RBI Futera Fusion XLF Installation And Operation Instructions Manual

Finned copper tube gas boilers (cb) & water heaters (cw) & pool heaters (cp)

Hide thumbs Also See for Futera Fusion XLF:

Installation and operation instructions manual (48 pages)

Table of Contents

Quick Links

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 (CB) &

Water Heaters (CW)

& Pool Heaters (CP)

Boiler Manual

Installation and Operation

Instructions

Need help?

Do you have a question about the Futera Fusion XLF and is the answer not in the manual?

Questions and answers

Summary of Contents for RBI Futera Fusion XLF

Page 1: Installation And Operation
FTFX-I0M-6 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 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 – Boiler Manual BEFORE YOU START If the information in this manual is not followed exactly, a fire or explosion may result causing RATINGS & CAPACITIES property, personal injury or loss of life. BOILER/WATER HEATER LOCATION Do not store or use gasoline or other flammable vapors COMBUSTION AIR &...
Page 3: Ratings & Capacities
3. Ensure that the floor is structurally sound and will support the weight of the boiler. Direct all questions to your RBI distributor or contact the RBI Customer Service Department at: 260 North Elm Street, Westfield, The Futera may be installed directly on combustible MA 01085 for US or 7555 Tranmere Drive, Mississauga ONT flooring, but never on carpeting.
Page 4 Finned copper tube gas boilers – Boiler Manual Combustion air contaminated with fluorocarbons Where communicating with the outdoors through horizontal or other halogenated compounds such as cleaning ducts, each opening shall have a minimum free area of 1 in 2000 Btu/hr, 1100 mm /kW of the total input rating of all solvents and refrigerants will result in the formation of acids in the combustion chamber.
Page 5: General Venting Guidelines
A UL listed stainless steel vent system must be corro-sion resistant fasteners and sealed using a suitable Silicone used unless this unit is fitted with an RBI supplied caulk. If PVC or CPVC is used, the joints must be cleaned non-metallic vent kit.
Page 6 UL 1738 for installations in the United States, Also follow the general instructions in the “COMBUSTION ULC S636 for installations in Canada. The certified vent AIR & VENTILATION” and “GENERAL VENTING terminal from RBI must also be used. GUIDELINES” sections.
Page 7 Finned copper tube gas boilers – Boiler Manual Horizontal Air Intake and Venting for a Single Direct Vent System Figure 1 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 1000 BTU'S...
Page 8 Finned copper tube gas boilers – Boiler Manual Vertical Air Intake and Venting for a Direct Vent System Figure 3 Locate exhaust terminal downwind to reduce flue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m...
Page 9: Common Venting
Common vent systems cannot be pressurized. A through inspection of the masonry chimney must be performed The Futera Fusion XLF is listed as a Category II appliance when to ensure that the chimney is clean, properly constructed lined, vented vertically into a listed metal chimney system. The chimney and sized.
Page 10: Outdoor Venting
Table 5 lists the minimum riser sizes required for the Fusion boiler. OUTDOOR VENTING Riser Diameters To Common Vent For Category II Venting Table 5 When installed outdoors the Futera Fusion XLF must be fitted Input MBH with the factory supplied outdoor hood, air intake adapter 2500/3000 with filter and exhaust terminal, see Figure 7.
Page 11: General Piping Requirements
Finned copper tube gas boilers – Boiler Manual GENERAL PIPING REQUIREMENTS Outdoor Venting Figure 7 Improper piping of this boiler will void the manufac- turer’s warranty and can cause boiler failure resulting in flooding and extensive property damage! Excessive water hardness causing scaling in the copper heat exchanger tubes is NOT covered under the manufac- turer’s warranty, see Table 8.
Page 12: Heating System Piping
Finned copper tube gas boilers – Boiler Manual Flow Switch Pump Requirements The flow switch supplied with the boiler must be wired to This low mass boiler requires a continuous minimum water flow the terminal strip in the control panel to prevent the boiler across the primary heat exchanger for proper operation.
Page 13 Finned copper tube gas boilers – Boiler Manual Fusion XLF Secondary Bypass Piping Figure 9 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...
Page 14 Finned copper tube gas boilers – Boiler Manual Typical Primary/Secondary, Low Temperature Piping System (See Notes) Figure 10 H-16 REV C NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum flow through unit. 2. Boiler and pump purging required. Air must be purged from 3-way valve after the boiler is filled. Use purge valves provided.
Page 15 Finned copper tube gas boilers – Boiler Manual Multiple Boiler Piping (See Notes) Figure 11 H-17 REV C NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum flow through each unit. 2. System loop pipe diameter must be sized large enough to handle maximum flow through all units. 3.
Page 16: Domestic Water Supply Piping
Finned copper tube gas boilers – Boiler Manual DOMESTIC WATER SUPPLY PIPING 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...
Page 17 Finned copper tube gas boilers – Boiler Manual Table 7 Futera Fusion XLF Primary Heat Exchanger Selection Graph For hard/soft water pump selection, must consult factory. Delta T/Boiler Recovery Table - Fahrenheit Table 8 Model 2500 3000 3500 4000 Inlet...
Page 18 Finned copper tube gas boilers – Boiler Manual Typical Unit Heating Piping (See Notes) Figure 12 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.
Page 19 Finned copper tube gas boilers – Boiler Manual Multiple Unit Heating Piping (See Notes) Figure 13 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.
Page 20: Gas Supply Piping
4100 3600 4" 17,500 12,000 9700 8300 7400 The Futera Fusion XLF comes from the factory ready to be 5" 31,700 21,800 17,500 15,000 13,300 piped to the gas supply. If for any reason the boiler is not for 6"...
Page 21: Electrical Wiring
Finned copper tube gas boilers – Boiler Manual When applicable, provisions for vent, bleed and gas relief lines ELECTRICAL WIRING must be made in accordance with the latest revision of ANSI Z223.1/NFPA 54. The main Dungs gas valve supplied with boiler does not require external venting.
Page 22: General Operation
WIRING & CONTROL SET-UP Before proceeding read and fully understand the instructions contained in this manual. Do not Follow the instructions in the Futera Fusion XLF attempt to operate this boiler if it has not been Control installation and operation instruction...
Page 23: Sequence Of Operation
Finned copper tube gas boilers – Boiler Manual Figure 15 HeatNet Control Panel HIGH VOLTAGE FLAME 250 VA TRANSFORMER TRANSFORMER TEST RUN SWITCH SAFEGUARD (on models 3500 and larger) VFD CONTROL DISPLAY MODULE WINDOW BACK BUTTON SELECT BUTTON FLAME SAFEGUARD LOCAL REMOTE PROTOCESSOR MANUAL RESET...
Page 24: Operating Instructions
Finned copper tube gas boilers – Boiler Manual OPERATING INSTRUCTIONS 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. FOR YOUR SAFETY READ BEFORE OPERATING.
Page 25 Finned copper tube gas boilers – Boiler Manual N’utilisez pas cet appareil s’il a été plongé dans l’eau, même Figure 16 Manometer connections to the test manifold (in partiellement. Faites inspecter l’appareil par un tecnicien control cabinet) qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été...
Page 26 Finned copper tube gas boilers – Boiler Manual Verify low fire operation Table 12 Pressure signal (Ps) - (Nat Gas) 1. Connect a manometer or Magnehelic gauge with the pressure 2500 3000 3500 4000 Firing side to the manifold pressure port. See Figure 16, for locations. rate Signal Signal...
Page 27 8. When finished, disable the low fire hold switch and replace test ports to normal state. Remove the manometer connections and close the control panel door. 9. The Futera Fusion XLF boiler allows for many modes of operation and control methods. Reference the HeatNet Control manual.
Page 28: Checking & Adjustments
Finned copper tube gas boilers – Boiler Manual CHECKING & ADJUSTMENTS Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows: Spark Gap Table 13 With the main and pilot gas manual valves in the closed position Gas supply pressure (Nat/LP) energize the unit.
Page 29: Heatnet Field Wiring
Finned copper tube gas boilers – Boiler Manual RBI Field Wiring to HeatNet Board (Board Revision 3.0 and Greater) Figure 19...
Page 30: Control Description
High Limit (Aquastat) (shutting it off) and effectively removes any chance of the gas valve receiving power. The Futera Fusion XLF series control will remain The high limit is located in the top control area of the boiler. powered to display the fault, latch the alarm relay/audible beeper, A remote capillary bulb is run to a well on the outlet side of and to access the log.
Page 31: Gas Pressure
Finned copper tube gas boilers – Boiler Manual The variable frequency drive, which controls Once the Futera Fusion XLF series VAR FREQ DRIVE: FLOW SWITCH ERROR: the blower, reports this fault in the event of over current or other boiler receives a call for heat, it closes the circulator pump relay. It conditions that would cause it to shut down.
Page 32: Combustion Air Damper
Finned copper tube gas boilers – Boiler Manual If the combustion air damper has If the shorted sensor fault is displayed, COMBUST AIR DAMPER: SHORTED ***** SENSOR: been selected for use (MASTER BOILER, AUX FUNCTIONS), the sensor in the position reported was originally detected, but and the proof switch does not make, this fault will be displayed.
Page 33: Maintenance
Finned copper tube gas boilers – Boiler Manual MAINTENANCE 5. The outside surfaces of the copper tubes should be free of any soot deposits. A slight black smudge is normal with some types of gases. Black soot indicates poor combustion. Disconnect electrical power and close the manual Green deposits indicate condensation due to low return water gas shut off valve before performing maintenance...
Page 34 Finned copper tube gas boilers – Boiler Manual Controls Manometer test port manifold 1. The Futera Fusion XLF includes a manometer test manifold. Use the “GENERAL OPERATION” and “CHECKING AND Connect the manometer pressure hose to the Pressure Tap ADJUSTMENTS” sections of this manual for reference.
Page 35 Finned copper tube gas boilers – Boiler Manual Figure 22 Futera Fusion XLF pressure sensor hose routing Switch Settings in WC Switch 2500 3000 3500 4000 Main Blower (–) 0.20 (–) 0.20 (–) 0.20 (–) 0.20 Blocked Flue (+) 3.00 (+) 3.00...
Page 36: Trouble-Shooting
Finned copper tube gas boilers – 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. for 24 VAC on J11A,J11B to Examples of 24 VAC Interlocks: identify which interlock has...
Page 37: Repair Parts
Finned copper tube gas boilers – Boiler Manual REPAIR PARTS Repair Parts Figure 23...
Page 38 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Repair Parts (CONTINUED) Figure 23 RIOM-115 REV B...
Page 39 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Burner 10-0322 10-0293 10-0323 10-0294 Burner O'ring (must order as kit 21-2009) Burner Gasket (must order as kit 21-2009) High Gas Pressure Switch (Manual Reset)
Page 40 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Pressure Relief Valve 50# 30-0369 Pressure Relief Valve 50# 30-0382 Pressure Relief Valve 50# 13-0026 Pressure Relief Valve 125# 13-0009...
Page 41 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Flame Safeguard, RM7895C 16-0024R Spark Generator 16-0036 Air Pressure Switch 11-0419 11-0420 Fan Prove Switch 11-0419 Transformer, 50 VA...
Page 42 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Pump Contactor, LC1D18G7, CB 15-0208 Relay Overload, LRD21, CB 15-0219 Pump Fuse, LP-CC-20, CB 48-0639 Fuse, 10A, 600V (VFD) 48-0609-1000...
Page 43: Start-Up Sheet
4. Release boiler to main flame trial for ignition. 5. Check for stable flame. 6. Record combustion and pressure signal (Ps) at minimum firing rate. (Reference Futera Fusion XLF Boiler IOM.) 7. Jumper the AA terminals to force 100% input.
Page 44: Commissioning The Boiler
Finned copper tube gas boilers – Boiler Manual COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE GAS PRESSURE AT SUPPLY TEST PORT INCHES WC INCHES WC CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) INCHES WC INCHES WC SAFETY TEST CHECKLIST ❑...
Page 45: Mass Code
Finned copper tube gas boilers – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installation Improper venting can result in excessive levels of must be performed by a licensed plumber or gas fitter. carbon monoxide which can cause severe personal injury or death! 1.
Page 46: Warranty
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.
Page 47 Finned copper tube gas boilers – Boiler Manual...
Page 48 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada  Phone: (413) 564-5515 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...