RBI FUTERA III Series Operating instructions

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 flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
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
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
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 inflammables à
proximité de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le
bâtiment.
• Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du
fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.
L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien
qualifié ou par le fournisseur de gaz.
The Futera III Series finned copper heating boiler/water
heaters have been design certified by CSA for use with
natural and propane gas under the latest revision of ANSIZ21.10.3/CSA 4.3, Gas Water Heaters, ANSI-Z21.13/CSA
4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers
and CAN1-3.1, Industrial and Commercial Gas Fired
Packaged Boilers. Each unit has been constructed and
hydrostatically tested for a maximum working pressure of
160 psi, 1103 kPa in accordance with Section IV of the
A.S.M.E. Boiler and Pressure Vessel Code.
CONTENTS
Before Your Start
Ratings & Capacities
Boiler/Water Heater Location
Combustion Air & Ventilation
General Venting Guidelines
Outdoor Venting
Common Vent Systems
General Piping Requirements
Heating System Piping
Domestic Water Supply Piping
Gas Supply Piping
Electrical Wiring
General Operation
Operating Instructions
Sequence of Operation
Checking & Adjustments
HeatNet Field Wiring
Control Description
Diagnostics
Maintenance
Trouble-Shooting
Repair Parts
Startup Sheet
page
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2
3
3
3
5
11
11
12
13
17
21
22
22
23
25
26
27
29
29
32
34
35
42
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.
BEFORE YOU START
This manual covers the application, installation, operation
and maintenance of a Futera III Series finned copper
heating boiler/water heater.
Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at: 260 North Elm
Street, Westfield, 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.
To obtain the safe, dependable, efficient operation and long
life for which this heating boiler/water heater was designed,
these instructions must be read, understood and followed.
2
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
RATINGS & CAPACITIES
6.
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.
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
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.
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!
NOTE: Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1
Top
Back
Left Side
Right Side
Front
2.
3.
Clearance to
Combustibles
in
mm
6
153
6
153
6
153
6
153
6
153
Service
Clearance
in
mm
30
762
24
610
12
306
12
306
30
762
To operate properly and safely this boiler/water heater
requires a continuous supply of air for combustion. NEVER
store objects on or around the boiler/water heater!
CAUTION: Combustion air contaminated with
fluorocarbons or other halogenated compounds such
as cleaning solvents and refrigerants will result in the
formation of acids in the combustion chamber. These
acids will cause premature failure of the boiler/water
heater voiding the warranty!
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.
Ensure that the floor is structurally sound and will
support the weight of the boiler/water heater.
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 fireplace, wood stove or any type of exhaust
fan must be checked for adequate combustion air when all
of these devices are in operation at one time. Sizing of an
outside air duct must be done to meet the requirements
of all such devices.
NOTE: The Futera III may be installed directly on
combustible flooring, but never on carpeting.
4.
5.
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.
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.
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”.
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
Table 2 – Make-up Air Louver Sizing
Required Cross Sectional Area
25% Free Area
Input
1/4 in 6.4 mm 75% Free Area
(MBH)
Wire Screen
Metal Louvers
Wooden Louvers
cm2
in2
cm2
in2
cm2
in2
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
All Air From Inside The Building
If the Futera III is to be located in a confined space,
the minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confined space without the intake
air option, Figures 5, 6 and 7, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
sufficient volume to meet the criteria for an unconfined
space. The total air requirements of all gas utilization
equipment, fireplaces, wood stoves or any type of
exhaust fan must be considered when making this
determination. Each opening must have a minimum free
area of 1 in2/1000 Btu/hr, 2200 mm2/kW based on the
total input rating of ALL gas utilization equipment in the
confined area. Each opening must be no less than
100 in2, 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.
Intake Air Option – General Guidelines
This configuration 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!
All Air From Outside The Building
When installed in a confined 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.
Single wall galvanized smoke pipe, single wall aluminum
pipe, flexible aluminum pipe, PVC or CPVC pipe can be
used for the intake air pipe. It must be sized per Table 3.
Where directly communicating with the outdoors
or communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 in2/4000 Btu/hr, 550 mm2/kW of the total input rating
of all of the equipment in the enclosure.
Table 3 - Intake Air Pipe Sizing
Model
For Vertical
Size
(Up to 60')
in
mm
500
8
203
750
8
203
1000
8
203
1250
10
254
1500
10
254
1750
12
305
2000
12
305
Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of
1 in2/2000 Btu/hr, 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 crosssectional area as the free area of the opening to which they
connect.
For Horizontal
(Up To 60')
in
mm
6
152
6
152
6
152
8
203
10
254
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.
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.
Canadian installations must comply with CSA B149.1 when
air supply is provided by natural air flow 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 in2 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.
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 infiltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
VENT SYSTEM OPTIONS
The flue 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 flue gas condensate. The flue
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.
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.
The Futera III may be vented the following ways:
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
flashed 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 certified intake
air terminal from RBI must be used, see Figures 1, 2
and 4.
1)
Direct Vent, Positive Pressure, Category IV uses a
vent system certified 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 certified 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.
3)
Vertical/Chimney Vent, Negative Pressure, Category II
uses a metal chimney system approved for Category II.
4)
Vertical Vent, Positive Pressure, Category IV uses a
vent system certified 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.
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!
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.
All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropriate
thimbles and fire-stops must be used where required.
WARNING: 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 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!
5
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
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 4 ft, 1.2 m
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
flue gases.
DIRECT VENT,
POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler/water heater blower is used
to push the flue products to the outdoors while drawing
combustion air from the outdoors. The Intake Air
Option instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! The vent system
must be sized per Table 4.
Table 4 – Category IV
Model
Size
500
750
1000
1250
1500
1750
2000
Pipe Diameter
(Up to 60')
in
5
5
6
6
8
10
10
mm
127
127
152
152
203
254
254
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 fire-stops.
Horizontal Direct Vent Systems – Figures 1 & 2
The vent materials used in horizontal vent systems must
be certified to UL 1738 for installations in the United States,
ULC S636 for installations in Canada. The certified vent
terminal from RBI must also be used.
An approved, nonrestrictive vent terminal must be used.
The top of a vertical vent system must extend at least
51/2 ft, 1.7 m above the roof surface and maximum snow
line that it passes through, 4 ft, 1.2 m above the intake air
terminal, see Figure 3.
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 firestops. For best results, horizontal vent systems should be
as short and straight as possible.
In addition the vent system must conform to the dimensions
shown in Figure 3. The penetration point in the roof must
be properly flashed and sealed.
The vent system must be gas tight. All seams and joints
in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
Combination Direct Vent Systems – Figure 4
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.
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.
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.
1000 BTU'S
Figure 2 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems
MBH
kW
146 TO 293
500 TO 1000
293 TO 586
1001 TO 2000
586 TO 1172
2001 TO 4000
4001 & LARGER 1172 & LARGER
FT
5
10
15
20
m
1.5
3.1
4.6
6.1
5 FT 1.5 m
2 IN. 5.0 cm
1.5 FT 0.5 m
7
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Figure 3 - Vertical Air Intake and Venting for Direct Vent System
10 FT 3.1 m
4 FT
1.2 m
5 1/2 FT
1.7 m
1.5 FT
0.5 m
5 FT
1.5 m
Figure 4 – Combination Direct Vent Systems
3 FT. 1 m
10 FT. 3.1 m
1.5 FT. .5 m
8
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: If an appliance using any type of a
mechanical draft system operating under positive
pressure is connected to a chimney flue, never
connect any other appliances to this flue. Doing
so can result in excessive levels of carbon
monoxide which can cause severe personal injury
or death!
SIDE WALL VENT,
POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler/water heater blower is used
to push the flue products horizontally to the outdoors, see
Figure 5. The air for combustion is taken from the space
in which the unit is installed. The applicable instructions
under the “COMBUSTION AIR & VENTILATION” section
must be followed! The vent guidelines under the Horizontal
Direct Vent Systems section must also be followed.
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 flue sizes required for the boiler/
water heater.
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 flue
collar and the vent connector when negative pressures
exceed 0.15 in, 3.8 mm W.C.
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: 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 flue, the flue must be large enough to safely vent
the combined output of all of the appliances.
Note: These sizes are based on a 20 ft, 6.1m chimney height.
Figure 5 – Side Wall Venting
4 FT
1.2 m
1/4 IN. PER F00T 20 mm/m
3 FT
0.9 m
24"
0.6 m
1.5 FT 0.5 m
9
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
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 flush with
the inside of the chimney flue, Figure 7. Fasten each single
wall vent connection with at least 3 corrosion resistant
sheet metal screws.
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 certified for Category
IV venting.
Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials.
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.
WA R N I N G : Fa i l u r e t o m a i n t a i n m i n i mu m
clearances between vent connectors and any
combustible material can result in a fire causing
extensive property damage, severe personal injury
or death!
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 flue collar to connect the
boiler/water heater to a masonry chimney. When using a
listed metal chimney system use the appropriate vent
connector.
Figure 6 – Vertical Venting
with a Metal Chimney System
Figure 7 – Vertical Venting
using a Lined Masonry Chimney
10 FT. 3.1 m
24"
.6 m
24"
.6 m
10
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Figure 7A – Outdoor Venting
Figure 7B – Multiple Outdoor Units
2 FT
(0.62 M)
GAS TRAIN COWLING
AIR INLET
UNDER COWLING
DISCHARGE VENT
FLUE TEST
PORT
3 FT
(1 M)
CONDENSATE
DRAIN WITH
PIG TAIL
RIOM-60 REV. A
RIOM-59-REV. A
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
OUTDOOR VENTING
When installed outdoors the Futera III must be fitted with
the factory supplied outdoor hood, air intake adapter with
filter 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.
a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système d’évacuation.
Avoid locations where wind deflection 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.
b) Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
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!
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.
COMMON VENT SYSTEMS
On multiple boiler common vent applications, the master
boiler may be required to be first on and installed closest
to the verticle chimney (consult factory).
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 fireplace dampers.
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.
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.
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 modifiée, 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
d) Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
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
w a t e r f l ow r a t e s , s e e Ta bl e 7 . R e t u r n w a t e r
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.
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 flame 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.
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.
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, fireplace dampers and
any other gas-burning appliance to their previous
condition of use.
Freeze Protection
Installations in areas where the danger of freezing exists
are not recommended unless proper freeze protection is
provided. The following precautions MUST be observed:
1. A continuous flow of water through the unit MUST be
maintained! The pump responsible for flow through the
boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed to
must be used. The pump must be capable of producing
a minimum of 15% more flow and overcoming a 20%
increase in head loss. Domestic water systems must be
isolated from the water heater by the use of a heat
exchanger or other approved method.
3. If the unit must be shut off for any reason the electric,
gas and water supplies MUST be shut off and the unit
and its pump completely drained.
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.
CAUTION: Improper outdoor installation of this unit
can cause boiler failure voiding the manufacturer’s
warranty!
12
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Flow Switch
The flow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to prevent
the boiler from firing unless there’s adequate water flow
through the unit. The flow switch must be installed in the
supply piping adjacent to the boiler outlet connection.
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!
CAUTION: Failure to properly install the flow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!
Figure 8 – Futera III Piping
Heating Boiler Piping Connections
The supply and return connections should be sized to suit
the system, see Table 6.
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualified
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.
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
flow 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 figures. 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 fires
and runs the pump for 20 to 600 seconds after the call for
heat is satisfied.
Low Water Cutoff
If a boiler is installed above any radiation elements it must
be fitted 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.
CAUTION: A temperature rise outside of the range
listed in Table 7 indicates that the flow 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.
Primary/Secondary Piping
Boilers connected to heating systems using zone valves,
zone pumps, or systems that have excessive flow rates or
return water temperatures less than 125˚F, 52˚C must be
isolated from these systems to protect the boiler.
The maximum allowable flow 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.
Variable Water Flows
Figure 9 shows a typical primary/secondary piping system.
A dedicated pump is used to maintain a constant water flow
through the boiler. This secondary pump is sized to
overcome the head loss of the boiler and secondary piping
system while supplying the flow rate required to maintain
the desired temperature rise across the boiler. The primary
pump is sized to provide the required flow 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.
Table 7 - Temperature Rise Table
Model
Number
500
750
1000
1250
1500
Model
Number
500
750
1000
1250
1500
1750
2000
Model
Number
750
1000
1250
1500
1750
2000
Model
Number
750
1000
1250
1500
1750
2000
ΔT = 20°F
Flow Rate
GPM
43.5
65.3
87.0
108.8
130.5
ΔT = 25°F
Flow Rate
GPM
34.8
52.2
69.6
87.0
104.4
121.8
139.2
ΔT = 30°F
Flow Rate
GPM
43.5
58.0
72.5
87.0
101.5
116.0
ΔT = 35°F
Flow Rate
GPM
37.3
49.7
62.1
74.6
87.0
99.4
ΔT = 11.1°C
Flow Rate
L/s
2.7
4.1
5.5
6.9
8.2
ΔT = 13.9°C
Pres. Drop Flow Rate
Ft
L/s
0.36
2.2
1.08
3.3
2.37
4.4
1.46
5.5
2.46
6.6
3.84
7.7
5.63
8.8
ΔT = 16.7°C
Pres. Drop Flow Rate
Ft
L/s
0.77
2.7
1.69
3.7
1.04
4.6
1.76
5.5
2.74
6.4
4.01
7.3
ΔT = 19.4°C
Pres. Drop Flow Rate
Ft
L/s
0.58
2.4
1.27
3.1
0.78
3.9
1.32
4.7
2.06
5.5
2.02
6.3
Pres. Drop
Ft
0.55
1.63
3.59
2.21
3.73
Pres. Drop
kPa
1.6
4.8
10.6
6.5
11.0
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 flow 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.
Pres. Drop
kPa
1.1
3.2
7.0
4.3
7.3
11.3
16.6
Pres. Drop
kPa
2.3
5.0
3.1
5.2
8.1
11.8
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.
Pres. Drop
kPa
1.7
3.8
2.3
3.9
6.1
8.9
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 flow-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:
Angle Valve
1. Boiler circuit piping must be sized
large enough to handle maximum flow
through unit.
2. Boiler pump sized to boiler design flow
requirements.
3. All boilers furnished with factory
mounted outlet water temperature
gauge.
4. Boiler pump purging required. Use
terminals supplied.
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valve
Notice: These drawings show suggested
piping configuration and valving.
Check with local codes and ordinances
for specific requirements.
Solenoid
Operated Valve
H-1 Rev 3
Self-Operated
Valve
Figure 10 - Low Temperature Piping with Thermostatic Valve
(See Notes and Adjustment Procedures)
Pressure
Reducing Valve
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
H-18 Rev 2
Gas Pressure
Regulator
Automatic
Air Vent
BackflowPrevention
Device
3-Way Valve
NOTES:
1.
2.
3.
4.
5.
6.
Expansion
Tank
For pump selection consult factory.
Boiler pump sized to boiler and thermostatic 3-way valve design flow requirements.
Boiler circuit piping must be sized large enough to handle maximum flow through unit.
All boilers furnished with factory mounted outlet water temperature gauge.
Boiler pump purging required. Use terminals supplied.
Valve is precalibrated for 140°F return temperature.
Notice: These drawings show suggested piping configuration and valving.
Check with local codes and ordinances for specific requirements.
15
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Figure 10A - Low Temperature Piping
(See Notes and Adjustment Procedures)
Pump
Gate Valve
Globe Valve
NOTES:
1. Boiler circuit piping must
be large enough to handle
maximum flow through unit.
2. Boiler pump sized to boiler
design flow requirements.
3. All boilers furnished with
factory mounted outlet
water temperature gauge.
4. Boiler pump purging required.
Use terminals supplied.
Adjustment Procedure
To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min+110° For Atmospheric
T1-Temp-Min=125° Sealed Combusion
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 stabiized. Make final adjustments.
5. Follow same adjustment procedure for
sealed combustion.
Notice: These drawings show
suggested piping configuration
and valving.Check with local
codes and ordinances for
specific requirements.
H-3 Rev 5
Angle Valve
Bufferfly Valve
Balance Valve
Ball Valve
Motorized Valve
Solenoid
Operated Valve
Self-Operated
Valve
Pressure
Reducing Valve
Figure 11 - Multiple Boiler Piping (See notes)
Check Valve
Pressure
Relief Valve
Flow Switch
Thermometer
Aquastat Union
Pressure Switch
Gas Pressure
Regulator
Automatic
Air Vent
BackflowPrevention
Device
H-15 Rev 4
NOTES:
1.
2.
3.
4.
5.
Boiler circuit piping must be large enough to handle maximum flow through unit.
Boiler pump sized to boiler design flow requirements.
All boilers furnished with factory mounted outlet water temperature gauge.
Boiler pump purging required. Use terminals supplied.
Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units.
Notice: These drawings show suggested piping configuration and valving.
Check with local codes and ordinances for specific requirements.
16
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water
conditions are encountered. See Table 8A.
DOMESTIC WATER SUPPLY PIPING
CAUTION: Proper controls must be used to prevent
water supplied for domestic use from exceeding 130˚F,
54˚C 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
120˚F, 49˚C. Local codes must be complied with!
CAUTION: The maximum allowable flow rate through a
Futera III water heater is 97 GPM, 6.1 L/s on 500 through
1000 models and 136 GPM, 8.9 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, see
Table 8B.
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. The
water heater must not be connected to any heating system
piping or components previously used with a non-potable
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.
RBI water heaters are designed to run scale free. Due to
the extreme variables of water conditions world wide it is
necessary to consider pH values and water hardness in
relationship to scaling. It is crucial to consider these two
variables when making heat exchanger and pump
selections. If local water conditions are extreme, follow the
guidelines in the Heat Exchanger Selection Table (Table
8A) and the Pumping Performance Table (Table 8B). 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.
NOTE: The storage tank must be located as close to
the water heater as possible to prevent excessive head
loss which will reduce flow.
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.
Water Chemistry
The 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.
17
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Table 8A - Futera III Heat Exchanger Selection Graph
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.
Table 8B - Futera III Pumping Performance Requirement
18
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Expansion Tank
An expansion tank or other means to control thermal
expansion must be installed in the water heating system if
back flow prevention devices are installed.
A balancing valve should be installed on the outlet side of
the water heater for purposes of adjusting the flow rate
through the heat exchanger. Thermometers are installed
on both the inlet and outlet of the water heater for
determining the temperature rise through the unit.
Pump Requirements
This low-mass water heater requires a continuous minimum water flow for proper operation. The low water flow
switch provided for this unit will shut down the water heater
if flow falls below the required minimum level. Table 8B
provides the heat exchanger pressure drop chart and
temperature rise table. The temperature rise across the
water heater must never exceed 35°F, 19.4°C.
The proper velocity through the water heater must be
maintained in accordance with Table 8B for efficient
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 8B the flow rate is too low. Scaling
and softening of the heat exchanger will occur.
Cold Water Supply
The cold water supply must be piped to the water heater’s
outlet piping between the water heater and the hot water
storage tank. This will prevent untempered water from
entering the water heater, see the Temperature Rise
Control section below. Two typical water heating systems
are shown in Figures 12 & 13.
Thermostatic Mixing Valve – Water Above 140˚F, 60˚C
Water can be stored at temperatures above 140˚F, 60˚C
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.
The mixing valve MUST be set to prevent a scald injury
from occurring, see the caution against scalding.
Temperature Rise Control
Water returned to the water heater inlet must not be less
than 125˚F, 52˚C or excessive condensation of the products
of combustion will damage the water heater voiding the
warranty. The method outlined below can be employed to
prevent this condition from occurring.
Storage of water for domestic use above 140°F, 60°C will
provide an increased quantity of tempered water and help
prevent the growth of water born bacteria.
19
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Figure 12 - Typical Water Heating Piping (MW Models Only)
(See Notes)
Pump
Valve
3
Globe Valve
1
8
4
Angle Valve
7
Bufferfly Valve
2
Balance Valve
D-1 Rev 6
Ball Valve
Motorized Valve
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Figure 13 - Multiple Water Heating Piping (MW Models Only)
(See Notes)
Solenoid
Operated Valve
Self-Operated
Valve
Pressure
Reducing Valve
SELF BALANCING DOUBLE REVERSE
RETURN MAKE-UP & SUPPLY, CIRCULATION
Check Valve
4
3
8
6
Pressure
Relief Valve
4
1
Flow Switch
7
2
Thermometer
7
2
Aquastat Union
D-4 Rev 6
6
Pressure Switch
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Gas Pressure
Regulator
Automatic
Air Vent
NOTES:
1.
2.
3.
4.
5.
Optional cold water make up and recirculation line location.
When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.
Thermal expansion tank may be required, check local codes.
When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.
CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.
The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and
Pumping Performance Table before making selection.
6. 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.
Notice: These drawings show suggested piping configuration and valving.
Check with local codes and ordinances for specific requirements.
20
Temperature &
Pressure
Relief Valve
Vacuum
Relief Valve
Drain Valve
(Typ.)
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Table 9 – Gas Pipe Capacity
GAS SUPPLY PIPING
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Pipe length in feet
30
40
Iron Pipe
10
50
60
80 100 150
20
Size, (in)
Maximum gas volume of pipe, (ft3/hr)
520 350 285 245 215 195 170 150 120
1"
1050 730 590 500 440 400 350 305 250
1 1/4"
1600 1100 890 760 670 610 530 460 380
1 1/2"
3050 2100 1650 1270 1270 1150 990 870 710
2"
WARNING: Check the boiler/water heater rating
plate to make sure that the boiler/water heater is
for the type of gas that will be used. If it isn’t, do
not connect the boiler/water heater to the gas
supply. Gas supply piping must be in accordance
with the National Fuel Code, ANSI Z223.1-latest
revision or applicable provisions of the local
building codes. Canadian installations must
comply with CAN/CGA B149.1 or .2 Installation
Code. Failure to comply with this warning can
result in extensive property damage, severe
personal injury or death!
Note: Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr.
Multiply the propane flow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
Table 10 – Equivalent Pipe Length Chart
The Futera III 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.
Type of pipe fitting
Nominal
90˚ Elbow
Tee1
Gate Valve2 Gas Cock2
Iron Pipe
Equivalent pipe length, (ft)
Size, (in)
1"
1.5
2.6
5.2
0.6
1 1/4"
1.9
3.5
6.9
0.8
1 1/2"
2.3
4.0
8.0
0.9
2"
3.0
5.2
10.3
1.2
Notes:
1. For flow through branch.
2. For flow at full open.
NOTE: A minimum gas supply pressure of 2 in, 51 mm,
W.C. natural or propane and maximum 14 in, 356 mm
W.C.. natural or propane, must be available at the safety
shutoff valve inlet with the unit(s) operating.
CAUTION: 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!
Table 9 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 fittings. Table 9 should be used
in conjunction with Table 10 to ensure that the gas supply
piping has the capacity to meet the demand.
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. The main Dungs gas valve supplied
with boiler/water heater does not require external venting.
Figure 14 depicts the proper way to connect the boiler/ water
heater to the gas supply piping. The manual shut-off valve
MUST be installed in the supply piping. It should be installed
5 ft, 1.5 m above the floor where required by local codes.
Provide a sediment trap at the bottom of the vertical section
of the gas supply pipe upstream of the gas controls.
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
putting the boiler into operation.
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.
Figure 14 – Gas Supply Piping
21
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Never use an open flame 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!
Refer to the wiring diagram supplied with the boiler/water
heater for proper wiring connections and boiler full load
amperage (FLA).
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
off valve, see Figure 14. 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-off valve.
WARNING: Before proceeding read and fully
understand the instructions contained in this
manual. Do not attempt 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!
GENERAL OPERATION
ELECTRICAL WIRING
Should overheating occur or the gas supply fail to shut off,
turn off the manual gas control valve to the appliance. Do
not interrupt water flow through the boiler/water heater.
Electrical Power Connections
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation! Verify proper operation after
servicing.
En cas de surchauffe ou si l’alimentation en gaz ne s’arrête
pas, fermez manuellement le robinet d’arrêt de l’admission
de gaz.
Hydronic Heating Boilers
Open the make-up water valve and slowly fill the boiler and
all of the radiation with water. Ensure that all bleed and
drain valves are closed.
AT T E N T I O N : Au m o m e n t d e l ’ e n t r e t i e n d e s
commandes, étiquetez tous les fils avant de les
débrancher. Des erreurs de câblage peuvent entraîner
un fonctionnement inadéquat et dangereux. S’assurer
que l’appareil fonctionne adéquatement une fois
l’entretirn terminé.
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.
The electrical connections to this boiler/water heater must
be made in accordance with all applicable local codes and
the latest revision of the National Electrical Code, ANSI /
NFPA-70. Installation should also conform with CSA C22.1
Canadian Electrical Code Part I if installed in Canada.
Open the system bleed and drain valves, one at a time, to
purge the air trapped in the heating system piping.
Install a separate 120 volt 15 amp or 20 amp circuit
breaker for the boiler/water heater and pump, see Table
11. A properly rated shut-off switch should be located
at the boiler/water heater. The 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.
With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed
valves. If strainers are used in the system piping, the makeup water valve should be closed and the strainers checked
and cleaned.
The system expansion tank should be checked to ensure
that the correct water level in the tank is maintained. The
tank should be less than half full of water with the system
full and adjusted to the correct operating pressure.
Table 11 - Futera III Electrical Requirements
Futera III
Model
Recommended
Circuit Breaker
(Amps)
*Running
Amps
MB/MW 500
MB/MW 750 - 1000
MB/MW 1250 - 2000
15
15
20
3.9
6.0
11.4
Star t the boiler as described in the “OPERATING
INSTRUCTIONS” section. Run the boiler for at least an
hour. The system pump(s) and all radiation units must be
operated during this time. Ensure that the make-up water
valve is open.
*Use separate circuit breaker that is properly sized for pump and
pump contactor.
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.
Line voltage field wiring of any controls or other devices
must conform to the temperature limitation of type TEW wire
at 95°F, 35°C above room temperature. Use copper
conductors with a minimum size of #14 awg. Use appropriate
wiring materials for units installed oudoors. The wire size
must be compatible with the total amp draw of the circuit.
Open the make-up water valve and adjust the system
pressure if necessary. The system should be checked and
bled after three days of operation.
22
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
N’utilisez pas cet appareil s’il a été plongé dans l’eau,
même partiellement. Faites inspecter l’appareil par un
tecnicien qualifié et remplacez toute partie du système
de contrôle et toute commande qui ont été plongés
dans l’eau.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN
MARCHE
Operating Instructions
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand.
1. STOP! Read the safety information above. If, at
any time, the appliance will not operate properly,
follow the instructions “TO TURN OFF GAS TO
APPLIANCE” and call your service technician or
gas supplier.
Cet appareil est muni d’un dispositif d’allumage qui
allume automatiquement la veilleuse. Ne tentez pas
d’allumer la veilleuse manuellement.
2. Set the operating control to off and disable any
outside (BMS) call for heat.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
3. Turn off all electric power to the appliance.
DANGER: Propane gas may not always be detected
by smell. Propane gas is heavier than air and can
collect in low areas.
4. Close main isolation gas valve (field supplied), Figure
14.
5. Purge the gas piping up to the manual valve ahead
of the main gas control of air. When the bleeding is
complete, check all gas joints up to the gas valve
for leaks.
Propane gas can ignite or explode if an ignition
source is present and result in death, serious
injury and property damage!
FOR YOUR SAFETY
• Have only qualified licensed professionals install,
service and maintain this appliance and your gas
system in accordance with all applicable codes.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not attempt to light any appliance.
3. Do not touch any electrical or electronic switches
in the building.
4. Do not use any phone in the building.
5. Call your gas supplier from a phone outside of the
building.
6. If you cannot reach your gas supplier call the fire
department.
6. Wait five (5) minutes to clear out any gas.
7. Install a fitting at the supply test port and connect
a manometer having a minimum range of 20 in,
508 mm WC to it, Figure 14.
8. Remove the 1/8" pipe plug from the pilot test port and
connect a manometer having a minimum range of
6 in, 154 mm WC to it.
9. Open the main isolation gas valve (field supplied),
Figure 14.
AVANT DE FAIRE FONCTIONNER, reniflez tout autour de
l’appareil pour déceler une odeur de gaz. Reniflez près du
plancher, car certains gaz sont plus lourds que l’air et
peuvent s’accumuler au niveau du sol.
10. Place the “Remote/Local” switch to Remote inside
control cabinet, Figure 15.
11. Turn the power switch on the front of the boiler to
“on”. It will light up when the power is on. If all
interlocks are properly closed, the display will say
“Standby”, Figure 15.
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 gaz
depuis un voisin. Suives les instructions du fournisseur.
•
Si vous ne pouvez rejoindre le fournisseur, appelez le
service de incendies.
12. Slide the Low Fire Hold Switch (on HeatNet control
board) to Low Fire position.
13. The boiler will begin the start sequence.
C. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control that has been
under water.
14. When the main display reads “PILOT RUNNING” and
the flame current is 5 VDC, switch the Honeywell
7800 to the “test” position, Figure 15. This will hold
the Honeywell 7800 in its ignition state.
23
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Improper wiring of the ignition
transformer can result in an explosion causing
extensive property damage, severe personal
injury or death!
15. Adjust the pilot pressure per the CHECKING,
ADJUSTMENT & OPERATION section.
16. Remove the demand from the 7800 control by
disabling the Low Fire switch allowing the boiler to
stop.
22. Open main isolation gas valve (field supplied).
Figure 15 - HeatNet Control Panel
TRANSFORMER
TEST RUN
SWITCH
MANUAL RESET
PUMP MOTOR
RELAY
LOCAL REMOTE
SWITCH
DISPLAY
WINDOW
BACK
BUTTON
HEAT NET
CONTROL
BOARD
23. Reset the Honeywell 7800. The boiler will start and
will run at minimum input rate.
FLAME
SAFEGUARD
MODULE
24. Setting the low fire: Allow the low fire to settle out for
a few minutes and observe the combustion reading.
Refer to “Combustion Reading” table for proper
combustion readings and elbow pressure, Table 12.
The low fire O2-CO2 can be adjusted in the field by
opening the low fire adjustment door located on the
forward facing side of the main gas valve. Inserting an
allen wrench and rotating the allen screw clock-wise
will increase the CO2 and lower the O2, rotating
counter clock-wise will decrease the CO 2 and
increase the O2. DO NOT LEAVE THE BURNER IN
AN INFRARED STATE. A few random speckles of
red are fine, but large concentrations of spots or large
areas of red are not. If large amounts of red
concentrations are observed, verify combustion
readings.
PROTOCESSOR
MODULE
(OPTIONAL)
IGNITION STATUS
WINDOW
UP BUTTON
DOWN BUTTON
25. Jumper the “AA” terminals located on the HeatNet
control board. The boiler input will rise to its
maximum input, “Run 100%”, see Figure 17.
POWER SWITCH
SELECT BUTTON
26. Allow the boiler to reach steady state and verify
supply gas pressure and check input rates as
explained in the “Gas Supply Piping” section. Also,
refer to “Combustion Reading” table for proper
combustion readings and elbow pressure, Table 12.
17. Close main isolation gas valve (field supplied), Figure
14.
18. Remove the manometer fitting from the pilot test
port and replace the plug. Place monitor tube on to
elbow test port located down stream of main gas
valve, Figure 14.
27. Remove jumper “AA” and allow boiler to settle into
minimum input. Observe the combustion readings
and make any final adjustments. When finished
disable the Low Fire Hold Switch and replace test
ports to normal state.
19. Switch the Honeywell 7800 back to “run”.
20. Create a min input demand as before (enable Low
Fire Hold switch.) The boiler will begin the start
sequence.
28. Boiler allows for many modes of operation and control
methods. Reference the “HeatNet Control Manual”.
Table 12 - Combustion Readings
21. Monitor the flame current on the 7800. No flame
current should be detected and the 7800 should
lock out. If flame current is detected at any time up
to the 7800 locking out, the 120V wiring on the
ignition transformer must be reversed and the test
run again to insure that no flame is detected.
CO2 %
O2 %
Natural Fuel
8.0 - 8.5 (min.)
8.3 - 8.8 (100%)
6.6 - 5.8 (min.)
6.2 - 5.2 (100%)
Propane Fuel
9.4 - 9.9 (min.)
9.7 - 10.3 (100%)
6.6 - 5.8 (min.)
6.2 - 5.2 (100%)
*For factory set gas manifold (elbow) pressures see
label on inner cabinet door.
24
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
INSTRUCTIONS DE MISE EN MARCHE
SEQUENCE OF OPERATION
1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.
NO DEMAND
Standby
1. The boiler is idle with no interlocks in the fault
condition.
2. Réglez le thermostat à la température la plus basse.
3. Coupez l'alimentation électrique de l'appareil.
DEMAND
Pre-Purge
1. The blower operates at purge RPM. The water flow
interlock must ‘make’ within 15 seconds after the
demand signal is initiated.
4. Cet appareil est muni d'un dispositif d'allumage qui
allume automatiquement la veilleuse. Ne tentez pas
d'allumer la veilleuse manuellement.
5. Fermer la vanne manuelle d'arrêt d'alimintation de
gaz.
2. The Honeywell 7800 starts a 10 second purge delay
once the air prove switch contacts close.
6. Attendre cinq (5) minutes pour laisser échapper tout
le gaz. Reniflez tout autour de l'appareil, y compris
près du plancher, pour déceler une odeur de gaz.
Si vous sentez une odeur de gaz, ARRÊTEZ!
Passez à l'étape B des instructions de sécurité sur
la portion supérieure de cette étiquette. S'il n'y a pas
d'odeur de gaz, passez à l'étape suivante.
Pilot Run - %Input
1. The blower operates at minimum ignition setting.
See the calibration section in the “HeatNet ControlIOM” to enter the calibration menus.
2. The ignition transformer is energized. The pilot
solenoid valve opens for the 10 second pilot ignition
trial.
7. Ouver la vanne manuelle d'arrêt d'alimintation de
gaz.
Main Run %Input
1. The main gas valve opens.
8. Mettez l'appareil sous tension.
9. Réglez le thermostat à la température désirée.
2. The ignition transformer is de-energized.
10. Si l'appareil ne se met pas en marche, suivez les
instructions intitulées couper l'admission de gaz de
l'appareil et appelez un technicien qualifié ou le
fournisseur de gaz.
3. The pilot solenoid valve closes.
4. The blower stays at the minimum input setting for
3 seconds then operates at demand % input. See
the calibration section in the “HeatNet Control-IOM”
to enter the calibration menus.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest setting.
NO DEMAND
Post-Purge
1. The main gas valve closes.
2. Turn off all electric power to the boiler if service is
to be performed.
3. Close the manual main and pilot gas shut-off valves.
2. The blower operates at purge RPM for 10 seconds.
COMMENT COUPER L'ADMISSION DE GAZ DE
L'APAREIL
1. Réglez le thermostat à la température la plus basse.
3. The boiler is idle with no interlocks in the fault
condition.
2. Coupez l'alimentation électrique de l'appareil s'il faut
procéder à l'entretien.
3. Fermer la vanne manuelle d'arrêt d'alimintation de
gaz.
25
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as
follows:
LP
Nat
Minimum (in W.C.)
2
2
Maximum (in W.C.)
14
14
CHECKING & ADJUSTMENTS
Spark Gap
With the main and pilot gas manual valves in the closed
position energize the unit. Observe the trial for ignition to
confirm that the spark is strong and continuous. If not check
and adjust the spark gap as shown in Figures 17 &18.
Measure pressure when the boiler is firing at full rate. Low
gas pressure could indicate undersized gas line or
insufficient gas supply.
Figure 16 – Spark Gap
“Static and operating gas pressure required at the gas
valve inlet is between 2" W.C. and 14" W.C. for natural gas
and 2" W.C. and 14" W.C. propane. If the gas pressure is
above this limit, a lock-up style 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 specific job site requirements.”
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation with
no adjustment required at elevations up to 2000 ft, 610 m.
At elevations above 2000 ft, 610 m input ratings should
be reduced by 4% for each 1000 ft, 305 m.
Pilot Adjustment
The pilot pressure has been factory set at 3" W.C. for natural
and LP gas and shouldn't need adjustment. To check the
pilot pressure close the manual main shut-off valve 2 and
the pilot gas shut-off valve, Figure 14. Remove the 1/8" pipe
plug from the pilot tee and connect a manometer having a
minimum range of 6 in, 152 mm WC to it. Open the pilot
gas shut-off valve. With the unit powered, generate a call
for heat. When the prepurge is complete the ignition/pilot
trial will begin. At this point put the Honeywell RM7800 test
switch in the test position. The control will hold in the ignition/
pilot sequence allowing you to check the pressure.
Check the input rate as follows:
1. Turn off all other gas appliances that use the same gas
meter as the boiler/water heater.
2. Call your gas supplier and ask for the heating value
of the gas.
3. Start the boiler/water heater and let it run for 15
minutes.
4. Using the gas meter and a stopwatch, clock the time
that it takes to burn 10 ft3, 0.28 m3 of gas and divide
this time by 10.
5. Insert the heating value and the time, in seconds, into
the formula below.
6. Input = (heating value, Btu/hr)(3600)/(time, seconds)
7. If the computed rate deviates by more than 5% from
the rated input value of the unit, consult factory.
To adjust the pilot the following steps must be taken:
1. Remove the pilot gas pressure regulator cap.
2. Turn the pressure regulator adjustment screw clockwise to increase the pressure and counterclockwise to
decrease it.
CAUTION: 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!
3. Replace the pressure regulator adjustment screw cap.
CAUTION: Never force the regulator adjustment screw
beyond the stop limits or damage to the regulator will
occur!
26
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
RBI Field Wiring To HeatNet Board
Figure 17
27
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
RBI HeatNet Field Wiring To Terminal Block
(Board Revision 2.0 and Greater)
NOTES:
1. Remove jumper “A” when using a low water
cutoff interlock.
2. For multiple boilers utilizing a system
air damper when in a master/member
configuration consult factory or reference
wiring diagram 42-0505 sheet 2 for wiring
connections.
3. For single boilers or multiple boilers with
individual dampers connect the end proving
switch to main terminal block 15 and 16.
Terminals 17 and 18 provide 120V power to
the damper motor.
4. There are two methods in which a 4-20mA
signal can be used to control HeatNet
equipped boilers.
Method 1
A 4-20mA signal can be used to directly
modulate each boiler from a remote panel or
building management system. On multiple
boiler installations, there is no communication
between boilers, no HeatNet system sensor;
therefore no master/member relationship
exists.
(Use Menu: Setup: Setpoints: Setpoint
Source: Auto)
Method 2
A 4-20mA signal can be used to change
the setpoint temperature the HeatNet is
maintaining. This can be used on single
or multiple boilers with a master/member
relationship. (Use Menu: Setup: Setpoints:
Setpoint Source: 4-20, then set the
parameters for the temperature and boiler
start point.)
5. The ‘local’ pump relay in the control panel is
rated for 1 hp, 1∅ motors. For larger or 3∅
reference factory wiring diagram.
28
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
HIGH LIMIT: When the high limit aquastat trips the
following message is displayed:
CONTROL DESCRIPTION
Low Water Cutoff
If the boiler is to be installed above radiation or if required
by other codes or regulations, install a low water cutoff in
appropriate piping. Wire the switch to the "Interlock"
contacts as illustrated on “Field Wiring” schematic. Ensure
that the low water cutoff device(s) will funtion properly.
FAULT
HIGH LIMIT
SYSTEM SET
160˚F
Operating Control
The preferred control setting for potable hot water is 130°F,
54°C. The operating control should be set to the lowest
setting that will satisfy the consumer's needs.
FAULT
10/27 9:16
SYSTEM SET
160˚F
WARNING: Setting the thermostat or operation
control too high can result in scalding resulting in
severe personal injury!
The high limit interlock breaks power to the ignition
control (shutting it off) and effectively removes any
chance of the gas valve receiving power. The FIII series
control will remain powered to display the fault, latch
the alarm relay/audible beeper, and to access the log.
The interlock is located on J5, HIGH LIMIT.
High Limit (Aquastat)
The high limit is located in the top control area of the boiler/
water heater. A remote capillary bulb is run to a well on
the outlet side of the supply header. The high limit can be
reset by depressing the red button.
The water heater high limit should be set a minimum of
20°F, 11°C higher than the operating control. Refer to the
HOT WATER SUPPLY section for the proper supply water
temperature.
INTERLOCK SPARE 3: This is a reserved interlock
input that is normally jumpered at the factory, but can
have a remote interlock connected as a field install. The
interlock is located on J11A, SPARE 3.
Flow Switch
A flow switch is provided in the water outlet piping to
prevent the boiler/water heater from firing without adequate
water flow through the heat exchanger.
FAULT
SYSTEM SET
INTERLOCK SPARE 3
160˚F
DIAGNOSTICS
The Futera III has a display that indicates the sequence of
operation. The display will also list faults should the unit fail
to operate. An explanation of each status message and fault
can be located in HeatNet Control Manual under status
screen fault display section.
STATUS SCREEN FAULT DISPLAY
There are numerous interlock switches and software
limits that are detected. Each of these, when tripped will
produce a display message, an audible beeping, and
an alarm relay closure. The fault is displayed first, then
after a second, the time the fault occurred is displayed.
This cycle will keep occurring until the fault is cleared.
These faults are:
29
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
FLOW SWITCH ERROR: Once the FIII series boiler
receives a call for heat, it closes the circulator pump
relay. It then waits 10 seconds to prove flow. If there is
no flow, the flow switch alarm will be set. Every 10
seconds the circulator pump relay will cycle ON for 10
seconds and then OFF for 10 seconds to try and
establish flow. The interlock connection is located on
J11B, WTR FLW.
LOW WATER CUTOFF: If there is a low water condition
reported by the low water cutoff switch this fault is
displayed. Check that there is water flow and water in
the boiler. There is a reset switch located on the LWCO
box. The interlock connection is located on J11A,
LWCO.
FAULT
SYSTEM SET
LOW WATER CUTOFF
FAULT
SYSTEM SET
WATER FLOW SWITCH
160˚F
160˚F
VAR FREQ DRIVE: The variable frequency drive, which
controls the blower, reports this fault in the event of over
current or other conditions that would cause it to shut
down. If this is the case, check the fault indicators on the
VFD. The interlock is located on J11A, VFD.
IGNITION CTRL ALARM: The ignition control alarm is
displayed if the ignition control detects a fault. This could
be a flame failure, air proving switch, or other fault
associated with the ignition control. When this fault
occurs, you will need to refer to the ignition control for
the reason.
FAULT
SYSTEM SET
VAR FREQ DRIVE
160˚F
FAULT
SYSTEM SET
IGNITION CTRL ALARM
160˚F
GAS PRESSURE: The optional gas pressure switches
(high pressure and low pressure) are connected in
series, so if either trip, a fault will be reported here. A
reset switch is located on the gas pressure switches.
The interlock is located on J11A, GAS PR.
FAULT
GAS PRESSURE
IRI ALARM: The optional IRI alarm is the alarm from
the gas valve. If this alarm is set check the gas valve.
SYSTEM SET
FAULT
IRI ALARM
160˚F
SYSTEM SET
160˚F
INTERLOCK SPARE 4: This is also a spare interlock
(similar to INTERLOCK SPARE 3) for future expansion
or use as a field interlock. The interlock is located on
J11B, SPARE 4.
FAULT
SYSTEM SET
INTERLOCK SPARE 4
160˚F
30
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
SHORTED ***** SENSOR: If the shorted sensor fault is
displayed, the sensor in the position reported was
originally detected, but has since shorted. The boiler will
shut down on any SHORTED sensor.
COMBUST AIR DAMPER: If the combustion air damper
has been selected for use (MASTER BOILER, AUX
FUNCTIONS), and the proof switch does not make, this
fault will be displayed.
When the combustion air damper is used, the master’s
BOILER3/DAMPER relay contacts at J13 are closed.
These should be wired to the combustion air damper
or preferably an isolation relay. The prove switch on
the combustion air damper must be wired to J10B,
SPARE 1.
FAULT
SYSTEM SET
SHORTED OUTSIDE SENSOR
160˚F
DELTA TEMP > 40°F: If the temperature across the
heat exchanger rises above the maximum designated
temperature for the FIII model boiler, a warning or
fault will be displayed. This protection is required to
prevent damage to the heat exchanger in the event
high differential temperatures are encountered. The
fault or warning condition may be changed in the AUX
FUNCTIONS menu under ALARM TYPE. The default
condition is WARNING with LIM->HALF RATE = YES.
FAULT
SYSTEM SET
COMBUSTION AIR DAMPER
160˚F
When the master boiler receives a call for heat and
needs to start a boiler, the BOILER3/DAMPER relay K5
closes. At the same time, the boiler is started, fires, and
continues to fire. If the combustion air damper does not
prove within the proof time specified in the combustion
air damper menu, the boiler will shut down and display
the fault. The fault on the Master boiler can be cleared
by removing the call for heat on the master boiler and
fixing the combustion air damper problem. A combustion
damper fault on a Member boiler can only be cleared by
power cycling.
When this condition exists and the ALARM TYPE is
set to WARNING and LIM-> HALF RATE, the boiler is
limited to 1/2 it’s input rate. So, if the boiler is trying to fire
at 80%, the rate is limited to 40% until the temperature
across the heat exchanger falls at least 10°F below the
maximum designated temperature for the FIII boiler
model. In this case: 40°F - 10°F = 30°F.
If the ALARM TYPE is set to FAULT, the boiler will
display the FAULT message and this condition will be
treated as an interlock, thus shutting down the boiler
until the Delta Temp drops 10°F below the maximum
designated temperature.
The Master boiler controls a system damper and Member
boilers control their own respective dampers. When the
call for heat is removed, the damper will remain open
for 30 seconds before closing. This allows for post purge
cycles to complete.
1/2 INPUT
LOCAL SET
DELTA TEMP > 40°F
OPEN ***** SENSOR: If the open sensor fault is
displayed, the sensor in the position reported was
originally detected, but has since opened. The boiler
will shut down on any OPEN sensor.
41˚F
FAULT
SYSTEM SET
OPEN OUTSIDE SENSOR
160˚F
31
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
7.
RETURN TEMP < 130°F: If the Return Inlet temperature
is less than 130°F this warning will be displayed. This
warning does not affect operation and does not set the
alarm relay. A log entry is made to aide in diagnosing
why this may be occuring. Condensing will occur with
return temperatures below 130°F and a shortened heat
exchanger life will occur.
8.
9.
Lift and remove the transition piece and burner together
from the boiler/water heater, taking care not to damage
the spark rods and or their alignment.
Disconnect the compression nut from the inside of the
transition piece.
Remove the transition piece, taking care not to damage
the spark rods and or their alignment.
Heat Exchanger Inspection
1. Close the manual shutoff valves in the gas supply lines
and turn off electrical power to the boiler/water heater.
2. Remove burner following the instructions in the Burner
Removal section.
3. Remove the front jacket panel and combustion chamber
door.
4. Inspect the inside and outside of the heat exchanger
for signs of damage, sooting or corrosion.
5. The outside surfaces of the copper tubes should be free
of any soot deposits. A slight black smudge is normal with
some types of gases. Black soot indicates poor
combustion. Green deposits indicate condensation due
to low return water temperatures. In either case the heat
exchanger must be cleaned thoroughly and the problem
resolved before the boiler/water heater is returned to
service.
6. If there are no signs of damage, sooting or corrosion,
reassemble the unit following the previous steps in
reverse order.
7. A badly corroded or damaged heat exchanger must
be replaced, see the Heat Exchanger Repair &
Replacement section.
PREPURGE
LOCAL SET
RETURN TEMP < 130°F
41˚F
MAINTENANCE
WARNING: Disconnect electrical power and close
the manual gas shut off valve before performing
maintenance or severe personal injury may
result!
CAUTION: 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!
The 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 19 for component identification.
Heat Exchanger Cleaning
1. Close the shut off valves in the inlet and outlet piping.
On heating systems close the system fill valve and
relieve the system pressure from the boiler by carefully
lifting the relief valve or opening the drain valve.
2. Disconnect the boiler/water heater from the system
piping.
3. Remove the eight bolts on the rear pipe enclosure
panel.
4. Remove the front jacket panel and combustion
chamber door.
5. Slide the heat exchanger out of the unit.
6. Remove the “V” baffle straps and “V” baffles.
7. Thoroughly clean the heat exchanger with water from
a high-pressure hose. Use a soft bristle brush if
necessary.
8. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
CAUTION: Improper burner servicing can result in
premature burner failure voiding the warranty!
Burner Removal
1. Close the manual shutoff valves in the gas supply line
and turn off electrical power to the boiler/water heater.
2. Remove the jacket top panel.
3. Disconnect the wires to the fan and remove the four
bolts that secure the fan to the transition piece.
4. Remove wires from the spark rods and remove the UV
sense from the transition piece.
5. Disconnect the compression nut at the back of the
transition piece to remove pilot gas tubing.
6. Remove the four nuts holding the transition piece to the
heat exchanger.
32
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
4.
Heat Exchanger Repair & Replacement
1. A leaking or otherwise damaged tube(s) can be
replaced as outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler/water
heater as outlined in the Heat Exchanger Cleaning
section.
3. Remove the pipe plugs from the inlet/outlet and return
headers opposite from the ends of the tube(s) being
replaced.
4. Carefully cut the damaged tube(s) in half, taking care
not to damage the adjacent tubes and remove.
5. Install and swage/expand in place the new tube(s).
6. Replace the pipe plugs using a suitable thread sealant
on each one.
7. Sagging or distorted heat exchanger tubes are an
indication of low water flow through the system. A
damaged heat exchanger must be replaced and the
condition that caused the damage resolved before the
boiler/water heater is returned to service.
8. Replace the heat exchanger and other components in
the reverse order of their removal.
9. The recommended torque value for the heat exchanger
plugs is approximately 45 ft. lbs, not to exceed 50 ft.
lbs.
5.
6.
The relief valve should not weep or discharge water
at normal system pressure. If it does, contact a
qualified service technician to have it inspected.
NEVER try to clean or repair the relief valve! If the
valve fails to operate properly, have it replaced!
The aquastat high limit controls the maximum water
temperature in the boiler. If the water temperature
reaches the set temperature before the demand for heat
has been met, the aquastat high limit should shut the
boiler off. The water temperature should never exceed
the maximum set point of 250°F, 121°C, for boilers
and 210°F, 99°C for water heaters. The aquastat high
limit cannot be repaired. If it fails to function properly,
replace it.
Visually check the pilot and main burner flames to
ensure proper operation, see Figure 18.
WARNING: A yellow, floating flame 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!
Figure 18 - Main Burner Flame
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
filter and wash with warm water and soap if dirty.
Controls
Use the “GENERAL OPERATION” and “CHECKING AND
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A float type low water cutoff device must be flushed
out per the manufacturers’ instructions. The probe on
a probe low water cut off must be removed, cleaned
and inspected at least once a year. Ensure that the
low water cutoffs operate properly. If not, replace
them.
3. The flow switch contacts must be open when water
flow is not present.
33
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Troubleshooting A Startup
Symptom
1.
An Interlock is tripped.
Identify Source
1. Is it a 24 VAC Interlock?
2. Is it a 120 VAC Interlock/
Alarm?
Check
Action
1. All 24 VAC Interlocks are
located on J11A and J11B.
Examples of 24 VAC Interlocks:
1.SPARE3
2. Variable Frequency Drive(VFD)
3. Low Water Cutoff(LWCO),
4. Gas Pressure
5. Spare 4
6. Operator OPLIM
7. Water Flow
8. Air Pressure from UV Sensor.
1.Use a multimeter and check
for 24 VAC on J11A,J11B to
identify which interlock has
tripped. Reset the Interlock or
check for disconnected wiring
or shorts.
2. All 120 VAC interlocks/Alarms
are located on J5. These include:
1.FLAME SAFE ALARM (Ignition
CTRL ALARM)
2. Valve Alarm (IRI ALARM)
3. XS_FACTORY (Reserved
4. HIGH LIMIT
1. Use a multimeter on J5 to
to check for 120 VAC on
these interlocks (except the
HIGH LIMIT). The High Limit
Interlock is displayed when
there is no 120 VAC, since
the HIGH LIMIT breaks the
120VAC to the Ignition
Control.
The Air Pressure from UV
Sensor interlock if displayed
will allow the boiler to
function, but it needs to be
functional while the boiler is
running for it to clear.
NOTE: Stray Voltages
Greater than 8 VAC and less
than 18 VAC on these
interlocks can cause
intermittant operation. If this
is the case, check for back
fed voltages from field wiring.
3. Internal Alarms
1. OPEN SENSOR
2. SHORTED SENSOR
3. COMBUSTION AIR DAMPER
Check sensor voltages at
J10A and J10B. The
Temperature sensor inputs
should be between 0 VDC
and 5 VDC measured across
the sensor. Example: At 77 F,
the voltage would read 2.5
VDC.
The combustion air damper
prove switch must be wired
across SPARE 1 and must be
a "DRY" contact. Do not
apply a voltage to this input,
the input supplies it's own
voltage/current.
2.
Proceed to HeatNet
Control Manual for
more details and
problem resolution.
34
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Figure 19 – Exploded View
SEE VIEW "B"
RIOM - 74
24
23
47
27
8
42
60A
10
39
SEE VIEW "C"
RIOM - 74
31
14
33
45
60
25
15A
29
15
15B
41
28
36
SEE VIEW "A"
RIOM - 74
37
57
30
40
32
46
35
38
33
13
RIOM-67 REV A
10
8
1
5
2
6
28A
8
1
3
27A
8
10
10
34A
9
4
2
11
1
45
RIOM-67 REV A
12
7
RIOM-67 REV A
5
35
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
36
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Futera III Model Size with Item Quantities Below
Ref #
1
Name of Part
Top/Bottom X Profile
Part #
500
750
1000
04-0523
3
3
3
2
2
2
04-0524
2
Middle X Profile
04-0525
04-0526
3
Top Y Profile
04-0530
4
4
Bottom Y Profile
04-0531
4
04-0532
4
4
1250
1500
1750
2000
3
3
3
3
2
2
2
2
4
4
4
4
4
04-0533
4
04-0534
4
04-0535
4
04-0536
4
04-0537
5
Top/Bottom Z Profile
4
04-0538
4
4
4
2
2
2
04-0539
6
Middle Z Profile
04-0540
04-0541
7
Bottom/Front X Profile
04-0527
1
1
1
04-0528
4
4
4
4
2
2
2
2
1
1
1
1
8
Frame Corner
20-0053
3
3
3
3
3
3
3
9
Frame Corner
04-0543
1
1
1
1
1
1
1
10
Crosses
20-0054
3
3
3
3
3
3
3
11
Drilled Crosses
04-0544
1
1
1
1
1
1
1
12
Bottom Corner
04-0542
4
4
4
4
4
4
4
13
Base Legs
04-0521
2
2
2
2
2
2
2
14
Gas Train Support Bracket Assembly
1
1
1
1
1
1
1
15
Burner Assembly for Turbo Pilot
04-0522
70-2343
70-2344
70-2529.1
1
70-2530.1
1
70-2531.1
1
70-2532.1
1
70-2533.1
1
70-2534.1
1
70-2535.1
15a
Transition Gasket
1
06-0026
1
1
1
06-0027
15b
Burner Gasket
1
06-0041
1
1
1
06-0042
16
1
1
1
1
1
1
1
Solenoid Valve w/Regulator, NG
11-0372
1
1
1
1
1
1
1
Solenoid Valve w/Regulator, LP*
11-0374
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
18
Gas Valve, DMV-SE512
11-0211
1
1
NS
Flange 1"
11-0212
2
2
NS
Flange 1 1/4"
11-0213
NS
Flange 1 1/2"
11-0214
NS
Orifice Gasket
06-0022
1
*Not used on turbo pilot assembly
37
1
1
1
1
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Futera III Model Size with Item Quantities Below
Ref #
NS
Name of Part
Orifice Plate
Part #
500
03-2911
1
03-2912
750
1000
1250
1500
1750
2000
1
03-2913
1
03-2914
1
03-2915
1
03-2916
1
03-2917
1
NS
Firing Valve 3/4"
NS
Manual Pilot Valve
11-0031
1
1
1
1
1
1
1
20
Ball Valve
11-0395
1
1
1
1
1
1
1
21
Firing Valve, 1"
11-0456
1
1
Firing Valve, 1 1/4"
11-0457
1
1
1
Firing Valve, 1 1/2"
11-0458
1
1
"A" Valve, 1"
11-0465
"A" Valve, 1 1/4"
11-0466
"A" Valve, 1 1/2"
11-0467
1
1
Blower, Fasco 7043
12-0016
Blower, Fasco 7035
12-0017
Mixing Box
70-2307
22
23
24
11-0461
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14-0203
1
1
1
1
1
1
1
14-0205
1
1
1
1
1
1
1
Flow Switch (Potter)
14-0201
1
1
1
1
1
1
1
Flow Switch (Outdoor Potter)
14-0202
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Frequency Drive
15-0231
1
1
1
Jacket Top Panel
70-2412
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
70-2413
Jacket Top Panel (Outdoor)
70-2440
70-2441
Upper Rear Panel
70-2414
70-2415
28A
Rear Panel (Outdoor)
70-2410
70-2411
29
Rear Pipe Enclosure Assembly
30
Lower Rear Jacket Panel
70-2333
70-2334
03-2822
1
03-2823
1
03-2824
1
03-2825
1
03-2826
1
03-2827
1
03-2828
31
Upper Left Jacket Panel
1
03-2831
1
1
1
03-2832
32
1
Flow Switch (Outdoor)
26
28
1
Flow Switch
27
27A
1
1
70-2308
25
1
Upper Right Jacket Panel
03-2833
1
03-2834
38
1
1
1
1
1
1
1
1
1
1
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Futera III Model Size with Item Quantities Below
Ref #
33
Name of Part
Lower Left & Right Jacket Panel
Part #
500
03-2835
2
03-2836
750
1000
1250
1500
1750
2
03-2837
2
03-2838
2
03-2839
2
03-2840
2
03-2841
34
Upper Front Jacket Panel (HeatNet)
2
70-2446
1
1
1
1
1
1
1
1
70-2447
1
34A
Front Jacket Panel (Outdoor)
70-2442
NS
Handle
20-0044
1
35
Lower Front Jacket Panel
70-2365
1
70-2443
70-2366
1
1
1
1
1
1
1
1
1
1
1
70-2368
1
70-2369
1
70-2370
1
70-2371
Combustion Chamber Top Panel
1
70-2356
1
1
1
3
3
70-2357
37
Manning Glass Insulation (per square foot)
05-0104
3
Combustion Chamber Rear/Side Panel
70-2319
1
70-2320
1
1
1
1
3
3
3
3
1
70-2321
1
70-2322
1
70-2323
1
70-2324
1
70-2325
Manning Glass Insulation (per square foot)
38
Combustion Chamber Door Assembly
1
05-0104
10
70-2358
1
70-2359
12
14
16
16
16
1
70-2361
1
70-2362
1
70-2363
1
70-2364
1
Manning Glass Insulation (per square foot)
05-0104
6
6
7
Pressure Relief Valve 50#
30-0360
1
1
1
Pressure Relief Valve 50#
30-0374
Pressure Relief Valve 50#
30-0379
Pressure Relief Valve 125#
30-0364
1
1
1
1
40
Latch
20-0046
2
2
2
41
Drain Valve Assembly (MB)
70-2561
1
1
1
1
1
1
1
1
1
70-2563
70-2564
NS
Drain Valve Gaskets
7
7
8
8
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
70-2562
Drain Valve Assembly (MW)
18
1
70-2360
39
1
1
70-2367
36
2000
06-0083
06-0084
39
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Futera III Model Size with Item Quantities Below
Ref #
42
Name of Part
Air Filter
Part #
500
750
1000
09-0483
1
1
1
09-0484
45
46
1250
1500
1750
2000
1
1
1
1
Tridicator 30 - 60 psi
13-0308
1
1
1
1
1
1
1
Tridicator 75 - 160 psi
13-0305
1
1
1
1
1
1
1
Heat Exchanger Assembly (Copper)
70-2515.1
1
Cast Iron Headers
70-2516.1
1
70-2517.1
1
70-2518.1
1
70-2519.1
1
70-2520.1
1
70-2521.1
Heat Exchanger Assembly (Copper)
Bronze Headers
1
70-2186.1
1
70-2187.1
1
70-2188.1
1
70-2189.1
1
70-2190.1
1
70-2191.1
1
70-2192.1
Heat Exchanger Assembly (Cupronickel)
70-2522.1
Cast Iron Headers
70-2523.1
1
1
1
70-2524.1
1
70-2525.1
1
70-2526.1
1
70-2527.1
1
70-2528.1
Heat Exchanger Assembly (Cupronickel)
Bronze Headers
1
70-2193.1
1
70-2194.1
1
70-2195.1
1
70-2196.1
1
70-2197.1
1
70-2198.1
1
70-2199.1
47
Air Damper Assembly
1
70-2352
1
1
1
70-2353
1
1
70-2354
1
1
48
High Limit, Jumo, (MB)
14-0013
1
1
1
1
1
1
1
High Limit, Jumo, (MW)
14-0014
1
1
1
1
1
1
1
NS
Operator, T6031A (pool heater)
14-0003
1
1
1
1
1
1
1
NS
Thermometer Well, 3/8 x 2
13-0102
2
2
2
2
2
2
2
NS
High Limit Well, 3/8 x 3
13-0104
2
2
2
2
2
2
2
NS
10K Temperature Sensor
14-0325
3
3
3
3
3
3
3
50
Transformer, 50 VA
15-0007
1
1
1
1
1
1
1
51
Purge Timer, ST7800
16-0007
1
1
1
1
1
1
1
52
Spark Generator, Q652B
16-0008
1
1
1
1
1
1
1
1
53
Flame Safeguard, RM7895C
16-0024R
1
1
1
1
1
1
NS
Keyboard Display Module, S7800A
16-0010
1
1
1
1
1
1
1
54
Main Board (HeatNet)
16-0038
1
1
1
1
1
1
1
55
Display Board (HeatNet)
40-0088
1
1
1
1
1
1
1
NS
Ferrite Clamp
16-0032
1
1
1
1
1
1
1
NS
Ribbon Cable 20" (HeatNet)
40-0115
1
1
1
1
1
1
1
40
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
Futera III Model Size with Item Quantities Below
Ref #
Name of Part
Part #
500
750
1000
1250
1500
1750
2000
NS
Power Switch
48-0013
1
1
1
1
1
1
1
NS
Toggle Switch
48-0010
1
1
1
1
1
1
1
56
Air Pressure Switch
11-0416
1
1
1
1
1
1
1
57
Blocked Flue Switch
11-0411
1
1
1
1
1
1
1
NS
Low Gas Pressure Switch (Manual Reset)
11-0414
1
1
1
1
1
1
1
NS
High Gas Pressure Switch (Manual Reset)
11-0411
1
1
1
1
1
1
1
NS
Terminal Block 6P
48-0157
1
1
1
1
1
1
1
NS
Terminal Block 4P
48-0161
1
1
1
1
1
1
1
NS
Resistor Assembly
70-9001
1
1
1
1
1
1
1
NS
UV Amplifier, R7849A
16-0006
1
1
1
1
1
1
1
NS
Base, Q7800A
16-0003
1
1
1
1
1
1
1
NS
Ignition Cable
44-0063
1
1
1
1
1
1
1
59
Control Box Panel
70-2372
1
1
1
1
1
1
1
1
1
1
1
1
1
1
70-2374
60
Transition Assembly
70-2305
70-2306
60a
Gasket
06-0043
1
1
1
06-0044
1
1
1
1
NS
Pump Contactor Relay
15-0137
1
1
1
1
1
1
1
NS
Rating Plate
82-0054
1
1
1
1
1
1
1
NS
Futera III Overlay (HeatNet)
82-0200
1
1
1
1
1
1
1
77
Keypad Overlay
82-0189
1
1
1
1
1
1
1
78
Mini Fan
12-0021
1
1
1
1
1
1
1
79
Air Shutoff Valve
11-0376
1
1
1
1
1
1
1
80
3/8" Aluminum Tubing
62-0102
2
2
2
2
2
2
2
81
.052 NG Orifice
10-0140
1
1
1
1
1
1
1
.040 LP Orifice
10-0139
1
1
1
1
1
1
1
82
UV Scanner
16-0009
1
1
1
1
1
1
1
1
1
1
1
83
Spark Plate Gasket
06-0110
1
1
1
NS
Spark Rod Assembly
70-2566
1
1
1
1
1
1
1
84
Electrode
16-0335
1
1
1
1
1
1
1
NS
Spark Rod O'ring
06-0008
1
1
1
1
1
1
1
NS
Electrode Retaining Collar
03-3755
1
1
1
1
1
1
1
NS
Retaining Collar Screws
57-0356
1
1
1
1
1
1
1
85
Flame Disc
10-0141
1
1
1
1
1
1
1
70-2567
86
1/2" Aluminum Tubing
62-0103
1
1
1
1
1
1
1
NS
Paint
66-0013
1
1
1
1
1
1
1
NS
Silicone
66-0151
1
1
1
1
1
1
1
NS
Vent Termination Hood 5"
09-0117
1
1
Vent Termination Hood 6"
09-0112
1
1
Vent Termination Hood 8"
09-0113
Vent Termination Hood 10"
09-0115
1
1
Air Intake Hood 6"
09-0102
Air Intake Hood 8"
09-0103
Air Intake Hood 10"
09-0104
Air Intake Hood 12"
09-0105
1
1
NS
1
1
1
1
1
1
41
START-UP REPORT
DATE:
JOB NAME:
TECHNICIAN:
LOCATION:
COMPANY:
MODEL:
PHONE NUMBER:
SERIAL #:
PRE-STA
T RTUP CHECK LIST
NO VISIBLE DAMAGE TO UNIT
PIPING PROPERLY CONNECTED
BOILER CIRCULATOR WIRED
VENT/STACK CONNECTED
INLET AIR FILTER INSTALLED AND CLEAN
PROPER SERVICE CLEARANCES PROVIDED
PUMP RUNNING, HEAT EXCHANGER FULL
GAS LINES PURGED, NO LEAKS, NO MISSING TEST
PLUGS
BOILER STA
T RTUP SEQUENCE
Note: Locate the AA terminals and minimum hold switch in the bottom-right of the electrical panel on the main
HeatNet board. Also locate the manometer test manifold in the bottom of the electrical panel.
1. Disable any external call for heat and toggle the remote/local switch to REMOTE.
2. Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition.
3. Set pressure to 3–3.5" w.c. (flame signal should read 5.0 VDC).
4. Release boiler to main flame trial for ignition.
5. Check for stable flame.
6. Record combustion and elbow pressure at minimum firing rate.
7. Jumper the AA terminals to force 100% input.
8. Record combustion and elbow pressure.
9. Remove the AA jumper to place the boiler at minimum rate.
10. Make any final adjustments on low fire.
11. Check all combustion results using a calibrated flue gas analyzer.
12. Release the LOW FIRE switch to place boiler in standby.
In addition to completing the Fusion/Futera III start-up report, complete the control set-up information in
the rear of the HeatNet manual.
42
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
COMBUSTION ANALYSIS
L
MINIMUM FIRING RATE
A
GAS PRESSURE AT ELBOW TEST PORT
100% FIRING RATE
A
INCHES W.C.
INCHES W.C.
CO2
%
%
O2
%
%
PPM
PPM
CO (PPM)
o
o
F
NET STACK TEMPERATURE
ELBOW PRESSURE (W.C.)
F
INCHES W.C.
INCHES W.C.
SAFETY TEST CHECKLIST
FLOW SWITCHES
AIR SWITCH
FLAME SAFEGUARD
LOW WATER CUT-OFF
HIGH LIMITS
Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140°F, 60°C. 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
A
HEATER
A
THE DELTA T BETWEEN THE HEATER INLET AND OUTLET IS CRITICAL TO PROPER FLOW. BEFORE YOU LEAVE THE JOBSITE, YOU MUST RECORD THE DELTA T.
THIS READING SHOULD NOT EXCEED
35oF, 19.4oC, NOR BE LOWER THAN 20oF,
11.1oC.
UNIT CYCLED MINIMUM OF 15 TIMES
CUSTOMER INSTRUCTED
ALL COVERS REPLACED
CUSTOMER GIVEN MANUAL
TARGET TEMPERATURE SET PER CUSTOMER
COMMISSIONED BY: ______________________________________
(SIGNATURE)
DATE: ____________________________
ADDITIONAL NOTES AND COMMENTS
43
DELTA T =
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
MACODE-3
NOTICE!
Commonwealth of Massachusetts
Installation Requirements
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building
or structure used in whole or in part for residential purposes, including those owned or operated
by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet
above finished grade, in the area of the venting, including but not limited to decks and porches,
the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard
wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe
that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the side wall horizontal vented gas
fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified
licensed professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl
space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may
be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a battery operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in
accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and
IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal
for the horizontally vented gas fueled heating appliance or equipment. The 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”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
WARNING: Improper venting can result in excessive levels of carbon monoxide which can
cause severe personal injury or death!
44
MACODE-3
NOTICE!
Commonwealth of Massachusetts
Installation Requirements
In the Commonwealth of Massachusetts, the installation
must be performed by a licensed plumber or gas fitter.
(b) Exemptions
The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most
current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or
structure separate from the dwelling, building or structure used in whole or in part for residential
purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a
venting system design or venting system components with the equipment, the instructions provided by
the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does
not provide the parts for venting the flue gases, but identifies “special venting systems”, the following
requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or
equipment installation instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that
system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of
the installation.
WARNING: Improper venting can result in excessive levels of carbon monoxide which can
cause severe personal injury or death!
45
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
46
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS
47
LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the
Industrial, Commercial, and other Non-Residential Use Boiler (the “Product”) will be free from defects in material or
workmanship for ten (10) years from the date of installation. Additional twenty one (21) year thermal shock warranty
on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or
workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in
material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the
Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in
material or workmanship for five (5) years from the date of installation. Additional twenty one (21) year thermal warranty
on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or
workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in
material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
This limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has
not been installed, maintained or operated in accordance with the furnished written instructions, or has been
altered or modified in any way.
These include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the
equipment and is not covered under the manufacturer’s warranty.
• Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity
through the tubes and is not covered by the manufacturer’s warranty. (See Installation Instructions for
proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or
any chemicals that produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the
heating equipment and voids the warranty.
• All copper fin boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric
combustion, 125°F, 52°C fan assist combustion. If a lower temperature is required, an external bypass should be
installed to prevent condensation. The manufacturer’s warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the the Product or
parts thereof.
(c) to damage as a result of settlement, distortion, collapse, or cracking of any foundation area, beams or pipes
surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United
States or Canada.
This limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned
with prior written approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or
workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with
respect to such repaired or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND
EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN
ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE
WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY
PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF
THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY
EACH JURISDICTION.
260 North Elm Street
7555 Tranmere Drive
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