12
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
NOTE: Shut off valves and unions should be installed
at the inlet and outlet connections of the boiler/hot
water heater to provide for isolation of the unit should
servicing be necessary.
Freeze Protection
This boiler/water heater is CSA designed certified for out-
door installation. Outdoor installations in areas where the
danger of freezing exists are not recommended unless
proper freeze protection is provided. The following
precautions MUST be observed:
1. A continuous flow of water through the unit MUST be
maintained! The pump responsible for flow through the
boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed to
must be used. The pump must be capable of producing
15% more flow and overcoming a 20% increase in head
loss. Domestic water systems must be isolated from the
water heater by the use of a heat exchanger or other
approved method.
3. If the unit must be shut off for any reason the electric,
gas and water supplies MUST be shut off and the unit
and its pump completely drained.
CAUTION
Improper outdoor installation of this unit can cause
boiler failure voiding the manufacturer’s warranty!
Relief Valve
Pipe the discharge of the pressure relief valve as shown
in Figure 10.
Figure 10 – Relief Valve Piping
Flow Switch
The flow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to prevent
the boiler from firing unless there’s adequate water flow
through the unit. The flow switch must be installed in the
supply piping adjacent to the boiler outlet connection.
CAUTION
Failure to properly install the flow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualified
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV,
and ANSI/ASME CSD-1, Standard for Controls and Safety
Devices for Automatically Fired Boilers. All applicable local
codes and ordinances must also be followed. A minimum
clearance of 1" must be maintained between heating
system pipes and all combustible construction. All heating
system piping must be supported by suitable hangers not
the boiler. The thermal expansion of the system must be
considered when supporting the system. A minimum
system pressure of 12 psig must be maintained.
Heating Boiler Piping Connections
The supply and return connections should be sized to suit
the system, see Table 6.
Table 6 – Supply & Return Pipe Sizing
Model Size
Supply Size (in) Return Size (in)
500 thru 1000 2" NPT
2" NPT
1250 thru 1950 2 1/2" NPT 2 1/2" NPT
Pump Requirements
This low mass boiler requires a continuous minimum water
flow for proper operation. The system pump must be sized
to overcome the head loss of the boiler and the heating
system in order to achieve the required temperature rise.
Table 7 provides the heat exchanger pressure drop and
temperature rise figures. The temperature rise across the
boiler must never exceed 35˚F (17˚C). The pump should
be wired to run continuously unless the optional pump
delay is installed. The adjustable pump delay turns the
pump on each time the burner fires and runs the pump for
6 to 600 seconds after the call for heat is satisfied.
CAUTION
A temperature rise listed in Table 7 indicates that the
flow rate through outside of the range the heat
exchanger is incorrect which will damage the heat
exchanger voiding the warranty! The maximum
allowable flow rate through a Futera II boiler is 75 GPM
on 500 through 1000 models and 110 GPM for 1250
through 1950 models. If higher flow rates are required
the optional Cupro-Nickel heat exchanger should be
considered.
WARNING
Never install any type of valve between the boiler/ water
heater and the relief valve or an explosion causing
extensive property damage, severe personal injury or death
may occur!
