Page 1
82-0317
Finned copper tube
Gas boilers (MB) &
Water heaters (MW)
Models 3000 & 4000 only
Boiler manual
Installation and operation
instructions
Also read and follow:
XLF HeatNet Control manual
is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with a 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.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service technician,
and to follow all guidelines in the User’s Information Manual.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 2
Finned copper tube gas boilers & water heaters – Boiler manual
RBI Futera XLF-Series boilers — Overview
XLF PRIMARY
COMPONENTS
Electrical enclosure (rear)1.
Blower and motor2.
Air inlet connection3.
Flue outlet connection4.
Gas entrance5.
Boiler water return6.
Boiler water supply7.
Gas valve8.
Power entrance box9.
DP switch — blocked air 10.
inlet
DP switch — blocked flue11.
DP switch — blower prov-12.
ing
DP switch — pilot air prov-13.
ing
Ignitor14.
Pilot gas valve and pilot gas 15.
pressure regulator
Flow switch16.
Low water cutoff17.
Pressure/temperature 18.
gauge
Relief valve19.
High gas pressure switch20.
Low gas pressure switch21.
19
10
11
12
18
16
7
1
13
14
15
2
3
17
6
XLF
Rear view
Air chamber cover removed
20
See the Futura XLF Control manual
for electrical component locations.
2
8
9
21
5
4
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 3
Finned copper tube gas boilers & water heaters – Boiler manual
BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 3
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 4
BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 4
COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . 4
BEFORE YOU START
is manual covers the application, installation, operation and maintenance of a Futera XLF Series nned copper heating boiler/water
heater.
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
To obtain the safe, dependable, ecient operation and long life for
which this heating boiler/water heater was designed, these instructions must be read, understood and followed.
e Futera XLF Series nned copper heating boiler/water heaters
have been design certied by CSA for use with natural and propane
gas under the latest revision of ANSI Z21.10.3/CSA 4.3, Gas Water Heaters, ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam
and Hot Water Boilers 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
Westeld, 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.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
3
Page 4
Finned copper tube gas boilers & water heaters – Boiler manual
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
This boiler/water heater is suitable for indoor and out-1.
door installations. Locate the boiler/water heater in an area
that provides good ac cess to t he uni t. Ser vi cing may
require the removal of jacket panels. Allow the minimum clear-
ances between adjacent construction and the boiler/water heater
as listed in Table 1.
Ser vice clearances are not mandator y, but are
recommended to ensure ease of service should it be
required.
Required clearancesTable 1
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
An optimum site will be level, central to the piping system, close 2.
to a chimney or outside wall and have adequate fresh air for
combustion. Ensure that the boiler/water heater is level from
front to back and from side to side. Use metal shims to level the
boiler/water heater. Electrical and electronic components must
also be protected from exposure to water during operation and
maintenance. DO NOT install this boiler/water heater in a lo-
cation that would subject any of the gas ignition components to
direct contact with water or excessive moisture during operation
or servicing.
Ensure that the oor is structurally sound and will support the 3.
weight of the boiler/water heater.
e Futera XLF may be installed directly on combustible
ooring, but never on carpeting.
Locate the boiler/water heater in an area that will prevent water 4.
damage to adjacent construction should a leak occur or during
routine maintenance. If such a location doesn’t exist, a suit-
able drain pan that’s adequately drained must be installed under
the unit.
Service
clearances
DO NOT place this boiler/water heater in a location that 5.
would restrict the introduction of combustion air into the unit
or subject it to a negative pressure, see “GENEL VENTING
GUIDELINES”.
NE VER place this b oile r/w ater heate r in a locatio n 6.
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!
If t he boiler /wa ter h eater is o perate d w hile
the building is under construction it MUST be
protected from wood, concrete, sheet rock and other
types of dust. Failure to properly protect the unit from
construction dust will damage the unit voiding the
warranty!
Buildings will require the installation of a fresh air duct or
other means of providing make-up air if the intake air option
isn’t used. Any building utilizing other gas burning appliances, a replace, wood stove or any type of exhaust fan must be checked for
adequate combustion air when all of these devices are in operation
at one time.
Sizing of an outside air duct must be done to meet the requirements
of all such devices.
4
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 5
Finned copper tube gas boilers & water heaters – Boiler manual
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!
All air from inside the building
If the Futera XLF is to be located in a conned space, the minimum
clearances listed in Table 1, page 4 must be maintained between it
and any combustible construction. W hen installed in a conned
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 sucient volume to meet the criteria for
an unconned 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 in
2
/1000 Btu/hr,
2200 mm2/kW based on the total input rating of ALL gas utilization
equipment in the conned area. Each opening must be no less than
100 in2, 64,516 mm2 in size. 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 boom opening must be within 12 inches,
305 mm of, but not less than 3 inches, 76 mm from, the boom of
the enclosure.
All air from outside the building
When installed in a conned 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 boom opening must be within 12 inches,
305 mm of, but not less than 3 inches, 76 mm from, the boom 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 mm2/kW of the total input rating of all of the equipment in
the enclosure.
When ducts are used, they must have the same cross-sectional area
as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure, consideration must be given to the
blockage eects of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 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 sup-
ply 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
2
/4000 Btu/hr, 550 mm2/kW of the total
2
/2000 Btu/hr,
2
per 7,000 Btuh (310 mm2 per kW) up to
and including 1 million Btuh, plus 1 in2 per 14,000 Btuh (155 mm2
per kW) in excess of 1 million Btuh.
Make-up Air Louver SizingTable 2
Input
MBH
3000 750 4838 1000 6452 3000 19354
4000 1000 6452 1334 8592 4000 25808
Wire screen
¼ inch (6.4 mm)
2
in
Required cross-sectional area
Metal louvers
75% free area
cm
2
2
in
cm
2
Wooden louvers
25% free area
2
in
cm
2
Intake air option — General guidelines
is conguration provides combustion air directly to the boiler/
water heater’s air intake adapter using a dedicated pipe when using
the direct vent option. Combustion air can be drawn in horizontally
through the same outside wall which terminates the exhaust gases
or vertically through the roof, see 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!
Intake air pipe sizingTable 3
Input
MBH
3000 10 254 8 203
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 CP VC is use d, 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
inltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake air option – Vertical guidelines
e maximum equivalent length for the vertical intake air pipe is
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.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
5
Page 6
Finned copper tube gas boilers & water heaters – Boiler manual
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 certied 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 fired 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
EXISTING COMMON VENT SYSTEMS
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.
Place in operation the appliance being inspected. Follow the 4.
lighting instructions. Adjust thermostat so appliance will operate continuously.
Test for spillage at the dra hood relief opening aer 5 minutes 5.
of main burner operation. Use the ame of a match or candle, or
smoke from a cigaree, cigar or pipe.
After it has been determined that each appliance remaining 6.
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.
Any improper operation of the common venting system should 7.
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
e ue 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.
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.
Seal any unused openings in the common venting system. 1.
Visually inspect the venting system for proper size and horizontal 2.
pitch and determine there is no blockage or restriction, leakage,
corrosion and other deciencies which could cause an unsafe
condition.
Insofar as is practical, close all building doors and win-3.
dows and all doors between the space in which the ap-
plianc es remaining co nnected to th e common venting
6
The Futera XLF may be vented the following ways:
OPTION 1 — Direct Vent, Positive Pressure 1.
Category IV (individual venting only) (page 7)
Combustion air is piped from the outdoors to the blower inlet.
Vent system is certied to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Maxi-
mum equivalent length of vent and air piping must not exceed
100 feet each.
OPTION 2 — Vertical Vent, Positive Pressure 2.
Category IV (individual venting only) (page 10)
Combustion air is obtained from the space in which the unit is
installed. Vent system is certied to UL 1738 for installations in
the United States, ULC S636 for installations in Canada. Maxi-
mum equivalent length of vent piping must not exceed 100 feet.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 7
Finned copper tube gas boilers & water heaters – Boiler manual
OPTION 3 — Side Wall Vent, Positive Pressure 3.
Category IV (individual venting only) (page 11)
Combustion air is obtained from the space in which the unit is
installed. Vent system is certied 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.
OPTION 4 — Vertical Vent, Negative Pressure 4.
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.
Category IV venting — vent pipe size Table 4
(Vent options 1, 2 or 3)
Input
MBH
3000 8 203
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
o
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 , 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 boom of the vent terminal(s) shall be located at least 5 , 1.5 m
above the air intake terminal(s) unless there is a minimum 5 , 1.5 m
horizontal separation between them.
Avoid terminal locations likely to be aected by winds, snowdris,
people and pets. Protect building materials and vegetation from degradation caused by the ue gases.
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 drawin g combusti on air from the o utdoor s. The Intake Ai r
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 materia ls us ed in horizontal vent sy stems m ust
be certied to UL 1738 for installations in the United States, ULC
S636 for installations in Canada. e certied vent terminal from
RBI must also be used.
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 400o F, 204oC. Structural penetrations must be made using approved re-stops. For best results, horizontal vent systems should be
as short and straight as possible.
o
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 51/2 , 1.7 m above the roof
surface and maximum snow line that it passes through, 4 , 1.2 m
above the intake air terminal, see Figure 3.
In addition the vent system must conform to the dimensions shown
in Figure 3, page 9. e penetration point in the roof must be properly
ashed and sealed.
e vent system must be gas tight. All seams and joints in metal pipes
must be joined and sealed in accordance with the vent system manufacturer’s instructions.
Combination direct vent systems
Figure 4 (vent/air pipe equivalent lengths up to100 feet maximum)
The boiler/water heater can be vented vertically with the in-
take air piped horizontally through an outside wall. Follow
the instruc tions in the Intake Ai r Opti on Hor izontal
Guidelines on page 6. Also follow the general instructions
in the “Combustion Air & Ventilation” and “General Venting Guidelines” sections.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
7
Page 8
Finned copper tube gas boilers & water heaters – Boiler manual
VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for a single direct vent system Figure 1
Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters.
When ru nnin g horiz ont al combustio n
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.
VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for multiple direct vent systems Figure 2
Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters.
8
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 9
Finned copper tube gas boilers & water heaters – Boiler manual
VENT OPTION 1: DIRECT VENT — Vertical air intake and venting for direct vent system Figure 4
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.
VENT OPTION 1: DIRECT VENT — Combination direct vent system Figure 3
Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
9
Page 10
Finned copper tube gas boilers & water heaters – Boiler manual
OPTION 2: VERTICAL VENTING
POSITIVE PRESSURE, CATEGORY IV
FIGURE 5 OR FIGURE 6
VENT PIPE EQUIVALENT LENGTH UP TO100 FEET MAXIMUM
Masonry chimneys, when used, must be lined with a
metal liner certied for Category IV venting.
A thorough inspectio n o f t he maso nry chimn ey must be
performed to ensure that the chimney is clean, properly construct-
VENT OPTION 2: VERTICAL CHIMNEY VENTING Figure 5
Vertical venting — with a metal chimney system
See Figure 4, page 7 for minimum pipe diameters.
ed, lined and sized. Exterior masonry chimneys should not be used
unless properly lined to prevent condensation and dra problems.
Table 5 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
re 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.
10
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 11
Finned copper tube gas boilers & water heaters – Boiler manual
OPTION 3: SIDE WALL VENTING
POSITIVE PRESSURE CATEGORY IV
FIGURE 7
VENT/AIR PIPE EQUIVALENT LENGTHS UP TO100 FEET MAXIMUM
In this configuration the boiler/water heater blower is used
to push the flue products horizontally to the outdoors, see
Fig ure 7. The air for combusti on is taken from the space
in which the unit is installed. e applicable instructions under the
VENT OPTION 3: SIDE WALL VENT — Side wall venting Figure 7
Vent pipe and air pipe equivalent lengths must not exceed 100 feet each.
“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.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
11
Page 12
Finned copper tube gas boilers & water heaters – Boiler manual
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.
CATEGORY II CHIMNEY
INSPECTION & SIZING
Masonry chimneys, when used, must be lined with a
metal liner certied for Category IV venting.
A thorough inspectio n o f t he maso nry chimn ey 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.
Riser diameters to common vent for Category II ventingTable 5
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.
Input — MBH in mm
3000 12 305
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 breech-
ing at a minimum rate of ¼ in per , 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
re causing extensive property damage, severe personal
injury or death!
12
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 13
Finned copper tube gas boilers & water heaters – Boiler manual
OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations Figure 8
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-3000 (4) boilers maximum.
XLF-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.
A barometric damper must be installed on the riser of each boiler, 1.
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 ap-
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
plicable codes, install a thermal spill switch on each barometric
damper.
Install a thermal spill switch on each barometric damper (when 2.
required by applicable codes).
Connect each boiler riser to the common vent with a y connec-3.
tion only.
Install an approved vent cap at the vent termination.4.
DIMENSIONS: 5.
B breeching length
C chimney height
D breeching diameter
F riser diameter (no smaller than the dimension given in
Table 5, page 12)
Size the chimney and breeching per local codes and vent pipe 6.
manufacturer's recommendations, using generally accepted
engineering practices.
13
Page 14
Finned copper tube gas boilers & water heaters – Boiler manual
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 piing and erosion of the internal surface
of the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result of high
water ow rates. See Table 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.
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!
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
Freeze protection
Installations in areas where the danger of freezing exists are not recommended unless proper freeze protection is provided. e following precautions MUST be observed:
A continuous flow of water through the unit MUST be 1.
maintained! The pump responsible for flow through the
boiler/water heater must run continuously!
An et hylene glycol /w ate r mix ture s uitable f or the 2.
minimum temperature that the unit w ill be exposed to
must be used . The pump must be capable of producing
a mi nimum of 15% mo re flow an d ove rcoming 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.
If the unit must be shut off for any reason the electric, 3.
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!
Relief valve
Pipe the discharge of the pressure relief valve as shown in Figure 9,
page 15.
General piping requirements
All heating system piping must be installed by a qualied technician
in accordance with the latest revision of the ANSI/ASME Boiler
and Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1,
Standard for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must also be followed. A minimum clearance of 1 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. The thermal expansion of the system must be con sidered w hen su pporti ng the system. A
min imum sy ste m pr essu re of 12 ps ig , 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.
Supply & Return Pipe SizingTable 6
Input
MBH
3000 4" FLANGE 4" FLANGE
4000 4" FLANGE 4" FLANGE
Supply
size
Return
size
14
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 15
Finned copper tube gas boilers & water heaters – Boiler manual
Futera XLF PipingFigure 9
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
15
Page 16
Finned copper tube gas boilers & water heaters – Boiler manual
Pump requirements
Expansion tank and air separator
This low mass boiler requires a continuous minimum water flow 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 aer the call for heat
is satised.
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 35oF, 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.
Temperature Rise Table Table 7
Model
Number
3000 261.0 15.20 16.5 44.7
4000 NA NA NA NA
Model
Number
3000 208.8 9.73 13.2 28.7
4000 278.4 * 17.30 17.6* 51.0
Model
Number
3000 174.0 6.75 11.0 19.9
4000 232.0 12.00 14.6 35.4
Model
Number
3000 149.1 2.80 9.4 14.6
4000 198.9 8.80 12.5 25.9
* This flow 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 flow rate is 315 GPM.
T = 20oF T = 11.1oC
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
o
T = 25
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
T = 30
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
T = 35
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
F T = 13.9oC
o
F T = 16.7oC
o
F T = 19.4oC
Low water cutoff
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to the wiring diagram supplied with the boiler/water heater for
proper wiring connections.
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.
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 flows
Figure 9, page 15 shows a typical primary/secondary piping system. A dedicated pump is used to maintain a constant water ow
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 not be more than 12 inches, 305
mm apart to ensure zero pressure drop in the primary system, see
Figure 9, page 15.
Low return water temperatures
To prevent the problems associated with condensation of the prod-
ucts of combustion due to low return water temperatures a primary/
secondary piping system with a bypass and bypass valve must be
installed, see Figures 10 and 11. 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 not
be more than 12 inches, 305 mm apart to ensure zero pressure drop
in the primary system, see Figures 10 and 11.
Multiple boiler systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 12, page 18.
Piping for use with cooling units
The bo iler, when used in connec tion with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be used to prevent
the chilled water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed to
refrigerated air from an air handling device, the piping system must
be equipped with ow-control valves or some other automatic means
of preventing gravity circulation of the boiler water during the cooling cycle.
16
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 17
Finned copper tube gas boilers & water heaters – Boiler manual
Typical Primary/Secondary Piping System Figure 10 (See Notes)
NOTES:
Boiler circuit piping must be sized large 1.
enough to handle maximum flow through
unit.
Boiler pump sized to boiler design flow 2.
requirements.
All boilers furnished with factory mounted 3.
outlet water temperature gauge.
Boiler pump purging required. Use termi-4.
nals supplied.
All primary/secondary piping systems re-5.
quire a remote operator.
Low Temperature Piping with Thermostatic Valve Figure 11
(See Notes and Adjustment Procedure)
These drawings show
suggested piping conguration and valving.
Check with local codes
and ordinances for specic requirements.
NOTES:
For pump selection consult factory.1.
Boiler pump sized to boiler and thermostatic 3-way valve design flow requirements.2.
Boiler circuit piping must be sized large enough to handle maximum flow through unit.3.
All boilers furnished with factory mounted outlet water temperature gauge.4.
Boiler pump purging required. Use terminals supplied.5.
Valve is pre-calibrated for 1406.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
o
F return temperature.
ADJUSTMENT PROCEDURE
(To maintain inlet temperature
above flue gas dewpoint)
T1 is the return water temperature.1.
o
Minimum temp, T1 = 140 2.
F, 60 oC.
Turn heater on and OPEN valves "A" 3.
and "B."
After steady-state operation is 4.
reached:
o
If T1 is less than 140 5.
F, 60 oC:
SLOWLY CLOSE valve "B" until T1 rises
to the desired operating temperature
(but NO LESS than the minimum,
140 oF, 60 oC).
If T1 is greater than desired operating 6.
temperature, slowly close valve "A"
until the temperature drops to the
desired operating temperature (but
NO LESS than the minimum, 140
o
F,
60 oC).
Check again after system operating 7.
temperature has stabilized. Then
make final adjustments.
17
Page 18
Finned copper tube gas boilers & water heaters – Boiler manual
Low Temperature Piping (See Notes and Adjustment Procedures)Figure 12
Adjustment Procedure
To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min = 140
1. Turn heater on and open valves A & B.
2. After steady-state operation, if T1 is less than
Temp-Min slowly close valve B until T1 climbs to
desired operating temperature above Temp-Min.
3. If T1 is greater than desired operating temperature, slowly close valve A to adjust to lower desired temperature above Temp-Min.
4. Check after system operating temperature has
stabilized. Make final adjustments.
5. Follow same adjustment procedure for sealed
combustion.
o
F, 60oC Sealed Combustion
Multiple Boiler Piping (See notes)Figure 13
These drawings show
suggested piping conguration and valving.
Check with local codes
and ordinances for specic requirements.
NOTES:
Boiler circuit piping must be large enough to handle maximum flow through unit.1.
Boiler pump sized to boiler design flow requirements.2.
All boilers furnished with factory mounted outlet water temperature gauge.3.
Boiler pump purging required. Use terminals supplied.4.
All primary/secondary piping systems require a remote operator.5.
Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units.6.
18
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 19
Finned copper tube gas boilers & water heaters – Boiler manual
DOMESTIC WATER SUPPLY PIPING
Proper controls must be used to prevent water supplied
for domestic use from exceeding 130oF, 54oC 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 with 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 excha nger may also b e 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 h eaters are designed to run sca le free. Due to
the extreme var iables of water conditions world w ide it i s
ne cessar y to c onside r pH v alues and water hardn ess 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 f low rate through the heat
exc hange r. Ther mo mete rs are in stal le d
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 ecient 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 soening 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
injur y from occurring , see the caution against
scalding.
Storage of water for domestic use above 140
60oC wil l prov ide an increased quantity of
tempered water and help prevent the growth of
water born bacteria.
o
o
F,
F,
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
19
Page 20
Finned copper tube gas boilers & water heaters – Boiler manual
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
is low-mass water heater requires a con-
tinuous mini-mum water ow for proper operation. e low water ow switch provided
for this unit will shut down the water heater
if ow falls below the required minimum
level. Table 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.
Cold Water Supply
e cold water supply must be piped to the
water heater’s outlet piping between the
water heater and the hot water storage tank.
is will prevent untempered water from en-
tering the water heater. See the Temperature
Rise Control section, page 19.
Two typical water heating systems are
shown in Figure 14, page 21 and Figure 15,
page 21.
Futera XLF Heat Exchanger SelectionTable 8
Futera XLF Pumping Performance Requirements Table 9
Water hardness
Heat exchanger type Cupro-nickel Copper Cupro-nickel
Boiler model GPM ∆P ∆T GPM ∆P ∆T GPM ∆P ∆T
MW-3000 SPECIAL
MW-4000 210 10.40 33.0 262 16.90 27.0
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 flow 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.
Soft Normal Hard
210 9.73 25.0 262 14.54 20.0
REQUIREMENTS
(Call factory
or representative)
20
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 21
Finned copper tube gas boilers & water heaters – Boiler manual
Typical Water Heating Piping (MW Models Only) (See Notes)Figure 14
Multiple Water Heating Piping (MW Models Only) Figure 15
(See Notes)
ese drawings show sug-
gested piping conguration
and valving. Check with
local codes and ordinances
for specic requirements.
NOTES:
Optional cold water make up and recirculation line location.1.
When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing com-2.
pound.
Thermal expansion tank may be required, check local codes.3.
When using optional factory mounted pump, max pipe length 30’ total, 6-904.
CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.5.
The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and 6.
Pumping Performance Table before making selection.
Common piping must be sized for maximum combined heater flow.7.
Hot water tanks should be equipped with a combination temperature & pressure relief valve.8.
MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.9.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
o
elbows, full pipe size.
21
Page 22
Finned copper tube gas boilers & water heaters – Boiler manual
GAS SUPPLY PIPING
Ch eck the bo il er/w ater h eate r rating p late
to make su re that the b oil er/ water heate r 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
prov isions 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.
Gas Supply PipingFigure 16
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 boom of the vertical section of the gas supply pipe upstream of
the gas controls.
Gas pipe capacities (natural gas)Table 10
Maximum pipe capacity in ft3/hr, based on 0.60 specific 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 flow capacities in ft3/hr. Multiply the propane
flow 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
3
to determine the propane Btu/hr capacity for a given pipe size and length.
22
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 23
Finned copper tube gas boilers & water heaters – Boiler manual
Equivalent length (feet) for typical fittingsTable 11
ELECTRICAL WIRING
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 fittings. Multiply values above by
0.75 for flanged fittings.
o
elbow Tee
90
Fitting or valve
(branch flow)
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!
Electrical power connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation!
Verify proper operation aer servicing.
Failure to comply could result in severe personal injury,
death or substantial property damage.
The electrical connections to thi s boiler/water
heater m ust be made i n ac cordance with all
appl icable loca l codes and the latest rev isi on
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 30 amp circuit breaker for the boiler/water heater and pump. See Table 12. A properly rated shut-o switch
should be located at the boiler/water heater. e boiler/water heater
must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code,
ANSI/NFPA-70.
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 puing 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.
Futera XLF Electrical RequirementsTable 12
Futera XLF
Model
3000 25 20
4000 25 20
* Use separate circuit breaker that is properly sized for pump
and pump contactor.
Required
Circuit Breaker
(amps)
Running
Amps *
Line vol tage f ield wi ring of any controls or o ther devices
must conform to the temperature limitation of ty pe T w ire
at 95oF, 35oC above room temperature. Use copper conductors
with a minimum size of #14 awg. 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.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
23
Page 24
Finned copper tube gas boilers & water heaters – Boiler manual
GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not aempt
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!
WIRING & CONTROL SETUP
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 aempting to re the boiler.
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 o ff, run the sy stem pump for at least 30
min ute s and bleed the sys tem pipi ng usin g 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 cor-
rect 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. e system pump(s) and all radiation units must be operated during this time. Ensure that the make-up
water valve is open.
Shut the boiler 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.
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 Cutoff
If the boiler is to be installed above radiation or if required
by other codes or regulations, instal l 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 seing that will
satisfy the consumer's needs.
Seing 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/wa-
ter heater. Remote capillary bulbs run to wells on the outlet side of
the supply header. e high limit can be reset by depressing the red
buon.
o
e water heater high limit should be set to a minimum of 20
higher than the operating control. Refer to the HOT WATER SUPPLY section for the proper supply water temperature.
Flow Switch
F, 11oC
Open the make-up water valve and adjust the system pressure if necessary. e system should be checked and bled aer three days of
operation.
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!
24
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 25
Finned copper tube gas boilers & water heaters – Boiler manual
HeatNet Control PanelFigure 17
SEQUENCE OF OPERATION
NO DEMAND
Standby
e boiler is idle with no interlocks in the fault condition.1.
DEMAND
Pre-Purge
e blower operates at purge RPM. e water ow interlock must 1.
‘make’ within 15 seconds aer the demand signal is initiated.
e Honeywell 7800 starts a 10 second purge delay once the air 2.
prove switch contacts close.
Pilot Run - %Input
e blower operates at minimum ignition seing. See the calibra-1.
tion section in the “HeatNet Control-IOM” to enter the calibration menus.
e ignition transformer is energized. e pilot solenoid valve 2.
opens for the 10 second pilot ignition trial.
Main Run %Input
e main gas valve opens.1.
e ignition transformer is de-energized.2.
e pilot solenoid valve closes.3.
Th e b low er stay s at t he mini mum in put se tti ng fo r 4.
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
e main gas valve closes.1.
e blower operates at purge RPM for 10 seconds.2.
e boiler is idle with no interlocks in the fault condition.3.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
25
Page 26
Finned copper tube gas boilers & water heaters – Boiler manual
e 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
If, at any time, the boiler will not operate properly, follow the in-1.
structions "TO TURN OFF GAS TO APPLIANCE," page 28,
and call your service technician or gas supplier.
Turn o all electrical power to the boiler.2.
Close main gas shut-off valve (field supplied), Figure 16, 3.
page 22.
Purge the gas piping up to the boiler's manual gas valve (located 4.
ahead of the main gas valve). When the bleeding is complete,
check all gas joints up to the gas valve for leaks.
Wait ve (5) minutes to clear out any gas.5.
Make sure all limits, pressures switches and safety device contacts 6.
are closed.
Open the main gas shut-o valve.7.
Disable any external call for heat, such as from a building manage-8.
ment system or remote operating controller.
Toggle the remote/local switch (in control cabinet see Fig-9.
ure 18) to
Turn on electrical power to the boiler.10.
Turn the power switch on the front of the boiler control cabinet 11.
to
e HeatNet display will light up when the power is on. If all in-12.
terlocks are properly closed, the display will say
refer to the XLF HeatNet Control IOM for troubleshooting.
Slide the HeatNet control's low re switch (on HeatNet control 13.
board) to the
e boiler will begin the start-up sequence.14.
Allow the boiler to pre-purge and enter the pilot ignition cycle.15.
If pilot lights (indicated by a good ame signal 5.0 V DC) proceed 16.
to step 18. (See Honeywell R7800 literature for use of a meter to
check ame signal if keypad readout is not available.)
If pilot is unstable (indicated by a low or erratic ame signal caus-17.
ing 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.
Pilot pressure adjustment:18.
REMOTE.
ON.
STANDBY. If not,
LOW FIRE position.
DISABLE,
Switch the Honeywell control to a.
TEST position within the
rst 10 seconds of the pilot ignition sequence.
Connect one side of a manometer or pressure gauge to the b.
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).
Manometer connections to the test manifold (in Figure 18
control cabinet)
Measure pilot gas pressure by pressing and holding the ser-c.
vice valve marked PILOT GAS.
Set pilot gas pressure to 3.0 inches w.c. (± 0.5 inch) by adjust-d.
ing the pilot gas pressure regulator, inside the air box. Access
from the boiler top cover. See Figure 19.
Access to air trim adjustment and pilot regulatorFigure 19
Check pilot air pressure using service valve marked e. PILOT
.
AIR
Pilot air pressure should be 0.60 inches w.c. (± 0.10 inches). f.
Combustion readings must be in the range specied
in the following instructions. Adjust the boiler as
necessary to ensure proper combustion.
26
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 27
Finned copper tube gas boilers & water heaters – Boiler manual
Verify low fire operation
Connect a manometer or Magnehelic gauge with the pressure 1.
side to the manifold pressure port and the other to the manifold
reference port. See Figure 18, page 26 for locations.
Set Honeywell R7800 control to RUN position. e boiler will 2.
operate at low re because the low re switch is in the low re
position.
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.
Measure the ue gas CO3.
low re CO2 to 8.0% – 8.5% by adjustment on the Dungs valve
with the boiler running at low re. Set
2
using a 3mm Allen wrench.
Turn the wrench in small increments (10 degrees at a time).a.
Allow time aer each adjustment for the boiler to reach steady b.
state.
Aer seing the CO4.
Press the a.
Ps (signal) buon and read the pressure. e pres-
, measure the pressure signal, Ps.
2
sure at low re should be as shown in Figure 13.
If the pressure is outside this range, follow instructions in the b.
XLF Control IOM to calibrate the ring rate. Increase rate
if the pressure signal is low, or decrease rate if the signal is
high.
Return to step 1 to adjust low re COc.
re ring rate.
aer changing low
2
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.
Pressure signal (Ps) Table 13
Firing
rate
%
100% 3000 -5.5 4000 -8.7
50% 1500 -1.4 2000 -2.1
33% 990 -0.6 1320 -0.9
25% 750 -0.35 1000 -0.6
20% 600 -0.25 800 -0.4
To determine signal in mm w.c., multiply signal in inches by 25.4.
XLF-3000 XLF-4000
Input
MBH
Signal
Inches w.c.
Input
MBH
Signal
Inches w.c.
To ensure proper boiler operation, boilers that use
room air must not be red at less than 33 % input.
Observe the burner ame aer seing low re. Make sure the 5.
ame is stable, but not too tight on the burner (causing infrared
operation).
Verify high fire operation
Jumper the AA terminals on the HeatNet board and allow the 1.
boiler to rise to maximum (100%) input.
Allow the boiler to reach steady state combustion at high re.2.
Verify high re blower speed as follows:3.
With the manometer (or gauge) connected to the test mani-a.
fold, press the
Ps (signal) buon and read the pressure.
e pressure at low re should be as shown in b. Figure 13.
If the pressure is NOT correct, follow step 4. c.
If the high re signal pressure is not correct:4.
Remove the jumper on A-A . e boiler will return to low a.
re.
Follow the instructions in the XLF Control IOM to calibrate b.
the high re ring rate. (Slide the HeatNet control calibrate
switch to
CAL. Follow the Control IOM procedure to navi-
gate to the HeatNet control calibration screen.)
e maximum ring rate value in the HeatNet control
is factory set at 90%. At this seing , at sea level, and
with typical vent length, the boiler will be at rate.
DO NOT increase the HeatNet control's maximum
rate seing above 90% unless needed for high altitude
installations.
If c.
Ps is too high, reduce the HeatNet control's maximum
ring rate seing 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.
If d.
Ps is too low, increase the ring rate seing by 2%. en
slide the calibration switch to
NORMAL and exit the Heat-
Net 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.
Check the pressure signal again. If the signal is now correct, e.
reconnect the jumper on AA and proceed to step 5.
If the pressure signal is still not correct, verify that the air trim f.
adjustment (see Figure 19, page 26) is in the half-open (factory seing) position. If it is at factory seing, you will need
to contact technical support at the factory to troubleshoot
the pressure signal issue.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
27
Page 28
Finned copper tube gas boilers & water heaters – Boiler manual
If the pressure signal is correct, measure the flue gas CO5.
should be between 9% and 9.5%.
2
. It
CHECKING & ADJUSTMENTS
If COa.
is correct, proceed to step 6.
2
If COb.
is not within this range, adjust the air trim adjust-
2
ment slightly (see Figure 19, page 26) on top of mixing box
to achieve a CO2 of 9% - 9.5%.
If adjusting the air trim adjustment does not correct the prob-c.
lem, contact technical support at the factory to troubleshoot
the problem.
If CO6.
and pressure signal are correct, allow the boiler to reach
2
steady state and verify supply gas pressure and check input rates
as explained in the Gas Supply Piping section.
Remove jumper on AA and allow boiler to sele into minimum 7.
input. Observe the combustion readings to ensure the boiler is
operating correctly.
When nished, disable the low re hold switch and replace test 8.
ports to normal state. Remove the manometer connections and
close the control panel door.
e Futera XLF boiler allows for many modes of operation and 9.
control methods. Reference the XLF HeatNet Control IOM.
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.
Spark GapFigure 20
TO TURN OFF GAS TO APPLIANCE
Set the operating control to its lowest seing.1.
Turn off al l electric pow er to the b oil er if ser vice is 2.
to be performed.
Close the manual main and pilot gas shut-o valves.3.
28
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 29
Finned copper tube gas boilers & water heaters – Boiler manual
Pilot adjustment
The pilot pressure has been factory set at 3 inches w.c., and 1.
shouldn't need adjustment.
To check the pilot pressure close the manual main shut-o a.
valve 2 and the pilot gas shut-o valve, Figure 16, page 22.
Remove the 1/8-inch pipe plug from the pilot gas pressure b.
regulator cap and connect a manometer having a minimum
range of 6 inches, 152 mm w.c. to it.
Open the pilot gas shut-o valve.c.
With the boiler powered, generate a call for heat.d.
When the prepurge is complete the ignition/pilot trial will e.
begin.
Put the Honeywell RM7800 test switch in the test position. f.
e control will hold in the ignition/pilot sequence, allowing
you to check the pressure.
To adjust the pilot the following steps must be taken:2.
Remove the pilot gas pressure regulator cap.a.
If the gas pressure is above the limit above, 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 specic
job site requirements.”
Input rate — Natural gas
Gas appliances are rated based on sea level operation w ith
no adjustment required at elevations up to 2000 f t, 610 m.
At elevation s above 2000 ft , 6 10 m inp ut ratings shou ld
be reduced by 4% for each 1000 , 305 m.
Turn the pressure regulator adjustment screw clock-wise to b.
increase the pressure and counterclockwise to decrease it.
Replace the pressure regulator adjustment screw cap.c.
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
Inches
water column
Minimum (in W.C.) 3.5 88.9
Maximum (in W.C.) 14 356
Measure pressure when the boiler is firing at full rate. Low 1.
gas pressure could indicate undersized gas line or insucient
gas supply.
Static and operating gas pressure required at the gas valve inlet is 2.
listed in the Table above.
mm
water column
Check the input rate as follows:
Turn o all other gas appliances that use the same gas meter as 1.
the boiler/water heater.
Call your gas su pplier and ask for t he h eating va lue 2.
of the gas.
Start the boiler/water heater and let it run for 15 minutes. 3.
Using the gas meter and a stopwatch, clock the time that it takes 4.
to burn 10
3
, 0.28 m3 of gas and divide this time by 10.
Insert the heating value and the time, in seconds, into the formula 5.
below.
Input = (heating value, Btu/hr)(3600)/(time, seconds) 6.
If the computed rate deviates by more than 5% from the rated 7.
input value of the unit, consult factory.
Never increase the input to the boiler/water heater
above that for which it is rated. Doing so can cause
premature failure of the boiler!
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
29
Page 30
Finned copper tube gas boilers & water heaters – Boiler manual
MAINTENANCE
Disconnect electrical power and close the manual gas
shut o valve before performing maintenance or severe
personal injury may result!
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 identication.
Improper burner servicing can result in premature
burner failure voiding the warranty!
Remove the front jacket panel and combustion chamber door. 3.
Inspect the inside an d outside of t he heat exchanger 4.
for signs of damage, sooting or corrosion.
The outside surfaces of the copper tubes should be free of 5.
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.
If there are no signs of damage, sooting or corrosion, reassemble 6.
the unit following the previous steps in reverse order.
A badly corro ded or dam age d h eat ex cha nge r m ust 7.
be replaced, see the Heat Exchanger Repair & Replacement section.
Pilot and burner removal
Close the manual shuto valves in the gas supply line and turn 1.
o electrical power to the boiler/water heater.
Remove the jacket top panel. 2.
Remove wires from the spark rods and remove the UV sensor 3.
from the transition piece.
Remove the pilot assembly:4.
Disconnect the compression nut at the front of the pilot a.
block.
Remove the pilot gas tubing.b.
Remove the (2) screws from the pilot block.c.
Remove the pilot assembly.d.
Disconnect the exible gas line from the manifold.5.
Disconnect the wires to the fan and remove the (2) bolts and the 6.
fan hold-down plates that secure the fan to the transition piece.
Li and remove the fan housing from the boiler/water heater, tak-7.
ing care not to damage the spark rods and or their alignment.
Remove the four nuts holding the transition piece to the heat 8.
exchanger.
Remove the transition piece, taking care not to damage the 9.
O-ring.
Remove the burner, taking care not to damage the gasket.10.
Replace all components aer servicing.11.
Heat exchanger cleaning
Close the shut o valves in the inlet and outlet piping. On heating 1.
systems close the system ll valve and relieve the system pressure
from the boiler by carefully liing the relief valve or opening the
drain valve.
Disconnect the boiler/water heater from the system piping. 2.
Remove the eight bolts on the rear pipe enclosure panel. 3.
Remove the front jacket panel and combustion chamber door. 4.
Slide the heat exchanger out of the unit. 5.
Remove the “V” bae straps and “V” baes. 6.
Thoroughly clean the heat exchanger with water from 7.
a high-pressure hose. Use a so bristle brush if necessary.
Replace the cleaned heat exchanger and other components in 8.
the reverse order of their removal.
Heat exchanger repair & replacement
A leaking or otherwise damaged tube(s) can be replaced as out-1.
lined in steps 2 through 8.
Remove the heat exchanger from the boiler/water heater as out-2.
lined in the Heat Exchanger Cleaning section.
Heat exchanger inspection
Close the manual shuto valves in the gas supply lines and turn 1.
o electrical power to the boiler/water heater.
Remove burner following the instructions in the Burner Removal 2.
section.
30
Remove the pipe plugs from the inlet/outlet and return headers 3.
opposite from the ends of the tube(s) being replaced.
Carefully cut the damaged tube(s) in half, taking care not to dam-4.
age the adjacent tubes and remove.
Install and swage/expand in place the new tube(s). 5.
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 31
Finned copper tube gas boilers & water heaters – Boiler manual
Replace the pipe plugs using a suitable thread sealant on each 6.
one.
Sagging or distorted heat exchanger tubes are an indication of low 7.
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.
Replace the heat exchanger and other components in the reverse 8.
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 “GENEL OPETION” and “CHECKING AND ADJUSTMENTS” sections of this manual for reference.
Check the operating controls for proper operation. 1.
A oat type low water cuto device must be ushed out per the 2.
manufacturers’ instructions.
e probe on a probe low water cut o must be removed, a.
cleaned and inspected at least once a year.
Ensure that the low water cutos operate properly. If not, re-b.
place them.
e ow switch contacts must be open when water ow is not 3.
present.
The re lief valve sho uld not w eep or discharg e water 4.
at normal system pressure. If it does, contact a qualied service
technician to have it inspected.
Main Burner FlameFigure 21
Manometer test port manifold
e Futera XLF includes a manometer test manifold. Connect 1.
the manometer pressure hose to the Pressure Tap port shown
in Figure 22.
Manometer connections to manifoldFigure 22
NEVER try to clean or repair the relief valve! If the valve
fails to operate properly, have it replaced!
e aquastat high limit controls the maximum water temperature 5.
in the boiler.
If the water temperature reaches the set temperature before a.
the demand for heat has been met, the aquastat high limit
should shut the boiler o.
e water temperature should never exceed the maximum b.
set point of 250
o
F, 121oC, for boilers and 210oF, 99oC for
water heaters.
e aquastat high limit cannot be repaired. If it fails to func-c.
tion properly, replace it.
Visually check the pilot and main burner ames to ensure proper 6.
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!
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
For pilot gas pressure and pilot air pressure readings, DO NOT 2.
connect the other side of the manometer. Leave the other side
open to room pressure.
For Ps (pressure signal) readings, connect the other side of the 3.
manometer to the manometer reference port as shown in Figure 22. ese pressure signals may be used for troubleshooting
when specied by factory support.
Figure 23, page 32 shows the sensor hose connections inside the 4.
Futera XLF air box.
31
Page 32
Finned copper tube gas boilers & water heaters – Boiler manual
Futera XLF pressure sensor hose routingFigure 23
32
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 33
Finned copper tube gas boilers & water heaters – Boiler manual
REPAIR PARTS
Exploded viewFigure 24
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
33
Page 34
Finned copper tube gas boilers & water heaters – Boiler manual
REPAIR PARTS CONTINUED
Figure 20 – Electrical componentsFigure 25
34
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 35
Finned copper tube gas boilers & water heaters – Boiler manual
REPAIR PARTS CONTINUED
Ref # Name of Part Part # 3000 4000
1 Top/Bottom X Profile 04-0524 3 3
2 Middle X Profile 04-0526 2 2
3 Top Y Profile 04-0530 4 4
4 Bottom Y Profile 04-0535 4
04-0537 4
5 Top/Bottom Z Profile 04-0539 4 4
6 Middle Z Profile 04-0541 2 2
7 Bottom/Front X Profile 04-0528 1 1
8 Frame Corner 20-0053 3 3
9 Frame Corner 04-0543 1 1
10 Crosses 20-0054 3 3
11 Drilled Crosses 04-0544 1 1
12 Bottom Corner 04-0542 4 4
13 Base Legs 04-0522 2 2
15 Burner 10-0297 1
10-0300 1
15a Burner O-ring 06-0006 1 1
15b Burner Gasket 06-0038 1 1
16 Gas Support Bracket 03-3768 2 2
17 High Gas Pressure Switch (Manual Reset) 11-0421 1 1
18 Gas Valve, MBC 11-0233 1
Gas Valve, MBC 11-0218 1
NS Valve Proving System, VPS504 (IRI) 11-0412 1 1
NS Flange 2" 11-0219 2 2
19 Low Gas Pressure Switch (Manual Reset) 11-0422 1 1
NS Firing Valve 3/4" 11-0461 1 1
NS Ball Valve 11-0395 1 1
20 Gas Hose 53-4001 1 1
21 Firing Valve, 2" 11-0459 1 1
22 "A" Valve, 2" 11-0454 1 1
23 Blower 12-0019 1 1
NS Pilot Flame Disc 10-0141 1 1
24 Air/Gas Mixing Box Assembly 70-3554 1 1
NS Gas Manifold 01-0203S 1 1
NS Manifold/Orifice Mounting Plate (Forward) 03-3721 1 1
NS Manifold/Orifice Mounting Plate (Rear) 03-3728 1 1
25 Mixing Box Gasket 06-0080 1 1
NS Gas Injectors 10-1002 2 2
NS Small Injector O-ring 06-0009 1 1
NS Large Injector O-ring 06-0010 1 1
26 Flow Switch 14-0203 1 1
Flow Switch (Potter) 14-0201 1 1
NS 2 1/2" Outlet Adapter 01-0031S 1 1
27 Jacket Top Panel 70-2413 1 1
28 Filter Box Assembly 70-3653 1 1
29 Rear Pipe Enclosure Assembly 70-3510 1 1
30 Lower Rear Jacket Panel 03-3787 1
03-3789 1
31 Upper Left Jacket Panel 03-3718 1 1
32 Upper Right Jacket Panel 03-2834 1 1
33 Lower Left & Right Jacket Panel 03-2839 2
03-2841 2
34 Upper Front Jacket Panel (HeatNet) 70-3617 1 1
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
35
Page 36
Finned copper tube gas boilers & water heaters – Boiler manual
REPAIR PARTS CONTINUED
Ref # Name of Part Part # 3000 4000
Handle 20-0063 1 1
35 Lower Front Jacket Panel 70-3536 1
70-3538 1
36 Combustion Chamber Top Panel 70-3561 1 1
Manning Glass Insulation (per square foot) 05-0104 9 9
37 Combustion Chamber Rear/Side Panel 70-3567 1
70-3569 1
Manning Glass Insulation (per square foot) 05-0104 16 26
38 Combustion Chamber Door Assembly 70-3573 1
70-3575 1
Manning Glass Insulation (per square foot) 05-0104 7 7
39 Pressure Relief Valve 50# 30-0379 1 1
Pressure Relief Valve 125# 30-0364 1 1
NS Latch 20-0045 1 1
41 Drain Valve Assembly (MB) 70-2562 1 1
Drain Valve Assembly (MW) 70-2564 1 1
42 Air Filter 09-0485 1
43 External Pilot Train Assembly, NG 70-3655 1 1
44 Tridicator 30 - 60 psi 13-0308 1 1
Tridicator 75 - 160 psi 13-0305 1 1
45 LWCO #550 14-0252 1 1
46 Heat Exchanger Assembly (Copper) 70-3577 1
70-3579 1
Heat Exchanger Assembly (cupronickel) 70-3581 1
70-3583 1
47 O-ring 06-0007 2 2
48 Frequency Drive 15-0230 1 1
49 Flame Safeguard, RM7897C 16-0024 1 1
50 Spark Ignitor 16-0036 1 1
51 Air Pressure Switch 11-0419 3 3
52 Fan Prove Switch 14-0066 1 1
NS Mounting Bracket 03-3752 2 2
53 Transformer, 50 VA 15-0007 1 1
NS High Limit, L4008E, (MB) 14-0112 1 1
NS High Limit, L4008E, (MW) 14-0105 1 1
NS High Limit, Emf-1, (MB) Auto Reset 14-0116 1 1
NS High Limit, Emf-1, (MW) Auto Reset 14-0118 1 1
NS Thermometer Well, 3/8 x 2 13-0102 2 2
NS High Limit Well, 3/8 x 3 13-0104 2 2
NS Alarm Button 48-0003 1 1
NS Toggle Switch 48-0014 1 1
NS Alarm/Toggle Bracket 03-2712 1 1
NS Terminal Block 6P 48-0157 1 1
NS Terminal Block 18P 48-0159 1 1
NS Relay, 2P, 24V (optional) 15-0121 1 1
NS Relay, 2P, 120V (optional) 15-0127 1 1
54 Main Board (HeatNet) 16-0038 1 1
NS Display Board (HeatNet) 40-0088 1 1
NS Ribbon Cable 30" 40-0115 1 1
NS Power Switch 48-0013 1 1
NS Toggle Switch 48-0010 1 1
NS 10K Temperature Sensor 14-0325 3 3
55 Service Valve Assembly 70-3666 1 1
36
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 37
Finned copper tube gas boilers & water heaters – Boiler manual
REPAIR PARTS CONTINUED
Ref # Name of Part Part # 3000 4000
NS Purge Timer, ST7800 16-0007 1 1
NS Keyboard Display Module, S7800A 16-0010 1 1
NS Ferrite Clamp 16-0035 1 1
58 Pilot Assembly 70-3615 1 1
58a Electrode 16-0335 1 1
58b Electrode Gasket 06-0008 1 1
58c View Port Assembly 70-2205 1 1
58d Mini Peeper, C7027A (UV scanner) 16-0009 1 1
58e Pilot block 01-0202s 1 1
NS UV Amplifier, R7849B 16-0037 1 1
NS Base, Q7800A 16-0003 1 1
NS Shielded VFD Cable 44-0059 1 1
59 Control Box Panel 70-3609 1 1
NS Harness Transformer 40-0120 1 1
NS Harness VFD 40-0124 1 1
NS Harness RM7800 40-0125 1 1
NS Harness On/Off Switch 40-0126 1 1
NS Harness Remote Local Switch 40-0127 1 1
NS Harness Alarm Switch 40-0128 1 1
60 Collar Fan Transition 01-0201s 1 1
60a Gasket 06-0004 1 1
60b Fan Hold Down Plate 04-0596 1 1
61 Pump Contactor Relay 15-0118 2 2
62 Mini Fan 12-0021 1 1
63 Air Funnel 04-1016 1 1
64 Solenoid Valve w/Regulator, NG 11-0372 1 1
65 Air Shut Off Valve 11-0376 1 1
66 Gas Orifice 10-0140 1 1
67 Pilot Tube 62-0102 2 2
69 Gas Train Stand 70-3651 1 1
70 Power Relay 15-0118 1 1
71 Pump Contactor 3PH 15-0211 1 1
72 Relay Overload 15-0218 1 1
NS Inline Fuse, 2Amp 48-0379 1 1
73 Fuse, 1.5HP, 230V (pump) 48-0629 3 3
74 Fuse, 25Amp, 600V (VFD) 48-0622 2 2
75 Terminal Strip 6P 48-0162 1 1
76 Power Service Box 48-0441 1 1
77 Fuse Block 2P 48-0641 1 1
78 Fuse Block 3P 48-0642 1 1
79 Keypad Overlay 82-0189 1 1
NS Drain Valve Gaskets 06-0084 1 1
NS Stainless Steel Wipes 66-0050 1 1
NS Rating Plate 82-0054 1 1
NS Futera III Overlay (HeatNet) 82-0200 1 1
NS Paint 66-0013 1 1
NS Silicone 66-0151 1 1
NS Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1
NS Air Intake Hood 8" 09-0103 1
Air Intake Hood 10" 09-0104 1
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
37
Page 38
Finned copper tube gas boilers & water heaters – Boiler manual
START-UP REPORT
DATE: JOB NAME:
TECHNICIAN: LOCATION:
COMPANY: MODEL:
PHONE NUMBER: SERIAL #:
PRESTARTUP 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.
Disable any external call for heat and toggle the remote/local switch to REMOTE.1.
Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition.2.
Set pressure to 3–3.5" w.c. (flame signal should read 5.0 VDC).3.
Release boiler to main flame trial for ignition.4.
Check for stable flame.5.
Record combustion and pressure signal (Ps) at minimum firing rate. (Reference XLF Boiler IOM.)6.
Jumper the AA terminals to force 100% input.7.
Record combustion and pressure signal (Ps). (Reference XLF Boiler IOM.)8.
Remove the AA jumper to place the boiler at minimum rate.9.
Record combustion and pressure signal (Ps). (Reference XLF Boiler IOM.)10.
Check all combustion results using a calibrated flue gas analyzer.11.
Release the LOW FIRE switch to place boiler in standby.12.
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.
38
38
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Page 39
Finned copper tube gas boilers & water heaters – Boiler manual
COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE
GAS PRESSURE AT ELBOW TEST PORT INCHES W.C. INCHES W.C.
CO
2
O
2
CO (PPM) PPM PPM
NET STACK TEMPERATURE
PRESSURE SIGNAL (Ps) INCHES W.C. INCHES W.C.
% %
% %
o
F
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 JOB-
SITE, YOU MUST RECORD THE DELTA T.
THIS READING SHOULD NOT EXCEED
o
F, 19.4oC, NOR BE LOWER THAN 20oF,
35
o
C.
11.1
o
F
COMMISSIONED BY: ______________________________________
(
SIGNATURE)
DATE: ____________________________
ADDITIONAL NOTES AND COMMENTS
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
39
DELTA T =
39
Page 40
Finned copper tube gas boilers & water heaters – Boiler manual
NOTICE!
Commonwealth of Massachusetts
Installation Requirements
MACODE-3
In the Commonwealth of Massachuses, the installation
must be performed by a licensed plumber or gas er.
For all side wall horizontally vented gas fueled equipment in-1.
stalled 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 satised:
INSTALLATION OF CARBON MONOXIDE DETEC-d.
TORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or
gaser shall observe that a hard wired carbon monoxide
detector with an alarm and baery back-up is installed on
the oor level where the gas equipment is to be installed. In
addition, the installing plumber or gas er shall observe that
a baery 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 qualied licensed professionals for the installation of hard wired carbon
monoxide detectors.
In the event that the side wall horizontally vented gas fu-i.
eled equipment is installed in a crawl space or an aic, the
hard wired carbon monoxide detector with alarm and
baery back-up may be installed on the next adjacent
oor level.
In the event that the requirements of this subdivision can ii.
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 baery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS. Each e.
carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/
UL 2034 listed and IAS certied.
SIGNAGE. A metal or plastic identication plate shall be f.
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”.
INSPECTION. e state or local gas inspector of the side g.
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!
Exemptions — The following equipment is exempt from 2.
248 CMR 5.08(2)(a) 1 through 4:
e equipment listed in Chapter 10 entitled “Equipment Not a.
Required To Be Vented” in the most current edition of NFPA
54 as adopted by the Board; and
Product Approved side wall horizontally vented gas fueled b.
equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for
residential purposes.
MANUFACTURER REQUIREMENTS GAS EQUIP-3.
MENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall hori-a.
zontally 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:
Detailed instructions for the installation of the venting i.
system design or the venting system components; and
A complete parts list for the venting system design or ii.
venting system.
MANUFACTURER REQUIREMENTS GAS EQUIP-4.
MENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall a.
horizontally vented gas fueled equipment does not provide
the parts for venting the ue gases, but identies “special venting systems”, the following requirements shall be satised by
the manufacturer:
e referenced “special venting system” instructions shall i.
be included with the appliance or equipment installation
instructions; and
e “special venting systems” shall be Product Approved ii.
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved 5.
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!
260 North Elm Street 7555 Tranmere Drive
Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
40
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
Loading...