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FTFX-I0M-2
82-0347
Finned Copper Tube
Gas Boilers (CB) &
Water Heaters (CW)
& Pool Heaters (CP)
Boiler Manual
Installation and Operation
Instructions
Also read and follow:
HeatNet Control Manual
Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
Construction dust and particulate, particularly drywall dust, will cause contamination of the burner, resulting in possible severe personal injury, death or substantial property damage. Th e boiler can only be operated with a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service technician, and to follow all guidelines in the User’s Information Manual.
Copyright 2012 Mestek, Inc.
If the information in this manual is not followed exactly, a fi re or explosion may result causing property, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other applianc
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données dans cett e notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides infl ammables à proximité de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.
L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifi é ou par le fournisseur de gaz.
Failure to properly vent this unit can cause excessive amounts of carbon monoxide resulting in severe personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRES-
SURE OF 125 PSI, 862 kPa WATER.
BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 2
RATINGS & CAPACITIES . . . . . . . . . . . . . . . . . . 3
BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 3
COMBUSTION AIR & VENTILATION . . . . . . . . . . . . . 3
GENERAL VENTING GUIDELINES. . . . . . . . . . . . . . 5
OUTDOOR VENTING . . . . . . . . . . . . . . . . . . . . . 10
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . 11
HEATING SYSTEM PIPING . . . . . . . . . . . . . . . . . 12
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . . 16
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . 20
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . 21
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . 22
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 22
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . 25
CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . . 26
HEATNET FIELD WIRING . . . . . . . . . . . . . . . . . . 27
CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . 28
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . 34
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . 35
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . . 41
MASS CODE . . . . . . . . . . . . . . . . . . . . . . . . . 43
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . 44
BEFORE YOU START
Th is manual covers the application, installation, operation and maintenance of a Futera Series fi nned copper heating boiler/water heater/pool heater.
To obtain the safe, dependable, effi cient operation and long life for which this heating boiler was designed, these instructions must be read, understood and followed.
Th e Futera Fusion Series fi nned copper heating boiler/water heaters have been design certifi ed by CSA for use with natural and propane gas under the latest revision of ANSI-Z21.10.3/CSA 4.3/Gas Water
Heaters, ANSI-Z21.3/CSA 4.9, Gas-fi red Low Pressure Steam and
Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired Pool Heaters and Can 1-3.1, Industrial and Commercial Gas Fired Packaged
Boilers. Each unit has been constructed and hydrostatically tested for a maximum working pressure of 125 psi, 862 kPa in accordance with Section IV of the A.S.M.E. Boiler and Pressure Vessel Code.
All aspects of the boiler 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.
2
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 Massachusett s, you MUST
FOLLOW the additional instructions contained in RBI’s instruction sheet MACODE-3. Which is located in the back of this manual.
Th e owner should maintain a record of all service work performed with the date and a description of the work done. Include the name of the service organization for future reference.
Direct all questions to your RBI distributor or contact the RBI
Customer Service Department at: 260 North Elm Street, Westfi eld,
MA 01085 for US or 7555 Tranmere Drive, Mississauga ONT L5S
1L4 for Canada. Always include the model and serial numbers from the rating plate of the boiler in question. For information utilizing the Fusion as a pool heater, see Addendum (UMPH) - Fusion Series
Gas Pool Heater.
RATINGS & CAPACITIES
Before undertaking the installation of the Futera Series boiler check the rating plate to ensure that the unit has been sized properly for the job. Th e “Net AHRI 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.
2. An optimum site will be level, central to the piping system, close to a chimney or outside wall and have adequate fresh air for combustion. Ensure that the boiler is level from front to back and from side to side. Use metal shims to level the boiler.
Electrical and electronic components must also be protected from exposure to water during operation and maintenance. DO
NOT install this boiler in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing.
3. Ensure that the fl oor is structurally sound and will support the weight of the boiler.
Th e Futera may be installed directly on combustible fl ooring, but never on carpeting.
4. Locate the boiler/water heater in an area that will prevent water damage to adjacent construction should a leak occur or during routine maintenance. If such a location doesn’t exist, a suitable drain pan that’s adequately drained must be installed under the unit.
5. DO NOT place this boiler/water heater in a location that would restrict the introduction of combustion air into the unit or sub-
L VENTING
GUIDELINES”.
6. NEVER place this boiler/water heater in a location that would subject it to temperatures at or near freezing, see the “FREEZE
PROTECTION” section on page 11.
Never store combustible materials, gasoline or any product containing fl ammable vapors or liquids in the vicinity of the boiler/water heater. Failure to comply with this warning can result in an explosion or fi re causing extensive property damage, severe personal injury or death!
BOILER/WATER HEATER LOCATION
1. Th is boiler/water heater is suitable for indoor and outdoor installations. Locate the boiler/water heater in an area that provides good access to the unit. Servicing may require the removal of jacket panels. Allow the minimum clearances between adjacent construction and the boiler/water heater as listed in Table 1.
Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.
Table 1
Top
Back
Left Side
Right Side
Front
Clearance to
Combustibles in mm
6
6
6
153
153
153
6 153
6 153
Service
Clearance in mm
30
24
24
24
30
762
610
306
306
762
COMBUSTION AIR & VENTILATION
Th is boiler/water heater must be supplied with combustion air in accordance with Section 5.3, Air for Combustion & Ventilation, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and all applicable local building codes. Canadian installations must comply with CAN/CGA B149.1 or
.2 Installation Code for Gas Burning Appliances and
Equipment, or applicable provisions of the local building codes. Failure to provide adequate combustion air for this boiler/water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
To operate properly and safely this boiler/water heater requires a continuous supply of air for combustion. NEVER store objects on or around the boiler/water heater!
3
Combustion air contaminated with fl uorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber. Th ese acids will cause premature failure of the boiler voiding the warranty!
If the boiler is operated while the building is under construction it MUST be protected from wood, concrete, sheet rock and other types of dust. Failure to properly protect the unit from construction dust will damage the unit voiding the warranty!
Buildings will require the installation of a fresh air duct or other means of providing make-up air if the intake air option isn’t used.
Any building utilizing other gas burning appliances, a fi replace, wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time. Sizing of an outside air duct must be done to meet the requirements of all such devices.
Never operate the Futera 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!
Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in 2 /4000 Btu/hr, 550 mm 2 /kW of the total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in 2 /
2000 Btu/hr, 1100 mm 2 /kW of the total input rating of all of the equipment in the enclosure.
When ducts are used, they must have the same cross-sectional area as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air requirements of the enclosure, consideration must be given to the blockage eff ects 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 fl ow from the outdoors for
natural draft , partial fan-assisted, fan-assisted, or power draft assisted burners, there shall be a permanent air supply opening(s) having a cross-sectional area of not less than 1 in 2 per 7,000
Btuh (310 mm 2 per kW) up to and including 1 million Btuh, plus 1 in 2 per 14,000 Btuh (155 mm 2 per kW) in excess of
1 million Btuh.
All Air From Inside The Building
If the Futera is to be located in a confi ned space, the minimum clearances listed in Table 1 must be maintained between it and any combustible construction. When installed in a confi ned space
without the intake air option, Figures 5 and 6, two permanent openings communicating with an additional room(s) are required.
Th e combined volume of these spaces must have suffi cient volume to meet the criteria for an unconfi ned space. Th e total air requirements of all gas utilization equipment, fi replaces, wood stoves or any type of exhaust fan must be considered when making this determination. Each opening must have a minimum free area of
1 in 2 /1000 Btu/hr, 2200 mm 2 /kW based on the total input rating of ALL gas utilization equipment in the confi ned area. Each opening must be no less than 100 in 2 , 64,516 mm 2 in size. Th e upper opening must be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the top of the enclosure. Th e bott om opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the bott om of the enclosure.
All Air From Outside The Building
When installed in a confi ned space without utilizing the intake
air option two permanent openings communicating directly with, or by ducts to, the outdoors or spaces that freely communicate with the outdoors must be present. Th e upper opening must be within 12 in, 305 mm of, but not less than 3 in, 76 mm from, the top of the enclosure. Th e bott om opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the bott om of the enclosure.
Table 2 Make-up Air Louver Sizing
Required Cross Sectional Area
1/4 in 6.4 mm 75% Free Area
Input
(MBH)
Wire Screen in 2 cm 2
Metal Louvers in 2 cm 2
25% Free Area
Wooden Louvers in 2 cm 2
2500 625 4031
3000 750 4838
3500 875 5645
4000 1000 6452
833 5382
1000 6452
1167 7522
1334 8592
2500 16,127
3000 19,354
3500 22,581
4000 25,808
Intake Air Option – General Guidelines
Th is confi guration provides combustion air directly to the boiler’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.
Common intake air systems may be used provided the common duct is sized properly. An intake combustion air damper should be installed if the common vent option is used in the intake air pipe of each heater. Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
Single wall galvanized smoke pipe, single wall aluminum pipe, fl exible aluminum pipe, PVC or CPVC pipe can be used for the intake air pipe. It must be sized per Table 3.
4
Table 3 Intake Air Pipe Sizing (Up to 100’)
Model
MBH
2500/3000
3500/4000
in
10
12
Vertical mm
254
305
8
10
Horizontal
in mm
203
254
Note: Max horizontal/vertical intake pipe 100’ equivalent.
GENERAL VENTING GUIDELINES
Th e vent installation must be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54-latest revision or applicable provisions of the local building codes. Canadian installations must comply with CAN/CGA B149.1 or .2 Installation Code. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
All vent systems must be fully supported by the building structure and not by the boiler/water heater. Appropriate thimbles and fi restops must be used where required.
Common vent systems must be properly engineered and sized, please contact the factory. It is required that the boiler nearest the vertical chimney be fi red fi rst when the horizontal distance exceeds 50% of the vertical distance. Refer to HeatNet manual on how to select the lead boiler.
A UL listed stainless steel vent system must be used unless this unit is fi tt ed with an RBI supplied nonmetallic vent kit. Failure to comply with this warning can cause excessive levels of carbon monoxide resulting in severe illness and death!
For instructions utilizing the non-metallic vent option, see Addendum (FTF-PVCVO) for PVC and (FTF-
PPVO) for Polypropylene.
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
e combustion air system MUST be supported by the building structure not the boiler/water heater.
A combustion air damper interlocked with the unit should be installed in the intake air pipe when the infi ltration of subfreezing air could occur, otherwise the unit could freeze up voiding the warranty!
Intake Air Option – Vertical Guidelines
Th e maximum equivalent length for the vertical intake air pipe is
100 ft , 30.5 m. Each 90° elbow and the intake air terminal are equal to 10 linear ft , 3.0 m of pipe, see Table 3.
An approved, nonrestrictive intake air terminal must be used. Th e intake air terminal must terminate as shown in Figure 3. Th e penetration point in the roof must be properly fl ashed and sealed.
Intake Air Option – Horizontal Guidelines
Th e maximum equivalent length for the horizontal intake air pipe is 100 ft , 30.5 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. Th e certifi ed intake air terminal from RBI must be used, see Figures 1, 2 and 4.
Vent System Options
Th e fl ue products in the vent system may be cooled below their dew point and form condensate in the fl ue. Th e materials used for a Category IV vent must be resistant to any corrosive damage from fl ue gas condensate. Th e fl ue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system.
Th e Futera Fusion may be vented the following ways:
1) Direct Vent, Positive Pressure, Category IV uses a vent system certifi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air is piped from the outdoors to the blower inlet.
2) Side Wall Vent, Positive Pressure, Category IV uses a vent system certifi ed to UL 1738 for installations in the
United States, ULC S636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
To ensure proper operation, boilers that are vented side wall and use room air must not be fi red less than
33% input.
3) Vertical Vent, Positive Pressure, Category IV uses a vent system certifi ed to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air is obtained from the outdoors or the space in which the unit is installed.
4) Vertical Vent, Negative Pressure, Category II (common
venting) requires negative pressure in vent (natural draft ).
Requires a metal chimney system approved for Category II venting. Th is method is required if common venting multiple
Fusion boilers.
All venting and combustion air material supplied by installer. All venting materials must be approved for the application. Consult the vent manufacturer’s product literature.
Th e maximum equivalent length for the fl ue outlet vent system for Category IV conditions is 100 ft ,
30.5 m. Use Table 4 for the equivalent lengths per fi tt ing. Table 4 - “Category IV Equivalent Length per
Fitt ing” chart is meant as a guideline for preliminary sizing. If vent length approaches 75% of maximum length listed, an engineered vent system calculation must be performed, consult factory.
5
Table 4 Category IV Equivalent Length Per Fitting
Model/Outlet
Diameter
Standard Tee
Boot Tee
*K
1.25
0.65
CB500
7"
15 ft
CB750
7"
15 ft
Equivalent Feet of Straight Pipe
CB1000
7"
15 ft
CB1250
8"
25 ft 25 ft 30 ft 30 ft
15 ft
CB1500
8"
35 ft
15 ft
CB1750
10"
40 ft
20 ft
CB2000
10"
40 ft
20 ft
Cap - Low Res (UL) 0.50
10 ft 10 ft 10 ft 10 ft 10 ft 15 ft 15 ft
45° w/Bird Screen 0.40
10 ft 10 ft 10 ft 10 ft 10 ft 10 ft 10 ft
Elbow - 90°
Elbow - 45°
0.38
0.15
10 ft
5 ft
10 ft
5 ft
10 ft
5 ft
10 ft
5 ft
10 ft
5 ft
15 ft
5 ft
15 ft
5 ft
*Equivalent lengths based on listed K - factors and (5X) pipe diameters straight length between fi ttings.
If any part of a single wall metal vent system passes through an unheated space, it must be insulated with insulation rated for 400°F,
204°C. Structural penetrations must be made using approved fi restops. For best results, horizontal vent systems should be as short and straight as possible.
Th e 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. Th e 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.
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. Th e bott om 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 aff ected by winds, snowdrift s, people and pets. Protect building materials and vegetation from degradation caused by the fl ue gases.
Must consult factory when venting single or multiple unit(s) over 100 equivalent feet. Mechanical system may be required.
Direct Vent, Positive Pressure,
Cateory IV
In this confi guration the boiler blower is used to push the fl ue products to the outdoors while drawing combustion air from the outdoors. Th e Intake Air Option instructions under the
“COMBUSTION AIR & VENTILATION” section must be followed! Th e vent system must be sized per Table 4.
Horizontal Direct Vent Systems –
Figures 1 & 2
Th e vent materials used in horizontal vent systems must be certifi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. Th e certifi ed vent terminal from RBI must also be used.
Vertical Direct Vent Systems – Figure 3
If any part of a single wall metal vent system passes through an unheated space, it must be insulated with insulation rated for 400°F,
204°C. Structural penetrations must be made using approved fi restops.
An approved, nonrestrictive vent terminal must be used. Th e top of a vertical vent system must extend at least 5 1 /
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.
In addition the vent system must conform to the dimensions shown in Figure 3. Th e penetration point in the roof must be properly fl ashed and sealed.
Th e vent system must be gas tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.
Combination Direct Vent Systems – Figure 4
Th e boiler 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 &
L VENTING GUIDELINES” sections.
6
Figure 1 Horizontal Air Intake and Venting for a Single Direct Vent System
1/4 IN. PER FOOT
20 mm/m
10 FT 3.1 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 diff erences due to prevailing winds. In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.
Figure 2 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
MBH
500 TO 1000
1001 TO 2000
2001 TO 4000
4001 & LARGER kW
146 TO 293
293 TO 586
586 TO 1172
1172 & LARGER
FT m
5 1.5
10 3.1
15 4.6
20 6.1 5 FT 1.5 m
1.5 FT 0.5 m
2 IN. 5.0 cm
7
Figure 3 Vertical Air Intake and Venting for a Direct Vent System
Locate exhaust terminal downwind to reduce fl ue gas recirculation.
10 FT 3.1 m
4 FT
1.2 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
5 FT
1.5 m
Figure 4 Horizontal Air Intake and Venting for Multiple Direct Vent Systems
8
Side Wall Vent, Positive Pressure,
Category IV – Figure 5
In this confi guration the boiler blower is used to push the fl ue products horizontally to the outdoors, see Figure 5. Th e air for combustion is taken from the space in which the unit is installed.
Th e applicable instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! Th e vent guidelines under the Horizontal Direct Vent Systems section must also be followed.
Figure 6 Vertical Venting with a Metal Chimney System
See Table 4, page 6 for minimum pipe dimensions
Figure 5 Side Wall Venting
To ensure proper operation, boilers that are vented side wall and use room air must not be fi red less than
33% input.
Vertical Vent, Positive Pressure,
Category IV – Figure 6
(Vent pipe equivalent length up to 100 ft , 30.5 m maximum)
Masonry chimneys, when used, must be lined with a metal liner certifi ed for Category IV venting.
A through inspection of the masonry chimney must be performed to ensure that the chimney is clean, properly constructed lined, and sized. Exterior masonry chimneys should not be used unless properly lined to prevent condensation and draft problems.
Vertical Chimney Venting
Negative pressure — Category II
(Common Venting)
Category II venting is required for multiple Fusion
XLF boilers connected to a common vent. Common vent systems cannot be pressurized.
Th e Fusion XLF is listed as a Category II appliance when vented vertically into a listed metal chimney system. Th e chimney must provide a negative pressure not greater than 0.10 in, 2.5 mm WC at the boiler fl ue collar with the unit running.
When using a listed metal chimney system the chimney system manufacturer’s instructions must be followed.
9
Th e vent piping must be large enough to safely vent the combined output of all of the appliances connected to the system.
If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney fl ue, never connect any other appliances to this fl ue. Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
Always provide a minimum clearance of 6 in, 152 mm between single wall vent pipe and any combustible materials.
Exit cones are favorable when used to increase the velocity of the fl ue gas exiting the stack and, may also help, in cold climates, to reduce ice buildup. Exit cone terminations must be supplied by others, installed per manufacturer’s instructions, and meet local and federal code.
generic exit cone
Category II Chimney Inspection & sizing
Masonry chimneys, when used, must be lined with a metal liner certifi ed for Category IV venting.
A thorough inspection of the masonry chimney must be performed to ensure that the chimney is clean, properly constructed, lined and sized. Exterior masonry chimneys should not be used unless properly lined to prevent draft problems.
Table 5 lists the minimum riser sizes required for the Fusion boiler.
When using a listed metal chimney system the chimney system manufacturer’s instructions must be followed.
Failure to maintain minimum clearances between vent connectors and any combustible materials can result in a fi re causing extensive property damage , severe personal injury or death!
Table 5 Riser Diameters To Common Vent For Category II Venting
Input MBH
2500/3000
3500/4000 in
12
14 mm
305
356
Note: These sizes are based on a 20 ft, 6.1 m chimney height.
Category II Vent Connections
Locate the boiler 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.
Th e boiler vent connectors should be sloped up toward the breeching at a minimum rate of 1/4 in per ft , 21 mm per m.
Always provide a minimum clearance of 6 in, 152 mm between single wall vent pipe and any combustible materials.
Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fi re causing extensive property damage, severe personal injury or death!
Vent Connections
Locate the boiler 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.
Th e vent connector should be sloped up toward the chimney at a minimum rate of 1/4 in/ft , 21 mm/m. On masonry chimneys the connector must terminate fl ush with the inside of the chimney fl ue.
OUTDOOR VENTING
When installed outdoors the Futera Fusion must be fi tt ed with the factory supplied outdoor hood, air intake adapter with fi lter and exhaust terminal, see Figure 7. Multiple units must be spaced per
Figure 8.
Th e 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 diff erently.
Avoid locations where wind defl ection off of adjacent walls, buildings or shrubbery might cause a downdraft . Th e unit(s) should be located at least 3 ft , 1 m from structures. Outdoor installations are not recommended in areas where the danger of snow blockage exists.
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!
Outdoor Installations
Th e Futera Boiler is certifi ed for outside installations in temperate climates only.
1. Th e condensate traps located under the secondary heat exchanger and the vent pipe must be wrapped with heat tape to ensure the traps never drop below 32°F.
2. Th e vent pipe must be insulated to prevent freezing of condensate in the pipe.
3. Th e boiler and system must be fi lled with an ethylene glycol/ water antifreeze mixture not to exceed 50% glycol by volume.
4. All water piping exposed to low temperatures must be insulated.
10
Figure 7 Outdoor Venting
Figure 8 Multiple Outdoor
2 FT
(0.62 M)
3 FT
(1 M)
RIOM-60 REV. A
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler will void the manufacturer’s warranty and can cause boiler failure resulting in fl ooding 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 pitt ing and
erosion of the internal surface of the copper heat exchanger tubes is NOT covered under the manufacturer’s warranty if the result of high water fl ow rates.
Shut off valves and unions should be installed at the inlet and outlet connections of the boiler to provide for isolation of the unit should servicing be necessary.
Freeze Protection
Installations in areas where the danger of freezing exists are not recommended unless proper freeze protection is provided. Th e following precautions MUST be observed:
1. A continuous fl ow of water through the unit MUST be maintained!
Th e pump responsible for fl ow through the boiler must run continuously!
2. An ethylene glycol/water mixture suitable for the minimum temperature that the unit will be exposed to must be used.
Th e boiler on board pump is capable of producing the required fl ow for systems maintaining a maximum 30% glycol water mixture. For mixtures higher than 30% ethylene glycol please contact factory. Domestic water systems must be isolated from the water heater by the use of a heat exchanger or other approved method.
3. If the unit must be shut off for any reason the electric, gas and water supplies MUST be shut off and the unit and its pump completely drained.
Improper outdoor installation of this unit can cause boiler failure voiding the manufacturer’s warranty!
Condensate Piping
Th e condensate trap provided with the boiler must be att ached to the bott om pan and piped to a suitable fl oor drain or condensate pump. If a condensate neutralization device is installed, it must be positioned prior to boiler room drain. Condensate fi ll trap must be maintained with fl uid.
Relief Valve
Pipe the discharge of the pressure relief valve as shown in Figure 9.
Never install any type of valve between the boiler and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!
11
Flow Switch
Th e fl ow switch supplied with the boiler must be wired to the terminal strip in the control panel to prevent the boiler from fi ring unless there’s adequate water fl ow through the unit. Th e fl ow switch must be installed in the supply piping adjacent to the boiler outlet connection.
Failure to properly install the fl ow switch may result in damage to the boiler heat exchanger voiding the warranty!
Pump Requirements
This low mass boiler requires a continuous minimum water flow across the primary heat exchanger for proper operation. Th e boiler pump is sized to overcome the head loss of the boiler primary and secondary heat exchanger and the near piping in order to achieve the required fl ow. Th e temperature rise across the primary heat exchanger must never exceed 35°F, 19.4°C. See Tables 8 and 9 for the total boiler recovery rate (gph) and inlet/outlet delta t based on the desired boiler inlet temperature. Th e adjustable pump delay turns the pump on each time the burner fi res and runs the pump for 20 to 600 seconds aft er the call for heat is satisfi ed.
Th e maximum allowable primary heat exchanger temperature rise is 35°F, 19.4°C.
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualifi ed technician in accordance with the latest revision of the ANSI/ASME Boiler and
Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1,
Standard for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must also be followed. A minimum clearance of 1 in, 25 mm must be maintained between heating system pipes and all combustible construction.
All heating system piping must be supported by suitable hangers not the boiler. Th e thermal expansion of the system must be considered when supporting the system. A minimum system pressure of 12 psig, 82.7 kPa must be maintained.
Factory Supplied - On Board - Circulating Pump
Th e factory installed - on board - pump is sized to work the total boiler head loss plus an additional (30 ft ) of pipe and (6 elbows).
Please consult factory for systems outside these parameters.
Low Water Cutoff
If a boiler is installed above any radiation elements it must be fi tt ed with a low water cutoff device.
Refer to the wiring diagram supplied with the boiler for proper wiring connections.
Bleed Air From Boiler
Open the boiler piping bleed valves one at a time, to purge the air trapped in the primary and secondary heat exchangers. Refer to piping drawings (Figures 7, 8 & 9) for bleed locations.
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.
Heating Boiler Piping Connections
Th e supply and return connections should be sized to suit the system, see Table 6.
Primary/Secondary Piping
Figure 10 shows a typical primary/secondary piping system. Boilers connected to heating systems using zone valves, zone pumps, or systems that have excessive fl ow rates must be isolated from these systems to protect the boiler.
Table 6 Supply & Return Pipe Sizing
Input MBH
2500 thru 4000
Supply Size
3 in FLANGE
Return Size
3 in FLANGE
Pump sizing based on the following: total boiler head loss plus 30 feet of piping and a maximum of six (6)
90° elbows and based on supply and return pipe diameter of 3" on 2500-3000 and 4" on 3500-4000.
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
Th e boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler. Appropriate valves must be used to prevent the chilled water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed to refrigerated air from an air handling device, the piping system must be equipped with fl ow-control valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle.
12
Figure 9 Fusion XLF Secondary Bypass Piping
Item
Number Description
7
8
5
6
3
4
1
2
3-Way Valve
Air Purging Valves
Flow Switch
Circulator
Pressure Relief Valve
T & P Gauge
Primary Heat Exchanger Drain Valves
Condensate Drain Trap
Notes:
1. Fill condensate drain trap with water or approved anti-freeze solution prior to start up.
2. Air purging valve may be located on pump fl ange.
P u m p
V al v e
B al a nc e V a lv e
P r e s s u r e
R e d u c i n g V al v e
C h e c k V al v e
P r e s s u r e
R e l i e f V al v e
F l o w S w i t c h
T h e r m o m e t e r
A qu a st a t U nio n
A ut o m a ti c
A i r Ven t
T e m p era t u r e &
P r e s s u r e
R e l i ef Va l v e
V a c u u m
R e l i e f V al v e
D r a i n V al v e
( T y p .)
3 - W a y
M i x i n g V al v e
13
Figure 10 Typical Primary/Secondary, Low Temperature Piping System (See Notes)
H-16 REV C
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit.
2. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is fi lled. Use purge valves provided. Purge valve may be located on pump fl ange. On multiple boiler installations the fl ow switch may fail due to trapped air. See manual for procedure.
3. All boilers furnished with factory mounted outlet water temperature gauge.
4. For HeatNet operation, a sensor is required and installed at a minimum of 12 inches from the primary tee.
Notice: These drawings show suggested piping confi guration, valving and are diagrammatic.
Check with local codes and ordinances for specifi c requirements.
14
Figure 11 Multiple Boiler Piping (See Notes)
H-17 REV C
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum fl ow through each unit.
2. System loop pipe diameter must be sized large enough to handle maximum fl ow through all units.
3. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is fi lled. Use purge valves provided. Purge valve may be located on pump fl ange. On multiple boiler installations the fl ow switch may fail due to trapped air. See manual for procedure.
4. All boilers furnished with factory mounted outlet water temperature gauge.
5. Condensate lines on each unit should be connected to a fl oor drain.
6. For HeatNet operation, a sensor is required and installation at a minimum of 12 inches from primary loop tee.
Notice: These drawings show suggested piping confi guration, valving and are diagrammatic.
Check with local codes and ordinances for specifi c requirements.
15
DOMESTIC WATER SUPPLY PIPING
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 temperature less than 120°F, 49°C. Local codes must be complied with!
General Piping Requirements
Th e Fusion XLF boiler can be used in combination with an indirect tank to provide hot water for domestic use. Piping and components must be suitable for use with potable water. Th e indirect storage tank must be equipped with a temperature and pressure relief valve that complies with ANSI Z21.22 or CAN-4.4 and CAN-4.6.
Th e storage tank must be located as close to the unit heater as possible to prevent excessive head loss which will reduce fl ow.
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 7. 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.
Expansion Tank
An expansion tank or other means to control thermal expansion must be installed in the water heating system if back fl ow prevention devices are installed.
Bleed Air From Unit Heater
Open the unit heater piping bleed valves one at a time, to purge the air trapped in the primary and secondary heat exchangers. Refer to piping drawings (Figures 10 & 11) for bleed locations.
Pump Requirements
Th is low-mass water heater requires a continuous minimum water fl ow for proper operation. Th e proper velocity through the unit heater must be maintained for effi cient operation and long life. If the temperature rise through the primary heat exchanger is lower than recommended the water velocity is too high. Premature erosion of the primary heat exchanger will occur. Conversely, if the temperature rise is too high, the fl ow rate is too low. Scaling and soft ening of the
e temperature rise across
the primary heat exchanger must never exceed 35°F, 19.4°C.
Th e factory mounted circulatory pump is sized to work the total boiler pressure drop and an additional 30 ft . of pipe and 6-90° elbows.
Water Chemistry
Th e required temperature rise across the primary heat exchanger is based on water having a hardness between 8 and 18 grains per gallon with a level of dissolved solids not exceeding 350 ppm. Water having a hardness less than 8 grains can cause excessive corrosion of the heat exchanger. Water that has a hardness greater than 18 grains per gallon and/or a level of dissolved solids exceeding 350 ppm will require a recalculation of the pump size and temperature rise.
A cupro-nickel primary heat exchanger may also be required. Th e manufacturer should be consulted when these water conditions are encountered. See Table 7.
Storage Tank Thermostatic Mixing Valve
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.
Th e mixing valve MUST be set to prevent a scald injury from occurring, see the caution against scalding.
Storage of water for domestic use above 140°F, 60°C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria.
16
Table 7 Futera Fusion Primary Heat Exchanger Selection Graph
For hard/soft water pump selection, must consult factory.
Table 8
Table 9
Delta T/Boiler Recovery Table - Fahrenheit
Inlet
Temp
(deg f)
60
80
100
120
140
2500
Flow
Rate
(gph)
2794
3316
4203
5903
10,457
Δt
(deg f)
105
85
65
45
25
Flow
Rate
(gph)
3171
3717
4617
6250
9804
Model
3000 3500
Δt
(deg f)
111
91
71
51
32
Flow
Rate
(gph)
3700
4337
5386
7292
11,438
Δt
(deg f)
111
91
71
51
32
4000
Flow
Rate
(gph)
4228
4956
6156
8334
13,072
Δt
(deg f)
111
91
71
51
32
Delta T/Boiler Recovery Table - Centigrade
Inlet
Temp
(deg c)
16
27
38
49
60
Flow
Rate
(l/h)
2500
Δt
(deg c)
10,560
12,536
15,886
22,314
39,529
58
47
36
25
14
Flow
Rate
(l/h)
11,987
14,051
17,452
23,627
37,058
Model
3000 3500
Δt
(deg c)
62
51
39
28
18
Flow
Rate
(l/h)
13,984
16,393
20,360
27,564
43,234
Δt
(deg c)
62
51
39
28
18
Flow
Rate
(l/h)
4000
Δt
(deg c)
15,982
18,735
23,269
31,502
49,411
62
51
39
28
18
17
Figure 12 Typical Unit Heating Piping (See Notes)
NOTES:
1. Locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound.
2. Thermal expansion tank may be required, check local codes.
3. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.
Be sure to specify when ordering the pH and water hardness. This must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph before making selection.
4. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
5. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.
6. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is fi lled. Use purge valves provided. Purge valve may be located on pump fl ange. On multiple boiler installations the fl ow switch may fail due to trapped air. See manual procedure.
Notice: These drawings show suggested piping confi guration and valving. Check with local codes and ordinances for specifi c requirements
.
18
Figure 13 Multiple Unit Heating Piping (See Notes)
NOTES:
1. Optional cold water make up and recirculation line location.
2. Locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound. For multiple tanks, self balancing reverse-return systems, a single HeatNet sensor is applied.
3. Thermal expansion tank may be required, check local codes.
4. CAUTION: TEST WATER HARDNESS AND pH AT JOB SITE.
Be sure to specify when ordering the pH and water hardness. This must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph before making selection.
5. Common piping must be sized for maximum combined heater fl ow.
6. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
7. MA Code requires an 1/8 in hole in check valve to compensate for thermal expansion.
8. Boiler and pump purging required. Air must be purged from 3-way valve after boiler is fi lled. Use purge valves provided. Purge valve may be located on pump fl ange. On multiple boiler installations the fl ow switch may fail due to trapped air. See manual procedure.
Notice: These drawings show suggested piping confi guration and valving. Check with local codes and ordinances for specifi c requirements.
19
GAS SUPPLY PIPING
Check the boiler rating plate to make sure that the boiler is for the type of gas that will be used. If it isn’t, do not connect the boiler 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!
Th e Futera Fusion XLF comes from the factory ready to be piped to the gas supply. If for any reason the boiler is not for the type of gas available at the installation site, call your RBI representative to resolve the problem.
A minimum gas supply pressure of 3.5 in, 88.9 mm,
WC natural or propane and maximum 14 in, 356
mm WC natural or propane, must be available at the safety shutoff valve inlet with the unit(s) operating, and not to exceed a maximum of a (1.0 in WC) drop when fi ring from minimum input to full load of the gas supply line and all the appliances running.
Table 10 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 fi tt ings. Table
10 should be used in conjunction with Table 10 to ensure that the gas supply piping has the capacity to meet the demand.
Figure 14 depicts the proper way to connect the boiler to the gas supply piping. Th e manual shut-off valve MUST be installed in the supply piping. It should be installed 5 ft , 1.5 m above the fl oor where required by local codes. Provide a sediment trap at the bott om of the vertical section of the gas supply pipe upstream of the gas controls.
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.
Table 10 Gas Pipe Capacity
Maximum pipe capacity in ft 3 /hr based on 0.60 specifi c gravity gas at a pressure of 0.5 psig or less and a 0.3 in WC pressure drop.
Pipe length in feet
Pipe
Size
10 20 30 40
Maximum gas volume of pipe, (ft 3 /hr)
50
1"
2 1/2"
3"
4"
5"
6"
Pipe
Size
4200
6400
11,300
23,100
2760
4400
7780
15,900
2220
3530
6250
12,700
1900
3020
5350
10,900
41,800
67,600
28,700
46,500
70
23,000
37,300
Pipe length in feet
80
19,700
31,900
90 60
1520
Maximum gas volume of pipe, (ft 3 /hr)
1400 1300 1220
1680
2680
4740
9600
17,500
28,300
100
1"
2 1/2"
3"
4"
5"
6"
Pipe
Size
2430
4290
8760
15,800
25,600
125
2230
3950
8050
14,600
2080
3670
7490
13,600
1950
3450
7030
12,700
23,600 22,000 20,600
Pipe length in feet
150 175 200
Maximum gas volume of pipe, (ft 3 /hr)
1160
1840
3260
6640
12,000
19,500
250
1"
2 1/2"
3"
4"
5"
6"
1020
1630
2890
5890
10,600
17,200
928
1480
2610
5330
9650
15,600
854
1360
2410
4910
8800
14,400
794
1270
2240
4560
8260
13,400
704
1120
1980
4050
7320
11,900
Note: For propane piping — Multiply the gas volume above by 0.62 for propane fl ow capacities in ft 3 /hr. Multiply the propane fl ow capacity by
2500 Btu/ft 3 to determine the propane Btu/hr capacity for a given pipe size and length.
Table 11 Equivalent Pipe Length Chart
Nominal
Iron Pipe
Size
90˚ Elbow
Fitting or valve
Tee
(branch fl ow)
Gate Valve Gas Cock
2"
2 1/2"
3"
4"
5"
6"
5.2
6.2
7.7
10.1
12.6
15.2
Equivalent pipe length, (ft)
10.3
12.3
15.3
20.2
25.2
30.4
1.2
1.4
1.8
2.4
2.9
3.5
3.0
3.5
4.5
6.0
7.3
13.4
Equivalent lengths above are for threaded fi ttings. Multiply values above by 0.75 for fl anged fi ttings.
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!
20
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. Th e main Dungs gas valve supplied with boiler does not require external venting.
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler. All gas connections MUST be leak tested before putt ing the boiler into operation.
Never use an open fl ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler by closing it’s manual shut off valve, see Figure 16. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler and its individual shutoff valve.
Figure 14 Gas Supply Piping
ELECTRICAL WIRING
Electrical Power Connections
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation aft er servicing.
Au moment de l’entretien des 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.
Th e electrical connections to this boiler 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.
A properly rated shut-off switch should be located at the boiler. Th e boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical
Code, ANSI/NFPA-70.
Line voltage fi eld 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 outdoors. Th e wire size must be compatible with the total amp draw of the circuit.
Refer to the wiring diagram supplied with the boiler for proper wiring connections and boiler full load amperage (FLA).
21
GENERAL OPERATION
Before proceeding read and fully understand the instructions contained in this manual. Do not att empt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual.
Failure to comply with this warning can result in extensive property damage, severe personal injury or death!
Should overheating occur or the gas supply fail to shut off , turn off the manual gas control valve to the appliance. Do not interrupt water fl ow through the boiler.
En cas de surchauff e ou si l’alimentation en gaz ne s’arrête pas, fermez manuellement le robinet d’arrêt de l’admission de gaz.
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE
METTRE EN MARCHE
A. Th is appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.
Hydronic Heating Boilers (Fill System)
Open the make-up water valve and slowly fi ll the boiler and all of the radiation with water. Ensure that all bleed and drain valves are closed.
Adjust the make-up water pressure regulator so a minimum 5 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 pressure at boiler under operating conditions.
Glycol systems require a minimum of 20 psig, 137.8 kPa at boiler operating conditions.
Open the boiler piping bleed valves one at a time, to purge the air trapped in the primary and secondary heat exchanger. Refer to piping drawings (Figures 10 & 11) for bleed locations.
With the boiler off , run the system pump for at least 30 minutes and bleed the system piping using the bleed valves. If strainers are used in the system piping, the make- up water valve should be closed and the strainers checked and cleaned.
Th e system expansion tank should be checked to ensure that the correct water level in the tank is maintained. Th e tank should be less than half full of water with the system full and adjusted to the correct operating pressure.
TIONS” section. Run the boiler for at least an hour. Th e system pump(s) and all radiation units must be operated during this time.
Ensure that the make-up water valve is open.
Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping. Close the make-up water valve and check and clean the strainers and make-up water pressure reducing valve.
Open the make-up water valve and adjust the system pressure if necessary. Th e system should be checked and bled aft er three days of operation.
for gas. Be sure to smell next to the fl oor because some gas is heavier than air and will sett le on the fl oor.
Propane gas may not always be detected by smell.
Propane gas is heavier than air and can collect in low areas.
Propane gas can ignite or explode if an ignition source is present and result in death, serious injury and property damage!
FOR YOUR SAFETY
• Have only qualifi ed 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 att empt 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 fi re department.
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.
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.
C. Do not use this appliance if any part has been under water.
Immediately call a qualifi ed service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.
22
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un tecnicien qualifi é et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.
Figure 15 Manometer connections to the test manifold (in control cabinet)
Operating instructions
1. If, at any time, the boiler will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE,” page 25, and call your service technician or gas supplier.
2. Turn off all electrical power to the boiler.
3. Close main gas shut-off valve (fi eld supplied), Figure 14.
4. Purge the gas piping up to the boiler’s manual gas valve (located ahead of the main gas valve). When the bleeding is complete, check all gas joints up to the gas valve for leaks.
5. Wait fi ve (5) minutes to clear out any gas.
6. Make sure all limits, pressures switches and safety device contacts are closed.
7. Open the main gas shut-off valve.
8. Disable any external call for heat, such as from a building management system or remote operating controller.
9. Toggle the remote/local switch (in control cabinet — see
Figure 18) to REMOTE .
10. Turn on electrical power to the boiler.
11. Turn the power switch on the front of the boiler control cabinet to ON .
12. Th e HeatNet display will light up when the power is on. If all interlocks are properly closed, the display will say STANDBY . If not, refer to the XLF HeatNet Control manual for troubleshooting.
13. Slide the HeatNet control’s low fi re switch (on HeatNet control board) to the LOW FIRE position.
14. Th e boiler will begin the start-up sequence.
15. Allow the boiler to pre-purge and enter the pilot ignition cycle.
16. If pilot lights (indicated by a good fl ame signal 5.0 V DC) proceed to step 18. (See Honeywell R7800 literature for use of a meter to check fl ame signal if keypad readout is not available.)
17. If pilot is unstable (indicated by a low or erratic fl ame signal causing pilot fl ame failure), toggle the low fi re switch to DISABLE , then back to ENABLE to start another cycle (reset the Honeywell control if necessary). Repeat for one or two more times to ensure the pilot line is purged of all air. If pilot is still unstable, the pilot gas pressure may need to be increased. See step 18.
18. Pilot pressure adjustment: a. Switch the Honeywell control to TEST position within the fi rst 10 seconds of the pilot ignition sequence. b. Connect one side of a manometer or pressure gauge to the manometer pressure port (barbed) on the pressure test manifold
(located inside control panel). See Figure 15. Leave the other side of the manometer open to the room.
c. Measure pilot gas pressure by pressing and holding the service valve marked PILOT GAS . d. Set pilot gas pressure to 3.0 in WC (± 0.5 in) by adjusting the pilot gas pressure regulator, inside the air box. Access from the boiler top cover. See Figure 16.
Figure 16 Access to air trim adjustment and pilot regulator e. Check pilot air pressure using service valve marked PILOT
AIR .
f. Pilot air pressure should be 0.60 in WC (± 0.10 in).
Combustion readings must be in the range specifi ed in the following instructions. Adjust the boiler as necessary to ensure proper combustion.
23
Verify low fi re operation
1. Connect a manometer or Magnehelic gauge with the pressure side to the manifold pressure port. See Figure 15, for locations.
2. Set Honeywell R7800 control to RUN position. Th e boiler will operate at low fi re because the low fi re switch is in the low fi re position.
3. Measure the fl ue gas CO
2
Set low fi re CO
2
with the boiler running at low fi re.
to 8.0% – 8.5% by adjustment on the Dungs valve using a 3mm Allen wrench. a. Turn the wrench in small increments (10 degrees at a time).
b. Allow time aft er each adjustment for the boiler to reach steady state.
4. Aft er sett ing the CO
2
, measure the pressure signal, Ps .
Ps (signal) butt on and read the pressure. Th e pressure at low fi re should be as shown in Table 12. b. If the pressure is outside of this range, follow the instructions in the HeatNet Control manual to set the required turndown. c. Utilize the ACTech drive to trim the low fi re pressure signal
(Ps) as follows: Press the “Mode” butt on on the AC Tech
Drive. d. Th e drive will now require a password. Use the Arrow Keys on the AC Tech Drive to enter the password value of “523” then press “Mode”. e. Th e parameters of the drive will be accessible at this point.
Use the Arrow Keys on the AC Tech Drive to scroll to P45.
Press “Mode” to view the entry; use the Arrow Keys to adjust the value to achieve the required combustion – CO2/O2, and pressure – (Ps) at low fi re based on the desired turn down. Th e default values are listed in Table 12. f. When complete press “Mode” again to save the value.
If using a U-tube manometer turned sideways for low pressure readings, you MUST turn the manometer upright before att empting to measure pressures at other than low fi re. Pressure signal could reach up to
11 in when the boiler is at high fi re, and can cause fl uid to be pulled out of the manometer into the boiler.
Should this occur, immediately shut down the boiler and contact the factory for procedure. Preferably, use a Magnehelic gauge instead of a U-tube manometer to measure the pressure to avoid this potential hazard.
Table 12 Pressure signal (Ps), ACTech (P45) - (Nat Gas)
2500 3000
Firing rate
(PS) in
WC
100% -9.50
20% -0.40
(P45) n/a
11.00
3500
(P46)
(PS) in
WC
87.00
-11.00
n/a -0.40
(P45) n/a
13.00
4000
(P46)
77.00
n/a
Firing rate
(PS) in
WC
100% -6.00
20% -0.40
(P45) n/a
10.50
(P46)
73.00
n/a
(PS) in
WC
-8.50
-0.40
(P45) n/a
10.50
(P46)
75.00
n/a
To determine signal in mm WC, multiply signal pressure by 25.4.
For LP Gas: All units are tested at factory. LP Combustion Values are located on Combustion Data label.
To ensure proper boiler operation, boilers that are vented sidewall and use room air must not be fi red at less than 33% input.
5. Observe the burner fl ame aft er sett ing low fi re. Make sure the fl ame is stable, but not too tight on the burner (causing infrared operation).
DO NOT LEAVE THE BURNER IN AN INFRARED STATE
.
A few random speckles of red are acceptable, but large concentrations of spots or large areas of red are not.
If large amounts of red concentrations are observed, verify combustion readings.
Leave the manometer connected to the test manifold.
It will be needed for high fi re operation testing.
Verify high fi re operation
1. Jumper the AA terminals on the HeatNet board and allow the boiler to rise to maximum (100%) input.
2. Allow the boiler to reach steady state combustion at high fi re.
3. Verify high fi re blower speed as follows: a. With the manometer (or gauge) connected to the test manifold, press the Ps (signal) butt on and read the pressure.
b. Th e pressure at high fi re should be as shown in Table 12.
c. If the pressure is NOT correct, follow step 4.
24
4. If the high fi re signal pressure is not correct: a. Follow the instructions in the HeatNet Control manual to calibrate the required input (Ps) for high altitude installations.
Th e maximum fi ring rate value in the HeatNet control is factory set at (90%). At this sett ing, for sea level applications and with typical vent lengths, the boiler will be at rate. DO
NOT increase above (90%) unless needed for high altitude installations.
b. For sea level installations only, the ACTech drive can be used to trim high fi re input (Ps) as follows: Press the “Mode” butt on on the AC Tech Drive. c. Th e drive will now require a password. Use the Arrow Keys on the AC Tech Drive to enter the password value of “523” then press “Mode”. d. Th e parameters of the drive will be accessible at this point.
Use the Arrow Keys on the AC Tech Drive to scroll to P46.
Press “Mode” to view the entry; use the Arrow Keys to adjust the value to achieve the required combustion – CO2/O2, and pressure – (Ps). Th e default values are listed in Table
12. e. When complete press “Mode” again to save the value.
5. If the pressure signal is correct, measure the fl ue gas CO should be between 9% and 9.5%.
2
. It a. If CO
2
is correct, proceed to step 6.
CO
2
is not within this range, adjust the air trim adjustment slightly (see Figure 16) on top of mixing box to achieve a
CO
2
of 9% - 9.5%. c. If adjusting the air trim adjustment does not correct the problem, contact technical support at the factory to troubleshoot the problem.
CO
2
and pressure signal are correct, allow the boiler to reach steady state and verify supply gas pressure and check input rates as explained in the Gas Supply Piping section.
7. Remove jumper on AA and allow boiler to sett le into minimum input. Observe the combustion readings to ensure the boiler is operating correctly.
8. When fi nished, disable the low fi re hold switch and replace test ports to normal state. Remove the manometer connections and close the control panel door.
9. Th e Futera XLF boiler allows for many modes of operation and control methods. Reference the HeatNet Control manual.
COMMENT COUPER L’ADMISSION DE GAZ DE
L’APAREIL
1. Réglez le thermostat à la température la plus basse.
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.
SEQUENCE OF OPERATION
NO DEMAND
Standby
1. Th e boiler is idle with no interlocks in the fault condition.
DEMAND
Pre-Purge
1. Th e blower operates at purge RPM. Th e water fl ow interlock
must ‘make’ within 15 seconds aft er the demand signal is initiated.
2. Th e Honeywell 7800 starts a 10 second purge delay once the air prove switch contacts close.
Pilot Run - % Input
1. Th e blower operates at minimum ignition sett ing. See the calibration section in the HeatNet Control manual to enter the calibration menus.
2. Th e ignition transformer is energized. Th e pilot solenoid valve opens for the 10 second pilot ignition trial.
Main Run % Input
1. Th e main gas valve opens.
2. Th e ignition transformer is de-energized.
3. Th e pilot solenoid valve closes.
4. Th e blower stays at the minimum input sett ing for 3 seconds then operates at demand % input. See the calibration section in the HeatNet Control manual to enter the calibration menus.
TO TURN OFF GAS TO APPLIANCE
1. Set the operating control to its lowest sett ing.
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.
NO DEMAND
Post-Purge
1. Th e main gas valve closes.
2. Th e blower operates at purge RPM for 10 seconds.
3. Th e boiler is idle with no interlocks in the fault condition.
25
CHECKING & ADJUSTMENTS
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
Spark Gap
With the main and pilot gas manual valves in the closed position energize the unit. Observe the trial for ignition to confi rm that the spark is strong and continuous. If not check and adjust the spark gap as shown in Figure 17.
Figure 17 Spark Gap
Table 13
Minimum
Maximum
Gas supply pressure (Nat/LP)
Inches water column mm water column
3.5
14
88.9
356
1. Measure pressure when the boiler is fi ring at full rate. Low gas pressure could indicate undersized gas line or insuffi cient gas supply.
2. Static and operating gas pressure required at the gas valve inlet is listed in the Table 13.
If the gas pressure is above the limit in Table 13, a lock-up style gas pressure regulator suitable for dead-end service,
(such as an Equimeter or Fisher) must be installed to prevent increase (creep) of gas pressure when the units are not operating and gas supply pressure, as indicated in Table 13, must be maintained to the inlet of the boiler gas train not to exceed a maximum of
(1.0 in WC) drop when fi ring from minimum input to full load of the gas supply line and all the appliances running.
Th is pressure regulator (supplied by others) may be installed at the service entrance to each unit or a “master” regulator sized to handle multiple units with adequate turndown capability may be utilized. Consult local gas utility or regulator manufacturer for recommendations to meet specifi c job site requirements.
Pilot Adjustment
1. Th e pilot pressure has been factory set at 3 in WC, and shouldn’t need adjustment.
a. With the boiler powered, generate a call for heat.
b. When the prepurge is complete the ignition/pilot trial will begin.
2. To adjust the pilot the following steps must be taken: a. Put the Honeywell RM7800 test switch in the test position.
Th e control will hold in the ignition/pilot sequence, allowing you to check the pressure.
b. Connect one side of a manometer or pressure gauge to the manometer pressure port (barbed) on the pressure test manifold (located inside control panel). See Figure 13.
Leave the other side of the manometer open to the room. c. Measure pilot gas pressure by pressing and holding the service valve marked PILOT GAS.
d. Set pilot gas pressure to 3.0 in WC (± 0.5 in) by adjusting the pilot gas pressure regulator, inside the air box. Access from the boiler top cover. See Figure 16.
e. Check pilot air pressure using service valve marked PILOT
AIR .
f. Pilot air pressure should be 0.60 in WC (± 0.10 in).
Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur!
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.
Check the input rate as follows:
1. Turn off all other gas appliances that use the same gas meter as the boiler.
2. Call your gas supplier and ask for the heating value of the gas.
3. Start the boiler and let it run for 15 minutes.
4. Using the gas meter and a stopwatch, clock the time that it takes to burn 10 ft 3 , 0.28 m 3 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.
Never increase the input to the boiler above that for which it is rated. Doing so can cause premature failure of the boiler!
26
Figure 18 RBI Field Wiring to HeatNet Board (BoardRevision 2.0 and Greater)
RIOM 86
27
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 function properly.
Th ese faults are:
HIGH LIMIT: When the high limit aquastat trips the following message is displayed:
FAULT
HIGH LIMIT
SYSTEM SET
160˚F
Operating Control
Th e preferred control sett ing for potable hot water is 130°F, 54°C.
Th e operating control should be set to the lowest sett ing that will satisfy the consumer’s needs.
Sett ing the thermostat or operation control too high can result in scalding resulting in severe personal injury!
FAULT
10/27 9:16
SYSTEM SET
160˚F
High Limit (Aquastat)
Th e high limit is located in the top control area of the boiler. A remote capillary bulb is run to a well on the outlet side of the supply header. Th e high limit can be reset by depressing the red butt on.
Th e unit 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.
Th e high limit interlock breaks power to the ignition control
(shutt ing it off ) and eff ectively removes any chance of the gas valve receiving power. Th e Futera Fusion XLF series control will remain powered to display the fault, latch the alarm relay/audible beeper, and to access the log. Th e interlock is located on J5, HIGH LIMIT.
INTERLOCK SPARE 3: Th is is a reserved interlock input that is normally jumpered at the factory, but can have a remote interlock connected as a fi eld install. Th e interlock is located on J11A,
SPARE 3.
Flow Switch
A fl ow switch is provided in the water outlet piping to prevent the boiler from fi ring without adequate water fl ow through the heat exchanger.
FAULT SYSTEM SET
INTERLOCK SPARE 3
160˚F
DIAGNOSTICS
Th e Futera Fusion XLF has a display that indicates the sequence of operation. Th e 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.
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 fl ow and water in the boiler. Th ere is a reset switch located on the LWCO box. Th e interlock connection is located on
J11A, LWCO.
Status Screen Fault Display
Th ere are numerous interlock switches and soft ware limits that are detected. Each of these, when tripped will produce a display message, an audible beeping, and an alarm relay closure. Th e fault is displayed fi rst, then aft er a second, the time the fault occurred is displayed. Th is cycle will keep occurring until the fault is cleared.
FAULT SYSTEM SET
LOW WATER CUTOFF
160˚F
28
VAR FREQ DRIVE: Th e 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. Th e interlock is located on
J11A, VFD.
FLOW SWITCH ERROR: Once the Futera Fusion series boiler receives a call for heat, it closes the circulator pump relay. It then waits 10 seconds to prove fl ow. If there is no fl ow, the fl ow 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 fl ow. Th e interlock connection is located on J11B, WTR
FLW.
FAULT
VAR FREQ DRIVE
SYSTEM SET
160˚F
FAULT SYSTEM SET
WATER FLOW SWITCH
160˚F
GAS PRESSURE: Th e 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. Th e interlock is located on J11A, GAS PR.
FAULT
GAS PRESSURE
SYSTEM SET
IGNITION CTRL ALARM: Th e ignition control alarm is displayed if the ignition control detects a fault. Th is could be a fl ame 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.
160˚F
FAULT SYSTEM SET
IGNITION CTRL ALARM
160˚F
INTERLOCK SPARE 4: Th is is also a spare interlock (similar to
INTERLOCK SPARE 3) for future expansion or use as a fi eld interlock. Th e interlock is located on J11B, SPARE 4.
IRI ALARM: Th e optional IRI alarm is the alarm from the gas valve. If this alarm is set check the gas valve.
FAULT SYSTEM SET
INTERLOCK SPARE 4
160˚F FAULT
IRI ALARM
SYSTEM SET
160˚F
29
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. Th ese should be wired to the combustion air damper or preferably an isolation relay.
Th e prove switch on the combustion air damper must be wired to
J10B, SPARE 1.
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, fi res, and continues to fi re. If the combustion air damper does not prove within the proof time specifi ed in the combustion air damper menu, the boiler will shut down and display the fault. Th e fault on the Master boiler can be cleared by removing the call for heat on the master boiler and fi xing the combustion air damper problem. A combustion damper fault on a Member boiler can only be cleared by power cycling.
Th e 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.
Th is allows for post purge cycles to complete.
OPEN ***** SENSOR: If the open sensor fault is displayed, the sensor in the position reported was originally detected, but has since opened. Th e boiler will shut down on any OPEN sensor.
FAULT SYSTEM SET
OPEN OUTSIDE SENSOR
160˚F
SHORTED ***** SENSOR: If the shorted sensor fault is displayed, the sensor in the position reported was originally detected, but has since shorted. Th e boiler will shut down on any SHORTED sensor.
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 Futera
Fusion model boiler, a warning or fault will be displayed. Th is protection is required to prevent damage to the heat exchanger in the event high diff erential temperatures are encountered. Th e fault or warning condition may be changed in the AUX FUNCTIONS menu under ALARM TYPE. Th e default condition is WARNING
When this condition exists and the ALARM TYPE is set to
TE, the boiler is limited to 1/2 it’s input rate. So, if the boiler is trying to fi re 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 Futera Fusion 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 shutt ing down the boiler until the Delta Temp drops 10°F below the maximum designated temperature.
1/2 INPUT LOCAL SET
DELTA TEMP > 40°F
41˚F
RETURN TEMP < 130°F: If the Return Inlet temperature is less than 130°F this warning will be displayed. Th is warning does not aff ect operation and does not set the alarm relay. A log entry is made to aide in diagnosing why this may be occurring. Condensing will occur with return temperatures below 130°F and a shortened heat exchanger life will occur.
PREPURGE LOCAL SET
RETURN TEMP < 130°F
41˚F
30
MAINTENANCE
Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result!
Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can damage the boiler!
Th e boiler 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’s performance. Refer to Figure 15 for component identifi cation.
Improper burner servicing can result in premature burner failure voiding the warranty!
Pilot and burner removal
1. Close the manual shutoff valves in the gas supply line and turn off electrical power to the boiler.
2. Remove the jacket top panel.
3. Remove wires from the spark rods and remove the UV sensor from the transition piece.
4. Remove the pilot assembly: a. Disconnect the compression nut at the front of the pilot block.
b. Remove the pilot gas tubing.
c. Remove the (2) screws from the pilot block.
d Remove the pilot assembly.
5. Disconnect the fl exible gas line from the manifold.
6. Disconnect the wires to the fan and remove the (2) bolts and the fan hold-down plates that secure the fan to the transition piece.
7. Lift and remove the fan housing from the boiler, taking care not to damage the spark rods and or their alignment.
8. Remove the four nuts holding the transition piece to the heat exchanger.
9. Remove the transition piece, taking care not to damage the O-ring.
10. Remove the burner, taking care not to damage the gasket.
11. Replace all components aft er servicing.
Heat exchanger inspection
1. Close the manual shutoff valves in the gas supply lines and turn off electrical power to the boiler.
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. Th e 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 is returned to service.
6. If there are no signs of damage, sooting or corrosion, reassemble the unit following the previous steps in reverse order.
7. A badly corroded or damaged heat exchanger must be replaced, see the Heat Exchanger Repair & Replacement section.
Heat exchanger cleaning
1. Close the shut off valves in the inlet and outlet piping. On heating systems close the system fi ll valve and relieve the system pressure from the boiler by carefully lift ing the relief valve or opening the drain valve.
2. Disconnect the boiler 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” baffl e straps and “V” baffl es.
7. Th oroughly clean the heat exchanger with water from a highpressure hose. Use a soft bristle brush if necessary.
8. Replace the cleaned heat exchanger and other components in the reverse order of their removal.
Heat exchanger repair & replacement
1. A leaking or otherwise damaged tube(s) can be replaced as outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler 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). Replace the pipe plugs using a suitable thread sealant on each one.
6. Sagging or distorted heat exchanger tubes are an indication of low water fl ow through the system. A damaged heat exchanger must be replaced and the condition that caused the damage resolved before the boiler is returned to service.
7. Replace the heat exchanger and other components in the reverse order of their removal.
Air intake & vent system
Th oroughly 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 fi lter and wash with warm water and soap if dirty.
31
Controls
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A fl oat type low water cutoff device must be fl ushed out per the manufacturers’ instructions.
a. Th e probe on a probe low water cut off must be removed, cleaned and inspected at least once a year.
b. Ensure that the low water cutoff s operate properly. If not, replace them.
3. Th e fl ow switch contacts must be open when water fl ow is not present.
4. Th e relief valve should not weep or discharge water at normal system pressure. If it does, contact a qualifi ed 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!
5. Th e aquastat high limit controls the maximum water temperature in the boiler.
a. If the water temperature reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the boiler off .
b. Th e water temperature should never exceed the maximum set point of 250 o F, 121 o C, for boilers and 210 for water heaters.
o F, 99 o C c. Th e aquastat high limit cannot be repaired. If it fails to function properly, replace it.
6. Visually check the pilot and main burner fl ames to ensure proper operation, see Figure 19.
A yellow, fl oating fl ame indicates a lack of combustion air. Do not operate the boiler until the problem is solved or severe personal injury or death may occur!
Manometer test port manifold
1. Th e Futera Fusion XLF includes a manometer test manifold.
Connect the manometer pressure hose to the Pressure Tap port shown in Figure 20. Th ese pressures signals may be used for troubleshooting when specifi ed by factory support.
2. Figure 21, shows the sensor hose connections inside the
Futera Fusion XLF air box.
Figure 20 Manometer connections to manifold
Figure 19 Main Burner Flame
32
Figure 21 Futera Fusion XLF pressure sensor hose routing
Switch
PS1
PS2
PS5
PS6
For
Main Blower
Blocked Flue
Blocked Inlet
Pilot Air
2500
(–) 0.20
(+) 3.00
(–) 2.00
(+) 0.36
Switch Settings in WC
3000 3500
(–) 0.20
(+) 3.00
(–) 2.00
(+) 0.36
(–) 0.20
(+) 4.00
(–) 2.00
(+) 0.36
4000
(–) 0.20
(+) 4.00
(–) 2.00
(+) 0.36
33
Troubleshooting A Startup
Symptom
An Interlock is tripped.
Identify Source
1. Is it a 24 VAC Interlock?
1.
2. Is it a 120 VAC Interlock/
Alarm?
3. Internal Alarms
Check
1. All 24 VAC Interlocks are located on J11A and J11B.
Examples of 24 VAC Interlocks:
1.SPARE3
2. V ariable 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.
2. All 120 VAC interlocks/Alarms are located on J5. These include:
1.FLAME SAFE ALARM (Ignition
CTRL ALARM)
2. V alve Alarm (IRI ALARM)
3. XS_FACTORY (Reserved
4. HIGH LIMIT
1. OPEN SENSOR
2. SHORTED SENSOR
3. COMBUSTION AIR DAMPER
Action
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.
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.
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.
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.
Check sensor voltages at
J10A and J10B. The
Temperature sensor inputs should be between 0 VDC and 5 VDC measured across 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 more
Manual details
for and problem resolution.
34
REPAIR PARTS
Figure 22 Repair Parts
35
REPAIR PARTS
(CONTINUED)
Figure 22 Repair Parts (CONTINUED)
36
REPAIR PARTS
(CONTINUED)
Ref # Name of Part
13
15
Left Base Channel
Right Base Channel
Burner
15a Burner O'ring
15b Burner Gasket
17 High Gas Pressure Switch (Manual Reset)
18 Gas Valve, MBC
Gas Valve, MBC
NS
19
21
Flange 1-1/2"
Flange 2"
Low Gas Pressure Switch (Manual Reset)
Firing Valve, 1-1/2"
22
23
Firing Valve, 2"
"A" Valve, 1-1/2"
"A" Valve, 2"
Blower
24
25
NS
Mixing Box Assy
Mixing Box Gasket
Gas Injectors, NG
Gas Injectors, LP
26
27
28
29
30
Flow Switch
Jacket Top Panel
Air Filter
Rear Pipe Enclosure Assy
Jacket Lower Rear Panel
31
32
33
Jacket Upper Left Panel
Jacket Upper Right Panel
Jacket Lower Left/Right Side Panel
34
NS
35
Jacket Upper Front Panel
Handle
Lower Front Jacket Panel
36
37
Combustion Chamber Top Panel
Manning Glass Insulation (per square foot)
Combustion Chamber Side/Rear Assy
Part #
04-1018
04-1022
10-0322
10-0293
10-0323
10-0294
03-2838
03-2839
03-2840
03-2841
70-3617.1
20-0063
70-3535
70-3536
70-3537
70-3538
70-3561
05-0104
70-3566
70-3567
70-3568
70-3569
10-1005
10-1007
10-1002
10-1006
10-1008
10-1004
14-0205
70-2413.1
09-0485
70-3510
03-3786
03-3787
03-3788
03-3789
70-2474
70-2471
11-0421
11-0227
11-0218
11-0214
11-0219
11-0422
11-0458
11-0459
11-0467
11-0454
12-0019
12-0023
70-3555
70-3554
1
1
1
1
1
2500
1
1
1
Model Size with Item Quantities Below
3000
1
1
3500
1
1
4000
1
1
1
1
1
1
1
2
1
1
1
1
1
(must order as kit 21-2009)
(must order as kit 21-2009)
1 1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
(must order as kit 21-2009)
1
1
2
1
1
1
1
1
1
1
2 2
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
9
1
1
9
1
9
1
1
9
1
1
1
37
REPAIR PARTS
(CONTINUED)
53
NS
NS
NS
NS
NS
NS
54
NS
NS
NS
55
Ref # Name of Part
38
39
NS
NS
41
44
45
46
NS
47
48
49
50
51
52
Part #
Combustion Chamber Door Assy
Pressure Relief Valve 50#
Pressure Relief Valve 125#
Latch
70-3572
70-3573
70-3574
70-3575
30-0384
13-0053
20-0045
Ball Valve
Drain Assy
11-0395
70-2561.1
70-2562.1
13-0308 Tridicator 30 - 60 psi
Tridicator 75 - 160 psi
LWCO #550LSV
13-0305
14-0256
Heat Exchanger Assembly (Copper) 70-3584R
Cast Iron 70-3585R
70-3586R
70-3587R
Heat Exchanger Assembly (Copper) 70-3576R
Bronze 70-3577R
70-3578R
70-3579R
Heat Exchanger Assembly (Cupronickel) 70-3588R
Cast Iron 70-3589R
70-3590R
70-3591R
Heat Exchanger Assembly (Cupronickel) 70-3580R
Bronze 70-3581R
70-3582R
70-3583R
03-3997
03-3998
Flange Gasket
Frequency Drive
Flame Safeguard, RM7895C
Spark Generator
Air Pressure Switch
Fan Prove Switch
03-3999
03-4000
03-3946
06-0062
15-0230
15-0234
16-0024R
16-0008
Transformer, 50 VA
High Limit, Jumo, (CB)
High Limit, Jumo, (CW)
High Limit, Jumo, (CB) Auto Reset
High Limit, Jumo, (CW) Auto Reset
Thermometer Well, 3/8 x 2
High Limit Well, 3/8 x 3
11-0419
11-0420
11-0419
15-0007
14-0013
14-0014
14-0114
14-0115
Main Board
Display Board
Ignition Cable
Ribbon Cable
Service Valve Assembly
13-0102
13-0104
16-0038R
40-0088
44-0063
40-0115
70-3666
38
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
2500
1
Model Size with Item Quantities Below
3000 3500 4000
1
1
1
1
2
1
1
1
1
2
1
1
2
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
1
1
1
1
1
1
2
2
1
2
2
1
2
2
1
2
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REPAIR PARTS
(CONTINUED)
Ref # Name of Part
56
NS
NS
NS
NS
NS
58
250v Transformer
Power Switch
Toggle Switch Remote/Local
10K Temperature Sensor
Purge Timer, ST7800
Keyboard Display Module, S7800A
Pilot/Flame Rod Kit
58a Electrode
58b O'ring
58c View Port Assembly
58d Mini Peeper, C7027A (not included in 70-3615)
NS
NS
59
60
Turbo Pilot Torch
UV Amplifi er, R7849B
Control Box Assembly
Fan Transition Collar
67
70
71
72
60a Blower O'Ring
60b Fan Holddown Plate
62
64
Mini Fan
Solenoid Valve w/Regulator, NG
65
66
Solenoid Valve w/Regulator, LP
Air Shut Off Valve
Pilot Orifi ce, .052 NG
Pilot Orifi ce, .040 LP
Pilot Tube 3/8
Power Relay
VFD Contactor
Relay Overload (5.5 - 8 Amp)
Relay Overload (9 - 13 Amp)
Relay Overload (2.5 - 4 Amp)
Relay Overload (4 - 6 Amp)
Relay Overload (12 - 18 Amp)
78
79
NS
NS
NS
NS
NS
73
74
Fuse, 3HP, 230V (pump)
Fuse, 5HP, 480V (pump)
Fuse, 15A, 600V (VFD)
Fuse, 25Amp, 600V (VFD)
75
Fuse (transformer)
Terminal Strip, 8P
75a Terminal Strip, 3P
76 Power Supply Box
77 Fuse Block, 2P (VFD)
Fuse Blcok, 2P (pump/transformer)
NS
Fuse Block, 3P (pump)
Keypad Overlay
Rating Plate
Futera XLF Overlay
Silicone Tubing
Silicone
Vent Termination Hood 8"
Vent Termination Hood 10"
Air Intake Hood 8"
Air Intake Hood 10"
Part #
06-0004
04-0596
12-0021
11-0372
11-0374
11-0376
10-0140
10-0139
62-0102
15-0118
15-0211
15-0214
15-0215
15-0216
15-0217
15-0219
15-0015
48-0013
48-0014
14-0325
16-0007
16-0010
70-3615
16-0335
06-0008
70-2205
16-0009
70-2559
16-0037
70-3609
01-0201S
48-0627
48-0637
48-0621
48-0622
48-0376
48-0154
48-0167
70-3750
48-0641
48-0643
48-0462
82-0189
82-0054
82-0192
06-0051
66-0151
09-0113
09-0115
09-0103
09-0104
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
Model Size with Item Quantities Below
2500 3000 3500
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
4000
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
2 2
3
3
3
2 2
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1 per foot
1
1
1
1
1 1
1 1
1 1
1 1
39
REPAIR PARTS
(CONTINUED)
Ref # Name of Part
80 Jacket Rear Front/Left Extension
Jacket Rear Front/Right Extension
81
82
83
84
Jacket Top Plate
Jacket Rear Top Panel
9" x 4-1/2" Gasket (8 hole)
Pipe Inlet Adapter
85
86
7-1/2" x 3-1/2" Gasket (4 hole)
Pump With Impeller
87
88
89
3-Way Valve
Pipe U-Elbow Assy
Pipe Rear Back Extension Panel
90
91
3" Black Flanged Tee
Pipe Connection Assy
92
93
8-1/2" x 4" Gasket (8 hole)
Pipe Outlet Adapter
94
95
Condensation Trap Assy
Jacket Rear Back/Right Extension
Jacket Rear Back/Left Extension
96
97
98
99
Economizer
Left/Right Base Channel
Channel Insert
Heat Exchanger Flat Bar
100 Junction Box Bracket
40
Part #
70-3754
06-0143
12-0666
12-0667
12-0665
13-0210
70-3752
03-3185.1
03-3185.2
03-3185.3
03-3185.4
53-2451
70-3712
70-3713
70-3714
70-3753
70-3777.1
70-3777.2
70-3777.3
70-3777.4
70-3776.1
70-3776.2
70-3776.3
70-3776.4
03-3186.1
03-3186.3
70-3786
70-3787
06-0144
70-3716
70-3717
06-0145
70-3708
70-3709
70-3751
70-4009
70-3779.1
70-3779.2
70-3779.3
70-3779.4
70-3778.1
70-3778.2
70-3778.3
70-3778.4
12-2005
12-2004
04-1151
70-4134
04-1161.1
04-1161.3
40-1096
2500
1
Model Size with Item Quantities Below
3000 3500 4000
1
1
1
1
1
1
1
1 1
1 1
1 1
2
1
2
1
2
1
2
1
6
1
6
1
1
6
1
6
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
1
1
1
1
1
1
1
1
1
1
1
1 1
2
2
2
2
2
2
1
2
2
1
2
2
1 1
2
1
2
1
START-UP REPORT
DATE:
TECHNICIAN:
COMPANY:
PHONE NUMBER:
JOB NAME:
LOCATION:
MODEL:
SERIAL #:
PRE-STARTUP 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 STARTUP SEQUENCE
Note: Locate the AA terminals and minimum hold switch in the bottom-right of the electrical panel on the main
HeatNet board. Also locate the manometer test manifold in the bottom of the electrical panel.
1. Disable any external call for heat and toggle the remote/local switch to REMOTE.
2. Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition.
3. Set pressure to 3–3.5 in WC (fl ame signal should read 5.0 VDC).
4. Release boiler to main fl ame trial for ignition.
5. Check for stable fl ame.
6. Record combustion and pressure signal (Ps) at minimum fi ring rate. (Reference Fusion XLF Boiler IOM.)
7. Jumper the AA terminals to force 100% input.
8. Record combustion and pressure signal (Ps). (Reference Fusion XLF Boiler IOM.)
9. Remove the AA jumper to place the boiler at minimum rate.
10. Check all combustion results using a calibrated fl ue gas analyzer.
11. Release the LOW FIRE switch to place boiler in standby.
In addition to completing the Futera Fusion XLF start-up report, complete the control set-up information in the rear of the HeatNet Control manual.
41
COMBUSTION ANALYSIS
GAS PRESSURE AT SUPPLY TEST PORT
CO
2
O
2
CO (PPM)
NET STACK TEMPERATURE
PRESSURE SIGNAL (Ps)
MINIMUM FIRING RATE
INCHES WC
PPM o F
%
%
INCHES WC
100% FIRING RATE
INCHES WC
PPM o F
%
%
INCHES WC
SAFETY TEST CHECKLIST
❑ FLOW SWITCHES
❑ LOW WATER CUT-OFF
❑ AIR SWITCH
❑ HIGH LIMITS
❑ FLAME SAFEGUARD
Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140 failure of the heat exchanger.
o F, 60 o C. Operating at lower return temperatures is likely to cause condensation in the primary heat exchanger, resulting in corrosion and possible
COMMISSIONING THE BOILER
❑ UNIT CYCLED MINIMUM OF 15 TIMES
❑ CUSTOMER INSTRUCTED
❑ ALL COVERS REPLACED
❑ CUSTOMER GIVEN MANUAL
❑ TARGET TEMPERATURE SET PER CUSTOMER
COMMISSIONED BY: ______________________________________
( SIGNATURE)
DATE: ____________________________
THE DELTA T BETWEEN THE HEATER IN-
LET AND OUTLET IS CRITICAL TO PROPER
FLOW. BEFORE YOU LEAVE THE JOBSITE,
YOU MUST RECORD THE DELTA T. THIS
READING SHOULD NOT EXCEED 35 o F,
19.4
o C, NOR BE LOWER THAN 20 o F, 11.1 o C.
DELTA T =
ADDITIONAL NOTES AND COMMENTS
42
NOTICE! Commonwealth of Massachusetts
In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fi tter.
1. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfi ed: d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfi tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the fl oor level where the gas equipment is to be installed. In addition, the installing plumber or gasfi tter 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 qualifi ed licensed professionals for the installation of hard wired carbon monoxide detectors.
i. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent fl oor level.
ii. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
e. 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 certifi ed. f. 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”.
g. 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.
Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
2. Exemptions — The following equipment is exempt from
248 CMR 5.08(2)(a) 1 through 4: a. 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 b. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED.
a. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: i. Detailed instructions for the installation of the venting system design or the venting system components; and ii. A complete parts list for the venting system design or venting system.
4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
a. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the fl ue gases, but identifi es “special venting systems”, the following requirements shall be satisfi ed by the manufacturer: i. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
5. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
43
LIMITED WARRANTY
Boilers
Industrial, Commercial and Other Non-Residential Use
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 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.
Th is limited warranty does not apply:
(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed, maintained or operated in accordance with the furnished writt en instructions, or has been altered or modifi ed in any way.
Th ese include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered under the manufacturer’s warranty.
• Excessive pitt ing and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.
• All copper fi n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation (bypass and valve arrangement included on the Futera Fusion Series). Th e manufacturer’s warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts thereof.
(c) to damage as a result of sett lement, distortion, collapse, or cracking of any foundation area, beams or pipes surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United States or Canada.
Th is limited warranty is conditional upon:
(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior writt en approval from the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship.
Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED
FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR
ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY
AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE
DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL
RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.
260 North Elm Street
Westfi eld, MA 01085
Phone: (413) 568-9571
Fax: (413) 568-9613
7555 Tranmere Drive
䡲 Mississauga, Ontario L5S 1L4 Canada
Phone: (905) 670-5888
Fax: (905) 670-5782 www.rbiwaterheaters.com
44
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