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 mb) & water heaters (model mw)
Hide thumbs Also See for FUTERA FUSION SERIES:

Advertisement

FUTERA FUSION 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.
WITH
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
CONTROL
FTF-IOM-HN-1
82-0312

Advertisement

Table of Contents
loading

Summary of Contents for RBI FUTERA FUSION SERIES

  • Page 1 FTF-IOM-HN-1 82-0312 FUTERA FUSION SERIES FINNED COPPER GAS BOILERS (MODEL MB) & WATER HEATERS (MODEL MW) WITH CONTROL 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 Series fi nned copper heating RBI Customer Service Department at: 260 North Elm boiler/water heater.
  • 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 undertaking the installation of the Futera 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 FUSION INSTALLATION AND OPERATION INSTRUCTIONS All Air From Inside The Building Table 2 – Make-up Air Louver Sizing If the Futera is to be located in a confined space, the Required Cross Sectional Area minimum clearances listed in Table 1 must be maintained 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. NOTE: All venting and combustion air material supplied by installer.
  • 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 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 2000 & Larger 1201 To 2000 901 To 1200 200 To 900 When running horizontal combustion air and venting for single or multiple units, exhaust and...
  • Page 8 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 3 - Vertical Air Intake and Venting for Direct Vent System Note: Locate exhaust terminal downwind to reduce fl ue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m...
  • Page 9 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS SIDE WALL VENT, Figure 6 – Vertical Venting POSITIVE PRESSURE, CATEGORY IV with a Metal Chimney System In this confi guration the boiler/water heater blower is used to push the fl ue products horizontally to the outdoors, see Figure 5.
  • Page 10: Outdoor Venting

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS OUTDOOR VENTING Figure 7A – Outdoor Venting When installed outdoors the Futera Fusion must be fi tted with the factory supplied outdoor hood, air intake adapter with fi lter and exhaust terminal, see Figure 7A. Multiple units must be spaced per Figure 7B.
  • 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 8 - 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 D-18 Rev.1 Air Vent Temperature &...
  • Page 20: Gas Supply Piping

    Size, (in) Equivalent pipe length, (ft) 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 WARNING: Never use an open fl ame to test for gas GENERAL OPERATION 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 N’utilisez pas cet appareil s’il a été plongé dans l’eau, OPERATING INSTRUCTIONS 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 23 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 15. Adjust the pilot pressure per the CHECKING, 22. Open main isolation gas valve (fi eld supplied). ADJUSTMENT & OPERATION section. 23. Reset the Honeywell 7800. The boiler will start and 16. Remove the demand from the 7800 control by will run at minimum input rate.
  • Page 24: Sequence Of Operation

    FUTERA FUSION 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 25: Checking & Adjustments

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS CHECKING & ADJUSTMENTS CAUTION: Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur! Spark Gap With the main and pilot gas manual valves in the closed WARNING: The air damper adjustments must position energize the unit.
  • Page 26: Heatnet Field Wiring

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS RBI Field Wiring To HeatNet Board Figure 16 NOTES: 1. For master/member systems depress the dip switches J21 and J23 to the “on” position. For the “on” position press the switch down and in towards the board. This needs to be done on the master and the last member to terminate the communication network.
  • Page 27 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS RBI HeatNet Field Wiring To Terminal Block Legend NOTES: 1. Remove jumper “A” when using a low water cutoff interlock. 2. For multiple boilers utilizing a single combustion air damper or system pump controlled by the master boiler consult factory or obtain publication RIOM-76 for wiring details.
  • Page 28: Control Description

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS CONTROL DESCRIPTION DIAGNOSTICS The Futera Fusion has a display that indicates the sequence of Low Water Cutoff operation. The display will also list faults should the unit fail If the boiler is to be installed above radiation or if required to operate.
  • Page 29 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS LOW WATER CUTOFF: If there is a low water condition FLOW SWITCH ERROR: Once the Futera Fusion reported by the low water cutoff switch this fault is series boiler receives a call for heat, it closes the displayed.
  • Page 30 FUTERA FUSION 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 31: Maintenance

    FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS RETURN TEMP < 130°F: If the Return Inlet temperature Disconnect the compression nut from the inside of the transition piece. is less than 130°F this warning will be displayed. This Remove the transition piece, taking care not to damage warning does not affect operation and does not set the the spark rods and or their alignment.
  • Page 32 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Repair & Replacement The relief valve should not weep or discharge water A leaking or otherwise damaged tube(s) can be at normal system pressure. If it does, contact a replaced as outlined in steps 2 through 8. qualified service technician to have it inspected.
  • Page 33 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Series "Heat Net Control" Troubleshooting (Firing the Futera Fusion Boiler) Variable Frequency Futera Fusion Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2.
  • Page 34: Trouble-Shooting

    FUTERA FUSION 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 FUSION INSTALLATION AND OPERATION INSTRUCTIONS Figure 20 - Repair Parts SEE VIEW "B" SEE VIEW "C" SEE VIEW "A" RIOM-72...
  • Page 36 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS...
  • 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 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 FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 A Valve, 1" 11-0465 A Valve, 1 1/4" 11-0466 A Valve, 1 1/2" 11-0467 Blower, Fasco 7043 12-0016 Blower, Fasco 7035...
  • Page 39 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 Manning Glass Insulation (per square foot) 05-0104 Combustion Chamber Door Assembly 70-2358...
  • Page 40 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Transformer, 40 VA 15-0002 Pump Contactor (C1, C2) 15-0118 Pump Contactor 3PH 15-0111 Purge Timer, ST7800 16-0007 Spark Generator, Q652B 16-0008...
  • Page 41 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS Futera Fusion Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Condensate Drain Assembly 70-4001 Economizer 12-2001 12-2002 12-2003 Condensate Hose (ft) 62-0301 Thermostatic Valve (CB) 2" Cast Iron 13-0201 Thermostatic Valve (CB) 2 1/2"...
  • Page 42: Startup Sheet

    FUTERA III / FUSION START UP SHEET DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL PHONE NUMBER: SERIAL #: PRE-START UP 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...
  • Page 43 FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS COMBUSTION ANALYSIS LOW FIRE 100% FIRE GAS PRESSURE (IN. W.C.) AT ELBOW TEST PORT (IN. W.C.) (IN. W.C.) CO (PPM) NET STACK TEMP. SAFETY TESTS CHECKLIST FLAME SAFEGUARD FLOW SWITCH AIR SWITCH HIGH-LIMIT LOW WATER CUTOFF COMMISSIONING THE BOILER/WATER HEATER UNIT CYCLED MIN.
  • Page 44 WORKSHEET Setup Menu Boilers # of Boilers Lead Stage Heat Band ° Setpoints Local Setpoint ° Operate Limit ° Op Lim Band ° Setpoint Source Outdoor Air Reset ° OA Reset OA Setpoint ° Override Reset Set OA Setpoints Water Temp At High OA Temp °...
  • Page 45 Log/ Runtime Run Hours Data Log Entry Size Boiler Cycles Aux Functions Combust Air Damper In Use? Output Relay # Proof Time System Clock Advanced Setup DIstributed Ctrl Control H-Net Master Local Address Console Address Modular Boiler Set Add Boiler Delay Shed Boiler Delay Modulate Delay Time Mod Max –...
  • Page 46 FUTERA FUSION 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 47 FUTERA FUSION 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 48: 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...

Table of Contents