RBI Futera XLF Series Manual
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RBI Futera XLF Series Manual

Finned copper tube gas boilers and water heaters
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See also: 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. 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.
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)
Models 3000 & 4000 only
Boiler manual
Installation and operation
instructions
Also read and follow:
XLF HeatNet Control manual
Construction dust and particulate, particularly drywall dust, will cause contamination of
FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
82-0317

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Summary of Contents for RBI Futera XLF Series

  • Page 1 82-0317 Finned copper tube Gas boilers (MB) & Water heaters (MW) Models 3000 & 4000 only Boiler manual Installation and operation instructions Also read and follow: XLF 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 DP switch —...

  • Page 3: Table Of Contents

    This manual covers the application, installation, operation and main- BOILER/WATER HEATER LOCATION . . . . . . . . . . . . 4 tenance of a Futera XLF Series finned copper heating boiler/water heater.

  • Page 4: Ratings & Capacities

    DO NOT place this boiler/water heater in a location that would restrict the introduction of combustion air into the unit Before undertaking the installation of the Futera XLF Series boiler/ or subject it to a negative pressure, see “GENERAL VENTING water heater check the rating plate to ensure that the unit has been sized GUIDELINES”.
  • Page 5 Finned copper tube gas boilers & water heaters – Boiler manual and including 1 million Btuh, plus 1 in per 14,000 Btuh (155 mm Never operate the Futera XLF in an environment subjected to a negative pressure unless it is Direct per kW) in excess of 1 million Btuh.

  • Page 6: General Venting Guidelines

    3 ft, 0.9 m intervals with overhead hangers. boiler installation. Close fireplace dampers. The certified intake air terminal from RBI must be used, see Figure 1, Place in operation the appliance being inspected. Follow the page 8, Figure 2, page 8 and Figure 4, page 9.

  • Page 7: Option 1: Direct Vent Positive Pressure

    UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certified vent terminal from combination direct vent systems RBI must also be used. Figure 4 (vent/air pipe equivalent lengths up to100 feet maximum) The maximum equivalent length for the horizontal vent pipe is 100 ft, 30.5 m.

  • Page 8: Inlet

    Finned copper tube gas boilers & water heaters – Boiler manual Figure 1 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for a single direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. W hen running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must...
  • Page 9 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 Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. Locate exhaust terminal from air intake downwind...

  • Page 10: Option 2: Vertical Venting Positive Pressure

    Finned copper tube gas boilers & water heaters – Boiler manual option 2: VerticAL VentinG ed, lined and sized. Exterior masonry chimneys should not be used unless properly lined to prevent condensation and draft problems. positiVe pressUre, cAteGory iV Table 5 lists the equivalent breeching and flue sizes required for the FiGUre 5 or FiGUre 6 boiler/water heater.

  • Page 11: Option 3: Side Wall Venting Positive Pressure

    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 (VENT/AIR PIPE EquIVALENT LENGTHS uP TO100 FEET MAxIMuM) guidelines under the Horizontal Direct Vent Systems section must In this configuration the boiler/water heater blower is used also be followed.

  • Page 12: Option 4: Vertical Chimney Venting Negative Pressure - Category

    Finned copper tube gas boilers & water heaters – Boiler manual option 4: VerticAL cHimney VentinG cAteGory ii cHimney neGAtiVe pressUre — cAteGory ii inspection & sizinG (MultIple BoIlers WIth coMMon ventInG) Masonry chimneys, when used, must be lined with a FiGUre 8 metal liner certified for Category IV venting.
  • Page 13 Finned copper tube gas boilers & water heaters – Boiler manual Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations See Table 5, page 12 for minimum riser diameter (dimension F) DO NOT common vent more than the following number of Futera XLF boilers: XLF-3000 (4) boilers maximum.

  • Page 14: General Piping Requirements

    Finned copper tube gas boilers & water heaters – Boiler manual GenerAL pipinG reQUirements Never install any type of valve between the boiler/ water heater and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur! Improper piping of this boiler/water heater will void the manufacturer’s warranty and can cause boiler...
  • Page 15 Finned copper tube gas boilers & water heaters – Boiler manual Figure 9 Futera xLF Piping FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
  • Page 16 Finned copper tube gas boilers & water heaters – Boiler manual pump requirements expansion tank and air separator This low mass boiler requires a continuous minimum wa- An expansion tank or other means to control thermal expansion ter flow for proper operation .

  • Page 17: Inlet

    Finned copper tube gas boilers & water heaters – Boiler manual Figure 10 Typical Primary/Secondary Piping System (See Notes) NOTES: Boiler circuit piping must be sized large enough to handle maximum flow through unit. Boiler pump sized to boiler design flow requirements.
  • Page 18 Finned copper tube gas boilers & water heaters – Boiler manual Figure 12 Low Temperature Piping (See Notes and Adjustment Procedures) Adjustment Procedure To Maintain Inlet Temperature Above Dew Point T1-Temp-Min = 140 F, 60 C Sealed Combustion 1. Turn heater on and open valves A & B. 2.

  • Page 19: Domestic Water Supply Piping

    315 GPM, 19.9 L/s. See Table 9, page 20. tempered water and help prevent the growth of RBI water heaters are designed to run scale free. Due to water born bacteria. the extreme variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling.
  • Page 20 In some areas of the country ad- ditional precautions must be observed due to unusual characteristics of the local water supply. Call the nearest RBI representative for details. To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed.
  • Page 21 Finned copper tube gas boilers & water heaters – Boiler manual Figure 14 Typical Water Heating Piping (MW Models Only) (See Notes) These drawings show sug- gested piping configuration and valving. Check with local codes and ordinances for specific requirements. Figure 15 Multiple Water Heating Piping (MW Models Only) (See Notes)

  • Page 22: 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 23: Electrical Wiring

    Finned copper tube gas boilers & water heaters – Boiler manual eLectricAL WirinG table 11 Equivalent length (feet) for typical fittings Pipe Fitting or valve electrical power connections size elbow Gate (branch flow) valve cock Label all wires prior to disconnection when servicing controls.

  • Page 24: General Operation

    Finned copper tube gas boilers & water heaters – Boiler manual 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 installed in accordance with the guidelines set forth in...

  • Page 25: Sequence Of Operation

    Finned copper tube gas boilers & water heaters – Boiler manual seQUence oF operAtion Figure 17 HeatNet Control Panel no DemAnD standby The boiler is idle with no interlocks in the fault condition. DemAnD pre-purge The blower operates at purge RPM. The water flow interlock must ‘make’...

  • Page 26: Operating Instructions

    Finned copper tube gas boilers & water heaters – Boiler manual other side of the manometer open to the room. DO NOT The following start-up procedure assumes that all water piping, gas piping and electrical connections are correct connect it to the reference port (left side of panel). as stated in this manual and the installation meets all State, Local, and City codes.
  • Page 27 Finned copper tube gas boilers & water heaters – Boiler manual Verify low fire operation Do not LeAVe tHe BUrner in An inFrAreD stAte A few random speckles of red are acceptable, but large Connect a manometer or Magnehelic gauge with the pressure concentrations of spots or large areas of red are not.

  • Page 28: To Turn Off Gas To Appliance

    Finned copper tube gas boilers & water heaters – Boiler manual If the pressure signal is correct, measure the flue gas CO . It cHecKinG & ADJUstments should be between 9% and 9.5%. Proper polarity of the ignition transformer wiring is If CO is correct, proceed to step 6.
  • Page 29 Finned copper tube gas boilers & water heaters – Boiler manual pilot adjustment If the gas pressure is above the limit above, a lock-up style gas pressure regulator suitable for dead-end The pilot pressure has been factory set at 3 inches w.c., and service, (such as an Equimeter or Fisher) must be shouldn't need adjustment.

  • Page 30: Maintenance

    Finned copper tube gas boilers & water heaters – Boiler manual mAintenAnce Remove the front jacket panel and combustion chamber door. Inspect the inside and outside of the heat exchanger Disconnect electrical power and close the manual gas for signs of damage, sooting or corrosion. shut off valve before performing maintenance or severe personal injury may result! The outside surfaces of the copper tubes should be free of...
  • Page 31 Finned copper tube gas boilers & water heaters – Boiler manual Replace the pipe plugs using a suitable thread sealant on each Figure 21 Main Burner Flame one. Sagging or distorted heat exchanger tubes are an indication of low water flow through the system. A damaged heat exchanger must be replaced and the condition that caused the damage resolved before the boiler/water heater is returned to service.
  • Page 32 Finned copper tube gas boilers & water heaters – Boiler manual Figure 23 Futera xLF pressure sensor hose routing FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.

  • Page 33: Repair Parts

    Finned copper tube gas boilers & water heaters – Boiler manual repAir pArts Figure 24 Exploded view FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
  • Page 34 Finned copper tube gas boilers & water heaters – Boiler manual repAir pArts (coNtiNued) Figure 25 Figure 20 – Electrical components FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.
  • Page 35 Finned copper tube gas boilers & water heaters – Boiler manual repAir pArts (coNtiNued) ref # name of part part # 3000 4000 Top/Bottom x Profile 04-0524 Middle x Profile 04-0526 Top Y Profile 04-0530 Bottom Y Profile 04-0535 04-0537 Top/Bottom Z Profile 04-0539 Middle Z Profile...
  • Page 36 Finned copper tube gas boilers & water heaters – Boiler manual repAir pArts (coNtiNued) ref # name of part part # 3000 4000 Handle 20-0063 Lower Front Jacket Panel 70-3536 70-3538 Combustion Chamber Top Panel 70-3561 Manning Glass Insulation (per square foot) 05-0104 Combustion Chamber Rear/Side Panel 70-3567...
  • Page 37 Finned copper tube gas boilers & water heaters – Boiler manual repAir pArts (coNtiNued) ref # name of part part # 3000 4000 Purge Timer, ST7800 16-0007 Keyboard Display Module, S7800A 16-0010 Ferrite Clamp 16-0035 Pilot Assembly 70-3615 Electrode 16-0335 Electrode Gasket 06-0008 View Port Assembly...

  • Page 38: Start-Up Report

    Finned copper tube gas boilers & water heaters – Boiler manual START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: pre-stArtUp cHecK List NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN ❑ ❑ PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED ❑...
  • Page 39 Finned copper tube gas boilers & water heaters – Boiler manual comBUstion AnALysis minimUm FirinG rAte 100% FirinG rAte GAS PRESSURE AT ELBOW TEST PORT INCHES W.C. INCHES W.C. CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) INCHES W.C. INCHES W.C. sAFety test cHecKList FLOW SWITCHES AIR SWITCH...
  • Page 40 Finned copper tube gas boilers & water heaters – Boiler manual notice! commonwealth of massachusetts installation requirements MACODE-3 in accordance with the provisions of 248 CMR 5.08(2)(a)1 In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fitter. through 4.

This manual is also suitable for:

Futera xlf 4000Futera xlf 3000

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