RBI FUTERA XLF Installation and Operation Instruction

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XLF-I0M-2

82-0317

Finned copper tube Gas boilers (MB) & Water heaters (MW)

Boiler manual

Installation and operation instructions

Also read and follow:

XLF 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 dustfree air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

A x these instructions near to the boiler. 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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RBI Futera XLF-Series boilers — Overview

XLF PRIMARY COMPONENTS

1. Electrical enclosure (rear)

2. Blower and motor

3. Air inlet connection

4. Flue outlet connection

5. Gas entrance

6. Boiler water return

7. Boiler water supply

8. Gas valve

9. Power entrance box

10. DP switch — blocked air inlet

11. DP switch — blocked  ue

12. DP switch — blower proving

13. DP switch — pilot air proving

14. Ignitor

15. Pilot gas valve and pilot gas pressure regulator

16. Flow switch

17. Low water cuto

18. Pressure/temperature gauge

19. Relief valve

20. High gas pressure switch

21. Low gas pressure switch

XLF

Rear view

Air chamber cover removed

See the Futura XLF Control manual

for electrical component locations.

inned copper tube gas boilers & water heaters – Boiler Manua

BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 3

RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 4

BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 4

COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . 4

GENERAL VENTING GUIDELINES. . . . . . . . . . . . . . 6

EXISTING COMMON VENT SYSTEMS . . . . . . . . . . . 6

VENT SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . 6

OPTION 1: DIRECT VENT POSITIVE PRESSURE —

CATEGORY IV HORIZONTAL OR VERTICAL . . . . . . . . 7

OPTION 2: VERTICAL VENTING POSITIVE PRESSURE, CATEGORY IV FIGURE 5 OR FIGURE 6 (VENT PIPE EQUIVALENT LENGTH UP TO100 FEET MAXIMUM) . . . 10

OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE

— CATEGORY IV FIGURE 7(VENT/AIR PIPE EQUIVALENT

LENGTHS UP TO100 FEET MAXIMUM) . . . . . . . . . . 11

OPTION 4: VERTICAL CHIMNEY VENTING NEGATIVE PRESSURE — CATEGORY II (MULTIPLE BOILERS WITH

COMMON VENTING) FIGURE 8 . . . . . . . . . . . . . . . 12

CATEGORY II CHIMNEY INSPECTION & SIZING . . . . . .12

CATEGORY II VENT CONNECTIONS . . . . . . . . . . . .12

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

HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . .14

DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . .19

TEMPERATURE RISE CONTROL . . . . . . . . . . . . . .19

GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . .22

ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . .23

GENERAL OPERATION . . . . . . . . . . . . . . . . . . .24

PROPANE GAS. . . . . . . . . . . . . . . . . . . . . . . . 24

WIRING & CONTROL SET-UP . . . . . . . . . . . . . . . . 24

CONTROLS & INTERLOCKS. . . . . . . . . . . . . . . . . 24

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . 25

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . .26

TO TURN OFF GAS TO APPLIANCE. . . . . . . . . . . . .28

CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . .28

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .30

REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . 33

START-UP REPORT . . . . . . . . . . . . . . . . . . . . . 38

BEFORE YOU START

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

 e Futera XLF 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 and CAN1-3.1, 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 ASME Boiler and Pressure Vessel Code.

All aspects of the boiler/water heater installation must conform to the requirements of the authority having jurisdiction, or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA54-latest revision. Where required 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.

If installed in the Commonwealth of Massachusetts, you MUST FOLLOW the additional instructions contained in RBI’s instruction sheet, MACODE-3, located in the back of this manual.

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

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

U. S.  260 North Elm Street West eld, MA 01085

Canada  7555 Tranmere Drive Mississauga ONT L5S 1L4

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

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RATINGS & CAPACITIES

Before undertaking the installation of the Futera XLF 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 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.

Service clearances are not mandatory, but are

recommended to ensure ease of service should it be required.

Table 1 Required clearances

From Clearance to

combustible surfaces

Inches mm Inches mm

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

Service

clearances

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14.

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 fire causing extensive property damage, severe personal injury or death!

COMBUSTION AIR & VENTILATION

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/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!

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.  ese acids will cause premature failure of the boiler/water heater voiding the warranty!

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

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!

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.

The Futera XLF 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

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 XLF 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!

would restrict the introduction of combustion air into the unit

or subject it to a negative pressure, see “GENE L VENTING

GUIDELINES”.

inned copper tube gas boilers & water heaters – Boiler Manua

All air from inside the building

If the Futera XLF is to be located in a con ned space, the minimum

clearances listed in Table1, page4 must be maintained between it and any combustible construction. When installed in a con ned space without the intake air option (as in Figure5,page10 through

Figure8,page13) two permanent openings communicating with

an additional room(s) are required. The 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, 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 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. The upper opening must be within 12inches, 305 mm of, but not less than 3 inches, 76 mm from, the

top of the enclosure.  e bo om opening must be within 12 inches,

305 mm of, but not less than 3 inches, 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inches, 305 mm of, but not less than 3 inches, 76 mm from, the

top of the enclosure.  e bo om opening must be within 12 inches,

305 mm of, but not less than 3 inches, 76 mm from, the bo om of

the enclosure.

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

minimum free area of 1 in

input rating of all of the equipment in the enclosure.

Where communicating with the outdoors through horizontal ducts,

each opening shall have a minimum free area of 1 in 1100 mm

/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 inch, 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

dra , partial fan-assisted, fan-assisted, or power dra -assisted burners,

there shall be a permanent air supply opening(s) having a cross-

sectional area of not less than 1 in

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.

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

/2000 Btu/hr,

per 7,000 Btuh (310 mm2 per

Table 2 Make-up Air Louver Sizing

Input MBH

2500 625 4031 833 5382 2500 16127

3000 750 4838 1000 6452 3000 19354

3500 875 5645 1167 7522 3500 22581

4000 1000 6452 1334 8592 4000 25808

Wire screen

¼ inch (6.4 mm)

Required cross-sectional area

Metal louvers 75% free area

Wooden louvers

25% free area

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 Figure1, page8 through Figure4, page9.

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!

Table 3 Intake air pipe sizing

Input

MBH

2500/3000 10 254 8 203

3500/4000 12 305 10 254

Vertical Horizontal

in mm in mm

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.

 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 100 , 30.5m. Each 90o 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, page9.  e penetration point in the roof must be properly  ashed and sealed.

inned copper tube gas boilers & water heaters – Boiler Manua

Intake air option – Horizontal guidelines

 e maximum equivalent length for the horizontal intake air pipe is 100  , 30.5 m. Each 90o 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 Figure1,

page8, Figure2, page8 and Figure4, page9.

GENERAL VENTING GUIDELINES

The 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 draft of 0.03 inch,

0.8mm to 0.1 inch, 2.5 mm W.C. at the flue 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!

Common-vent systems  The boiler closest to

the vertical vent must be assigned as the master boiler and always  red FIRST to ensure proper

draft and reliable operation

if any questions. Improper installation can result in

excessive levels of carbon monoxide which can cause severe personal injury or death!

. Consult the factory

system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they will operate at maximum speed. Do not operate a summer exhaust fan for a boiler installation. Close  replace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

5. 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.

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

7. 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.

VENT SYSTEM OPTIONS

The flue products in the vent system may be cooled below their

dew point and form condensate in the  ue.  e materials used for a

Category IV vent must be resistant to any corrosive damage from  ue

gas condensate.  e  ue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system.

Category IV vent/air piping lengths must not exceed

100equivalent feet. If longer runs are required, use a

Category II (negative pressure) vent system, specially engineered/designed to meet all applicable codes.

EXISTING COMMON VENT SYSTEMS

If an existing boiler/water heater is removed from an existing 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.

1. Seal any unused openings in the common venting system.

2. 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.

3. 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

The Futera XLF may be vented the following ways:

1. OPTION 1 — Direct Vent, Positive Pressure

Category IV (individual venting only) (page7)

Combustion air is piped from the outdoors to the blower inlet. Vent system is certi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. Maximum equivalent length of vent and air piping must not exceed 100feet each.

2. OPTION 2 — Vertical Vent, Positive Pressure

Category IV (individual venting only) (page10)

Combustion air is obtained from the space in which the unit is installed. Vent system is certi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. Maximum equivalent length of vent piping must not exceed

100feet.

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3. OPTION 3 — Side Wall Vent, Positive Pressure

Category IV (individual venting only) (page11)

Combustion air is obtained from the space in which the unit is

installed. Vent system is certi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada.

Maximum equivalent length of vent and air piping must not

exceed 100feet each.

To ensure proper boiler operation, boilers that use

room air must not be  red at less than 33% input.  is applies to OPTION3 and OPTION4 venting.

4. OPTION 4 — Vertical Vent, Negative Pressure

Category II (common venting) (page12)

Requires negative pressure in vent (natural dra ). Requires a

metal chimney system approved for Category II venting.  is method is required if common venting multiple XLF boilers.

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.

Table 4 Category IV venting — vent pipe size

(Vent options 1, 2 or 3)

Input

MBH

2500/3000 8 203

3500/4000 10 254

Pipe diameter

in mm

 e vent system must be both gas tight and water-tight. 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, 204oC.

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ft, 2.1m above adjacent public

walkway.

Canadian installations require a minimum of 6ft,

18.3m clearance from electric meters, gas meters, regulators and relief equipment for compliance with CANB149.1.

 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.

OPTION 1: DIRECT VENT POSITIVE PRESSURE  CATEGORY IV HORIZONTAL OR VERTICAL

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!  e vent system must be sized per Table4.

Horizontal direct vent systems Figures1 &2

The vent materials used in horizontal vent systems must

be certi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada.  e certi ed vent terminal from

RBI must also be used.

 e maximum equivalent length for the horizontal vent pipe is 100 ,

30.5m. Each 90  , 3.0m of pipe. If any part of a single wall metal vent system passes through an unheated space, it must be insulated with insulation rated for 400oF, 204oC. Structural penetrations must be made using approved  re-stops. For best results, horizontal vent systems should be as short and straight as possible.

elbow and the vent terminal are equal to 10linear

Vertical direct vent systems

Figure3 (vent/air pipe equivalent lengths up to100 feet maximum)

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

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

204oC. Structural penetrations must be made using approved  re-

stops.

An approved, nonrestrictive vent terminal must be used.  e top of a vertical vent system must extend at least 5.5 , 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, page9.  e penetration point in the roof must be properly  ashed and sealed.

The vent system must be gas tight. All seams and joints in metal

pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.

Combination direct vent systems Figure4 (vent/air pipe equivalent lengths up to100 feet maximum)

The boiler/water heater can be vented vertically with the

intake air piped horizontally through an outside wall. Follow the instructions in the Intake Air Option  Horizontal

Guidelines on page6. Also follow the general instructions

in the “Combustion Air & Ventilation” and “General Venting

Guidelines” sections.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 1 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for a single direct vent system

Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table3 or 4 for min. pipe diameters.

When running horizontal combustion

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

Figure 2 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for multiple direct vent systems

Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table3 or 4 for min. pipe diameters.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 4 VENT OPTION 1: DIRECT VENT — Vertical air intake and venting for direct vent system

Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table3 or 4 for min. pipe diameters.

Locate exhaust terminal downwind from air intake

to reduce potential for flue gas recirculation. Failure to comply could result in severe personal injury or death.

Figure 3 VENT OPTION 1: DIRECT VENT — Combination direct vent system

Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table3 or 4 for min. pipe diameters.

inned copper tube gas boilers & water heaters – Boiler Manua

OPTION 2: VERTICAL VENTING POSITIVE PRESSURE, CATEGORY IV

FIGURE5 OR FIGURE6

VENT PIPE EQUIVALENT LENGTH UP TO 100 FEET 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,

Figure 5 VENT OPTION 2: VERTICAL CHIMNEY VENTING

Vertical venting — with a metal chimney system See Figure4, page7 for minimum pipe diameters.

lined and sized. Exterior masonry chimneys should not be used unless properly lined to prevent condensation and dra problems. Table4 lists the equivalent breeching and  ue sizes required for the

boiler/water heater.

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.

 e vent connector should be sloped up toward the chimney at a

minimum rate of ¼ in/ , 21 mm/m. On masonry chimneys the

connector must terminate  ush with the inside of the chimney  ue, Figure8, page13.

Always provide a minimum clearance of 6 inches, 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 fire causing extensive property damage, severe personal injury or death!

Figure 6 VENT OPTION 2: VERTICAL CHIMNEY VENTING

Vertical venting — using a lined masonry chimney See Figure4, page7 for minimum pipe diameters.

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OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE CATEGORY IV

FIGURE7

VENT/AIR PIPE EQUIVALENT LENGTHS UP TO 100 FEET MAXIMUM

In this configuration the boiler/water heater blower is used

to push the flue products horizontally to the outdoors, see

Figure 7. The 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.

To ensure proper boiler operation, boilers that use

room air must not be  red at less than 33% input.

Figure 7 VENT OPTION 3: SIDE WALL VENT — Side wall venting

Vent pipe and air pipe equivalent lengths must not exceed 100 feet each.

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OPTION 4: VERTICAL CHIMNEY VENTING NEGATIVE PRESSURE  CATEGORY II

MULTIPLE BOILERS WITH COMMON VENTING

FIGURE8

Category II venting is required for multiple XLF boilers

connected to a common vent. Common vent systems cannot be pressurized.

 e FuteraXLF is listed as a CategoryII appliance when vented

vertically into a listed metal chimney system. See Figure8, page13

(multiple boilers).  e chimney must provide a negative pressure

not greater than 0.15inch, 3.8 mm w.c. at the boiler/water heater  ue collar with the unit running.

When using a listed metal chimney system the chimney

system manufacturer’s instructions must be followed.

 e vent piping must be large enough to safely vent the

combined output of all of the appliances connected to

the system.

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!

To ensure proper boiler operation, boilers that use

room air must not be  red at less than 33% input.

CATEGORY II CHIMNEY

INSPECTION & SIZING

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 dra problems.

Table5 lists the minimum riser sizes required for the XLF boiler/ water heater.

Table 5 Riser diameters to common vent for Category II venting

Input — MBH in mm

2500/3000 12 305

3500/4000 14 356

Note:  ese sizes are based on a 20  , 6.1m chimney height.

CATEGORY II 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.

 e boiler vent connectors should be sloped up toward the breeching

at a minimum rate of ¼in per ft, 21mm per m. On masonry chimneys the connector must terminate  ush with the inside of the chimney liner (as shown in Figure6, page10).

Always provide a minimum clearance of 6 inches, 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 fire causing extensive property damage, severe personal injury or death!

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Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations

See Table5, page12 for minimum riser diameter (dimension F)

DO NOT common vent more than the following

number of Futera XLF boilers: XLF-2500/3000 (4) boilers maximum. XLF-3500/4000 (3) boilers maximum.

Legend for Figure8

 e boiler nearest the vertical chimney must always

be  red  rst.

A negative pressure of 0.02 to 0.08inches w.c. is

required in each boiler's riser when all boilers are operating at full input.

Provide clearance from the boiler of no less than

6 inches to combustible surfaces or 24inches for service.

1. A barometric damper must be installed on the riser of each boiler, 24inches above the vent elbow. [Exception: If the vent system is designed using accepted engineering practices, and the design calculations prove there is no need for barometric dampers, the barometric dampers may be omitted.] When required by applicable codes, install a thermal spill switch on each barometric damper.

2. Install a thermal spill switch on each barometric damper (when required by applicable codes).

3. Connect each boiler riser to the common vent with a y connection only.

4. Install an approved vent cap at the vent termination.

5. DIMENSIONS: B breeching length C chimney height D breeching diameter F riser diameter (no smaller than the dimension given in Table5, page12)

6. Size the chimney and breeching per local codes and vent pipe manufacturer's recommendations, using generally accepted engineering practices.

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GENERAL PIPING REQUIREMENTS

Improper piping of this boiler/water heater will void

the manufacturer’s warranty and can cause boiler failure resulting in flooding and extensive property

damage! Excessive water hardness causing scaling in the copper heat exchanger tubes is NOT covered under the manufacturer’s warranty. See Table8, page20. Excessive pi ing and erosion of the internal surface

of the copper heat exchanger tubes is NOT covered under the manufacturer’s warranty if the result of high water  ow rates. See Table7, page16. Return water temperatures below 140oF, 60oC will result in heat

exchanger damage from excessive condensation voiding the manufacturer’s warranty, see Primary/ Secondary Piping. See Figure9, page15.

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. The following precautions MUST be observed:

1. A continuous flow of water through the unit MUST be maintained! The pump responsible for flow through the

boiler/water heater must run continuously!

2. An ethylene glycol/water mixture suitable for the minimum temperature that the unit will be exposed to must be used. The pump must be capable of producing

a minimum of 15% more flow and overcoming a 20% increase in head loss. Domestic water systems must be isolated from the water heater by the use of a heat exchanger or

other approved method.

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

Improper outdoor installation of this unit can cause

boiler failure voiding the manufacturer’s warranty!

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 inch, 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,

per Table6.

Table 6 Supply & Return Pipe Sizing

Input

MBH

2500/3000 4" FLANGE 4" FLANGE

3500/4000 4" FLANGE 4" FLANGE

Supply

size

Return

size

Pump requirements

Relief valve

Pipe the discharge of the pressure relief valve as shown in Figure9, page15.

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!

This low mass boiler requires a continuous minimum water  ow for proper operation.  e boiler pump must be

sized to overcome the head loss of the boiler and the near-boiler piping in order to achieve the required temperature rise. Table7

provides the heat exchanger pressure drop and temperature rise  gures.  e temperature rise across the boiler must never exceed 35oF, 19.4oC.  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.

inned copper tube gas boilers & water heaters – Boiler Manua

A temperature rise outside of the range listed in Table7

will result in damage to the heat exchanger, voiding the warranty!  e maximum allowable temperature rise through the boiler is 35

Figure 9 Futera XLF Piping

F, 19.4oC.

 e maximum allowable  ow rate through a Futera

XLF boiler is 260 GPM, 16.4 L/s when equipped with

copper tubes. A cupronickel heat exchanger allows for

315 GPM, 19.9 L/s.

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Table 7 Temperature Rise Table

Model

Number

2500 217.5 10.05 13.7 29.6

3000 261.0 15.20 16.5 44.8

3500 304.5* 20.26 19.2* 59.7

4000 NA NA NA NA

Model

Number

2500 174.0 6.45 11.0 19.0

3000 208.8 9.73 13.2 28.7

3500 243.6 13.40 15.4 39.5

4000 278.4 * 17.30 17.6* 51.0

Model

Number

2500 145.0 3.71 9.1 10.9

3000 174.0 6.75 11.0 19.9

3500 203.0 9.56 12.8 28.2

4000 232.0 12.00 14.6 35.4

Model

Number

2500 124.3 2.79 7.8 8.2

3000 149.1 4.65 9.4 13.7

3500 174.0 7.19 10.9 21.2

4000 198.9 10.48 12.5 30.9

* This  ow rate exceeds the recommended maximum for a boiler with

a standard copper heat exchanger. Use a greater temperature rise or consult manufacturer. Consider a cupro-nickel heat exchanger, because its maximum  ow rate is 315 GPM.

∆T = 20oF ∆T = 11.1oC

Flow Rate Pres. Drop Flow Rate Pres. Drop

GPM Ft L/s kPa

∆T = 25oF ∆T = 13.9oC

Flow Rate Pres. Drop Flow Rate Pres. Drop

GPM Ft L/s kPa

∆T = 30oF ∆T = 16.7oC

Flow Rate Pres. Drop Flow Rate Pres. Drop

GPM Ft L/s kPa

∆T = 35oF ∆T = 19.4oC

Flow Rate Pres. Drop Flow Rate Pres. Drop

GPM Ft L/s kPa

Primary/secondary piping

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

or systems that have excessive  ow rates or return water temperatures

less than 140oF, 60oC must be isolated from these systems to protect the boiler.

Variable water  ows

Figure10, shows a typical primary/secondary piping system. A dedicated pump is used to maintain a constant water flow through the boiler.  is boiler pump is sized to overcome the head

loss of the boiler and near-boiler piping system while supplying the  ow rate required to maintain the desired temperature rise across the boiler heat exchanger.  e system pump is sized to provide the required  ow to the heating system.  e boiler piping connections to the heating system piping must be a maximum 6 pipe diameters

between centers to ensure zero pressure drop in the primary system.

Low return water temperatures

To prevent the problems associated with condensation of the

products of combustion due to low return water temperatures a

primary/secondary piping system with a bypass and bypass valve

must be installed, see Figures11 and 12.  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 boiler piping connections to the heating system piping

must be a maximum 6 pipe diameters between centers to ensure zero

pressure drop in the primary system.

Multiple boiler systems

Systems using multiple boilers can also be installed using a primary/

secondary manifold system, Figure13.

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.

Low water cuto

If a boiler is installed above any radiation elements it must be   ed with a low water cuto device.

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.

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

Expansion tank and 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.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 10 Typical Primary/Secondary Piping System (See Notes)

NOTES:

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

2. Boiler pump sized to boiler design flow requirements.

3. All boilers furnished with fac tory mounted outlet water temperature gauge.

4. Boiler pump purging required. Use terminals supplied.

H-1 Rev 3

Figure 11 Low Temperature Piping with Thermostatic Valve

(See Notes and Adjustment Procedure)

These drawings show

suggested piping con guration and valving. Check with local codes and ordinances for speci c requirements.

ADJUSTMENT PROCEDURE

(To maintain inlet temperature

above  ue gas dewpoint)

1. T1 is the return water temperature.

2. Minimum temp, T1 = 140

F, 60oC.

3. Turn heater on and OPEN valves "A" and "B."

4. After steady-state operation is reached:

H-18 Rev 2

5. If T1 is less than 140

F, 60oC: SLOWLY CLOSE valve "B" until T1 rises to the desired operating temperature (but NO LESS than the minimum,

140oF, 60oC).

6. If T1 is greater than desired operating temperature, slowly close valve "A" until the temperature drops to the

NOTES:

1. For pump selection consult factory.

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

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

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

5. Boiler pump purging required. Use terminals supplied.

6. Valve is pre-calibrated for 140

F return temperature.

desired operating temperature (but NO LESS than the minimum, 140

60oC).

7. Check again after system operating temperature has stabilized. Then make  nal adjustments.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 12 Low Temperature Piping (See Notes and Adjustment Procedures)

Figure 13 Multiple Boiler Piping (See notes)

H-3 Rev 5

These drawings show

suggested piping con guration and valving. Check with local codes

and ordinances for spe-

ci c requirements.

NOTES:

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

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

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

4. Boiler pump purging required. Use terminals supplied.

5. Secondary loop pipe diameter must be sized large enough to handle maximum  ow through all units.

H-15 Rev 4

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DOMESTIC WATER SUPPLY PIPING

Proper controls must be used to prevent water supplied

for domestic use from exceeding 130oF, 5 4oC 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 120oF, 49oC. Local codes must be complied with!

General piping requirements

Ensure that the water heater is equipped with bronze headers. Piping

and components connected to the water heater must be suitablefor use with potablewater.  e water heater must not be connected to any heating system piping or components previously used w ith a nonpotable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 cupronickel heat exchanger may also be required. The

manufacturer should be consulted when these water conditions are encountered. See Table8, page20.

 e maximum allowable  ow rate through a Futera XLF

water heater is 260GPM, 16.4L when equipped with copper tubes.  e cupronickel heat exchanger allows for 315GPM, 19.9L/s. See Table9, page20.

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

TEMPERATURE RISE CONTROL

Water returned to the water heater inlet must

not be less than 140oF, 60oC 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 flow rate through the heat exchanger. Thermometers are installed on both the inlet and outlet of the water heater for determining the temperature rise through the unit.

The proper velocity through the water heater

must be maintained in accordance with Table9, page20 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9, page20 the  ow rate is too low. Scaling and so ening of the heat exchanger will occur.

 ermostatic Mixing Valve – Water Above 140

60oC Water can be stored at temperatures above

140oF, 60oC 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

60oC will provide an increased quantity of tempered water and help prevent the growth of water born bacteria.

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Selection Table(Table8) and the Pumping Performance Table (Table9). 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.

To properly size the pump a grain hardness

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

Expansion Tank

An expansion tank or other means to control

thermal expansion must be installed in the water heating system if back  ow prevention devices are installed.

Pump Requirements

This low-mass water heater requires a

continuous minimum water flow for proper operation. The low water flow switch provided for this unit will shut down the water heater if  ow falls below the required minimum level. Table9 provides the heat exchanger pressure drop chart and temperature rise table.  e temperature rise across the water heater must never exceed

35oF, 19.4oC.

Table 8 Futera XLF Heat Exchanger Selection

Table 9 Futera XLF Pumping Performance Requirements

Water hardness

Heat exchanger type Cupro-nickel Copper Cupro-nickel

Boiler model GPM P T GPM P T GPM P T

MW-2500 MW-3000

MW-3500 MW-4000

Soft Normal Hard

SPECIAL

REQUIREMENTS

(Call factory

or representative)

210 9.73 25.0 262 14.54 20.0

210 10.40 33.0 262 16.90 27.0

Cold Water Supply

The cold water supply must be piped to

the water heater’s outlet piping between the water heater and the hot water storage

ΔT = Temperature change = (Outlet temp – Inlet temp) in oF

ΔP = Head loss = (Inlet pressure – Outlet pressure) in feet of water column

To achieve the proper  ow rate, adjust outlet valve on heater piping to obtain correct ΔT

Call factory if grains of hardness is less than 3 or greater than 24.

tank.  is will prevent untempered water from entering the water heater. See the

Temperature Rise Control section, page19.

Two typical water heating systems are

shown in Figures14 and 15.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 14 Typical Water Heating Piping (MW Models Only) (See Notes)

Figure 15 Multiple Water Heating Piping (MW Models Only)

(See Notes)

 ese drawings show sug-

gested piping con guration and valving. Check with local codes and ordinances for speci c requirements.

NOTES:

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

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

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

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

5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.

6. The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and Pumping Performance Tablebefore making selection.

7. Common piping must be sized for maximum combined heater  ow.

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

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

inned copper tube gas boilers & water heaters – Boiler Manua

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 B149.2 Installation Code. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

 e Futera XLF 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.

With all units operating the gas supply pressure (natural

gas) at the safety shuto valve inlet must be:

Minimum 3.5inches, 88.9mm, W.C. Maximum 14inches, 356mm, W.C.

Tables10 and 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10 should be used in conjunction with Table11 to ensure that the gas supply piping has the capacity to meet the demand.

Figure 16 Gas Supply Piping

Figure16 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.

Table 10 Gas pipe capacities (natural gas)

Maximum pipe capacity in ft3/hr, based on 0.60 speci c gravity natural gas at a pressure of 0.5 psig or less and a 0.5" w.c. pressure drop,

for iron pipe with nominal size below, and for total equivalent length (in feet):

Pipe

size

Note: For propane piping — Multiply the gas volume capacities above by 0.62 for propane  ow capacities in ft3/hr. Multiply the propane  ow capacity by 2500 Btu/ft

10 20 30 40 50 60 70 80 90 100 125 150 175 200 250

2" 4,020 2,760 2,220 1,900 1,680 1,520 1,400 1,300 1,220 1,160 1,020 928 854 794 704

2½" 6,400 4,400 3,530 3,020 2,680 2,430 2,230 2,080 1,950 1,840 1,630 1,480 1,360 1,270 1,120

3" 11,300 7,780 6,250 5,350 4,740 4,290 3,950 3,670 3,450 3,260 2,890 2,610 2,410 2,240 1,980

4" 23,100 15,900 12,700 10,900 9,660 8,760 8,050 7,490 7,030 6,640 5,890 5,330 4,910 4,560 4,050

5" 41,800 28,700 23,000 19,700 17,500 15,800 14,600 13,600 12,700 12,000 10,600 9,650 8,880 8,260 7,320

6" 67,600 46,500 37,300 31,900 28,300 25,600 23,600 22,000 20,600 19,500 17,200 15,600 14,400 13,400 11,900

to determine the propane Btu/hr capacity for a given pipe size and length.

inned copper tube gas boilers & water heaters – Boiler Manua

Table 11 Equivalent length (feet) for typical  ttings

Pipe

size

2" 5.2 10.3 1.2 3.0

2½" 6.2 12.3 1.4 3.5

3" 7.7 15.3 1.8 4.5

4" 10.1 20.2 2.4 6.0

5" 12.6 25.2 2.9 7.3

6" 15.2 30.4 3.5 13.4

Equivalent lengths above are for threaded  ttings. Multiply values above by

0.75 for  anged  ttings.

elbow Tee

Fitting or valve

(branch  ow)

Gate

valve

Gas

cock

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.

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!

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.

Never use an open  ame to test for gas leaks. Always use

an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Whenever the gas supply piping is pressure tested the boiler/water

heater gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler/water heater by closing it’s manual shut o valve, see Figure16, page22. 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. Failure to comply could result in severe personal injury,

death or substantial property damage.

The electrical connections to this boiler/water

heater must be made in accordance with all applicable local codes and the latest revision

of the National Electrical Code, ANSI/ NFPA-70. Installation should also conform with CSA C22.1 Canadian Electrical Code Part I if installed in Canada.

Install a separate 240 volt circuit breaker for the boiler/water heater . (See Table12). A properly rated shut-o sw itch 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 12 Futera XLF Electrical Requirements

Futera XLF

Model

2500-4000 25 17

* Use separate circuit breaker that is properly sized for pump

and pump contactor.

Line voltage field wiring of any controls or other devices

must conform to the temperature limitation of type TEW or equivalent at 189oF, 105oC. Use appropriate wiring materials for units installed outdoors.  e wire size must be compatible with the total amp draw of the circuit.

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

proper wiring connections and wire size.

Required

Circuit Breaker

(amps)

FLA *

inned copper tube gas boilers & water heaters – Boiler Manua

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.

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 minimum 12 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 off, run the system pump for at least 30

minutes and bleed the system piping using the bleed valves. If strainers are used in the system piping, the make- up water valve should be closed and the strainers checked and cleaned.

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

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

Open the make-up water valve and adjust the system pressure if necessary.  e system should be checked and bled a er three days of operation.

WIRING & CONTROL SETUP

Follow the instructions in the Futera XLF Control

installation and operation instruction manual shipped with the boiler to wire the boiler and set up the HeatNet control.  e control must be set up before a empting to  re the boiler.

See Figure17, page25 for location of electrical components.

In addition to the information in the FuteraXLF Control IOM, see the following information on controls and interlocks.

CONTROLS & INTERLOCKS

Low Water Cuto

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

by other codes or regulations, install a low water cutoff in appropriate piping. Wire the switch to the "Interlock" contacts as illustrated on “Field Wiring” schematic. Ensure that the low water cuto device(s) will function properly.

Operating Control

 e operating control should be set to the lowest se ing that will

satisfy the consumer's needs.

Se ing the thermostat or operation control too high

can result in scalding resulting in severe personal injury!

High Limits (Aquastats)

 e high limits are located in the top control area of the boiler/water

heater. Remote capillary bulbs run to wells on the outlet side of the supply header. The high limit can be reset by depressing the red bu on.

The water heater high limit should be set to a minimum of 20 11oC 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.

PROPANE GAS

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!

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 17 HeatNet Control Panel

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. The blower operates at minimum ignition setting. 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. The blower stays at the minimum input setting 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.

inned copper tube gas boilers & water heaters – Boiler Manua

The following start-up procedure assumes that all

water piping, gas piping and electrical connections

are correct as stated in this manual and the installation

meets all State, Local, and City codes.

See the FuteraXLF Control IOM for troubleshooting

information and control operation.

OPERATING INSTRUCTIONS

Operating instructions

1. If, at any time, the boiler will not operate properly, follow the instructions "TO TURN OFF GAS TO APPLIANCE," page28,

and call your service technician or gas supplier.

2. Turn o all electrical power to the boiler.

3. Close main gas shut-o valve ( eld supplied), Figure16, page22.

4. Purge the gas piping up to the boiler's manual gas valve (located ahead of the main gas valve). When the bleeding is complete, check all gas joints up to the gas valve for leaks.

5. Wait  ve (5) minutes to clear out any gas.

6. Make sure all limits, pressures switches and safety device contacts are closed.

7. Open the main gas shut-o valve.

8. Disable any external call for heat, such as from a building

management system or remote operating controller.

9. Toggle the remote/local switch (in control cabinet  see

Figure18) to

10. Turn on electrical power to the boiler.

11. Turn the power switch on the front of the boiler control cabinet to

ON.

12.  e HeatNet display will light up when the power is on. If all interlocks are properly closed, the display will say

not, refer to the XLF HeatNet Control IOM for troubleshooting.

13. Slide the HeatNet control's low  re switch (on HeatNet control

board) to the

14.  e boiler will begin the start-up sequence.

15. Allow the boiler to pre-purge and enter the pilot ignition cycle.

16. If pilot lights (indicated by a good  ame signal 5.0 V DC) proceed to step 18. (See Honeywell R7800 literature for use of a meter to

check  ame signal if keypad readout is not available.)

17. If pilot is unstable(indicated by a low or erratic flame signal

causing pilot  ame failure), toggle the low  re switch to

then back to ENABLE to start another cycle (reset the Honeywell

control if necessary). Repeat for one or two more times to ensure

the pilot line is purged of all air. If pilot is still unstable, the pilot

gas pressure may need to be increased. See step18.

18. Pilot pressure adjustment:

a. Switch the Honeywell control to

 rst 10 seconds of the pilot ignition sequence.

REMOTE.

STANDBY. If

LOW FIRE position.

DISABLE,

TEST position within the

b. Connect one side of a manometer or pressure gauge to the

manometer pressure port (barbed) on the pressure test manifold

(located inside control panel). See Figure18. Leave the other

side of the manometer open to the room. DO NOT connect it to the reference port (le side of panel).

Figure 18 Manometer connections to the test manifold (in

control cabinet)

c. Measure pilot gas pressure by pressing and holding the

service valve marked PILOT GAS.

d. Set pilot gas pressure to 3.0 inches w.c. (± 0.5 inch) by

adjusting the pilot gas pressure regulator, inside the air box.

Access from the boiler top cover. See Figure19.

Figure 19 Access to air trim adjustment and pilot regulator

e. Check pilot air pressure using service valve marked PILOT

AIR

f. Pilot air pressure should be 0.60 inches w.c. (± 0.10 inches).

Combustion readings must be in the range speci ed

in the following instructions. Adjust the boiler as necessary to ensure proper combustion.

inned copper tube gas boilers & water heaters – Boiler Manua

Verify low  re operation

1. Connect a manometer or Magnehelic gauge with the pressure side to the manifold pressure port and the other to the manifold reference port. See Figure18, page26 for locations.

2. Set Honeywell R7800 control to RUN position.  e boiler will operate at low  re because the low  re switch is in the low  re position.

3. Measure the  ue gas CO low  re CO2 to 8.0% – 8.5% by adjustment on the Dungs valve

with the boiler running at low  re. Set

using a 3mm Allen wrench. a. Turn the wrench in small increments (10degrees at a time). b. Allow time a er each adjustment for the boiler to reach steady

state.

4. A er se ing the CO a. Press the

, measure the pressure signal, Ps.

Ps (signal) button and read the pressure. The

pressure at low  re should be as shown in Figure13 .

b. If the pressure is outside this range, follow instructions in the

XLF Control IOM to calibrate the  ring rate. Increase rate if

the pressure signal is low, or decrease rate if the signal is high.

c. Return to step 1 to adjust low  re CO

 r e  r i n g r a t e .

a er changing low

If using a U-tube manometer turned sideways for low

pressure readings, you MUST turn the manometer upright before attempting to measure pressures at other than low  re. Pressure signal will reach up to 9 inches when the boiler is at high  re, and can cause  uid to be pulled out of the manometer into the boiler. Should this occur, immediately shut down the boiler and contact the factory for procedure. Preferably, use a Magnehelic gauge instead of a U-tube manometer to measure the pressure to avoid this potential hazard.

Table 13 Pressure signal (Ps) (Nat Gas)

Firing

rate

100% -9.40 -5.50 -5.80 -8.70

20% -0.60 -0.25 -0.40 -0.40

To determine signal in mm w.c., multiply signal pressure by 25.4.

XLF-2500 XLF-3000 XLF-3500 XLF-4000

Signal

Inches w.c.

Signal

Inches w.c.

Signal

Inches w.c.

Signal

Inches w.c.

For LP Gas: All units are tested at factory. LP Combustion Values are

located on Combustion Data label.

To ensure proper boiler operation, boilers that use

room air must not be  red at less than 33% input.

5. Observe the burner  ame a er se ing low  re. Make sure the  ame is stable, but not too tight on the burner (causing infrared operation).

DO NOT LEAVE THE BURNER IN AN INFRARED STATE.

A few random speckles of red are acceptable, but large concentrations of spots or large areas of red are not. If large amounts of red concentrations are observed, verify combustion readings.

Leave the manometer connected to the test manifold.

It will be needed for high  re operation testing.

Verify high  re operation

1. Jumper the AA terminals on the HeatNet board and allow the boiler to rise to maximum (100%) input.

2. Allow the boiler to reach steady state combustion at high  re.

3. Verify high  re blower speed as follows: a. With the manometer (or gauge) connected to the test manifold,

press the

Ps (signal) bu on and read the pressure.

b.  e pressure at low  re should be as shown in Figure13 . c. If the pressure is NOT correct, follow step 4.

4. If the high  re signal pressure is not correct: a. Remove the jumper on A-A.  e boiler will return to low  re. b. Follow the instructions in the XLF Control IOM to calibrate

the high  re  ring rate. (Slide the HeatNet control calibrate switch to

CAL. Follow the Control IOM procedure to

navigate to the HeatNet control calibration screen.)

 e maximum  ring rate value in the HeatNet control

is factory set at 90%. At this se ing, at sea level, and with typical vent length, the boiler will be at rate. DO NOT increase the HeatNet control's maximum rate se ing above 90% unless needed for high altitude installations.

Ps is too high, reduce the HeatNet control's maximum

c. If

 ring rate se ing by 2%.  en slide the calibration switch to

NORMAL and exit the HeatNet control's calibration screens.

Replace the jumper on A-A and allow the boiler to return to high  re. Return to step2 to repeat the process. If necessary, repeat this sequence, reducing the  ring rate by 2% each time.

d. If

Ps is too low, increase the  ring rate se ing by 2%.  en

slide the calibration switch to

NORMAL and exit the

HeatNet control's calibration screens. Replace the jumper on A-A and allow the boiler to return to high  re. Return to step2 to repeat the process. If necessary, repeat this sequence, increasing the  ring rate by 2% each time.

e. Check the pressure signal again. If the signal is now correct,

reconnect the jumper on AA and proceed to step 5.

f. If the pressure signal is still not correct, verify that the air

trim adjustment (see Figure19, page26) is in the half-open

(factory setting) position. If it is at factory setting, you

will need to contact technical support at the factory to troubleshoot the pressure signal issue.

5. If the pressure signal is correct, measure the flue gas CO should be between 9% and 9.5%.

a. If CO b. If CO

is correct, proceed to step 6.

is not within this range, adjust the air trim adjustment

slightly (see Figure19, page26) on top of mixing box to

. It

achieve a CO2 of 9% - 9.5%.

c. If adjusting the air trim adjustment does not correct the

problem, contact technical support at the factory to troubleshoot the problem.

inned copper tube gas boilers & water heaters – Boiler Manua

6. If CO2 and pressure signal are correct, allow the boiler to reach steady state and verify supply gas pressure and check input rates as explained in the Gas Supply Piping section.

7. Remove jumper on AA and allow boiler to se le into minimum input. Observe the combustion readings to ensure the boiler is

operating correctly.

8. When  nished, disable the low  re hold switch and replace test ports to normal state. Remove the manometer connections and

close the control panel door.

9.  e Futera XLF boiler allows for many modes of operation and

control methods. Reference the XLF HeatNet Control IOM.

TO TURN OF F 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.

CHECKING & ADJUSTMENTS

Proper polarity of the ignition transformer wiring is

import. Improper wiring of the ignition transformer can result in an explosion causing extensive property damage, severe personal injury or death!

Spark gap

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

energize the unit. Look through the sight glass in the pilot tube

to observe the trial for ignition. Make sure that the spark is strong

and continuous. If not, check and adjust the spark gap as shown in

Figure20.

Figure 20 Spark Gap

inned copper tube gas boilers & water heaters – Boiler Manua

Pilot adjustment

1. The pilot pressure has been factory set at 3 inches w.c., and shouldn't need adjustment.

a. With the boiler powered, generate a call for heat. b. When the prepurge is complete the ignition/pilot trial will

begin.

2. To adjust the pilot the following steps must be taken: a. 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.

b. Connect one side of a manometer or pressure gauge to the

manometer pressure port (barbed) on the pressure test manifold (located inside control panel). See  gure 18. Leave the other side of the manometer open to the room. DO NOT connect it to the reference port (le side of panel).

c. Measure pilot gas pressure by pressing and holding the

service valve marked PILOT GAS.

d. Set pilot gas pressure to 3.0 inches w.c. (± 0.5 inch) by

adjusting the pilot gas pressure regulator, inside the air box.

Access from the boiler top cover. See Figure 19.

e. Check pilot air pressure using service valve marked PILOT

AIR.

f. Pilot air pressure should be 0.60 inches w.c. (± 0.10 inches).

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:

Gas supply pressure (Nat/LP)

Inches

water column

Minimum (in W.C.) 3.5 88.9

Maximum (in W.C.) 14 356

water column

If the gas pressure is above the limit in the table below,

a lock-up style gas pressure 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.

This pressure regulator (supplied by others) may

be installed at the service entrance to each unit or

a “master” regulator sized to handle multiple units may be utilized. Consult local gas utility or regulator manufacturer for recommendations to meet 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 ft, 610 m.

At elevations above 2000 ft, 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

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.

, 0.28m3 of gas and divide this time by 10.

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!

1. Measure pressure when the boiler is firing at full rate. Low gas pressure could indicate undersized gas line or insu cient gas supply.

2. Static and operating gas pressure required at the gas valve inlet is listed in the Tableabove.

inned copper tube gas boilers & water heaters – Boiler Manua

MAINTENANCE

Disconnect electrical power and close the manual gas

shut o valve before performing maintenance or severe

personal injury may result!

Servicing , inspection and adjustment must be done by

a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can damage the boiler/water heater!

 e boiler/water heater must be cleaned and inspected at least once

a year and before each heating season. Make sure that the burner and ignition components are free from dust, soot, dirt, corrosion or other deposits that would impair the boiler/water heater ‘s performance. Refer to Figure20, page28 for component identi cation.

Improper burner servicing can result in premature

burner failure voiding the warranty!

Pilot and 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. Remove wires from the spark rods and remove the UV sensor

from the transition piece.

4. Remove the pilot assembly: a. Disconnect the compression nut at the front of the pilot

block. b. Remove the pilot gas tubing. c. Remove the (2) screws from the pilot block. d. Remove the pilot assembly.

5. Disconnect the  exible gas line from the manifold.

6. Disconnect the wires to the fan and remove the (2) bolts and the fan hold-down plates that secure the fan to the transition piece.

7. Lift and remove the fan housing from the boiler/water heater, taking care not to damage the spark rods and or their alignment.

8. Remove the four nuts holding the transition piece to the heat exchanger.

9. Remove the transition piece, taking care not to damage the

O-ring.

10. Remove the burner, taking care not to damage the gasket.

11. Replace all components a er servicing.

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

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

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

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

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

Heat exchanger cleaning

1. Close the shut 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. Thoroughly 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).

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.

inned copper tube gas boilers & water heaters – Boiler Manua

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.

Air intake & vent system

Thoroughly inspect the air intake and vent systems for any

signs of blockage, corrosion or leakage. Immediately replace any unsound vent system piping. Inspect the air  lter and wash with

warm water and soap if dirty.

Controls

Use the “GENERAL OPERATION” 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.

a.  e probe on a probe low water cut o must be removed,

cleaned and inspected at least once a year.

b. 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. The 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.

Figure 21 Main Burner Flame

Manometer test port manifold

1.  e Futera XLF includes a manometer test manifold. Connect the manometer pressure hose to the Pressure Tap port shown in Figure22.

Figure 22 Manometer connections to manifold

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.

a. 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 .

b.  e water temperature should never exceed the maximum

set point of 250

F, 121oC, for boilers and 210oF, 99oC for

water heaters.

c. The 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21.

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!

2. For pilot gas pressure and pilot air pressure readings, DO NOT connect the other side of the manometer. Leave the other side open to room pressure.

3. For Ps (pressure signal) readings, connect the other side of

the manometer to the manometer reference port as shown in Figure 22. These pressure signals may be used for troubleshooting when speci ed by factory support.

4. Figure23, page32 shows the sensor hose connections inside the

FuteraXLF air box.

inned copper tube gas boilers & water heaters – Boiler Manua

Figure 23 Futera XLF pressure sensor hose routing

REPAIR PARTS

Figure 24 Exploded view

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Figure 25 Figure20 – Electrical components

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Model Size with item Quantities Below

Ref # Name of Part Part # 2500 3000 3500 4000

1 Top/Bottom X Pro le 04-0524 3333

2 Middle X Pro le 04-0526 2222

3 Top Y Pro le 04-0530 4444

4 Bottom Y Pro le

5 Top/Bottom Z Pro le 04-0539 4444

6 Middle Z Pro le 04-0541 2222

7 Bottom/Front X Pro le 04-0528 1111

8 Frame Corner 20-0053 8888

9 Frame Corner 04-0543 1111

10 Crosses 20-0054 4444

11 Drilled Crosses 04-0544 1111

12 Bottom Corner 04-0542 4444

Base Legs Left Side 04-1018 1111

Base Legs Right Side 04-1022 1111

15 Burner

15a Burner O'ring 06-0006 1111

15b Burner Gasket 06-0038 1111

16 Gas Support Bracket 03-3768 2222

17 High Gas Pressure Switch (Manual Reset) 11-0421 1111

18 Gas Valve, MBC

Flange 1 1/2" 2

Flange 2" 11-0219 2 2 2

19 Low Gas Pressure Switch (Manual Reset) 11-0422 1111

20 Gas Hose 53-4001 N/A 1 1 1

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

Firing Valve, 2" 11-0459 1 1 1

22 "A" Valve, 1 1/2" 11-0467 1

"A" Valve, 2" 11-0454 1 1 1

23 Blower 12-0019 1111

NS Pilot Flame Disc 10-0141 1111

24 Air/Gas Mixing Box Assembly

NS Gas Manifold

04-0535 4 4

04-0537 4 4

10-0322 1

10-0297 1

10-0323 1

10-0300 1

11-0223 1

11-0218 1 1

70-3643 1

70-3610 1 1 1

01-0207 1

01-0203S 1 1 1

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Model Size with item Quantities Below

Ref # Name of Part Part # 2500 3000 3500 4000

NS Manifold/Ori ce Mounting Plate (Forward)

Manifold/Ori ce Mounting Plate (Rear) 03-3728 1 1 1

25 Mixing Box Gasket 06-0080 1111

NS Gas Injectors, NG

26 Flow Switch 14-0203 1111

27 Jacket Top Panel 70-2413.1 1111

NS Jacket Top Panel (Outdoor) 70-3640

28 Air Filter 09-0485 1111

29 Rear Pipe Enclosure Assembly 70-3510 1111

30 Lower Rear Jacket Panel

NS Rear Panel (Outdoor)

NS Left Hand Rear Panel (Outdoor)

31 Upper Left Jacket Panel 03-2832 1111

32 Upper Right Jacket Panel 03-2834 1111

NS Upper Right Jacket Panel (Outdoor) 70-4131 1111

33 Lower Left & Right Jacket Panel

34 Upper Front Jacket Panel 70-3617 1111

NS Upper Front Panel (Outdoor) 70-2443

NS Handle 20-0063 1111

35 Lower Front Jacket Panel

NS Lower Front Jacket Panel (Outdoor)

Combustion Chamber Top Panel 70-3561 1111

Manning Glass Insulation (per square foot) 05-0104 9999

03-3734 1

03-3721 1 1 1

10-1005 1

10-1002 2 2 2

03-3786 1

03-3787 1

03-3788 1

03-3789 1

03-3810 1

03-3811 1 1 1

70-4113 1

70-4115 1 1 1

03-2838 2

03-2839 2

03-2840 2

03-2841 2

70-3535 1

70-3536 1

70-3537 1

70-3538 1

70-3565 1

70-3568 1 1 1

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Model Size with item Quantities Below

Ref # Name of Part Part # 2500 3000 3500 4000

37 Combustion Chamber Rear/Side Panel

Manning Glass Insulation (per square foot) 05-0104 24 24 26 26

38 Combustion Chamber Door Assembly

Manning Glass Insulation (per square foot) 05-0104 7777

Pressure Relief Valve 50# 30-0384 1111

Pressure Relief Valve 125# 13-0053 1111

NS Latch 20-0045 2222

Drain Valve Assembly (MB) 70-2562 1111

Drain Valve Assembly (MW) 70-2564 1111

NS Drain Valve Gaskets 06-0084 1111

43 External Pilot Train Assembly

NS Ball Valve 11-0395 1111

Tridicator 30 - 60 psi 13-0308 1111

Tridicator 75 - 160 psi 13-0305 1111

45 LWCO #550LSV 14-0256 1111

46 Heat Exchanger Assembly (Copper)

Cast Iron 70-3585.1 1

Heat Exchanger Assembly (Copper)

Bronze 70-3577.1 1

Heat Exchanger Assembly (Cupronickel)

Cast Iron 70-3589.1 1

Heat Exchanger Assembly (Cupronickel)

Bronze 70-3581.1 1

47 Header Gasket 06-0062 2222

70-3566 1

70-3567 1

70-3568 1

70-3569 1

70-3572 1

70-3573 1

70-3574 1

70-3575 1

70-3655 1 1 1

70-3584.1 1

70-3586.1 1

70-3587.1 1

70-3576.1 1

70-3578.1 1

70-3579.1 1

70-3588.1 1

70-3590.1 1

70-3591.1 1

70-3580.1 1

70-3582.1 1

70-3583.1 1

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Model Size with item Quantities Below

Ref # Name of Part Part # 2500 3000 3500 4000

48 Frequency Drive 15-0230 1111

49 Flame Safeguard, RM7895C 16-0024R 1111

50 Spark Ignitor 16-0008 1111

51 Air Pressure Switch 11-0419 1111

52 Fan Prove Switch

NS Mounting Bracket 03-3752 1111

53 Transformer, 50 VA 15-0007 1111

NS High Limit, Jumo, (MB) 14-0013 1111

NS High Limit, Jumo, (MW) 14-0014 1111

NS High Limit, Jumo, (MB) Auto Reset 14-0114 N/A 1 1 1

NS High Limit, Jumo, (MW) Auto Reset 14-0115 N/A 1 1 1

NS Thermometer Well, 3/8 x 2 13-0102 1 2 2 2

NS High Limit Well, 3/8 x 3 13-0104 1 2 2 2

NS Alarm Button 48-0003 1111

NS Alarm/Toggle Bracket 03-3754 1111

NS Terminal Block 6P 48-0157 1111

NS Terminal Block 18P 48-0159 1111

NS Relay, 2P, 24V (optional) 15-0121 1111

NS Relay, 2P, 120V (optional) 15-0127 1111

54 Main Board 16-0038 1111

NS Display Board 40-0088 1111

NS Ignition Cable 44-0063 1111

NS Ribbon Cable 40-0115 1111

NS Power Switch 48-0013 1111

NS Toggle Switch 48-0014 1111

NS 10K Temperature Sensor 14-0325 3333

55 Service Valve Assembly 70-3669 1111

NS Purge Timer, ST7800 16-0007 1111

NS Keyboard Display Module, S7800A 16-0010 1111

NS Ferrite Clamp 16-0032 1111

58 Pilot/Flame Rod Kit 70-3615 1111

58a Electrode 16-0335 2222

58b O'ring 06-0008 1111

58c View Port Assembly 70-2205 1111

58d Mini Peeper, C7027A 16-0009 1111

58e Pilot Block 01-0205 1111

NS UV Ampli er, R7849B 16-0037 1111

NS Base, Q7800A 16-0003 1111

11-0420 1111

11-0419 1111

inned copper tube gas boilers & water heaters – Boiler Manua

REPAIR PARTS CONTINUED

Model Size with item Quantities Below

Ref # Name of Part Part # 2500 3000 3500 4000

59 Control Box Panel 70-3609 1111

60 Collar Fan Transition 01-0201S 1111

60a Gasket 06-0004 1111

60b Fan Hold Down Plate 04-0596 1111

62 Mini Fan 12-0021 1111

63 Air Funnel 04-1016 1111

Solenoid Valve w/Regulator, NG 11-0372 1111

Solenoid Valve w/Regulator, LP 11-0374 1111

65 Air Shut O Valve 11-0376 1111

Pilot Ori ce, .052 NG 10-0140 1111

Pilot Ori ce, .040 LP 10-0139 1111

67 Pilot Tube 62-0102 2222

69 Gas Train Stand 70-3651 1111

70 Power Relay 15-0118 1111

71 Pump Contactor 3PH 15-0211 1111

Relay Overload (5.5 - 8 Amp) 15-0214 1111

Relay Overload (9 - 13 Amp) 15-0215 1111

Relay Overload (2.5 - 4 Amp) 15-0216 1111

Relay Overload (4 - 6 Amp) 15-0217 1111

Relay Overload (12 - 18 Amp) 15-0219 1111

Fuse, 2HP, 230V (pump) 48-0626 3333

Fuse, 3HP, 230V (pump) 48-0627 3333

Fuse, 2HP, 460V (pump) 48-0624 3333

Fuse, 3HP, 460V (pump) 48-0625 3333

Fuse, 5HP, 460V (pump) 48-0631 3333

74 Fuse, 25Amp, 600V ( VFD) 48-0622 2222

75 Terminal Strip 6P 48-0162 1111

76 Power Service Box 48-0441 1111

77 Fuse Block 2P 48-0641 1111

78 Fuse Block 3P 48-0642 1111

79 Keypad Overlay 82-0189 1111

NS Rating Plate 82-0054 1111

NS Futera III Overlay 82-0192 1111

NS Paint 66-0013 1111

NS Silicone 66-0151 1111

Vent Termination Hood 8" 09-0113 1 1

Vent Termination Hood 10" 09-0115 1 1

Air Intake Hood 8" 09-0103 1 1

Air Intake Hood 10" 09-0104 1 1

inned copper tube gas boilers & water heaters – Boiler Manua

START-UP REPORT

DATE: JOB NAME:

TECHNICIAN: LOCATION:

COMPANY: MODEL:

PHONE NUMBER: SERIAL #:

PRESTARTUP CHECK LIST

❑ NO VISIBLE DAMAGE TO UNIT ❑ INLET AIR FILTER INSTALLED AND CLEAN

❑ PIPING PROPERLY CONNECTED ❑ PROPER SERVICE CLEARANCES PROVIDED

❑ BOILER CIRCULATOR WIRED ❑ PUMP RUNNING, HEAT EXCHANGER FULL

❑ VENT/STACK CONNECTED ❑ GAS LINES PURGED, NO LEAKS, NO MISSING TEST

PLUGS

BOILER STARTUP SEQUENCE

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 manifold in the bottom of the electrical panel.

1. Disable any external call for heat and toggle the remote/local switch to REMOTE.

2. Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition.

3. Set pressure to 3–3.5" w.c. ( ame signal should read 5.0 VDC).

4. Release boiler to main  ame trial for ignition.

5. Check for stable  ame.

6. Record combustion and pressure signal (Ps) at minimum  ring rate. (Reference XLF Boiler IOM.)

7. Jumper the AA terminals to force 100% input.

8. Record combustion and pressure signal (Ps). (Reference XLF Boiler IOM.)

9. Remove the AA jumper to place the boiler at minimum rate.

10. Record combustion and pressure signal (Ps). (Reference XLF Boiler IOM.)

11. Check all combustion results using a calibrated  ue gas analyzer.

12. Release the LOW FIRE switch to place boiler in standby.

In addition to completing the Futera XLF start-up report, complete the control set-up information in the rear of the

FuteraXLF Control Installation and operation manual.

inned copper tube gas boilers & water heaters – Boiler Manua

COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE

GAS PRESSURE AT ELBOW TEST PORT INCHES W.C. INCHES W.C.

CO (PPM) PPM PPM

NET STACK TEMPERATURE

PRESSURE SIGNAL (Ps) INCHES W.C. INCHES W.C.

SAFETY TEST CHECKLIST

❑ FLOW SWITCHES ❑ AIR SWITCH ❑ FLAME SAFEGUARD

❑ LOW WATER CUT-OFF ❑ HIGH LIMITS

Verif y that the piping and controls ensure the boiler return water temperature does NOT drop below 140 oF, 60 oC. 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.

COMMISSIONING THE BOILER/WATER HEATER

❑ UNIT CYCLED MINIMUM OF 15 TIMES

❑ CUSTOMER INSTRUCTED

❑ ALL COVERS REPLACED

❑ CUSTOMER GIVEN MANUAL

❑ TARGET TEMPERATURE SET PER CUSTOMER

THE DELTAT BETWEEN THE HEATER IN-

LET AND OUTLET IS CRITICAL TO PROPER FLOW. BEFORE YOU LEAVE THE JOBSITE, YOU MUST RECORD THE DELTA T.

THIS READING SHOULD NOT EXCEED

F, 19.4oC, NOR BE LOWER THAN 20oF,

11.1

COMMISSIONED BY: ______________________________________ (

SIGNATURE)

DELTA T =

DATE: ____________________________

ADDITIONAL NOTES AND COMMENTS

NOTICE!

inned copper tube gas boilers & water heaters – Boiler Manua

Commonwealth of Massachusetts

Installation Requirements

MACODE-3

In the Commonwealth of Massachuse s, the installation

must be performed by a licensed plumber or gas   er.

1. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above  nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satis ed:

d. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas  er 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 gas fitter 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 ba ery back-up may be installed on the next adjacent  oor level.

ii. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a ba ery operated carbon monoxide detector with an alarm shall be installed.

e. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon monoxide detector as required in accordance w ith the above provisions shall comply with NFPA 720 and be ANSI/ UL 2034 listed and IAS certi ed.

f. SIGNAGE. A metal or plastic identi cation 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.  e 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.  e 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.  e 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 satis ed by the manufacturer:

i.  e referenced “special venting system” instructions shall

be included with the appliance or equipment installation instructions; and

ii.  e “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!

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.

The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in material or workmanship for  ve (5) years from the date of installation. Additional twenty one (21) year thermal warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.

 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 i s 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.

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

www.rbiwaterheaters.com

RBI FUTERA XLF Installation and Operation Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual