RBI FUTERA FUSION Series Installation & Operation Manual
RBI FUTERA FUSION Series Installation & Operation Manual

RBI FUTERA FUSION Series Installation & Operation Manual

Futera fusion series finned copper gas boilers (model cb) & water heaters (model cw)
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FUTERA FUSION SERIES FINNED COPPER
GAS BOILERS (MODEL CB)
& WATER HEATERS (MODEL CW)
INSTALLATION & OPERATION MANUAL
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI, 1103 kPa WATER.
WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.
WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
260 North Elm Street
7555 Tranmere Drive
Westfi eld, 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
FTF-IOM-1

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Summary of Contents for RBI FUTERA FUSION Series

  • Page 1 FTF-IOM-1 FUTERA FUSION SERIES FINNED COPPER GAS BOILERS (MODEL CB) & WATER HEATERS (MODEL CW) INSTALLATION & OPERATION MANUAL DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
  • Page 2: Table Of Contents

    Include the name of the service organization for future This manual covers the application, installation, operation reference. and maintenance of a Futera Fusion Series fi nned copper heating boiler/water heater. Direct all questions to your RBI distributor or contact the RBI Customer Service Department at: 260 North Elm To obtain the safe, dependable, effi...
  • Page 3: Ratings & Capacities

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS RATINGS & CAPACITIES NEVER place this boiler/water heater in a location that would subject it to temperatures at or near freezing, Before under taking the installation of the Futera see the “FREEZE PROTECTION” section on page 11. Fusion Series boiler/water heater check the rating plate to ensure that the unit has been sized properly WARNING: Never store combustible materials,...
  • Page 4 The RBI air intake adapter freely communicate with the outdoors must be present. The must be fi tted to the blower inlet. Combustion air can be...
  • Page 5: Vent System Options

    5 ft 1.5 m they must be supported at 3 ft, installer. 0.9 m intervals with overhead hangers. The certifi ed intake air terminal from RBI must be used, see Figures 1, 2 and 4. GENERAL VENTING GUIDELINES...
  • Page 6 ULC S636 for installations in Canada. The certifi ed vent line that it passes through, 4 ft, 1.2 m above the intake air terminal from RBI must also be used. terminal, see Figure 3. The maximum equivalent length for the horizontal vent pipe In addition the vent system must conform to the dimensions is 60 ft, 18.3 m.
  • Page 7 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 1– Horizontal Combustion Air and Venting for a Single Unit 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 1.5 FT 0.5 m 2000 & Larger 1201 To 2000 901 To 1200 200 To 900 1000 BTU'S Horizontal Distance, X...
  • Page 8 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 3 - Vertical Air Intake and Venting for Direct Vent System 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 Figure 4 – Combination Direct Vent Systems 3 FT.
  • Page 9 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS SIDE WALL VENT, POSITIVE PRESSURE, CATEGORY IV In this confi guration the boiler/water heater blower is used to push the fl ue products horizontally to the outdoors, see Figure 5. The air for combustion is taken from the space in which the unit is installed.
  • Page 10 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 6 – Vertical Venting with a Metal Chimney System 10 FT. 3.1 m...
  • Page 11: General Piping Requirements

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Flow Switch GENERAL PIPING REQUIREMENTS The fl ow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent CAUTION: Improper piping of this boiler/water heater the boiler from fi...
  • Page 12 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 – Futera Fusion Piping Pump Valve Balance Valve Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer Aquastat Union Automatic Air Vent Temperature & Pressure Relief Valve Vacuum Relief Valve Drain Valve (Typ.) 3-Way...
  • Page 13 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS CAUTION: A temperature rise outside of the range Low Water Cutoff listed in Table 7 indicates that the fl ow rate through the If a boiler is installed above any radiation elements it must heat exchanger is incorrect which will damage the heat be fi...
  • Page 14 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 - Typical Primary/Secondary, Low Temperature Piping System (See Notes) Pump Valve Balance Valve Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer Aquastat Union Automatic Air Vent H-16 Temperature & Pressure Relief Valve NOTES:...
  • Page 15 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 11 - Multiple Boiler Piping (See notes) Pump Valve Balance Valve Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer Aquastat Union Automatic Air Vent Temperature & Pressure Relief Valve Vacuum Relief Valve Drain Valve (Typ.)
  • Page 16: Domestic Water Supply Piping

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 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 CAUTION: Proper controls must be used to prevent relationship to scaling.
  • Page 17 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Table 8A - Futera Fusion Heat Exchanger Selection Graph To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed. Proper For hard/soft water pump selection, must consult factory. pump sizing will improve heater performance and help ensure heater longevity.
  • Page 18 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 12 - Typical Water Heating Piping (CW Models Only) (See Notes) Pump Valve Balance Valve Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer Aquastat Union D-17 Automatic Air Vent Temperature & Pressure Relief Valve Vacuum...
  • Page 19 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 13 - Multiple Water Heating Piping (CW Models Only) (See Notes) Pump Valve Balance Valve Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer Aquastat Union Automatic Air Vent D-18 Temperature & Pressure Relief Valve Vacuum...
  • Page 20: Gas Supply Piping

    Equivalent pipe length, (ft) Size, (in) site, call your RBI representative to resolve the problem. 1" 1 1/4" NOTE: A minimum gas supply pressure of 2 in, 51 mm, 1 1/2"...
  • Page 21: Electrical Wiring

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS GENERAL OPERATION WARNING: Never use an open fl ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can WARNING: Before proceeding read and fully cause extensive property damage, severe personal understand the instructions contained in this injury or death!
  • Page 22: Operating Instructions

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS C. Do not use this appliance if any part has been under OPERATING INSTRUCTIONS water. Immediately call a qualifi ed service technician FOR YOUR SAFETY READ BEFORE OPERATING. to inspect the appliance and to replace any part of the control system and any gas control that has been POUR VOTRE SÉCURITÉ...
  • Page 23 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 10. Monitor the fl ame current on the Honeywell Burner 2. Mettez l’appareil à l’arrêt ou réglez celui-ci au minimum. Control 7897C. No fl ame current should be detected and the 7897C should lock out. If fl ame current is 3.
  • Page 24: Checking & Adjustments

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 16. Laisser la chaudière compléter la séquence d’allumage Figure 16 – Spark Rod Position and Pilot Flame et atteindre son plein régime. Vérifiez le débit SEE DETAIL A tel qu’indiqué à la section «VÉRIFICATION ET 1/4 to 7/8 OF AN in 2 5/16 in 6.4 mm TO 22.2 mm...
  • Page 25: Control Description

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Required Gas Pressure Operating Control Provide gas supply pressure at inlet to boiler gas train as The preferred control setting for potable hot water is 130°F, follows: 54°C. The operating control should be set to the lowest setting that will satisfy the consumer's needs.
  • Page 26 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Installer Level Settings Boiler Purge (PMP DLY) After a demand is satisfi ed, the control continues to operate the boiler pump for a period of time. The length of time that Modes of Operation (MODE): The control allows for four the boiler pump continues to run is based on the PMP DLY modes of operation in order to defi...
  • Page 27: Diagnostics

    LOCKOUT TEKTRA ALARM: Indicates a problem with the is listed below. RBI Modulating Control. This is usually the result of a short or open circuit in one of the temperature sensors. Inspect STANDBY FUTERA FUSION: Indicates that power is being the sensor in question to see if it is connected properly.
  • Page 28 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS The outside surfaces of the copper tubes should Air Intake & Vent System be free of any soot deposits. A slight black smudge Thoroughly inspect the air intake and vent systems for is normal with some types of gases. Black soot any signs of blockage, corrosion or leakage.
  • Page 29: Trouble-Shooting

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE-SHOOTING PROBLEM POSSIBLE CAUSES REMEDIES No power to control circuit. Power not connected. Wire unit to line voltage. External circuit breaker open. Reset breaker. Transformer fuse open. Replace fuse. No action on call for heat. Primary limit or •...
  • Page 30 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE-SHOOTING PROBLEM POSSIBLE CAUSES REMEDIES Unit sparks but pilot will not fi re. Low gas pressure. Check gas supply pressure during ignition trial, adjust as necessary. Pilot valve manual knob closed. Open pilot valve manual knob. Pilot valve wires not connected.
  • Page 31: Repair Parts

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 – Exploded View...
  • Page 32 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 33 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Top/Bottom X Profi le 04-0523 04-0524 Middle X Profi le 04-0525 04-0526 Top Y Profi le 04-0530 Bottom Y Profi...
  • Page 34 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Ball Valve 11-0395 Firing Valve, 1" 11-0456 Firing Valve, 1 1/4" 11-0457 Firing Valve, 1 1/2" 11-0458 "A"...
  • Page 35 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Combustion Chamber Rear/Side Panel 70-2319 70-2320 70-2321 70-2322 70-2323 70-2324 70-2325 Combustion Chamber Door Assembly 70-2358 70-2359 70-2360...
  • Page 36 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Pump Contactor (C1, C2) 15-0118 Purge Timer, ST7800 16-0007 Spark Generator, Q652B 16-0008 Flame Safeguard, RM7897C 16-0024 Main Board 40-0068...
  • Page 37 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Vertical Frame Extension Profi le 04-1055 04-1056 04-1057 04-1058 04-1059 04-1060 04-1061 Vertical Center Frame Extension Profi le 04-1052 04-1053 04-1054...
  • Page 38: Startup Sheet

    FUTERA III / FUSION STARTUP SHEET DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL PHONE NUMBER: SERIAL #: PRE-STARTUP CHECK LIST INLET AIR FILTER INSTALLED AND CLEAN NO VISUAL DAMAGE TO UNIT PROPER SERVICE CLEARANCE PROVIDED PIPING PROPERLY CONNECTED PUMP RUNNING, HEAT EXCHANGER FULL BOILER CIRCULATOR WIRED GAS LINES PURGED, NO LEAKS, NO MISSING VENT/STACK CONNECTED...
  • Page 39 TESTING MODULATING BOILER CONTROL he boiler to control itself through the Modulating Boiler Control. Check sticker on the inside of the door Allow t or the Installation Manual for instructions on using the boiler control. BOIL TARGET TANK DIFF PUMP DELAY (MODE 3) BOILER OUT BOIL MAX...
  • Page 40 260 North Elm Street 7555 Tranmere Drive Westfi eld, 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...

Table of Contents