RBI Futera III Manual
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RBI Futera III Manual

Finned copper tube gas boilers & water heaters 500 to 4,000 btuh input
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This manual is intended only for use by a qualified 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.
burner, resulting in possible severe personal injury, death or substantial property damage. The 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.
Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualified service technician, and
to follow all guidelines in the User' s Information Manual.
Finned copper tube
Gas boilers &

Water heaters

500 to 4,000 Btuh Input
HeatNet®
Control adjustment and
operation instructions
Also read and follow:
Futera
Futera Fusion Boiler manual or
Futera XLF Boiler manual
Construction dust and particulate, particularly drywall dust, will cause contamination of the
manual
III
Boiler manual or
Copyright 2009 Mestek, Inc.
HN-IOM-1
3382-0331

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Summary of Contents for RBI Futera III

  • Page 1: Water Heaters

    HN-IOM-1 3382-0331 Finned copper tube Gas boilers & Water heaters 500 to 4,000 Btuh Input manual HeatNet® Control adjustment and operation instructions Also read and follow: Futera Boiler manual or Futera Fusion Boiler manual or Futera XLF Boiler manual This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.

  • Page 2: Control Overview

    Finned copper tube gas boilers & water heaters – Control manual /XLF/FUSION Futera -Series boilers — HeatNet control Control overview The HeatNet control monitors boiler temperature and limit circuit inputs, modulating boiler firing rate to meet demand. The control uses microprocessor electronics, watching time-average response from the system to anticipate how much heat the system needs.
  • Page 3 Finned copper tube gas boilers & water heaters – Control manual /XLF/FUSION Futera -Series boilers — HeatNet control Electrical components Electrical enclosure Control panel — 4-line digi- tal display and navigation buttons (on front of control panel door — see opposite page) On/off switch —...
  • Page 4 Finned copper tube gas boilers & water heaters – Control manual /XLF/FUSION Futera -Series boilers — HeatNet control 1 Stand-alone boiler ..... . page 6 •...
  • Page 5 Finned copper tube gas boilers & water heaters – Control manual Contents • 4-20mA direct operation — Up to 5 boilers can be controlled by an external con- trol that provides a 4-20ma input signal. The external controls must also activate each boiler by closing a contact across the boiler’...
  • Page 6 Finned copper tube gas boilers & water heaters – Control manual Stand-alone boiler • Two-stage fired by using the T1 and T2 terminals. Clos- ing one of these brings the boiler on at MIN firing rate. Disconnect all electrical power Electrical shock hazard —...
  • Page 7 Finned copper tube gas boilers & water heaters – Control manual Stand-alone boiler (cont.) Call for heat operation PLUS delta temp mode — pump is on during heat After setting up the boiler per the I & OM Instructions, you calls, during pump postpurge time, and the pump will continue to run after can set MIN, MAX and IGNITION firing rates using the the postpurge timing until the temperature difference across the boiler is less...
  • Page 8 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: HeatNet modulation Set termination DIP switches Disconnect all electrical power Electrical shock hazard — The HeatNet network needs to recognize the beginning sources to the boiler before making any electrical connections. and end of the network.
  • Page 9 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: HeatNet modulation (cont.) Pump options Close the external manual gas valve Summer pump jog — enable to operate the circulator before proceeding. DO on every boiler pump once per week (at 12:01 AM on any specified day) NOT open any gas valve, or attempt to when the heater is shut down for summer shutdown.
  • Page 10 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: HeatNet modulation (cont.) Table 3 Control parameters for HeatNet networks Parameter Requirement — MASTER boiler Requirement — MEMBER boiler BOILERS LEAD STAGE # . . . . . . . . . . . . . HEAT BAND .
  • Page 11 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: HeatNet modulation (cont.) Table 3 Control parameters for HeatNet networks (continued) Parameter Requirement — MASTER boiler Requirement — MEMBER boiler DOMESTIC HOT WATER DHW BOILER? . . . . . . . . . . . . . Select YES if boiler/system is for DHW Set if boiler is enabled to run on local on loss of signal DHW SETPOINT .
  • Page 12 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: HeatNet modulation (cont.) The control’ s firmware version number will display. Make sure the After about 30 seconds, the master boiler should recognize the mem- firmware of all boilers is compatible. All boilers in a multiple boiler ap- ber boilers.
  • Page 13 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: BMS operation Option 1: Combined BMS/HeatNet Table 4 MODBUS holding (read/write) registers This method uses an RS485 digital communications cable Data Description Valid with the MODBUS protocol to control a boiler or HeatNet Address network.
  • Page 14 Finned copper tube gas boilers & water heaters – Control manual Multiple boilers: BMS operation (cont.) BACnet or LonWorks protocols Table 6 MODBUS input (read-only) registers Install the correct protocessor to adapt to building manage- ment systems using BACnet or LonWorks protocols. Each Data Description Valid Values/Range...
  • Page 15 Finned copper tube gas boilers & water heaters – Control manual External 4-20ma control Option 2: Direct modulation, up to 5 boilers Disconnect all electrical power Electrical shock hazard — sources to the boiler before making any electrical connections. Set up parameters as for a stand-alone boiler, beginning on Label all wires prior to disconnection when servicing controls.
  • Page 16 Finned copper tube gas boilers & water heaters – Control manual Configuring for DHW applications DHW options The HeatNet control allows four options for providing DHW heating. These are: Method 1 — , connected to ❑ A tank-temperature sensor the DHW Sensor input allows direct control of tank tem- perature.
  • Page 17 Finned copper tube gas boilers & water heaters – Control manual Configuring for DHW applications (continued) Post purge will increase tank temperature DHW Method 1 — Adding additional heat to above SETPOINT — the DHW tank after the setpoint temperature is DHW tank sensor reached will increase tank temperature ABOVE (on DHW Sensor terminals)
  • Page 18 Finned copper tube gas boilers & water heaters – Control manual Configuring for DHW applications (continued) Method 2 post purge option DHW Method 2 — When the tank thermostat opens, the boiler stops firing, but the Tank thermostat control DHW relay will remain on for the POST PURGE time set in the DHW Setup menu.
  • Page 19 Finned copper tube gas boilers & water heaters – Control manual Configuring for DHW applications (continued) Method 3 setup procedure DHW Method 3 — ❑ — Install a 10k tank temperature sensor in Tank sensor the tank. Wire it to the master boiler HEADER SENSOR DHW tank sensor (on HEADER Sensor terminals) terminals, J10A terminals 7/8 (Figure 4, page 23).

  • Page 20: Power Supply

    Finned copper tube gas boilers & water heaters – Control manual Wiring Power supply • — A header sensor (SYS- Header (SYSTEM HEADER) sensor is required TEM HEADER) must be installed in the system supply piping for HeatNet con- Refer to the Boiler Manual/wiring diagram and rating plate trolled systems.
  • Page 21 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) DHW wiring Override operation control setup — MEMBER boilers must be set up with operating parameters necessary during their override (local) operation. • To operate the boiler for domestic water heating with a storage tank, install and pipe the tank according to the tank A HeatNet boiler will respond to overrides in the following order.
  • Page 22 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 3 HeatNet control field wiring (also see Boiler Installation & Operation Instructions) — Verify against wiring diagram supplied with boiler PUMPS REQUIRE RELAYS OR STARTERS directly operate a pump using the —...
  • Page 23 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 4 HeatNet temperature sensors P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 24 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 5 Field wiring — relays, interlocks and boiler status P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 25 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 6 Primary/secondary piping — component electrical connections Component electrical connections Combustion air damper proving switch Combustion air damper motor enable DHW tank sensor (when used in lieu of DHW aquastat) DHW tank aquastat (when used in lieu of DHW sensor)
  • Page 26 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 7 Field wiring connections for 4-20mA remote operation If using a 0–10VDC signal, multiply any references to current in the manual by 0.5. For example: 5ma x 0.5 = 2.5 VDC.
  • Page 27 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 8 Field wiring connections for on/off and two-stage firing options P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 28 Finned copper tube gas boilers & water heaters – Control manual Wiring (continued) Figure 9 Installation of optional BACnet or LonWorks bridge — Protocessor (for MODBUS operation) P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 29 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments The HEATNET control display Figure 10 HeatNet display during Standby (no call for heat) — pressing the DOWN key on the Starting the display keypad changes the display as shown. LOCAL SET or SYSTEM SET can be adjusted Check all wiring to make sure it is complete and all wires are securely connected.
  • Page 30 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 7 SETUP menus (see Table 9, page 35 for explanations) To enter Setup: From STANDBY, hold for 5 seconds. (If SKIP PASSWORD is set to OFF, you will have to enter the password.) Then press with cursor on SETUP.
  • Page 31 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 7 SETUP menus (see Table 9, page 35 for explanations) (continued) Level 1 Level 2 Level 3 Default {Range} Typical line to change value next item next item next item...
  • Page 32 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 7 SETUP menus (see Table 9, page 35 for explanations) (continued) Level 1 Level 2 Level 3 Default {Range} Typical line to change value next item next item next item...
  • Page 33 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 8 ADVANCED SETUP menus (see Table 9, page 35 for explanations) To enter Setup: From STANDBY, hold for 5 seconds. (If SKIP PASSWORD is set to OFF, you will have to enter the password.) Then press with cursor on SETUP.
  • Page 34 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 8 ADVANCED SETUP menus (see Table 9, page 35 for explanations) (continued) Level 1 Level 2 Level 3 Default {Range} Typical line to change value next item next item next item...
  • Page 35 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 9 Setup menus — parameter explanations Menu item Under . . . Explanation FIRMWARE VERSION V X.XX All boilers in a multiple boiler application should preferably have the same firmware version to ensure consistency.
  • Page 36 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 9 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation OP LIM BAND SETPOINTS If the boiler outlet water temperature rises toward the OPERATE LIMIT setting, the HeatNet control will begin to reduce the boiler’s firing rate when the temperature gets...
  • Page 37 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 9 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation WWS SETPOINT The boiler and its circulator shut down when the outside air temperature is above WWS OUTDOOR AIR SETPOINT if outdoor air reset is enabled (ON).
  • Page 38 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 9 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation POST PRGE TIME The boiler pump can run after boiler shutdown to distribute heat remaining in the boiler PUMP OPTIONS water.
  • Page 39 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Table 9 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation PROOF TIME Set proof time long enough to be sure the combustion air damper can open and activate its AUX FUNCTIONS end switch.
  • Page 40 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments Control menus and adjustments (continued) (continued) Table 9 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation POST PURGE This is the time that the DHW relay remains on after the DHW call ends. DOMESTIC HOT WATER DHW MASTER? DOMESTIC HOT WATER...
  • Page 41 ADVANCED SETUP SENSORS Type Z is a thermistors sensor (as supplied by RBI). Type Z sensors are NTC thermistors, 10Kohms at 77 °F, 335.67 Kohms at -40 °F, 185 Kohms at 150 °F, +/- 1 °F, -40 to 140 °F.
  • Page 42 SYSTEM accuracy of the installation/operation information. The control displays the firmware version number when SETUP is accessed. To update the control’s firmware, obtain a disk from RBI or download the current file from the RBI website. See instructions on the following page for the procedure to load firmware to the HeatNet control, either from a PC or from a flash drive, as explained.
  • Page 43 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Downloading HeatNet firmware Navigate to ADVANCED SETUP / SYSTEM: LOAD FIRM- WARE. Firmware can be downloaded to the control through the USB port (J6) Select YES using the arrow keys.
  • Page 44 Finned copper tube gas boilers & water heaters – Control manual Control menus and adjustments (continued) Calibration of firing rates (blower speeds) This screen is for display only, and shows the setting for DELTA TEMP (see SETUP instructions on previous pages). This section describes use of the HeatNet control to set blower speeds for minimum input (MIN OUTPUT), maximum input (MAX OUTPUT) and pilot ignition pe- riod (IGNITION).

  • Page 45: Starting The System

    Finned copper tube gas boilers & water heaters – Control manual Boiler operation and status display Starting the system The upper left of the display will show boiler condition (prepurge, etc.) as the boiler begins its cycle. After the boiler begins firing, the screen will show RUN % as above.

  • Page 46: Troubleshooting

    Finned copper tube gas boilers & water heaters – Control manual Troubleshooting Accessing the data log Notice the snapshot #. This is a log entry, of which there are up to 1,000. The log stores major events that have occurred during the operation of As soon as you enter the view log screen, it displays the last log entry the boiler.
  • Page 47 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 10 Line #4 log entries Line #4 entry Explanation If one or more of the setbacks is enabled, these entries will occur when the setback is started or SETBACK#1 IS ACTIVE ended.
  • Page 48 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 10 Status screen fault displays (continued) Line #4 entry Explanation OPEN OUTSIDE SENSOR, This indicates a sensor was detected open or not connected. SUPPLY SENSOR, RETURN SENSOR, HEADER SENSOR, DHW SENSOR SHORT OUTSIDE SENSOR,...

  • Page 49: Fault Indications

    Some faults will cause the control to shut down the boiler or system and display the message. CALL FACTORY. Should this message appear, immediately contact RBI for assistance. The HeatNet control monitors both boiler and external interlocks, and will DO NOT attempt to correct the condition without shut down the boiler and display a fault code when a problem occurs.
  • Page 50 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 11 Status screen fault displays (continued) FAULT EVENT & CAUSE/Discussion DISPLAY Action required to INTERLOCK reset from fault TERMINALS Occurs on opening of gas pressure switches connected to FAULT SUPPLY Automatically resets...
  • Page 51 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 11 Status screen fault displays (continued) FAULT EVENT & CAUSE/Discussion DISPLAY Action required to INTERLOCK reset from fault TERMINALS Occurs on opening of a low water cutoff switch connected Automatically LOW WATER CUTOFF FAULT...
  • Page 52 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 12 Troubleshooting suggestions Situation Suggested procedure Check 120VAC power on the service connector, J1. Verify power is connected per wiring diagrams. Nothing happens when the power ❑...
  • Page 53 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 12 Troubleshooting suggestions (continued) Situation Suggested procedure In H-Net method, the control auto-detects the boilers in the system and adjusts the number of boilers Unable to change the # of Boilers ❑...
  • Page 54 Finned copper tube gas boilers & water heaters – Control manual Troubleshooting (continued) Table 12 Troubleshooting suggestions (continued) Situation Suggested procedure Turn the ON/OFF switch off. Then depress and hold the ESC key while turning it back on. This will load You have forgotten the password.
  • Page 55 Finned copper tube gas boilers & water heaters – Control manual Setup worksheet (record all parameters here) SETUP MENU SETUP MENU Menu item Default Value Menu item Default Value PUMP/VALVE OPTION BOILERS REMAINS ON: # OF BOILERS FLOW PROVE 10 seconds LEAD STAGE # NIGHT SETBACK HEAT BAND...
  • Page 56 Finned copper tube gas boilers & water heaters – Control manual Setup worksheet (record all parameters here) (continued) SETUP MENU SETUP MENU Menu item Default Value Menu item Default Value SETBACK LOW TEMP: SETBACK TIME TEMP LESS THAN 40°F START DAY HEAT EXCHANGER TIME ALARM TYPE...
  • Page 57 Finned copper tube gas boilers & water heaters – Control manual Setup worksheet (record all parameters here) (continued) ADVANCED SETUP MENU ADVANCED SETUP MENU Menu item Default Value Menu item Default Value MODULATE DELAY TIME CALIBRATED? MINUTES MINUTES SECONDS SECONDS SENSOR # MOD MAX –...
  • Page 58 Finned copper tube gas boilers & water heaters – Control manual Notes P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 59 Finned copper tube gas boilers & water heaters – Control manual Notes P/N HN-IOM-1 82-0331 Copyright 2009 Mestek, Inc.
  • Page 60 Finned copper tube gas boilers & water heaters – Control manual Control specifications Control Microprocessor based PID modulating control ( NOT a safety limit ) Environment –40 °F to 140 °F < 90% RH non-condensing Input Power 24 VAC, 250 ma Switched Line 120 VAC single phase (120 VAC models only)

This manual is also suitable for:

Futera xlfFutera fusion

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