RBI Futera Fusion XLF Installation And Operation Instructions Manual

Finned copper tube gas boilers

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Installation and operation instructions manual (48 pages)

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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 (CB)

Boiler manual

Installation and operation

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Summary of Contents for RBI Futera Fusion XLF

Page 1 FTFX-I0M-1 82-0347 Finned copper tube Gas boilers (CB) 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
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual If the information in this manual is not followed BEFORE YOU START ....2 exactly, a fi re or explosion may result causing property, RATINGS &...
Page 3: Ratings & Capacities
3. Ensure that the fl oor is structurally sound and will support the weight of the boiler. Direct all questions to your RBI distributor or contact the RBI Customer Service Department at: 260 North Elm Street, Westfi eld, Th e Futera may be installed directly on combustible MA 01085 for US or 7555 Tranmere Drive, Mississauga ONT L5S fl ooring, but never on carpeting.
Page 4 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Combustion air contaminated with fl uorocarbons Where directly communicating with the outdoors or communi- or other halogenated compounds such as cleaning cating with the outdoors through vertical ducts, each opening shall solvents and refrigerants will result in the formation have a minimum free area of 1 in /4000 Btu/hr, 550 mm...
Page 5: General Venting Guidelines
Finned copper tube gas boilers – Boiler Manual A UL listed stainless steel vent system must be used Table 3 Intake Air Pipe Sizing (Up to 100’) unless this unit is fi tt ed with an RBI supplied non- Model Vertical Horizontal metallic vent kit.
Page 6: Horizontal Direct Vent Systems
Th e vent materials used in horizontal vent systems must be certifi ed VENTILATION” and “GENERA L VENTING GUIDELINES” to UL 1738 for installations in the United States, ULC S636 for sections. installations in Canada. Th e certifi ed vent terminal from RBI must also be used.
Page 7 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual 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 venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall)
Page 8 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 3 Vertical Air Intake and Venting for a Direct Vent System Locate exhaust terminal downwind to reduce fl ue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT...
Page 9: Common Venting
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Side Wall Vent, Positive Pressure, Figure 6 Vertical Venting with a Metal Chimney System See Table 4, page 6 for minimum pipe dimensions Category IV – Figure 5 In this confi guration the boiler blower is used to push the fl ue products horizontally to the outdoors, see Figure 5.
Page 10: Outdoor Venting
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Th e vent piping must be large enough to safely vent the Always provide a minimum clearance of 6 in, 152 mm between combined output of all of the appliances connected single wall vent pipe and any combustible materials.
Page 11: General Piping Requirements
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual GENERAL PIPING REQUIREMENTS Figure 7 Outdoor Venting Improper piping of this boiler will void the manufac- turer’s warranty and can cause boiler failure resulting in fl ooding and extensive property damage! Excessive water hardness causing scaling in the copper heat exchanger tubes is NOT covered under the manufac-...
Page 12: Heating System Piping
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Th e maximum allowable primary heat exchanger Flow Switch temperature rise is 35°F, 19.4°C. Th e fl ow switch supplied with the boiler must be wired to the terminal strip in the control panel to prevent the boiler from fi ring unless there’...
Page 13 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 9 Fusion XLF Secondary Bypass Piping P u m p V al v e B al a nc e V a lv e P r e s s u r e R e d u c i n g V al v e C h e c k V al v e...
Page 14 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 10 Typical Primary/Secondary, Low Temperature Piping System (See Notes) H-16 REV C NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit. 2.
Page 15 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 11 Multiple Boiler Piping (See Notes) H-17 REV C NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through each unit. 2.
Page 16: Domestic Water Supply Piping
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual DOMESTIC WATER SUPPLY PIPING Expansion Tank An expansion tank or other means to control thermal expansion Proper controls must be used to prevent water supplied must be installed in the water heating system if back fl ow prevention for domestic use from exceeding 130°F, 54°C or a devices are installed.
Page 17 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 12 Typical Unit Heating Piping (See Notes) D-17 REV. C NOTES: 1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound.
Page 18 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 13 Multiple Unit Heating Piping (See Notes) D-18 REV. D NOTES: 1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound.
Page 19: Gas Supply Piping
67,600 46,500 37,300 31,900 28,300 Th e Futera Fusion XLF comes from the factory ready to be piped Pipe length in feet Pipe to the gas supply. If for any reason the boiler is not for the type of Size...
Page 20: Electrical Wiring
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual When applicable, provisions for vent, bleed and gas relief lines must ELECTRICAL WIRING be made in accordance with the latest revision of ANSI Z223.1/ NFPA 54.
Page 21: General Operation
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual GENERAL OPERATION OPERATING INSTRUCTIONS Before proceeding read and fully understand the instructions contained in this manual. Do not att empt FOR YOUR SAFETY READ BEFORE OPERATING. to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual.
Page 22 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual N’utilisez pas cet appareil s’il a été plongé dans l’eau, même Figure 15 Manometer connections to the test manifold (in partiellement. Faites inspecter l’appareil par un tecnicien qualifi é control cabinet) et remplacez toute partie du système de contrôle et toute commande qui ont été...
Page 23 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Verify low fi re operation Table 11 Pressure signal (Ps), ACTech (P45) - (Nat Gas) 1. Connect a manometer or Magnehelic gauge with the pressure 2500 3000 side to the manifold pressure port.
Page 24: Sequence Of Operation
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual 4. If the high fi re signal pressure is not correct: COMMENT COUPER L’ADMISSION DE GAZ DE a. Follow the instructions in the HeatNet Control manual to L’APAREIL calibrate the required input (Ps) for high altitude installations.
Page 25: Checking & Adjustments
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual CHECKING & ADJUSTMENTS Required gas pressure Provide gas supply pressure at inlet to boiler gas train as follows: Spark Gap Table 12 With the main and pilot gas manual valves in the closed position Gas supply pressure (Nat/LP) energize the unit.
Page 26: Heatnet Field Wiring
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 18 RBI Field Wiring to HeatNet Board (BoardRevision 2.0 and Greater) RIOM 86...
Page 27: Control Description
160˚F DIAGNOSTICS If there is a low water condition reported Th e Futera Fusion XLF has a display that indicates the sequence of LOW WATER CUTOFF: operation. Th e display will also list faults should the unit fail to by the low water cutoff switch this fault is displayed. Check that there is water fl ow and water in the boiler.
Page 28: Gas Pressure
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Th e variable frequency drive, which controls Once the Futera Fusion series boiler VAR FREQ DRIVE: FLOW SWITCH ERROR: the blower, reports this fault in the event of over current or other receives a call for heat, it closes the circulator pump relay.
Page 29: Combustion Air Damper
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual If the combustion air damper has If the shorted sensor fault is displayed, COMBUST AIR DAMPER: SHORTED ***** SENSOR: been selected for use (MASTER BOILER, AUX FUNCTIONS), the sensor in the position reported was originally detected, but and the proof switch does not make, this fault will be displayed.
Page 30: Maintenance
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual 5. Th e outside surfaces of the copper tubes should be free of MAINTENANCE any soot deposits. A slight black smudge is normal with some types of gases.
Page 31 Finned copper tube gas boilers – Boiler Manual Controls Manometer test port manifold 1. Th e Futera Fusion XLF includes a manometer test manifold. Use the “GENERA L OPERA TION” and “CHECKING AND Connect the manometer pressure hose to the Pressure Tap port ADJUSTMENTS”...
Page 32 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual Figure 21 Futera Fusion XLF pressure sensor hose routing Switch Settings in WC Switch 2500 3000 3500 4000 Main Blower (–) 0.20 (–) 0.20 (–) 0.20...
Page 33: Trouble-Shooting
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual 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 – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS Figure 22 Repair Parts...
Page 35 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Figure 22 Repair Parts (CONTINUED)
Page 36 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Left Base Channel 04-1018 Right Base Channel 04-1022 Burner...
Page 37 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Jacket Lower Rear Panel 03-3786 03-3787 03-3788...
Page 38 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Tridicator 30 - 60 psi 13-0308 Tridicator 75 - 160 psi 13-0305...
Page 39 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 High Limit, Jumo, (MB) 14-0013 High Limit, Jumo, (MW) 14-0014...
Page 40 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Pilot Orifi ce, .052 NG 10-0140 Pilot Orifi ce, .040 LP 10-0139...
Page 41 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Jacket Rear Front/Left Extension 70-3777.1 70-3777.2 70-3777.3...
Page 42 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual REPAIR PARTS (CONTINUED) Model Size with Item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Pipe Outlet Adapter 70-3708 70-3709 70-3751 Condensation Trap Assy...
Page 43: Start-Up Sheet
10. Check all combustion results using a calibrated fl ue gas analyzer. 11. Release the LOW FIRE switch to place boiler in standby. In addition to completing the Futera Fusion XLF start-up report, complete the control set-up information in the rear of the HeatNet Control manual.
Page 44: Combustion Analysis
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE GAS PRESSURE AT SUPPLY TEST PORT INCHES WC INCHES WC CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) INCHES WC INCHES WC SAFETY TEST CHECKLIST...
Page 45: Installation Requirements
Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusetts, the installation Improper venting can result in excessive levels of must be performed by a licensed plumber or gas fi tter. carbon monoxide which can cause severe personal injury or death! 1.
Page 46: 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 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 47 Finned copper tube gas boilers – Boiler Manual Finned copper tube gas boilers – Boiler Manual...
Page 48 260 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...