RBI FUTERA III Series HeatNet Installation & Operation Manual
RBI FUTERA III Series HeatNet Installation & Operation Manual

RBI FUTERA III Series HeatNet Installation & Operation Manual

Futera iii series finned copper with heatnet control gas boilers (model mb) & water heaters (model mw)

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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 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
Westfi eld, MA 01085
Phone: (413) 568-9571
Fax: (413) 568-9613
WITH
CONTROL
7555 Tranmere Drive
Mississauga, Ontario L5S 1L4 Canada
Phone: (905) 670-5888
Fax: (905) 670-5782
www.rbiwaterheaters.com
FTIII-IOM-HN-2
82-0300
10/09

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Summary of Contents for RBI FUTERA III Series HeatNet

  • Page 1 FTIII-IOM-HN-2 82-0300 FUTERA III SERIES FINNED COPPER WITH CONTROL 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.
  • Page 2: Table Of Contents

    BEFORE YOU START reference. This manual covers the application, installation, operation Direct all questions to your RBI distributor or contact the and maintenance of a Futera III Series finned copper RBI Customer Service Department at: 260 North Elm heating boiler/water heater.
  • Page 3: Ratings & Capacities

    FUTERA III 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 undertaking the installation of the Futera III Series see the “FREEZE PROTECTION” section on page 12. boiler/water heater check the rating plate to ensure that the unit has been sized properly for the job.
  • Page 4 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS All Air From Inside The Building Table 2 – Make-up Air Louver Sizing If the Futera III is to be located in a confi ned space, Required Cross Sectional Area the minimum clearances listed in Table 1 must be Input 1/4 in 6.4 mm 75% Free Area...
  • Page 5: Vent System Options

    Canada. Combustion air is obtained from the space in 0.9 m intervals with overhead hangers. The certifi ed intake which the unit is installed. air terminal from RBI must be used, see Figures 1, 2 and 4. 3) Vertical/Chimney Vent, Negative Pressure, Category II uses a metal chimney system approved for Category II.
  • 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 III INSTALLATION AND OPERATION INSTRUCTIONS Figure 1– Horizontal Air Intake and Venting for a Single Direct Vent System 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 1.5 FT 0.5 m When running horizontal combustion air and 1000 BTU'S 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 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 WARNING: If an appliance using any type of a SIDE WALL VENT, mechanical draft system operating under positive POSITIVE PRESSURE, CATEGORY IV pressure is connected to a chimney fl ue, never In this confi guration the boiler/water heater blower is used connect any other appliances to this fl...
  • Page 10 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS VERTICAL VENT, The vent connector should be sloped up toward the POSITIVE PRESSURE, CATEGORY IV chimney at a minimum rate of 1/4 in/ft, 21 mm/m. On masonry chimneys the connector must terminate fl ush with (Vent pipe equivalent length up to 60 ft, 18.3 m maximum) the inside of the chimney fl...
  • Page 11: Outdoor Venting

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 7A – Outdoor Venting Figure 7B – Multiple Outdoor Units 2 FT GAS TRAIN COWLING (0.62 M) AIR INLET UNDER COWLING DISCHARGE VENT FLUE TEST PORT 3 FT (1 M) CONDENSATE DRAIN WITH PIG TAIL RIOM-60 REV.
  • Page 12: General Piping Requirements

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Dans la mesure du possible, fermer toutes les portes Tout mauvais fonctionnement du systéme d’évacu-tion et les fenêtres du bâtiment et toutes les portes entre commun devrait étré corrigé de façor que l’installation l’espace où les appareils toujours raccordés du système soit conforme au National Fue Gas Code, ANSI d’évacuation sont installés et les autres espaces du Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/...
  • Page 13: Heating System Piping

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Relief Valve Flow Switch Pipe the discharge of the pressure relief valve as shown The fl ow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent in Figure 8.
  • Page 14 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Pump Requirements Low Water Cutoff This low mass boiler requires a continuous minimum water If a boiler is installed above any radiation elements it must fl ow for proper operation. The system pump must be sized be fi...
  • Page 15 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 - Typical 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. 2.
  • Page 16 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 10A - Low Temperature 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 17: Domestic Water Supply Piping

    120˚F, 49˚C. Local codes must be complied with! Table 8B. 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 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 fl ow rate expansion must be installed in the water heating system if through the heat exchanger.
  • Page 20 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 13 - Multiple Water Heating Piping (MW Models Only) Self-Operated (See Notes)
  • Page 21: Gas Supply Piping

    Iron Pipe not for the type of gas available at the installation site, call Size, (in) Equivalent pipe length, (ft) 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 WARNING: Never use an open fl ame to test for gas Refer to the wiring diagram supplied with the boiler/water leaks. Always use an approved leak detection heater for proper wiring connections and boiler full load method.
  • Page 23: Operating Instructions

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS OPERATING INSTRUCTIONS N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un FOR YOUR SAFETY READ BEFORE OPERATING. tecnicien qualifi é et remplacez toute partie du système de contrôle et toute commande qui ont été...
  • Page 24 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS 15. Adjust the pilot pressure per the CHECKING, WARNING: Improper wiring of the ignition ADJUSTMENT & OPERATION section. transformer can result in an explosion causing extensive property damage, severe personal 16. Remove the demand from the 7800 control by injury or death! disabling the Low Fire switch allowing the boiler to stop.
  • Page 25: Sequence Of Operation

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS INSTRUCTIONS DE MISE EN MARCHE SEQUENCE OF OPERATION 1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette. NO DEMAND Standby 2. Réglez le thermostat à la température la plus basse. 1.
  • Page 26: Checking & Adjustments

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS CHECKING & ADJUSTMENTS Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows: Spark Gap With the main and pilot gas manual valves in the closed Minimum (in W.C.) position energize the unit.
  • Page 27: Heatnet Field Wiring

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS RBI Field Wiring To HeatNet Board Figure 17...
  • Page 28 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS RBI HeatNet Field Wiring To Terminal Block (Board Revision 2.0 and Greater) NOTES: 1. Remove jumper “A” when using a low water cutoff interlock. 2. For multiple boilers utilizing a system air damper when in a master/member confi...
  • Page 29: Control Description

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS CONTROL DESCRIPTION HIGH LIMIT: When the high limit aquastat trips the following message is displayed: Low Water Cutoff If the boiler is to be installed above radiation or if required FAULT SYSTEM SET by other codes or regulations, install a low water cutoff in HIGH LIMIT appropriate piping.
  • Page 30 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS FLOW SWITCH ERROR: Once the FIII series boiler LOW WATER CUTOFF: If there is a low water condition receives a call for heat, it closes the circulator pump reported by the low water cutoff switch this fault is relay.
  • Page 31 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS COMBUST AIR DAMPER: If the combustion air damper SHORTED ***** SENSOR: If the shorted sensor fault is has been selected for use (MASTER BOILER, AUX displayed, the sensor in the position reported was FUNCTIONS), and the proof switch does not make, this originally detected, but has since shorted.
  • Page 32: Maintenance

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS RETURN TEMP < 130°F: If the Return Inlet temperature Lift and remove the transition piece and burner together from the boiler/water heater, taking care not to damage is less than 130°F this warning will be displayed. This the spark rods and or their alignment.
  • Page 33 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS The relief valve should not weep or discharge water Heat Exchanger Repair & Replacement A leaking or otherwise damaged tube(s) can be at normal system pressure. If it does, contact a qualified service technician to have it inspected. replaced as outlined in steps 2 through 8.
  • Page 34: Trouble-Shooting

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Troubleshooting A Startup Symptom Identify Source Check Action An Interlock is tripped. 1. Is it a 24 VAC Interlock? 1. All 24 VAC Interlocks are 1.Use a multimeter and check located on J11A and J11B. for 24 VAC on J11A,J11B to Examples of 24 VAC Interlocks: identify which interlock has...
  • Page 35: Repair Parts

    FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 19 – Exploded View SEE VIEW "B" RIOM - 74 SEE VIEW "C" RIOM - 74 SEE VIEW "A" RIOM - 74 RIOM-67 REV A RIOM-67 REV A RIOM-67 REV A...
  • Page 36 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 37 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 Profi le 04-0523 04-0524 Middle X Profi le 04-0525 04-0526 Top Y Profi le 04-0530 Bottom Y Profi...
  • Page 38 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Orifi ce Plate 03-2911 03-2912 03-2913 03-2914 03-2915 03-2916 03-2917 Firing Valve 3/4" 11-0461 Manual Pilot Valve 11-0031 Ball Valve...
  • Page 39 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Lower Left & Right Jacket Panel 03-2835 03-2836 03-2837 03-2838 03-2839 03-2840 03-2841 Upper Front Jacket Panel (HeatNet) 70-2446 70-2447 Front Jacket Panel (Outdoor)
  • Page 40 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Air Filter 09-0483 09-0484 Tridicator 30 - 60 psi 13-0308 Tridicator 75 - 160 psi 13-0305 Heat Exchanger Assembly (Copper) 70-2515.1...
  • Page 41 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Futera III Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Power Switch 48-0013 Toggle Switch 48-0010 Air Pressure Switch 11-0416 Blocked Flue Switch 11-0411 Low Gas Pressure Switch (Manual Reset) 11-0414 High Gas Pressure Switch (Manual Reset)
  • Page 42: Startup Sheet

    START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STA T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL VENT/STACK CONNECTED GAS LINES PURGED, NO LEAKS, NO MISSING TEST...
  • Page 43 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS 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 ELBOW PRESSURE (W.C.) INCHES W.C. INCHES W.C. SAFETY TEST CHECKLIST FLOW SWITCHES AIR SWITCH FLAME SAFEGUARD LOW WATER CUT-OFF...
  • Page 44 FUTERA III 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 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. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board;...
  • Page 46 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 47 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 48 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...

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