RBI Futera II Series Installation & Operating Instructions Manual

FTII-IOM-3

FUTERA II SERIES FINNED COPPER

GAS BOILERS & WATER HEATERS

INSTALLATION & OPERATING

INSTRUCTION

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI WATER.

WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.

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 fire department.

Installation and service must be performed by a qualified installer, service agency or
the gas supplier.

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER HEATER.

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 1300 Midway Boulevard
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

www.rbiwaterheaters.com

Mississauga, Ontario L5T 2G8 Canada

䡲

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

AVERTISSMENT. Assurez-vous de bien suivre les instructions données dans cette 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 inflammables 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
qualifié ou par le fournisseur de gaz.

CONTENTS

Before Your Start page 2
Ratings & Capacities page 3
Location page 3
Combustion Air & Ventilation page 3
Venting Guidelines page 5
Common Vent Systems page 11
General Piping Requirements page 11
Heating System Piping page 12
Domestic Water Supply Piping page 15
Gas Supply Piping page 17
Electrical Wiring page 17
Boiler/Water Heater Operation page 18
Operating Instructions page 18
Checking, Adjustment & Operation page 19
Diagnostics page 22
Maintenance page 22
Trouble-Shooting page 24

Repair Parts page 25

BEFORE YOU START

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

To obtain the safe, dependable, efficient operation and long
life for which this heating boiler/water heater was designed,
these instructions must be read, understood and followed.

The Futera II Series finned copper heating boiler/water
heaters have been design certified by CSA for use with
natural and propane gas under the latest revision of ANSI­Z21.10.3/CSA 4.3, Gas Water Heaters, ANSI-Z21.13/CSA

4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers
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 in accordance with Section IV of the A.S.M.E. Boiler
and Pressure Vessel Code.

All aspects of the boiler/water heater installation must
conform to the requirements of the authority having juris­diction, or, in the absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1-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
requirements of CSA B149.1 or .2, Installation Code for
Gas Burning Appliances and Equipment.

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

Direct all questions to your RBI Water Heaters distributor
or contact the RBI Customer Service Department at: 260
North Elm Street, Westfield, MA 01085 for US or 1300
Midway Boulevard, Mississauga ONT L5T 2G8 for Canada.
Always include the model and serial numbers from the
rating plate of the boiler/water heater in question.

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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

RATINGS & CAPACITIES

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

BOILER/WATER HEATER LOCATION

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

Table 1 Clearance to Service

Combustibles Clearance

Top 24" (610 mm) 36" (914 mm)
Back 14" (356 mm) 24" (610 mm)
Left Side 6" (153 mm) 12" (306 mm)
Right Side 6" (153 mm) 12" (306 mm)
Front 8" (203 mm) 36" (914 mm)

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 floor is structurally sound and will support
the weight of the boiler/water heater.

NOTE:
The Futera II may be installed directly on combustible
flooring, 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.

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

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

COMBUSTION AIR & VENTILATION

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

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

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

CAUTION
If the boiler/water heater is operated while the building
is under construction it MUST be protected from wood,
concrete, sheet rock and other types of dust or the unit
will be damaged 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 fireplace, 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.

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 VENTING
GUIDELINES.

6. NEVER place this boiler/water heater in a location that
would subject it to temperatures at or near freezing. See
the Freeze Protection Section on page 12.

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

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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

All Air From Inside The Building

If the Futera II is to be located in a confined space the
minimum clearances listed in Table 1 must be maintained
between it and any combustible construction. When
installed in a confined space without the intake air option
two permanent openings communicating with an additional
room(s) are required. The combined volume of these
spaces must have sufficient volume to meet the criteria for
an unconfined space. The total air requirements of all gas
utilization equipment, fireplaces, wood stoves or any type
of exhaust fan must be considered when making this
determination. Each opening must have a minimum free
area of 1 in

2

/1000 Btu/hr (2200 mm2/kW) based on the total
input rating of ALL gas utilization equipment in the confined
area. Each opening must be no less than 100 square
inches (64516 mm

2

) in size. The upper opening must be
within 12 inches (300 mm) of, but not less than 3 inches
(80 mm) from, the top of the enclosure. The bottom opening
must be within 12 inches (300 mm) of, but not less than 3
inches (80 mm) from, the bottom of the enclosure.

All Air From Outside The Building
When installed in a confined space without the intake air
option two permanent openings communicating directly

with, or by ducts to, the outdoors or spaces that freely
communicate with the outdoors must be present. The upper
opening must be within 12 inches (300 mm) of, but not less
than 3 inches (80 mm) from, the top of the enclosure. The
bottom opening must be within 12 inches (300 mm) of, but
not less than 3 inches (80 mm) from, the bottom of the
enclosure.

must be given to the blockage effects of louvers, grills and
screens. Screens must have a minimum mesh size of 1/
4" (6.4mm). If the free area through a louver or grill is not
known ducts should be sized per Table 2 above.

Intake Air Option – General Guidelines

This configuration provides combustion air directly to the
boiler/water heater’s air intake using a dedicated pipe when
using the direct vent option. The RBI air intake adapter
must be fitted to the blower inlet. Combustion air can be
drawn in horizontally through an outside wall or vertically
through the roof, see Figures 1, 2, 3 & 4.

WARNING
Each boiler/water heater must have it’s own intake air
system. Common intake air systems are not to be used!
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, flexible aluminum pipe, PVC or CPVC pipe can be
used for the intake air pipe. It must be sized per Table 3.

Table 3 – Intake Air Pipe Sizing

2

Model Size Pipe Diameter in

(mm2)
500 8 (203)
750, 1000 10 (254)
1250, 1500 12 (305)
1750, 1950 14 (356)

Where directly communicating with the outdoors or
communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 in
Btu/hr (550 mm

2

/kW) of the total input rating of all of the

2

/4000

equipment in the enclosure.

Where communicating with the outdoors through hori­zontal ducts, each opening shall have a minimum free area

2

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

of 1 in
of all of the equipment in the enclosure.

When ducts are used, they must have the same cross­sectional area as the free area of the opening to which
they connect.

Table 2 – Make-up Air Duct Sizing

2

Required Cross Sectional Duct Area in

(cm2)
Input 1/4" (6.4 mm) Metal Wooden
(MBH) Wire Screen Louvers Louvers
500 125 (806) 167 (1077) 500 (3226)
750 187 (1206) 250 (1613) 750 (4839)
1000 250 (1613) 333 (2148) 1000 (6452)
1250 313 (2019) 416 (2684) 1250 (8065)
1500 375 (2419) 500 (3226) 1500 (9677)
1750 437 (2819) 583 (3761) 1750 (11,290)
1950 486 (3135) 649 (4187) 1950 (12,581)

When calculating the free area necessary to meet the
make-up air requirements of the enclosure, consideration

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

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

A stack damper interlocked with the unit should be instal­led in the intake air pipe when the infiltration of subfreez­ing air could occur, otherwise the unit could freeze up.

Intake Air Option – Vertical Guidlines

The maximum equivalent length for the vertical intake air
pipe is 60 feet (19.7 m). Each 90˚ elbow and the intake
air cap are equal to 10 linear feet (3.3 m) of pipe.

A listed, nonrestrictive intake air cap must be used. The
intake air cap must terminate as shown in Figure 3. The
penetration point in the roof must be properly flashed and
sealed.

Intake Air Option – Horizontal Guidlines

The maximum equivalent length for the horizontal intake
air pipe is 60 feet (19.7 m). Each 90˚ elbow and the intake
air terminal are equal to 10 linear feet (3.3 m) of pipe. If
horizontal runs exceed 5 feet (1.5 m) they must be
supported at 3 foot (0.98 m) intervals with overhead
hangers. The certified intake air terminal from RBI must be
used, see Figures 1, 2 and 4.

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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

GENERAL VENTING GUIDELINES

WARNING The vent installation must be in accordance
with Part 7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1-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 fire-stops must be used where required.

WARNING Each boiler/water heater must have it’s own
vent system. Common positive pressure vent systems are
not to be used! Improper installation can result in excessive
levels of carbon monoxide which can cause severe
personal injury or death!

Note: When a barometric damper is used it must be
installed directly to the boiler/water heater flue outlet
to ensure proper operation.

VENT SYSTEM OPTIONS

The Futera II may be vented the following ways:

1) Direct Vent (Positive Pressure), uses a vent system

certified to UL 1738 for installations in the United
States, ULS636 for installations in Canada.
Combustion air is piped from the outdoors to the
blower inlet.

2) Side Wall Vent (Positive Pressure), uses a vent

system certified to UL 1738 for installations in the
United States, ULS636 for installations in Canada.
Combustion air is obtained from the space in which
the unit is installed.

Horizontal Direct Vent Systems – Figures 1 & 2

The vent materials used in horizontal vent systems must
be certified to UL 1738 for installations in the United States,
ULS636 for installations in Canada. The certified vent
terminal from RBI must also be used.

The maximum equivalent length for the horizontal vent
pipe is 60 feet (19.7 m). Each 90˚ elbow and the intake

air terminal are equal to 10 linear feet (3.3 m) of pipe. To
maximize the performance of single wall sheet metal vent
systems locate 90˚ elbows as far from the boiler as possible
and from one another. For best results, horizontal vent
systems should be as short and straight as possible.

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

When horizontal vent runs exceed 5 feet (1.5 m) they must be
supported at 3 foot (0.98 m) intervals with overhead
hangers. The vent system must be pitched down, toward the
vent terminal, 1/4" per foot (21 mm per meter). 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.

Horizontal vent systems shall terminate at least 4 feet (1.3
m) below, 4 feet (1.3 m) horizontally from or 1 foot (0.23
m) above any door, window or gravity air inlet into any
building. It must not terminate less than 4 feet (1.3 m)
horizontally from, and in no case above or below, unless
a 4 feet (1.3 m) horizontal distance is maintained, from
electric meters, gas meters, regulators and relief equipment
and not less than 7 feet (2.3 m) from any adjacent public
walkway. The bottom of the vent terminal(s) shall be located
at least 5 feet (1.5 m) above the air intake terminal(s).
Avoid terminal locations likely to be affected by winds,
snowdrifts, people and pets.

3) Vertical/Chimney Vent (Negative Pressure), uses an

approved metal chimney system or masonry chimney.
Combustion air is obtained from the space in which
the unit is installed.

4) Outdoor Installation uses the outdoor option kit.

DIRECT VENT (POSITIVE PRESSURE)

In this configuration the boiler/water heater blower is used
to push the flue products to the outdoors while drawing
combustion air from the outdoors. The Intake Air Option
instructions under the COMBUSTION AIR &
VENTILATION SECTION must be followed! The vent
system must be sized per Table 4.

Table 4 – Direct Vent Pipe Size, Positive Pressure

Model Size Pipe Diameter in.(mm)
500 6 (152)
750 8 (203)
1000 9 (229)
1250, 1500 10 (254)
1750, 1950 12 (305)

Protect building materials and vegetation from degradation
caused by the flue gases.

Vertical Direct Vent Systems – Figure 3

The maximum length for the vertical vent pipe is 30 feet
(19.7m) plus two 90˚ elbows. 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. Structural
penetrations must be made using approved fire-stops.

A listed, nonrestrictive vent cap must be used. The top of
a vertical vent system must extend at least 5
m) above the roof surface that it passes through, 4 feet
(1.3 m) above the intake air cap, see Figure 3.

1

/2 feet (1.8

5

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

In addition the vent system must conform to the dimensions
shown in Figure 3. The penetration point in the roof must
be properly flashed and sealed.

Figure 1– Horizontal Air Intake and Venting for a Single Direct Vent System

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

Figure 2 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems

6

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 3 - Vertical Air Intake and Venting for Direct Vent System

Combination Direct Vent Systems – Figure 4

The boiler/water heater can be vented vertically with the
intake air piped horizontally through an outside wall. Follow
the instructions in the Intake Air Option –

Figure 4 – Combination Direct Vent Systems

Horizontal Guidelines on page 4. Also follow the general

instructions in the COMBUSTION AIR & VENTILATION
and GENERAL VENTING GUIDELINES sections.

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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

SIDE WALL VENT (POSITIVE PRESSURE)

In this configuration the boiler/water heater blower is used
to push the flue products horizontally to the outdoors, see
Figure 5. The air for combustion is taken from the space
in which the unit is installed. The applicable instructions

Figure 5 – Side Wall Venting

under the COMBUSTION AIR & VENTILATION SECTION
must be followed! The vent guidelines under the
Horizontal Direct Vent Systems section must also be
followed.

VERTICAL/CHIMNEY VENT (NEGATIVE
PRESSURE) The Futera II is listed as a Category I

appliance when vented vertically into a listed metal
chimney system or properly sized masonry chimney,
Figures 6 & 7. The chimney must provide a negative
pressure of 0.02 to 0.08 in. W.C. at the boiler/water heater
flue collar with the unit running. A single acting barometric
damper must be attached directly to the flue collar
increaser as shown.

Note: DO NOT remove the damper stops. For proper
operation the damper must remain as single acting.

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

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

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

Chimney Inspection & Sizing

A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly
con-structed and properly sized. Exterior masonry
chimneys should not be used unless properly lined to
prevent condensation and draft problems. Table 5 lists the
equivalent breeching and flue sizes required for the boiler/
water heater.

Table 5 – Equivalent breeching & chimney size,

Negative Pressure

Model Size Breech & Flue Diameter in (mm)
500 8 (203)
750, 1000 10 (254)
1250, 1500 12 (305)
1750, 1950 14 (356)

Note: These sizes are based on a 20 foot (6.1m) chimney height.

Vent Connections

Locate the boiler/water heater as close to the chimney as
possible. Use the shortest, straightest vent connector
possible for the installation. If horizontal runs exceed 5 feet
(1.5 m) they must be supported at 3 foot (0.9 m) intervals
with overhead hangers. Use a type B, single wall stainless
or single wall galvanized steel vent pipe the same diameter
as the flue collar to connect the boiler/water heater to a
masonry chimney. When using a listed metal chimney
system use the appropriate vent connector.

8

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

The vent system should be sloped up toward the chimney
at a minimum rate of 1/4 inch/foot (2 cm/m). On masonry
chimneys the connector must terminate flush with the
inside of the chimney flue, Figure 7. Fasten each single wall
vent connection with at least 3 corrosion resistant sheet
metal screws.

WARNING
Never install a vent pipe of a diameter different thatn that
of the boiler/water heater's flue outlet. Failure to comply with
this warning can result in excessive levels of carbon
monoxide which can cause severe personal injury or death.

Figure 6 – Vertical Venting with a Metal Chimney System

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

WARNING
Failure to maintain minimum clearances between vent
connectors and any combustible material can result in a
fire causing extensive property damage, severe personal
injury or death!

9

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 7 – Vertical Venting using a Masonry Chimney

OUTDOOR VENTING

When installed outdoors the Futera II must be fitted with
the factory supplied outdoor hood, air intake adapter with
filter and exhaust terminal, see Figure 8.

The boiler/water heater must be at least 10 feet (3.2 m)
from any door, window or gravity air inlet into any building
and at least 3 feet (0.98 m) from any overhang unless local
codes dictate differently.

Figure 8 – Outdoor Venting

Do not place the boiler/water heater in a location that would
subject it to runoff from adjacent buildings.

Multiple outdoor units must be spaced as shown in Figure
9 to prevent flue gasses from one unit from being inngested
by an adjacent unit.

Figure 9 – Multiple Outdoor Units

10