RBI FUTERA XLF Installation and Operation Instruction

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.

inned copper tube gas boilers & water heaters – Boiler Manua

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!

inned copper tube gas boilers & water heaters – Boiler Manua

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.

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RBI FUTERA XLF Installation and Operation Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual