RBI FUTERA II Series Installation And Operation Instructions Manual

Futera ii series finned copper tube gas boilers (fb) & water heaters (fw)

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Page 1 FTII-IOM-8 82-0253 Finned copper tube Gas boilers (FB) & Water heaters (FW) Boiler manual Installation and operation instructions Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Page 2: Table Of Contents
BEFORE YOUR START ......2 and maintenance of a Futera II Series finned copper heating boiler/water heater/pool heater.
Page 3: Ratings & Capacities
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 II Series See the “Freeze Protection” section on page 15. boiler/water heater check the rating plate to ensure that the unit has been sized properly for the job.
Page 4 3 in, 76 mm from, the top of the enclosure. using the direct vent option. The RBI air intake adapter The bottom opening must be within 12 in, 305 mm of, but must be ﬁ...
Page 5: General Venting Guidelines
3 ft, 0.9 m intervals with overhead hangers. The certiﬁ ed combustion air terminal from RBI must 2) Side Wall Vent, Positive Pressure, Category III uses be used and installed as shown in Figures 3 and 4.
Page 6 ULC S636 for installations in Canada. The certiﬁ ed vent ﬂ ue gases. terminal from RBI must also be used. Vertical Direct Vent Systems – Figure 5 The maximum equivalent length for the horizontal vent The maximum equivalent length for the vertical pipe is pipe is 60 ft, 18.3 m.
Page 7 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 1 - Air Intake Vertical or Thru Wall Figure 2 - Venting Thru Wall/Vertical...
Page 8 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 3 – Horizontal Air Intake and Venting for a Single Direct Vent System WARNING: 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 wall) in order to prevent pressure differences due to prevailing winds.
Page 9 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 5 - 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 6 – Combination Direct Vent Systems 3 FT.
Page 10 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS SIDE WALL VENT, VERTICAL/CHIMNEY VENT, POSITIVE PRESSURE, CATEGORY III NEGATIVE PRESSURE, CATEGORY I In this conﬁ guration the boiler/water heater blower is used The Futera II is listed as a Category I appliance when to push the ﬂ...
Page 11 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS WA R N I N G : Fa i l u r e t o m a i n t a i n m i n i mu m The vent connector should be sloped up toward the chimney at a minimum rate of 1/4 in/ft, 21 mm/m.
Page 12 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 – Vertical Venting with a Metal Chimney System...
Page 13: Outdoor Venting
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 – Vertical Venting using a Masonry Chimney 24" .6 m OUTDOOR VENTING Avoid locations where wind deflection off of adjacent When installed outdoors the Futera II must be ﬁ tted with walls, buildings or shrubbery might cause a downdraft. the factory supplied outdoor hood, air intake adapter with The unit(s) should be located at least 3 ft, 0.9 m from ﬁ...
Page 14: Common Vent Systems
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS e) Test for spillage at the draft hood relief opening after 5 COMMON VENT SYSTEMS minutes of main burner operation. Use the ﬂ ame of a If an existing boiler/water heater is removed from a match or candle, or smoke from a cigarette, cigar or common venting system, the common venting system may pipe.
Page 15 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS NOTE: Shut off valves and unions should be installed CAUTION: Improper outdoor installation of this unit at the inlet and outlet connections of the boiler/hot can cause boiler failure voiding the manufacturer’s water heater to provide for isolation of the unit should warranty! servicing be necessary.
Page 16: Heating System Piping
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS HEATING SYSTEM PIPING Table 5 - Temperature Rise Table ΔT = 20°F ΔT = 11.1°C Model Flow Rate Pres. Drop Flow Rate Pres. Drop General Piping Requirements Number All heating system piping must be installed by a qualiﬁ ed 42.5 0.53 technician in accordance with the latest revision of the...
Page 17 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Low Water Cutoff Low Return Water Temperatures If a boiler is installed above any radiation elements it must To prevent the problems associated with condensation of be ﬁ tted with a low water cutoff device. the products of combustion due to low return water temperatures a primary/secondary piping system with a Refer to the wiring diagram supplied with the boiler/water...
Page 18 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 13 - Typical Boiler Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve NOTES: Angle Valve 1. Boiler circuit piping must be sized Bufferfly Valve large enough to handle maximum ﬂ ow through unit.
Page 19 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 14A - Low Temperature Boiler Piping (See Notes and Adjustment Procedures) Pump Gate Valve Globe Valve NOTES: 1. Boiler circuit piping must Angle Valve be large enough to handle Adjustment Procedure maximum ﬂ ow through unit. To Maintain Inlet Temperature 2.
Page 20: Domestic Water Supply Piping
120˚F, 49˚C. Local codes must be complied with! General Piping Requirements RBI water heaters are designed to run scale free. Due to Ensure that the water heater is equipped with bronze the extreme variables of water conditions world wide it is headers.
Page 21 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Table 5A - Futera II Heat Exchanger Selection Graph Table 5B - Futera II Pumping Performance Requirement...
Page 22 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Expansion Tank A balancing valve should be installed on the outlet side of An expansion tank or other means to control thermal the water heater for purposes of adjusting the ﬂ ow rate expansion must be installed in the water heating system if through the heat exchanger.
Page 23 Bufferfly Valve Balance Valve D-1 Rev 6 Ball Valve Motorized Valve Attention: Not all RBI stock storage tanks incorporate this tapping: See Note 1. Solenoid Operated Valve Figure 17 - Multiple Water Heating Piping (FW Models Only) (See Notes) Self-Operated...
Page 24: Gas Supply Piping
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. NOTE: A minimum gas supply pressure of 6 in, 152 mm W.C.
Page 25: Electrical Wiring
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS ELECTRICAL WIRING Hydronic Heating Boilers Open the make-up water valve and slowly ﬁ ll the boiler and all of the radiation with water. Ensure that all bleed and Electrical Power Connections drain valves are closed. CAUTION: Label all wires prior to disconnection when Adjust the make-up water pressure regulator so a minimum servicing controls.
Page 26 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS DANGER: Propane gas may not always be detected Wait ﬁ ve (5) minutes to clear out any gas. Then smell by smell. Propane gas is heavier than air and can for gas, including near the floor. If you smell gas, collect in low areas.
Page 27: Checking & Adjustments
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Pilot Operation CHECKING & ADJUSTMENTS With the manual main gas valve and manual pilot gas valve On initial light-off, the installer may alter the preset factory closed energize the unit and allow it to try for ignition until settings to attain satisfactory combustion.
Page 28 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS When ﬁ re tested at the factory the unit’s input was Figure 21 – Air Box Pressure Tap rated and the gas pressure(s) recorded on the test label afﬁ xed to the jacket next to the junction box. To conﬁ...
Page 29: Control Description
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS “Static and operating gas pressure required at the gas Check the input rate as follows: valve inlet is between 5" W.C. and 14" W.C. for natural gas Turn off all other gas appliances that use the same gas and 11"...
Page 30: Diagnosticspage
Call For Low Fire: This green light will illuminate when there The RBI Digital Temperature Controller has three buttons: is a low ﬁ re heat demand either from the RBI Temperature “P”, “up” and “down”. The controller will display the current Controller or a Building Management Control.
Page 31: Maintenance
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS MAINTENANCE A badly corroded or damaged heat exchanger must be replaced, see the Heat Exchanger Repair & Replacement section. WARNING: Disconnect electrical power and close the manual gas shut off valve before performing Heat Exchanger Cleaning maintenance or severe personal injury may result! Close the shut off valves in the inlet and outlet piping.
Page 32 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Controls Use the “GENERAL OPERATION” and “CHECKING AND WARNING: A yellow, ﬂ oating ﬂ ame indicate a lack ADJUSTMENTS” sections of this manual for reference. of combustion air. Do not operate the boiler/water Check the thermostat or operating controls for proper heater until the problem is solved or severe operation.
Page 33: Trouble-Shooting
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE-SHOOTING OPERATIONAL PROBLEMS CORRECTIVE ACTION The On/Off toggle switch doesn’t illuminate. Ensure that proper voltage is being supplied to the unit. Inspect the circuit breaker for the boiler/water heater circuit. Ensure that the power switch operates properly and is wired correctly.
Page 34: Repair Parts
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 24 – Exploded View...
Page 35 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Base Panel Assembly 70-2163 70-2164 Gas Train Support Bracket 70-2141 70-2141.1 Base Panel Heat Exchanger Legs 03-1728 03-1729 Combustion Chamber Top Panel...
Page 36 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Pressure Switch (.58 WC) 70-9028 Pressure Switch (.80 WC) 70-9029 Pressure Switch (1.40 WC) 70-9039 Pressure Switch (1.10 WC) 70-9040...
Page 37 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Combustion Chamber Rear/Side Panel 70-2144 70-2145 70-2146 70-2147 70-2148 70-2149 70-2150 Jacket Front Panel 70-2055 70-2056 70-2057...
Page 38 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Jacket Lower Rear Panel 03-1760 03-1761 03-1762 03-1763 03-1764 03-1765 03-1766 Jacket Lower Rear Panel (SS) 03-1760.1 03-1761.1 03-1762.1...
Page 39 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Firing Valve, 1" 11-0456 Firing Valve, 1 1/4" 11-0457 Firing Valve, 1 1/2" 11-0458 Combustion Chamber Door Assembly 70-2156 70-2157...
Page 40 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 1950 Tridicator 0-100 psi (PRV 30 - 50 psi) 13-0308 Tridicator 0-230 psi (PRV 60 - 160 psi) 13-0305 Flow Switch 14-0203...
Page 41: Start Up Sheet
FUTERA II START UP SHEET Date of Start Up: RBI Ref. #: Serial # ('s): Boiler #1 Model# Boiler #2 Boiler #3 Boiler #4 Boiler #5 The above information will be used to identify each boiler in the system. You should make every attempt to afﬁ...
Page 42 SAFETY CHECKS AND ADJUSTMENTS Readings Or Checks By Boiler Number STEP DESCRIPTION Low water cut off Low gas pressure High gas pressure Operator okay and set @: High limit okay and set @: Blocked ﬂ ue switch drops out at ("W.C."): Flame fail time: With fan running: Record air box pressure "W.C."...
Page 43 FUTERA II START UP CHECK LIST The following items must be ﬁ eld veriﬁ ed as complete prior to the scheduling of factory authorized start up. 1. All electrical is installed and checked: ............2. All water connections are made: ..............3.
Page 44: Mass Code Page
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁ...
Page 45 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas ﬁ tter. (b) Exemptions The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1.
Page 46: Warranty
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. The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in...
Page 48: North Elm Street Westﬁ Eld, Ma
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS 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...

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