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FTFX-I0M-1
Finned copper tube
Gas boilers (CB)
82-0347
Boiler manual
Installation and operation
instructions
Also read and follow:
HeatNet control manual
is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
A x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a quali ed service
technician, and to follow all guidelines in the User’s Information Manual.
10/12 Copyright 2012 Mestek, Inc.
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If the information in this manual is not followed
exactly, a re or explosion may result causing property,
personal injury or loss of life.
Do not store or use gasoline or other ammable vapors
and liquids in the vicinity of this or any other applianc
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the re
department.
Installation and service must be performed by a quali ed
installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données
dans ce e notice pour réduire au minimum le risque
d’incendie ou d’explosion ou pour éviter tout dommoge
matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides in ammables à proximité de cet
appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment.
BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 3
BOILER LOCATION . . . . . . . . . . . . . . . . . . . . . 3
COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . 3
GENERAL VENTING GUIDELINES. . . . . . . . . . . . . . 5
OUTDOOR VENTING. . . . . . . . . . . . . . . . . . . . .10
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . 11
HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . .12
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . .16
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . .19
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . .20
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . 21
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 21
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . .24
CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . .25
HEATNET FIELD WIRING . . . . . . . . . . . . . . . . . .26
CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . 27
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .30
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . .33
REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . 34
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . .43
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . .46
• Appelez immédiatement votre fournisseur de gas depuis
un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le
service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien quali é ou par le
fournisseur de gaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
BEFORE YOU START
is manual covers the application, installation, operation and
maintenance of a Futera Series nned copper heating boiler.
To obtain the safe, dependable, e cient operation and long life
for which this heating boiler was designed, these instructions must
be read, understood and followed.
e Futera Series nned copper heating boiler have been design
certi ed by CSA for use with natural and propane gas under the
latest revision of ANSI-Z21.10.3/CSA 4.3. 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 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.
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In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for Gas
Burning Appliances and Equipment.
If installed in the Commonwealth of Massachuse s, you MUST
FOLLOW the additional instructions contained in RBI’s instruction
sheet MACODE-3. Which is located in the back of this manual.
e owner should maintain a record of all service work performed
with the date and a description of the work done. Include the name
of the service organization for future reference.
Direct all questions to your RBI distributor or contact the RBI
Customer Service Department at: 260 North Elm Street, West eld,
MA 01085 for US or 7555 Tranmere Drive, Mississauga ONT L5S
1L4 for Canada. Always include the model and serial numbers from
the rating plate of the boiler in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Futera Series boiler check
the rating plate to ensure that the unit has been sized properly for
the job. e “Net AHRI Ratings” specify the equivalent amount of
direct copper radiation that the unit can supply under normal
conditions. Also ensure that the unit has been set up for the type
of gas available at the installation site. Other impor tant considerations
are the availability of an adequate electrical supply, fresh air for
combustion and a suitable chimney or vent system.
BOILER LOCATION
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 is level from front to back
and from side to side. Use metal shims to level the boiler.
Electrical and electronic components must also be protected
from exposure to water during operation and maintenance. DO
NOT install this boiler in a location that would subject any of
the gas ignition components to direct contact with water or
excessive moisture during operation or servicing.
3. Ensure that the oor is structurally sound and will support
the weight of the boiler.
e Futera may be installed directly on combustible
ooring, but never on carpeting.
4. Locate the boiler 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 in a location that would restrict
the introduction of combustion air into the unit or subject it
to a negative pressure, see “GENE L VENTING GUIDELINES”.
6. NEVER place this boiler in a location that would subject it
to temperatures at or near freezing, see the “FREEZE
PROTECTION” section on page 11.
Never store combustible materials, gasoline or any
product containing ammable vapors or liquids in
the vicinity of the boiler. Failure to comply with this
warning can result in an explosion or re causing
extensive property damage, severe personal injury or
death!
1. is boiler is suitable for indoor and outdoor installations. Locate
the boiler in an area that provides good access to the unit.
Servicing may require the removal of jacket panels. Allow the
minimum clearances between adjacent construction and the
boiler as listed in Table 1.
Service clearances are not mandatory, but are recom-
mended to ensure ease of service should it be required.
Table 1
Clearance to
Combustibles
To p 6 153 30 762
Back 6 153 24 610
Left Side 6 153 12 306
Right Side 6 153 12 306
Front 6 153 30 762
in mm in mm
Service
Clearance
COMBUSTION AIR & VENTILATION
is boiler 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
can result in excessive levels of carbon monoxide which
can result in severe personal injury or death!
To operate properly and safely this boiler requires a continuous
supply of air for combustion. NEVER store objects on or around the
boiler!
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Combustion air contaminated with uorocarbons
or other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. ese acids will
cause premature failure of the boiler voiding the
warranty!
If the boiler is operated while the building is under
construction it MUST be protected from wood,
concrete, sheet rock and other types of dust. Failure
to properly protect the unit from construction dust
will damage the unit voiding the warranty!
Buildings will require the installation of a fresh air duct or other
means of providing make-up air if the intake air option isn’t used.
Any building utilizing other gas burning appliances, a replace, wood
stove or any type of exhaust fan must be checked for adequate
combustion air when all of these devices are in operation at one
time. Sizing of an outside air duct must be done to meet the
requirements of all such devices.
Never operate the Futera in an environment subjected
to a negative pressure unless it is Direct Vented. Failure
to comply with this warning can result in excessive
levels of carbon monoxide causing severe personal
injury or death!
Where directly communicating with the outdoors or communi-
cating with the outdoors through vertical ducts, each opening shall
have a minimum free area of 1 in
2
/4000 Btu/hr, 550 mm2/kW
of the total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1 in
2
2000 Btu/hr, 1100 mm2/kW of the total input rating of all of
the equipment in the enclosure.
When ducts are used, they must have the same cross-sectional area
as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up
air requirements of the enclosure, consideration must be given
to the blockage e ects of louvers, grills and screens. Screens must
have a minimum mesh size of 1/4 in, 6.4 mm. If the free area
through a louver or grill is not known, ducts should be sized per
Table 2.
Canadian installations must comply with CSA B149.1 when
air supply is provided by natural air ow from the outdoors for
natural dra , partial fan-assisted, fan-assisted, or power dra -
assisted burners, there shall be a permanent air supply opening(s)
having a cross-sectional area of not less than 1 in
2
per 7,000
Btuh (310 mm2 per kW) up to and including 1 million Btuh,
plus 1 in2 per 14,000 Btuh (155 mm2 per kW) in excess of
1 million Btuh.
/
All Air From Inside The Building
If the Futera is to be located in a con ned space, the minimum
clearances listed in Table 1 must be maintained between it and any
combustible construction. When installed in a con ned space
without the intake air option, Figures 5 and 6, two permanent
openings communicating with an additional room(s) are required.
e combined volume of these spaces must have su cient volume
to meet the criteria for an uncon ned space. e total air
requirements of all gas utilization equipment, replaces, wood stoves
or any type of exhaust fan must be considered when making this
determination. Each opening must have a minimum free area of
1 in2/1000 Btu/hr, 2200 mm2/kW based on the total input rating
of ALL gas utilization equipment in the con ned area. Each opening
must be no less than 100 in2, 64,516 mm2 in size. e upper
opening must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. e bo om opening must
be within 12 in, 305 mm of, but not less than 3 in, 76 mm from,
the bo om of the enclosure.
All Air From Outside The Building
When installed in a con ned space without utilizing the intake
air option two permanent openings communicating directly with,
or by ducts to, the outdoors or spaces that freely communicate
with the outdoors must be present. e upper opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the
top of the enclosure. e bo om opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the bo om of
the enclosure.
Table 2 Make-up Air Louver Sizing
Required Cross Sectional Area
2
75% Free Area
Metal Louvers
2
in
cm
1/4 in 6.4 mm
Input
(MBH)
2500 625 4031 833 5382 2500 16,127
3000 750 4838 1000 6452 3000 19,354
3500 875 5645 1167 7522 3500 22,581
4000 1000 6452 1334 8592 4000 25,808
Wire Screen
2
cm
in
2
25% Free Area
Wooden Louvers
in
2
cm
2
Intake Air Option – General Guidelines
is con guration provides combustion air directly to the boiler’s
air intake adapter using a dedicated pipe when using the direct vent
option. Combustion air can be drawn in horizontally through the
same outside wall which terminates the exhaust gases or vertically
through the roof, see Figures 1, 2, 3 & 4.
Common intake air systems may be used provided
the common duct is sized properly. An intake
combustion air damper should be installed if the
common vent option is used in the intake air pipe of
each heater. Improper installation can result in excessive
levels of carbon monoxide which can cause severe
personal injury or death!
Single wall galvanized smoke pipe, single wall aluminum pipe,
exible aluminum pipe, PVC or CPVC pipe can be used for the
intake air pipe. It must be sized per Table 3.
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Table 3 Intake Air Pipe Sizing (Up to 100’)
Model
MBH
2500/3000 10 254 8 203
3500/4000 12 305 10 254
Note: Max horizontal/vertical intake pipe 100’ equivalent.
Vertical Horizontal
in mm in mm
All joints in metal intake air systems must be secured using corro-
sion resistant fasteners and sealed using a suitable Silicone caulk.
If PVC or CPVC is used, the joints must be cleaned with a suitable
solvent and connected using a solvent based PVC cement. e
combustion air system MUST be supported by the building
structure not the boiler.
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
in ltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake Air Option – Vertical Guidelines
e maximum equivalent length for the vertical intake air pipe is
100 , 30.5 m. Each 90° elbow and the intake air terminal are
equal to 10 linear , 3.0 m of pipe, see Table 3.
An approved, nonrestrictive intake air terminal must be used. e
intake air terminal must terminate as shown in Figure 3. e
penetration point in the roof must be properly ashed and sealed.
A UL listed stainless steel vent system must be used
unless this unit is ed with an RBI supplied nonmetallic vent kit. Failure to comply with this warning
can cause excessive levels of carbon monoxide resulting
in severe illness and death!
For instructions utilizing the non-metallic vent option,
see Addendum (FTF-PVCVO) for PVC and (FTFPPVO) for Polypropylene.
Vent System Options
e ue products in the vent system may be cooled below their
dew point and form condensate in the ue. e materials used for
a Category IV vent must be resistant to any corrosive damage
from ue gas condensate. e ue from a Category IV vent system
must have a condensate drain with provisions to properly collect
and dispose of any condensate that may occur in the venting system.
e Futera Fusion may be vented the following ways:
1) Direct Vent, Positive Pressure, Category IV uses a vent
system certi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air
is piped from the outdoors to the blower inlet.
2) Side Wall Vent, Positive Pressure, Category IV uses
a vent system certi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
Intake Air Option – Horizontal Guidelines
e maximum equivalent length for the horizontal intake air pipe
is 100 , 30.5 m. Each 90° elbow and the intake air terminal
are equal to 10 linear , 3.0 m of pipe. If horizontal runs exceed
5 , 1.5 m they must be supported at 3 , 0.9 m intervals with
overhead hangers. e certi ed intake air terminal from RBI must
be used, see Figures 1, 2 and 4.
GENERAL VENTING GUIDELINES
e vent installation must be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54-latest revision or applicable provisions of the local building codes. Canadian
installations must comply with CAN/CGA B149.1
or .2 Installation Code. Improper venting can result
in excessive levels of carbon monoxide which can
result in severe personal injury or death!
All vent systems must be fully supported by the building structure
and not by the boiler. Appropriate thimbles and re-stops must be
used where required.
Common vent systems must be properly engineered
and sized, please contact the factory.
To ensure proper operation, boilers that are vented
side wall and use room air must not be red less than
33% input.
3) Vertical Vent, Positive Pressure, Category IV uses a
vent system certi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air
is obtained from the outdoors or the space in which the unit
is installed.
4) Vertical Vent, Negative Pressure, Category II (common
venting) requires negative pressure in vent (natural dra ).
Requires a metal chimney system approved for Category II
venting. is method is required if common venting multiple
Fusion boilers.
All venting and combustion air material supplied by
installer. All venting materials must be approved for
the application. Consult the vent manufacturer’s
product literature.
e maximum equivalent length for the ue outlet
vent system for Category IV conditions is 100 ,
30.5 m. Use Table 4 for the equivalent lengths per
ing. Table 4 - “Category IV Equivalent Length per
Fi ing” chart is meant as a guideline for preliminary
sizing. If vent length approaches 75% of maximum
length listed, an engineered vent system calculation
must be performed, consult factory.
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Table 4 Category IV Equivalent Length Per Fitting
Equivalent Feet
Model/Outlet
Diameter
Standard Tee 1.25 35 ft 35 ft 40 ft 40 ft
Boot Tee 0.65 15 ft 15 ft 20 ft 20 ft
Cap - Low Res (UL)
45° w/Bird Screen
Elbow - 90° 0.38 10 ft 10 ft 15 ft 15 ft
Elbow - 45° 0.15 5 ft 5 ft 7 ft 7 ft
*Equivalent lengths based on listed K - factors and (5X) pipe
diameters straight length between ttings.
*K
0.5 15 ft 15 ft 15 ft 15 ft
0.4 10 ft 10 ft 15 ft 15 ft
25008"30008"3500
of Straight Pipe
10"
4000
10"
If any part of a single wall metal vent system passes through an
unheated space, it must be insulated with insulation rated for 400°F,
204°C. Structural penetrations must be made using approved re-
stops. For best results, horizontal vent systems should be as short
and straight as possible.
e vent system must be both gas tight and watertight. All seams
and joints in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
When horizontal vent runs exceed 5 , 1.5 m they must be supported
at 3 , 0.9 m intervals with overhead hangers. e vent system
must be pitched down, toward the vent terminal, 1/4 in/ , 20 mm/m.
If any part of a single wall metal vent system passes through an
unheated space it must be insulated with insulation rated for 400°F,
204°C.
Horizontal vent systems shall terminate at least 4 , 1.2 m below,
4 , 1.2 m horizontally from or 1 , 0.30 m above any door, window
or gravity air inlet into any building. It must not terminate less than
4 , 1.2 m horizontally from, and in no case above or below, unless
a 4 , 1.2 m horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment and not less than 7 ,
2.1 m above adjacent public walkway. e bo om of the vent
terminal(s) shall be located at least 5 , 1.5 m above the air intake
terminal(s) unless there is a minimum 5 , 1.5 m horizontal
separation between them. Avoid terminal locations likely to be
a ected by winds, snowdri s, people and pets. Protect building
materials and vegetation from degradation caused by the ue gases.
Must consult factory when venting single or multiple
unit(s) over 100 equivalent feet. Mechanical system
may be required.
Direct Vent, Positive Pressure,
Cateory IV
In this con guration the boiler blower is used to push the
ue products to the outdoors while drawing combustion air
from the outdoors. e Intake Air Option instructions under the
“COMBUSTION AIR & VENTILATION” section must be
followed! e vent system must be sized per Table 4.
Horizontal Direct Vent Systems
Figures 1 & 2
e vent materials used in horizontal vent systems must be certi ed
to UL 1738 for installations in the United States, ULC S636 for
installations in Canada. e certi ed vent terminal from RBI must
also be used.
Vertical Direct Vent Systems – Figure 3
If any part of a single wall metal vent system passes through an
unheated space, it must be insulated with insulation rated for 400°F,
204°C. Structural penetrations must be made using approved re-
stops.
An approved, nonrestrictive vent terminal must be used. e top
of a vertical vent system must extend at least 5
1
/2 , 1.7 m above
the roof surface and maximum snow line that it passes through,
4 , 1.2 m above the intake air terminal, see Figure 3.
In addition the vent system must conform to the dimensions shown
in Figure 3. e penetration point in the roof must be properly
ashed and sealed.
e vent system must be gas tight. All seams and joints in metal
pipes must be joined and sealed in accordance with the vent system
manufacturer’s instructions.
Combination Direct Vent Systems – Figure 4
e boiler can be vented vertically with the intake air piped
horizontally through an outside wall. Follow the instructions in the
Intake Air Option – Horizontal Guidelines on page 5. Also follow
the general instructions in the “COMBUSTION AIR &
VENTILATION” and “GENE L VENTING GUIDELINES”
sections.
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Figure 1 Horizontal Air Intake and Venting for a Single Direct Vent System
16 FT 4.9 m
1.5 FT 0.5 m
1/4 IN. PER FOOT
20 mm/m
When running horizontal combustion air and venting for
single or multiple units, exhaust and combustion air
terminals must be installed on the same plane (outside wall)
in order to prevent pressure di erences due to prevailing
winds. In cold climates, double-wall or insulated inlet pipe
recommended to prevent condensation.
Figure 2 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
MBH
500 TO 1000
1001 TO 2000
2001 TO 4000
4001 & LARGER
kW
146 TO 293
293 TO 586
586 TO 1172
1172 & LARGER
FT m
5 1.5
10 3.1
15 4.6
20 6.1
5 FT 1.5 m
1.5 FT 0.5 m
2 IN. 5.0 cm
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10 FT 3.1 m
4 FT
1.2 m
5 FT
1.5 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
Figure 3 Vertical Air Intake and Venting for a Direct Vent System
Locate exhaust terminal downwind to reduce ue gas recirculation.
Figure 4 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
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Side Wall Vent, Positive Pressure,
Category IV – Figure 5
In this con guration the boiler blower is used to push the ue
products horizontally to the outdoors, see Figure 5. e air for
combustion is taken from the space in which the unit is installed.
e applicable instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! e vent guidelines
under the Horizontal Direct Vent Systems section must also be
followed.
Figure 5 Side Wall Venting
Figure 6 Vertical Venting with a Metal Chimney System
See Table 4, page 6 for minimum pipe dimensions
To ensure proper operation, boilers that are vented
side wall and use room air must not be red less than
33% input.
Vertical Vent, Positive Pressure,
Category IV – Figure 6
(Vent pipe equivalent length up to 100 , 30.5 m maximum)
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
A through inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed lined, and
sized. Exterior masonry chimneys should not be used unless
properly lined to prevent condensation and dra problems.
Vertical Chimney Venting
Negative pressure — Category II
(Common Venting)
Category II venting is required for multiple Fusion
XLF boilers connected to a common vent. Common
vent systems cannot be pressurized.
e Fusion XLF is listed as a CategoryII appliance when vented
vertically into a listed metal chimney system. e chimney must
provide a negative pressure not greater than 0.10in, 2.5 mm WC
at the boiler ue collar with the unit running.
When using a listed metal chimney system the chimney
system manufacturer’s instructions must be followed.
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g
e vent piping must be large enough to safely vent the
combined output of all of the appliances connected
to the system.
If an appliance using any type of a mechanical dra
system operating under positive pressure is connected
to a chimney ue, never connect any other appliances
to this ue. Doing so can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Category II Chimney Inspection & sizing
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
A thorough inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed, lined
and sized. Exterior masonry chimneys should not be used unless
properly lined to prevent dra problems.
Table5 lists the minimum riser sizes required for the Fusion boiler.
Table 5 Riser Diameters To Common Vent For Category II Venting
Input MBH
2500/3000
3500/4000 14 356
Note: These sizes are based on a 20 ft, 6.1 m chimney height.
in mm
12 305
Category II Vent Connections
Locate the boiler as close to the chimney as possible. Use the shortest,
straightest vent connector possible for the installation. If horizontal
runs exceed 5 , 1.5 m they must be supported at 3 , 0.9 m inter vals
with overhead hangers.
e boiler vent connectors should be sloped up toward the breeching
at a minimum rate of 1/4 in per , 21mm per m.
Always provide a minimum clearance of 6 in, 152 mm
single wall vent pipe and any combustible materials.
between
Always provide a minimum clearance of 6 in, 152 mm between
single wall vent pipe and any combustible materials.
Exit cones are favorable when used to increase
the velocity of the ue gas exiting the stack and,
may also help, in cold climates, to reduce ice buildup. Exit cone terminations must be supplied by
others, installed per manufacturer’s instructions,
and meet local and federal code.
eneric exit cone
When using a listed metal chimney system the chimney
system manufacturer’s instructions must be followed.
Failure to maintain minimum clearances between vent
connectors and any combustible materials can result
in a re causing extensive property damage, severe
personal injury or death!
OUTDOOR VENTING
When installed outdoors the Futera Fusion must be ed with the
factory supplied outdoor hood, air intake adapter with lter and
exhaust terminal, see Figure 7. Multiple units must be spaced per
Figure 8.
e boiler/heater must be at least 2 , .62 m from any door, window
or gravity air inlet into any building and at least 3 , 1 m from any
overhang unless local codes dictate di erently.
Avoid locations where wind de ection o of adjacent walls,
buildings or shrubbery might cause a downdra . e unit(s) should
be located at least 3 , 1 m from structures. Outdoor installations
are not recommended in areas where the danger of snow blockage
exists.
Do not place the boiler/water heater in a location that
would subject it to runo from adjacent buildings or
damage may occur voiding the warranty!
Failure to maintain minimum clearances between
vent connectors and any combustible material can
result in a re causing extensive property damage,
severe personal injury or death!
Vent Connections
Locate the boiler as close to the chimney as possible. Use the shortest,
straightest vent connector possible for the installation. If horizontal
runs exceed 5 , 1.5 m they must be supported at 3 , 0.9 m
intervals with overhead hangers.
e vent connector should be sloped up toward the chimney at a
minimum rate of 1/4 in/ , 21 mm/m. On masonry chimneys the
connector must terminate ush with the inside of the chimney ue.
10
Outdoor Installations
e Futera Boiler is certi ed for outside installations
in temperate climates only.
1. e condensate traps located under the secondary heat exchanger
and the vent pipe must be wrapped with heat tape to ensure the
traps never drop below 32°F.
2. e vent pipe must be insulated to prevent freezing of condensate
in the pipe.
3. e boiler and system must be lled with an ethylene glycol/
water antifreeze mixture not to exceed 50% glycol by volume.
4. All water piping exposed to low temperatures must be insulated.
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A
Figure 7 Outdoor Venting
Figure 8 Multiple Outdoor
2 FT
(0.62 M)
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler will void the manufac-
turer’s warranty and can cause boiler failure resulting
in ooding and extensive property damage! Excessive
water hardness causing scaling in the copper heat
exchanger tubes is NOT covered under the manufacturer’s warranty, see Table 8. Excessive pi ing and
erosion of the internal surface of the copper heat
exchanger tubes is NOT covered under the manufacturer’s warranty if the result of high water ow rates.
Shut o valves and unions should be installed at the
inlet and outlet connections of the boiler to provide for
isolation of the unit should servicing be necessary.
Freeze Protection
Installations in areas where the danger of freezing exists are not
recommended unless proper freeze protection is provided. e
following precautions MUST be observed:
A continuous ow of water through the unit MUST be maintained!
1.
e pump responsible for ow through the boiler must run
continuously!
2. An ethylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used.
e pump must be capable of producing a minimum of 15%
more ow and overcoming a 20% increase in head loss.
Domestic water systems must be isolated from the water heater
by the use of a heat exchanger or other approved method.
3. If the unit must be shut o for any reason the electric, gas and
water supplies MUST be shut o and the unit and its pump
completely drained.
Improper outdoor installation of this unit can cause
boiler failure voiding the manufacturer’s warranty!
3 FT
(1 M)
RIOM-60 REV.
Condensate Piping
e condensate trap provided with the boiler must be a ached to
the bo om pan and piped to a suitable oor drain or condensate
pump. If a condensate neutralization device is installed, it must be
positioned prior to boiler room drain. Condensate ll trap must
be maintained with uid.
Relief Valve
Pipe the discharge of the pressure relief valve as shown in Figure 9.
Never install any type of valve between the boiler and
the relief valve or an explosion causing extensive
property damage, severe personal injury or death may
occur!
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Flow Switch
e ow switch supplied with the boiler must be wired to the
terminal strip in the control panel to prevent the boiler from ring
unless there’s adequate water ow through the unit. e ow switch
must be installed in the supply piping adjacent to the boiler outlet
connection.
Failure to properly install the ow switch may result
in damage to the boiler heat exchanger voiding the
warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a quali ed technician
in accordance with the latest revision of the ANSI/ASME Boiler and
Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1,
Standard for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must also be
followed. A minimum clearance of 1 in, 25 mm must be maintained
between heating system pipes and all combustible construction.
All heating system piping must be supported by suitable hangers
not the boiler. e thermal expansion of the system must be
considered when supporting the system. A minimum system
pressure of 12 psig, 82.7 kPa must be maintained.
Bleed Air From Boiler
Open the boiler piping bleed valves one at a time, to purge the air
trapped in the primary and secondary heat exchangers. Refer to
piping drawings (Figures 7, 8 & 9) for bleed locations.
Heating Boiler Piping Connections
e supply and return connections should be sized to suit the system,
see Table 6.
Table 6 Supply & Return Pipe Sizing
Input MBH Supply Size Return Size
2500 thru 4000 3 in FLANGE 3 in FLANGE
e maximum allowable primary heat exchanger
temperature rise is 35°F, 19.4°C.
Factory Supplied - On Board - Circulating Pump
e factory installed - on board - pump is sized to work the total
boiler head loss plus an additional (30 ) of pipe and (6 elbows)
- (min pipe diameter of inlet/outlet boiler water connections - see
Table 6). Please consult factory for systems outside these parameters.
Low Water Cuto
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to the wiring diagram supplied with the boiler for proper
wiring connections.
Expansion Tank & Air Separator
An expansion tank or other means to control thermal expansion
must be installed in the heating system. An expansion tank must
be installed close to the boiler on the suction side of the pump. An
air scoop and automatic air vent must also be installed to eliminate
air trapped in the system.
Primary/Secondary Piping
Figure 10 shows a typical primar y/secondary piping system. Boilers
connected to heating systems using zone valves, zone pumps, or
systems that have excessive ow rates must be isolated from these
systems to protect the boiler.
Multiple Boiler Systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 11.
Piping For Use With Cooling Units
e boiler, when used in connection with a refrigeration system,
must be installed so the chilled medium is piped in parallel with
the boiler. Appropriate valves must be used to prevent the chilled
water from entering the boiler.
Pump Requirements
is low mass boiler requires a continuous minimum water ow
for proper operation. e boiler pump is sized to overcome the
head loss of the boiler and the near piping in order to achieve the
required temperature rise. e temperature rise across the boiler
must never exceed 35°F, 19.4°C. e adjustable pump delay turns
the pump on each time the burner res and runs the pump for 20
to 600 seconds a er the call for heat is satis ed.
12
When a boiler is connected to a heating coil that may be exposed
to refrigerated air from an air handling device, the piping system
must be equipped with ow-control valves or some other automatic
means of preventing gravity circulation of the boiler water during
the cooling cycle.
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Figure 9 Fusion XLF Secondary Bypass Piping
P u m p
V al v e
B al a nc e V a lv e
P r e s s u r e
R e d u c i n g V al v e
C h e c k V al v e
P r e s s u r e
R e l i e f V al v e
Item
Number
Description
1 3-Way Valve
2 Air Purging Valves
3 Flow Switch
4 Circulator
5 Pressure Relief Valve
6 T & P Gauge
7 Primary Heat Exchanger Drain Valves
8 Condensate Drain Trap
Notes:
1. Fill condensate drain trap with water or approved
anti-freeze solution prior to start up.
2. Air purging valve may be located on pump ange.
F l o w S w i t c h
T h e r m o m e t e r
A qu a st a t U nio n
A ut o m a ti c
A i r Ven t
T e m p era t u r e &
P r e s s u r e
R e l i ef Va l v e
V a c u u m
R e l i e f V al v e
D r a i n V al v e
( T y p .)
3 - W a y
M i x i n g V al v e
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Figure 10 Typical Primary/Secondary, Low Temperature Piping System (See Notes)
H-16 REV C
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum ow through unit.
2. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual for procedure.
3. All boilers furnished with factory mounted outlet water temperature gauge.
4. For HeatNet operation, a sensor is required and installed at a minimum of 12 inches from the primary tee.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
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Figure 11 Multiple Boiler Piping (See Notes)
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum ow through each unit.
2. System loop pipe diameter must be sized large enough to handle maximum ow through all units.
3. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge
valves provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch
may fail due to trapped air. See manual for procedure.
4. All boilers furnished with factory mounted outlet water temperature gauge.
5. Condensate lines on each unit should be connected to a oor drain.
6. For HeatNet operation, a sensor is required and installation at a minimum of 12 inches from primary loop tee.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
H-17 REV C
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DOMESTIC WATER SUPPLY PIPING
Proper controls must be used to prevent water supplied
for domestic use from exceeding 130°F, 54°C or a
scald injury wi ll occur! When higher water temperatures
are required for appliances such as a dishwasher, a
mixing valve or some other tempering means must be
installed. Households with small children may require
water temperature less than 120°F, 49°C. Local codes
must be complied with!
General Piping Requirements
e Fusion XLF boiler can be used in combination with an indirect
tank to provide hot water for domestic use. Piping and components
must be suitable for use with potable water. e indirect storage tank
must be equipped with a temperature and pressure relief valve that
complies with ANSI Z21.22 or CAN-4.4 and CAN-4.6.
e storage tank must be located as close to the unit
heater as possible to prevent excessive head loss which
will reduce ow.
Bleed Air From Unit Heater
Open the unit 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 10 & 11) for bleed locations.
Expansion Tank
An expansion tank or other means to control thermal expansion
must be installed in the water heating system if back ow prevention
devices are installed.
Pump Requirements
is low-mass water heater requires a continuous minimum water
ow for proper operation. e proper velocity through the unit heater
must be maintained for e cient operation and long life. If the
temperature rise through the unit heater is lower than recommended
the water velocity is too high. Premature erosion of the heat exchanger
will occur. Conversely, if the temperature rise is too high, the ow rate
is too low. Scaling and so ening of the heat exchanger will occur. e
temperature rise across the primary heat exchanger must
never exceed 35°F, 19.4°C.
e factory mounted circulatory pump is sized to work
the total boiler pressure drop and an additional 30 . of
pipe and 6-90° elbows.
Storage Tank Thermostatic Mixing Valve
Water can be stored at temperatures above 140°F, 60°C provided
that a thermostatically controlled mixing valve is used to temper
the hot water to an acceptable temperature before it’s supplied for
domestic use.
e mixing valve MUST be set to prevent a scald injury from
occurring, see the caution against scalding.
Table 7 Delta T/Boiler Recovery Table - Fahrenheit
Inlet
Temp
(deg f)
60 2794 105 3171 111 3700 111 4228 111
80 3316 85 3717 91 4337 91 4956 91
100 4203 65 4617 71 5386 71 6156 71
120 5903 45 6250 51 7292 51 8334 51
140 10,457 25 9804 32 11,438 32 13,072 32
Table 8 Delta T/Boiler Recovery Table - Centigrade
Inlet
Temp
(deg c)
16 10,560 58 11,987 62 13,984 62 15,982 62
27 12,536 47 14,051 51 16,393 51 18,735 51
38 15,886 36 17,452 39 20,360 39 23,269 39
49 22,314 25 23,627 28 27,564 28 31,502 28
60 39,529 14 37,058 18 43,234 18 49,411 18
2500 3000 3500 4000
Flow
Rate
(gph)∆t(deg f)
2500 3000 3500 4000
Flow
Rate
(l/h)∆t(deg c)
Flow
Rate
(gph)∆t(deg f)
Flow
Rate
(l/h)∆t(deg c)
Model
Flow
Rate
(gph)∆t(deg f)
Model
Flow
Rate
(l/h)∆t(deg c)
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.
Flow
Rate
(gph)∆t(deg f)
Flow
Rate
(l/h)∆t(deg c)
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Figure 12 Typical Unit Heating Piping (See Notes)
D-17 REV. C
NOTES:
1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank.
Install sensor with heat sensing compound.
2. Thermal expansion tank may be required, check local codes.
3. Hot water tanks should be equipped with a combination temperature and pressure relief valve. Valve shall discharge
to a safe place with an air gap. Refer to local codes.
4. MA Code requires an 1/8 inch hole in check valve to compensate for thermal expansion.
5. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is lled. Use purge valves
provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch may fail due
to trapped air. See manual procedure.
6. Contractor shall verify, with authority having jurisdiction, for the requirements of an acid neutralization tank.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
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Figure 13 Multiple Unit Heating Piping (See Notes)
D-18 REV. D
NOTES:
1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank.
Install sensor with heat sensing compound.
2. Thermal expansion tank may be required, check local codes.
3. Common piping must be sized for maximum combined heater ow.
4. Hot water tanks should be equipped with a combination temperature & pressure relief valve. Valve shall discharge to
a safe place with an air gap. Refer to local codes.
5. MA Code requires an 1/8 inch hole in check valve to compensate for thermal expansion.
6. Boiler and pump purging required. Air must be purged from 3-way valve after boiler is lled. Use purge valves
provided. Purge valve may be located on pump ange. On multiple boiler installations the ow switch may fail due
to trapped air. See manual procedure.
7. Contractor shall verify, with authority having jurisdiction, for the requirements of an acid neutralization kit.
Notice: These drawings show suggested piping con guration, valving and are diagrammatic.
Check with local codes and ordinances for speci c requirements.
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GAS SUPPLY PIPING
Check the boiler rating plate to make sure that the
boiler is for the type of gas that will be used. If it isn’t,
do not connect the boiler to the gas supply. 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!
e Futera Fusion XLF comes from the factory ready to be piped
to the gas supply. If for any reason the boiler is not for the type of
gas available at the installation site, call your RBI representative to
resolve the problem.
A minimum gas supply pressure of 3.5 in, 88.9 mm,
WC natural or propane and maximum 14 in, 356
mm WC natural or propane, must be available at the
safety shuto valve inlet with the unit(s) operating,
and not to exceed a maximum of a (1.0 in WC) drop
when ring from minimum input to full load of the
gas supply line and all the appliances running.
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 ings. Table
9 should be used in conjunction with Table 9 to ensure that the gas
supply piping has the capacity to meet the demand.
Figure 14 depicts the proper way to connect the boiler to the gas
supply piping. e manual shut-o valve MUST be installed in the
supply piping. It should be installed 5 , 1.5 m above the oor where
required by local codes. Provide a sediment trap at the bo om of the
vertical section of the gas supply pipe upstream of the gas controls.
A ground joint union should be installed between the boiler gas
controls and the supply piping. Each of these items are needed to
ensure long life and ease of servicing. Always use a pipe sealant
that is suitable for use with LP gas.
Table 9 Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specifi c gravity gas
at a pressure of 0.5 psig or less and a 0.3 in WC pressure drop.
Pipe
Size
1" 4200 2760 2220 1900 1680
2 1/2" 6400 4400 3530 3020 2680
3" 11,300 7780 6250 5350 4740
4" 23,100 15,900 12,700 10,900 9600
5" 41,800 28,700 23,000 19,700 17,500
6" 67,600 46,500 37,300 31,900 28,300
Pipe
Size
1" 1520 1400 1300 1220 1160
2 1/2" 2430 2230 2080 1950 1840
3" 4290 3950 3670 3450 3260
4" 8760 8050 7490 7030 6640
5" 15,800 14,600 13,600 12,700 12,000
6" 25,600 23,600 22,000 20,600 19,500
Pipe
Size
1" 1020 928 854 794 704
2 1/2" 1630 1480 1360 1270 1120
3" 2890 2610 2410 2240 1980
4" 5890 5330 4910 4560 4050
5" 10,600 9650 8800 8260 7320
6" 17,200 15,600 14,400 13,400 11,900
Note: For propane piping — Multiply the gas volume above by 0.62 for
propane fl ow capacities in ft3/hr. Multiply the propane fl ow capacity by
2500 Btu/ft3 to determine the propane Btu/hr capacity for a given pipe
size and length.
Table 10 Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size
2" 5.2 10.3 1.2 3.0
2 1/2" 6.2 12.3 1.4 3.5
3" 7.7 15.3 1.8 4.5
4" 10.1 20.2 2.4 6.0
5" 12.6 25.2 2.9 7.3
6" 15.2 30.4 3.5 13.4
Equivalent lengths above are for threaded fi ttings. Multiply values above
by 0.75 for fl anged fi ttings.
10 20 30 40 50
Maximum gas volume of pipe, (ft
60 70 80 90 100
Maximum gas volume of pipe, (ft
125 150 175 200 250
Maximum gas volume of pipe, (ft3/hr)
90˚ Elbow
Pipe length in feet
Pipe length in feet
Pipe length in feet
Fitting or valve
Tee
(branch fl ow)
Equivalent pipe length, (ft)
Gate Valv e Gas Cock
3
3
/hr)
/hr)
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!
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When applicable, provisions for vent, bleed and gas relief lines must
be made in accordance with the latest revision of ANSI Z223.1/
NFPA 54. e main Dungs gas valve supplied with boiler does not
require external venting.
Safe lighting and other performance criteria were met with the
gas manifold and control assembly provided on the boiler. All gas
connections MUST be leak tested before pu ing the boiler into
operation.
Never use an open ame to test for gas leaks. Always use
an approved leak detection method. Failure to comply
with this warning can cause extensive property damage,
severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler gas
controls must be protected. If the test pressure is equal to, or less
than 1/2 ps ig , 3.5 kPa isolate the boiler by closing it’s manual shut
o valve, see Figure 16. If the test pressure is greater than, or equal
to 1/2 ps ig , 3.5 kPa, disconnect the boiler and its individual shuto valve.
Figure 14 Gas Supply Piping
ELECTRICAL WIRING
Electrical Power Connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation! Verify proper operation a er
servicing.
Au moment de l’entretien des commandes, étiquetez
tous les fils avant de les débrancher. Des erreurs de
câblage peuvent entraîner un fonctionnement
inadéquat et dangereux. S’assurer que l’appareil
fonctionne adéquatement une fois l’entretirn terminé.
e electrical connections to this boiler must be made in accordance
with all applicable local codes and the latest revision of the National
Electrical Code, ANSI/NFPA-70. Installation should also conform
with CSA C22.1 Canadian Electrical Code Part I if installed in Canada.
A properly rated shut-o switch should be located at the boiler. e
boiler must be grounded in accordance with the authority having
jurisdiction, or if none, the latest revision of the National Electrical
Code, ANSI/NFPA-70.
Line voltage eld wiring of any controls or other devices must
conform to the temperature limitation of type TEW wire at 95°F,
35°C above room temperature. Use copper conductors with a
minimum size of #14 awg. Use appropriate wiring materials for
units installed outdoors. e wire size must be compatible with
the total amp draw of the circuit.
Refer to the wiring diagram supplied with the boiler for proper
wiring connections and boiler full load amperage (FLA).
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GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not a empt
to operate this boiler if it has not been installed in
accordance with the guidelines set forth in this manual.
Failure to comply with this warning can result in
extensive property damage, severe personal injury
or death!
Should overheating occur or the gas supply fail to shut o , turn
o the manual gas control valve to the appliance. Do not interrupt
water ow through the boiler.
En cas de surchau e ou si l’alimentation en gaz ne s’arrête pas, fermez
manuellement le robinet d’arrêt de l’admission de gaz.
Hydronic Heating Boilers (Fill System)
Open the make-up water valve and slowly ll the boiler and all
of the radiation with water. Ensure that all bleed and drain valves
are closed.
Adjust the make-up water pressure regulator so a minimum 5 psig,
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 pressure at boiler under operating
conditions.
Glycol systems require a minimum of 20 psig, 137.8 kPa
at boiler operating conditions.
Open the boiler piping bleed valves one at a time, to purge
the air trapped in the primary and secondary heat
exchanger. Refer to piping drawings (Figures 10 & 11) for
bleed locations.
With the boiler o , run the system pump for at least 30 minutes
and bleed the system piping using the bleed valves. If strainers are
used in the system piping, the make- up water valve should be closed
and the strainers checked and cleaned.
e system expansion tank should be checked to ensure that the
correct water level in the tank is maintained. e tank should be
less than half full of water with the system full and adjusted
to the correct operating pressure.
Start the boiler as described in the “OPE TING INSTRUC
TIONS” section. Run the boiler for at least an hour. e system
pump(s) and all radiation units must be operated during this time.
Ensure that the make-up water valve is open.
Shut the boiler o and open the bleed valves to purge the air trapped
in the heating system piping. Close the make-up water valve and
check and clean the strainers and make-up water pressure reducing
valve.
Open the make-up water valve and adjust the system pressure if
necessary. e system should be checked and bled a er three days
of operation.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE
A. is appliance is equipped with an ignition device which auto-
matically lights the pilot. Do not try to light the pilot by hand.
Cet appareil est muni d’un dispositif d’allumage qui allume
automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.
B. BEFORE OPE TING smell all around the appliance area
for gas. Be sure to smell next to the oor because some gas is
heavier than air and will se le on the oor.
Propane gas may not always be detected by smell.
Propane gas is heavier than air and can collect in low
areas.
Propane gas can ignite or explode if an ignition source
is present and result in death, serious injury and
property damage!
FOR YOUR SAFETY
• Have only quali ed licensed professionals install, service and
maintain this appliance and your gas system in accordance with
all applicable codes.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not a empt to light any appliance.
3. Do not touch any electrical or electronic switches in the
building.
4. Do not use any phone in the building.
5. Call your gas supplier from a phone outside of the building.
6. If you cannot reach your gas supplier call the re department.
AVANT DE FAIRE FONCTIONNER, reniflez tout autour de
l’appareil pour déceler une odeur de gaz. Reniflez près du
plancher, car certains gaz sont plus lourds que l’air et peuvent
s’accumuler au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des
téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gaz depuis un
voisin. Suives les instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur, appelez le service
de incendies.
C. Do not use this appliance if any part has been under water.
Immediately call a quali ed service technician to inspect the
appliance and to replace any part of the control system and any
gas control that has been under water.
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N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
partiellement. Faites inspecter l’appareil par un tecnicien quali é
et remplacez toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
Operating instructions
1. If, at any time, the boiler will not operate properly, follow the
instructions “TO TURN OFF GAS TO APPLIANCE,” page25,
and call your service technician or gas supplier.
2. Turn o all electrical power to the boiler.
3. Close main gas shut-o valve ( eld supplied), Figure14.
4. Purge the gas piping up to the boiler’s manual gas valve (located
ahead of the main gas valve). When the bleeding is complete,
check all gas joints up to the gas valve for leaks.
5. Wait ve (5) minutes to clear out any gas.
6. Make sure all limits, pressures switches and safety device contacts
are closed.
7. Open the main gas shut-o valve.
8. Disable any external call for heat, such as from a building
management system or remote operating controller.
9. Toggle the remote/local switch (in control cabinet see
Figure18) to
10. Turn on electrical power to the boiler.
11. Turn the power switch on the front of the boiler control cabinet
to
ON.
12. e HeatNet display will light up when the power is on. If all
interlocks are properly closed, the display will say
not, refer to the XLF HeatNet Control manual for troubleshooting.
13. Slide the HeatNet control’s low re switch (on HeatNet control
board) to the
14. e boiler will begin the start-up sequence.
15. Allow the boiler to pre-purge and enter the pilot ignition cycle.
16. If pilot lights (indicated by a good ame signal 5.0 V DC) proceed
to step 18. (See Honeywell R7800 literature for use of a meter
to check ame signal if keypad readout is not available.)
17. If pilot is unstable(indicated by a low or erratic ame signal
causing pilot ame failure), toggle the low re switch to
then back to ENABLE to start another cycle (reset the Honeywell
control if necessary). Repeat for one or two more times to ensure
the pilot line is purged of all air. If pilot is still unstable, the pilot
gas pressure may need to be increased. See step18.
18. Pilot pressure adjustment:
a. Switch the Honeywell control to
rst 10 seconds of the pilot ignition sequence.
b. Connect one side of a manometer or pressure gauge to the
manometer pressure port (barbed) on the pressure test manifold
(located inside control panel). See Figure15. Leave the other
side of the manometer open to the room.
REMOTE.
STANDBY. If
LOW FIRE position.
DISABLE,
TEST position within the
Figure 15 Manometer connections to the test manifold (in
control cabinet)
c. Measure pilot gas pressure by pressing and holding the
service valve marked PILOT GAS.
d. Set pilot gas pressure to 3.0 in WC (± 0.5 in) by adjusting
the pilot gas pressure regulator, inside the air box. Access
from the boiler top cover. See Figure16.
Figure 16 Access to air trim adjustment and pilot regulator
e. Check pilot air pressure using service valve marked PILOT
.
AIR
f. Pilot air pressure should be 0.60 in WC (± 0.10 in).
Combustion readings must be in the range speci ed
in the following instructions. Adjust the boiler as
necessary to ensure proper combustion.
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Verify low re operation
1. Connect a manometer or Magnehelic gauge with the pressure
side to the manifold pressure port. See Figure15, for locations.
2. Set Honeywell R7800 control to RUN position. e boiler will
operate at low re because the low re switch is in the low re
position.
3. Measure the ue gas CO
Set low re CO2 to 8.0% – 8.5% by adjustment on the Dungs
with the boiler running at low re.
2
valve using a 3mm Allen wrench.
a. Turn the wrench in small increments (10degrees at a time).
b. Allow time a er each adjustment for the boiler to reach
steady state.
4. A er se ing the CO
a. Press the
, measure the pressure signal, Ps.
2
Ps (signal) bu on and read the pressure. e
pressure at low re should be as shown in Table11.
b. If the pressure is outside of this range, follow the instruc-
tions in the HeatNet Control manual to set the required
turndown.
c. Utilize the ACTech drive to trim the low re pressure signal
(Ps) as follows: Press the “Mode” bu on on the AC Tech
Drive.
d. e drive will now require a password. Use the Arrow Keys
on the AC Tech Drive to enter the password value of “523”
then press “Mode”.
e. e parameters of the drive will be accessible at this point.
Use the Arrow Keys on the AC Tech Drive to scroll to P45.
Press “Mode” to view the entry; use the Arrow Keys to adjust
the value to achieve the required combustion – CO2/O2,
and pressure – (Ps) at low re based on the desired turn
down. e default values are listed in Table 11.
f. When complete press “Mode” again to save the value.
If using a U-tube manometer turned sideways for low
pressure readings, you MUST turn the manometer
upright before a empting to measure pressures at
other than low re. Pressure signal could reach up to
11 in when the boiler is at high re, and can cause
uid to be pulled out of the manometer into the boiler.
Should this occur, immediately shut down the boiler
and contact the factory for procedure. Preferably, use
a Magnehelic gauge instead of a U-tube manometer
to measure the pressure to avoid this potential hazard.
Table 11 Pressure signal (Ps), ACTech (P45) - (Nat Gas)
2500 3000
Firing
rate
100% -9.50 n/a 87.00 -11.00 n/a 77.00
20% -0.40 11.00 n/a -0.40 13.00 n/a
Firing
rate
100% -6.00 n/a 73.00 -8.50 n/a 75.00
20% -0.40 10.50 n/a -0.40 10.50 n/a
To determine signal in mm WC, multiply signal pressure by 25.4.
(PS)
in
WC
(PS)
in
WC
(P45) (P46)
3500 4000
(P45) (P46)
(PS)
in
WC
(PS)
in
WC
(P45) (P46)
(P45) (P46)
For LP Gas: All units are tested at factory. LP Combustion Values
are located on Combustion Data label.
To ensure proper boiler operation, boilers that are
vented sidewall and use room air must not be red
at less than 33% input.
5. Observe the burner ame a er se ing low re. Make sure the
ame is stable, but not too tight on the burner (causing infrared
operation).
DO NOT LEAVE THE BURNER IN AN INFRARED STATE.
A few random speckles of red are acceptable, but large
concentrations of spots or large areas of red are not.
If large amounts of red concentrations are observed,
verify combustion readings.
Leave the manometer connected to the test manifold.
It will be needed for high re operation testing.
Verify high re operation
1. Jumper the AA terminals on the HeatNet board and allow the
boiler to rise to maximum (100%) input.
2. Allow the boiler to reach steady state combustion at high re.
3. Verify high re blower speed as follows:
a. With the manometer (or gauge) connected to the test manifold,
press the
Ps (signal) bu on and read the pressure.
b. e pressure at high re should be as shown in Table11.
c. If the pressure is NOT correct, follow step 4.
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4. If the high re signal pressure is not correct:
a. Follow the instructions in the HeatNet Control manual to
calibrate the required input (Ps) for high altitude installations.
e maximum ring rate value in the HeatNet control is
factory set at (90%). At this se ing, for sea level applications
and with typical vent lengths, the boiler will be at rate. DO
NOT increase above (90%) unless needed for high altitude
installations.
b. For sea level installations only, the ACTech drive can be used
to trim high re input (Ps) as follows: Press the “Mode”
bu on on the AC Tech Drive.
c. e drive will now require a password. Use the Arrow Keys
on the AC Tech Drive to enter the password value of “523”
then press “Mode”.
d. e parameters of the drive will be accessible at this point.
Use the Arrow Keys on the AC Tech Drive to scroll to P46.
Press “Mode” to view the entry; use the Arrow Keys to adjust
the value to achieve the required combustion – CO2/O2,
and pressure – (Ps). e default values are listed in Table
11.
e. When complete press “Mode” again to save the value.
5. If the pressure signal is correct, measure the ue gas CO
should be between 9% and 9.5%.
a. If CO
b. If CO
is correct, proceed to step 6.
2
is not within this range, adjust the air trim adjustment
2
slightly (see Figure16) on top of mixing box to achieve a
2
. It
CO2 of 9% - 9.5%.
c. If adjusting the air trim adjustment does not correct the
problem, contact technical support at the factory to
troubleshoot the problem.
6. If CO
and pressure signal are correct, allow the boiler to reach
2
steady state and verify supply gas pressure and check input rates
as explained in the Gas Supply Piping section.
7. Remove jumper on AA and allow boiler to se le into minimum
input. Observe the combustion readings to ensure the boiler
is operating correctly.
8. When nished, disable the low re hold switch and replace test
ports to normal state. Remove the manometer connections and
close the control panel door.
9. e Futera XLF boiler allows for many modes of operation
and control methods. Reference the HeatNet Control manual.
COMMENT COUPER L’ADMISSION DE GAZ DE
L’APAREIL
1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut procéder
à l’entretien.
3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. e boiler is idle with no interlocks in the fault condition.
DEMAND
Pre-Purge
1. e blower operates at purge RPM. e water ow interlock
must ‘make’ within 15 seconds a er the demand signal is initiated.
2. e Honeywell 7800 starts a 10 second purge delay once the
air prove switch contacts close.
Pilot Run - %Input
1. e blower operates at minimum ignition se ing. See the
calibration section in the HeatNet Control manual to enter the
calibration menus.
2. e ignition transformer is energized. e pilot solenoid valve
opens for the 10 second pilot ignition trial.
Main Run %Input
1. e main gas valve opens.
2. e ignition transformer is de-energized.
3. e pilot solenoid valve closes.
4. e blower stays at the minimum input se ing for 3 seconds
then operates at demand % input. See the calibration section
in the HeatNet Control manual to enter the calibration menus.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest se ing.
2. Turn o all electric power to the boiler if service is to be performed.
3. Close the manual main and pilot gas shut-o valves.
24
NO DEMAND
Post-Purge
1. e main gas valve closes.
2. e blower operates at purge RPM for 10 seconds.
3. e boiler is idle with no interlocks in the fault condition.
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CHECKING & ADJUSTMENTS
Spark Gap
With the main and pilot gas manual valves in the closed position
energize the unit. Observe the trial for ignition to con rm that the
spark is strong and continuous. If not check and adjust the spark
gap as shown in Figure 17.
Figure 17 Spark Gap
Required gas pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
Table 12
Gas supply pressure (Nat/LP)
Inches
water column
Minimum 3.5 88.9
Maximum 14 356
1. Measure pressure when the boiler is ring at full rate. Low
gas pressure could indicate undersized gas line or insu cient
gas supply.
2. Static and operating gas pressure required at the gas valve inlet
is listed in the Table12.
If the gas pressure is above the limit in table 12, a
lock-up style gas pressure regulator suitablefor dead-
end service, (such as an Equimeter or Fisher) must be
installed to prevent increase (creep) of gas pressure
when the units are not operating and not to exceed
a maximum of (1.0 in WC) drop when ring from
minimum input to full load of the gas supply line and
all the appliances running.
mm
water column
Pilot adjustment
1. e pilot pressure has been factory set at 3 in WC, and shouldn’t
need adjustment.
a. With the boiler powered, generate a call for heat.
b. When the prepurge is complete the ignition/pilot trial will
begin.
2. To adjust the pilot the following steps must be taken:
a. Put the Honeywell RM7800 test switch in the test position.
e control will hold in the ignition/pilot sequence, allow ing
you to check the pressure.
b. Connect one side of a manometer or pressure gauge to
the manometer pressure port (barbed) on the pressure
test manifold (located inside control panel). See Figure 13.
Leave the other side of the manometer open to the room.
c. Measure pilot gas pressure by pressing and holding the
service valve marked PILOT GAS.
d. Set pilot gas pressure to 3.0 in WC (± 0.5 in) by adjusting
the pilot gas pressure regulator, inside the air box. Access
from the boiler top cover. See Figure 16.
e. Check pilot air pressure using service valve marked PILOT
AIR.
f. Pilot air pressure should be 0.60 in WC (± 0.10 in).
Never force the regulator adjustment screw beyond
the stop limits or damage to the regulator will occur!
is pressure regulator (supplied by others) may be
installed at the service entrance to each unit or a “master”
regulator sized to handle multiple units with adequate
turndown capability may be utilized. Consult local gas
utility or regulator manufacturer for recommendations
to meet speci c job site requirements.
Input rate — Natural gas
Gas appliances are rated based on sea level operation with no
adjustment required at elevations up to 2000 , 610m. At elevations
above 2000 , 610m input ratings should be reduced by 4% for
each 1000 , 305m.
Check the input rate as follows:
1. Turn o all other gas appliances that use the same gas meter
as the boiler.
2. Call your gas supplier and ask for the heating value of the gas.
3. Start the boiler and let it run for 15 minutes.
4. Using the gas meter and a stopwatch, clock the time that it takes
to burn 10
5. Insert the heating value and the time, in seconds, into the formula
below.
6. Input = (heating value, Btu/hr)(3600)/(time, seconds)
7. If the computed rate deviates by more than 5% from the rated
input value of the unit, consult factory.
3
, 0.28m3 of gas and divide this time by 10.
Never increase the input to the boiler above that for
which it is rated. Doing so can cause premature failure
of the boiler!
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Figure 18 RBI Field Wiring to HeatNet Board (BoardRevision 2.0 and Greater)
RIOM 86
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CONTROL DESCRIPTION
Low Water Cuto
If the boiler is to be installed above radiation or if required by other
codes or regulations, install a low water cuto in appropriate piping.
Wire the switch to the “Interlock” contacts as illustrated on “Field
Wiring” schematic. Ensure that the low water cuto device(s) will
function properly.
Operating Control
e preferred control se ing for potable hot water is 130°F, 54°C.
e operating control should be set to the lowest se ing that will
satisfy the consumer’s needs.
Se ing the thermostat or operation control too high
can result in scalding resulting in severe personal
injury!
High Limit (Aquastat)
e high limit is located in the top control area of the boiler. A
remote capillary bulb is run to a well on the outlet side of the
supply header. e high limit can be reset by depressing the red
bu on.
ese 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
e high limit interlock breaks power to the ignition control
(sh u ing it o ) and e ectively removes any chance of the gas valve
receiving power. e Futera Fusion XLF series control will remain
powered to display the fault, latch the alarm relay/audible beeper,
and to access the log. e interlock is located on J5, HIGH LIMIT.
e unit 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 ow switch is provided in the water outlet piping to prevent
the boiler from ring without adequate water ow through the heat
exchanger.
DIAGNOSTICS
e Futera Fusion XLF has a display that indicates the sequence of
operation. e display will also list faults should the unit fail to
operate. An explanation of each status message and fault can be
located in HeatNet Control Manual under status screen fault display
section.
Status Screen Fault Display
ere are numerous interlock switches and so ware limits that
are detected. Each of these, when tripped will produce a display
message, an audible beeping, and an alarm relay closure. e fault
is displayed rst, then a er a second, the time the fault occurred
is displayed. is cycle will keep occurring until the fault is cleared.
INTERLOCK SPARE 3: is is a reserved interlock input that
is normally jumpered at the factory, but can have a remote interlock connected as a eld install. e interlock is located on J11A,
SPARE 3.
FAULT
SYSTEM SET
INTERLOCK SPARE 3
160˚F
LOW WATER CUTOFF: If there is a low water condition reported
by the low water cuto switch this fault is displayed. Check that
there is water ow and water in the boiler. ere is a reset switch
located on the LWCO box. e interlock connection is located on
J11A, LWCO.
FAULT
SYSTEM SET
LOW WATER CUTOFF
160˚F
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VAR FREQ DRIVE: e variable frequency drive, which controls
the blower, reports this fault in the event of over current or other
conditions that would cause it to shut down. If this is the case,
check the fault indicators on the VFD. e interlock is located on
J11A, VFD.
FAULT
VAR FREQ DRIVE
SYSTEM SET
160˚F
GAS PRESSURE: e optional gas pressure switches (high pressure
and low pressure) are connected in series, so if either trip, a fault
will be reported here. A reset switch is located on the gas pressure
switches. e interlock is located on J11A, GAS PR.
FAULT
GAS PRESSURE
SYSTEM SET
160˚F
FLOW SWITCH ERROR: Once the Futera Fusion series boiler
receives a call for heat, it closes the circulator pump relay. It then
waits 10 seconds to prove ow. If there is no ow, the ow switch
alarm will be set. Every 10 seconds the circulator pump relay will
cycle ON for 10 seconds and then OFF for 10 seconds to try and
establish ow. e interlock connection is located on J11B, WTR
FLW.
FAULT
WATER FLOW SWITCH
SYSTEM SET
160˚F
IGNITION CTRL ALARM: e ignition control alarm is displayed
if the ignition control detects a fault. is could be a ame failure,
air proving switch, or other fault associated with the ignition control.
When this fault occurs, you will need to refer to the ignition control
for the reason.
FAULT
IGNITION CTRL ALARM
SYSTEM SET
INTERLOCK SPARE 4: is is also a spare interlock (similar to
INTERLOCK SPARE 3) for future expansion or use as a eld
interlock. e interlock is located on J11B, SPARE 4.
FAULT
INTERLOCK SPARE 4
SYSTEM SET
160˚F
160˚F
IRI ALARM: e optional IRI alarm is the alarm from the gas
valve. If this alarm is set check the gas valve.
FAULT
IRI ALARM
SYSTEM SET
160˚F
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COMBUST AIR DAMPER: If the combustion air damper has
been selected for use (MASTER BOILER, AUX FUNCTIONS),
and the proof switch does not make, this fault will be displayed.
When the combustion air damper is used, the master’s BOILER3/
DAMPER relay contacts at J13 are closed. ese should be wired
to the combustion air damper or preferably an isolation relay.
e prove switch on the combustion air damper must be wired to
J10B, SPARE 1.
FAULT
SYSTEM SET
COMBUSTION AIR DAMPER
160˚F
When the master boiler receives a call for heat and needs to start a
boiler, the BOILER3/DAMPER relay K5 closes. At the same time,
the boiler is started, res, and continues to re. If the combustion air
damper does not prove within the proof time speci ed in the
combustion air damper menu, the boiler will shut down and display
the fault. e fault on the Master boiler can be cleared by removing
the call for heat on the master boiler and xing the combustion air
damper problem. A combustion damper fault on a Member boiler
can only be cleared by power cycling.
SHORTED ***** SENSOR: If the shorted sensor fault is displayed,
the sensor in the position reported was originally detected, but
has since shorted. e boiler will shut down on any SHORTED
sensor.
FAULT
SYSTEM SET
SHORTED OUTSIDE SENSOR
160˚F
DELTA TEMP > 40°F: If the temperature across the heat exchanger
rises above the maximum designated temperature for the Futera
Fusion model boiler, a warning or fault will be displayed. is
protection is required to prevent damage to the heat exchanger in the
event high di erential temperatures are encountered. e fault or
warning condition may be changed in the AUX FUNCTIONS
menu under ALARM TYPE. e default condition is WARNING
with LIM->HALF TE = YES.
When this condition exists and the ALARM TYPE is set to
WARNING and LIM-> HALF TE, the boiler is limited to 1/2
it’s input rate. So, if the boiler is trying to re at 80%, the rate is
limited to 40% until the temperature across the heat exchanger
falls at least 10°F below the maximum designated temperature
for the Futera Fusion boiler model. In this case: 40°F - 10°F = 30°F.
e Master boiler controls a system damper and Member boilers
control their own respective dampers. When the call for heat is
removed, the damper will remain open for 30 seconds before closing.
is allows for post purge cycles to complete.
OPEN ***** SENSOR: If the open sensor fault is displayed, the
sensor in the position reported was originally detected, but has
since opened. e boiler will shut down on any OPEN sensor.
FAULT
SYSTEM SET
OPEN OUTSIDE SENSOR
160˚F
If the ALARM TYPE is set to FAULT, the boiler will display the
FAULT message and this condition will be treated as an interlock,
thus shu ing down the boiler until the Delta Temp drops 10°F
below the maximum designated temperature.
1/2 INPUT
LOCAL SET
DELTA TEMP > 40°F
41˚F
RETURN TEMP < 130°F: If the Return Inlet temperature is less
than 130°F this warning will be displayed. is warning does not
a ect operation and does not set the alarm relay. A log entry is
made to aide in diagnosing why this may be occurring. Condensing
will occur with return temperatures below 130°F and a shortened
heat exchanger life will occur.
PREPURGE
LOCAL SET
RETURN TEMP < 130°F
41˚F
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MAINTENANCE
Disconnect electrical power and close the manual gas
shut o valve before performing maintenance or severe
personal injury may result!
Serv icing, 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!
e boiler 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’s performance. Refer to Figure15 for
component identi cation.
Improper burner servicing can result in premature
burner failure voiding the warranty!
Pilot and burner removal
1. Close the manual shuto valves in the gas supply line and turn
o electrical power to the boiler.
2. Remove the jacket top panel.
3. Remove wires from the spark rods and remove the UV sensor
from the transition piece.
4. Remove the pilot assembly:
a. Disconnect the compression nut at the front of the pilot block.
b. Remove the pilot gas tubing.
c. Remove the (2) screws from the pilot block.
d Remove the pilot assembly.
5. Disconnect the exible gas line from the manifold.
6. Disconnect the wires to the fan and remove the (2) bolts and the
fan hold-down plates that secure the fan to the transition piece.
7. Li and remove the fan housing from the boiler, taking care not
to damage the spark rods and or their alignment.
8. Remove the four nuts holding the transition piece to the heat
exchanger.
9. Remove the transition piece, taking care not to damage the O-ring.
10. Remove the burner, taking care not to damage the gasket.
11. Replace all components a er servicing.
Heat exchanger inspection
1. Close the manual shuto valves in the gas supply lines and turn
o electrical power to the boiler.
2. Remove burner following the instructions in the Burner Removal
section.
3. Remove the front jacket panel and combustion chamber door.
4. Inspect the inside and outside of the heat exchanger for signs
of damage, sooting or corrosion.
5. e outside surfaces of the copper tubes should be free of
any soot deposits. A slight black smudge is normal with
some types of gases. Black soot indicates poor combustion.
Green deposits indicate condensation due to low return water
temperatures. In either case the heat exchanger must be cleaned
thoroughly and the problem resolved before the boiler is
returned to service.
6. If there are no signs of damage, sooting or corrosion, reassemble
the unit following the previous steps in reverse order.
7. A badly corroded or damaged heat exchanger must be replaced,
see the Heat Exchanger Repair & Replacement section.
Heat exchanger cleaning
1. Close the shut o valves in the inlet and outlet piping. On heating
systems close the system ll valve and relieve the system pressure
from the boiler by carefully li ing the relief valve or opening
the drain valve.
2. Disconnect the boiler from the system piping.
3. Remove the eight bolts on the rear pipe enclosure panel.
4. Remove the front jacket panel and combustion chamber door.
5. Slide the heat exchanger out of the unit.
6. Remove the “V” ba e straps and “V” ba es.
7. oroughly clean the heat exchanger with water from a highpressure hose. Use a so bristle brush if necessary.
8. Replace the cleaned heat exchanger and other components in
the reverse order of their removal.
Heat exchanger repair & replacement
1. A leaking or otherwise damaged tube(s) can be replaced as
outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler 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). Replace the
pipe plugs using a suitablethread sealant on each one.
6. Sagging or distorted heat exchanger tubes are an indication of
low water ow through the system. A damaged heat exchanger
must be replaced and the condition that caused the damage
resolved before the boiler is returned to service.
7. Replace the heat exchanger and other components in the reverse
order of their removal.
Air intake & vent system
oroughly inspect the air intake and vent systems for any signs of
blockage, corrosion or leakage. Immediately replace any unsound
vent system piping. Inspect the air lter and wash with warm water
and soap if dirty.
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Controls
Use the “GENE L OPE TION” and “CHECKING AND
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A oat type low water cuto device must be ushed out per
the manufacturers’ instructions.
a. e probe on a probe low water cut o must be removed,
cleaned and inspected at least once a year.
b. Ensure that the low water cuto s operate properly. If not,
replace them.
3. e ow switch contacts must be open when water ow is not
present.
4. e relief valve should not weep or discharge water at normal
system pressure. If it does, contact a quali ed service technician
to have it inspected.
NEVER try to clean or repair the relief valve! If the
valve fails to operate properly, have it replaced!
5. e aquastat high limit controls the maximum water temperature
in the boiler.
a. If the water temperature reaches the set temperature before
the demand for heat has been met, the aquastat high limit
should shut the boiler o .
b. e water temperature should never exceed the maximum
set point of 250
for water heaters.
c. e aquastat high limit cannot be repaired. If it fails to
function properly, replace it.
6. Visually check the pilot and main burner ames to ensure proper
operation, see Figure19.
o
F, 121oC, for boilers and 210oF, 99oC
Manometer test port manifold
1. e Futera Fusion XLF includes a manometer test manifold.
Connect the manometer pressure hose to the Pressure Tap port
shown in Figure20. ese pressures signals may be used for
troubleshooting when speci ed by factory support.
2. Figure 21, shows the sensor hose connections inside the
FuteraFusion XLF air box.
Figure 20 Manometer connections to manifold
A yellow, oating ame indicates a lack of combustion
air. Do not operate the boiler until the problem is
solved or severe personal injury or death may occur!
Figure 19 Main Burner Flame
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Figure 21 Futera Fusion XLF pressure sensor hose routing
Switch For
PS1 Main Blower (–) 0.20 (–) 0.20 (–) 0.20 (–) 0.20
PS2 Blocked Flue (+) 3.00 (+) 3.00 (+) 4.00 (+) 4.00
PS5 Blocked Inlet (–) 2.00 (–) 2.00 (–) 2.00 (–) 2.00
PS6 Pilot Air (+) 0.36 (+) 0.36 (+) 0.36 (+) 0.36
2500 3000 3500 4000
Switch Settings in WC
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Troubleshooting A Startup
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ActionCheckIdentify SourceSymptom
An Interlock is tripped.
1.
1. Is it a 24 VAC Interlock?
2. Is it a 120 VAC Interlock/
Alarm?
3. Internal Alarms
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/Alarm s
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. OPEN SENSOR
2. SHORTED SENSOR
3. COMBUSTION AIR DAMPER
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.
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.
2.
Proceed to HeatNet
more details and
problem resolution.
for
Manual Control
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.
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REPAIR PARTS
Figure 22 Repair Parts
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REPAIR PARTS CONTINUED
Figure 22 Repair Parts (CONTINUED
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
Left Base Channel 04-1018 1111
13
Right Base Channel 04-1022 1111
15 Burner
15a Burner O'ring 06-0006 1111
15b Burner Gasket 06-0038 1111
17 High Gas Pressure Switch (Manual Reset) 11-0421 1111
Gas Valve, MBC 11-0227 1 1
18
Gas Valve, MBC 11-0218 1 1
Flange 1-1/2" 11-0214 2 2
NS
Flange 2" 11-0219 2 2
19 Low Gas Pressure Switch (Manual Reset) 11-0422 1111
Firing Valve, 1-1/2" 11-0458 1 1
21
Firing Valve, 2" 11-0459 1 1
"A" Valve, 1-1/2" 11-0467 1 1
22
"A" Valve, 2" 11-0454 1 1
23 Blower
10-0322 1
10-0293 1
10-0323 1
10-0294 1
12-0019 1 1
24 Mixing Box Assy
25 Mixing Box Gasket 06-0080 1111
NS Gas Injectors, NG
Gas Injectors, LP
26 Flow Switch 14-0205 1111
27 Jacket Top Panel 70-2413.1 1111
28 Air Filter 09-0485 1111
29 Rear Pipe Enclosure Assy 70-3510 1111
36
12-0023 1 1
70-3555 1 1
70-3554 1 1
10-1005 1
10-1007 1
10-1002 2 2
10-1006 1
10-1008 1
10-1004 1 1
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
30 Jacket Lower Rear Panel
31 Jacket Upper Left Panel 70-2474 1111
32 Jacket Upper Right Panel 70-2471 1111
33 Jacket Lower Left/Right Side Panel
34 Jacket Upper Front Panel 70-3617.1 1111
NS Handle 20-0063 1111
35 Lower Front Jacket Panel
Combustion Chamber Top Panel 70-3561 1111
36
03-3786 1
03-3787 1
03-3788 1
03-3789 1
03-2838 2
03-2839 2
03-2840 2
03-2841 2
70-3535 1
70-3536 1
70-3537 1
70-3538 1
Manning Glass Insulation (per square foot) 05-0104 9999
37 Combustion Chamber Side/Rear Assy
38 Combustion Chamber Door Assy
Pressure Relief Valve 50# 30-0384 1111
39
Pressure Relief Valve 125# 13-0053 1111
NS Latch 20-0045 2222
NS Ball Valve 11-0395 1111
41 Drain Assy
70-3566 1
70-3567 1
70-3568 1
70-3569 1
70-3572 1
70-3573 1
70-3574 1
70-3575 1
70-2561.1 1 1
70-2562.1 1 1
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
Tridicator 30 - 60 psi 13-0308 1111
44
Tridicator 75 - 160 psi 13-0305 1111
45 LWCO #550LSV 14-0256 1111
46 Heat Exchanger Assembly (Copper)
Cast Iron 70-3585R 1
Heat Exchanger Assembly (Copper)
Bronze 70-3577R 1
Heat Exchanger Assembly (Cupronickel)
Cast Iron 70-3589R 1 1
Heat Exchanger Assembly (Cupronickel)
Bronze 70-3581R 1
NS Heat Exchanger "V" Ba es
70-3584R 1
70-3586R 1
70-3587R 1
70-3576R 1
70-3578R 1
70-3579R 1
70-3588R 1
70-3590R 1
70-3591R 1
70-3580R 1
70-3582R 1
70-3583R 1
03-3997 1
Heat Exchanger "V" Ba e Strap 03-3946 2222
47 Flange Gasket 06-0062 2222
48 Frequency Drive
49 Flame Safeguard, RM7895C 16-0024R 1111
50 Spark Generator 16-0008 1111
51 Air Pressure Switch 11-0419 1111
52 Fan Prove Switch
53 Transformer, 50 VA 15-0007 1111
38
03-3998 1
03-3999 1
03-4000 1
15-0230 1 1
15-0234 1 1
11-0420 1111
11-0419 1111
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
NS High Limit, Jumo, (MB) 14-0013 1111
NS High Limit, Jumo, (MW) 14-0014 1111
NS High Limit, Jumo, (MB) Auto Reset 14-0114 1 1 1
NS High Limit, Jumo, (MW) Auto Reset 14-0115 1 1 1
NS Thermometer Well, 3/8 x 2 13-0102 1222
NS High Limit Well, 3/8 x 3 13-0104 1222
54 Main Board 16-0038 1111
NS Display Board 40-0088 1111
NS Ignition Cable 44-0063 1111
NS Ribbon Cable 40-0115 1111
55 Service Valve Assembly 70-3666 1111
56 250v Transformer 15-0015 1 1
NS Power Switch 48-0013 1111
NS Toggle Switch Remote/Local 48-0014 1111
NS 10K Temperature Sensor 14-0325 3333
NS Purge Timer, ST7800 16-0007 1111
NS Keyboard Display Module, S7800A 16-0010 1111
58 Pilot/Flame Rod Kit 70-3615 1111
58a Electrode 16-0335 2222
58b O'ring 06-0008 1111
58c View Port Assembly 70-2205 1111
58d Mini Peeper, C7027A (not included in 70-3615) 16-0009 1111
NS Turbo Pilot Torch 70-2559 1111
NS UV Ampli er, R7849B 16-0037 1111
59 Control Box Assembly 70-3609 1111
60 Fan Transition Collar 01-0201S 1111
60a Blower O'Ring 06-0004 1111
60b Fan Holddown Plate 04-0596 1111
62 Mini Fan 12-0021 1111
Solenoid Valve w/Regulator, NG 11-0372 1111
64
Solenoid Valve w/Regulator, LP 11-0374 1111
65 Air Shut O Valve 11-0376 1111
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
Pilot Ori ce, .052 NG 10-0140 1111
66
Pilot Ori ce, .040 LP 10-0139 1111
67 Pilot Tube 3/8 62-0102 2222
70 Power Relay 15-0118 1111
71 VFD Contactor 15-0211 1111
Relay Overload (5.5 - 8 Amp) 15-0214 1111
72
Relay Overload (9 - 13 Amp) 15-0215 1111
Relay Overload (2.5 - 4 Amp) 15-0216 1111
Relay Overload (4 - 6 Amp)
Relay Overload (12 - 18 Amp)
Fuse, 3HP, 230V (pump) 48-0627 3
73
Fuse, 5HP, 480V (pump) 48-0637 2 2 3
Fuse, 15A, 600V (VFD) 48-0621 3 3
Fuse, 25Amp, 600V (VFD) 48-0622 2 2
74
Fuse (transformer) 48-0376 2 2
75 Terminal Strip, 8P 48-0154 1111
75a Terminal Strip, 3P 48-0637 1111
76 Power Supply Box 70-3750 1111
Fuse Block, 2P (VFD) 48-0641 1 1
77
Fuse Blcok, 2P (pump/transformer) 48-0643 1111
78 Fuse Block, 3P (pump) 48-0462 2 2
79 Keypad Overlay 82-0189 1111
NS Rating Plate 82-0054 1111
NS Futera XLF Overlay 82-0192 1111
NS Silicone Tubing 06-0051 per foot
15-0217 1111
15-0219 1111
NS Silicone 66-0151 1111
Vent Termination Hood 8" 09-0113 1 1
NS
Vent Termination Hood 10" 09-0115 1 1
Air Intake Hood 8" 09-0103 1 1
NS
Air Intake Hood 10" 09-0104 1 1
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
80 Jacket Rear Front/Left Extension
Jacket Rear Front/Right Extension
81 Jacket Top Plate
82 Jacket Rear Top Panel
83 9" x 4-1/2" Gasket (8 hole) 06-0144 2222
84 Pipe Inlet Adapter
85 7-1/2" x 3-1/2" Gasket (4 hole) 06-0143 6666
70-3777.1 1
70-3777.2 1
70-3777.3 1
70-3777.4 1
70-3776.1 1
70-3776.2 1
70-3776.3 1
70-3776.4 1
03-3186.1 1 1
03-3186.3 1 1
70-3786 1 1
70-3787 1 1
70-3716 1
70-3717 1
70-3754 1 1
86 Pump With Impeller
87 3-Way Valve 13-0210 1111
88 Pipe U-Elbow Assy 70-3752 1111
89 Pipe Rear Back Extension Panel
90 3" Black Flanged Tee 53-2451 1111
91 Pipe Connection Assy
92 8-1/2" x 4" Gasket (8 hole) 06-0145 1111
12-0666 1 1
12-0667 1
12-0665 1
03-3185.1 1
03-3185.2 1
03-3185.3 1
03-3185.4 1
70-3712 1
70-3713 1
70-3714 1
70-3753 1
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REPAIR PARTS CONTINUED
Model Size with Item Quantities Below
Ref # Name of Part Part # 2500 3000 3500 4000
93 Pipe Outlet Adapter
94 Condensation Trap Assy 70-4009 1111
95 Jacket Rear Back/Right Extension
Jacket Rear Back/Left Extension
96 Economizer
97 Left/Right Base Channel 04-1151 2222
98 Channel Insert 70-4134 2222
99 Heat Exchanger Flat Bar
70-3708 1
70-3709 1
70-3751 1 1
70-3779.1 1
70-3779.2 1
70-3779.3 1
70-3779.4 1
70-3778.1 1
70-3778.2 1
70-3778.3 1
70-3778.4 1
12-2005 1 1
12-2004 1 1
04-1161.1 2 2
04-1161.3 2 2
100 Junction Box Bracket 40-1096 1111
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START-UP REPORT
DATE: JOB NAME:
TECHNICIAN: LOCATION:
COMPANY: MODEL:
PHONE NUMBER: SERIAL #:
PRESTARTUP CHECK LIST
❑ NO VISIBLE DAMAGE TO UNIT ❑ INLET AIR FILTER INSTALLED AND CLEAN
❑ PIPING PROPERLY CONNECTED ❑ PROPER SERVICE CLEARANCES PROVIDED
❑ BOILER CIRCULATOR WIRED ❑ PUMP RUNNING, HEAT EXCHANGER FULL
❑ VENT/STACK CONNECTED ❑ GAS LINES PURGED, NO LEAKS, NO MISSING TEST
PLUGS
BOILER STARTUP SEQUENCE
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 manifold in the bottom of the electrical panel.
1. Disable any external call for heat and toggle the remote/local switch to REMOTE.
2. Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition.
3. Set pressure to 3–3.5 in WC ( ame signal should read 5.0 VDC).
4. Release boiler to main ame trial for ignition.
5. Check for stable ame.
6. Record combustion and pressure signal (Ps) at minimum ring rate. (Reference Fusion XLF Boiler IOM.)
7. Jumper the AA terminals to force 100% input.
8. Record combustion and pressure signal (Ps). (Reference Fusion XLF Boiler IOM.)
9. Remove the AA jumper to place the boiler at minimum rate.
10. Check all combustion results using a calibrated ue gas analyzer.
11. Release the LOW FIRE switch to place boiler in standby.
In addition to completing the Futera Fusion XLF start-up report, complete the control set-up information in the rear
of the HeatNetControl manual.
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COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE
GAS PRESSURE AT SUPPLY TEST PORT INCHES WC INCHES WC
CO
2
O
2
CO (PPM) PPM PPM
NET STACK TEMPERATURE
PRESSURE SIGNAL (Ps) INCHES WC INCHES WC
%%
%%
o
F
SAFETY TEST CHECKLIST
❑ FLOW SWITCHES ❑ AIR SWITCH ❑ FLAME SAFEGUARD
❑ LOW WATER CUT-OFF ❑ HIGH LIMITS
Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140oF, 60oC. 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.
COMMISSIONING THE BOILER
❑ UNIT CYCLED MINIMUM OF 15 TIMES
❑ CUSTOMER INSTRUCTED
❑ ALL COVERS REPLACED
❑ CUSTOMER GIVEN MANUAL
❑ TARGET TEMPERATURE SET PER CUSTOMER
COMMISSIONED BY: ______________________________________
(
SIGNATURE)
THE DELTAT BETWEEN THE HEATER IN-
LET AND OUTLET IS CRITICAL TO PROPER
FLOW. BEFORE YOU LEAVE THE JOBSITE,
YOU MUST RECORD THE DELTA T. THIS
READING SHOULD NOT EXCEED 35
o
19.4
C, NOR BE LOWER THAN 20oF, 11.1oC.
DELTA T =
o
F
o
F,
DATE: ____________________________
ADDITIONAL NOTES AND COMMENTS
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Commonwealth of Massachusetts
NOTICE!
Installation Requirements MACODE-3
In the Commonwealth of Massachusetts, the installation
must be performed by a licensed plumber or gas tter.
1. For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in whole
or in part for residential purposes, including those owned or
operated by the commonwealth and where the side wall exhaust
vent termination is less than seven (7) feet above nished grade,
in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satis ed:
d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the
time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gas tter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the oor level
where the gas equipment is to be installed. In addition, the
installing plumber or gas tter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of
the property owner to secure the services of quali ed
licensed professionals for the installation of hard wired
carbon monoxide detectors.
i. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent
oor level.
ii. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be
installed.
e. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034
listed and IAS certi ed.
f. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
g. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed
in accordance with the provisions of 248 CMR 5.08(2)(a)1
through 4.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
2. Exemptions — The following equipment is exempt from
248 CMR 5.08(2)(a) 1 through 4:
a. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
b. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in part
for residential purposes.
3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED.
a. When the manufacturer of Product Approved side wall
horizontally vented gas equipment provides a venting
system design or venting system components with the
equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
i. Detailed instructions for the installation of the venting
system design or the venting system components; and
ii. A complete parts list for the venting system design or
venting system.
4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
a. When the manufacturer of a Product Approved side wall
horizontally vented gas fueled equipment does not provide
the parts for venting the ue gases, but identi es “special
venting systems”, the following requirements shall be
satis ed by the manufacturer:
i. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
ii. The “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
5. A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions,
and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
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LIMITED WARRANTY
Boilers
Industrial, Commercial and Other Non-Residential Use
e “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other
Non-Residential Use Boiler (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation.
Additional twenty one (21) year thermal shock warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to
have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler parts are warranted against defects in material and workmanship for one (1) year
from date of installation or 18 months from date of shipment from RBI.
is limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed,
maintained or operated in accordance with the furnished wri en instructions, or has been altered or modi ed in any way.
ese include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered
under the manufacturer’s warranty.
• Excessive pi ing and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and
is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that
produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.
• All copper n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan
assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation (bypass and valve
arrangement included on the Futera Fusion Series). e manufacturer’s warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts thereof.
(c) to damage as a result of se lement, distortion, collapse, or cracking of any foundation area, beams or pipes surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United States or Canada.
is limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior wri en
approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired
or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED
FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR
ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY
AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE
DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL
RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.
260 North Elm Street 7555 Tranmere Drive
West eld, MA 01085 䡲 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
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Finned copper tube gas boilers – Boiler Manual
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nned copper tube gas boilers – Boiler Manua
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F
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260 North Elm Street 7555 Tranmere Drive
West eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
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