RBI FUTERA II Installation and Operation Instruction

FTII-IOM-8

Finned copper tube Gas boilers (FB) & Water heaters (FW)

82-0253

Boiler manual

Installation and operation instructions

 is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related

instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of

the burner, resulting in possible severe personal injury, death or substantial property damage.  e boiler can only be operated with a dustfree air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

A x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a quali ed

service technician, and to follow all guidelines in the User’s Information Manual.

260 North Elm Street 7555 Tranmere Drive Westﬁ eld, MA 01085 Mississauga, ONT. L5S IL4 Canada Tel: (413) 568-9571 Tel: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782

www.rbiwaterheaters.com

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

CONTENTS

BEFORE YOUR START . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BOILER/WATER HEATER LOCATION . . . . . . . . . . . . . . . 3

COMBUSTION AIR & VENTILATION . . . . . . . . . . . . . . . . . 3

GENERAL VENTING GUIDELINES . . . . . . . . . . . . . . . . . 5

OUTDOOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

COMMON VENT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 14

GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . . . 14

HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . . 16

DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . . . . 20

GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 25

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 25

CHECKING & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . 27

CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 29

DIAGNOSTICSPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

START UP SHEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

MASS CODE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

BEFORE Y OU START

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

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

The Futera II Series finned copper heating boiler/water heaters have been design certified by CSA for use with natural and propane gas under the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas W ater Heaters , ANSI-Z21.13/ CSA 4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired Pool Heaters and CAN1-3.1, Industrial and Commercial Gas Fired Packaged Boilers. Each unit has been constructed and hydrostatically tested for a maximum working pressure of 160 psi, 1103 kPa in accordance with Section IV of the A.S.M.E. Boiler and Pressure Vessel Code.

All aspects of the boiler/water heater installation must conform to the requirements of the authority having jurisdiction, or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision. Where required b y the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1.

In Canada, the installation must be in accordance with the requirements of CSA B149.1 or .2, Installation Code for Gas Burning Appliances and Equipment.

If installed in the Commonwealth of Massachusetts, you MUST FOLLOW the additional instructions located in the back of this manual (MACODE-3).

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

Direct all questions to your RBI distributor or contact the RBI Customer Service Department at:

U.S. — 260 North Elm Street Westﬁ eld, MA 01085

Canada — 7555 Tranmere Drive Mississauga ONT L5S 1L4

Always include the model and serial numbers from the rating plate of the boiler/water heater in question.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

RATINGS & CAPACITIES

Before undertaking the installation of the Futera II Series boiler/water heater check the rating plate to ensure that the unit has been sized properly for the job. The “Net I=B=R Ratings” specify the equivalent amount of direct copper radiation that the unit can supply under normal conditions. Also ensure that the unit has been set up for the type of gas available at the installation site. Other important considerations are the availability of an adequate electrical supply, fresh air for combustion and a suitable chimney or vent system.

BOILER/WATER HEATER LOCATION

1. This boiler/water heater is suitable for indoor and outdoor installations. Locate the boiler/water heater in an area that provides good access to the unit. Servicing may require the removal of jacket panels. Allow the minimum clearances between adjacent construction and the boiler/water heater as listed in Table 1.

NOTE: Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.

Table 1 Clearance to Service Combustibles Clearance in mm in mm

Top 24 610 30 762 Back 14 356 24 610 Left Side 6 153 12 306 Right Side 6 153 12 306 Front 8 203 30 762

2. An optimum site will be level, central to the piping system, close to a chimney or outside wall and have adequate fresh air for combustion. Ensure that the boiler/water heater is level from front to back and from side to side. Use metal shims to level the boiler/water heater. Electrical and electronic components must also be protected from exposure to water during operation and maintenance. DO NOT install this boiler/water heater in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing.

3. Ensure that the ﬂ oor is structurally sound and will support the weight of the boiler/water heater.

NOTE: The Futera II may be installed directly on combustible ﬂ ooring, but never on carpeting.

4. Locate the boiler/water heater in an area that will

prevent water damage to adjacent construction should a leak occur or during routine maintenance. If such a location doesn’t exist, a suitable drain pan that’s adequately drained must be installed under the unit.

5. DO NOT place this boiler/water heater in a location that

would restrict the introduction of combustion air into the unit or subject it to a negative pressure, see “GENERAL VENTING GUIDELINES”.

6. NEVER place this boiler/water heater in a location that would subject it to temperatures at or near freezing. See the “Freeze Protection” section on page 15.

CAUTION: Units installed outdoors MUST be protected from ice and snow accumulation or the unit will be damaged voiding the warranty!

WARNING: Never store combustible materials, gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler/water heater. Failure to comply with this warning can result in an explosion or fire causing extensive property damage, severe personal injury or death!

COMBUSTION AIR & VENTILATION

WARNING: This boiler/water heater must be supplied with combustion air in accordance with Section 5.3, Air for Comb ustion & Ventilation, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and all applicable local building codes. Canadian installations must comply with CAN/ CGA B149.1 or .2 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes. Failure to provide adequate combustion air for this boiler/ water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

To operate properly and safely this boiler/water heater requires a continuous supply of air for combustion. NEVER store objects on or around the boiler/water heater!

CAUTION: Combustion air contaminated with ﬂ uorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber. These acids will cause premature failure of the boiler/water heater voiding the warranty!

CAUTION: If the boiler/water heater is operated while the building is under construction it MUST be protected from wood, concrete, sheet rock and other types of dust. Failure to properly protect the unit from construction dust will damage the unit voiding the warranty!

Buildings will require the installation of a fresh air duct or other means of providing make-up air if the intake air option isn’t used. Any building utilizing other gas burning appliances, a ﬁ replace, wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time. Sizing of an outside air duct must be done to meet the requirements of all such devices.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

WARNING: Never operate the Futera II in an environment subjected to a negative pressure unless it is Direct Vented. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!

All Air From Inside The Building

If the Futera II is to be located in a conﬁ ned space, the minimum clearances listed in Table 1 must be maintained between it and any combustible construction. When installed in a confined space without the intake air option, Figures 7, 8 and 9, two permanent openings communicating with an additional room(s) are required. The combined volume of these spaces must have sufﬁ cient volume to meet the criteria for an unconﬁ ned space. The total air requirements of all gas utilization equipment, ﬁ replaces, wood stoves or any type of exhaust fan must be considered when making this determination. Each opening must have a minimum free area of 1 in hr, 2200 mm gas utilization equipment in the confined area. Each opening must be no less than 100 in

/kW based on the total input rating of ALL

, 64,516 mm2 in size. The upper opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the top of the enclosure. The bottom opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the bottom of the enclosure.

All Air From Outside The Building When installed in a conﬁ ned space without utilizing the intake air option two permanent openings communicating directly with, or by ducts to, the outdoors or spaces that freely communicate with the outdoors must be present. The upper opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the top of the enclosure. The bottom opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the bottom of the enclosure.

Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of

/4000 Btu/hr, 550 mm2/kW of the total input rating

1 in

of all of the equipment in the enclosure. Where communicating with the outdoors through horizontal

ducts, each opening shall have a minimum free area of

/2000 Btu/hr, 1100 mm2/kW of the total input rating

1 in

of all of the equipment in the enclosure. When ducts are used, they must have the same cross-

sectional area as the free area of the opening to which they connect.

When calculating the free area necessary to meet the make-up air requirements of the enclosure, consideration must be given to the blockage effects of louvers, grills and screens. Screens must have a minimum mesh size of 1/4 in, 6.4 mm. If the free area through a louver or grill is not known, ducts should be sized per Table 2.

/1000 Btu/

Table 2 – Make-up Air Louver Sizing

Required Cross Sectional Area Input 1/4 in 6.4 mm (MBH) Wire Screen Metal Louvers Wooden Louvers in

75% Free Area 25% Free Area

500 125 806 167 1077 500 3226 750 187 1206 250 1613 750 4839 1000 250 1613 333 2148 1000 6452 1250 313 2019 416 2684 1250 8065 1500 375 2419 500 3226 1500 9677 1750 437 2819 583 3761 1750 11,290 1950 486 3135 649 4187 1950 12,580

Canadian installations must comply with CSA B149.1 when air supply is provided by natural air ﬂ ow from the outdoors for natural draft, partial fan-assisted, fan-assisted, or power draft-assisted burners, there shall be a permanent air supply opening(s) having a cross-sectional area of not less than 1 in and including 1 million Btuh, plus 1 in

(155 mm

per 7,000 Btuh (310 mm2 per kW) up to

per kW) in excess of 1 million Btuh.

per 14,000 Btuh

Intake Air Option – General Guidelines

This conﬁ guration provides combustion air directly to the boiler/water heater’s air intake using a dedicated pipe when using the direct vent option. The RBI air intake adapter must be ﬁ tted to the blower inlet. Combustion air can be drawn in horizontally through the same outside wall which terminates the exhaust gases or vertically through the roof, see Figures 2, 3, 4, 5 & 6.

WARNING: Common intake air systems may be used provided the common duct is sized properly and an intake combustion air damper is installed in the intake air pipe of each heater. Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

All joints in metal intake air systems must be secured using corrosion resistant fasteners and sealed using a suitable Silicone caulk. If PVC or CPVC is used, the joints must be cleaned with a suitable solvent and connected using a solvent based PVC cement. The combustion air system

MUST be supported by the building structure not the boiler/water heater.

CAUTION: A combustion air damper interlocked with the unit should be installed in the intake air pipe when the inﬁ ltration of subfreezing air could occur, otherwise the unit could freeze up voiding the warranty!

Intake Air Option – Vertical Guidelines

The maximum equivalent length for the vertical intake air pipe is 60 ft, 18.3 m. Each 90˚ elbow and the intake air terminal are equal to 10 linear ft, 3.1 m of pipe.

An approved, nonrestrictive intake air terminal must be used. The intake air terminal must terminate as shown in Figure 5. The penetration point in the roof must be properly ﬂ ashed and sealed.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Intake Air Option – Horizontal Guidelines

The maximum equivalent length for the horizontal combustion air pipe on installations that used the Direct V ent option is 60 ft, 18.3 m. The maximum equivalent length for the horizontal combustion air pipe on installations that use the Horizontal Pow er V ent option is 100 ft, 30.5 m. Each 90° elbow and the combustion air terminal are equal to 10 linear ft, 3.1 m of pipe. If horizontal runs exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m intervals with ov erhead hangers. The certiﬁ ed combustion air terminal from RBI must be used and installed as shown in Figures 3 and 4.

GENERAL VENTING GUIDELINES

WARNING: The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54latest revision or applicable provisions of the local building codes. Canadian installations must comply with CAN/CGA B149.1 or .2 Installation Code. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

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

VENT SYSTEM OPTIONS

The Futera II may be vented the following ways:

1) Direct Vent, Positive Pressure, Category III uses a

vent system certiﬁ ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. Combustion air is piped from the outdoors to the blower inlet.

2) Side Wall Vent, P ositive Pressure, Category III uses

a vent system certiﬁ ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.

3) Horizontal Vent, Negative Pressure, Category I

for horizontal vent runs equivalent to more than 60 ft, 18.3 m (90 degree elbow = 10 equivalent feet), a dedicated wall mounted power venter must be used. The vent system can be single wall galvaniz ed steel or type B vent pipe. Combustion air is obtained from the space in which the unit is installed or from the outdoors.

A barometric damper must be installed when the horzontal run is longer than 60 equivalent feet (90 degree elbow = 10 equivalent f eet). If this is the case, a power venter must also be used.

WARNING: Common vent systems must be properly engineered and sized to provide a negative draft of 0.01 to 0.08 in, 0.25 to 2.0 mm W .C. at the ﬂ ue outlet. Common positive pressure vent systems are not to be used. Improper installation can result in excessive levels of carbon monoxide, which can cause severe personal injury or death!

NOTE: A single acting barometric damper must be installed directly to the boiler/water heater ﬂ ue outlet, if required. This does not apply to outdoor units or direct vent positive pressure units.

NOTE: Some venting applications may require the stop to be removed for smooth operation. The barometric damper should be located after the ﬂ ue collector, refer to Figures 2, 7A and 8 for proper location. Be sure that the damper is mounted horizontally (never vertically). Carefully follow the instructions provided with the barometric damper.

In Canada, B149 (7.25 Draft Regulators) states the damper shall be of double-acting type.

WARNING: To avoid spillage into the room of dangerous ﬂ ue gas containing carbon monoxide, the opening in damper must never face against the ﬂ ow of ﬂ ue gas.

If horizontal run is less than 60 equivalent feet, do not use a barometric damper. Follow applicab le instructions under the “DIRECT VENT, POSITIVE PRESSURE” section, page 6.

4) Vertical/Chimney Vent, Negative Pressure,

Category I uses an approved metal chimney system or masonry chimney. Combustion air is obtained from the space in which the unit is installed. A barometric damper must be installed near the ﬂ ue outlet when venting vertically.

5) Outdoor Installation uses the outdoor option kit.

Barometric damper is not required.

NOTE: All venting, combustion air material supplied by installer.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

DIRECT VENT , POSITIVE PRESSURE, CATEGORY III

In this conﬁ guration the boiler/water heater blower is used to push the ﬂ ue products to the outdoors while drawing combustion air from the outdoors. The equivalent length of the vent system must not exceed 60 ft., 18.3 m. The Intake Air Option instructions under the “COMBUSTION AIR & VENTILATION” section must be followed! The vent system must be sized per Figure 2, Outlet Sizes.

Horizontal Direct Vent Systems – Figures 3 & 4 The vent materials used in horizontal vent systems must be certiﬁ ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certiﬁ ed vent terminal from RBI must also be used.

The maximum equivalent length for the horizontal vent pipe is 60 ft, 18.3 m. Each 90˚ elbow and the vent terminal are equal to 10 linear ft, 3.1 m of pipe. If any part of a single wall metal vent system passes through an unheated space, it must be insulated with insulation rated for 400°F, 204°C. Structural penetrations m ust be made using approved fire-stops. For best results, horizontal vent systems should be as short and straight as possible.

The vent system must be both gas tight and watertight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.

When horizontal vent runs exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m intervals with overhead hangers. The vent system must be pitched down, toward the vent terminal, 1/4 in/ft, 20 mm/m. If an y part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400˚F, 204°C.

Horizontal vent systems shall terminate at least 4 ft,

1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,

0.30 m above any door, window or gravity air inlet into

any building. It must not terminate less than 4 ft, 1.2 m horizontally from, and in no case above or below, unless a 4 ft, 1.2 m horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment and not less than 7 ft, 2.1 m from any adjacent public walkway. The bottom of the vent terminal(s) shall be located at least 5 ft, 1.5 m above the air intake terminal(s) unless there is a minimum 5 ft, 1.5 m horizontal separation between them. Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the ﬂ ue gases.

Vertical Direct Vent Systems – Figure 5

The maximum equivalent length for the vertical pipe is 60 ft, 18.3 m. Each 90˚ elbow and the vent terminal are equal to 10 linear ft, 3.1 m of pipe. If any part of a single wall metal vent system passes through an unheated space, it must be insulated with insulation rated for 400˚F, 204°C. Structural penetrations must be made using approved ﬁ restops.

An approved nonrestrictive intake air teminal must be used. The top of a vertical vent system must extend at least

/2 ft, 1.7 m above the roof surface and maximum snow

line that it passes through, 4 ft, 1.2 m above the intake air terminal, see Figure 5.

In addition the vent system must conform to the dimensions shown in Figure 5. The penetration point in the roof must be properly ﬂ ashed and sealed.

The vent system must be gas tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.

Combination Direct Vent Systems – Figure 6

The boiler/water heater can be vented vertically with the intake air piped horizontally through an outside wall. Follow the instructions in the Intake Air Option – Horizontal Guidelines on page 5. Also follow the general instructions in the “COMBUSTION AIR & VENTILATION” and “GENERAL VENTING GUIDELINES” sections.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 1 - Air Intake Vertical or Thru Wall

Figure 2 - Venting Thru Wall/Vertical

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 3 – Horizontal Air Intake and Venting for a Single Direct Vent System

WARNING: When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall) in order to prevent pressure differences due to prevailing winds. In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.

Figure 4 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

10 FT 3.1 m

4 FT

1.2 m

5 FT

1.5 m

1.5 FT

0.5 m

5 1/2 FT

1.7 m

Figure 5 - Vertical Air Intake and Venting for Direct Vent System

Figure 6 – Combination Direct Vent Systems

3 FT. 1 m

1.5 FT. .5 m

10 FT. 3.1 m

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

SIDE W ALL VENT , POSITIVE PRESSURE, CATEGORY III

In this conﬁ guration the boiler/water heater blower is used to push the ﬂ ue products horizontally to the outdoors, see Figure 7. The air for combustion is taken from the space in which the unit is installed. The applicable instructions under the “COMBUSTION AIR & VENTILATION” section must be followed! The vent guidelines under the Horizontal Direct Vent Systems section must also be followed.

HORIZONT AL VENT , NEGATIVE PRESSURE, CATEGORY I

In this conﬁ guration a wall-mounted power venter must be used to pull the ﬂ ue products horizontally from the unit and vent them to the outdoors, see Figures 3, 4 & 7A. The air for combustion is taken from the space in which the unit is installed, or from the outdoors. The applicable instructions under the “COMBUSTION AIR & VENTILATION” section must be followed!

To maximize the performance of single wall sheet metal vent systems locate 90˚ elbows as far from the boiler as possible and from one another. For best results, horizontal vent systems should be as short and straight as possible.

When horizontal vent runs exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m inter vals with overhead hangers. The vent system must be pitched down, toward the vent terminal, 1/4 in/ft, 21 mm/m. If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400˚F, 204˚C.

Horizontal vent systems shall terminate at least 4 ft,

1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,

0.30 m above any door, window or gravity air inlet

into any building. It must not terminate less than 4 ft, 1.2 m horizontally from, and in no case above or below, unless a 4 ft, 1.2 m horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment and not less than 7 ft, 2.1 m from any adjacent public walkway.The bottom of the vent terminal(s) shall be located at least 5 ft, 1.5 m above the air intake terminal(s) unless there is a minimum 5 ft,

1.5 m horizontal separation between them. Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the ﬂ ue gases.

To determine the appropriate power venter for the boiler/water heater, see Table 3. Follow the power venter manufacturer’s installation instructions.

Table 3 - Power Venter Sizes Futera II Power Venter Max. Pipe Length

Model Model FT m

500 - 750 HS-3 100 31 1000-1250 HS-4 100 31 1500-1950 HS-5 100 31

VERTICAL/CHIMNEY VENT , NEGATIVE PRESSURE, CATEGORY I

The Futera II is listed as a Category I appliance when vented vertically into a listed metal chimney system or properly sized masonry chimney, Figures 8 & 9. The chimney must provide a negative pressure of 0.01 to 0.08 in, 0.25 to 2.0 mm W.C . at the boiler/water heater ﬂ ue collar with the unit running. A barometric damper must be attached directly to the ﬂ ue collar increaser as shown.

Multiple Futera II’s can be vented into a single vertical chimney provided that the breeching and chimney are properly sized per the latest revision of the National Fuel Gas Code, ANSI Z223.1.

When more than one appliance is connected to the same chimney ﬂ ue, the ﬂ ue must be large enough to safely vent the combined output of all of the appliances.

WARNING: If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney ﬂ ue, never connect any other appliances to this ﬂ ue. Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

Chimney Inspection & Sizing

A thorough inspection of the masonry chimney must be performed to ensure that the chimney is clean, properly constructed and properly sized. Exterior masonry chimneys should not be used unless properly lined to prevent condensation and draft problems. Table 3A lists the equivalent breeching and ﬂ ue sizes required for the boiler/ water heater.

Table 3A - Equivalent Breeching & Chimney Size, Negative Pressure

Model Size Pipe Diameter in mm 500 8 203 750, 1000 10 254 1250, 1500 12 305 1750, 1950 14 356

Note: These sizes are based on a 20 ft, 6.1m chimney height.

Vent Connections

Locate the boiler/water heater as close to the chimney as possible. Use the shortest, straightest vent connector possible for the installation. If horizontal runs exceed 5 ft,

1.5 m they must be supported at 3 ft, 0.9 m intervals with overhead hangers. Use a type B, single wall stainless or single wall galvanized steel vent pipe the same diameter as the ﬂ ue collar to connect the boiler/water heater to a masonry chimney, see Figure 2. When using a listed metal chimney system use the appropriate vent connector.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

The vent connector should be sloped up toward the chimney at a minimum rate of 1/4 in/ft, 21 mm/m. O n masonry chimneys the connector must terminate ﬂ ush with the inside of the chimney ﬂ ue, Figure 9. Fasten each single wall vent connection with at least 3 corrosion resistant sheet metal screws.

Always provide a minimum clearance of 6 in, 152 mm between single wall vent pipe and any combustible materials. Type B1 vent may be used, clearance between it and any combustible material must be as listed.

Figure 7 – Side Wall Venting, Positive Pressure

4 FT

1.2 m

3 FT

0.9 m

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

1/4 IN. PER F00T 20 mm/m

24"

0.6 m

1.5 FT 0.5 m

Figure 7A – Power Venting, Negative Pressure

1.5 FT 0.5 m

4 FT

1.2 m

3 FT

0.9 m

7 FT

2.1 m

0.6 m

1/4 IN. PER F00T 20 mm/m

24"

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 8 – Vertical Venting with a Metal Chimney System

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

24"

.6 m

Figure 9 – Vertical Venting using a Masonry Chimney

OUTDOOR VENTING

When installed outdoors the Futera II must be ﬁ tted with the factory supplied outdoor hood, air intake adapter with ﬁ lter. Horizontal discharge tee supplied by others, see Figure 10. Multiple units must be spaced per Figure 11 to prevent ﬂ ue gases from being ingested by adjacent units.

The boiler/water heater must be at least 10 ft, 3.1 m from any door, window or gravity air inlet into any building and at least 3 ft, 0.9 m from any overhang unless local codes dictate differently.

Figure 10 – Outdoor Venting

Avoid locations where wind deflection off of adjacent walls, buildings or shrubbery might cause a downdraft. The unit(s) should be located at least 3 ft, 0.9 m from structures. Outdoor installations are not recommended in areas where the danger of snow blockage exists.

CAUTION: Do not place the boiler/water heater in a location that would subject it to runoff from adjacent buildings or damage may occur voiding the warranty!

Figure 11 – Multiple Outdoor Units

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

COMMON VENT SYSTEMS

If an existing boiler/water heater is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it. At the time of removal of an existing boiler/water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation

Seal any unused openings in the common venting system

a) Sceller toutes les ouvertures non utilisées du sys-

tème d’évacuation. b) Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

Inspecter de façon visuelle le système d’évacu-ation pour déterminer la grosser et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement de fruite, de corrosion et autres défaillances qui pourraient présenter des risques.

c) Insofar as is practical, close all building doors and

windows and all doors between the space in which the

appliances remaining connected to the common venting

system are located and other spaces of the building. Turn

on clothes dryers and any appliance not connected to the

common venting system. Turn on any exhaust fans, such

as range hoods and bathroom exhaust, so they will operate

at maximum speed. Do not operate a summer exhaust

fan for a boiler installation. Close ﬁ replace dampers. Dans la mesure du possible, fermer toutes les portes

et les fenêtres du bâtiment et toutes les portes entre

l’espace où les appareils toujours raccordés du système

d’évacuation sont installés et les autres espaces du

bâtiment. Mettre en marche les sécheuses, tous les

appareils non raccordés au système d’évacuation

commun et tous les ventilateurs d’extr action comme les

hottes de cuisinère et les ventilateurs des salles de bain.

S’assurer queces ventilateurs fonctionnent à la vitesse

maximale. Ne pas faire fonctionner les ventilateurs

d’été. Fermer les registres des cheminées. d) Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

Mettre l’appareil inspecté en marche. Suivre les

instructions d’allumage. Régler le thermostat de façon

que l’appareil fonctionne de façon continue.

e) Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the ﬂ ame of a match or candle, or smoke from a cigarette, cigar or pipe.

Faire fonctionner le brûleur principal pendant 5 min

ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la flamme d’une allunette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

h) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gas-burning appliance to their previous condition of use.

Une fois qu’il a été d éterminé, selon la métode

indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façor adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

g) Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and or CAN/CGA B149 Installation Codes.

Tout mauvais fonctionnement du systéme d’évacu-tion commun devrait étré corrigé de façor que l’installation soit conforme au National Fue Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/ CGA-B149. Si la grosseur d’une section du système d’ évacuation doit étré modiﬁ ée, le système devrait étré modifié pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/ NFPA 54 et (ou) des codes d’installation CAN/CGA-B149.

GENERAL PIPING REQUIREMENTS

CAUTION: Improper piping of this boiler/water heater will void the manufacturer’s warranty and can cause boiler failure resulting in flooding and extensive property damage! Excessive water hardness causing scaling in the copper heat exchanger tubes is NOT covered under the manufacturer’ s warranty. Excessive pitting and erosion of the internal surface of the copper heat exchanger tubes is NOT covered under the manufacturer’s warranty if the result of high water ﬂ ow rates, see Table 5. Return water temperatures below 125˚F, 52°C will result in heat exchanger damage from excessive condensation voiding the manufacturer’s warranty , see Primary / Secondary Piping, Figure 13.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

NOTE: Shut off valves and unions should be installed at the inlet and outlet connections of the boiler/hot water heater to provide for isolation of the unit should servicing be necessary.

Freeze Protection

This boiler/water heater is CSA designed certiﬁ ed for outdoor installation. Outdoor installations in areas where the danger of freezing exists are not recommended unless proper freeze protection is provided. The following precautions MUST be observed:

1. A continuous ﬂ ow of water through the unit MUST be maintained! The pump responsible for ﬂ ow through the boiler/water heater must run continuously!

2. An ethylene glycol/water mixture suitable for the

minimum temperature that the unit will be exposed to must be used. The pump must be capable of producing a minimum of 15% more ﬂ ow and overcoming a 20% increase in head loss. Domestic water systems must be isolated from the water heater by the use of a heat exchanger or other approved method.

3. If the unit must be shut off for any reason the electric, gas and water supplies MUST be shut off and the unit and its pump completely drained.

CAUTION: Improper outdoor installation of this unit can cause boiler failure voiding the manufacturer’s warranty!

Relief Valve

Pipe the discharge of the pressure relief valve as shown in Figure 12.

WARNING: Never install any type of valve between the boiler/water heater and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

Flow Switch

The ﬂ ow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent the boiler from ﬁ ring unless there’s adequate water ﬂ ow through the unit. The ﬂ ow switch must be installed in the supply piping adjacent to the boiler outlet connection.

CAUTION: Failure to properly install the ﬂ ow switch may result in damage to the boiler/water heater heat exchanger voiding the warranty!

Figure 12 – Futera II Piping

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualiﬁ ed technician in accordance with the latest revision of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1, Standard for Controls and Safety Devices for Automatically Fired Boilers. All applicable local codes and ordinances must also be followed. A minimum clearance of 1 in, 25 mm must be maintained between heating system pipes and all combustible construction. All heating system piping must be supported by suitable hangers not the boiler. The thermal expansion of the system must be considered when supporting the system. A minimum system pressure of 12 psig, 82.7 kPa must be maintained.

Heating Boiler Piping Connections

The supply and return connections should be sized to suit the system, see Table 4.

Table 4 – Supply & Return Pipe Sizing

Model Size Supply Size Return Size 500 thru 1000 2" NPT 2" NPT 1250 thru 1950 2 1/2" NPT 2 1/2" NPT

Pump Requirements

This low mass boiler requires a continuous minimum water ﬂ ow for proper operation. The system pump must be sized to overcome the head loss of the boiler and the heating system in order to achieve the required temperature rise. Table 5 provides the heat exchanger pressure drop and temperature rise ﬁ gures. The temperature rise across the boiler must never exceed 35°F, 19.4°C. The adjustable pump delay turns the pump on each time the burner ﬁ res and runs the pump for 6 to 600 seconds after the call for heat is satisﬁ ed.

Table 5 - Temperature Rise Table

ΔT = 20°F ΔT = 11.1°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop Number GPM Ft L/s kPa 500 42.5 0.53 2.7 1.5 750 63.8 1.57 4.0 4.6 1000 85.0 3.44 5.4 10.1 1250 106.3 2.11 6.7 6.2 1500 127.5 3.57 8.1 10.5

ΔT = 25°F ΔT = 13.9°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop Number GPM Ft L/s kPa 500 34.0 0.35 2.1 1.0 750 51.0 1.04 3.2 3.1 1000 68.0 2.27 4.3 6.7 1250 85.0 1.40 5.4 4.1 1500 102.0 2.36 6.4 7.0 1750 119.0 3.67 7.5 10.8 1950 132.6 5.14 8.4 15.1

ΔT = 30°F ΔT = 16.7°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop Number GPM Ft L/s kPa 750 42.5 0.70 2.7 2.2 1000 56.7 1.60 3.6 4.8 1250 70.8 1.00 4.5 2.9 1500 85.0 1.70 5.4 5.0 1750 99.2 2.60 6.3 7.7 1950 110.5 3.70 7.0 10.8

ΔT = 35°F ΔT = 19.4°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop Number GPM Ft L/s kPa 750 36.4 0.60 2.3 1.6 1000 48.6 1.20 3.1 3.6 1250 60.7 0.70 3.8 2.2 1500 72.9 1.30 4.6 3.7 1750 85.0 2.00 5.4 5.8 1950 94.7 2.80 6.0 8.1

CAUTION: A temperature rise outside of the range listed in Table 5 indicates that the ﬂ ow rate through the heat exchanger is incorrect which will damage the heat exchanger voiding the warranty! The maximum allowable temperature rise is 35°F, 19.4°C.

The maximum allowable ﬂ ow rate through a Futera II boiler is 97 GPM, 6.1 L/s on 500 through 1000 models and 136 GPM, 8.6 L/s for 1250 through 1950 models. The Cupro-Nickel heat exchanger allows for 108 GPM,

6.8 L/s on 500 through 1000 models and 151 GPM,

9.5 L/s on 1250 through 1950 models.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Low Water Cutoff

If a boiler is installed above any radiation elements it must be ﬁ tted with a low water cutoff device.

Refer to the wiring diagram supplied with the boiler/water heater for proper wiring connections.

Expansion Tank & Air Separator An expansion tank or other means to control thermal expansion must be installed in the heating system. An expansion tank must be installed close to the boiler on the suction side of the pump. An air scoop and automatic air vent must also be installed to eliminate air trapped in the system.

Primary/Secondary Piping Boilers connected to heating systems using zone valves, zone pumps, or systems that have excessive ﬂ ow rates or return water temperatures less than 125˚F, 52˚C must be isolated from these systems to protect the boiler.

Variable W ater Flows Figure 13 shows a typical primary/secondary piping system. A dedicated pump is used to maintain a constant water ﬂ ow through the boiler . This secondary pump is sized to overcome the head loss of the boiler and secondary piping system while supplying the ﬂ ow rate required to maintain the desired temperature rise across the boiler. The primary pump is sized to provide the required ﬂ ow to the heating system. The secondary piping connections to the primary system piping must not be more than 12 in, 305 mm apart to ensure zero pressure drop in the primary system, see Figure 13.

Low Return Water Temperatures To prevent the problems associated with condensation of the products of combustion due to low return water temperatures a primary/secondary piping system with a bypass and bypass valve must be installed, see Figure 14. The bypass and bypass valve must be sized the same as the secondary piping. A balancing valve must also be installed in the supply side of the secondary piping downstream of the bypass. The balancing valve should be adjusted to divert some of the heated discharge water into the return water until the required inlet water temperature is achieved. The primary and secondary pumps should be sized to provide the required ﬂ ow through each system. The secondary piping connections to the primary system piping must not be more than 12 in, 305 mm apart to ensure zero pressure drop in the primary system, see Figure 14.

Multiple Boiler Systems

Systems using multiple boilers can also be installed using a primary/secondary manifold system, Figure 15.

Piping For Use With Cooling Units

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

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

Operated Valve

Air Vent

Pressure Switch

Aquastat Union

Gas Pressure

Regulator

Automatic

Thermometer

Flow Switch

Pressure

Relief Valve

Reducing Valve

Self-Operated

Check Valve

Pressure

Val ve

Pump

Motorized Valve

Solenoid

Ball Valve

Bufferfly Valve

Angle Valve

Gate Valve

Globe Valve

Balance Valve

BackflowPrevention

Device

3-Way Valve

Expansion

Tan k

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 13 - Typical Boiler Primary/Secondary Piping System

(See Notes)

NOTES:

1. Boiler circuit piping must be sized

large enough to handle maximum ﬂ ow through unit.

2. Boiler pump sized to boiler design ﬂ ow

requirements.

3. All boilers furnished with factory

mounted outlet water temperature gauge.

4. Boiler pump purging required. Use

terminals supplied.

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

H-1 Rev 3

Figure 14 - Low Temperature Piping with Thermostatic Valve

(See Notes and Adjustment Procedures)

H-18 Rev 2

NOTES:

1. For pump selection consult factory.

2. Boiler pump sized to boiler and thermostatic 3-way valve design ﬂ ow requirements.

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

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

5. Boiler pump purging required. Use terminals supplied.

6. Valve is precalibrated for 140°F return temperature. Notice: These drawings show suggested piping conﬁ guration and valving.

Check with local codes and ordinances for speciﬁ c requirements.

Operated Valve

Air Vent

Pressure Switch

Aquastat Union

Gas Pressure

Regulator

Automatic

Thermometer

Flow Switch

Pressure

Relief Valve

Reducing Valve

Self-Operated

Check Valve

Pressure

Val ve

Pump

Motorized Valve

Solenoid

Ball Valve

Bufferfly Valve

Angle Valve

Gate Valve

Globe Valve

Balance Valve

BackflowPrevention

Device

3-Way Valve

Expansion

Tan k

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 14A - Low Temperature Boiler Piping

(See Notes and Adjustment Procedures)

Adjustment Procedure

To Maintain Inlet Temperature

Above Dew Point

T1-Temp-Min+110° For Atmospheric

T1-Temp-Min=125° Sealed Combusion

1. Turn heater on and open valves A & B.

2. After steady-state operation, if T1 is less than Temp-Min slowly close valve B until T1 climbs to desired operating temperature above Temp-Min.

3. If T1 is greater than desired operating temperature, slowly close valve A to adjust to lower desired temperature above Temp-Min.

4. Check after system operating temperature has stabiized. Make ﬁ nal adjustments.

5. Follow same adjustment procedure for sealed combustion.

NOTES:

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

2. Boiler pump sized to boiler design ﬂ ow requirements.

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

4. Boiler pump purging required. Use terminals supplied.

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

H-3 Rev 5

Figure 15 - Multiple Boiler Piping (See Notes)

H-15 Rev 4

NOTES:

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

2. Boiler pump sized to boiler design ﬂ ow requirements.

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

4. Boiler pump purging required. Use terminals supplied.

5. Secondary loop pipe diameter must be sized large enough to handle maximum ﬂ ow through all units. Notice: These drawings show suggested piping conﬁ guration and valving.

Check with local codes and ordinances for speciﬁ c requirements.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

DOMESTIC WATER SUPPLY PIPING

CAUTION: Proper controls must be used to prevent water supplied for domestic use from exceeding 130˚F, 54˚C or a scald injury will occur! When higher water temperatures are required for appliances such as a dishwasher, a mixing valve or some other tempering means must be installed. Households with small children may require water temperatures less than 120˚F, 49˚C. Local codes must be complied with!

General Piping Requirements

Ensure that the water heater is equipped with bronze headers. Piping and components connected to the water heater must be suitable for use with potable water. The water heater must not be connected to any heating system piping or components previously used with a non-potable water heating appliance. No toxic chemicals, such as those used for boiler treatment, are to be introduced into the potable water used for space heating. If a hot water storage tank is used in the system it must be equipped with a temperature and pressure relief valve that complies with ANSI Z21.22 or CAN-4.4 and CAN-4.6.

NOTE: The storage tank must be located as close to the water heater as possible to prevent excessive head loss which will reduce ﬂ ow.

A cupro-nickel heat exchanger may also be required. The manufacturer should be consulted when these water conditions are encountered. See Table 5A.

CAUTION: Futera II water heater is 97 GPM, 6.1 L/s on 500 through 1000 models and 136 GPM, 8.6 L/s for 1250 thr ough 1950 models. The Cupro-Nickel heat exchanger allows for 108 GPM, 6.8 L/s on 500 through 1000 models and 151 GPM, 9.5 L/s on 1250 through 1950 models. See Table 5B.

RBI water heaters are designed to run scale free. Due to the extreme variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling. It is crucial to consider these two variables when making heat exchanger and pump selection. If local water conditions are extreme, follow the guidelines in the Heat Exchanger Selection Table (Table 5A) and the Pumping Performance Table (Table 5B). Scale free operation can be achieved by using water with a hardness between 8 and 18 and by maintaining the pH between 5 and 9. Follow the conditions listed under NORMAL in the table. In some areas of the country additional precautions must be observed due to unusual characteristics of the local water supply. Call the nearest RBI representative for details.

The maximum allowable ﬂ ow rate through a

Water Chemistry

The required temperature rise across the water heater is based on water having a hardness between 8 and 18 grains per gallon with a level of dissolved solids not exceeding 350 ppm. Water having a hardness less than 8 grains can cause excessive corrosion of the heat exchanger. Water that has a hardness greater than 18 grains per gallon and/or a level of dissolved solids exceeding 350 ppm will require a recalculation of the pump size and temperature rise.

To properly size the pump a grain hardness and pH test must be taken at the installation site before order is placed. Proper pump sizing will improve heater performance and help ensure heater longevity.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

T able 5A - Futera II Heat Exchanger Selection Graph

T able 5B - Futera II Pumping Performance Requirement

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Expansion T ank

An expansion tank or other means to control thermal expansion must be installed in the water heating system if back ﬂ ow prevention devices are installed.

Pump Requirements This low-mass water heater requires a continuous minimum water ﬂ ow for proper operation. The low water ﬂ ow switch provided for this unit will shut down the water heater if ﬂ ow falls below the required minimum level. Table 5Bprovides the heat exchanger pressure drop chart and temperature rise table. The temperature rise across the

water heater must never exceed 35°F, 19.4°C. Cold Water Supply

The cold water supply must be piped to the water heater’s outlet piping between the water heater and the hot water storage tank. This will prevent untempered water from entering the water heater, see the Temperature Rise Control section below. Two typical water heating systems are shown in Figures 16 & 17.

Temperature Rise Control Water returned to the water heater inlet must not be less than 125˚F, 52˚C or excessive condensation of the products of combustion will damage the water heater voiding the warranty. The method outlined below can be employed to prevent this condition from occurring.

A balancing valve should be installed on the outlet side of the water heater for purposes of adjusting the ﬂ ow rate through the heat exchanger. Thermometers are installed on both the inlet and outlet of the water heater for determining the temperature rise through the unit.

The proper velocity through the water heater must be maintained in accordance with Table 5B for efficient operation and long life. If the temperature rise through the water heater is lower than recommended the water velocity is too high. Premature erosion of the heat exchanger will occur. Conversely, if the temperature rise is higher than recommended in Table 5B the ﬂ ow rate is too low. Scaling and softening of the heat exchanger will occur.

Thermostatic Mixing Valve – Water Above 140˚F, 60˚C Water can be stored at temperatures above 140˚F, 60˚C provided that a thermostatically controlled mixing valve is used to temper the hot water to an acceptable temperature before it’s supplied for domestic use.

The mixing valve MUST be set to prevent a scald injury from occurring, see the caution against scalding.

Storage of water for domestic use above 140°F, 60°C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria.

Operated Valve

Air Vent

Pressure Switch

Aquastat Union

Gas Pressure

Regulator

Automatic

Thermometer

Flow Switch

Pressure

Relief Valve

Reducing Valve

Self-Operated

Check Valve

Pressure

Valve

Pump

Motorized Valve

Solenoid

Ball Valve

Bufferfly Valve

Angle Valve

Valve

Globe Valve

Balance Valve

Vacuum

Relief Valve

Temperature &

Pressure

Relief Valve

Drain Valve

(Typ.)

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 16 - Typical Water Heating Piping (FW Models Only)

(See Notes)

Attention:

Not all RBI stock storage tanks

incorporate this tapping: See Note 1.

Figure 17 - Multiple Water Heating Piping (FW Models Only)

(See Notes)

SELF BALANCIN G DOUBLE REVERSE RETURN MAKE-UP & SUPPLY, CIRCULATION

D-1 Rev 6

D-4 Rev 6

Attention:

Not all RBI stock storage tanks

incorporate this tapping: See Note 1.

NOTES:

1. Optional cold water make up and recirculation line location.

2. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.

3. Thermal expansion tank may be required, check local codes.

4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.

5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE. The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and

Pumping Performance Table before making selection.

6. Common piping must be sized for maximum combined heater ﬂ ow.

7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.

8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion. Notice: These drawings show suggested piping conﬁ guration and valving.

Check with local codes and ordinances for speciﬁ c requirements.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

GAS SUPPLY PIPING

WARNING: Check the boiler/water heater rating plate to make sure that the boiler/water heater is for the type of gas that will be used. If it isn’t, do not connect the boiler/water heater to the gas supply. Gas supply piping must be in accordance with the National Fuel Code, ANSI Z223.1-latest revision or applicable provisions of the local building codes. Canadian installations must comply with CAN/CGA B149.1 or .2 Installation Code. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

The Futera II comes from the factory ready to be piped to the gas supply. If for any reason the boiler/water heater is not for the type of gas available at the installation site, call your RBI representative to resolve the problem.

NOTE: A minimum gas supply pressure of 6 in, 152 mm W.C. natural or 11 in, 279 mm W.C. propane and maximum 14 in, 356 mm W.C. natural or propane, must be available at the safety shutoff valve inlet with the unit(s) operating.

Table 6 should be used to ensure that the gas supply piping is sized properly. If more than one appliance is supplied by the same supply pipe, the piping must be sized based on the maximum possible demand. Do not neglect the pressure drop due to pipe ﬁ ttings. Table 6 should be used in conjunction with Table 7 to ensure that the gas supply piping has the capacity to meet the demand.

Table 7 – Equivalent Pipe Length Chart

Nominal Iron Pipe Size, (in)

1" 1 1/4" 1 1/2"

Notes: 1. For ﬂ ow through branch.

2. For ﬂ ow at full open.

90˚ Elbow

2.6

3.5

4.0

5.2

Type of pipe ﬁ tting

Tee

Equivalent pipe length, (ft)

5.2

6.9

8.0

10.3

Gate Valv e

0.6

0.8

0.9

1.2

Figure 18 – Gas Supply Piping

Gas Cock

1.5

1.9

2.3

3.0

Figure 18 depicts the proper way to connect the boiler/ water heater to the gas supply piping. The manual shutoff valve MUST be installed in the supply piping. It should be installed 5 ft, 1.5 m above the ﬂ oor where required by local codes. Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls.

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 6 – Gas Pipe Capacity

Maximum pipe capacity in ft at a pressure of 0.5 psig or less and a 0.3" W.C. pressure drop.

Nominal Iron Pipe Size, (in)

1" 1 1/4" 1 1/2"

Note: Multiply the gas volume by 0.62 for propane ﬂ ow capacity 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.

520 1050 1600 3050

350

730 1100 2100

/hr based on 0.60 speciﬁ c gravity gas

Pipe length in feet

215 440 670

1270

195 400 610

1150

Maximum gas volume of pipe, (ft

285

245

590

500

890

760

1650

1270

170 350 530 990

/hr)

100

150 305 460 870

150

120 250 380 710

CAUTION: Always use a wrench on the gas valve body when making gas connections to it. Never o ver-tighten the piping entering the gas valve body or gas valve failure may result!

When applicable, provisions for vent, bleed and gas relief lines must be made in accordance with the latest revision of ANSI Z223.1/NFPA 54.

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler. All gas connections MUST be leak tested before putting the boiler into operation.

WARNING: Never use an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe per sonal injury or death!

Whenever the gas supply piping is pressure tested the boiler/water heater gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler/water heater by closing it’s manual shut off valve, see Figure 18. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/water heater and its individual shut-off valve.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

ELECTRICAL WIRING

Electrical Power Connections CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing.

ATTENTION: Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

The electrical connections to this boiler/water heater must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/ NFPA-70. Installation should also conform with CSA C22.1 Canadian Electrical Code Part I if installed in Canada.

Install a separate 120 volt 15 amp circuit for the boiler/w ater heater. A properly rated shut-off switch should be located at the boiler/water heater. The boiler/water heater must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70.

Line voltage ﬁ eld wiring of any controls or other devices must conform to the temperature limitation of type T 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.

Refer to the wiring diagram supplied with the boiler/water heater for proper wiring connections.

GENERAL OPERATION

Hydronic Heating Boilers

Open the make-up water valve and slowly ﬁ ll the boiler and all of the radiation with water. Ensure that all bleed and drain valves are closed.

Adjust the make-up water pressure regulator so a minimum 12 psig, 82.7 kPa system pressure is maintained at the highest point in the system piping. If a mak e-up w ater pump is used adjust it to maintain a minimum 12 psig, 82.7 kPa system pressure.

Open the system bleed and drain valves, one at a time, to purge the air trapped in the heating system piping.

With the boiler off, run the system pump for at least 30 minutes and bleed the system piping using the bleed valves. If strainers are used in the system piping, the make- up water valve should be closed and the strainers checked and cleaned.

The system expansion tank should be checked to ensure that the correct water level in the tank is maintained. The tank should be less than half full of water with the system full and adjusted to the correct operating pressure.

Start the boiler as described in the “OPERATING INSTRUCTIONS” section. Run the boiler for at least an hour. The system pump(s) and all radiation units must be operated during this time. Ensure that the make-up water valve is open.

Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping. Close the makeup water valve and check and clean the strainers and make-up water pressure reducing valve.

Open the make-up water valve and adjust the system pressure if necessary. The system should be checked and bled after three days of operation.

WARNING: Before proceeding read and fully understand the instructions contained in this manual. Do not attempt to operate this boiler/water heater if it has not been installed in accordance with the guidelines set forth in this manual. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. Do not interrupt water ﬂ ow through the boiler/water heater.

En cas de surchauffe ou si l’alimentation en gaz ne s’arrête pas, fermez manuellement le robinet d’arrêt de l’admission de gaz.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING. POUR VO TRE SÉCURITÉ LISEZ AVANT DE METTRE EN

MARCHE

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to light the pilot by hand.

Cet appareil est muni d’un dispositif d’allumage qui

allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.

B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell ne xt to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

DANGER: Propane gas may not always be detected by smell. Propane gas is heavier than air and can collect in low areas.

Propane gas can ignite or explode if an ignition source is present and result in death, serious injury and property damage!

FOR YOUR SAFETY

• Have only qualiﬁ ed licensed professionals install, service and maintain this appliance and your gas system in accordance with all applicable codes.

• If you suspect a leak:

1. Have everyone leave the building immediately.

2. Do not attempt to light any appliance.

3. Do not touch any electrical or electronic switches in the building.

4. Do not use any phone in the building.

5. Call your gas supplier from a phone outside of the building.

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

AVANT DE FAIRE FONCTIONNER, reniﬂ ez tout autour de l’appareil pour déceler une odeur de gaz. Reniﬂ ez près du plancher, car certains gaz sont plus lourds que l’air et peuvent s’accumuler au niveau du sol.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez à aucun interr upteur; ne pas vous servir des téléphones se trouvant dans le bâtiment. Appelez immédiatement votre fournisseur de gaz

• depuis un voisin. Suives les instructions du fournisseur .

• Si vous ne pouvez rejoindre le fournisseur, appelez le service de incendies.

C. Do not use this appliance if any part has been under

water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

5. Wait ﬁ ve (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above (to the left) on this label. If you do not smell gas, go to the next step.

6. Connect a manometer having a minimum capacity of 20 in, 508 mm WC to the gas pressure test port, see Figure 22. Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas valve have been thoroughly checked for leaks.

7. Open the manual pilot valve.

8. Turn on all electric power to the boiler.

9. Set the operating control or thermostat to the desired setting.

10. The pilot should automatically light. Do not try to light the pilot by hand!

11. With the pilot lit, open the main gas shut-off valve.

12. The burner should light with proper boiler operation.

INSTRUCTIONS DE MISE EN MARCHE

1. ARRÊTEZ! Lisez les instructions de sécur ité sur la portion supérieure de cette étiquette.

2. Réglez le thermostat à la température la plus basse.

3. Coupez l’alimentation électrique de l’appareil.

4. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

6. Attendre cinq (5) minutes pour laisser échapper tout le gaz. Reniﬂ ez tout autour de l’appareil, y compris près du plancher, pour déceler une odeur de gaz. Si vous sentez une odeur de gaz, ARRÊTEZ! Passez à l’étape B des instructions de sécurité sur la portion supérieure de cette étiquette. S’il n’y a pas d’odeur de gaz, passez à l’étape suivante.

7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.

8. Mettez l’appareil sous tension.

9. Réglez le thermostat à la température désirée.

10. Si l’appareil ne se met pas en marche, suivez les instructions intitulées «Comment couper l’admission de gaz de l’appareil» et appelez un technicien qualiﬁ é ou le fournisseur de gaz.

N’utilisez pas cet appareil s’il a été plongé dans l’eau,

même partiellement. Faites inspecter l’appareil par un tecnicien qualiﬁ é et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

CAUTION: To prevent being burned, stand clear of the boiler during ignition and don’t touch any hot metal parts!

Operating Instructions

1. STOP! Read the safety information above. If, at any time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE”.

2. Set the operating control or thermostat to off or its lowest setting.

3. Turn off all electric power to the appliance.

4. Close the manual main and pilot gas shut-off valves.

To Turn Off Gas To Appliance

1. Set the operating control or thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Close the manual main and pilot gas shut-off valves.

Comment Couper L’Admission De Gaz De L’Apareil

1. Réglez le thermostat à la température la plus basse.

2. Coupez l’alimentation électr ique de l’appareil s’il faut procéder à l’entretien. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

CHECKING & ADJUSTMENTS

On initial light-off, the installer may alter the preset factory settings to attain satisfactory combustion. An accurate manometer and ﬂ ue gas analyzer must be used. Please see Fire Testing section 4 for combustion guidelines.

Spark Gap

With the main and pilot gas manual valves in the closed position energize the unit. Observe the trial for ignition to conﬁ rm that the spar k is strong and continuous. If not, check and adjust the spark gap as shown in Figures 19 &

20.

Figure 19 – Spark Gap & Pilot Flame

RSUB-75

Figure 20 – Spark Rod Position Detail

Pilot Operation

With the manual main gas valve and manual pilot gas valve closed energize the unit and allow it to try for ignition until it goes into ﬂ ame failure. The trial for ignition indicator light should illuminate immediately after the trial for ignition starts and stay on for approximately 15 seconds. The trial for ignition indicator light should go out and the ﬂ ame failure indicator light illuminate immediately after ﬂ ame failure. Open the manual pilot gas valve. A normal pilot ignition sequence should take place within 6 minutes of the initial ﬂ ame failure. The trial for ignition indicator light should stay on. Recycle the pilot several times to confirm reliable operation.

Pilot Adjustment The pilot burner ﬂ ame should be well deﬁ ned and 2 to

/2 in, 50 to 64 mm above the surface of the burner, Figure

19. To adjust the pilot the following steps must be taken:

1. Remove the pilot gas pressure regulator cap.

2. Turn the pressure regulator adjustment screw clockwise to increase the ﬂ ame and counterclockwise to decrease it.

3. Replace the pressure regulator adjustment screw cap.

Fire Testing

1. For an on/off unit conﬁ rm that the low-ﬁ re side of the two-stage gas valve is set to its maximum setting.

For a two-stage unit a 1/16" thick silicon spacer should

be installed under the low-ﬁ re adjusting screw. Without this spacer it won’t be possible to consistently set the low-ﬁ re pressure to 2.4 in, 61 mm W.C.

2. Follow the instructions in the “OPERATING INSTRUCTIONS” section starting on page 25 to ﬁ re the main burner. Upon ignition of the main burner adjust the high ﬁ re adjusting screw to obtain the high ﬁ re pressure listed in Table 8. On a two-stage unit disconnect the power from the high ﬁ re side of the gas valve and adjust the low ﬁ re, regulator. If the unit short cycles on low ﬁ re adjust the air box pressure and gas back pressure as outlined below.

CAUTION: Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur!

Table 8 – Pressure Settings, Inches W.C.

Model Natural Gas LP Gas Size Low High Low High in mm in mm in mm in mm 500 n/a n/a 3.0 76 n/a n/a 7.0 178 750 2.4 61 3.0 76 6.0 152 7.0 178 1000 2.4 61 3.0 76 6.0 152 7.0 178 1250 2.4 61 3.0 76 6.0 152 7.0 178 1500 2.4 61 3.0 76 6.0 152 7.0 178 1750 2.4 61 3.0 76 6.0 152 7.0 178 1950 2.4 61

3.0 76 6.0 152 7.0 178

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

3. When ﬁ re tested at the factory the unit’s input was rated and the gas pressure(s) recorded on the test label afﬁ xed to the jacket next to the junction box. To conﬁ rm the input of the unit follow the instructions in the INPUT RATE section below. The gas pressure setting(s) for dual fuel units may vary; refer to the test label on the unit.

4. An undiluted ﬂ ue gas sample must be taken at the ﬂ ue outlet using a calibrated ﬂ ue gas analyzer. Allow the unit to run for 15 minutes before taking the sample. For a natural gas unit the low ﬁ re CO reading should be 7.3%-7.5% and 8.5%-8.8% for propane gas. The high ﬁ re CO

reading should be

7.5%-8.0% and 8.8%-9.4% for propane gas. Exceeding 8.0% on natural gas or 9.4% on propane gas CO inlet air damper to achieve the correct CO

will shorten the life of the burner. Adjust the

readings.

5. If the pressure settings vary from those listed in Table 8, please afﬁ x a new label or notice to the boiler, which shows these new settings. However, do not sacriﬁ ce or compromise safe combustion, carbon monoxide limits, or safety settings to achieve these ﬁ gures. The pressures listed in Table 8 are guidelines obtainable under ideal conditions.

6. To test the ignition safety shutoff device, close the manual shutoff valve in the gas supply line. Within 5 seconds of main burner ﬂ ame extinction, the main gas valve solenoid should close with an audible noise. After 15 seconds the module should lockout and the trial for ignition end. After 5 minutes a second trial for ignition should occur. Open the manual shutoff v alve in the gas supply line and reset the ignition control system. A normal ignition sequence should take place. If the burner hasn’t lit after the last ignition try, the gas valve will close and the system will go into lock out only on CSD-1 units otherwise, the boiler will retry every 5 minutes. Inspect the ignition system to determine what the problem is.

7. With the main burner in operation, close the manual ﬁ ring valve. As soon as the main burner ﬂ ames go out, open the manual firing valve. A normal ignition sequence should take place. If the burner fails to light the system will make one more ignition attempt.

8. With the burners in operation, interrupt the power to the control circuit by lowering the operating control or thermostat. The main burners should go out. Reset the operating control or thermostat, a normal ignition sequence should follow.

Air Box Pressure

Connect a manometer to the air box pressure tap located behind the control cover, Figure 21.

Figure 21 – Air Box Pressure Tap

If vented vertically ensure that the barometric damper is capable of maintaining the air box pressure listed in Table

9. An air box pressure lower that that listed in Table 9 can signiﬁ cantly reduce the life of the burner.

Long horizontal vents will result in an air box pressure higher that that listed in Table 9. It may be necessary to open the air damper to obtain the correct combustion settings.

Required Gas Pressure

Connect a manometer to the gas pressure test port upstream of the ﬁ ring valve, Figure 22. Close the manual shut off valve for the pilot gas. Ensure that the ﬁ ring valve is in the open position. Energize the unit and allow it to try for ignition until it goes into ﬂ ame failure. If the gas back pressure is signiﬁ cantly different from that listed in Table 9 the air/gas mixing tube may be misaligned.

Provide gas supply pressure at inlet to boiler gas train as follows: LP Nat

Minimum (in W.C.) 11 5 Maximum (in W.C.) 14 14

Measure pressure when the boiler is ﬁ ring at full rate. Low gas pressure could indicate undersized gas line or insufﬁ cient gas supply.

Table 9 lists the factory settings for the air box pressure and gas back pressure that were set using a minimum length of vent pipe. It may be necessary to adjust the air shutter on the blower to achieve acceptable combustion readings for certain installations.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

“Static and operating gas pressure required at the gas valve inlet is between 5" W.C. and 14" W.C. for natural gas and 11" W.C . and 14" W.C . for propane. If the gas pressure is above this limit, a lock-up style regulator suitab le for dead end service such as an Equimeter or Fisher must be installed to prevent increase (creep) of gas pressure when the units are not operating. This pressure regulator (supplied by others) may be installed at the service entrance to each unit or a “master” regulator sized to handle multiple units may be utilized. Consult local gas utility or regulator manufacturer for recommendations to meet speciﬁ c job site requirements.”

Figure 22 – Air Adjustment & Gas Pressure Test Port

Check the input rate as follows:

1. Turn off all other gas appliances that use the same gas meter as the boiler/water heater.

2. Call your gas supplier and ask for the heating value of the gas.

3. Start the boiler/water heater and let it run for 15 minutes.

4. Using the gas meter and a stopwatch, clock the time that it takes to burn 10 ft this time by 10.

5. Insert the heating value and the time, in seconds, into the formula below.

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 adjust the manifold pressure accordingly. DO NOT adjust the manifold pressure by more than 5%. If a proper rate cannot be maintained without adjusting the manifold pressure beyond the 5% limit, the main burner oriﬁ ces must be replaced. If the input rate is too low, go to the next larger size of main burner oriﬁ ces. If the input rate is too high, go to the next smaller size.

CAUTION: Never increase the input to the boiler/water heater above that for which it is rated. Doing so can cause premature failure of the boiler!

, 0.28 m3 of gas and divide

Table 9 – Pressure Settings, W.C.

Model Air Box Pres. Gas Back Pres. Size in mm in mm 500 1.3 33 0.3 7.6 750 2.1 53 0.6 15.2 1000 3.0 76 0.6 15.2 1250 2.1 53 0.3 7.6 1500 2.5 64 0.3 7.6 1750 3.2 81 0.3 7.6 1950 3.4 86 0.3 7.6

Input Rate, Natural Gas

Gas appliances are rated based on sea level oper ation with no adjustment required at elevations up to 2000 ft, 610 m. At elevations above 2000 ft, 610 m input ratings should be reduced by 4% for each 1000 ft, 305 m.

CONTROL DESCRIPTION

Low Water Cutoff

If the boiler is to be installed above radiation or if required by other codes or regulations, install a low water cutoff in appropriate piping. Wire the switch and any external controls in series to the “Interlock” contacts in the control box, see the wiring diagrams included with the unit for details. Ensure that the low water cutoff device(s)

will function properly.

Boiler Thermostat

If a thermostat is to be used to control the boiler always follow the instructions included with the thermostat. Proper location of the thermostat will ensure efﬁ cient trouble-free operation of the boiler. Mount the thermostat to an inside wall at a height approximately 5 ft, 1.5 m above the ﬂ oor.

Avoid placing the thermostat in areas that will not provide an accurate measurement of the room temperature. Locating the thermostat behind a door, in an alcove, close to a source of thermal radiation or in a drafty area will cause poor or sporadic heating.

For a thermostat that employs an adjustable heat anticipator, adjust the anticipator to match the current measured in the thermostat circuit. An increased anticipator setting may be necessary if the unit cycles frequently. If the room temperature over-shoots the thermostat setting, reduce the anticipator setting.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Operating Control

The operating control on the water heater is set to its lowest setting when the water heater leaves the factory. The preferred control setting for potable hot water is 130°F, 54°C. The operating control should be set to the lowest setting that will satisfy the consumer's needs.

Instructions To Change Degrees Fahrenheit To Celsius

Press the “P” button once, the display should read “SP”. With display reading SP, press and hold the “P & Up & Down” buttons simultaneously for more than 5 seconds, display should indicate “Pb.1”. Press the P button (not holding) several times until “Y.0” is displayed then press and hold for “P” for 2 seconds . Displa y should read “C111” press “P” once to display “C112”, using the up / down buttons select the number that corresponds to measurement unit and number of decimal points desired.

Note: If you don’t enter the conﬁ guration codes (C111, C112, etc.) thru Y.0 parameter, you will only be able to read the setting and not change it.

The display unit C or F and the decimal place is determined by parameter. You can also use this procedure to change sensor type in an emergency if an exact replacement probe is not readily available. (C111)

The RBI Digital Temperature Controller has three buttons: “P”, “up” and “down”. The controller will display the current inlet water temperature to the boiler. Press the “P” button once to enter the adjust menu. From there you can access these settings:

SP Setpoint or Target Temperature: The Setpoint is the inlet water temperature that the operating control will try to match by staging the boiler between Off, Stage 1 and Stage 2.

D1 Boiler Differential: The Boiler Differential is centered around the setpoint so that when the sensor reads 1/2 of D1 below the setpoint, stage 1 will be energized. When the sensor reads a temperature 1/2 of D1 above the setpoint, stage will turn off.

D2 Interstage Differential: The Interstage Differential is the difference in temperature between stage 1 being called on, and stage 2 being called on.

High Limit (Aquastat)

The high limit is located in the top control area of the boiler/ water heater. A remote capillar y bulb is run to a well on the outlet side of the supply header. The high limit can be reset by depressing the red button.

The water heater high limit should be set a minimum of 20°F, 11°C higher than the operating control. Refer to the HOT WATER SUPPLY section for the proper supply water temperature.

Flow Switch

A ﬂ ow switch is provided in the water outlet piping to prevent the boiler/water heater from ﬁ ring without adequate water ﬂ ow through the heat exchanger.

DIAGNOSTICS

The Futera II has a number of indicator lights that are intended to display the current operation and to indicate any possible problems. The function of each light is listed below.

On/Off Switch: The toggle switch will illuminate when po wer is being supplied to the unit.

Call For Low Fire: This g reen light will illuminate when there is a low ﬁ re heat demand either from the RBI Temperature Controller or a Building Management Control.

Call For High Fire: This green light will illuminate when there is a high fire heat demand either from the RBI T emperature Controller or a Building Management Control.

Trial Ignition: This yellow light will illuminate when the pilot gas valve is energized.

Main Burner: This green light will illuminate when the main gas valve is energized.

High Limit: This red light will illuminate when the outlet water temperature has exceeded the setting on the High Limit control during call for heat.

Low Water: This red light will illuminate when there is not proper water ﬂ ow during a call for heat.

Low Air Flow: This red light will illuminate when there is not proper combustion air ﬂ ow during a call for heat.

WARNING: Setting the thermostat or operation control too high can result in scalding resulting in severe personal injury!

Flame Failure: Illuminate whenever the ignition control is unable to establish a pilot ﬂ ame within the trial for ignition period. This light will also illuminate if the Flame Safeguard Ignition Control is in lockout for other reasons.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

MAINTENANCE

WARNING: Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result!

CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can damage the boiler /water heater!

The boiler/water heater must be cleaned and inspected at least once a year and before each heating season. Make sure that the burner and ignition components are free from dust, soot, dirt, corrosion or other deposits that would impair the boiler/water heater’s performance. Refer to page 34 for component identiﬁ cation.

CAUTION: Improper burner servicing can result in premature burner failure voiding the warranty!

Burner Removal & Inspection

1. Close the manual shutoff valves in the gas supply lines and turn off electrical power to the boiler/water heater.

2. Remove the jacket top panel.

3. Remove the combustion chamber top panel.

4. Remove the air gas mixing tube.

5. Disconnect the pilot tubing and ignition/sensing lead from the burner.

6. Remove the four nuts that attach the burner to the heat exchanger.

7. Carefully lift the burner out of the unit.

8. Inspect the burner for damage or signs of deterioration. Use a brush or compressed air to remo ve any debris from the burner ports.

9. DO NOT install a damaged or badly corroded burner, replace it.

10. Install the burner making sure that the burner gasket is not torn or deteriorated. If it is, replace it.

11. Reassemble the unit following the removal steps in reverse order.

Heat Exchanger Inspection

1. Close the manual shutoff valves in the gas supply lines and turn off electrical power to the boiler/water heater.

2. Remove burner following the instructions in the Burner Removal & Inspection section.

3. Remove the front jacket panel and combustion chamber door.

4. Inspect the inside and outside of the heat exchanger for signs of damage, sooting or corrosion.

5. The outside surfaces of the copper tubes should be free of any soot deposits. A slight black smudge is normal with some types of gases. Black soot indicates poor combustion. Green deposits indicate condensation due to low return water temperatures. In either case the heat exchanger must be cleaned thoroughly and the problem resolved before the boiler/water heater is returned to service.

6. If there are no signs of damage, sooting or corrosion, reassemble the unit following the previous steps in reverse order.

7. A badly corroded or damaged heat exchanger must be replaced, see the Heat Exchanger Repair &

Replacement section.

Heat Exchanger Cleaning

1. Close the shut off valves in the inlet and outlet piping. On heating systems close the system ﬁ ll valve and relieve the system pressure from the boiler b y carefully lifting the relief valve or opening the drain valve.

2. Disconnect the boiler/water heater from the system piping.

3. Remove the eight bolts on the rear pipe enclosure panel.

4. Remove the front jacket panel and combustion chamber door.

5. Slide the heat exchanger out of the unit.

6. Remove the “V” bafﬂ e straps and “V” bafﬂ es.

7. Thoroughly clean the heat exchanger with water from a high-pressure hose. Use a soft bristle brush if necessary.

8. Replace the cleaned heat exchanger and other components in the reverse order of their removal.

Heat Exchanger Repair & Replacement

1. A leaking or otherwise damaged tube(s) can be replaced as outlined in steps 2 through 8.

2. Remove the heat exchanger from the boiler/water heater as outlined in the Heat Exchanger Cleaning section.

3. Remove the pipe plugs from the inlet/outlet and return headers opposite from the ends of the tube(s) being replaced.

4. Carefully cut the damaged tube(s) in half taking care not to damage the adjacent tubes and remove.

5. Install and swage/expand in place the new tube(s).

6. Replace the pipe plugs using a suitable tread sealant on each one.

7. Sagging or distorted heat exchanger tubes are an indication of low water ﬂ ow through the system. A damaged heat exchanger must be replaced and the condition that caused the damage resolved before the boiler/water heater is returned to service.

8. Replace the heat exchanger and other components in the reverse order of their removal.

9. The torque values for the bolts that secure the removable headers are 30-50 ft lbs. Once bolts have been started and secured the tightening sequence is as follows:

1) Middle top

2) Middle Bottom

3) Right Top

4)n Left Bottom

5) Left Top

6) Right Bottom

Air Intake & Vent System

Thoroughly inspect the air intake and vent systems for any signs of blockage, corrosion or leakage. Immediately replace any unsound vent system piping. Inspect the air ﬁ lter and wash with warm water and soap if dirty.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Controls

Use the “GENERAL OPERATION” and “CHECKING AND ADJUSTMENTS” sections of this manual for reference.

1. Check the thermostat or operating controls for proper operation.

2. A ﬂ oat type low water cutoff device must be ﬂ ushed out per the manufacturers’ instructions. The probe on a probe low water cut off must be removed, cleaned and inspected at least once a year. Ensure that the low water cutoff operates properly . If not, replace them.

3. The ﬂ ow switch contacts must be open when water ﬂ ow is not present.

4. The relief valve should not weep or discharge water at normal system pressure. If it does, contact a qualified service technician to have it inspected. NEVER try to clean or repair the relief valve! If the valve fails to operate properly, have it replaced!

5. The aquastat high limit controls the maximum water temperature in the boiler. It is adjustable from 140°F, 60˚C to 250°F, 121°C. If the w ater temperature reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the boiler off. The water temperature should never exceed the maximum set point of 250°F, 121°C. The aquastat high limit cannot be repaired. If it fails to function properly, replace it.

6. Visually check the pilot and main burner ﬂ ames to ensure proper operation, see Figures 19 & 23.

WARNING: A yellow, ﬂ oating ﬂ ame indicate a lack of combustion air. Do not operate the boiler/water heater until the problem is solved or severe personal injury or death may occur!

Figure 23 – Main Burner Flame

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

TROUBLE-SHOOTING

OPERATIONAL PROBLEMS CORRECTIVE ACTION

1. The On/Off toggle switch doesn’t illuminate. Ensure that proper voltage is being supplied to the unit.

Inspect the circuit breaker for the boiler/water heater

circuit.

Ensure that the power switch operates properly and is

wired correctly.

Check the transformer for proper operation.

2. The “Low Water” indicator light illuminates. Ensure that the boiler/water heater has been completely purged of air.

Ensure that the pump is operating properly/rotating in the

proper direction.

Ensure that all system valves are in the correct position

and that no restrictions in the piping are present.

Conﬁ rm that the ﬂ ow switch is wired correctly and

functions properly.

3. The “Low Air Flow” indicator light illuminates. Check the light.

Inspect the vent and air intake systems to ensure that

blockages are not present.

Ensure that the vent and air intake systems conform to

the guidelines in this manual.

Conﬁ rm that the blocked ﬂ ue switch connections are

correct and that it is functioning properly.

Ensure that the blower air inlet damper & pressure switch

are adjusted for the correct air box pressure.

4. The “Trial for Ignition” indicator light illuminates, Conﬁ rm that the ignition module is properly wired. but the igniter does not spark.

Inspect the igniter and ensure that the spark gap is

correct.

Ensure that the ignition module is properly grounded.

5. The “Main Burner” ignites, but the natural gas Ensure that at least the minimum inlet pressure is high ﬁ re manifold pressure is less than 2.5 in. W.C. supplied at the inlet of the gas valve.

6. The Boiler/Water Heater rumbles on start up. Ensure that the burner is set up per the "CHECKING & ADJUSTMENTS" section.

Ensure that the unit is properly vented.

Conﬁ rm that the ignition lead isn’t grounded out.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 24 – Exploded View

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

1 Base Panel Assembly 70-2163 1 1 1 70-2164 1 1 1 1 2 Gas Train Support Bracket 70-2141 1 1 1 70-2141.1 1 1 1 1 3 Base Panel Heat Exchanger Legs 03-1728 1 1 1 03-1729 1 1 1 1 4 Combustion Chamber Top Panel 03-1731 1 1 1 03-1732 1 1 1 1 5 Rear Pipe Enclosure Panel Assembly 70-2108 1 1 1 70-2109 1 1 1 1 6 Jacket Top Panel 70-2106 1 1 1 70-2107 1 1 1 1 Jacket Top Panel (SS) 70-2106.1 1 1 1 70-2107.1 1 1 1 1 Outdoor Enclosure Assembly 70-2103 1 70-2104 1 1 7 Jacket Upper Rear Panel 03-1753 1 1 1 03-1755 1 1 1 1 Jacket Upper Rear Panel (SS) 03-1753.1 1 1 1 03-1755.1 1 1 1 1 9 Light Board, 120V 40-0071 1 1 1 1 1 1 1 10 Upper Front Panel Assembly 70-2062 1 1 1 70-2063 1 1 1 1 Upper Front Panel Assembly (SS) 70-2062.1 1 1 1 70-2063.1 1 1 1 1 Handle 20-0044 1 1 1 1 1 1 1 11 Air/Gas Mixing Tube Assembly 70-2183 1 1 1 70-2184 1 1 1 1 12 Fan Assembly, 1/4HP 70-2200 1 1 1 Fan Assembly, 1/2HP 70-2201 1 1 Fan Assembly, 3/4HP 70-2204 1 1 Fan Assembly (Old Style) 70-2202 1 1 Motor (Old Style) 12-0104 1 1 Impeller (Old Style) 12-0301 1 1 13 Pilot Tube Assembly 70-2185 1 1 1 70-2185.1 1 1 1 1 14 Spark Generator, Q652B 16-0008 1 1 1 1 1 1 1 NS Purge Timer, ST7800 16-0007 1 1 1 1 1 1 1 NS Mini Peeper, C7027A 16-0009 1 1 1 1 1 1 1 NS Rocker Switch 48-0012 1 1 1 1 1 1 1 NS Ignition Reset Switch (CSD-1) 48-0005 1 1 1 1 1 1 1 NS Pump Contactor 1PH 15-0118 1 1 1 1 1 1 1 NS Pump Contactor 3PH 15-0111 1 1 1 1 1 1 1 NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 1 1 1 1 1 1 NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1 1 NS Terminal Block 12P 48-0158 1 1 1 1 1 1 1 NS NS Pump Delay Relay, 115AC 15-0114 1 1 1 1 1 1 1 NS 10 sec Delay Relay 15-0133 1 1 1 1 1 1 1 NS 20 sec Pilot Off Relay (prior to 0305) 15-0109 1 1 1 1 1 1 1 NS Flame Failure Relay, 1P (prior to 0305) 15-0106 1 1 1 1 1 1 1 NS Flame Failure Relay, 120V (R1) 15-0125 1 1 1 1 1 1 1

7 sec Prepurge Relay, MOR24A (prior to 0305)

15-0119 1 1 1 1 1 1 1

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

21 Pressure Switch (.58 WC) 70-9028 1 Pressure Switch (.80 WC) 70-9029 1 Pressure Switch (1.40 WC) 70-9039 1 1 Pressure Switch (1.10 WC) 70-9040 1 Pressure Switch (2.00 WC) 70-9041 1 Pressure Switch (2.20 WC) 70-9042 1 22 Manual Pilot "B" Valve 11-0031 1 1 1 1 1 1 1 NS Ball Valve 11-0395 1 1 1 1 1 1 1 NS Drain Valve 11-0461 1 1 1 1 1 1 1 NS Drain Valve Assembly (FB) 30-0420K 1 1 1 30-0424K 1 1 1 1 Drain Valve Assembly (FW) 30-0425K 1 1 1 30-0426K 1 1 1 1 Drain Valve Assembly (FB) (Outdoor) 30-0427K 1 1 1 30-0428K 1 1 1 1 Drain Valve Assembly (FW) (Outdoor) 30-0436K 1 1 1 30-0437K 1 1 1 1 23 Electrode/Spark Rod 16-0301 1 1 1 1 1 1 1 24 Ignition Cable 44-0056 1 1 1 1 1 1 1 25 Pressure Switch Tubing 06-0051 2 2 2 2 2 2 2 26 Solenoid Valve w/Regulator, NG 11-0372 1 1 1 1 1 1 1 Solenoid Valve w/Regulator, LP 11-0374 1 1 1 1 1 1 1 28 View Port Assembly 70-2205 1 1 1 1 1 1 1 29 View Port Glass 20-0006 1 1 1 1 1 1 1 NS Combustion Chamber Gasket 66-0101 25 25 25 25 25 25 25 30 Jacket Gasket Material 66-0102 25 25 25 25 25 25 25 31 Burner Gasket 06-0011 1 1 1 06-0012 1 1 1 1 32 Flame Safeguard, RM7896C 16-0002 1 1 1 1 1 1 1 NS RM7800 Base 16-0003 1 1 1 1 1 1 1 NS Keyboard Display Module, S7800A 16-0010 1 1 1 1 1 1 1 NS UV Ampliﬁ er, R7849A 16-0006 1 1 1 1 1 1 1 33 High Limit, L4008E, (FW) 14-0105 1 1 1 1 1 1 1 High Limit, L4008E, (FB) 14-0112 1 1 1 1 1 1 1 34 Operator, Jumo 16-0025 1 1 1 1 1 1 1 NS Temperature Probe Assembly 16-0026 1 1 1 1 1 1 1 NS Well, 3/8 x 3 13-0104 1 1 1 1 1 1 1 NS Well Gasket 06-0015 1 1 1 1 1 1 1 NS Operator, T6031A (pool heater) 14-0003 1 1 1 1 1 1 1 35 Burner Stud 57-0213 2 2 2 2 2 2 2 36 Burner Nut 57-0491 2 2 2 2 2 2 2 37 Top Panel View Port Frame & Glass 20-0032 1 1 1 1 1 1 1 38 Heat Exchanger "V" Bafﬂ e Strap 03-1619 2 2 2 03-1620 2 2 2 2

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

39 Combustion Chamber Rear/Side Panel 70-2144 1 70-2145 1 70-2146 1 70-2147 1 70-2148 1 70-2149 1 70-2150 1 40 Jacket Front Panel 70-2055 1 70-2056 1 70-2057 1 70-2058 1 70-2059 1 70-2060 1 70-2061 1 40 Jacket Front Panel (SS) 70-2055.1 1 70-2056.1 1 70-2057.1 1 70-2058.1 1 70-2059.1 1 70-2060.1 1 70-2061.1 1 Handle 20-0044 1 1 1 1 1 1 1 41 Jacket Left Side Panel 03-1767 1 03-1768 1 03-1769 1 03-1770 1 03-1771 1 03-1772 1 03-1773 1 Jacket Left Side Panel (SS) 03-1767.1 1 03-1768.1 1 03-1769.1 1 03-1770.1 1 03-1771.1 1 03-1772.1 1 03-1773.1 1 Jacket Right Side Panel 03-1774 1 03-1775 1 03-1776 1 03-1777 1 03-1778 1 03-1779 1 03-1780 1 Jacket Right Side Panel (SS) 03-1774.1 1 03-1775.1 1 03-1776.1 1 03-1777.1 1 03-1778.1 1 03-1779.1 1 03-1780.1 1

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

42 Jacket Lower Rear Panel 03-1760 1 03-1761 1 03-1762 1 03-1763 1 03-1764 1 03-1765 1 03-1766 1 Jacket Lower Rear Panel (SS) 03-1760.1 1 03-1761.1 1 03-1762.1 1 03-1763.1 1 03-1764.1 1 03-1765.1 1 03-1766.1 1 43 Sealing Collar Assembly 70-2220 1 70-2221 1 70-2222 1 70-2223 1 1 70-2224 1 1 44 Main Burner Assembly, UV Flame Sensing 70-2213 1 70-2214 1 70-2215 1 70-2216 1 70-2217 1 70-2218 1 70-2219 1 45 On/Off Gas Valve, V48A, 1", 120V 11-0371 1 1 On/Off Gas Valve, V48A, 1 1/4", 120V 11-0364 1 1 1 On/Off Gas Valve, V48A, 1 1/2", 120V 11-0365 1 1 46 2 Stage Gas Valve, V4944B, 1", 120V 11-0166 1 1 2 Stage Gas Valve, V4944B, 1 1/4", 120V 11-0167 1 1 1 2 Stage Gas Valve, V4944B, 1 1/2", 120V 11-0168 1 1 2 Stage Gas Valve, V4944L, 1", 120V 11-0180 1 1 2 Stage Gas Valve, V4944L, 1 1/4", 120V 11-0170 1 1 1 1 1 47 Main Gas Oriﬁ ce, NG 10-0051 1 10-0052 1 10-0053 1 10-0054 1 10-0055 1 10-0056 1 10-0057 1 Main Gas Oriﬁ ce, LP 10-0058 1 10-0059 1 10-0060 1 10-0061 1 10-0062 1 10-0063 1 10-0064 1 48 A Valve, 1" 11-0465 1 1 A Valve, 1 1/4" 11-0466 1 1 1 A Valve, 1 1/2" 11-0467 1 1

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

49 Firing Valve, 1" 11-0456 1 1 Firing Valve, 1 1/4" 11-0457 1 1 1 Firing Valve, 1 1/2" 11-0458 1 1 50 Combustion Chamber Door Assembly 70-2156 1 70-2157 1 70-2158 1 70-2159 1 70-2160 1 70-2161 1 70-2162 1 51 Heat Exchanger Assembly (Copper) 70-2515 1 Cast Iron 70-2516 1 70-2517 1 70-2518 1 70-2519 1 70-2520 1 70-2521 1 Heat Exchanger Assembly (Copper) 70-2186 1 Bronze 70-2187 1 70-2188 1 70-2189 1 70-2190 1 70-2191 1 70-2192 1 Heat Exchanger Assembly (Cupronickel) 70-2522 1 Cast Iron 70-2523 1 70-2524 1 70-2525 1 70-2526 1 70-2527 1 70-2528 1 Heat Exchanger Assembly (Cupronickel) 70-2193 1 Bronze 70-2194 1 70-2195 1 70-2196 1 70-2197 1 70-2198 1 70-2199 1 52 Heat Exchanger "V" Bafﬂ e 03-1612 20 03-1613 20 03-1614 20 03-1615 28 03-1616 28 03-1617 28 03-1618 28 53 High Limit Well, 3/8 x 3 13-0104 2 2 2 2 2 2 2 55 Heat Exchanger Flange Bolts 57-0124 8 8 8 8 8 8 8 56 Manifold Flange Screw 57-0012 8 8 8 8 8 8 8 NS Pressure Relief Valve 50# 30-0360 1 1 1 Pressure Relief Valve 50# 30-0374 1 Pressure Relief Valve 50# 30-0379 1 1 1 Pressure Relief Valve 125# 30-0364 1 1 1 1 1 1 1

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950

NS Tridicator 0-100 psi (PRV 30 - 50 psi) 13-0308 1 1 1 1 1 1 1 Tridicator 0-230 psi (PRV 60 - 160 psi) 13-0305 1 1 1 1 1 1 1 NS Flow Switch 14-0203 1 1 1 1 1 1 1 Flow Switch (Outdoor) 14-0205 1 1 1 1 1 1 1 Flow Switch (Potter) 14-0201 1 1 1 1 1 1 1 Flow Switch (Outdoor Potter) 14-0202 1 1 1 1 1 1 1 57 Air Filter 09-0497 1 1 1 09-0498 1 1 09-0499 1 1 NS Damper Blade Assembly 70-2258 1 1 1 70-2259 1 1 70-2260 1 1 58 Air Intake Damper Weldment 70-2272 1 1 1 70-2273 1 1 70-2274 1 1 Air Intake Damper Weldment (SS) 70-2272.1 1 1 1 70-2273.1 1 1 70-2274.1 1 1 NS Air Filter Holder Assembly 70-2269 1 1 1 70-2270 1 1 70-2271 1 1 Air Filter Holder Assembly (SS) 70-2269.1 1 1 1 70-2270.1 1 1 1 70-2271.1 1 1 NS Rating Plate 82-0054 1 1 1 1 1 1 1 NS FII Overlay 82-0196 1 1 1 1 1 1 1 NS Paint 66-0013 1 1 1 1 1 1 1 NS Silicone 66-0151 1 1 1 1 1 1 1 NS Vent Termination Hood 8" 09-0113 1 Vent Termination Hood 10" 09-0115 1 1 Vent Termination Hood 12" 09-0116 1 1 Vent Termination Hood 14" 09-0141 1 1 NS Air Intake Hood 10" 09-0104 1 1 1 Air Intake Hood 12" 09-0105 1 1 Air Intake Hood 14" 09-0106 1 1 NS Barometric Damper 8" 09-0404 1 NS Barometric Damper 10" 09-0403 1 1 NS Barometric Damper 12" 09-0401 1 1 NS Barometric Damper 14" 09-0402 1 1

FUTERA II START UP SHEET

Date of Start Up: RBI Ref. #:

Serial # ('s): Boiler #1 Model#

Boiler #2 Boiler #3

Boiler #4

Boiler #5

The above information will be used to identify each boiler in the system. You should make every attempt to afﬁ x the boiler number as noted here to the boiler physically.

START UP PROCEDURE AND DATA

Readings Or Checks By Boiler Number STEP DESCRIPTION 1 2 3 4 5 1 No leaks, valves open, pump running, exchanger full 2 Gas lines purged, no leaks, no missing test plugs 3 Manometer installed in test port upstream of ﬁ ring valve 4 Manometer installed to air box pressure tap 5 Wiring checked and veriﬁ ed with supplied diagram 6 All terminals identiﬁ ed properly and tight 7 Fan (no gas): Verify no air leaks through outer cabinet 8 With fan running: Record air box pressure "W.C." 9 With fan running: Record back pressure "W.C." 10 Vent conﬁ guration (HOR: horizontal VER: vertical) 11 Equivalent vent length (each ﬁ tting is 10' equivalent) 12 Breaching size: 13 Barometric installed/location: 14 Through wall venting with factory supplied termination: 15 Pilot adjusted to within 1 turn of max (natural gas only) 16 Spark is strong and continous w/o gas: 17 Pilot ﬁ res-advances to main several times (main gas off) 18 Voltage: 19 Manifold pressure "W.C." (see tag on boiler) High Fire 20 Manifold pressure "W.C." (see tag on boiler) Low Fire 21 O2 Lo Fire% 22 O2 Hi Fire % 23 CO2 Lo Fire % 24 CO2 Hi Fire % 25 CO Lo Fire PPM 26 CO Hi Fire PPM 27 Efﬁ ciency Lo Fire % 28 Efﬁ ciency Hi Fire % 29 Inlet Temp (F) 30 Outlet Temp (F) 31

Temp. rise across the exchanger (don’t exceed 35°F, 19.4°C)

SAFETY CHECKS AND ADJUSTMENTS

Readings Or Checks By Boiler Number STEP DESCRIPTION 1 2 3 4 5 1 Low water cut off 2 Low gas pressure 3 High gas pressure 4 Operator okay and set @: 5 High limit okay and set @: 6 Blocked ﬂ ue switch drops out at ("W.C."): 7 Flame fail time: 8 With fan running: Record air box pressure "W.C." 9 With fan running: Record back pressure "W.C."

COMMISSIONING THE UNIT

Readings Or Checks By Boiler Number STEP DESCRIPTION 1 2 3 4 5 1 Remove manometers and replace plugs 2 Complete this start up form for rep 3 Fill out factory start up form (w/boiler) 4 Correct each boiler’s settings sticker: 5 Replace all covers (no air leaks): 6 All valves opened and adjusted: 7 Boiler pump is running 8 Final operator setting: 9 Final high limit setting: 10 Boiler left in operation: 11 Boiler to require return visit: 12 End user instructed on operation: 13 Contractor instructed on operation: 14 15 16

Start up report and procedure completed by: (please print) From (company name) Phone #:

AUTHORIZED TECH’S SIGNATURE: Date:

Notes/Comments:

FUTERA II START UP CHECK LIST

The following items must be ﬁ eld veriﬁ ed as complete

prior to the scheduling of factory authorized start up.

1. All electrical is installed and checked: ...........................................................  Yes  No

2. All water connections are made: ....................................................................  Yes  No

3. System is ﬂ ooded and pressure tested: .........................................................  Yes  No

4. All pumps (primary or secondary) are running: ..............................................  Yes  No

5. Flow switches installed and adjusted: ............................................................  Yes  No

6. Drain valve installed on outlet prior to isolation (boiler only): .........................  Yes  No

7. T/P gauge installed on outlet prior to isolation (boiler only): ..........................  Yes  No

8. Low water cut off installed and wired: ............................................................  Yes  No

9. Lead/lag/external controls installed and tested: .............................................  Yes  No

10. All gas connections are complete: .................................................................  Yes  No

11. Gas pressure veriﬁ ed between 5" and 14" W.C. .............................................  Yes  No

12. Gas lines purged and tested for leaks: ...........................................................  Yes  No

13. All stacks/vents connected per spec: .............................................................  Yes  No

14. Air inlet duct work and related items installed: ...............................................  Yes  No

15. All boiler related equipment operational: ........................................................  Yes  No

16. ......................  Yes  No

17. ......................  Yes  No

18. ......................  Yes  No

19. ......................  Yes  No

20. ......................  Yes  No

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

MACODE-3

NOTICE!

Commonwealth of Massachusetts

Installation Requirements

(a) 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 ﬁ nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁ ed:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁ tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl

space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level.

b. 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 abov e requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁ ed.

3. SIGNAGE. A metal or plastic identiﬁ cation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet abo ve grade directly in line with the e xhaust 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”.

4. INSPECTION. The state or local gas inspector of the side w all 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.

WARNING: Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

MACODE-3

NOTICE!

Commonwealth of Massachusetts

Installation Requirements

In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas ﬁ tter.

(b) Exemptions

The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. 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

2. 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.

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:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does

not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems”, the following requirements shall be satisﬁ ed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. 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.

(e) 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.

WARNING: Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

LIMITED WARRANTY

Boilers/Water Heaters

Industrial, Commercial and Other Non-Residential Use

The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Boiler (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation. Additional twenty one (21) year thermal shock warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.

The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in material or workmanship for ﬁ ve (5) years from the date of installation. Additional twenty one (21) year thermal warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in

material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI. This limited warranty does not apply:

(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has

not been installed, maintained or operated in accordance with the furnished written instructions, or has been altered or modiﬁ ed in any way.

These include but not limited to:

• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered under the manufacturer’s warranty.

• Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)

• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.

• All copper ﬁ n boilers should not operate with a return water temperature less than 110°F , 43°C atmospheric combustion, 125°F , 52°C fan assist combustion. If a lower temperature is r equired, an external bypass should be installed to prevent condensation. The manufacturer’ s warranty does not cover damage done by condensation.

(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts

thereof.

surrounding the Product.

(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United

States or Canada.

This limited warranty is conditional upon: (a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned

with prior written approval from the Manufacturer. All returns must be freight prepaid.

(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or

workmanship.

Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

260 North Elm Street 7555 Tranmere Drive Westﬁ 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

RBI FUTERA II Installation and Operation Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual