RBI FUTERA III Series Installation And Operating Instructions Manual

Finned copper tube gas boilers & water heaters

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Manual (61 pages)

Installation & operation manual (40 pages)

Control manual (128 pages)

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See also: User's Information Manual , Control Manual

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. Install, start and service the boiler only in the sequence and methods given in these

instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction.

of the burner, resulting in possible severe personal injury, death or substantial property damage. Th e boiler can only be operated with

a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated

by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service

technician, and to follow all guidelines in the User' s Information Manual.

Finned copper tube

Gas boilers (MB) &

Water heaters (MW)

Boiler manual

Installation and operation

instructions

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Summary of Contents for RBI FUTERA III Series

Page 1 FTIII-I0M-HN-4 82-0300 Finned copper tube Gas boilers (MB) & Water heaters (MW) Boiler manual Installation and operation instructions Also read and follow: HeatNet® Control Manual 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
Th is manual covers the application, installation, operation and installateur ou un service d’entretien qualifi é ou par le maintenance of a Futera III Series fi nned copper heating boiler/ fournisseur de gaz. water heater/pool heater (Canada only). To obtain the safe,...
Page 3: Ratings & Capacities
“FREEZE RATINGS & CAPACITIES PROTECTION” section on page 12. Before undertaking the installation of the Futera III Series boiler/ Never store combustible materials, gasoline or any water heater check the rating plate to ensure that the unit has been product containing fl ammable vapors or liquids in the sized properly for the job.
Page 4 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Where directly communicating with the outdoors or communi- Combustion air contaminated with fl uorocarbons cating with the outdoors through vertical ducts, each opening shall or other halogenated compounds such as cleaning have a minimum free area of 1 in /4000 Btu/hr, 550 mm...
Page 5: General Venting Guidelines
5 ft , 1.5 m they must be supported at 3 ft , 0.9 m intervals with application. Consult the vent manufacturer’ s product overhead hangers. Th e certifi ed intake air terminal from RBI must literature. be used, see Figures 1, 2 and 4.
Page 6: Horizontal Direct Vent Systems
UL 1738 for installations in the United States, ULC S636 for installations in Canada. Th e certifi ed vent terminal from RBI must Th e vent system must be gas tight. All seams and joints in metal also be used.
Page 7 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Figure 1 Hoizontal Air Intake an 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 venting for single or multiple units, exhaust and combustion air ter- 1000 BTU’S...
Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Figure 3 Vertical Air Intake and Venting for a 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...
Page 9 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il If an appliance using any type of a mechanical draft SIDE WALL VENT, POSITIVE PRESSURE, system operating under positive pressure is connected CATEGORY IV to a chimney fl ue, never connect any other appliances to this fl ue.
Page 10: Outdoor Venting
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Always provide a minimum clearance of 6 in, 152 mm between VERTICAL VENT, POSITIVE PRESSURE, single wall vent pipe and any combustible materials. CATEGORY IV Failure to maintain minimum clearances between vent (Vent pipe equivalent length up to 60 ft , 18.3 m maximum) connectors and any combustible material can result...
Page 11: Common Vent Systems
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Avoid locations where wind defl ection off of adjacent walls, buildings COMMON VENT SYSTEMS or shrubbery might cause a downdraft . Th e unit(s) shouild be On multiple boiler common vent applications, the master boiler located at least 3 ft , 1 m from structures.
Page 12: Freeze Protection
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il e) Test for spillage at the draft hood relief opening aft er 5 Shut off valves and unions should be installed at the minutes of main burner operation. Use the fl ame of a match inlet and outlet connections of the boiler/hot water or candle, or smoke from a cigarett e, cigar or pipe.
Page 13: Heating System Piping
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Figure 8 Futera III Piping HEATING SYSTEM PIPING Heating Boiler Piping Connections Th e supply and return connections should be sized to suit the system, see Table 6.
Page 14: Low Water Cutoff
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il A temperature rise outside of the range listed in Table Expansion Tank & Air Separator 7 indicates that the fl ow rate through the heat exchanger An expansion tank or other means to control thermal expansion is incorrect which will damage the heat exchanger must be installed in the heating system.
Page 15 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Figure 9 Typical Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve NOTES: Angle Valve 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit.
Page 16 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 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...
Page 17: Domestic Water Supply Piping
Th ermostatic Mixing Valve – Water Above 140°F, 60°C Water can be stored at temperatures above 140°F, 60°C provided that a RBI water heaters are designed to run scale free. Due to the extreme thermostatically controlled mixing valve is used to temper the hot variables of water conditions world wide it is necessary to water to an acceptable temperature before it’...
Page 18 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Table 8A Futera III Heat Exchanger Selection Graph Table 8B Futera III Pumping Performance Requirement...
Page 19 D-1 Rev 6 Bufferfly Valve Aquastat Union Balance Valve Pressure Switch Attention: Not all RBI stock storage tanks incorporate this tapping: See Note 1. Ball Valve Gas Pressure Regulator Figure 13 Multiple Water Heating Piping (MW Models Only) (See Notes)
Page 20: Gas Supply Piping
If for any reason the boiler/water heater is not for the type 2" 3050 2100 1650 1270 1270 1150 990 of gas available at the installation site, call your RBI representative Note: Multiply the gas volume by 0.62 for propane ﬂ ow capacity in ft /hr.
Page 21: Electrical Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Refer to the wiring diagram supplied with the boiler/water heater Never use an open fl ame to test for gas for proper wiring connections and boiler full load amperage (FLA). leaks.
Page 22: Operating Instructions
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il C. Do not use this appliance if any part has been under water. OPERATING INSTRUCTIONS Immediately call a qualifi ed service technician to inspect the FOR YOUR SAFETY READ BEFORE OPERATING.
Page 23 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 24. Sett ing the low fi re: Allow the low fi re to sett le out for a few Figure 15 HeatNet Control Panel minutes and observe the combustion reading.
Page 24: Sequence Of Operation
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il COMMENT COUPER L’ADMISSION DE GAZ DE Figure 14(a) L’APAREIL 1. Réglez le thermostat à la température la plus basse. 2. Coupez l’alimentation électrique de l’appareil s’il faut procéder à...
Page 25: Checking & Adjustments
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il CHECKING & ADJUSTMENTS Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows: Spark Gap Minimum (in. W.C.) With the main and pilot gas manual valves in the closed position Maximum (in.
Page 26: Heatnet Field Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il RBI FIELD WIRING TO HEATNET BOARD Figure 17...
Page 27 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il RBI HEATNET FIELD WIRING TO TERMINAL BLOCK (BoardRevision 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...
Page 28: Control Description
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il CONTROL DESCRIPTION STATUS SCREEN FAULT DISPLAY Th ere are numerous interlock switches and soft ware limits that are detected. Each of these, when tripped will produce a display message, Low Water Cutoff an audible beeping, and an alarm relay closure.
Page 29: Gas Pressure
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il Th e variable frequency drive, which controls Once the FIII series boiler receives a VAR FREQ DRIVE: FLOW SWITCH ERROR: the blower, reports this fault in the event of over current or other call for heat, it closes the circulator pump relay.
Page 30: Combustion Air Damper
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il If the combustion air damper has been SHORTED ***** SENSOR: If the shorted sensor fault is COMBUST AIR DAMPER: selected for use (MASTER BOILER, AUX FUNCTIONS), and displayed, the sensor in the position reported was originally detected, the proof switch does not make, this fault will be displayed.
Page 31: Maintenance
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 6. If there are no signs of damage, sooting or corrosion, reassemble MAINTENANCE the unit following the previous steps in reverse order. Disconnect electrical power and close the manual gas 7.
Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il A yellow, fl oating fl ame indicates a lack of combustion Controls air. Do not operate the boiler/water heater until the Use the “GENERA L OPERA TION” and “CHECKING AND AD- problem is solved or severe personal injury or death JUSTMENTS”...
Page 33: Trouble-Shooting
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il 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.
Page 34: Repair Parts
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS Figure 19 Exploded View...
Page 35 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED)
Page 36 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Burner for Turbo Pilot 70-2529.1 70-2530.1 70-2531.1...
Page 37 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Combustion Top Panel 70-2356 70-2357 Manning Glass Insulation (per square foot)
Page 38 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Inlet Adapters 01-0044GL 01-0045GL 01-0046GL Outlet Adapters...
Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 1000 1250 1500 1750 2000 Spark Rod Assembly 70-2566 70-2567 Electrode...
Page 40: Start-Up Sheet
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il START-UP REPORT DATE : JOB NAME: T E C HNI C IAN: L OCATION: CO MPANY : MO DEL : PH O NE N U MBER : S ERIAL # : PRE -STA T T R T UP CHE CK LIST...
Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS PRESSURE AT SUPPLY TEST PORT INCHES W.C . I NCHES W.C .
Page 42: Mass Code
Finned copper tube gas boilers & water heaters – Boiler Manual b il & B il NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels of tion must be performed by a licensed plumber or gas carbon monoxide which can cause severe personal fi tter.
Page 43: Limited Warranty
Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. 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.
Page 44 260 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 Copyright 2012 Mestek, Inc.