RBI FUTERA XLF MB6000 Manual

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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.

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

(MB6000, MB8000,

MB10000)

Boiler Manual

Installation and Operation

Instructions

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Summary of Contents for RBI FUTERA XLF MB6000

Page 1 LSXLF-IOM-4 82-0652 Finned Copper Tube Gas Boilers (MB6000, MB8000, MB10000) 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 Finned copper tube gas boilers – Boiler Manual RBI Futera XLF-Series boilers — Overview 13 Pilot air proving switch 14 Spark generator 11 Blocked flue switch 10 Blocked air switch Blower proving switch Blower and motor Electrical enclosure (rear) Pilot gas valve and...
Page 3: Table Of Contents
Temperature Rise Control Include the name of the service organization for future reference. Gas Supply Piping Direct all questions to your RBI distributor or contact the Electrical Wiring RBI Customer Service Department at: General Operation U.
Page 4: Ratings & Capacities
Finned copper tube gas boilers – Boiler Manual RATINGS & CAPACITIES Never store combustible materials, gasoline or any product containing flammable vapors or liquids in Before undertaking the installation of the Futera XLF Series the vicinity of the boiler. Failure to comply with this boiler check the rating plate to ensure that the unit has been sized warning can result in an explosion or fire causing properly for the job.
Page 5 10 linear ft, 3.0 m of pipe. If horizontal runs exceed 5 ft, 1.5 m ¼ in (6.4 mm) 75% free area 25% free area they must be supported at 3 ft, 0.9 m intervals with overhead hangers. The certified intake air terminal from RBI must be used, see Figure 1, 6000 1500 89676 2000...
Page 6: General Venting Guidelines
Finned copper tube gas boilers – Boiler Manual GENERAL VENTING GUIDELINES spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they The vent installation must be in accordance with Part will operate at maximum speed.
Page 7: Option1: Direct Vent Positive Pressure - Category
Horizontal vent systems shall terminate at least 4 ft, 1.2 m below, 4 ft, The RBI Futera XLF is supplied with a factory installed 1.2 m horizontally from or 1 ft, 0.30 m above any door, window or Z-Flex flue outlet adapter. A manufacturers supplied gravity air inlet into any building.
Page 8: Approved Stainless Steel Vent Manufacturers
Finned copper tube gas boilers – Boiler Manual Table 5 Approved Stainless Steel Vent Manufacturers (CAT II/IV) Make Model DuraVent FasNSeal Vent M&G DuraVent DuraSeal Vent Heatfab Saf-T Vent Metal-Fab CORR/GUARD Security Chimneys Secure Seal Schebler Chimney Systems e Vent VAN-PACKER Z-Flex Z-Vent...
Page 9: Adapters
*Factory Installed The RBI Futera XLF is supplied with a factory installed Z-Flex flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers.
Page 10 Finned copper tube gas boilers – 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 11 Finned copper tube gas boilers – 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 12 Finned copper tube gas boilers – Boiler Manual Figure 4 VENT OPTION 1: DIRECT VENT — Vertical Air Intake and Venting for Direct Vent System (CATEGORY IV) Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation. Failure to comply could result in severe personal injury or death.
Page 13: Option 2: Vertical Venting Positive Pressure, Category
Finned copper tube gas boilers – Boiler Manual OPTION 2: VERTICAL VENTING POSITIVE PRESSURE (CATEGORY IV), NEGATIVE PRESSURE (CATEGORY I & II) FIGURE 5 & FIGURE 6 Masonry chimneys, when used, must be lined with a properly lined to prevent condensation and draft problems. When metal liner certified for Category II &...
Page 14: Option 3: Side Wall Venting Positive Pressure -Category
Finned copper tube gas boilers – Boiler Manual OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE —CATEGORY IV FIGURE 7 In this configuration the boiler blower is used to push “Combustion Air & Ventilation” section must be followed! The vent the flue products horizontally to the outdoors, see guidelines under the Horizontal Direct Vent Systems section must Figure ...
Page 15: Option 4: Vertical Chimney Venting Negative Pressure
Finned copper tube gas boilers – 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 16 Finned copper tube gas boilers – Boiler Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
Page 17 Finned copper tube gas boilers – Boiler Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) supply inlet horizontally...
Page 18 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Finned copper tube gas boilers – Boiler Manual Figure A - Other Than Direct Vent Terminal Clearances - Concluded 3 ft (91 cm) above if within 10 ft (3 m) Clearance to a mechanical air supply 6 ft (1.83 m) inlet...
Page 19 Finned copper tube gas boilers – Boiler Manual Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical Venting — Multiple-Boiler Installations See Table 8 & 8a 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 20: General Piping Requirements
Finned copper tube gas boilers – Boiler Manual GENERAL PIPING REQUIREMENTS Flow Switch The flow switch supplied with the boiler must be wired to the terminal strip in the control panel to prevent the boiler from firing Improper piping of this boiler will void the unless there’...
Page 21 Finned copper tube gas boilers – Boiler Manual A temperature rise outside of the range listed in Table 10 The maximum allowable flow rate through a Futera XLF boiler is 520 GPM, 32.8 L/s when equipped will result in damage to the heat exchanger, voiding the warranty! The maximum allowable temperature rise with copper tubes.
Page 22 Finned copper tube gas boilers – Boiler Manual Expansion tank and air separator Table 10 Temperature Rise Table An expansion tank or other means to control thermal expansion ∆T = 20 ∆T = 11.1 Model must be installed in the heating system. An expansion tank must be Flow Rate Pres.
Page 23 Finned copper tube gas boilers – 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. 3.
Page 24 Finned copper tube gas boilers – 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. Boiler circuit piping must be sized large enough to handle maximum flow through unit. 2.
Page 25: Domestic Water Supply Piping
630 GPM, 39.7 L/s. See Table 10. injury from occurring, see the caution against scalding. RBI boilers are designed to run scale free. Due to the extreme variables of water conditions world wide it is necessary to consider Storage of water for domestic use above 140 pH values and water hardness in relationship to scaling.
Page 26 Finned copper tube gas boilers – Boiler Manual To properly size the pump a grain hardness Pump Requirements Two typical water heating systems are and pH test must be taken at the installation shown in Figures 14 and 15. This low-mass boiler requires a continuous site before the order is placed.
Page 27 Finned copper tube gas boilers – Boiler Manual Figure 14 Typical Single Boiler with Indirect Storage Tank Piping 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.
Page 28: Gas Supply Piping
The Futera XLF comes from the factory ready to be piped to the gas Drip supply. If for any reason the boiler is not for the type of gas available Union at the installation site, call your RBI representative to resolve the Pilot problem. supply...
Page 29: Electrical Wiring
Finned copper tube gas boilers – Boiler Manual When applicable, provisions for vent, bleed and gas relief lines must Table 13 Equivalent Length (feet) for Typical Fittings 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 30: General Operation
Finned copper tube gas boilers – 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 if it has not been installed in installation and operation instruction manual accordance with the guidelines set forth in this shipped with the boiler to wire the boiler and set...
Page 31: Sequence Of Operation
Finned copper tube gas boilers – Boiler Manual SEQUENCE OF OPERATION Figure 17 HeatNet Control Panel HEATNET PROTOCESSOR FLAME MANUAL RESET TEST/RUN CONTROL MODULE VFD CONTROL BOX SAFTGUARD NO DEMAND TRANSFORMER HI-LIMIT SWITCH (OPTIONAL) BOARD MODULE Standby 1. The boiler is idle with no interlocks in the fault condition. DEMAND Pre-Purge 1.
Page 32: Operating Instructions
Finned copper tube gas boilers – Boiler Manual b. Connect one side of a manometer or magnehelic gauge to The following start-up procedure assumes that all each of the pilot gas pressure and air pressure ports (Left & water piping, gas piping and electrical connections are correct as stated in this manual and the installation Right Modules) located on the pressure test manifold inside meets all State, Local, and City codes.
Page 33 Finned copper tube gas boilers – 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 each of the (Left &...
Page 34: To Turn Off Gas To Appliance
Finned copper tube gas boilers – Boiler Manual 5. If the pressure signal is correct, measure the flue gas CO . Refer to CHECKING & ADJUSTMENTS "Combustion Reading" Tables 16 and 17 for proper combustion readings. Proper polarity of the ignition transformer wiring is (Each module must be measured independently).
Page 35 Finned copper tube gas boilers – 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 36: Maintenance
Finned copper tube gas boilers – 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 37 Finned copper tube gas boilers – Boiler Manual 6. Replace the pipe plugs using a suitable thread sealant on each one. Figure 21 Main Burner Flame 7. 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 is returned to service.
Page 38 Finned copper tube gas boilers – Boiler Manual Figure 23 Futera XLF Pressure Sensor Hose Routing SWITCH SETTINGS IN "W.C." SWITCH 6000 8000 10000 MAIN (-) 0.20 (-) 0.20 (-) 0.20 BLOWER (LS) BLOCKED (+) 2.0 (+) 2.0 (+) 2.0 FLUE (LS) BLOCKED (-) 2.0...
Page 39: Repair Parts
Finned copper tube gas boilers – Boiler Manual REPAIR PARTS Figure 24 Exploded View SEE VIEW "B" XLF 6000 ONLY XLF 6000 ONLY SEE VIEW "A" SEE VIEW "C" SEE VIEW "D" SEE VIEW "B" XLF 6000 ONLY XLF 6000 ONLY SEE VIEW "A"...
Page 40 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Figure 25 Figure 20 – Electrical Components XLF 8000 & 10000 GAS TRAIN VIEW "B" VIEW "A" VIEW "B" XLF 6000 GAS TRAIN VIEW "C" VIEW "D"...
Page 41 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 6000 8000 10000 Burner 10-0293 10-0294 10-0324 Burner O'ring (must order as kit 21-2009) Burner Gasket (must order as kit 21-2009) High Gas Pressure Switch (Manual Reset) 11-0421...
Page 42 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 6000 8000 10000 Heat Exchanger Assembly (Copper) 70-3819-002R Cast Iron 70-3819-004R 70-3819-005R Individual copper/cupronickel tubes (available for field repair) model and serial number required Tube Expansion Tool 30-0761 Heat Exchanger Assembly (Cupronickel)
Page 43 Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 6000 8000 10000 Air Shut Off Valve 11-0376 Pilot Orifice, .052 NG 10-0140 Pilot Orifice, .040 LP 10-0139 Pilot Tube 3/8 62-0102-03918...
Page 44: Start-Up Report
Finned copper tube gas boilers – 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 ❑...
Page 45 Finned copper tube gas boilers – 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 46 Finned copper tube gas boilers – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 approve the installation unless, upon inspection, the In the Commonwealth of Massachusetts, the installation inspector observes carbon monoxide detectors and signage must be performed by a licensed plumber or gas fitter. installed in accordance with the provisions of 248 CMR 1.
Page 47 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.
Page 48 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (833) 265-5371 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com Copyright 2017 Mestek, Inc.

This manual is also suitable for:

Futera xlf mb8000 Futera xlf mb10000