RBI FUTERA III Series Installation & Operation Manual
Futera iii series finned copper gas boilers (model mb) & water heaters (model mw)
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- Manual (61 pages) ,
- Installation and operating instructions manual (44 pages) ,
- Control manual (128 pages)
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FUTERA III SERIES FINNED COPPER
GAS BOILERS (MODEL MB)
& WATER HEATERS (MODEL MW)
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 flammable 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 fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personnal 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
1300 Midway Boulevard
Westfield, MA 01085
Mississauga, Ontario L5T 2G8 Canada
Phone: (413) 568-9571
Phone: (905) 670-5888
Fax: (413) 568-9613
Fax: (905) 670-5782
www.rbiwaterheaters.com
FTIII-IOM-1
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Summary of Contents for RBI FUTERA III Series
- Page 1 FTIII-IOM-1 FUTERA III SERIES FINNED COPPER GAS BOILERS (MODEL MB) & WATER HEATERS (MODEL MW) 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.
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Page 2: Table Of Contents
If installed in the Commonwealth of Massachusetts, you Diagnostics page 27 MUST FOLLOW the additional instructions contained in Maintenance page 28 RBI’s instruction sheet MA IOM. If you don’t have a copy Trouble-Shooting page 30 call your RBI representative. Repair Parts page 31... -
Page 3: Ratings & Capacities
RATINGS & CAPACITIES NEVER place this boiler/water heater in a location that Before undertaking the installation of the Futera III Series would subject it to temperatures at or near freezing, boiler/water heater check the rating plate to ensure that the see the “FREEZE PROTECTION”... - Page 4 The RBI air intake adapter freely communicate with the outdoors must be present. The must be fitted to the blower inlet. Combustion air can be...
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Page 5: Vent System Options
1) Direct Vent, Positive Pressure, Category IV uses a 0.9 m intervals with overhead hangers. The certified intake vent system certified to UL 1738 for installations in the air terminal from RBI must be used, see Figures 1, 2 United States, ULS636 for installations in Canada. and 4. - Page 6 ULS636 for installations in Canada. The certified 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 III INSTALLATION AND OPERATION INSTRUCTIONS Figure 1– Horizontal Air Intake and Venting for a Single Direct Vent System 4 FT 1.2 m 1/4 IN. PER FOOT 20 mm/m 3 FT 0.9 m 16 FT 4.9 m 5 FT 1.5 m 5 FT 1.5 m 1.5 FT 0.5 m When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals...
- Page 8 FUTERA III 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 III INSTALLATION AND OPERATION INSTRUCTIONS SIDE WALL VENT, WARNING: If an appliance using any type of a POSITIVE PRESSURE, CATEGORY IV mechanical draft system operating under positive In this configuration the boiler/water heater blower is used pressure is connected to a chimney flue, never to push the flue products horizontally to the outdoors, see connect any other appliances to this flue.
- Page 10 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Always provide a minimum clearance of 6 in, 152 mm Vent Connections between single wall vent pipe and any combustible Locate the boiler/water heater as close to the chimney as materials. possible. Use the shortest, straightest vent connector possible for the installation.
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Page 11: Common Vent Systems
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 7 – Vertical Venting using a Lined Masonry Chimney 24" .6 m COMMON VENT SYSTEMS Inspecter de façon visuelle le système d’évacu-ation If an existing boiler/water heater is removed from a pour déterminer la grosser et l’inclinaison horizontale common venting system, the common venting system may qui conviennent et s’assurer que le système est exempt then be too large for the proper venting of the remaining... -
Page 12: General Piping Requirements
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS GENERAL PIPING REQUIREMENTS d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. CAUTION: Improper piping of this boiler/water heater will void the manufacturer’s warranty and can cause Mettre l’appareil inspecté... -
Page 13: Heating System Piping
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 – Futera III Piping HEATING SYSTEM PIPING Pump Requirements This low mass boiler requires a continuous minimum water General Piping Requirements flow for proper operation. The system pump must be sized All heating system piping must be installed by a qualified to overcome the head loss of the boiler and the heating technician in accordance with the latest revision of the system in order to achieve the required temperature rise. - Page 14 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Table 7 - Temperature Rise Table Primary/Secondary Piping Boilers connected to heating systems using zone valves, ∆T = 20°F ∆ T = 11.1 ° C Flow Rate Pres. Drop Model Flow Rate Pres. Drop zone pumps, or systems that have excessive flow rates or Number return water temperatures less than 125˚F, 52˚C must be...
- Page 15 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 - Typical Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve Angle Valve Bufferfly Valve Balance Valve Ball Valve Motorized Valve Solenoid Operated Valve H-1 Rev 2 Self-Operated Valve Figure 10 - Low Temperature Piping Pressure (See Notes and Adjustment Procedures) Reducing Valve...
- Page 16 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 11 - Multiple Boiler Piping (See notes) Pump Gate Valve Globe Valve Angle Valve Bufferfly Valve Balance Valve Ball Valve Motorized Valve Solenoid Operated Valve Self-Operated Valve Pressure Reducing Valve Check Valve Pressure Relief Valve H-15 Rev 2 Flow Switch...
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Page 17: Domestic Water Supply Piping
General Piping Requirements Ensure that the water heater is equipped with bronze RBI water heaters are designed to run scale free. Due to headers. Piping and components connected to the water the extreme variables of water conditions world wide it is heater must be suitable for use with potable water. - Page 18 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Table 8A - Futera III 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 pump sizing will improve heater performance and help ensure heater longevity. Table 8B - Futera III Pumping Performance Requirement...
- Page 19 FUTERA III 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 flow rate expansion must be installed in the water heating system if through the heat exchanger.
- Page 20 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 12 - Typical Water Heating Piping (MW Models Only) (See Notes) Pump Valve Globe Valve Angle Valve Bufferfly Valve D-1 Rev 4 Balance Valve Ball Valve Motorized Valve Figure 13 - Multiple Water Heating Piping (MW Models Only) (See Notes) Solenoid Operated Valve...
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Page 21: Gas Supply Piping
Equivalent pipe length, (ft) Size, (in) 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 22: Electrical Wiring
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS GENERAL OPERATION WARNING: Never use an open flame 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! manual. -
Page 23: Operating Instructions
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS OPERATING INSTRUCTIONS C. Do not use this appliance if any part has been under FOR YOUR SAFETY READ BEFORE OPERATING. water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the POUR VOTRE SÉCURITÉ... - Page 24 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS 10. Monitor the flame current on the Honeywell Burner 2. Mettez l’appareil à l’arrêt ou réglez celui-ci au minimum. Control 7895C. No flame current should be detected and the 7895C should lock out. If flame current is 3.
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Page 25: Checking & Adjustments
FUTERA III 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 tel SEE DETAIL A 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 26: Control Description
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS “Static and operating gas pressure required at the gas High Limit (Aquastat) valve inlet is between 2" W.C. and 14" W.C. for natural gas The high limit is located in the top control area of the boiler/ and 2"... -
Page 27: Diagnostics
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Tank Differential (TANK DIFF), Mode 3 Only Mode 3: Domestic Hot Water (DHW) generation. The A differential setting that operates 1/2 above and below the Futera III is piped in parallel with the storage tank. An TANK TARGET is selectable using the TANK DIFF item in additional sensor is required to monitor the tank the Adjust menu. -
Page 28: Maintenance
LOCKOUT TEKTRA ALARM: Indicates a problem with the exchanger must be cleaned thoroughly and the problem RBI Modulating Control. This is usually the result of a short resolved before the boiler/water heater is returned to or open circuit in one of the temperature sensors. Inspect service. - Page 29 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS A badly corroded or damaged heat exchanger must Controls be replaced, see the Heat Exchanger Repair & Use the “GENERAL OPERATION” and “CHECKING AND Replacement section. ADJUSTMENTS” sections of this manual for reference. Check the operating controls for proper operation. Heat Exchanger Cleaning A float type low water cutoff device must be flushed Close the shut off valves in the inlet and outlet piping.
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Page 30: Trouble-Shooting
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE-SHOOTING OPERATIONAL PROBLEM CORRECTIVE ACTION “Standby Futera III” is not shown. 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 31: Repair Parts
FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 – Exploded View... - Page 32 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...
- Page 33 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Top/Bottom X Profile 04-0523 04-0524 Middle X Profile 04-0525 04-0526 Top Y Profile 04-0530 Bottom Y Profile 04-0531 04-0532...
- Page 34 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Firing Valve 3/4" 11-0461 Ball Valve 11-0395 Firing Valve, 1" 11-0456 Firing Valve, 1 1/4" 11-0457 Firing Valve, 1 1/2"...
- Page 35 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Combustion Chamber Door Assembly 70-2358 70-2359 70-2360 70-2361 70-2362 70-2363 70-2364 Pressure Relief Valve 50# 30-0360 Pressure Relief Valve 50# 30-0374...
- Page 36 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Blocked Flue Switch 11-0411 Terminal Block 6P 48-0157 Terminal Block 4P 48-0161 Mini Peeper, C7027A 16-0009 UV Amplifier, R7849A 16-0006...
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Page 37: Startup Sheet
FUTERA III MODULATION STARTUP SHEET DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL #: PHONE NUMBER: SERIAL #: PRE-STARTUP CHECK LIST NO VISUAL DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCE PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL VENT/STACK CONNECTED GAS LINES PURGED, NO LEAKS, NO MISSING... - Page 38 TESTING MODULATING BOILER CONTROL Remove jumpers from the AA and T1 terminals. Allow the boiler to control itself through the Modulating Boiler Control. Check sticker on the inside of the door or the Installation Manual for instructions on using the boiler control.
- Page 39 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...
- Page 40 260 North Elm Street 1300 Midway Boulevard Westfield, MA 01085 Mississauga, Ontario L5T 2G8 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...
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