RBI Futera II Modulation Installation And Operation Instructions Manual

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Page 1

FTIII-I0M-HN-7

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.

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Finned copper tube gas boilers & water heaters – Boiler Manual

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.

• 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 PRES-

SUREOF 160PSI,1103 kPaWATER.

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

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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Finned copper tube gas boilers & water heaters – Boiler Manual

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 13.

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

Top 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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Finned copper tube gas boilers & water heaters – Boiler Manual

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 in2/4000 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 in2/

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 in2 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

75% Free Area

Metal Louvers

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

25% Free Area

Wooden Louvers

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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Finned copper tube gas boilers & water heaters – Boiler Manual

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.

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.

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 – (CATEGORY I, II, IV)

Correctly identify the type of vent system the appliance

requires before proceeding. Category identication is

noted on the unit rating plate.

e ue products in a Category II and IV vent system may be

cooled below their dew point and form condensate in the ue. e materials used for a Category II and IV vent must be resistant to any corrosive damage from ue gas condensate. e ue from

a Category II and 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

uses a metal chimney system approved for Category II.

VerticalVent,PositivePressure,CategoryIV

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.

VerticalVent/ChimneyVent(750-2000),NegativePressureNon-Condensing,CategoryI

uses an approved metal chimney system or masonry chimney. Combustion air is obtained from 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.

e maximum equivalent length for the ue outlet vent

system for Category IV conditions is 60 , 18.3 m.

Use Table 4 for the equivalent lengths per ing. Table 4 “Category Equivalent Length Per Fiing”

chart is meant as a guideline for preliminary sizing.

If vent length approaches 75% of maximum length

listed an engineered vent system calculation must be

performed, consult factory.

uses a vent

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Finned copper tube gas boilers & water heaters – Boiler Manual

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/

Outlet Diameter

Standard Tee 1.25 15 ft 20 ft 25 ft Boot Tee 0.65 10 ft 10 ft 15 ft Cap - Low Res. (UL) 0.50 10 ft 10 ft 10 ft 45° w/Bird Screen 0.40 7 ft 7 ft 10 ft Elbow – 90° 0.38 10 ft 10 ft 10 ft Elbow – 45° 0.15 5 ft 5 ft 5 ft

Model/

Outlet Diameter

Standard Tee 1.25 25 ft 35 ft 40 ft 40 ft Boot Tee 0.65 15 ft 15 ft 20 ft 20 ft Cap - Low Res. (UL) 0.50 10 ft 10 ft 15 ft 15 ft 45° w/Bird Screen 0.40 10 ft 10 ft 10 ft 10 ft Elbow – 90° 0.38 10 ft 10 ft 15 ft 15 ft Elbow – 45° 0.15 5 ft 5 ft 5 ft 5 ft

Equivalent Feet of Straight Pipe (ft)

K 500 750 1000

5" 5" 6"

Equivalent Feet of Straight Pipe (ft)

K 1250 1500 1750 2000

6" 8" 10" 10"

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.

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.

When horizontal vent runs exceed 5 , 1.5 m they must be supported

at 3 , 0.9 m intervals with overhead hangers. e vent system must be pitched down, toward the vent terminal, 1/4 in/, 20 mm/m.

If any part of a single wall metal vent system passes through an

unheated space it must be insulated with insulation rated for 400°F,

204°C.

Horizontal vent systems shall terminate at least 4 , 1.2 m below, 4 , 1.2 m horizontally from or 1 , 0.30 m above any door, window

or gravity air inlet into any building. It must not terminate less than

4 , 1.2 m horizontally from, and in no case above or below, unless

a 4 , 1.2 m horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment and not less than 7 ,

2.1 m above adjacent public walkway. e boom of the vent terminal(s) shall be located at least 5 , 1.5 m above the air intake terminal(s) unless there is a minimum 5 , 1.5 m horizontal separation between them. Avoid terminal locations likely to be aected by winds, snowdris, people and pets. Protect building materials and vegetation from degradation caused by the ue gases.

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 51/2 , 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.

Page 7

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 1 Hoizontal Air Intake an Venting for a Single Direct Vent System (Category IV)

1/4 IN. PER FOOT

20 mm/m

1.5 FT 0.5 m

1/4 IN. PER FOOT

20 mm/m

16 FT 4.9 m

1.5 FT 0.5 m

When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall) in order to prevent pressure 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 (Category IV)

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

Page 8

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 3 Vertical Air Intake and Venting for a Direct Vent System (Category IV)

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 (Category IV)

3 FT. 1 m

1.5 FT. .5 m

10 FT. 3.1 m

Page 9

Finned copper tube gas boilers & water heaters – Boiler Manual

SIDE WALL VENT, POSITIVE PRESSURE,

CATEGORY IV – Figure 5

VERTICAL VENT, NEGATIVE PRESSURE –

CATEGORY I & II

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, POSITIVE PRESSURE,

CATEGORY IV – Figures 7 & 9

(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.

e Futera III when listed as a Category II appliance and vent-

ed vertically into a listed metal chimney system, Figures 7 & 9.

e chimney must provide a negative pressure not greater than 0.10

in, 2.5 mm W.C. at the boiler/water heater ue collar with the unit

running. e Futera III when listed as a Category I appliance and vented vertically into a listed metal chimney system, Figures 6 & 8.

e chimney must provide a negative pressure not greater than

0.01to0.10in, 0.25 to 2.5 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 0.10in, 2.5 mm W.C.

W hen using a listed metal chimney system the chimney

system manufacturer’s instructions must be followed.

Masonry chimneys, when used with Category II

appliances, must be lined with a metal liner certied to UL 1738 for installations in the United States and ULC S636 for installations in Canada.

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.

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!

Figure 5 Side Wall Venting (Category IV )

Page 10

Finned copper tube gas boilers & water heaters – Boiler Manual

Chimney Inspection & Sizing – Category I and II

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. Tables 5 & 6 list the equivalent breeching and ue sizes required for the boiler/water heater.

Correctly identify the ty pe of vent system the appliance

requires before proceeding. Category identication is noted on the unit rating label.

Table 5 Equivalent Breeching & Chimney Size, Negative Pressure

(Category I)

Model Size Pipe Diameter

500 750 1000 1250 1500 1750 2000

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

Table 6 Equivalent Breeching & Chimney Size, Negative Pressure

(Category II)

Model Size Pipe Diameter

500 750 1000 1250 1500 1750 2000

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

–

8 10 10 10 12 12

in 6 6

7 8 8 10 10

– 203 254 254 254 305 305

mm 152 152

178 203 203

254 254

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, Figures 8 & 9. Fasten each single wall vent connection with at least 3 corrosion resistant sheet metal screws.

Always provide a minimum clearance of 6 in, 152 mm between

single wall vent pipe and any combustible materials.

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.

generic exit cone

Figure 6 Vertical Venting with a Metal Chimney System

(Category I)

Figure 7 Vertical Venting with a Metal Chimney System

(Category II)

Page 11

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 8 Vertical Venting Using a Lined Masonry Chimney

(Category I)

Figure 9 Vertical Venting Using a Lined Masonry Chimney

(Category II)

Figure 10 Outdoor Venting (Category IV)

DISCHARGE VENT

AIR INLET LOUVERS

Figure 11 Multiple Outdoor Units

2 FT

(0.62M)

3 FT (1M)

RIOM-60 REV.B

Page 12

Finned copper tube gas boilers & water heaters – Boiler Manual

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 10. Multiple units must be spaced per Figure 11.

e boiler/heater must be at least 2 , .62 m from any door, window

or gravity air inlet into any building and at least 3 , 1 m from any overhang unless local codes dictate dierently.

Avoid locations where wind deection o of adjacent walls, buildings

or shrubbery might cause a downdra. e unit(s) should be located at least 3 , 1 m from structures. Outdoor installations are not recommended in areas where the danger of snow blockage exists.

Do not place the boiler/water heater in a location that

would subject it to runo from adjacent buildings or damage may occur voiding the warranty!

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.

Inspecter de façon visuelle le système d’évacuation pour déterminer

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 v enting system.Tu rn on any exhaus t 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.

Mere l’appareil inspecté en marche. Suivre les instructions

d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

e) Test for spillage at the 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.

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 9. 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 8. Return water temperatures below 125°F, 52°C will result in heat exchanger damage from excessive condensation voiding the manufacturer’s warranty, see Primary/Secondary Piping, Figure 13.

Page 13

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 12 Futera III Piping

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!

Valve

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

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!

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 7.

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!

Table 7 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”

Page 14

Finned copper tube gas boilers & water heaters – Boiler Manual

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 8 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.

A temperature rise outside of the range listed in Table

8 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.

Low Water Cutoﬀ

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.

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 8 Temperature Rise Table

∆T = 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

∆T = 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

∆T = 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

∆T = 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 3.02

2.74

62.1 0.78

∆T = 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

∆T = 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

∆T = 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

∆T = 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

Primary/Secondary Piping

Boilers connected to heating systems using zone valves, zone pumps, or

systems that have excessive flow 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 13 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 secondary piping connections to the primary system piping must not be more than 12 in, 305 mm apart to ensure zero pressure drop in the primary system, see Figure 13.

Low Return Water Temperatures

To prevent the problems associated with condensation of the products

of combustion due to low return water temperatures a primary/secondary piping system with a bypass conguration must be installed, see Figure

14. 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 14.

Multiple Boiler Systems

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

Piping For Use With Cooling Units

The boiler, when used in connection with a refrigeration system, must be

installed so the chilled medium is piped in parallel with the boiler. Appropriate

valves must be used to prevent the chilled water from entering the boiler.

When a boiler is connected to a heating coil that may be exposed to

refrigerated air from an air handling device, the piping system must be equipped with ow-control valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle.

Page 15

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 13 Typical Primary/Secondary Piping System (See Notes)

NOTES:

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

2. Boiler pump sized to boiler design ﬂow requirements.

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

4. Boiler pump purging required. Use terminals supplied.

5. For HeatNet operation, a sensor is required and installed at a minimum of 12” from primary loop tee.

Notice: These drawings show suggested piping conﬁguration and valving. Check with the local codes and ordinances for speciﬁc requirements.

H-1 Rev 5

Figure 14 Low Temperature Piping with Thermostatic Valve (See Notes and Adjustment Procedures)

NOTES:

1. For pump selection consult factory.

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

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

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

5. Boiler pump purging required. Use terminals

H-18 Rev 4

supplied.

6. Valve is pre-calibrated for 140oF return temperature.

7. For HeatNet operation a sensor is required and installed at a minimum of 12” from primary loop tee. supplied.

Notice: These drawings show suggested piping conﬁguration and valving. Check with the local codes and ordinances for speciﬁc requirements.

Page 16

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 15 Multiple Boiler Piping (See Notes)

H-15 Rev 6

NOTES:

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

2. Boiler pump sized to boiler design ﬂow 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 ﬂow through all units.

6. For HeatNet operation, a sensor is required and installed at a minimum of 12” from primary loop tee.

Notice: Theses drawings show suggested piping conﬁguration and valving. Check with local codes and ordinances for speciﬁc requirements.

Page 17

Finned copper tube gas boilers & water heaters – Boiler Manual

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!

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.

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.

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 9.

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 9) and the Pumping Performance (Table 10). 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.

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 10 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 16 & 17.

Temperature Rise Control

Water returned to the water heater inlet must not be less than 125°F,

52°C or excessive condensation of the products of combustion will

damage the water heater voiding the warranty. 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 10 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 10 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 Water

can be stored at temperatures above 140°F, 60°C provided that a

thermostatically controlled mixing valve is used to temper the hot water to an acceptable temperature before it’s supplied for domestic use.

e mixing valve MUST be set to prevent a scald injury from

occurring, see the caution against scalding.

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.

Page 18

Finned copper tube gas boilers & water heaters – Boiler Manual

Table 9 Futera III Heat Exchanger Selection Graph

Table 10 Futera III Pumping Performance Requirement

Page 19

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 16 Typical Water Heating Piping (MW Models Only)

These drawings show sug-

gested piping conﬁguration and valving. Check with local codes and ordinances

Figure 17 Multiple Water Heating Piping (MW Models Only)

for speciﬁc requirements.

(See Notes)

NOTES:

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

2. When using intermittent pump and pump delay, locate remote HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound. For multiple tanks, self balancing reverse-return systems, a single HeatNet sensor is applied.

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.

6. 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.

7. Common piping must be sized for maximum combined heater ﬂow.

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

9. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.

Notice: ese drawings show suggested piping conﬁguration and valving. Check with local codes and ordinances for speciﬁc requirements.

Page 20

Finned copper tube gas boilers & water heaters – Boiler Manual

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 11 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

11 should be used in conjunction with Table 12 to ensure that the

gas supply piping has the capacity to meet the demand.

Figure 18 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 11 Gas Pipe Capacity

Maximum pipe capacity in ft3/hr based on 0.60 speciﬁc gravity gas at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.

Nominal

Iron Pipe

Size

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 ﬂow capacity in ft3/hr. Multiply the propane ﬂow capacity by 2500 Btu/ft the propane Btu/hr capacity for a given pipe size and length.

Table 12 Equivalent Pipe Length Chart

Nominal

Iron Pipe

Size

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 ﬂow through branch.

2. For ﬂow at full open.

10 20 30 40 50 60 80 100 150

Maximum gas volume of pipe, (ft3/hr)

90° Elbow Te e

Pipe length, (ft)

to determine

Type of pipe ﬁtting

Gate Valve2Gas Cock

Equivalent pipe length, (ft)

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 18 Gas Supply Piping

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.

Page 21

Finned copper tube gas boilers & water heaters – Boiler Manual

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!

Refer to the wiring diagram supplied with the boiler/water heater for proper wiring connections and boiler full load amperage (FLA).

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 18. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/

water heater and its individual shut-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.

Install a separate 120 volt 15 amp or 20 amp circuit breaker for the

boiler/water heater and pump, see Table 13. 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 13 Futera III Electrical Requirements

Recommended

Futera III Circuit Breaker *Running

Model (Amps) Amps

500 15 3.9

750 - 1000 15 6.0

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.

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.

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.

Page 22

Finned copper tube gas boilers & water heaters – Boiler Manual

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 18.

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

18.

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 20.

9. Open the main isolation gas valve (eld supplied), Figure 18.

10. Place the “Remote/Local” switch to Remote inside control cabinet, Figure 19.

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 19.

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 19. 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.

17. Close main isolation gas valve (eld supplied), Figure 18.

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 the1/8" hose piped directly o of the manifold test port, Figure 20.

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.

Page 23

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 19 HeatNet Control Panel

Table 16 Elbow Pressure signal (Nat Gas) - Category I

Firing

rate

100%

85%* -3.1 -7.1 -3.2 -3.8 -6.2 -6.8

To determine signal in mm wc, multiply signal pressure by 25.4.

* Maximum turndown on units listed as CAT I

Table 16a Elbow Pressure signal (Nat Gas) - Category II and IV

500 750 1000 1250 1500 1750 2000

Signal Inches

N/A

Signal Inches

-4.4 -8.2 -3.7 -5.8 -7.3 -8.5

Signal Inches

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.

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” tables 14 and 15 for proper combustion readings and table 16 and 16a for proper elbow pressure signal at low re.

Table 14 Combustion Readings (Category I)

Natural Fuel Propane Fuel

For factory set gas manifold (elbow) pressures see label on inner cabinet door.

Table 15 Combustion Readings (Category II and IV)

For factory set gas manifold (elbow) pressures see label on inner cabinet door.

8.0 - 8.2 (min.) 9.4 - 9.6 (min.)

8.2 - 8.5 (100%) 9.6 - 9.9 (100%)

6.6 - 6.2 (min.) 6.6 - 6.2 (min.)

6.2 - 5.8 (100%) 6.2 - 5.8 (100%)

Natural Fuel Propane Fuel

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%)

Firing

rate

100% -2.2 -4.5 -7.1 -4.3 -6.0 -8.5 -8.7

33% -0.5 -0.6 -0.7 -0.6 -0.8 -1.0 -1.0

25% -0.2 -0.3 -0.5 -0.3 -0.5 -0.6 -0.6

To determine signal in mm wc, multiply signal pressure by 25.4.

500 750 1000 1250 1500 1750 2000

Signal Inches

Correctly identif y the type of vent system the appliance

requires before proceeding. Category identication is

noted on the unit rating plate.

e low re O2-CO2 can be adjusted in the eld by opening the

low re adjustment door located on the forward facing side of the main gas valve, see Figure 20. Inserting an allen wrench and rotating the allen screw clock-wise will increase the CO rotating counter clock-wise will decrease the CO2 and increase the

and lower the O2,

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. The boiler input will rise to its maximum input, “Run 100%”, see Figure 22.

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” tables 14 and 15 for proper combustion readings, and table 16 and 16a for proper elbow pressure signal at high re. e high ve trim is located on the outlet ange of the gas valve, see Figure 20. O2-CO

can be adjusted by inserting a screw 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”.

Page 24

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 20

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.

Page 25

Finned copper tube gas boilers & water heaters – Boiler Manual

CHECKING & ADJUSTMENTS

Spark Gap

With the main and pilot gas manual valves in the closed position

energize the unit. Observe the trial for ignition to conrm that the spark is strong and continuous. If not check and adjust the spark gap as shown in Figure 21.

Figure 21 Spark Gap

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 18. 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!

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.

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!

Page 26

Finned copper tube gas boilers & water heaters – Boiler Manual

RBI FIELD WIRING TO HEATNET BOARD

Figure 22 RBI Field Wiring to HeatNet Board (Board Revision 3.0 and greater)

Page 27

Finned copper tube gas boilers & water heaters – Boiler Manual

Figure 23

RBI HEATNET FIELD WIRING TO TERMINAL BLOCK

NOTES:

1. Remove jumper “A” when using a low water cutoﬀ interlock.

2. For multiple boilers utilizing a system air damper when in a master/member conﬁguration consult factory or reference wiring diagram 42-0501 sheet 3 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.

Page 28

Finned copper tube gas boilers & water heaters – Boiler Manual

CONTROL DESCRIPTION

Low Water Cutoﬀ

If the boiler is to be installed above radiation or if required by other

codes or regulations, install a low water 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!

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

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.

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.

FAULT

SYSTEM SET

10/27 9:16

160˚F

e high limit interlock breaks power to the ignition control

(shu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.

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

Page 29

Finned copper tube gas boilers & water heaters – Boiler Manual

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

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

Page 30

Finned copper tube gas boilers & water heaters – Boiler Manual

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.

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

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.

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.

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.

1/2 INPUT DELTA TEMP > 40°F

LOCAL SET

FAULT

SYSTEM SET

OPEN OUTSIDE SENSOR

160˚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

Page 31

Finned copper tube gas boilers & water heaters – Boiler Manual

MAINTENANCE

Disconnect electrical power and close the manual gas

shut o valve before performing maintenance or severe personal injury may result!

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.

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 25 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.

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.

Page 32

Finned copper tube gas boilers & water heaters – Boiler Manual

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 24.

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 24 Main Burner Flame

Page 33

Finned copper tube gas boilers & water heaters – Boiler Manual

Troubleshooting A Startup

ActionCheckIdentify SourceSymptom

An Interlock is tripped.

1. 1. Is it a 24 VA C Interlock?

2. Is it a 120 VA C Interlock/ Alarm?

3. Internal Alarms

1. All 24 VA C Interlocks are located on J11A and J11B. Examples of 24 VA C 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 VA C interlocks/Alarms are located on J5. These include:

1.FLAME SAFE ALARM (Ignition CTRL ALARM)

2. Valve Alarm (IRI ALARM)

3. XS_FACTORY (Reserved

4. HIGH LIMIT

1. OPEN SENSOR

2. SHORTED SENSOR

3. COMBUSTION AIR DAMPER

1.Use a multimeter and check for 24 VA C 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 VA C on these interlocks (except the HIGH LIMIT). The High Limit Interlock is displayed when there is no 120 VA C, since the HIGH LIMIT breaks the 120VA C to the Ignition Control.

NOTE: Stray Voltages Greater than 8 VA C and less than 18 VA C 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.

Proceed to HeatNet Control Manual for

more details and

problem resolution.

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.

Page 34

Finned copper tube gas boilers & water heaters – Boiler Manual

REPAIR PARTS

Figure 25 Exploded View

Page 35

Finned copper tube gas boilers & water heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

RIOM-74 REV E

Page 36

Finned copper tube gas boilers & water heaters – Boiler Manual

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

15a

Transition Gasket

15b

Burner Gasket

Solenoid Valve w/Regulator, NG

Solenoid Valve w/Regulator, LP

Flange 1" (Inlet)

Flange 1-1/2" (Inlet) 11-0214 2 2

18 Gas Valve

Test Port (CSD-1) 11-0354 2 2 2 2 2 2 2

Flange 1" (Outlet) 11-0228 1 1 1 1

Flange 1-1/2" (Outlet) 11-0229 1 1 1

NS Oriﬁce Gasket 06-0022 1 1 1 1 1 1 1

Gas Injectors NG 10-1009 1 1 1 1

Gas Injectors NG 10-1002 1 1 1

Gas Injectors LP 10-1010 1 1 1 1 1 1 1

20 Ball Valve 11-0395 1 1 1 1 1 1 1

Firing Valve, 1" 11-0456 1 1

Firing Valve, 1-1/2" 11-0458 1 1 1

“A” Valve, 1" 11-0465 1 1

“A” Valve, 1-1/4" 11-0466 1 1 1

“A” Valve, 1-1/2" 11-0467 1 1

Blower, Fasco 7043 70-2348-001 1 1 1

Blower, Fasco 7035 12-0017 1 1 1 1

Flow Switch 14-0203 1 1 1 1 1 1 1

Flow Switch (Outdoor) 14-0205 1 1 1 1 1 1 1

Flow Switch (Potter) 14-0201 1 1 1 1 1 1 1

Flow Switch (Outdoor Potter) 14-0202 1 1 1 1 1 1 1

26 Frequency Drive 15-0237-001 1 1 1 1 1 1 1

27 Jacket Top Panel

36 Combustion Chamber Top Panel

Manning Glass Insulation (per square foot)

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

(must order as kit 21-2007)

(must order as kit 21-2008)

(must order as kit 21-2007)

(must order as kit 21-2008)

11-0372 1 1 1 1 1 1 1

11-0374 1 1 1 1 1 1 1

11-0231 1 1 1 1 1

11-0230 1 1 1 1

11-0227 1 1 1

70-2412 1 1 1

70-2413 1 1 1 1

70-2356 1 1 1

70-2357 1 1 1 1

05-0104 4 4 4 5 5 5 5

Page 37

Finned copper tube gas boilers & water heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000

2" Blanket Insulation (per sq ft) 05-0200 20 22 24 26 26 30 30

Red Silicone Gasket (per ft / sold per roll 50’)

Pressure Relief Valve 50# 30-0360 1 1 1

Pressure Relief Valve 50# 30-0374 1

Pressure Relief Valve 50# 30-0379 1 1 1

Pressure Relief Valve 125# 30-0364 1 1 1 1 1 1 1

40 Latch 20-0046 2 2 2 2 2 2 2

42 Air Filter Upgrade Kit

Air Filter

Tridicator 30 - 60 psi 13-0308 1 1 1 1 1 1 1

Tridicator 75 - 160 psi 13-0305 1 1 1 1 1 1 1

46 Heat Exchanger Assembly (Copper)

Cast Iron (prior to 0209 must replace

combustion chamber top panel #36)

Heat Exchanger Assembly (Copper)

Bronze

Individual copper/cupronickel tubes* available for ﬁeld repair *model and serial number required

Tube Expansion Tool

Heat Exchanger Assembly (Cupronickel)

Cast Iron (prior to 0209 must replace

combustion chamber top panel #36)

Heat Exchanger Assembly (Cupronickel)

Bronze

06-0146 50 50 50 50 50 50 50

21-2005 1 1 1

21-2006 1 1 1 1

09-0483 1 1 1

09-0484 1 1 1 1

70-2515.1R 1

70-2516.1R 1

70-2517.1R 1

70-2518.1R 1

70-2519.1R 1

70-2520.1R 1

70-2521.1R 1

70-2186.1R 1

70-2187.1R 1

70-2188.1R 1

70-2189.1R 1

70-2190.1R 1

70-2191.1R 1

70-2192.1R 1

30-0761 1 1 1 1 1 1 1

70-2522.1R 1

70-2523.1R 1

70-2524.1R 1

70-2525.1R 1

70-2526.1R 1

70-2527.1R 1

70-2528.1R 1

70-2193.1R 1

70-2194.1R 1

70-2195.1R 1

70-2196.1R 1

70-2197.1R 1

70-2198.1R 1

70-2199.1R 1

Page 38

Finned copper tube gas boilers & water heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000

NS Inlet Adapters (Flanged)

Outlet Adapters (Flanged)

Outlet Adapters (Threaded)

Inlet/Outlet Header Gasket

NS Heat Exchanger “V” Baﬄe

Heat Exchanger “V” Baﬄe Strap

High Limit, Jumo, (MB) 14-0013 1 1 1 1 1 1 1

High Limit, Jumo, (MW) 14-0014 1 1 1 1 1 1 1

NS Operator, T6031A (pool heater) 14-0003 1 1 1 1 1 1 1

NS High Limit Well, 3/8 x 3 13-0104 2 2 2 2 2 2 2

NS 10K Temperature Sensor 14-0325 3 3 3 3 3 3 3

50 Transformer, 50 VA 15-0007 1 1 1 1 1 1 1

51 Purge Timer, ST7800 16-0007 1 1 1 1 1 1 1

52 Spark Generator, Q652B 16-0036 1 1 1 1 1 1 1

53 Flame Safeguard, RM78957C 16-0024R 1 1 1 1 1 1 1

NS Keyboard Display Module, S7800A 16-0010 1 1 1 1 1 1 1

54 Main Board (HeatNet) 16-0047 1 1 1 1 1 1 1

55 Display Board (HeatNet) 40-0088 1 1 1 1 1 1 1

NS Ribbon Cable 40-0115 1 1 1 1 1 1 1

NS Power Switch 48-0013 1 1 1 1 1 1 1

NS Toggle Switch Remote / Local 48-0014 1 1 1 1 1 1 1

56 Air Pressure Switch 11-0416 1 1 1 1 1 1 1

NS Low Gas Pressure Switch (Manual Reset) 11-0422 1 1 1 1 1 1 1

NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1 1

NS High Gas Pressure Switch Adapter 11-0423 1 1 1 1 1 1 1

NS UV Ampliﬁer, R7849A 16-0006 1 1 1 1 1 1 1

NS Ignition Cable 44-0063 1 1 1 1 1 1 1

60 Transition Assembly (prior to 0209

must upgrade to turbo pilot by

replacing burner, spark rod and

transition assembly)

01-0044GL

01-0045GL

01-0046GL

01-0047GL

01-0042 1 1 1

01-0043 1 1 1 1

03-1612 20

03-1613 20

03-1614 20

03-1615 28

03-1616 28

03-1617 28

03-1618 28

03-1619 2 2 2

03-1620 2 2 2 2

70-2305 1 1 1

70-2306 1 1 1 1

1 1 1

1 1 1 1

1 1 1

1 1 1 1

(must order as kit 21-2007)

(must order as kit 21-2008)

Page 39

Finned copper tube gas boilers & water heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 2000

60a Gasket

61 Pump Contactor Relay 15-0137 1 1 1 2 2 2 2

NS Rating Plate 82-0054 1 1 1 1 1 1 1

NS Futera III Overlay (HeatNet) 82-0200 1 1 1 1 1 1 1

77 Keypad Overlay 82-0189 1 1 1 1 1 1 1

78 Mini Fan 12-0021 1 1 1 1 1 1 1

79 Air Solenoid Valve 11-0376 1 1 1 1 1 1 1

80 3/8" Aluminum Tubing 62-0102 1 1 1 1 1 1 1

Pilot Oriﬁce, .052 NG 10-0140 1 1 1 1 1 1 1

Pilot Oriﬁce, .040 LP 10-0139 1 1 1 1 1 1 1

82 Mini Peeper, C7027A 16-0009 1 1 1 1 1 1 1

83 Spark Plate Gasket

NS Spark Rod Assembly

84 Electrode 16-0335 1 1 1 1 1 1

NS Spark Rod O’ring 06-0008 1 1 1 1 1 1

86 1/2" Aluminum Tubing 62-0103 1 1 1 1 1 1

NS Silicone 66-0151 1 1 1 1 1 1

NS Silicone Tubing 06-0051 2 2 2 2 2 2

Vent Termination Hood 5" 09-0117 1 1

Vent Termination Hood 6" 09-0112 1 1

Vent Termination Hood 8" 09-0113 1

Vent Termination Hood 10" 09-0115 1

Air Intake Hood 6" 09-0102 1 1 1

Air Intake Hood 8" 09-0103 1

Air Intake Hood 10" 09-0104 1

Air Intake Hood 12" 09-0105 1

06-0102 1 1 1

06-0037 1 1 1 1

70-2566 1 1 1

70-2567 1 1 1

(must order as kit 21-2007)

(must order as kit 21-2008)

Page 40

Finned copper tube gas boilers & water heaters – Boiler Manual

START-UP REPORT

dby.

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

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

et pressure to 3–3.5" w.c. (ﬂame signal should read 5.0 VDC)

Release boiler to main ﬂame trial for ignition

heck for stable ﬂame

ecord combustion and manifold pressure at minimum ﬁring rate.

um p er the AA terminals to force 100% input

ecord combustion and manifold pressure.

emove the AA j umper to place the boiler at minimum rate

ake any ﬁnal adjustments on low ﬁre.1

heck all combustion results using a calibrated ﬂue gas anal y zer

e l ease t h e LOW FIRE switc h to p l ace b oi l er in stan

HE CK LI

N C E

JOB NAME:

OCATION:

DEL CATEGORY:

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.

Page 41

Finned copper tube gas boilers & water heaters – Boiler Manual

YSIS

00%

)

______________________________________

)

STI O N

F I N

F IN

GAS PRESSURE AT SUPPLY TEST PORT INCHES W.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

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

N C HE S W. C.

FLAME SAFEGUAR

COMMISSIONED BY:

SIGNATURE

DATE: ___________________________

TI ON

N O TE

C O MMENTS

ELTA T =

Page 42

Finned copper tube gas boilers & water heaters – Boiler Manual

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 ﬁtter.

1. For all side wall horizontally vented gas fueled equipment

installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁnished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁed:

d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the

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

i. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂoor 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 certiﬁed.

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 ﬂue gases, but identiﬁes “special venting systems”, the following requirements shall be satisﬁed 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!

Page 43

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.

Page 44

260 North Elm Street 7555 Tranmere Drive Westﬁeld, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782

www.rbiwaterheaters.com

RBI Futera II Modulation Installation And Operation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual