RBI Futera II Modulation Installation And Operation Instructions Manual
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 qualied 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.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service
technician, and to follow all guidelines in the User’s Information Manual.
12/15 Copyright 2015 Mestek, Inc.
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:
• Donottrytolight anyappliance.
• Donot touch anyelectrical switch. Do not use any
phoneinyourbuilding.
• Immediatelycallyourgassupplierfromaneighbor’s
phone.Followthe gassupplier’sinstructions.
• If you cannot reach your gas supplier, call the re
department.
Installationandservicemustbeperformedbyaqualied
installer,serviceagencyorthegassupplier.
Assurez-vous de bien suivre les instructions données
dans cee 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 inammables à proximité de cet
appareiloudetoutautre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Nepastenterd’allumerd’appareil.
• Netouchezà aucuninterrupteur;ne pasvousservir
destéléphonessetrouvantdansle bâtiment.
• Appelezimmédiatementvotrefournisseurdegasdepuis
unvoisin.Suivezles intructionsdufournisseur.
• Sivousnepurvezrejoindrelefournisseur,appelezle
servicedes incendies.
L’installation et l’entretien doivent être assurés par un
installateurou un service d’entretienqualié ou par le
fournisseurdegaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNEDAND TESTEDACCORDINGTOA.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRES-
SUREOF 160PSI,1103 kPaWATER.
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, ecient 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 certied 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 Massachuses, 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,
Westeld, 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 “GENEL 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 eects 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 1millionBtuh, 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 conned space, the minimum
clearances listed in Table 1 must be maintained between it and any
combustible construction. When installed in a conned space
withouttheintakeairoption, Figures 5, 6 and 7, two permanent
openings communicating with an additional room(s) are required.
e combined volume of these spaces must have sucient volume
to meet the criteria for an unconned 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 conned 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 boom opening must
be within 12 in, 305 mm of, but not less than 3 in, 76 mm from,
the boom of the enclosure.
All Air From Outside The Building
When installed in a conned space withoututilizingtheintake
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 boom opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the boom of
the enclosure.
Table 2 Make-up Air Louver Sizing
Required Cross Sectional Area
2
75% Free Area
Metal Louvers
2
in
cm
Input
(MBH)
500 125 806 167 1077 500 3226
750 187 1206 250 1613 750 4839
1000 250 1613 333 2148 1000 6452
1250 313 2019 416 2684 1250 8065
1500 375 2419 500 3226 1500 9677
1750 437 2819 583 3761 1750 11,290
1999 500 3226 667 4303 2000 12,900
1/4 in 6.4 mm
Wire Screen
2
in
cm
2
25% Free Area
Wooden Louvers
in
2
cm
2
Intake Air Option – General Guidelines
is conguration 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
structurenotthe boiler/waterheater.
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
inltration 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 certied 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 identication 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) DirectVent,PositivePressure,CategoryIV uses a vent
system certied 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 WallVent,PositivePressure,Category IV uses a
vent system certied to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
3)
Vertical/ChimneyVent,NegativePressure,CategoryII
uses a metal chimney system approved for Category II.
4)
VerticalVent,PositivePressure,CategoryIV
system certied 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.
5)
VerticalVent/ChimneyVent(750-2000),NegativePressureNon-Condensing,CategoryI
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 Fiing”
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
5
Finned copper tube gas boilers & water heaters – Boiler Manual
DIRECT VENT, POSITIVE PRESSURE,
CATEGORY IV
In this conguration 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 certied
to UL 1738 for installations in the United States, ULC S636 for
installations in Canada. e certied 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 boom 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
aected by winds, snowdris, 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 “GENEL VENTING GUIDE
LINES” sections.
6
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 dierences 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
7
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
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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 conguration 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 certied 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
0.01to0.10in, 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 0.10in, 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 certied
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 )
9
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 identication is
noted on the unit rating label.
Table 5 Equivalent Breeching & Chimney Size, Negative Pressure
(Category I)
Model Size Pipe Diameter
in
500
750
1000
1250
1500
1750
2000
Note: These sizes are based on a 20 ft, 6.1m chimney height.
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
mm
–
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)
10
Figure 7 Vertical Venting with a Metal Chimney System
(Category II)
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
11
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 dierently.
Avoid locations where wind deection 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 deciencies 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. Mere en marche les sécheuses, tous
les appareils non raccordés au système d’évacuation commun et
12
tous les ventilateurs d’extraction comme les hoes 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.
Mere 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 aer 5
minutes of main burner operation. Use the ame of a match
or candle, or smoke from a cigaree, 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 allunee ou d’une chandelle ou la fumée
d’une cigaree, d’un cigare ou d’une pipe.
f) Aer 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. Remere 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 modiée, le système devrait étré
modié 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 piing 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.
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 qualied 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”
13
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 aer the call for heat is satised.
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
14
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 conguration 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.
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