
Figure 14 – Gas Supply Piping
20
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Never use an open fl 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 psig, 3.5 kPa
isolate the boiler/water heater by closing it’s manual shut
off valve, see Figure 14. If the test pressure is greater than,
or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/water
heater and its individual shut-off valve.
ELECTRICAL WIRING
Electrical Power Connections
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation! Verify proper operation after
servicing.
ATTENTION: Au moment de l’entretien des
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.
GENERAL OPERATION
WARNING: Before proceeding read and fully
understand the instructions contained in this
manual. Do not attempt 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
off, turn off the manual gas control valve to the appliance.
Do not interrupt water fl ow through the boiler/water
heater.
En cas de surchauffe ou si l’alimentation en gaz ne s’arrête
pas, fermez manuellement le robinet d’arrêt de l’admission
de gaz.
Hydronic Heating Boilers (Fill System)
Open the make-up water valve and slowly fi 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
12 psig, 82.7 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
system pressure.
The electrical connections to this boiler/water heater must
be made in accordance with all applicable local codes and
the latest revision of the National Electrical Code, ANSI /
NFPA-70. Installation should also conform with CSA C22.1
Canadian Electrical Code Part I if installed in Canada.
A properly rated shut-off switch should be located
at the boiler/water heater. The 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 fi 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. The wire size
must be compatible with the total amp draw of the circuit.
Refer to the wiring diagram supplied with the boiler/water
heater for proper wiring connections and boiler full load
amperage (FLA).
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 9 &
11) for bleed locations.
With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed
valves. If strainers are used in the system piping, the makeup water valve should be closed and the strainers checked
and cleaned.
The system expansion tank should be checked to ensure
that the correct water level in the tank is maintained. The
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 “OPERATING
INSTRUCTIONS” section. Run the boiler for at least an
hour. The system pump(s) and all radiation units must be
operated during this time. Ensure that the make-up water
valve is open.
Shut the boiler off and open the bleed valves to purge the
air trapped in the heating system piping. Close the makeup water valve and check and clean the strainers and
make-up water pressure reducing valve.
Open the make-up water valve and adjust the system
pressure if necessary. The system should be checked and
bled after three days of operation.
21
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN
MARCHE
A. This appliance is equipped with an ignition device
which automatically 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 OPERATING smell all around the appliance
area for gas. Be sure to smell next to the fl oor because
some gas is heavier than air and will settle on the fl oor.
N’utilisez pas cet appareil s’il a été plongé dans l’eau,
même partiellement. Faites inspecter l’appareil par un
tecnicien qualifi 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 off and disable any
outside (BMS) call for heat.
3. Turn off all electric power to the appliance.
DANGER: 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 qualifi 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 attempt 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 fi re
department.
AVANT DE FAIRE FONCTIONNER, renifl ez tout autour de
l’appareil pour déceler une odeur de gaz. Renifl ez 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 qualifi 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.
4. Close main isolation gas valve (fi 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 fi ve (5) minutes to clear out any gas.
7. Install a fi tting 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" pipe plug from the pilot test port and
connect a manometer having a minimum range of
6 in, 154 mm WC to it.
9. Open the main isolation gas valve (fi eld supplied),
Figure 14.
10. Place the “Remote/Local” switch to Remote inside
control cabinet, Figure 15.
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 15.
12. Slide the Low Fire Hold Switch (on HeatNet control
board) to Low Fire position.
13. The boiler will begin the start sequence.
14. When the main display reads “PILOT RUNNING” and
the fl ame current is 5 VDC, switch the Honeywell
7800 to the “test” position, Figure 15. This will hold
the Honeywell 7800 in its ignition state.
22
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
15. Adjust the pilot pressure per the CHECKING,
ADJUSTMENT & OPERATION section.
16. Remove the demand from the 7800 control by
disabling the Low Fire switch, allowing the boiler to
stop.
Figure 15 - 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
WARNING: 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 (fi eld supplied).
23. Reset the Honeywell 7800. The boiler will start and
will run at minimum input rate.
24. Setting the low fire: Allow the low fire to settle
out for a few minutes and observe the combustion
reading. Refer to “Combustion Reading” table for
proper combustion readings and elbow pressure,
Table 12.
The low fi re O2-CO2 can be adjusted in the fi eld by
opening the low fi re adjustment door located on the
forward facing side of the main gas valve. Inserting
an allen wrench and rotating the allen screw clockwise will increase the CO
and lower the O2, rotating
2
counter clock-wise will decrease the CO2 and
increase the O2. DO NOT LEAVE THE BURNER IN AN INFRARED STATE. A few random speckles of
red are fine, but large concentrations of spots or
large areas of red are not. If large amounts of red
concentrations are observed, verify combustion
readings.
POWER SWITCH
SELECT BUTTON
17. Close main isolation gas valve (fi eld supplied), Figure
14.
18. Remove the manometer fitting from the pilot test
port and replace the plug. Place monitor tube on to
elbow test port located down stream of main gas
valve, Figure 14.
19. Switch the Honeywell 7800 back to “run”.
20. Create a min input demand as before (enable Low
Fire Hold switch). The boiler will begin the start
sequence.
21. Monitor the fl ame current on the 7800. No fl ame
current should be detected and the 7800 should
lock out. If fl 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 fl ame is detected.
25. Jumper the “AA” terminals located on the HeatNet
control board. The boiler input will rise to its
maximum input, “Run 100%”, see Figure 17.
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 12.
27. Remove jumper “AA” and allow boiler to settle into
minimum input. Observe the combustion readings
and make any fi nal adjustments. When fi 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.
Table 12 - Combustion Readings
Natural Fuel Propane Fuel
CO2 %
8.3 - 8.8 (100%) 9.7 - 10.3 (100%)
6.2 - 5.2 (100%) 6.2 - 5.2 (100%)
8.0 - 8.5 (min.) 9.4 - 9.9 (min.)
6.6 - 5.8 (min.) 6.6 - 5.8 (min.)
O2 %
*For factory set gas manifold (elbow) pressures see
label on inner cabinet door.
23
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
INSTRUCTIONS DE MISE EN MARCHE
1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.
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 veilleuse manuellement.
5. Fermer la vanne manuelle d'arrêt d'alimintation de
gaz.
6. Attendre cinq (5) minutes pour laisser échapper tout
le gaz. Renifl 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 cette étiquette. 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. Mettez l'appareil sous tension.
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. The boiler is idle with no interlocks in the fault
condition.
DEMAND
Pre-Purge
1. The blower operates at purge RPM. The water fl ow
interlock must ‘make’ within 15 seconds after the
demand signal is initiated.
2. The Honeywell 7800 starts a 10 second purge delay
once the air prove switch contacts close.
Pilot Run - %Input
1. The blower operates at minimum ignition setting.
See the calibration section in the “HeatNet ControlIOM” to enter the calibration menus.
2. The ignition transformer is energized. The pilot
solenoid valve opens for the 10 second pilot ignition
trial.
Main Run %Input
1. The main gas valve opens.
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 qualifi é ou le
fournisseur de gaz.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest setting.
2. Turn off all electric power to the boiler if service is
to be performed.
3. Close the manual main and pilot gas shut-off 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.
2. The ignition transformer is de-energized.
3. The pilot solenoid valve closes.
4. The blower stays at the minimum input setting 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. The main gas valve closes.
2. The blower operates at purge RPM for 10 seconds.
3. The boiler is idle with no interlocks in the fault
condition.
24
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
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
confi rm that the spark is strong and continuous. If not check
and adjust the spark gap as shown in Figure 16.
Figure 16 – Spark Gap
Pilot Adjustment
The pilot pressure has been factory set at 3" for natural
and LP gas and shouldn't need adjustment. To check
the pilot pressure close the manual main shut-off valve
2 and the pilot gas shut-off valve, Figure 14. Remove
the 1/8" pipe plug from the pilot tee and connect a
manometer having a minimum range of 6 in, 152 mm
WC to it. Open the pilot gas shut-off 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. The 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 clockwise to increase the pressure and counterclockwise to
decrease it.
3. Replace the pressure regulator adjustment screw cap.
CAUTION: Never force the regulator adjustment screw
beyond the stop limits or damage to the regulator will
occur!
WARNING: The 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 W.C.) 2 2
Maximum (in W.C.) 14 14
Measure pressure when the boiler is fi ring at full rate. Low
gas pressure could indicate undersized gas line or
insuffi cient gas supply.
“Static and operating gas pressure required at the gas
valve inlet is between 2" W.C. and 14" W.C. for natural gas
and 2" W.C. and 14" W.C. 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. This pressure regulator
(supplied by others) may be installed at the service
entrance to each unit or a “master” regulator sized to
handle multiple units may be utilized. Consult local gas
utility or regulator manufacturer for recommendations to
meet specifi c job site requirements.”
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation with
no adjustment required at elevations up to 2000 ft, 610 m.
At elevations above 2000 ft, 610 m input ratings should
be reduced by 4% for each 1000 ft, 305 m.
Check the input rate as follows:
1. Turn off 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 ft
this time by 10.
5. Insert the heating value and the time, in seconds, into
the formula below.
7. If the computed rate deviates by more than 5% from
the rated input value of the unit, consult factory.
CAUTION: 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
25
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Figure 17
RBI Field Wiring To HeatNet Board
(Board Revision 2.0 and Greater)
RIOM 86
26
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
RBI HeatNet Field Wiring To Terminal Block
(Board Revision 2.0 and Greater)
NOTES:
1. Remove jumper “A” when using a low water
cutoff interlock.
2. For multiple boilers utilizing a system
air damper when in a master/member
confi 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.)
27
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
CONTROL DESCRIPTION
Low Water Cutoff
If the boiler is to be installed above radiation or if required
by other codes or regulations, install a low water cutoff in
appropriate piping. Wire the switch to the "Interlock"
contacts as illustrated on “Field Wiring” schematic. Ensure
that the low water cutoff device(s) will funtion properly.
Operating Control
The preferred control setting for potable hot water is 130°F,
54°C. The operating control should be set to the lowest
setting that will satisfy the consumer's needs.
WARNING: Setting the thermostat or operation
control too high can result in scalding resulting in
severe personal injury!
High Limit (Aquastat)
The 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. The high limit can be
reset by depressing the red button.
The 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.
Flow Switch
A fl ow switch is provided in the water outlet piping to
prevent the boiler/water heater from fi ring without adequate
water fl ow through the heat exchanger.
DIAGNOSTICS
The Futera Fusion has a display that indicates the
sequence of operation. The 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
There are numerous interlock switches and software
limits that are detected. Each of these, when tripped will
produce a display message, an audible beeping, and
an alarm relay closure. The fault is displayed fi rst, then
after a second, the time the fault occurred is displayed.
This cycle will keep occurring until the fault is cleared.
These faults are:
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
The high limit interlock breaks power to the ignition
control (shutting it off) and effectively removes any
chance of the gas valve receiving power. The Futera
Fusion series control will remain powered to display the
fault, latch the alarm relay/audible beeper, and to access
the log. The interlock is located on J5, HIGH LIMIT.
INTERLOCK SPARE 3: This is a reserved interlock
input that is normally jumpered at the factory, but can
have a remote interlock connected as a fi eld install. The
interlock is located on J11A, SPARE 3.
FAULT
SYSTEM SET
INTERLOCK SPARE 3
160˚F
28
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
LOW WATER CUTOFF: If there is a low water condition
reported by the low water cutoff switch this fault is
displayed. Check that there is water fl ow and water in
the boiler. There is a reset switch located on the LWCO
box. The interlock connection is located on J11A,
LWCO.
FAULT
SYSTEM SET
LOW WATER CUTOFF
160˚F
VAR FREQ DRIVE: The 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. The interlock is located on J11A, VFD.
FAULT
VAR FREQ DRIVE
SYSTEM SET
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
fl ow. If there is no fl ow, the fl 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 fl ow. The interlock connection is
located on J11B, WTR FLW.
FAULT
SYSTEM SET
WATER FLOW SWITCH
160˚F
IGNITION CTRL ALARM: The ignition control alarm is
displayed if the ignition control detects a fault. This could
be a fl 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.
160˚F
GAS PRESSURE: The 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.
Theinterlock is located on J11A, GAS PR.
FAULT
SYSTEM SET
GAS PRESSURE
160˚F
INTERLOCK SPARE 4: This is also a spare interlock
(similar to INTERLOCK SPARE 3) for future expansion
or use as a fi eld interlock. The interlock is located on
J11B, SPARE 4.
FAULT
INTERLOCK SPARE 4
SYSTEM SET
FAULT
SYSTEM SET
IGNITION CTRL ALARM
160˚F
IRI ALARM: The optional IRI alarm is the alarm from
the gas valve. If this alarm is set check the gas valve.
FAULT
SYSTEM SET
IRI ALARM
160˚F
160˚F
29
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
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.
These should be wired to the combustion air damper
or preferably an isolation relay. The 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, fi res, and
continues to fi re. If the combustion air damper does not
prove within the proof time specifi ed in the combustion
air damper menu, the boiler will shut down and display
the fault. The fault on the Master boiler can be cleared
by removing the call for heat on the master boiler and
fi 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. The 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. This protection is
required to prevent damage to the heat exchanger in the
event high differential temperatures are encountered.
The fault or warning condition may be changed in the
AUX FUNCTIONS menu under ALARM TYPE. The
default condition is WARNING with LIM->HALF RATE
= YES.
When this condition exists and the ALARM TYPE is
set to WARNING and LIM-> HALF RATE, the boiler is
limited to 1/2 it’s input rate. So, if the boiler is trying to fi 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.
The 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. This 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. The 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 shutting 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
30
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
RETURN TEMP < 130°F: If the Return Inlet temperature
is less than 130°F this warning will be displayed. This
warning does not affect operation and does not set the
alarm relay. A log entry is made to aide in diagnosing
why this may be occuring. 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
MAINTENANCE
WARNING: Disconnect electrical power and close
the manual gas shut off valve before performing
maintenance or severe personal injury may
result!
CAUTION: 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!
The 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 19 for component identifi cation.
CAUTION: Improper burner servicing can result in
premature burner failure voiding the warranty!
Burner Removal
1. Close the manual shutoff valves in the gas supply line
and turn off 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. Lift 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 shutoff valves in the gas supply lines
and turn off 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. The 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 off valves in the inlet and outlet piping.
On heating systems close the system fi ll valve and
relieve the system pressure from the boiler by carefully
lifting 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” baffl e straps and “V” baffl es.
7. Thoroughly clean the heat exchanger with water from
a high-pressure hose. Use a soft bristle brush if
necessary.
8. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
31
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
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 fl 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
Thoroughly 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
fi lter and wash with warm water and soap if dirty.
4. The relief valve should not weep or discharge water
at normal system pressure. If it does, contact a
qualified 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. The 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 off. The water temperature should never exceed
the maximum set point of 250°F, 121°C, for boilers
and 210°F, 99°C for water heaters. The aquastat high
limit cannot be repaired. If it fails to function properly,
replace it.
6. Visually check the pilot and main burner fl ames to
ensure proper operation.
WARNING: A yellow, fl oating fl ame indicates a lack
of combustion air. Do not operate the boiler/water
heater until the problem is solved or severe
personal injury or death may occur!
Figure 18 - Main Burner Flame
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 fl oat type low water cutoff device must be fl ushed
out per the manufacturers’ instructions. The probe on
a probe low water cut off must be removed, cleaned
and inspected at least once a year. Ensure that the
low water cutoffs operate properly. If not, replace
them.
3. The fl ow switch contacts must be open when water
fl ow is not present.
32
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Troubleshooting A Startup
ActionCheckIdentify SourceSymptom
An Interlock is tripped.
1.
1. Is it a 24 VAC Interlock?
2. Is it a 120 VAC Interlock/
Alarm?
1. All 24 VAC Interlocks are
located on J11A and J11B.
Examples of 24 VAC Interlocks:
1.SPARE3
2. Variable Frequency Drive(VFD)
3. Low Water Cutoff(LWCO),
4. Gas Pressure
5. Spare 4
6. Operator OPLIM
7. Water Flow
8. Air Pressure from UV Sensor.
2. All 120 VAC interlocks/Alarms
are located on J5. These include:
1.FLAME SAFE ALARM (Ignition
CTRL ALARM)
2. Valve Alarm (IRI ALARM)
3. XS_FACTORY (Reserved
4. HIGH LIMIT
1.Use a multimeter and check
for 24 VAC on J11A,J11B to
identify which interlock has
tripped. Reset the Interlock or
check for disconnected wiring
or shorts.
The Air Pressure from UV
Sensor interlock if displayed
will allow the boiler to
function, but it needs to be
functional while the boiler is
running for it to clear.
1. Use a multimeter on J5 to
to check for 120 VAC on
these interlocks (except the
HIGH LIMIT). The High Limit
Interlock is displayed when
there is no 120 VAC, since
the HIGH LIMIT breaks the
120VAC to the Ignition
Control.
NOTE: Stray Voltages
Greater than 8 VAC and less
than 18 VAC on these
interlocks can cause
intermittant operation. If this
is the case, check for back
fed voltages from field wiring.
2.
Proceed to HeatNet
problem resolution.
for
Manual Control
more details and
3. Internal Alarms
1. OPEN SENSOR
2. SHORTED SENSOR
3. COMBUSTION AIR DAMPER
Check sensor voltages at
J10A and J10B. The
Temperature sensor inputs
should be between 0 VDC
and 5 VDC measured across
the sensor. Example: At 77 F,
the voltage would read 2.5
VDC.
The combustion air damper
prove switch must be wired
across SPARE 1 and must be
a "DRY" contact. Do not
apply a voltage to this input,
the input supplies it's own
voltage/current.
33
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
10
Figure 19 - Repair Parts
SEE VIEW "C"
15A
15B
15
31
33
SEE VIEW "A"
40
35
2
4
11
75
12
7
5
29
41
SEE VIEW "B"
42
39
45
67
66
25
69
63
30
64
62
65
68
47
24
60A
27
60
38
23
13
62
14
28
43
37
32
33
57
46
36
3
8
5
10
8
3
1
9
10
2
4
11
75
12
7
5
4
12
70
1
6
76
71
8
1
2
10
72
8
71
70
12
1
73
74
75
34
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Futera Fusion Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
1 Top/Bottom X Profi le 04-0523 3 3 3
04-0524 3 3 3 3
2 Middle X Profi le 04-0525 2 2 2
04-0526 2 2 2 2
3 Top Y Profi le 04-0530 4 4 4 4 4 4 4
4 Bottom Y Profi le 04-0531 2
04-0532 2
04-0533 2
04-0534 2
04-0535 2
04-0536 2
04-0537 2
5 Top/Bottom Z Profi le 04-0538 4 4 4
04-0539 4 4 4 4
6 Middle Z Profi le 04-0540 2 2 2
04-0541 2 2 2 2
7 Bottom/Front X Profi le 04-0527 1 1 1
04-0528 1 1 1 1
8 Frame Corner 20-0053 3 3 3 3 3 3 3
9 Frame Corner 04-0543 1 1 1 1 1 1 1
10 Crosses 20-0054 3 3 3 3 3 3 3
11 Drilled Crosses 04-0544 1 1 1 1 1 1 1
35
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Futera Fusion Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
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 any external call for heat and toggle the remote/local switch to REMOTE
.
oggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition
2
et pressure to 3–3.5" w.c. (ame signal should read 5.0 VDC)
3.
Release boiler to main ame trial for ignition
4
heck for stable ame
.
ecord combustion and elbow pressure at minimum ring rate.
umper the AA terminals to
ecord combustion and elbow pressure.
emove the AA jumper to place the boiler at minimum rate
9
ake any nal adjustments on low re.10.
heck all combustion results using a calibrated ue gas analyzer
11
elease the LOW FIRE switch to place boiler in stan
12
T
T
HECK
E
force 100% input
U
NCE
JOB NAME:
OCATION:
DEL
ERIAL #
INLET AIR FILTER INSTALLED AND CLEA
PROPER SERVICE CLEARANCES PROVIDE
UMP RUNNING, HEAT EXCHANGER FUL
GAS LINES PURGED, NO LEAKS, NO MISSING TEST
LUG
old in the bottom of the electrical panel
In addition to completing the Fusion/Futera III start-up report, complete the control set-up information in
the rear of the HeatNet manual.
41
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
A
YSIS
TE
00% F
TE
T
.
.
O
)
E
C.
ST
S
CH
D
S
B
R
H
S
THED
-
-
-
.
T
1
D
D
L
T
R
______________________________________
)
_
S
A
M
STION
FIN
1
IN
GAS PRESSURE AT ELBOW TEST POR
C
CO (PPM
NETSTACK TEMPERATUR
ELBOW PRESSURE (W.C.) INCHES W.
TY
EST
LOW SWITCHE
OW WATER CUT-OFF
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.
COMMISSIONIN
NIT CYCLED MINIMUM OF 15 TIME
CUSTOMER INSTRUCTE
ALL COVERS REPLACE
USTOMER GIVEN MANUA
ARGET TEMPERATURE SET PER CUSTOME
HECKLI
IRSWIT
IGH LIMIT
I
E
INCHES W.C
LET AND OUTLET IS CRITICAL TO PROP
ER FLOW. BEFORE YOU LEAVE THE JOB
NCHES W.C
M
NCHES W.C.
FLAME SAFEGUAR
ELTA T BETWEEN THE HEATER IN
ITE, YOU MUST RECORD THE DELTAT
HIS READING SHOULD NOT EXCEED
, 19.4
5
.
C, NOR BE LOWER THAN 20,
.
COMMISSIONED BY:
DATE: ___________________________
TION
NOTE
COMMENTS
SIGNATURE
ELTA T =
42
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
Commonwealth of Massachusetts
NOTICE!
Installation Requirements MACODE-3
In the Commonwealth of Massachusetts, the
installation must be performed by a licensed
plumber or gas fi 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 finished grade, in the area of the venting,
including but not limited to decks and porches, the following
requirements shall be satisfi 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
gasfi tter shall observe that a hard wired carbon monoxide
detector with an alarm and battery back-up is installed
on the floor level where the gas equipment is to be
installed. In addition, the installing plumber or gasfi 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 qualified 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 fl 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 certifi ed.
f. SIGNAGE. A metal or plastic identifi cation 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 flue gases, but
identifies “special venting systems”, the following
requirements shall be satisfi 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!
43
LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the
Industrial, Commercial, and other Non-Residential Use Boiler (the “Product”) will be free from defects in material or
workmanship for ten (10) years from the date of installation. Additional twenty one (21) year thermal shock warranty
on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or
workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler/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.
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the
Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in
material or workmanship for fi ve (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.
This limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has
not been installed, maintained or operated in accordance with the furnished written instructions, or has been
altered or modifi ed in any way.
These 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 pitting 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 fi 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. The 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 the Product or
parts thereof.
(c) to damage as a result of settlement, distortion, collapse, or cracking of any foundation area, beams or pipes
surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United
States or Canada.
This limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned
with prior written approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or
workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with
respect to such repaired or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND
EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN
ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE
WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY
PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF
THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY
EACH JURISDICTION.
260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
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