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FTIII-I0M-HN-4
82-0300
Finned copper tube
Gas boilers (MB) &
Water heaters (MW)
Boiler manual
Installation and operation
instructions
Also read and follow:
HeatNet® Control Manual
is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
A x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a quali ed service
technician, and to follow all guidelines in the User’s Information Manual.
4/12 Copyright 2012 Mestek, Inc.
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If the information in this manual is not followed
exactly, a re or explosion may result causing property,
personal injury or loss of life.
Do not store or use gasoline or other ammable vapors
and liquids in the vicinity of this or any other applianc
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the re
department.
Installation and service must be performed by a quali ed
installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données
dans ce e notice pour réduire au minimum le risque
d’incendie ou d’explosion ou pour éviter tout dommoge
matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides in ammables à proximité de cet
appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gas depuis
un voisin. Suivez les intructions du fournisseur.
BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 3
BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 3
COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . 3
GENERAL VENTING GUIDELINES. . . . . . . . . . . . . . 5
OUTDOOR VENTING. . . . . . . . . . . . . . . . . . . . .10
COMMON VENT SYSTEMS . . . . . . . . . . . . . . . . . 11
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . 12
HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . .13
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . . 17
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . .20
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . 21
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . 21
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . .22
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . .24
CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . .25
HEATNET FIELD WIRING . . . . . . . . . . . . . . . . . .26
CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . .28
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . .28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . .33
REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . 34
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . .40
MASS CODE . . . . . . . . . . . . . . . . . . . . . . . . .42
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . 43
• Si vous ne purvez rejoindre le fournisseur, appelez le
service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien quali é ou par le
fournisseur de gaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
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BEFORE YOU START
is manual covers the application, installation, operation and
maintenance of a Futera III Series nned copper heating boiler/
water heater/pool heater (Canada only). To obtain the safe,
dependable, e cient operation and long life for which this heating
boiler/water heater was designed, these instructions must be read,
understood and followed.
e Futera III Series nned copper heating boiler/water heaters
have been design certi ed by CSA for use with natural and propane
gas under the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water
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 (Canada only) 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.
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All aspects of the boiler/water heater installation must conform to
the requirements of the authority having jurisdiction, or, in the
absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54-latest revision. Where required by the authority
having jurisdiction, the installation must conform to the Standard
for Controls and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
In Canada, the installation must be in accordance with the require-
ments of CSA B149.1 or .2, Installation Code for Gas Burning
Appliances and Equipment.
If installed in the Commonwealth of Massachuse s, you MUST
FOLLOW the additional instructions contained in RBI’s instruction
sheet MACODE-3. Which is located in the back of this manual.
e owner should maintain a record of all service work performed
with the date and a description of the work done. Include the name
of the service organization for future reference.
Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at: 260 North Elm Street,
West eld, MA 01085 for US or 7555 Tranmere Drive, Mississauga
ONT L5S 1L4 for Canada. Always include the model and serial
numbers from the rating plate of the boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the Futera III Series boiler/
water heater check the rating plate to ensure that the unit has been
sized properly for the job. e “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.
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 oor is structurally sound and will support the
weight of the boiler/water heater.
e Futera III may be installed directly on combustible
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 “GENE L VENTING
GUIDELINES”.
6. NEVER place this boiler/water heater in a location that would
subject it to temperatures at or near freezing, see the “FREEZE
PROTECTION” section on page 12.
Never store combustible materials, gasoline or any
product containing ammable vapors or liquids in the
vicinity of the boiler/water heater. Failure to comply
with this warning can result in an explosion or re
causing extensive property damage, severe personal
injury or death!
BOILER/WATER HEATER LOCATION
1. is boiler/water heater is suitable for indoor and oudooor
installations. Locate the boiler/water heater in an area
that provides good access to the unit. Servicing may
require the removal of jacket panels. Allow the minimum
clearances between adjacent construction and the boiler/water
heater as listed in Table 1.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1
Clearance to
Combustibles
To p 6 153 30 762
Back 6 153 24 610
Left Side 6 153 12 306
Right Side 6 153 12 306
Front 6 153 30 762
in mm in mm
Service
Clearance
COMBUSTION AIR & VENTILATION
is boiler/water heater must be supplied with
combustion air in accordance with Section 5.3, Air
for Combustion & Ventilation, of the latest revision
of the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and all applicable local building codes. Canadian
installations must comply with CAN/ CGA B149.1
or .2 Installation Code for Gas Burning Appliances
and Equipment, or applicable provisions of the local
building codes. Failure to provide adequate combustion
air for this boiler/water heater can result in excessive
levels of carbon monoxide which can result in severe
personal injury or death!
To operate properly and safely this boiler/water heater requires a
continuous supply of air for combustion. NEVER store objects on
or around the boiler/water heater!
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Combustion air contaminated with uorocarbons
or other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. ese acids will
cause premature failure of the boiler/water heater
voiding the warranty!
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 replace, wood
stove or any type of exhaust fan must be checked for adequate
combustion air when all of these devices are in operation at one
time. Sizing of an outside air duct must be done to meet the
requirements of all such devices.
Never operate the Futera III in an environment
subjected to a negative pressure unless it is Direct
Vented. Failure to comply with this warning can result
in excessive levels of carbon monoxide causing severe
personal injury or death!
Where directly communicating with the outdoors or communi-
cating with the outdoors through vertical ducts, each opening shall
have a minimum free area of 1 in
2
/4000 Btu/hr, 550 mm2/kW
of the total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1 in
2
2000 Btu/hr, 1100 mm2/kW of the total input rating of all of
the equipment in the enclosure.
When ducts are used, they must have the same cross-sectional area
as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure, consideration must be given to the
blockage e ects of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 in, 6.4 mm. If the free area through a
louver or grill is not known, ducts should be sized per Table 2.
Canadian installations must comply with CSA B149.1 when air
supply is provided by natural air ow from the outdoors for natural
draft, partial fan-assisted, fan-assisted, or power dra -assisted
burners, there shall be a permanent air supply opening(s) having
a cross-sectional area of not less than 1 in
2
per 7,000 Btuh
(310 mm2 per kW) up to and including 1 million Btuh, plus
1 in2 per 14,000 Btuh (155 mm2 per kW) in excess of
1 million Btuh.
/
All Air From Inside The Building
If the Futera III is to be located in a con ned space, the minimum
clearances listed in Table 1 must be maintained between it and any
combustible construction. When installed in a con ned space
without the intake air option, Figures 5, 6 and 7, two permanent
openings communicating with an additional room(s) are required.
e combined volume of these spaces must have su cient volume
to meet the criteria for an uncon ned space. e total air
requirements of all gas utilization equipment, replaces, wood stoves
or any type of exhaust fan must be considered when making this
determination. Each opening must have a minimum free area of
1 in2/1000 Btu/hr, 2200 mm2/kW based on the total input rating
of ALL gas utilization equipment in the con ned area. Each opening
must be no less than 100 in2, 64,516 mm2 in size. e upper
opening must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. e bo om opening must
be within 12 in, 305 mm of, but not less than 3 in, 76 mm from,
the bo om of the enclosure.
All Air From Outside The Building
When installed in a con ned space without utilizing the intake
air option two permanent openings communicating directly with,
or by ducts to, the outdoors or spaces that freely communicate
with the outdoors must be present. e upper opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the
top of the enclosure. e bo om opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the bo om of
the enclosure.
Table 2 Make-up Air Louver Sizing
Required Cross Sectional Area
2
75% Free Area
Metal Louvers
2
in
cm
Input
(MBH)
500 125 806 167 1077 500 3226
750 187 1206 250 1613 750 4839
1000 250 1613 333 2148 1000 6452
1250 313 2019 416 2684 1250 8065
1500 375 2419 500 3226 1500 9677
1750 437 2819 583 3761 1750 11,290
1999 500 3226 667 4303 2000 12,900
1/4 in 6.4 mm
Wire Screen
2
cm
in
2
25% Free Area
Wooden Louvers
in
2
cm
2
Intake Air Option – General Guidelines
is con guration provides combustion air directly to the boiler/
water heater’s air intake adapter using a dedicated pipe when using
the direct vent option. Combustion air can be drawn in horizontally
through the same outside wall which terminates the exhaust gases
or vertically through the roof, see Figures 1, 2, 3 & 4.
Common intake air systems may be used provided the
common duct is sized properly. An intake combustion
air damper should be installed if the common vent
option is used in the intake air pipe of each heater.
Improper installation can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Single wall galvanized smoke pipe, single wall aluminum pipe,
exible aluminum pipe, PVC or CPVC pipe can be used for the
intake air pipe. It must be sized per Table 3.
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Table 3 Intake Air Pipe Sizing
Model
Size
500
750 8 203 6 152
1000 8 203 6 152
1250 10 254 8 203
1500 10 254 10 254
1750 12 305 12 305
2000 12 305 12 305
For Vertical For Horizontal
(Up to 60’) (Up to 60’)
in mm in mm
8 203 6 152
All joints in metal intake air systems must be secured using corro-
sion resistant fasteners and sealed using a suitable Silicone caulk.
If PVC or CPVC is used, the joints must be cleaned with a suitable
solvent and connected using a solvent based PVC cement. e
combustion air system MUST be supported by the building
structure not the boiler/water heater.
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
in ltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake Air Option – Vertical Guidelines
e maximum equivalent length for the vertical intake air pipe is
60 , 18.3 m. Each 90° elbow and the intake air terminal are equal
to 10 linear , 3.0 m of pipe, see Table 3.
An approved, nonrestrictive intake air terminal must be used. e
intake air terminal must terminate as shown in Figure 3. e
penetration point in the roof must be properly ashed and sealed.
Intake Air Option – Horizontal Guidelines
e maximum equivalent length for the horizontal intake air pipe
is 60 , 18.3 m. Each 90° elbow and the intake air terminal
are equal to 10 linear , 3.0 m of pipe. If horizontal runs exceed
5 , 1.5 m they must be supported at 3 , 0.9 m intervals with
overhead hangers. e certi ed intake air terminal from RBI must
be used, see Figures 1, 2 and 4.
Common vent systems must be properly engineered
and sized to provide a negative dra of .03 in, 0.8 mm
to .1 in, 2.5 mm W.C. at the 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!
VENT SYSTEM OPTIONS
e ue products in the vent system may be cooled below
their dew point and form condensate in the ue. e materials
used for a Category IV vent must be resistant to any corrosive
damage from ue gas condensate. e ue from a Category IV
vent system must have a condensate drain with provisions to
properly collect and dispose of any condensate that may occur in
the venting system.
e Futera III may be vented the following ways:
1) Direct Vent, Positive Pressure, Category IV uses a vent
system certi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air
is piped from the outdoors to the blower inlet.
2) Side Wall Vent, Positive Pressure, Category IV uses a
vent system certi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
Vertical/Chimney Vent, Negative Pressure, Category II
3)
uses a metal chimney system approved for Category II.
Vertical Vent, Positive Pressure, Category IV
4)
system certi ed to UL 1738 for installations in the United States,
ULC S636 for installations in Canada. Combustion air is
obtained from the outdoors or the space in which the unit is
installed.
All venting and combustion air material supplied by
installer. All venting materials must be approved for the
application. Consult the vent manufacturer’s product
literature.
uses a vent
GENERAL VENTING GUIDELINES
e vent installation must be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54-latest revision or applicable provisions of the local building codes. Canadian
installations must comply with CAN/CGA B149.1
or .2 Installation Code. Improper venting can result
in excessive levels of carbon monoxide which can
result in severe personal injury or death!
All vent systems must be fully supported by the building structure
and not by the boiler/water heater. Appropriate thimbles and restops must be used where required.
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DIRECT VENT, POSITIVE PRESSURE,
CATEGORY IV
In this con guration the boiler/water heater blower is used
to push the ue products to the outdoors while drawing combustion
air from the outdoors. e Intake Air Option instructions under
the “COMBUSTION AIR & VENTILATION” section must be
followed! e vent system must be sized per Table 4.
Table 4 Category IV
Model
Size
500
750 5 127
1000 6 152
1250 6 152
1500 8 203
1750 10 254
2000 10 254
Pipe Diameter (Min.)
(Up to 60’)
in mm
5 127
Horizontal Direct Vent Systems
Figures 1 & 2
e vent materials used in horizontal vent systems must be certi ed
to UL 1738 for installations in the United States, ULC S636 for
installations in Canada. e certi ed vent terminal from RBI must
also be used.
e maximum equivalent length for the horizontal vent pipe is
60 , 18.3 m. Each 90° elbow and the vent terminal are equal to
10 linear , 3.0 m of pipe. If any part of a single wall metal vent
system passes through an unheated space, it must be insulated with
insulation rated for 400°F, 204°C. Structrual penetrations must
be made using approved re-stops. For best results, horizontal vent
systems should be as short and straight as possible.
e vent system must be both gas tight and watertight. All seams
and joints in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
Horizontal vent systems shall terminate at least 4 , 1.2 m below,
4 , 1.2 m horizontally from or 1 , 0.30 m above any door, window
or gravity air inlet into any building. It must not terminate less than
4 , 1.2 m horizontally from, and in no case above or below, unless
a 4 , 1.2 m horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment and not less than 7 ,
2.1 m above adjacent public walkway. e bo om of the vent
terminal(s) shall be located at least 5 , 1.5 m
above the air intake
terminal(s) unless there is a minimum 5 , 1.5 m horizontal
separation between them. Avoid terminal locations likely to be
a ected by winds, snowdri s, people and pets. Protect building
materials and vegetation from degradation caused by the ue gases.
Vertical Direct Vent Systems – Figure 3
If any part of a single wall metal vent system passes through an
unheated space, it must be insulated with insulation rated for 400°F,
204°C. Structural penetrations must be made using approved re-
stops.
An approved, nonrestrictive vent terminal must be used e top
of a vertical vent system must extend at least 5
1
/2 , 1.7 m above
the roof surface and maximum snow line that it passes through,
4 , 1.2 m above the intake air terminal, see Figure 3.
In addition the vent system must conform to the dimensions shown
in Figure 3. e penetration point in the roof must be properly
ashed and sealed.
e vent system must be gas tight. All seams and joints in metal
pipes must be joined and sealed in accordance with the vent system
manufacturer’s instructions.
Combination Direct Vent Systems – Figure 4
e boiler/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 “GENE L VENTING GUIDE
LINES” sections.
When horizontal vent runs exceed 5 , 1.5 m they must be supported
at 3 , 0.9 m intervals with overhead hangers. e vent system
must be pitched down, toward the vent terminal, 1/4 in/ , 20 mm/m.
If any part of a single wall metal vent system passes through an
unheated space it must be insulated with insulation rated for 400°F,
204°C.
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Figure 1 Hoizontal Air Intake an Venting for a Single Direct Vent System
16 FT 4.9 m
1.5 FT 0.5 m
1/4 IN. PER FOOT
20 mm/m
When running horizontal combustion air and venting for
single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall)
in order to prevent pressure di erences due to prevailing
winds. In cold climates, double-wall or insulated inlet pipe
recommended to prevent condensation.
Figure 2 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
MBH
500 TO 1000
1001 TO 2000
2001 TO 4000
4001 & LARGER
kW
146 TO 293
293 TO 586
586 TO 1172
1172 & LARGER
FT m
5 1.5
10 3.1
15 4.6
20 6.1
5 FT 1.5 m
1.5 FT 0.5 m
1000 BTU’S
2 IN. 5.0 cm
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Figure 3 Vertical Air Intake and Venting for a Direct Vent System
4 FT
1.2 m
1.5 FT
0.5 m
5 FT
1.5 m
5 1/2 FT
1.7 m
10 FT 3.1 m
Figure 4 Combination Direct Vent Systems
3 FT. 1 m
10 FT. 3.1 m
1.5 FT. .5 m
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SIDE WALL VENT, POSITIVE PRESSURE,
CATEGORY IV
In this con guration the boiler/water heater blower is used to push
the ue products horizontally to the outdoors, see Figure 5. e
air for combustion is taken from the space in which the unit is
installed. e applicable instructions under the “COMBUSTION
AIR & VENTILATION” section must be followed! e vent
guidelines under the Horizontal Direct Vent Systems section must
also be followed.
VERTICAL VENT, NEGATIVE PRESSURE,
CATEGORY II
e Futera III is listed as a Category II appliance when vented
vertically into a listed metal chimney system, Figures 6 & 7. e
chimney must provide a negative pressure not greater than 0.15
in, 3.8 mm W.C. at the boiler/water heater ue collar with the
unit running. A barometric damper must be installed between the
ue collar and the vent connector when negative pressures exceed
0.15 in, 3.8 mm W.C.
W hen using a listed metal chimney system the chimney
system manufacturer’s instructions must be followed.
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
If an appliance using any type of a mechanical dra
system operating under positive pressure is connected
to a chimney ue, never connect any other appliances
to this ue. Doing so can result in excessive levels
of carbon monoxide which can cause severe personal
injury or death!
Chimney Inspection & Sizing
A thorough inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed, lined
and sized. Exterior masonry chimneys should not be used unless
properly lined to prevent condensation and dra problems. Table
5 lists the equivalent breeching and ue sizes required for the boiler/
water heater.
Table 5 Equivalent Breeching & Chimney Size, Negative Pressure
Model Size Pipe Diameter
in
500
750
1000
1250
1500
1750
2000
Note: These sizes are based on a 20 ft, 6.1m chimney height.
6
6
7
8
8
10
10
mm
152
152
178
203
203
254
254
When more than one appliance is connected to the same chimney
ue, the ue must be large enough to safely vent the combined
output of all of the appliances.
Figure 5 Side Wall Venting
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g
VERTICAL VENT, POSITIVE PRESSURE,
CATEGORY IV
(Vent pipe equivalent length up to 60 , 18.3 m maximum)
Masonry chimneys, when used, must be lined with a
metal liner certi ed for Category IV venting.
A thorough inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed lined, and
sized. Exterior masonry chimneys should not be used unless
properly lined to prevent condensation and dra problems.
Vent Connections
Locate the boiler/water heater as close to the chimney as
possible. Use the shortest, straightest vent connector possible for
the installation. If horizontal runs exceed 5 , 1.5 m they must be
supported at 3 , 0.9 m intervals with overhead hangers. Use a
single wall stainless steel vent pipe the same diameter as the ue
collar to connect the boiler/water heater to a masonry chimney.
When using a listed metal chimney system use the appropriate vent
connector.
e vent connector should be sloped up toward the chimney at a
minimum rate of 1/4 in/ , 21 mm/m. On masonry chimneys
the connector must terminate ush with the inside of the chimney
ue, Figure 7. 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.
Failure to maintain minimum clearances between vent
connectors and any combustible material can result
in a re causing extensive property damage, severe
personal injury or death!
Exit cones are favorable when used to increase
the velocity of the ue gas exiting the stack and,
may also help, in cold climates, to reduce ice buildup. Exit cone terminations must be supplied by
others, installed per manufacturer’s instructions,
and meet local and federal code.
eneric exit cone
OUTDOOR VENTING
When installed outdoors the Futera III must be ed with the factory
supplied outdoor hood, air intake adapter with lter and exhaust
terminal, see Figure 7A. Multiple units must be spaced per Figure 7B.
e boiler/heater must be at least 2 , .62 m from any door, window
or gravity air inlet into any building and at least 3 , 1 m from any
overhang unless local codes dictate di erently.
Figure 6 Vertical Venting with a Metal Chimney System Figure 7 Vertical Venting Using a Lined Masonry Chimney
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A
Avoid locations where wind de ection o of adjacent walls, buildings
or shrubbery might cause a downdra . e unit(s) shouild be
located at least 3 , 1 m from structures. Outdoor installations are
not recommended in areas where the danger of snow blockage
exists.
Do not place the boiler/water heater in a location that
would subject it to runo from adjacent buildings or
damage may occur voiding the warranty!
Figure 7A Outdoor Venting
GAS TRAIN COWLING
AIR INLET
UNDER COWLING
DISCHARGE VENT
FLUE TEST
PORT
COMMON VENT SYSTEMS
On multiple boiler common vent applications, the master boiler
may be required to be rst on and installed closest to the verticle
chimney (consult factory).
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 fonction-nent pas:
système d’évacuation
a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système 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 de ciencies which could cause an unsafe
condition.
RIOM-59-REV. A
Figure 7B Multiple Outdoor Units
3 FT
(1 M)
2 FT
(0.62 M)
CONDENSATE
DRAIN WITH
PIG TAIL
Inspecter de façon visuelle le système d’évacuation pour déter-
miner la grosser et l’inclinaison horizontale qui conviennentet
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 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. Me re en marche
les sécheuses, tous les appareils non raccordés au système
d’évacuation commun et tous les ventilateurs d’extraction
comme les ho es de cuisinère et les ventilateurs des salles de
bain.
S’assurer que ces 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.
RIOM-60 REV.
Me re l’appareil inspecté en marche. Suivre les instructions
d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.
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e) Test for spillage at the dra hood relief opening a er 5
minutes of main burner operation. Use the ame of a match
or candle, or smoke from a cigare e, 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 amme d’une allune e ou d’une chandelle ou la fumée
d’une cigare e, d’un cigare ou d’une pipe.
f) A er 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,
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. Reme re 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.
Shut o valves and unions should be installed at the
inlet and outlet connections of the boiler/hot water
heater to provide for isolation of the unit should
servicing be necessary.
Freeze Protection
Installations in areas where the danger of freezing exists are not
recommended unless proper freeze protection is provided. e
following precautions MUST be observed:
1. A continuous ow of water through the unit MUST be maintained! e pump responsible for 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. e
pump must be capable of producing a minimum of 15% more
ow and overcoming a 20% increase in head loss. Domestic
water systems must be isolated from the water heater by the
use of a heat exchanger or other approved method.
3. If the unit must be shut o for any reason the electric, gas and
water supplies MUST be shut o and the unit and its pump
completely drained.
Improper outdoor installation of this unit can cause
boiler failure voiding the manufacturer’s warranty!
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 modi ée, le système
devrait étré modi é 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
Improper piping of this boiler/water heater will void
the manufacturer’s warranty and can cause boiler
failure resulting in ooding and extensive property
damage! Excessive water hardness causing scaling in
the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty, see Table 8.
Excessive pi ing and erosion of the internal surface
of the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result of high
water ow rates, see Table 7. 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 9.
Valve
Pipe the discharge of the pressure relief valve as shown in Figure 8.
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
e ow switch supplied with the boiler/water heater must be wired
to the terminal strip in the control panel to prevent the boiler from
ring unless there’s adequate water ow through the unit. e ow
switch must be installed in the supply piping adjacent to the boiler
outlet connection.
Failure to properly install the ow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
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Figure 8 Futera III Piping
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HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a quali ed technician
in accordance with the latest revision of the ANSI/ASME Boiler
and Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1,
Standard for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must also be
followed. A minimum clearance of 1 in, 25 mm must be maintained
between heating system pipes and all combustible construction.
All heating system piping must be supported by suitable hangers
not the boiler. e thermal expansion of the system must be
considered when supporting the system. A minimum system
pressure of 12 psig, 82.7 kPa must be maintained.
Heating Boiler Piping Connections
e supply and return connections should be sized to suit the system,
see Table 6.
Table 6 Supply & Return Pipe Sizing (Flanged)
Model Size Supply Size Return Size
500 thru 1000 2” 2”
1250 thru 2000 2 1/2” 2 1/2”
Pump Requirements
is low mass boiler requires a continuous minimum water ow
for proper operation. e 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 7 provides the heat exchanger
pressure drop and temperature rise gures. e temperature rise
across the boiler must never exceed 35°F, 19.4°C. e adjustable
pump delay turns the pump on each time the burner res and runs
the pump for 20 to 600 seconds a er the call for heat is satis ed.
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A temperature rise outside of the range listed in Table
7 indicates that the ow rate through the heat exchanger
is incorrect which will damage the heat exchanger
voiding the warranty! e maximum allowable
temperature rise is 35°F, 19.4°C.
e maximum allowable ow rate through a Futera III
boiler is 97 GPM, 6.1 L/s on 500 through 1000 models
and 136 GPM, 8.6 L/s for 1250 through 2000 models.
e Cupro-Nickel heat exchanger allows for 108 GPM,
6.8 L/s on 500 through 1000 models and 151 GPM,
9.5 L/s on 1250 through 2000 models.
Table 7 Temperature Rise Table
ΔT = 20°F
Model
Number
500
750
1000
1250
1500
Model
Number
500
750
1000
1250
1500
1750
2000
Model
Number
750
1000
1250
1500
1750 101.5
2000
Model
Number
750
1000
1250
1500
1750
2000
Flow Rate Pres. Drop
GPM Ft
43.5 0.55
65.3 1.63
87.0 3.59
108.8 2.21
130.5 3.73
ΔT = 25°F
Flow Rate Pres. Drop
GPM Ft
34.8 0.36
52.2 1.08
69.6 2.37
87.0 1.46
104.4 2.46
121.8 3.84
139.2 5.63
ΔT = 30°F
Flow Rate Pres. Drop
GPM Ft
43.5 0.77
58.0 1.69
72.5 1.04
87.0 1.76
116.0 4.01
ΔT = 35°F
Flow Rate Pres. Drop
GPM Ft
37.3 0.58
49.7 1.27
74.6 1.32
87.0 2.06
99.4 2.02
2.74
62.1 0.78
ΔT = 11.1°C
Flow Rate Pres. Drop
L/s kPa
2.7 1.6
4.1 4.8
5.5 10.6
6.9 6.5
8.2 11.0
ΔT = 13.9°C
Flow Rate Pres. Drop
L/s kPa
2.2 1.1
3.3 3.2
4.4 7.0
5.5 4.3
6.6 7.3
7.7 11.3
8.8 16.6
ΔT = 16.7°C
Flow Rate Pres. Drop
L/s kPa
2.7 2.3
3.7 5.0
4.6 3.1
5.5 5.2
6.4 8.1
7.3 11.8
ΔT = 19.4°C
Flow Rate Pres. Drop
L/s kPa
2.4 1.7
3.1 3.8
3.9 2.3
4.7 3.9
5.5 6.1
6.3 8.9
Low Water Cuto
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to the wiring diagram supplied with the boiler/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 ow rates or return water temperatures less than 125°F, 52°C must be isolated from these systems
to protect the boiler.
Variable Water Flows
Figure 9 shows a typical primary/secondary piping system. A
dedicated pump is used to maintain a constant water ow through
the boiler. is secondary pump is sized to overcome the head loss
of the boiler and secondary piping system while supplying the ow
rate required to maintain the desired temperature rise across the
boiler. e primary pump is sized to provide the required ow to
the heating system. e secondar y 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 9.
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 con guration must
be installed, see Figure 10. e bypass system must be sized the
same as the secondary piping. e primary and secondary pumps
should be sized to provide the required ow through each system.
e 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 10.
Multiple Boiler Systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 11.
Piping For Use With Cooling Units
e boiler, when used in connection with a refrigeration system,
must be installed so the chilled medium is piped in parallel with
the boiler. Appropriate valves must be used to prevent the chilled
water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed
to refrigerated air from an air handling device, the piping system
must be equipped with ow-control valves or some other automatic
means of preventing gravity circulation of the boiler water during
the cooling cycle.
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Figure 9 Typical Primary/Secondary Piping System (See Notes)
NOTES:
1. Boiler circuit piping must be sized
large enough to handle maximum ow
through unit.
2. Boiler pump sized to boiler design 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 con guration and valving.
Check with local codes and ordinances for
speci c requirements.
Pump
Gate Valve
Globe Valve
Angle Valve
Bufferfly Val ve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
Figure 10 Low Temperature Piping with Thermostatic Valve (See Notes and Adjustment Procedures)
Self-Operated
Val ve
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
Backflow-
Prevention
Device
NOTES:
1. For pump selection consult factory.
2. Boiler pump sized to boiler and thermostatic 3-way valve design ow requirements.
3. Boiler circuit piping must be sized large enough to handle maximum 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 con guration and valving.
Check with local codes and ordinances for speci c requirements.
3-Way Valve
Expansion
Tan k
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Figure 11 Multiple Boiler Piping (See Notes)
Pump
Gate Valve
Globe Valve
Angle Valve
Bufferfly Val ve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
H-15 Rev 4
NOTES:
1. Boiler circuit piping must be large enough to handle maximum ow through unit.
2. Boiler pump sized to boiler design 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 ow through all units.
Notice: These drawings show suggested piping con guration and valving.
Check with local codes and ordinances for speci c requirements.
Self-Operated
Val ve
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
BackflowPrevention
Device
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DOMESTIC WATER SUPPLY PIPING
Proper controls must be used to prevent water sup-
plied 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. e 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.
e storage tank must be located as close to the water
heater as possible to prevent excessive head loss which
will reduce ow.
To properly size the pump a grain hardness and pH test
must be taken at the installation site before the order is placed.
Proper pump sizing will improve heater performance and help
ensure heater longevity.
Expansion Tank
An expansion tank or other means to control thermal expansion
must be installed in the water heating system if back ow prevention devices are installed.
Pump Requirements
is low-mass water heater requires a continuous mini-mum water
ow for proper operation. e low water ow switch provided for
this unit will shut down the water heater if ow falls below the
required minimum level. Table 8B provides the heat exchanger pres-
sure drop chart and temperature rise table. e temperature rise
across the water heater must never exceed 35°F, 19.4°C.
Cold Water Supply
e cold water supply must be piped to the water heater’s outlet
piping between the water heater and the hot water storage tank.
is 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 12 & 13.
Water Chemistry
e 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.
A cupro-nickel heat exchanger may also be required. e manufacturer should be consulted when these water conditions are
encountered. See Table 8A.
e maximum allowable ow rate through a Futera III
water heater is 97 GPM, 6.1 L/s on 500 through 1000
models and 136 GPM, 8.9 L/s for 1250 through 2000
models. e cupro-nickel heat exchanger allows for
108 GPM, 6.8 L/s on 500 through 1000 models and
151 GPM, 9.5 L/s on 1250 through 2000 models, see
Table 8B.
RBI water heaters are designed to run scale free. Due to the extreme
variables of water conditions world wide it is necessary to
consider pH values and water hardness in relationship to scaling.
It is crucial to consider these two variables when making heat
exchanger and pump selections. If local water conditions are extreme,
follow the guidelines in the Heat Exchanger Selection Table (Table
8A) and the Pumping Performance Table (Table 8B). 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.
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. e 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 ow rate through
the heat exchanger. ermometers are installed on both the inlet
and outlet of the water heater for determining the temperature rise
through the unit.
e proper velocity through the water heater must be maintained
in accordance with Table 8B for e cient operation and long life.
If the temperature rise through the water heater is lower than
recommended the water velocity is too high. Premature erosion of
the heat exchanger will occur. Conversely, if the temperature rise
is higher than recommended in Table 8B the ow rate is too low.
Scaling and so ening of the heat exchanger will occur.
ermostatic Mixing Valve – Water Above 140°F, 60°C Wa te r
can be stored at temperatures above 140°F, 60°C provided that a
thermostatically controlled mixing valve is used to temper the hot
water to an acceptable temperature before it’s supplied for domestic
use.
e mixing valve MUST be set to prevent a scald injury from
occurring, see the caution against scalding.
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.
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Table 8A Futera III Heat Exchanger Selection Graph
Table 8B Futera III Pumping Performance Requirement
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Figure 12 Typical Water Heating Piping (MW Models Only)
3
8
2
1
4
7
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Figure 13 Multiple Water Heating Piping (MW Models Only) (See Notes)
SELF BALANCIN G DOUBLE REVERSE
RETURN MAKE-UP & SUPPLY, CIRCULATION
4
3
6
1
7
2
8
7
D-1 Rev 6
4
Pump
Valve
Globe Valve
Angle Valve
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
Self-Operated
Valve
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
Temperature &
Pressure
Relief Valve
Vacuum
Relief Valve
Drain Valve
(Typ.)
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. ermal 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.
e 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 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: ese drawings show suggested piping con guration and valving.
Check with local codes and ordinances for speci c requirements.
2
6
D-4 Rev 6
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
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GAS SUPPLY PIPING
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!
e Futera III 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.
A minimum gas supply pressure of 2 in, 51mm, W.C.
natural or propane and maximum 14 in, 356 mm W.C.
natural or propane, must be available at the safety
shuto valve inlet with the unit(s) operating.
Table 9 should be used to ensure that the gas supply piping is sized
properly. If more than one appliance is supplied by the same supply
pipe, the piping must be sized based on the maximum possible
demand. Do not neglect the pressure drop due to pipe ings. Table
9 should be used in conjunction with Table 10 to ensure that the
gas supply piping has the capacity to meet the demand.
Figure 14 depicts the proper way to connect the boiler/water heater
to the gas supply piping. e manual shut-o valve MUST be
installed in the supply piping. It should be installed 5 , 1.5 m
above the oor where required by local codes. Provide a sediment
trap at the bo om of the vertical section of the gas supply pipe
upstream of the gas controls.
A ground joint union should be installed between the boiler gas
controls and the supply piping. Each of these items are needed to
ensure long life and ease of servicing. Always use a pipe sealant
that is suitable for use with LP gas.
Table 9 Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specifi c gravity gas
at a pressure of 0.5 psig or less and a 0.3” WC pressure drop.
Nominal
Iron Pipe
Size, (in)
1" 520 350 285 245 215 195 170 150 120
1 1/4" 1050 730 590 500 440 400 350 305 250
1 1/2" 1600 1100 890 760 670 610 530 460 380
2" 3050 2100 1650 1270 1270 1150 990 870 710
Note: Multiply the gas volume by 0.62 for propane fl ow capacity in ft
Multiply the propane fl ow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
Table 10 Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size, (in)
1" 2.6 5.2 0.6 1.5
1 1/4" 3.5 6.9 0.8 1.9
1 1/2" 4.0 8.0 0.9 2.3
2" 5.2 10.3 1.2 3.0
Notes: 1. For fl ow through branch.
2. For fl ow at full open.
10 20 30 40 50 60 80 100 150
Maximum gas volume of pipe, (ft
90° Elbow Tee
Pipe length in feet
Type of pipe fi tting
1
Gate Valv e2Gas Cock
Equivalent pipe length, (ft)
3
/hr)
3
/hr.
2
Always use a wrench on the gas valve body when
making gas connections to it. Never over-tighten the
piping entering the gas valve body or gas valve failure
may result!
Figure 14 Gas Supply Piping
20
When applicable, provisions for vent, bleed and gas relief lines must
be made in accordance with the latest revision of ANSI Z223.1/
NFPA 54. e main Dungs gas valve supplied with boiler/water
heater does not require external venting.
Safe lighting and other performance criteria were met with the gas
manifold and control assembly provided on the boiler. All gas
connections MUST be leak tested before pu ing the boiler into
operation.
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Never use an open ame to test for gas
leaks. Always use an approved leak detection method.
Failure to comply with this warning can cause extensive
property damage, severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler/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 o valve, see Figure 14. If the test pressure
is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/
water heater and its individual shut-o valve.
ELECTRICAL WIRING
Electrical Power Connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation! Verify proper operation a er
servicing.
Au moment de l’entretien des commandes, étiquetez
tous les ls avant de les débrancher. Des erreurs de
câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne
adéquatement une fois l’entretirn terminé.
e electrical connections to this boiler/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.
Refer to the wiring diagram supplied with the boiler/water heater
for proper wiring connections and boiler full load amperage (FLA).
GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not a empt
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 o , turn o
the manual gas control valve to the appliance. Do not interrupt
water ow through the boiler/water heater.
En cas de surchau e ou si l’alimentation en gaz ne s’arrête pas, fermez
manuellement le robinet d’arrêt de l’admission de gaz.
Hydronic Heating Boilers
Open the make-up water valve and slowly ll the boiler and all of
the radiation with water. Ensure that all bleed and drain valves are
closed.
Adjust the make-up water pressure regulator so a minimum12 psig,
82.7 kPa system pressure is maintained at the highest point in the
system piping. If a make-up water pump is used adjust it to maintain
a minimum 12 psig, 82.7 kPa system pressure.
Open the system bleed and drain valves, one at a time, to purge
the air trapped in the heating system piping.
Install a separate 120 volt 15 amp or 20 amp circuit breaker for the
boiler/water heater and pump, see Table 11. A properly rated shuto switch should be located at the boiler/water heater. e 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.
Table 11 Futera III Electrical Requirements
Recommended
Futera III Circuit Breaker *Running
Model (Amps) Amps
MB/MW 500 15 3.9
MB/MW 750 - 1000 15 6.0
MB/MW 1250 - 2000 20 11.4
*Use separate circuit breaker that is properly sized for pump and
pump contactor.
Line voltage eld wiring of any controls or other devices must
conform to the temperature limitation of type TEW wire at 95°F,
35°C above room temperature. Use copper conductors with a
minimum size of #14 awg. Use appropriate wiring materials for
units installed oudoors. e wire size must be compatible with the
total amp draw of the circuit.
With the boiler o , run the system pump for at least 30 minutes
and bleed the system piping using the bleed valves. If strainers are
used in the system piping, the make- up water valve should be closed
and the strainers checked and cleaned.
e system expansion tank should be checked to ensure that the
correct water level in the tank is maintained. e tank should be
less than half full of water with the system full and adjusted to the
correct operating pressure.
Start the boiler as described in the “OPE TING INSTRUCTIONS”
section. Run the boiler for at least an hour. e system pump(s)
and all radiation units must be operated during this time. Ensure
that the make-up water valve is open.
Shut the boiler o and open the bleed valves to purge the air trapped
in the heating system piping. Close the make-up water valve and
check and clean the strainers and make-up water pressure reducing
valve.
Open the make-up water valve and adjust the system pressure if
necessary. e system should be checked and bled a er three days
of operation.
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OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE
A. is appliance is equipped with an ignition device which 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 OPE TING smell all around the appliance area for
gas. Be sure to smell next to the oor because some gas is heavier
than air and will se le on the oor.
Propane gas may not always be detected by smell.
Propane gas is heavier than air and can collect in low
areas.
Propane gas can ignite or explode if an ignition source
is present and result in death, serious injury and
property damage!
FOR YOUR SAFETY
• Have only quali ed licensed professionals install, service and
maintain this appliance and your gas system in accordance with
all applicable codes.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not a empt to light any appliance.
3. Do not touch any electrical or electronic switches in the
building.
4. Do not use any phone in the building.
5. Call your gas supplier from a phone outside of the building.
6. If you cannot reach your gas supplier call the re department.
AVANT DE FAIRE FONCTIONNER, reni ez tout autour de
l’appareil pour déceler une odeur de gaz. Reni ez près du
plancher, car certains gaz sont plus lourds que l’air et peuvent
s’accumuler au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des
téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gaz depuis un
voisin. Suives les instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur, appelez le service
de incendies.
C. Do not use this appliance if any part has been under water.
Immediately call a quali ed service technician to inspect the
appliance and to replace any part of the control system and any
gas control that has been under water.
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
partiellement. Faites inspecter l’appareil par un tecnicien quali é
et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.
Operating Instructions
1. STOP! Read the safety information above. If, at any time, the
appliance will not operate properly, follow the instructions “TO
TURN OFF GAS TO APPLIANCE” and call your service
technician or gas supplier.
2. Set the operating control to o and disable any outside (BMS)
call for heat.
3. Turn o all electric power to the appliance.
4. Close main isolation gas valve ( eld supplied), Figure 14.
5. Purge the gas piping up to the manual valve ahead of the main
gas control of air. When the bleeding is complete, check all gas
joints up to the gas valve for leaks.
6. Wait ve (5) minutes to clear out any gas.
7. Install a ing at the supply test port and connect a manometer
having a minimum range of 20 in, 508 mm WC to it, Figure
14.
8. Remove the 1/8" pipe plug from the pilot test port located on
the CV100 pilot/reg combination gas valve and connect a
manometer having a minimum range of 6 in, 154 mm WC to
it, Figure 14(a).
9. Open the main isolation gas valve ( eld supplied), Figure 14.
10. Place the “Remote/Local” switch to Remote inside control
cabinet, Figure 15.
11. Turn the power switch on the front of the boiler to “on”. It will
light up when the power is on. If all interlocks are properly
closed, the display will say “Standby”, Figure 15.
12. Slide the Low Fire Hold Switch (on HeatNet control board)
to Low Fire position.
13. e boiler will begin the start sequence.
14. When the main display reads “PILOT RUNNING” and the
ame current is 5 VDC, switch the Honeywell 7800 to the “test”
position, Figure 15. is will hold the Honeywell 7800 in its
ignition state.
15. Adjust the pilot pressure per the CHECKING, ADJUSTMENT
& OPE TION section.
16. Remove the demand from the 7800 control by disabling the
Low Fire switch allowing the boiler to stop.
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Figure 15 HeatNet Control Panel
TRANSFORMER
MANUAL RESET
PUMP MOTOR
RELAY
LOCAL REMOTE
SWITCH
DISPLAY
WINDOW
BACK
BUTTON
TEST RUN
SWITCH
HEAT NET
CONTROL
BOARD
FLAME
SAFEGUARD
MODULE
PROTOCESSOR
MODULE
(OPTIONAL)
IGNITION STATUS
WINDOW
UP BUTTON
DOWN BUTTON
POWER SWITCH
24. Se ing the low re: Allow the low re to se le out for a few
minutes and observe the combustion reading. Refer to
“Combustion Reading” table for proper combustion readings
and elbow pressure, Table 12.
e low re O
-CO2 can be adjusted in the eld by opening
2
the low re adjustment door located on the forward facing side
of the main gas valve, see Figure 14(a). Inserting an allen wrench
and rotating the allen screw clock-wise will increase the CO
and lower the O2, rotating counter clock-wise will decrease the
CO2 and increase the O2. DO NOT LEAVE THE BURNER
IN AN INF RED STATE. A few random speckles of red
are ne, but large concentrations of spots or large areas of red
are not. If large amounts of red concentrations are observed,
verify combustion readings.
25. Jumper the “AA” terminals located on the HeatNet control board.
e boiler input will rise to its maximum input, “Run 100%”,
see Figure 17.
26. Allow the boiler to reach steady state and verify supply gas
pressure and check input rates as explained in the “Gas Supply
Piping” section. Also, refer to “Combustion Reading” table for
proper combustion readings and elbow pressure, Table 12. e
high ve trim is located on the outlet ange of the gas valve,
see Figure 14(a). O
-CO
can be adjusted by inserting a screw
2
2
driver and rotating clockwise to increase the CO2 and lower
the O2 . Rotating counterclockwise will decrease the CO2 and
increase the O2.
27. Remove jumper “AA” and allow boiler to se le into minimum
input. Observe the combustion readings and make any nal
adjustments. When nished disable the Low Fire Hold Switch
and replace test ports to normal state. 28. Boiler allows for
many modes of operation and control methods. Reference the
“HeatNet Control Manual”.
2
SELECT BUTTON
17. Close main isolation gas valve ( eld supplied), Figure 14.
18. Remove the manometer ing from the pilot test port and
replace the plug. Place monitor tube on to the test port tee
located along the1/3" hose piped directly o of the manifold
test port, Figure 14(a).
19. Switch the Honeywell 7800 back to “run”.
20. Create a min input demand as before (enable Low Fire Hold
switch.) e boiler will begin the start sequence.
21. Monitor the ame current on the 7800. No ame current should
be detected and the 7800 should lock out. If ame current is
detected at any time up to the 7800 locking out, the 120V wiring
on the ignition transformer must be reversed and the test run
again to insure that no ame is detected.
Improper wiring of the ignition transformer can result
in an explosion causing extensive property damage,
severe personal injury or death!
22. Open main isolation gas valve ( eld supplied).
23. Reset the Honeywell 7800. e boiler will start and will run
at minimum input rate.
Table 12 Combustion Readings
Natural Fuel Propane Fuel
CO
O
%
2
%
2
8.0 - 8.5 (min.) 9.4 - 9.9 (min.)
8.8 - 9.8 (100%) 10.3 - 11.5 (100%)
6.6 - 5.8 (min.) 6.6 - 5.8 (min.)
5.2 - 3.5 (100%) 5.2 - 3.5 (100%)
For factory set gas manifold (elbow) pressures see label on
inner cabinet door.
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Figure 14(a)
INSTRUCTIONS DE MISE EN MARCHE
1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion
supérieure de ce e étique e.
2. Réglez le thermostat à la température la plus basse..
3. Coupez l’alimentation électrique de l’appareil.
4. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse
manuellement.
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
6. A endre cinq (5) minutes pour laisser échapper tout le gaz.
Reni 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 ce e étique e. 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. Me ez 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 couper l’admission de gaz de l’appareil et appelez un
technicien quali é ou le fournisseur de gaz.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest se ing.
2. Turn o all electric power to the boiler if service is to be
performed.
3. Close the manual main and pilot gas shut-o valves.
COMMENT COUPER L’ADMISSION DE GAZ DE
L’APAREIL
1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut procéder
à l’entretien.
3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. e boiler is idle with no interlocks in the fault condition.
DEMAND
Pre-Purge
1. e blower operates at purge RPM. e water ow interlock
must ‘make’ within 15 seconds a er the demand signal is
initiated.
2. e Honeywell 7800 starts a 10 second purge delay once the
air prove switch contacts close.
Pilot Run - % Input
1. e blower operates at minimum ignition se ing. See the
calibration section in the “HeatNet Control-IOM” to enter the
calibration menus.
2. e ignition transformer is energized. e pilot solenoid valve
opens for the 10 second pilot ignition trial.
Main Run % Input
1. e main gas valve opens.
2. e ignition transformer is de-energized.
3. e pilot solenoid valve closes.
4. e blower stays at the minimum input se ing for 3 seconds
then operates at demand % input. See the calibration section
in the “HeatNet Control-IOM” to enter the calibration menus.
NO DEMAND
Post-Purge
1. e main gas valve closes.
2. e blower operates at purge RPM for 10 seconds.
3. e boiler is idle with no interlocks in the fault condition.
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CHECKING & ADJUSTMENTS
Spark Gap
With the main and pilot gas manual valves in the closed position
energize the unit. Observe the trial for ignition to con rm that the
spark is strong and continuous. If not check and adjust the spark
gap as shown in Figures 17 &18.
Figure 16 Spark Gap
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
LP Nat
Minimum (in. W.C.) 2 2
Maximum (in. W.C.) 14 14
Measure pressure when the boiler is ring at full rate. Low
gas pressure could indicate undersized gas line or insu cient gas
supply.
“Static and operating gas pressure required at the gas valve inlet is
between 2" W.C. and 14" W.C. for natural gas and 2" W.C. and
14" W.C. propane. If the gas pressure is above this limit, a lock-up
style regulator suitable for dead end service such as an Equimeter
or Fisher must be installed to prevent increase (creep) of gas
pressure when the units are not operating. is pressure regulator
(supplied by others) may be installed at the service entrance to
each unit or a “master” regulator sized to handle multiple units may
be utilized. Consult local gas utility or regulator manufacturer for
recommendations to meet speci c job site requirements.”
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 , 610 m. At elevations
above 2000 , 610 m input ratings should be reduced by 4% for
each 1000 , 305 m.
Pilot Adjustment
e pilot pressure has been factory set at 3 in. W.C. for natural and
LP gas and shouldn’t need adjustment. To check the pilot pressure
close the manual main shut-o valve 2 and the pilot gas shut-o
valve, Figure 14. Remove the 1/8" pipe plug from the pilot tee and
connect a manometer having a minimum range of 6 in, 152 mm
WC to it. Open the pilot gas shut-o valve. With the unit powered,
generate a call for heat. When the prepurge is complete the ignition/
pilot trial will begin. At this point put the Honeywell RM7800 test
switch in the test position. e control will hold in the ignition/
pilot sequence allowing you to check the pressure.
To adjust the pilot the following steps must be taken:
1. Remove the pilot gas pressure regulator cap.
2. Turn the pressure regulator adjustment screw clock-wise to
increase the pressure and counterclockwise to decrease it.
3. Replace the pressure regulator adjustment screw cap.
Never force the regulator adjustment screw beyond the stop
limits or damage to the regulator will occur!
Check the input rate as follows:
1. Turn o 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
3
, 0.28 m3 of gas and divide 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, consult factory.
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!
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Figure 17
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RBI HEATNET FIELD WIRING TO TERMINAL BLOCK
(BoardRevision 2.0 and Greater)
NOTES:
1. Remove jumper “A” when using a low water
cuto interlock.
2. For multiple boilers utilizing a system air damper
when in a master/member con guration consult
factory or reference wiring diagram 42-0505
sheet 2 for wiring connections.
3. For single boilers or multiple boilers with
individual dampers connect the end proving
switch to main terminal block 15 and 16.
Terminals 17 and 18 provide 120V power to the
damper motor.
4. There are two methods in which a 4-20mA
signal can be used to control HeatNet equipped
boilers.
Method 1
A 4-20mA signal can be used to directly
modulate each boiler from a remote panel or
building management system. On multiple
boiler installations, there is no communication
between boilers, no HeatNet system sensor;
therefore no master/member relationship exists.
(Use Menu: Setup: Setpoints: Setpoint Source:
Auto)
Method 2
A 4-20mA signal can be used to change
the setpoint temperature the HeatNet is
maintaining. This can be used on single
or multiple boilers with a master/member
relationship. (Use Menu: Setup: Setpoints:
Setpoint Source: 4-20, then set the parameters
for the temperature and boiler start point.)
5. The ‘local’ pump relay in the control panel is
rated for 1 hp, 1Ø motors. For larger or 3Ø
reference factory wiring diagram.
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CONTROL DESCRIPTION
Low Water Cuto
If the boiler is to be installed above radiation or if required by other codes
or regulations, install a low water cuto in appropriate piping. Wire the switch
to the “Interlock” contacts as illustrated on “Field Wiring” schematic. Ensure
that the low water cuto device(s) will funtion properly.
Operating Control
e preferred control se ing for potable hot water is 130°F, 54°C.
e operating control should be set to the lowest se ing that will
satisfy the consumer’s needs.
Se ing the thermostat or operation control too high
can result in scalding resulting in severe personal injury!
High Limit (Aquastat)
e high limit is located in the top control area of the boiler/water
heater. A remote capillary bulb is run to a well on the outlet side
of the supply header. e high limit can be reset by depressing
the red bu on.
e 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 ow switch is provided in the water outlet piping to prevent the
boiler/water heater from ring without adequate water ow through
the heat exchanger.
STATUS SCREEN FAULT DISPLAY
ere are numerous interlock switches and so ware limits that are
detected. Each of these, when tripped will produce a display message,
an audible beeping, and an alarm relay closure. e fault is displayed
rst, then a er a second, the time the fault occurred is displayed.
is cycle will keep occurring until the fault is cleared. ese faults
are:
HIGH LIMIT: When the high limit aquastat trips the following
message is displayed:
FAULT
SYSTEM SET
HIGH LIMIT
160˚F
FAULT
10/27 9:16
SYSTEM SET
160˚F
e high limit interlock breaks power to the ignition control
(sh u ing it o ) and e ectively removes any chance of the gas valve
receiving power. e FIII series control will remain powered to
display the fault, latch the alarm relay/audible beeper, and to access
the log. e interlock is located on J5, HIGH LIMIT.
INTERLOCK SPARE 3: is is a reserved interlock input that is
normally jumpered at the factory, but can have a remote interlock
connected as a eld install. e interlock is located on J11A, SPARE 3.
DIAGNOSTICS
e Futera III has a display that indicates the sequence of
operation. e display will also list faults should the unit fail
to operate. An explanation of each status message and fault
can be located in HeatNet Control Manual under status screen
fault display section.
28
FAULT
SYSTEM SET
INTERLOCK SPARE 3
160˚F
LOW WATER CUTOFF: If there is a low water condition reported
by the low water cuto switch this fault is displayed. Check that
there is water ow and water in the boiler. ere is a reset switch
located on the LWCO box. e interlock connection is located
on J11A, LWCO.
FAULT
SYSTEM SET
LOW WATER CUTOFF
160˚F
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VAR FREQ DRIVE: e variable frequency drive, which controls
the blower, reports this fault in the event of over current or other
conditions that would cause it to shut down. If this is the case, check
the fault indicators on the VFD. e interlock is located on J11A, VFD.
FAULT
VAR FREQ DRIVE
SYSTEM SET
160˚F
GAS PRESSURE: e optional gas pressure switches (high pressure
and low pressure) are connected in series, so if either trip, a fault
will be reported here. A reset switch is located on the gas pressure
switches. e interlock is located on J11A, GAS PR.
FAULT
GAS PRESSURE
SYSTEM SET
160˚F
FLOW SWITCH ERROR: Once the FIII series boiler receives a
call for heat, it closes the circulator pump relay. It then waits 10
seconds to prove ow. If there is no ow, the ow switch alarm will
be set. Every 10 seconds the circulator pump relay will cycle ON
for 10 seconds and then OFF for 10 seconds to try and establish
ow. e interlock connection is located on J11B, WTR FLW.
FAULT
WATER FLOW SWITCH
SYSTEM SET
160˚F
IGNITION CTRL ALARM: e ignition control alarm is displayed
if the ignition control detects a fault. is could be a ame failure,
air proving switch, or other fault associated with the ignition control. When this fault occurs, you will need to refer to the ignition
control for the reason.
FAULT
IGNITION CTRL ALARM
SYSTEM SET
INTERLOCK SPARE 4: is is also a spare interlock (similar to
INTERLOCK SPARE 3) for future expansion or use as a eld
interlock. e interlock is located on J11B, SPARE 4.
FAULT
INTERLOCK SPARE 4
SYSTEM SET
160˚F
160˚F
IRI ALARM: e optional IRI alarm is the alarm from the gas valve.
If this alarm is set check the gas valve.
FAULT
IRI ALARM
SYSTEM SET
160˚F
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COMBUST AIR DAMPER: If the combustion air damper has been
selected for use (MASTER BOILER, AUX FUNCTIONS), and
the proof switch does not make, this fault will be displayed.
When the combustion air damper is used, the master’s BOILER3/
DAMPER relay contacts at J13 are closed. ese should be wired
to the combustion air damper or preferably an isolation relay. e
prove switch on the combustion air damper must be wired to J10B,
SPARE 1.
FAULT
SYSTEM SET
COMBUSTION AIR DAMPER
160˚F
When the master boiler receives a call for heat and needs to start
a boiler, the BOILER3/DAMPER relay K5 closes. At the same
time, the boiler is started, res, and continues to re. If the
combustion air damper does not prove within the proof time
speci ed in the combustion air damper menu, the boiler will shut
down and display the fault. e fault on the Master boiler can be
cleared by removing the call for heat on the master boiler and xing
the combustion air damper problem. A combustion damper fault
on a Member boiler can only be cleared by power cycling.
e Master boiler controls a system damper and Member boilers
control their own respective dampers. When the call for heat is
removed, the damper will remain open for 30 seconds before closing.
is allows for post purge cycles to complete.
SHORTED ***** SENSOR: If the shorted sensor fault is
displayed, the sensor in the position reported was originally detected,
but has since shorted. e boiler will shut down on any SHORTED
sensor.
FAULT
SYSTEM SET
SHORTED OUTSIDE SENSOR
160˚F
DELTA TEMP > 40°F: If the temperature across the heat
exchanger rises above the maximum designated temperature for
the FIII model boiler, a warning or fault will be displayed. is
protection is required to prevent damage to the heat exchanger in
the event high di erential temperatures are encountered. e fault
or warning condition may be changed in the AUX FUNCTIONS
menu under ALARM TYPE. e default condition is WARNING
with LIM->HALF TE = YES.
When this condition exists and the ALARM TYPE is set to
WARNING and LIM-> HALF TE, the boiler is limited to 1/2
it’s input rate. So, if the boiler is trying to re at 80%, the rate is
limited to 40% until the temperature across the heat exchanger falls
at least 10°F below the maximum designated temperature for the
FIII boiler model. In this case: 40°F - 10°F = 30°F.
If the ALARM TYPE is set to FAULT, the boiler will display the
FAULT message and this condition will be treated as an interlock,
thus shu ing down the boiler until the Delta Temp drops 10°F
below the maximum designated temperature.
OPEN ***** SENSOR: If the open sensor fault is displayed, the
sensor in the position reported was originally detected, but has since
opened. e boiler will shut down on any OPEN sensor.
FAULT
SYSTEM SET
OPEN OUTSIDE SENSOR
160˚F
1/2 INPUT
LOCAL SET
DELTA TEMP > 40°F
41˚F
RETURN TEMP < 130°F: If the Return Inlet temperature is
less than 130°F this warning will be displayed. is warning does
not a ect operation and does not set the alarm relay. A log entry is
made to aide in diagnosing why this may be occuring. Condensing
will occur with return temperatures below 130°F and a shortened
heat exchanger life will occur.
PREPURGE
LOCAL SET
RETURN TEMP < 130°F
41˚F
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MAINTENANCE
Disconnect electrical power and close the manual gas
shut o valve before performing maintenance or severe
personal injury may result!
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!
e boiler/water heater must be cleaned and inspected at least once
a year and before each heating season. Make sure that the burner
and ignition components are free from dust, soot, dirt, corrosion
or other deposits that would impair the boiler/water heater’s
performance. Refer to Figure 19 for component identi cation.
Improper burner servicing can result in premature
burner failure voiding the warranty!
Burner Removal
1. Close the manual shuto valves in the gas supply line and turn
o electrical power to the boiler/water heater.
2. Remove the jacket top panel.
3. Disconnect the wires to the fan and remove the four bolts that
secure the fan to the transition piece.
4. Remove wires from the spark rods and remove the UV sense
from the transition piece.
5. Disconnect the compression nut at the back of the transition
piece to remove pilot gas tubing.
6. Remove the four nuts holding the transition piece to the heat
exchanger.
7. Li and remove the transition piece and burner together from
the boiler/water heater, taking care not to damage the spark
rods and or their alignment.
8. Disconnect the compression nut from the inside of the transition
piece.
9. Remove the transition piece, taking care not to damage the
spark rods and or their alignment.
Heat Exchanger Inspection
1. Close the manual shuto valves in the gas supply lines and turn
o electrical power to the boiler/water heater.
2. Remove burner following the instructions in the Burner
Removal section.
3. Remove the front jacket panel and combustion chamber door.
4. Inspect the inside and outside of the heat exchanger for signs
of damage, sooting or corrosion.
5. e outside surfaces of the copper tubes should be free of any
soot deposits. A slight black smudge is normal with some types
of gases. Black soot indicates poor combustion. Green deposits
indicate condensation due to low return water temperatures. In
either case the heat exchanger must be cleaned thoroughly and
the problem resolved before the boiler/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 o valves in the inlet and outlet piping. On heating systems close the system ll valve and relieve the system
pressure from the boiler by carefully li ing the relief valve or
opening the drain valve.
2. Disconnect the boiler/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” ba e straps and “V” ba es.
7. oroughly clean the heat exchanger with water from
a high-pressure hose. Use a so bristle brush if necessary.
8. Replace the cleaned heat exchanger and other components in
the reverse order of their removal.
Heat Exchanger Repair & Replacement
1. A leaking or otherwise damaged tube(s) can be replaced as
outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler/water heater as
outlined in the Heat Exchanger Cleaning section.
3. Remove the pipe plugs from the inlet/outlet and return headers
opposite from the ends of the tube(s) being replaced.
4. Carefully cut the damaged tube(s) in half, taking care not to
damage the adjacent tubes and remove.
5. Install and swage/expand in place the new tube(s).
6. Replace the pipe plugs using a suitable thread sealant on each
one.
7. Sagging or distorted heat exchanger tubes are an indication of
low water 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. e recommended torque value for the heat exchanger plugs
is approximately 45 . lbs, not to exceed 50 . lbs.
Air Intake & Vent System
oroughly inspect the air intake and vent systems for any
signs of blockage, corrosion or leakage. Immediately replace any
unsound vent system piping. Inspect the air lter and wash with
warm water and soap if dirty.
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Controls
Use the “GENE L OPE TION” and “CHECKING AND ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A oat type low water cuto device must be ushed out per
the manufacturers’ instructions. e probe on a probe low water
cut o must be removed, cleaned and inspected at least once
a year. Ensure that the low water cuto s operate properly. If not,
replace them.
3. e ow switch contacts must be open when water ow is not
present.
4. e relief valve should not weep or discharge water at normal
system pressure. If it does, contact a quali ed service technician
to have it inspected. NEVER try to clean or repair the relief
valve! If the valve fails to operate properly, have it replaced!
5. e aquastat high limit controls the maximum water temperature
in the boiler. If the water temperature reaches the set temperature
before the demand for heat has been met, the aquastat high
limit should shut the boiler o . e water temperature should
never exceed the maximum set point of 250°F, 121°C, for
boilers and 210°F, 99°C for water heaters. e aquastat high
limit cannot be repaired. If it fails to function properly, replace
it.
6. Visually check the pilot and main burner ames to ensure proper
operation, see Figure 18.
A yellow, oating ame indicates a lack of combustion
air. Do not operate the boiler/water heater until the
problem is solved or severe personal injury or death
may occur!
Figure 18 Main Burner Flame
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Troubleshooting A Startup
ActionCheckIdentify SourceSymptom
1.
An Interlock is tripped.
1. Is it a 24 VAC Interlock?
2. Is it a 120 VAC Interlock/
Alarm?
3. Internal Alarms
1. All 24 VAC Interlocks are
located on J11A and J11B.
Examples of 24 VAC Interlocks:
1.SPARE3
2. Variable Frequency Drive(VFD)
3. Low Water Cutoff(LWCO),
4. Gas Pressure
5. Spare 4
6. Operator OPLIM
7. Water Flow
8. Air Pressure from UV Sensor.
2. All 120 VAC interlocks/Alarm s
are located on J5. These include:
1.FLAME SAFE ALARM (Ignition
CTRL ALARM)
2. Valve Alarm (IRI ALARM)
3. XS_FACTORY (Reserved
4. HIGH LIMIT
1. OPEN SENSOR
2. SHORTED SENSOR
3. COMBUSTION AIR DAMPER
1.Use a multimeter and check
for 24 VAC on J11A,J11B to
identify which interlock has
tripped. Reset the Interlock or
check for disconnected wiring
or shorts.
The Air Pressure from UV
Sensor interlock if displayed
will allow the boiler to
function, but it needs to be
functional while the boiler is
running for it to clear.
1. Use a multimeter on J5 to
to check for 120 VAC on
these interlocks (except the
HIGH LIMIT). The High Limit
Interlock is displayed when
there is no 120 VAC, since
the HIGH LIMIT breaks the
120VAC to the Ignition
Control.
NOTE: Stray Voltages
Greater than 8 VAC and less
than 18 VAC on these
interlocks can cause
intermittant operation. If this
is the case, check for back
fed voltages from field wiring.
Check sensor voltages at
J10A and J10B. The
Temperature sensor inputs
should be between 0 VDC
and 5 VDC measured across
the sensor. Example: At 77 °F,
the voltage would read 2.5
VDC.
2.
Proceed to HeatNet
Control Manual
more details and
problem resolution.
for
The combustion air damper
prove switch must be wired
across SPARE 1 and must be
a "DRY" contact. Do not
apply a voltage to this input,
the input supplies it's own
voltage/current.
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REPAIR PARTS
Figure 19 Exploded View
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REPAIR PARTS (CONTINUED)
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
15 Burner for Turbo Pilot
Burner / Pilot Ori ce Assembly (prior to 0209
must replace transition assembly & electrode)
15a Transition Gasket
15b Burner Gasket
18 Gas Valve
Test Port (CSD-1) 11-0354 1 111111
NS Flange 1" (Outlet) 11-0228 1 1 1 1
NS Flange 1" (Inlet) 11-0231 1 1 1 1
NS Flange 1 1/4" 11-0213 2
NS Flange 1 1/2" (Inlet) 11-0214 2 2
NS Flange 1 1/2" (Outlet) 11-0229 1 1 1
NS Ori ce Gasket 06-0022 1 111111
Gas Injectors NG 10-1009 1 1 1 1
NS
Gas Injectors NG 10-1002 1 1 1
Gas Injectors LP 10-1010 1 111111
Firing Valve, 1" 11-0456 1 1
21
Firing Valve, 1 1/4" 11-0457 1 1
Firing Valve, 1 1/2" 11-0458 1 1 1
Blower, Fasco 7043 12-0016-1 1 1 1
23
Blower, Fasco 7035 12-0017 1111
Flow Switch 14-0203 1 111111
25
Flow Switch (Outdoor) 14-0205 1 111111
Flow Switch (Potter) 14-0201 1 111111
Flow Switch (Outdoor Potter) 14-0202 1 111111
26 Frequency Drive 15-0231 1 111111
27 Jacket Top Panel
Jacket Top Panel (Outdoor)
70-2529.1 1
70-2530.1 1
70-2531.1 1
70-2532.1 1
70-2533.1 1
70-2534.1 1
70-2535.1 1
70-2529 1
70-2530 1
70-2531 1
70-2532 1
70-2533 1
70-2534 1
70-2535 1
06-0026 1 1 1
06-0027 1111
06-0041 1 1 1
06-0042 1111
11-0230 1 1 1 1
11-0227 1 1 1
70-2412 1 1 1
70-2413 1111
70-2440 1 1 1
70-2441 1111
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
36 Combustion Top Panel
Manning Glass Insulation (per square foot) 05-0104 4 445555
Pressure Relief Valve 50# 30-0360 1 1 1
39
Pressure Relief Valve 50# 30-0374 1
Pressure Relief Valve 50# 30-0379 1 1 1
Pressure Relief Valve 125# 30-0364 1 111111
40 Latch 20-0046 2 222222
NS Drain Valve Gaskets
NS Air Filter
Tridicator 30 - 60 psi 13-0308 1 111111
45
Tridicator 75 - 160 psi 13-0305 1 111111
46
Heat Exchanger Assembly (Copper)
Cast Iron (prior to 0209 must replace
combustion chamber top panel #36)
Heat Exchanger Assembly (Copper)
Bronze
Heat Exchanger Assembly (Cupronickel)
Cast Iron (prior to 0209 must replace
combustion chamber top panel #36)
Heat Exchanger Assembly (Cupronickel)
Bronze
70-2356 1 1 1
70-2357 1111
06-0083 1 1 1
06-0084 1111
09-0483 1 1 1
09-0484 1111
70-2515.1 1
70-2516.1 1
70-2517.1 1
70-2518.1 1
70-2519.1 1
70-2520.1 1
70-2521.1 1
70-2186.1 1
70-2187.1 1
70-2188.1 1
70-2189.1 1
70-2190.1 1
70-2191.1 1
70-2192.1 1
70-2522.1 1
70-2523.1 1
70-2524.1 1
70-2525.1 1
70-2526.1 1
70-2527.1 1
70-2528.1 1
70-2193.1 1
70-2194.1 1
70-2195.1 1
70-2196.1 1
70-2197.1 1
70-2198.1 1
70-2199.1 1
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
NS Inlet Adapters
Outlet Adapters
Inlet/Outlet Header Gasket
NS Heat Exchanger "V" Ba e
High Limit, Jumo, (MB) 14-0013 1 111111
48
High Limit, Jumo, (MW) 14-0014 1 111111
NS Operator, T6031A (pool heater) 14-0003 1 111111
NS High Limit Well, 3/8 x 3 13-0104 2 222222
NS 10K Temperature Sensor 14-0325 3 333333
50 Transformer, 50 VA 15-0007 1 111111
51 Purge Timer, ST7800 16-0007 1 111111
52 Spark Generator, Q652B 16-0008 1 111111
53 Flame Safeguard, RM78957C 16-0024R 1 111111
NS Keyboard Display Module, S7800A 16-0010 1 111111
54 Main Board (HeatNet) (green) 16-0038 1 111111
55 Display Board (HeatNet) 40-0088 1 111111
NS Ribbon Cable 40-0115 1 111111
NS Power Switch 48-0013 1 111111
NS Toggle Switch Remote / Local 48-0014 1 111111
56 Air Pressure Switch 11-0416 1 111111
NS Low Gas Pressure Switch (Manual Reset) 11-0422 1 111111
NS High Gas Pressure Switch (Manual Reset) 11-0411 1 111111
NS High Gas Pressure Switch Base 11-0423 1 111111
NS UV Ampli er, R7849A 16-0006 1 111111
NS Ignition Cable 44-0063 1 111111
60 Transition Assembly
60a Gasket
61 Pump Contactor Relay 15-0137 1 112222
NS Rating Plate 82-0054 1 111111
NS Futera III Overlay (HeatNet) 82-0200 1 111111
77 Keypad Overlay 82-0189 1 111111
01-0044GL 1 1 1
01-0045GL 1111
01-0046GL 1 1 1
01-0047GL 1111
06-0202 2 2 2
06-0201 2222
03-1612 20
03-1613 20
03-1614 20
03-1615 28
03-1616 28
03-1617 28
03-1618 28
70-2305 1 1 1
70-2306 1111
06-0043 1 1 1
06-0044 1111
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000
NS Spark Rod Assembly
84 Electrode 16-0335 1 111111
NS Spark Rod O'ring 06-0008 1 111111
NS Silicone 66-0151 1 111111
NS Silicone Tubing 66-0051 2 222222
Vent Termination Hood 5" 09-0117 1 1
NS
Vent Termination Hood 6" 09-0112 1 1
Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1 1
Air Intake Hood 6" 09-0102 1 1 1
NS
Air Intake Hood 8" 09-0103 1
Air Intake Hood 10" 09-0104 1
Air Intake Hood 12" 09-0105 1 1
70-2566 1 1 1
70-2567 1111
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F
:
T
CO
:
MO
:
:
S
:
ST
A
C
ST
T
N
D
D
D
L
V
D
S
R
f
.
.
T
f
.
.
.
.
.
.
J
.
.
.
0.
.
.
dby.
.
START-UP REPORT
DATE
E C HNI C IAN:
MPANY
PH O NE N U MBER
PRE
NO VISIBLE DAMAGE TO UNI
IPING PROPERLY CONNECTE
B O ILER CIRC U LAT O R WIRE
ENT / STACK C O NNECTE
LE
Note: Locate the AA terminals and minimum hold switch in the bottom-right of the electrical panel on the main
HeatNet board. Also locate the manometer test mani
Disable an y external call f or heat and toggle the remote/local switch to REMOTE
.
oggle the LOW FIRE switch to c y cle the boiler then hold at trial
2
et pressure to 3–3.5" w.c. (ame signal should read 5.0 VDC)
3.
Release boiler to main ame trial for ignition
4
heck for stable ame
.
ecord combustion and manifold pressure at minimum ring rate.
um p er the AA terminals to
ecord combustion and manifold pressure.
emove the AA j umper to place the boiler at minimum rate
9
ake any nal adjustments on low re. 1
heck all combustion results using a calibrated ue gas anal y zer
11
e l ease t h e LOW FIRE switc h to p l ace b oi l er in stan
12
T
HE CK LI
T
E
U
N C E
force 100% input
JOB NAME:
OCA TION:
DEL
ERIAL #
INLET AIR FILTER IN S TALLED AND C LEA
PROPER SERVICE CLEARANCES PROVIDE
UMP RUNNING, HEAT EX C HANGER FUL
GAS LINES PURGED, N O LEAKS, N O MISSING TEST
L U G
old in the bottom o f the electrical panel
or pilot ignition
In addition to completing the Fusion/Futera III start-up report, complete the control set-up information in
the rear of the HeatNet manual.
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F
M
A F
00%
.
.
O
)
E
C.
ST
S
CH
D
S
B
R
R
H
S
D
D
L
T
R
______________________________________
)
_
DD
S
STI O N
nned copper tube gas boilers & water heaters – Boiler Manua
I N
1
F IN
GAS PRESSURE AT SUPPLY TEST PORT INCHES W.C
C
CO ( PPM
NET S TA C K TEMPERAT U R
MANIFOLD PRESSURE (W.C.) IN C HE S W.
AF TY
L O W SWITCHE
OW WATER CUT-OFF
C O MMISSIONIN
NIT CYCLED MINIMUM O F 15 TIME
CUSTOMER INSTRUCTE
ALL COVERS REPLACE
UST O MER GIVEN MANUA
ARGET TEMPERAT U RE SET PER C U ST O ME
E S T
Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140°F, 60°C. Operating
at lower return temperatures is likely to cause condensation in the primary heat exchanger, resulting in corrosion and possible
failure of the heat exchanger.
HE CK LI
IR S WIT
IGH LIMIT
I
E
E
THE DELTA T BETWEEN THE HEATER
INLET AND OUTLET IS CRITICAL TO
PROPER FLOW. BEFORE YOU LEAVE
THE JOBSITE, YOU MUST RECORD THE
DELTA T. THIS READING SHOULD NOT
EXCEED 35°F, 19.4°C, NOR BE LOWER
THAN 20°F, 11.2°C.
NCHES W.C
M
N C HE S W. C.
FLAME SAFEGUAR
COMMISSIONED BY:
DATE: ___________________________
A
TI ON
N O TE
SIGNATURE
ELTA T =
C O MMENTS
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Commonwealth of Massachusetts
NOTICE!
Installation Requirements MACODE-3
In the Commonwealth of Massachusetts, the installa-
tion must be performed by a licensed plumber or gas
tter.
1. For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in whole
or in part for residential purposes, including those owned or
operated by the commonwealth and where the side wall exhaust
vent termination is less than seven (7) feet above nished grade,
in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satis ed:
d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the
time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gas tter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the oor level
where the gas equipment is to be installed. In addition, the
installing plumber or gas tter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of
the property owner to secure the services of quali ed
licensed professionals for the installation of hard wired
carbon monoxide detectors.
i. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent
oor level.
ii. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be
installed.
e. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034
listed and IAS certi ed.
f. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
g. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed
in accordance with the provisions of 248 CMR 5.08(2)(a)1
through 4.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
2. Exemptions — The following equipment is exempt from
248 CMR 5.08(2)(a) 1 through 4:
a. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
b. Product Approved side wall horizontally vented gas
fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in
whole or in part for residential purposes.
3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED.
a. When the manufacturer of Product Approved side wall
horizontally vented gas equipment provides a venting
system design or venting system components with the
equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
i. Detailed instructions for the installation of the venting
system design or the venting system components; and
ii. A complete parts list for the venting system design or
venting system.
4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
a. When the manufacturer of a Product Approved side wall
horizontally vented gas fueled equipment does not provide
the parts for venting the ue gases, but identi es “special
venting systems”, the following requirements shall be
satis ed by the manufacturer:
i. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
ii. The “special venting systems” shall be Product
Approved by the Board, and the instructions for that
system shall include a parts list and detailed installation
instructions.
5. A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions,
and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
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LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
e “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other
Non-Residential Use Boiler (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation.
Additional twenty one (21) year thermal shock warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to
have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler/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.
e “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other
Non-Residential Use Water Heater (the “Product”) will be free from defects in material or workmanship for five (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.
is limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed,
maintained or operated in accordance with the furnished wri en instructions, or has been altered or modi ed in any way.
ese include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered
under the manufacturer’s warranty.
• Excessive pi ing and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and
is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that
produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.
• All copper n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan
assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation. e manufacturer’s
warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts thereof.
(c) to damage as a result of se lement, distortion, collapse, or cracking of any foundation area, beams or pipes surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United States or Canada.
is limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior wri en
approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired
or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED
FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR
ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY
AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE
DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL
RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.
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260 North Elm Street 7555 Tranmere Drive
West eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
Copyright 2012 Mestek, Inc.
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