RBI MW-500, MW-1250, MW-750, MW-1000, MW-200 Installation & Operation Manual

FTIII-IOM-HN-2

82-0300

FUTERA III SERIES FINNED COPPER

WITH CONTROL

GAS BOILERS (MODEL MB)

& WATER HEATERS (MODEL MW)

INSTALLATION & OPERATION MANUAL

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI, 1103 kPa WATER.

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

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

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch. Do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.

• If you cannot reach your gas supplier, call the fi re department.

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

WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!

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

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085  Mississauga, Ontario L5S 1L4 Canada
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

www.rbiwaterheaters.com

10/09

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

AVERTISSMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour
réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel,
toute blessure ou la mort

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides infl ammables à
proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le
bâtiment.

• Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du
fournisseur.

• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien
qualifi é ou par le fournisseur de gaz.

CONTENTS

Before Your Start page 2
Ratings & Capacities page 3
Boiler/Water Heater Location page 3
Combustion Air & Ventilation page 3
General Venting Guidelines page 5
Outdoor Venting page 11
Common Vent Systems page 11
General Piping Requirements page 12
Heating System Piping page 13
Domestic Water Supply Piping page 17
Gas Supply Piping page 21
Electrical Wiring page 22
General Operation page 22
Operating Instructions page 23
Sequence of Operation page 25
Checking & Adjustments page 26
HeatNet Field Wiring page 27
Control Description page 29
Diagnostics page 29
Maintenance page 32
Trouble-Shooting page 34
Repair Parts page 35
Startup Sheet page 42

BEFORE YOU START

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

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

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

4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers
and CAN1-3.1, Industrial and Commercial Gas Fired
Packaged Boilers. Each unit has been constructed and
hydrostatically tested for a maximum working pressure of
160 psi, 1103 kPa in accordance with Section IV of the
A.S.M.E. Boiler and Pressure Vessel Code.

All aspects of the boiler/water heater installation must
conform to the requirements of the authority having juris­diction, or, in the absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1/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. Which is 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: 260 North Elm
Street, Westfi eld, MA 01085 for US or 7555 Tranmere
Drive, Mississauga ONT L5S 1L4 for Canada. Always
include the model and serial numbers from the rating plate
of the boiler/water heater in question.

2

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

RATINGS & CAPACITIES

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

BOILER/WATER HEATER LOCATION

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

NOTE: Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.

Table 1
Clearance to Service
Combustibles Clearance
in mm in 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

2. An optimum site will be level, central to the piping
system, close to a chimney or outside wall and have
adequate fresh air for combustion. Ensure that the
boiler/water heater is level from front to back and from
side to side. Use metal shims to level the boiler/water
heater. Electrical and electronic components must also
be protected from exposure to water during operation
and maintenance. DO NOT install this boiler/water
heater in a location that would subject any of the gas
ignition components to direct contact with water or
excessive moisture during operation or servicing.

3. Ensure that the fl oor is structurally sound and will
support the weight of the boiler/water heater.

NOTE: The Futera III may be installed directly on
combustible fl ooring, but never on carpeting.

4. Locate the boiler/water heater in an area that will

prevent water damage to adjacent construction should
a leak occur or during routine maintenance. If such
a location doesn’t exist, a suitable drain pan that’s
adequately drained must be installed under the unit.

5. DO NOT place this boiler/water heater in a location that

would restrict the introduction of combustion air into
the unit or subject it to a negative pressure, see
“GENERAL VENTING GUIDELINES”.

6. NEVER place this boiler/water heater in a location that
would subject it to temperatures at or near freezing,
see the “FREEZE PROTECTION” section on page 12.

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

COMBUSTION AIR & VENTILATION

WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
Section 5.3, Air for Combustion & Ventilation, of the
latest revision of the National Fuel Gas Code, ANSI
Z223.1/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!

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

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

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

3

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

All Air From Inside The Building

If the Futera III is to be located in a confi ned space,
the minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confi ned space without the intake
air option, Figures 5, 6 and 7, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
suffi cient volume to meet the criteria for an unconfi ned
space. The total air requirements of all gas utilization
equipment, fireplaces, wood stoves or any type of
exhaust fan must be considered when making this
determination. Each opening must have a minimum free
area of 1 in

2

/1000 Btu/hr, 2200 mm2/kW based on the

total input rating of ALL gas utilization equipment in the
confined area. Each opening must be no less than

2

100 in

, 64,516 mm2 in size. The upper opening must

be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. The bottom
opening must be within 12 in, 305 mm of, but not less
than 3 in, 76 mm from, the bottom of the enclosure.

All Air From Outside The Building
When installed in a confi ned space without utilizing the
intake air option two permanent openings communicating
directly with, or by ducts to, the outdoors or spaces that
freely communicate with the outdoors must be present. The
upper opening must be within 12 in, 305 mm of, but not
less than 3 in, 76 mm from, the top of the enclosure. The
bottom opening must be within 12 in, 305 mm of, but not
less than 3 in, 76 mm from, the bottom 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

2

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

1 in

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

2

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

1 in

of all of the equipment in the enclosure.

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

When calculating the free area necessary to meet the
make-up air requirements of the enclosure, consideration
must be given to the blockage effects of louvers, grills and
screens. Screens must have a minimum mesh size of
1/4 in, 6.4 mm. If the free area through a louver or grill is
not known, ducts should be sized per Table 2.

Table 2 – Make-up Air Louver Sizing

Required Cross Sectional Area

Input 1/4 in 6.4 mm
(MBH) Wire Screen Metal Louvers Wooden Louvers
in

2

cm

75% Free Area 25% Free Area

2

in

2

cm

2

in

2

cm

2

500 125 806 167 1077 500 3226
750 187 1206 250 1613 750 4839
1000 250 1613 333 2148 1000 6452
1250 313 2019 416 2684 1250 8065
1500 375 2419 500 3226 1500 9677
1750 437 2819 583 3761 1750 11,290
1999 500 3226 667 4303 2000 12,900

Intake Air Option – General Guidelines
This confi guration provides combustion air directly to the
boiler/water heater’s air intake adapter using a dedicated
pipe when using the direct vent option. Combustion air can
be drawn in horizontally through the same outside wall
which terminates the exhaust gases or vertically through
the roof, see Figures 1, 2, 3 & 4.

WARNING: Common intake air systems may be
used provided the common duct is sized properly.
An intake combustion air damper should be
installed if the common vent option is used in the
intake air pipe of each heater. Improper installation
can result in excessive levels of carbon monoxide
which can cause severe personal injury or death!

Single wall galvanized smoke pipe, single wall aluminum
pipe, fl exible aluminum pipe, PVC or CPVC pipe can be
used for the intake air pipe. It must be sized per Table 3.

Table 3 - Intake Air Pipe Sizing

Model For Vertical For Horizontal
Size (Up to 60') (Up To 60')
in mm in mm
500 8 203 6 152
750 8 203 6 152
1000 8 203 6 152
1250 10 254 8 203
1500 10 254 10 254
1750 12 305 12 305
2000 12 305 12 305

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

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

Canadian installations must comply with CSA B149.1 when
air supply is provided by natural air fl ow from the outdoors
for natural draft, partial fan-assisted, fan-assisted, or
power draft-assisted burners, there shall be a permanent
air supply opening(s) having a cross-sectional area of not
less than 1 in
and including 1 million Btuh, plus 1 in

(155 mm

2

per 7,000 Btuh (310 mm2 per kW) up to

2

per kW) in excess of 1 million Btuh.

2

per 14,000 Btuh

4

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

CAUTION: A combustion air damper interlocked with
the unit should be installed in the intake air pipe when
the infi ltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!

Intake Air Option – Vertical Guidelines

The maximum equivalent length for the vertical intake
air pipe is 60 ft, 18.3 m. Each 90˚ elbow and the intake
air terminal are equal to 10 linear ft, 3.0 m of pipe, see
Table 3.

An approved, nonrestrictive intake air terminal must be
used. The intake air terminal must terminate as shown in
Figure 3. The penetration point in the roof must be properly
fl ashed and sealed.

Intake Air Option – Horizontal Guidelines

The maximum equivalent length for the horizontal intake
air pipe is 60 ft, 18.3 m. Each 90˚ elbow and the intake air
terminal are equal to 10 linear ft, 3.0 m of pipe. If horizontal
runs exceed 5 ft, 1.5 m they must be supported at 3 ft,

0.9 m intervals with overhead hangers. The certifi ed intake
air terminal from RBI must be used, see Figures 1, 2
and 4.

GENERAL VENTING GUIDELINES

WARNING: The vent installation must be in
accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54­latest 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!

VENT SYSTEM OPTIONS

The fl ue products in the vent system may be cooled below
their dew point and form condensate in the flue. The
materials used for a Category IV vent must be resistant to
any corrosive damage from fl ue gas condensate. The fl 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.

The Futera III may be vented the following ways:

1) Direct Vent, Positive Pressure, Category IV uses a

vent system certifi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada.
Combustion air is piped from the outdoors to the
blower inlet.

2) Side Wall Vent, Positive Pressure, Category IV uses

a vent system certifi ed to UL 1738 for installations
in the United States, ULC S636 for installations in
Canada. Combustion air is obtained from the space in
which the unit is installed.

Vertical/Chimney Vent, Negative Pressure , Category II

3)

uses a metal chimney system approved for Categor y II.

Vertical Vent, Positive Pressure, Category IV

4)

vent system certifi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada.
Combustion air is obtained from the outdoors or the
space in which the unit is installed.

NOTE: 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.

uses a

All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropriate
thimbles and fi re-stops must be used where required.

WARNING: Common vent systems must be
properly engineered and sized to provide a
negative draft of .03 in, 0.8 mm to .1 in, 2.5 mm W. C.
at the fl ue outlet. Common positive pressure vent
systems are not to be used. Improper installation
can result in excessive levels of carbon monoxide
which can cause severe personal injury or death!

5

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

DIRECT VENT,
POSITIVE PRESSURE, CATEGORY IV

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

Table 4 – Category IV

Model Pipe Diameter
Size (Up to 60')
in mm
500 5 127
750 5 127
1000 6 152
1250 6 152
1500 8 203
1750 10 254
2000 10 254

Horizontal Direct Vent Systems – Figures 1 & 2
The vent materials used in horizontal vent systems must
be certifi ed to UL 1738 for installations in the United States,
ULC S636 for installations in Canada. The certifi ed vent
terminal from RBI must also be used.

The maximum equivalent length for the horizontal vent pipe
is 60 ft, 18.3 m. Each 90˚ elbow and the vent terminal are
equal to 10 linear ft, 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 400°F, 204°C.
Structrual penetrations must be made using approved fi re­stops. For best results, horizontal vent systems should be
as short and straight as possible.

Horizontal vent systems shall terminate at least 4 ft,

1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft,

0.30 m above any door, window or gravity air inlet into

any building. It must not terminate less than
horizontally from, and in no case above or below, unless
a 4 ft, 1.2 m horizontal distance is maintained, from electric
meters, gas meters, regulators and relief equipment and
not less than 7 ft, 2.1 m above adjacent public walkway.
The bottom of the vent terminal(s) shall be located at
least 5 ft, 1.5 m above the air intake terminal(s) unless
there is a minimum 5 ft, 1.5 m horizontal separation
between them. Avoid terminal locations likely to be affected
by winds, snowdrifts, people and pets. Protect building
materials and vegetation from degradation caused by the
fl ue gases.

Vertical Direct Vent Systems – Figure 3

If any part of a single wall metal vent system passes
through an unheated space, it must be insulated with
insulation rated for 400˚F, 204°C. Structural penetrations
must be made using approved fi re-stops.

An approved, nonrestrictive vent terminal must be used.
The top of a vertical vent system must extend at least

1

/2 ft, 1.7 m above the roof surface and maximum snow

5

line that it passes through, 4 ft, 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. The penetration point in the roof must
be properly fl ashed and sealed.

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

4 ft, 1.2 m

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

When horizontal vent runs exceed 5 ft, 1.5 m they must be
supported at 3 ft, 0.9 m intervals with overhead hangers.
The vent system must be pitched down, toward the vent
terminal, 1/4 in/ft, 20 mm/m. If any part of a single wall metal
vent system passes through an unheated space it must be
insulated with insulation rated for 400˚F, 204°C.

Combination Direct Vent Systems – Figure 4
The boiler/water heater can be vented vertically with the
intake air piped horizontally through an outside wall. Follow
the instructions in the Intake Air Option – Horizontal
Guidelines on page 5. Also follow the general instructions
in the “COMBUSTION AIR & VENTILATION” and
“GENERAL VENTING GUIDELINES” sections.

6

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

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

1/4IN.PERFOOT

20mm/m

16FT 4.9m

1.5FT 0.5m

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

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

MBH

500 TO 1000

1001 TO 2000
2001 TO 4000

4001 & LARGER

kW
146 TO 293
293 TO 586

586 TO 1172

1172 & LARGER

FT m

5 1.5
10 3.1
15 4.6
20 6.1

5 FT 1.5 m

1.5 FT 0.5 m

1000BTU'S

2 IN. 5.0 cm

7

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

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

4 FT

1.2 m

1.5 FT

0.5 m

10 FT 3.1 m

5 1/2 FT

1.7 m

Figure 4 – Combination Direct Vent Systems

3 FT. 1 m

5 FT

1.5 m

10 FT. 3.1 m

1.5 FT. .5 m

8

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

SIDE WALL VENT,
POSITIVE PRESSURE, CATEGORY IV

In this confi guration the boiler/water heater blower is used
to push the fl ue products horizontally to the outdoors, see
Figure 5. The air for combustion is taken from the space
in which the unit is installed. The applicable instructions
under the “COMBUSTION AIR & VENTILATION” section
must be followed! The vent guidelines under the Horizontal
Direct Vent Systems section must also be followed.

VERTICAL VENT,
NEGATIVE PRESSURE, CATEGORY II

The Futera III is listed as a Category II appliance when
vented vertically into a listed metal chimney system,
Figures 6 & 7. The chimney must provide a negative
pressure not greater than 0.15 in, 3.8 mm W.C. at the
boiler/water heater flue collar with the unit running. A
barometric damper must be installed between the fl ue
collar and the vent connector when negative pressures
exceed 0.15 in, 3.8 mm W.C.

NOTE: When using a listed metal chimney system the
chimney system manufacturer’s instructions must be
followed.

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

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

Chimney Inspection & Sizing

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

Table 5 - Equivalent Breeching & Chimney Size,
Negative Pressure

Model Size Pipe Diameter
in mm
500 6 152
750 6 152
1000 7 178
1250 8 203
1500 8 203
1750 10 254
2000 10 254

Note: These sizes are based on a 20 ft, 6.1m chimney height.

Figure 5 – Side Wall Venting

1.5 FT 0.5 m

4 FT

1.2 m

3 FT

0.9 m

1/4 IN. PER F00T 20 mm/m

24"

0.6 m

9

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

VERTICAL VENT,
POSITIVE PRESSURE, CATEGORY IV

(Vent pipe equivalent length up to 60 ft, 18.3 m maximum)

WARNING: Masonry chimneys, when used, must
be lined with a metal liner certifi ed for Category
IV venting.

A through inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly
constructed lined, and sized. Exterior masonry chimneys
should not be used unless properly lined to prevent
condensation and draft problems.

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 ft,

1.5 m they must be supported at 3 ft, 0.9 m intervals with
overhead hangers. Use a single wall stainless steel vent
pipe the same diameter as the fl ue collar to connect the
boiler/water heater to a masonry chimney. When using a
listed metal chimney system use the appropriate vent
connector.

The vent connector should be sloped up toward the
chimney at a minimum rate of 1/4 in/ft, 21 mm/m. On
masonry chimneys the connector must terminate fl ush with
the inside of the chimney fl ue, Figure 7. Fasten each single
wall vent connection with at least 3 corrosion resistant
sheet metal screws.

Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials.

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

Figure 6 – Vertical Venting
with a Metal Chimney System

24"

.6 m

Figure 7 – Vertical Venting
using a Lined Masonry Chimney

10 FT. 3.1 m

24"

.6 m

10

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

A

Figure 7A – Outdoor Venting Figure 7B – Multiple Outdoor Units

2 FT

(0.62 M)

RIOM-59-REV. A

GAS TRAIN COWLING

AIR INLET
UNDER COWLING

DISCHARGE VENT

FLUE TEST
PORT

CONDENSATE
DRAIN WITH
PIG TAIL

3 FT

(1 M)

RIOM-60 REV.

OUTDOOR VENTING

When installed outdoors the Futera III must be fi tted with
the factory supplied outdoor hood, air intake adapter with
fi lter and exhaust terminal, see Figure 7A. Multiple units
must be spaced per Figure 7B.

The boiler/heater must be at least 2 ft, .62 m from any
door, window or gravity air inlet into any building and at
least 3 ft, 1 m from any overhang unless local codes dictate
differently.

Avoid locations where wind defl ection off of adjacent walls,
buildings or shrubbery might cause a downdraft. The
unit(s) shouild be located at least 3 ft, 1 m from structures.
Outdoor installations are not recommended in areas where
the danger of snow blockage exists.

CAUTION: Do not place the boiler/water heater in a
location that would subject it to runoff from adjacent
buildings or damage may occur voiding the warranty!

COMMON VENT SYSTEMS

On multiple boiler common vent applications, the master
boiler may be required to be fi rst on and installed closest
to the verticle chimney (consult factory).

If an existing boiler/water heater is removed from a
common venting system, the common venting system may
then be too large for the proper venting of the remaining
appliances connected to it. At the time of removal of an
existing boiler/water heater, the following steps shall be
followed with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.

Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’évacuation
commun et qui fonctionne alors que d’autres appareils
toujours raccordés au système d’évacuation ne fonction­nent pas: système d’évacuation

a) Seal any unused openings in the common venting system.

Sceller toutes les ouvertures non utilisées du sys­ tème d’évacuation.

b) Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.

Inspecter de façon visuelle le système d’évacu-ation
pour déterminer la grosser et l’inclinaison horizontale
qui conviennent et s’assurer que le système est exempt
d’obstruction, d’étranglement de fruite, de corrosion et
autres défaillances qui pourraient présenter des risques.

c) Insofar as is practical, close all building doors and

windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building. Turn
on clothes dryers and any appliance not connected to the
common 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 fi replace dampers.

11

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

Dans la mesure du possible, fermer toutes les portes
et les fenêtres du bâtiment et toutes les portes entre
l’espace où les appareils toujours raccordés du système
d’évacuation sont installés et les autres espaces du
bâtiment. Mettre en marche les sécheuses, tous les
appareils non raccordés au système d’évacuation
commun et tous les ventilateurs d’extraction comme les
hottes de cuisinère et les ventilateurs des salles de bain.
S’assurer que ces ventilateurs fonctionnent à la vitesse
maximale. Ne pas faire fonctionner les ventilateurs
d’été. Fermer les registres des cheminées.

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

Mettre l’appareil inspecté en marche. Suivre les

instructions d’allumage. Régler le thermostat de façon
que l’appareil fonctionne de façon continue.

e) Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the fl ame of a
match or candle, or smoke from a cigarette, cigar or
pipe.

Faire fonctionner le brûleur principal pendant 5 min

ensuite, déterminer si le coupe-tirage déborde à
l’ouverture de décharge. Utiliser la flamme d’une
allunette ou d’une chandelle ou la fumée d’une
cigarette, d’un cigare ou d’une pipe.

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

Une fois qu’il a été d éterminé, selon la métode
indiquée ci-dessus, que chaque appareil raccordé au
système d’évacuation est mis à l’air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les appareils
au gaz à leur position originale.

g) Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When resizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Appendix F in the National Fuel
Gas Code, ANSI Z223.1/ NFPA 54 and or CAN/CGA
B149 Installation Codes.

Tout mauvais fonctionnement du systéme d’évacu-tion
commun devrait étré corrigé de façor que l’installation
soit conforme au National Fue Gas Code, ANSI
Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/
CGA-B149. Si la grosseur d’une section du système
d’ évacuation doit étré modifi ée, le système devrait étré
modifié pour respecter les valeurs minimales des
tableaux pertinents de l’appendice F du National Fuel
Gas Code, ANSI Z223.1/ NFPA 54 et (ou) des codes
d’installation CAN/CGA-B149.

GENERAL PIPING REQUIREMENTS

CAUTION: 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. Excessive pitting 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 flow rates, see Table 7. Return water
temperatures below 125˚F, 52°C will result in heat
exchanger damage from excessive condensation
voiding the manufacturer’s warranty, see Primary /
Secondary Piping, Figure 9.

NOTE: Shut off valves and unions should be installed
at the inlet and outlet connections of the boiler/hot
water heater to provide for isolation of the unit should
servicing be necessary.

Freeze Protection

Installations in areas where the danger of freezing exists
are not recommended unless proper freeze protection is
provided. The following precautions MUST be observed:

1. A continuous fl ow of water through the unit MUST be
maintained! The pump responsible for fl ow through the
boiler/water heater must run continuously!

2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed to
must be used. The pump must be capable of producing
a minimum of 15% more fl ow and overcoming a 20%
increase in head loss. Domestic water systems must be
isolated from the water heater by the use of a heat
exchanger or other approved method.

3. If the unit must be shut off for any reason the electric,

gas and water supplies MUST be shut off and the unit
and its pump completely drained.

CAUTION: Improper outdoor installation of this unit
can cause boiler failure voiding the manufacturer’s
warranty!

12

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

Relief Valve

Pipe the discharge of the pressure relief valve as shown
in Figure 8.

WARNING: 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!

Figure 8 – Futera III Piping

Flow Switch

The fl ow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to prevent
the boiler from fi ring unless there’s adequate water fl ow
through the unit. The fl ow switch must be installed in the
supply piping adjacent to the boiler outlet connection.

CAUTION: Failure to properly install the fl ow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualifi ed
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV,
and ANSI/ASME CSD-1, Standard for Controls and Safety
Devices for Automatically Fired Boilers. All applicable local
codes and ordinances must also be followed. A minimum
clearance of 1 in, 25 mm must be maintained between
heating system pipes and all combustible construction. All
heating system piping must be supported by suitable
hangers not the boiler. The thermal expansion of the
system must be considered when supporting the system.
A minimum system pressure of 12 psig, 82.7 kPa must
be maintained.

Heating Boiler Piping Connections

The supply and return connections should be sized to suit
the system, see Table 6.

Table 6 – Supply & Return Pipe Sizing (Flanged)

ModelSize SupplySize Return Size
500 thru 1000 2" 2"
1250 thru 2000 2 1/2" 2 1/2"

13

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

Pump Requirements

This low mass boiler requires a continuous minimum water
fl ow for proper operation. The system pump must be sized
to overcome the head loss of the boiler and the heating
system in order to achieve the required temperature rise.
Table 7 provides the heat exchanger pressure drop and
temperature rise fi gures. The temperature rise across the
boiler must never exceed 35˚F, 19.4˚C. The adjustable
pump delay turns the pump on each time the burner fi res
and runs the pump for 20 to 600 seconds after the call for
heat is satisfi ed.

CAUTION: A temperature rise outside of the range
listed in Table 7 indicates that the fl ow rate through the
heat exchanger is incorrect which will damage the heat
exchanger voiding the warranty! The maximum
allowable temperature rise is 35°F, 19.4°C.

The maximum allowable fl ow rate through a Futera III
boiler is 97 GPM, 6.1 L/s on 500 through 1000 models
and 136 GPM, 8.6 L/s for 1250 through 2000 models.
The Cupro-Nickel heat exchanger allows for 108 GPM,

6.8 L/s on 500 through 1000 models and 151 GPM,

9.5 L/s on 1250 through 2000 models.

Table 7 - Temperature Rise Table

ΔT = 20°F ΔT = 11.1°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
500 43.5 0.55 2.7 1.6
750 65.3 1.63 4.1 4.8
1000 87.0 3.59 5.5 10.6
1250 108.8 2.21 6.9 6.5
1500 130.5 3.73 8.2 11.0

ΔT = 25°F ΔT = 13.9°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
500 34.8 0.36 2.2 1.1
750 52.2 1.08 3.3 3.2
1000 69.6 2.37 4.4 7.0
1250 87.0 1.46 5.5 4.3
1500 104.4 2.46 6.6 7.3
1750 121.8 3.84 7.7 11.3
2000 139.2 5.63 8.8 16.6

ΔT = 30°F ΔT = 16.7°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
750 43.5 0.77 2.7 2.3
1000 58.0 1.69 3.7 5.0
1250 72.5 1.04 4.6 3.1
1500 87.0 1.76 5.5 5.2
1750 101.5 2.74 6.4 8.1
2000 116.0 4.01 7.3 11.8

ΔT = 35°F ΔT = 19.4°C

Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
750 37.3 0.58 2.4 1.7
1000 49.7 1.27 3.1 3.8
1250 62.1 0.78 3.9 2.3
1500 74.6 1.32 4.7 3.9
1750 87.0 2.06 5.5 6.1
2000 99.4 2.02 6.3 8.9

Low Water Cutoff

If a boiler is installed above any radiation elements it must
be fi tted with a low water cutoff device.

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

Expansion Tank & Air Separator
An expansion tank or other means to control thermal
expansion must be installed in the heating system. An
expansion tank must be installed close to the boiler on the
suction side of the pump. An air scoop and automatic air
vent must also be installed to eliminate air trapped in the
system.

Primary/Secondary Piping
Boilers connected to heating systems using zone valves,
zone pumps, or systems that have excessive fl ow rates or
return water temperatures less than 125˚F, 52˚C must be
isolated from these systems to protect the boiler.

Variable Water Flows
Figure 9 shows a typical primary/secondary piping system.
A dedicated pump is used to maintain a constant water fl ow
through the boiler. This secondary pump is sized to
overcome the head loss of the boiler and secondary piping
system while supplying the fl ow rate required to maintain
the desired temperature rise across the boiler. The primary
pump is sized to provide the required fl ow to the heating
system. The secondary piping connections to the primary
system piping must not be more than 12 in, 305 mm apart
to ensure zero pressure drop in the primary system, see
Figure 9.

Low Return Water Temperatures
To prevent the problems associated with condensation of
the products of combustion due to low return water
temperatures a primary/secondary piping system with a
bypass and bypass valve must be installed, see Figure
10 and 10A. The bypass system must be sized the same
as the secondary piping. The primary and secondary
pumps should be sized to provide the required fl ow through
each system. The secondary piping connections to
the primary system piping must not be more than 12 in,
305 mm apart to ensure zero pressure drop in the primary
system, see Figure 10 and 10A.

Multiple Boiler Systems

Systems using multiple boilers can also be installed using
a primary/secondary manifold system, Figure 11.

Piping For Use With Cooling Units

The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be used
to prevent the chilled water from entering the boiler.

When a boiler is connected to a heating coil that may be
exposed to refrigerated air from an air handling device, the
piping system must be equipped with fl ow-control valves
or some other automatic means of preventing gravity
circulation of the boiler water during the cooling cycle.

14

FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

Figure 9 - Typical Primary/Secondary Piping System

(See Notes)

Pump

Gate Valve

Globe Valve

NOTES:

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

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

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

4. Boiler pump purging required. Use
terminals supplied.

Notice: These drawings show suggested
piping confi guration and valving.
Check with local codes and ordinances
for specifi c requirements.

Figure 10 - Low Temperature Piping with Thermostatic Valve

(See Notes and Adjustment Procedures)

H-1 Rev 3

Angle Valve

Bufferfly Val ve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Val ve

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

NOTES:

1. For pump selection consult factory.

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

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

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

5. Boiler pump purging required. Use terminals supplied.

6. Valve is precalibrated for 140°F return temperature.

Notice: These drawings show suggested piping confi guration and valving.
Check with local codes and ordinances for specifi c requirements.

15

H-18 Rev 2

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Automatic

Air Vent

Backflow­Prevention

Device

3-Way Valve

Expansion

Tan k