RBI Futera XLF Installation And Operation Instructions Manual

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

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Summary of Contents for RBI Futera XLF

Page 1: Installation And Operation
XLF-I0M-9 82-0317 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: Power Entrance Box
Finned copper tube gas boilers & water heaters – Boiler Manual Futera -Series boilers — Overview XLF PRIMARY COMPONENTS Electrical enclosure (rear) Blower and motor Air inlet connection Flue outlet connection Gas entrance Boiler water return Boiler water supply Gas valve Power entrance box 10.
Page 3: Table Of Contents
. . . . . . . . . . . . . . . . 4 maintenance of a Futera XLF Series finned copper heating boiler/ water heater/pool heater (Canada Only).
Page 4: Ratings & Capacities
6. NEVER place this boiler/water heater in a location that would subject it to temperatures at or near freezing, Before undertaking the installation of the Futera XLF Series boiler/ see the “FREEZE PROTECTION” section. water heater check the rating plate to ensure that the unit has been Never store combustible materials, gasoline or any sized properly for the job.
Page 5 All air from inside the building Table 2 Make-up Air Louver Sizing If the Futera XLF is to be located in a confined space, the minimum Required cross-sectional area clearances listed in Table 1, must be maintained between it and Wire screen...
Page 6: General Venting Guidelines
4. Place in operation the appliance being inspected. Follow the they must be supported at 3 ft, 0.9 m intervals with overhead hangers. lighting instructions. Adjust thermostat so appliance will operate The certified intake air terminal from RBI must be used, see Figure 1, continuously. Figure 2 and Figure 4.
Page 7: Option1: Direct Vent Positive Pressure - Category
UL 1738 for installations in the United States, ULC literature. S636 for installations in Canada. The certified vent terminal from RBI must also be used. Table 4 Category IV Equivalent Length Per Fitting If any part of a single wall metal vent system passes through an...
Page 8: Inlet
Finned copper tube gas boilers & water heaters – Boiler Manual Vertical direct vent systems — Figure 3 The vent system must be gas tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system If any part of a single wall metal vent system passes through an manufacturer’...
Page 9 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 2 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for multiple direct vent systems (CATEGORY IV) Figure 3 VENT OPTION 1: DIRECT VENT — Combination direct vent system (CATEGORY IV)
Page 10 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 4 VENT OPTION 1: DIRECT VENT — Vertical air intake and venting for direct vent system (CATEGORY IV) Locate exhaust terminal from air intake downwind to reduce potential for flue gas recirculation.
Page 11: Option 2: Vertical Venting Positive Pressure, Category
Category IV see Table 4 for minimum vent diameters. The Correctly identify the type of vent system the appliance Futera XLF when listed as a Category I or II appliance and vented requires before proceeding. Category identification is vertically into a listed metal chimney system, must provide a negative noted on the unit rating label.
Page 12: Option 3: Side Wall Venting Positive Pressure -Category
Finned copper tube gas boilers & water heaters – Boiler Manual OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE —CATEGORY IV FIGURE 7 “Combustion Air & Ventilation” section must be followed! The vent In this configuration the boiler/water heater blower is used to push the flue products horizontally to the outdoors, see guidelines under the Horizontal Direct Vent Systems section must also be followed.
Page 13: Category Ii Chimney Inspection & Sizing
Finned copper tube gas boilers & water heaters – Boiler Manual OPTION 4: VERTICAL CHIMNEY VENTING CHIMNEY INSPECTION & SIZING — NEGATIVE PRESSURE — CATEGORY I & II CATEGORY I & II (MULTIPLE BOILERS WITH COMMON VENTING) A thorough inspection of the masonry chimney must be performed to ensure that the chimney is clean, properly constructed, FIGURE 8 lined and sized.
Page 14: Outdoor Venting
Finned copper tube gas boilers & water heaters – Boiler Manual OUTDOOR VENTING (2500-5000) When installed outdoors the Futera XLF must be fitted with the fac- tory supplied outdoor hood, air intake adapter with filter and exhaust terminal, see Figure 7A. Multiple units must be spaced per Figure 7B.
Page 15 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations See Table 5 & 5a for minimum riser diameter (dimension F) Legend for Figure 8 2. Install a thermal spill switch on each barometric damper (when required by applicable codes).
Page 16: General Piping Requirements
Finned copper tube gas boilers & water heaters – Boiler Manual Never install any type of valve between the boiler/ Figure 7B Multiple Outdoor Units water heater and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur! Flow Switch The flow switch supplied with the boiler/water heater must be wired...
Page 17 A temperature rise outside of the range listed in Table 7 the call for heat is satisfied. will result in damage to the heat exchanger, voiding the warranty! The maximum allowable temperature rise through the boiler is 35 F, 19.4 Figure 9 Futera XLF Piping...
Page 18: Multiple Boiler Systems
Finned copper tube gas boilers & water heaters – Boiler Manual Low water cutoff The maximum allowable flow rate through a Futera XLF boiler is 260 GPM, 16.4 L/s when equipped If a boiler is installed above any radiation elements it must be fitted with copper tubes.
Page 19 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 10 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 20 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 13 Multiple Boiler Piping (See notes) These drawings show suggested piping con- figuration and valving. Check with local codes and ordinances for spe- cific requirements. H-15 Rev 6 NOTES: 1.
Page 21: Domestic Water Supply Piping
The cupronickel heat exchanger allows for 315 GPM, 19.9 L/s. See Table 9. 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.
Page 22: Expansion Tank
Finned copper tube gas boilers & water heaters – Boiler Manual guidelines in the Heat Exchanger Selection Table 8 Futera XLF Heat Exchanger Selection Table (Table 8) and the Pumping Performance Table (Table 9). Scale free operation can be achieved by using water with a hardness between 8 and 18 and by...
Page 23 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 14 Figure 16 Typical Water Heating Piping (MW Models Only) (See Notes) Typical Water Heating Piping (MW Models Only) These drawings show sug- gested piping configuration and valving. Check with local codes and ordinances for specific requirements.
Page 24: Gas Supply Piping
The Futera XLF comes from the factory ready to be piped to the gas supply. If for any reason the boiler/water heater is not for the type of gas available at the installation site, call your RBI representative to resolve the problem.
Page 25: Electrical Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual ELECTRICAL WIRING Table 11 Equivalent length (feet) for typical fittings Electrical Power Connections Fitting or valve Pipe Gate size elbow (branch flow) valve cock Label all wires prior to disconnection when servicing controls.
Page 26: General Operation
WIRING & CONTROL SET-UP Before proceeding read and fully understand the instructions contained in this manual. Do not attempt Follow the instructions in the Futera XLF Control to operate this boiler/water heater if it has not been installation and operation instruction manual...
Page 27: Sequence Of Operation
Finned copper tube gas boilers & water heaters – Boiler Manual SEQUENCE OF OPERATION Figure 17 HeatNet Control Panel NO DEMAND 250 VA TRANSFORMER TRANSFORMER HIGH VOLTAGE TEST RUN FLAME SAFEGUARD SWITCH (on model 5000 only) VFD CONTROL DISPLAY MODULE WINDOW Standby IGNITION STATUS...
Page 28: Operating Instructions
Finned copper tube gas boilers & water heaters – Boiler Manual b. Connect one side of a manometer or pressure gauge to the The following start-up procedure assumes that all water piping, gas piping and electrical connections pilot gas pressure port (barbed) on the pressure test manifold (located inside control panel).
Page 29 Finned copper tube gas boilers & water heaters – Boiler Manual For LP Gas: All units are tested at factory. LP Combustion Values are Verify low fire operation located on Combustion Data label. 1. Connect a manometer or Magnehelic gauge with the pressure side to the Ps signal port.
Page 30: To Turn Off Gas To Appliance
Remove the manometer connections and close the control panel door. 9. The Futera XLF boiler allows for many modes of operation and control methods. Reference the XLF HeatNet Control IOM. TO TURN OFF GAS TO APPLIANCE 1.
Page 31: Pilot Adjustment
Finned copper tube gas boilers & water heaters – Boiler Manual Pilot adjustment If the gas pressure is above the limit in the table below, a lock-up style gas pressure regulator suitable for 1. The pilot pressure has been factory set at 3 in WC, and shouldn’t dead-end service, (such as an Equimeter or Fisher) need adjustment.
Page 32: Maintenance
Finned copper tube gas boilers & water heaters – Boiler Manual MAINTENANCE 3. Remove the front jacket panel and combustion chamber door. 4. Inspect the inside and outside of the heat exchanger for signs of Disconnect electrical power and close the manual gas damage, sooting or corrosion.
Page 33 Manometer test port manifold manufacturers’ instructions. 1. The Futera XLF includes a manometer test manifold. Connect a. The probe on a probe low water cut off must be removed, the manometer pressure hose to the Pressure Tap port shown in cleaned and inspected at least once a year.
Page 34 Finned copper tube gas boilers & water heaters – Boiler Manual Figure 23 Futera XLF pressure sensor hose routing...
Page 35: Repair Parts
Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS Figure 24 Exploded view...
Page 36 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (CONTINUED) Figure 25 Figure 20 – Electrical components...
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 # 2500 3000 3500 4000 5000 Burner 10-0322 10-0293 10-0323 10-0294 10-0324 Burner O’ring (must order as kit 21-2009) Burner Gasket (must order as kit 21-2009)
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 # 2500 3000 3500 4000 5000 Heat Exchanger Assembly (Copper) 70-3584R Cast Iron 70-3585R 70-3586R 70-3587R 70-3726R...
Page 39 Fuse, 3HP, 460V (pump) 48-0625 Fuse, 5HP, 460V (pump) 48-0631 Fuse, 25Amp, 600V (VFD) 48-0622 Keypad Overlay 82-0189 Rating Plate 82-0054 Futera XLF Overlay 82-0192 Silicone Tubing 06-0051 per foot Silicone 66-0151 Vent Termination Hood 8" 09-0113 Vent Termination Hood 10"...
Page 40: Start-Up Report
11. Check all combustion results using a calibrated flue gas analyzer. 12. Release the LOW FIRE switch to place boiler in standby. In addition to completing the Futera XLF start-up report, complete the control set-up information in the rear of the Futera XLF Control Installation and operation manual.
Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE GAS PRESSURE AT SUPPLY TEST PORT IN WC IN WC CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) IN WC IN WC SAFETY TEST CHECKLIST ❑...
Page 42: Installation Requirements
Finned copper tube gas boilers & water heaters – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 approve the installation unless, upon inspection, the In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fitter. inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 1.
Page 43: Limited Warranty
Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
Page 44: North Elm Street Westfield, Ma
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 Copyright 2012 Mestek, Inc.