RBI Futera II Modulation Installation And Operation Instructions Manual

Finned copper tube gas boilers (mb) & water heaters (mw

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This manual is intended only for use by a qualified 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.

of the burner, resulting in possible severe personal injury, death or substantial property damage. The 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.

Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualified service

technician, and to follow all guidelines in the User' s Information Manual.

Finned Copper Tube

Gas Boilers (MB) &

Water Heaters (MW)

Boiler Manual

Installation and Operation

Instructions

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Summary of Contents for RBI Futera II Modulation

Page 1: Installation And Operation
FTIII-I0M-HN-7 82-0300 Finned Copper Tube Gas Boilers (MB) & Water Heaters (MW) Boiler Manual Installation and Operation Instructions Also read and follow: HeatNet® Control Manual This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Page 2: Table Of Contents
Finned copper tube gas boilers & water heaters – Boiler Manual If the information in this manual is not followed BEFORE YOU START . . . . . . . . . . . . . . . . . . . . 2 exactly, a fire or explosion may result causing property, RATINGS &...
Page 3: Ratings & Capacities
If such a location doesn’t exist, a suitable Direct all questions to your RBI distributor or contact the drain pan that’ s adequately drained must be installed under the RBI Customer Service Department at: 260 North Elm Street, unit.
Page 4 Finned copper tube gas boilers & water heaters – Boiler Manual Combustion air contaminated with fluorocarbons Where directly communicating with the outdoors or communi- cating with the outdoors through vertical ducts, each opening shall or other halogenated compounds such as cleaning have a minimum free area of 1 in /4000 Btu/hr, 550 mm solvents and refrigerants will result in the formation...
Page 5: General Venting Guidelines
5 ft, 1.5 m they must be supported at 3 ft, 0.9 m intervals with installed. overhead hangers. The certified intake air terminal from RBI must be used, see Figures 1, 2 and 4. 5) Vertical Vent/Chimney Vent (750-2000), Negative Pres- sure Non-Condensing, Category I uses an approved metal chimney system or masonry chimney.
Page 6: Horizontal Direct Vent Systems
AIR & VENTILATION” and “GENERAL VENTING GUIDE- The vent materials used in horizontal vent systems must be certified LINES” sections. to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certified vent terminal from RBI must also be used.
Page 7 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 1 Hoizontal Air Intake an Venting for a Single Direct Vent System (Category IV) 1/4 IN. PER FOOT 20 mm/m 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 16 FT 4.9 m 1.5 FT 0.5 m 1.5 FT 0.5 m...
Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 3 Vertical Air Intake and Venting for a Direct Vent System (Category IV) 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m 5 FT 1.5 m...
Page 9 Finned copper tube gas boilers & water heaters – Boiler Manual SIDE WALL VENT, POSITIVE PRESSURE, VERTICAL VENT, NEGATIVE PRESSURE – CATEGORY IV – Figure 5 CATEGORY I & II In this configuration the boiler/water heater blower is used to push The Futera III when listed as a Category II appliance and vent- the flue products horizontally to the outdoors, see Figure 5.
Page 10 Finned copper tube gas boilers & water heaters – Boiler Manual Chimney Inspection & Sizing – Category I and II Vent Connections A thorough inspection of the masonry chimney must be performed to Locate the boiler/water heater as close to the chimney as ensure that the chimney is clean, properly constructed, lined and sized.
Page 11 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 9 Vertical Venting Using a Lined Masonry Chimney Figure 8 Vertical Venting Using a Lined Masonry Chimney (Category II) (Category I) Figure 10 Outdoor Venting (Category IV) Figure 11 Multiple Outdoor Units DISCHARGE VENT 2 FT...
Page 12: Outdoor Venting
Finned copper tube gas boilers & water heaters – Boiler Manual OUTDOOR VENTING tous les ventilateurs d’ e xtraction comme les hottes de cuisinère et les ventilateurs des salles de bain. When installed outdoors the Futera III must be fitted with the factory S’assurer que ces ventilateurs fonctionnent à...
Page 13: Heating System Piping
Finned copper tube gas boilers & water heaters – Boiler Manual Figure 12 Futera III Piping Flow Switch Shut off valves and unions should be installed at the inlet and outlet connections of the boiler/hot water The flow switch supplied with the boiler/water heater must be wired to heater to provide for isolation of the unit should the terminal strip in the control panel to prevent the boiler from firing servicing be necessary.
Page 14: Multiple Boiler Systems
Finned copper tube gas boilers & water heaters – Boiler Manual Pump Requirements Low Water Cutoff This low mass boiler requires a continuous minimum water flow If a boiler is installed above any radiation elements it must be fitted for proper operation. The system pump must be sized to overcome with a low water cutoff device.
Page 15 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 13 Typical Primary/Secondary Piping System (See Notes) NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum flow through unit. 2. Boiler pump sized to boiler design flow requirements.
Page 16 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 15 Multiple Boiler Piping (See Notes) H-15 Rev 6 NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum flow through unit. 2. Boiler pump sized to boiler design flow requirements. 3.
Page 17: Domestic Water Supply Piping
Thermostatic Mixing Valve – Water Above 140°F, 60°C Water can be stored at temperatures above 140°F, 60°C provided that a RBI water heaters are designed to run scale free. Due to the extreme thermostatically controlled mixing valve is used to temper the hot variables of water conditions world wide it is necessary to water to an acceptable temperature before it’...
Page 18 Finned copper tube gas boilers & water heaters – Boiler Manual Table 9 Futera III Heat Exchanger Selection Graph Table 10 Futera III Pumping Performance Requirement...
Page 19 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 16 Typical Water Heating Piping (MW Models Only) These drawings show sug- gested piping configuration and valving. Check with local codes and ordinances Figure 17 for specific requirements. Multiple Water Heating Piping (MW Models Only) (See Notes) NOTES:...
Page 20: Gas Supply Piping
If for any reason the boiler/water heater is not for the type 2" 3050 2100 1650 1270 1270 1150 990 of gas available at the installation site, call your RBI representative Note: Multiply the gas volume by 0.62 for propane flow capacity in ft /hr.
Page 21: Electrical Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual Refer to the wiring diagram supplied with the boiler/water heater Never use an open flame to test for gas leaks. Always for proper wiring connections and boiler full load amperage (FLA). use an approved leak detection method.
Page 22: Operating Instructions
Finned copper tube gas boilers & water heaters – Boiler Manual OPERATING INSTRUCTIONS N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un tecnicien qualifié FOR YOUR SAFETY READ BEFORE OPERATING. et remplacez toute partie du système de contrôle et toute com- mande qui ont été...
Page 23 Finned copper tube gas boilers & water heaters – Boiler Manual Table 16 Elbow Pressure signal (Nat Gas) - Category I Figure 19 HeatNet Control Panel 1000 1250 1500 1750 2000 Firing Signal Signal Signal Signal Signal Signal Signal rate Inches Inches Inches...
Page 24: Sequence Of Operation
Finned copper tube gas boilers & water heaters – Boiler Manual COMMENT COUPER L’ADMISSION DE GAZ DE Figure 20 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’ e ntretien. 3.
Page 25: Checking & Adjustments
Finned copper tube gas boilers & water heaters – Boiler Manual CHECKING & ADJUSTMENTS Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows: Spark Gap Minimum (in. W.C.) 2 2 With the main and pilot gas manual valves in the closed position Maximum (in. W.C.) 14 energize the unit.
Page 26: Heatnet Field Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual RBI FIELD WIRING TO HEATNET BOARD Figure 22 RBI Field Wiring to HeatNet Board (Board Revision 3.0 and greater)
Page 27 Finned copper tube gas boilers & water heaters – Boiler Manual RBI HEATNET FIELD WIRING TO TERMINAL BLOCK Figure 23 NOTES: 1. Remove jumper “A” when using a low water cutoff interlock. 2. For multiple boilers utilizing a system air damper...
Page 28: Control Description
Finned copper tube gas boilers & water heaters – Boiler Manual CONTROL DESCRIPTION STATUS SCREEN FAULT DISPLAY There are numerous interlock switches and software limits that are Low Water Cutoff detected. Each of these, when tripped will produce a display message, an audible beeping, and an alarm relay closure.
Page 29: Gas Pressure
Finned copper tube gas boilers & water heaters – Boiler Manual The variable frequency drive, which controls Once the FIII series boiler receives a VAR FREQ DRIVE: FLOW SWITCH ERROR: the blower, reports this fault in the event of over current or other call for heat, it closes the circulator pump relay.
Page 30: Combustion Air Damper
Finned copper tube gas boilers & water heaters – Boiler Manual If the combustion air damper has been SHORTED ***** SENSOR: If the shorted sensor fault is COMBUST AIR DAMPER: selected for use (MASTER BOILER, AUX FUNCTIONS), and displayed, the sensor in the position reported was originally detected, the proof switch does not make, this fault will be displayed.
Page 31: Maintenance
Finned copper tube gas boilers & water heaters – Boiler Manual MAINTENANCE 6. If there are no signs of damage, sooting or corrosion, reassemble the unit following the previous steps in reverse order. Disconnect electrical power and close the manual gas 7.
Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual Controls A yellow, floating flame indicates a lack of combustion air. Do not operate the boiler/water heater until the Use the “GENERAL OPERATION” and “CHECKING AND AD- problem is solved or severe personal injury or death JUSTMENTS”...
Page 33: Trouble-Shooting
Finned copper tube gas boilers & water heaters – Boiler Manual Troubleshooting A Startup Symptom Identify Source Check Action An Interlock is tripped. 1. Is it a 24 VAC Interlock? 1. All 24 VAC Interlocks are 1.Use a multimeter and check located on J11A and J11B.
Page 34: Repair Parts
Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS Figure 25 Exploded View...
Page 35 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) RIOM-74 REV E...
Page 36 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Burner for Turbo Pilot 70-2529.1 70-2530.1 70-2531.1 70-2532.1 70-2533.1 70-2534.1 70-2535.1...
Page 37 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 2" Blanket Insulation (per sq ft) 05-0200 Red Silicone Gasket (per ft / sold per roll 50’) 06-0146 Pressure Relief Valve 50# 30-0360...
Page 38 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Inlet Adapters (Flanged) 01-0044GL 01-0045GL Outlet Adapters (Flanged) 01-0046GL 01-0047GL Outlet Adapters (Threaded)
Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Gasket (must order as kit 21-2007) (must order as kit 21-2008) Pump Contactor Relay 15-0137 Rating Plate...
Page 40: Start-Up Sheet
Finned copper tube gas boilers & water heaters – Boiler Manual START-UP REPORT DATE : JOB NAME: T E C HNI C IAN: L OCATION: CO MPANY : MODEL CATEGORY: PH O NE N U MBER : S ERIAL # : PRE -STA T T R T UP CHE CK LIST NO VISIBLE DAMAGE TO UNI T...
Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS PRESSURE AT SUPPLY TEST PORT INCHES W.C . I NCHES W.C . CO ( PPM ) PP M NET S TA C K TEMPERAT U R E...
Page 42: Mass Code
Finned copper tube gas boilers & water heaters – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels of tion must be performed by a licensed plumber or gas carbon monoxide which can cause severe personal fitter.
Page 43: Limited Warranty
Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
Page 44 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com 05/14 Copyright 2014 Mestek, Inc.