RBI FUTERA II Series Installation And Operation Instructions Manual Download Page 48

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FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

www.rbiwaterheaters.com

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

Summary of Contents for FUTERA II Series

Page 1: ...y death or substantial property damage Do not use the boiler during construction Construction dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust freeairsupply Followtheinstructionmanualprocedurestoductairtotheboilerairintake Iftheboilerhas...

Page 2: ... Heaters and CAN1 3 1 Industrial and Commercial Gas Fired Packaged Boilers Each unit has been constructed and hydrostatically tested for a maximum working pressure of 160 psi 1103 kPa in accordance with Section IV of the A S M E Boiler and Pressure Vessel Code All aspects of the boiler water heater installation must conform to the requirements of the authority having juris diction or in the absenc...

Page 3: ... water heater in a location that would restrict the introduction of combustion air into the unit or subject it to a negative pressure see GENERAL VENTING GUIDELINES 6 NEVER place this boiler water heater in a location that would subject it to temperatures at or near freezing See the Freeze Protection section on page 15 CAUTION Units installed outdoors MUST be protected from ice and snow accumulati...

Page 4: ...ust be given to the blockage effects of louvers grills and screens Screens must have a minimum mesh size of 1 4 in 6 4 mm If the free area through a louver or grill is not known ducts should be sized per Table 2 Table 2 Make up Air Louver Sizing Required Cross Sectional Area Input 1 4 in 6 4 mm 75 Free Area 25 Free Area MBH Wire Screen Metal Louvers Wooden Louvers in2 cm2 in2 cm2 in2 cm2 500 125 8...

Page 5: ...ngth for the horizontal combustion air pipe on installations that use the Horizontal Power Vent option is 100 ft 30 5 m Each 90 elbow and the combustion air terminal are equal to 10 linear ft 3 1 m of pipe If horizontal runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The certified combustion air terminal from RBI must be used and installed as shown in Fi...

Page 6: ...1 ft 0 30 m above any door window or gravity air inlet into any building It must not terminate less than 4 ft 1 2 m horizontally from and in no case above or below unless a 4 ft 1 2 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 ft 2 1 m from any adjacent public walkway The bottom of the vent terminal s shall be located at le...

Page 7: ...7 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 1 Air Intake Vertical or Thru Wall Figure 2 Venting Thru Wall Vertical ...

Page 8: ...nting for Multiple Direct Vent Systems WARNING 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 in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation ...

Page 9: ... AND OPERATION INSTRUCTIONS Figure 5 Vertical Air Intake and Venting for Direct Vent System Figure 6 Combination Direct Vent Systems 10 FT 3 1 m 4 FT 1 2 m 5 FT 1 5 m 1 5 FT 0 5 m 5 1 2 FT 1 7 m 1 5 FT 5 m 10 FT 3 1 m 3 FT 1 m ...

Page 10: ... appropriate power venter for the boiler water heater see Table 3 Follow the power venter manufacturer s installation instructions Table 3 Power Venter Sizes VERTICAL CHIMNEY VENT NEGATIVE PRESSURE CATEGORY I The Futera II is listed as a Category I appliance when vented vertically into a listed metal chimney system or properly sized masonry chimney Figures 8 9 The chimney must provide a negative p...

Page 11: ...t least 3 corrosion resistant sheet metal screws Always provide a minimum clearance of 6 in 152 mm between single wall vent pipe and any combustible materials Type B1 vent may be used clearance between it and any combustible material must be as listed WARNING Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive property ...

Page 12: ...12 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 Vertical Venting with a Metal Chimney System ...

Page 13: ...ted by adjacent units The boiler water heater must be at least 10 ft 3 1 m from any door window or gravity air inlet into any building and at least 3 ft 0 9 m from any overhang unless local codes dictate differently Avoid locations where wind deflection off of adjacent walls buildings or shrubbery might cause a downdraft The unit s should be located at least 3 ft 0 9 m from structures Outdoor inst...

Page 14: ...ions Adjust thermostat so appliance will operate continuously Mettre l appareil inspecté en marche Suivre les instructions d allumage Régler le thermostat de façon que l appareil fonctionne de façon continue e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe Faire fonctionner le br...

Page 15: ...r 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 Figure 12 Futera II Piping CAUTION Improper outdoor installation of this unit can cause boiler failure voiding the manufacturer s warranty Relief Valve...

Page 16: ...he 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 outside of the range listed inTable 5 indicates that the flow rate through the heat exchanger is incorrect which will damage the heat exchanger voiding the warranty The maximum allowable temperature rise is 35 F 19 4 C The maxi...

Page 17: ...ressure drop in the primary system see Figure 13 Low Return Water Temperatures To prevent the problems associated with condensation of the products of combustion due to low return water temperatures a primary secondary piping system with a bypass and bypass valve must be installed see Figure 14 The bypass and bypass valve must be sized the same as the secondary piping A balancing valve must also b...

Page 18: ...it 2 Boiler pump sized to boiler design flow requirements 3 All boilers furnished with factory mounted outlet water temperature gauge 4 Boiler pump purging required Use terminals supplied Notice These drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements H 18 Rev 2 NOTES 1 For pump selection consult factory 2 Boiler pump sized to b...

Page 19: ...just to lower desired temperature above Temp Min 4 Check after system operating temperature has stabiized Make final adjustments 5 Follow same adjustment procedure for sealed combustion H 3 Rev 5 NOTES 1 Boiler circuit piping must be large enough to handle maximum flow through unit 2 Boiler pump sized to boiler design flow requirements 3 All boilers furnished with factory mounted outlet water temp...

Page 20: ...ause excessive corrosion of the heat exchanger Water that has a hardness greater than 18 grains per gallon and or a level of dissolved solids exceeding 350 ppm will require a recalculation of the pump size and temperature rise A cupro nickel heat exchanger may also be required The manufacturer should be consulted when these water conditions are encountered See Table 5A CAUTION The maximum allowabl...

Page 21: ...21 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Table 5A Futera II Heat Exchanger Selection Graph Table 5B Futera II Pumping Performance Requirement ...

Page 22: ...g the warranty The method outlined below can be employed to prevent this condition from occurring A balancing valve should be installed on the outlet side of the water heater for purposes of adjusting the flow rate through the heat exchanger Thermometers are installed on both the inlet and outlet of the water heater for determining the temperature rise through the unit The proper velocity through ...

Page 23: ...total 6 90 elbows full pipe size 5 CAUTION MEASURE WATER HARDNESS AND pH AT JOB SITE The pH and water hardness must be measured before selecting heat exchanger and pump Consult the Heat Exchanger Graph and Pumping Performance Table before making selection 6 Common piping must be sized for maximum combined heater flow 7 Hot water tanks should be equipped with a combination temperature pressure reli...

Page 24: ... 10 3 Gate Valve2 0 6 0 8 0 9 1 2 Gas Cock2 1 5 1 9 2 3 3 0 Nominal Iron Pipe Size in Notes 1 For flow through branch 2 For flow at full open GAS SUPPLY PIPING WARNING Check the boiler water heater rating plate to make sure that the boiler water heater is for the type of gas that will be used If it isn t do not connect the boiler water heater to the gas supply Gas supply piping must be in accordan...

Page 25: ...ater En cas de surchauffe ou si l alimentation en gaz ne s arrête pas fermez manuellement le robinet d arrêt de l admission de gaz Hydronic Heating Boilers Open the make up water valve and slowly fill the boiler and all of the radiation with water Ensure that all bleed and drain valves are closed Adjust the make up water pressure regulator so a minimum 12 psig 82 7 kPa system pressure is maintaine...

Page 26: ...areil 1 Réglez le thermostat à la température la plus basse 2 Coupez l alimentation électrique de l appareil s il faut procéder à l entretien 3 Fermer la vanne manuelle d arrêt d alimintation de gaz DANGER Propane gas may not always be detected by smell Propane gas is heavier than air and can collect in low areas Propane gas can ignite or explode if an ignition source is present and result in deat...

Page 27: ... 50 to 64 mm above the surface of the burner Figure 19 To adjust the pilot the following steps must be taken 1 Remove the pilot gas pressure regulator cap 2 Turn the pressure regulator adjustment screw clock wise to increase the flame and counterclockwise to decrease it 3 Replace the pressure regulator adjustment screw cap Fire Testing 1 For an on off unit confirm that the low fire side of the two...

Page 28: ...er will retry every 5 minutes Inspect the ignition system to determine what the problem is 7 With the main burner in operation close the manual firing valve As soon as the main burner flames go out open the manual firing valve A normal ignition sequence should take place If the burner fails to light the system will make one more ignition attempt 8 With the burners in operation interrupt the power ...

Page 29: ...econds 7 If the computed rate deviates by more than 5 from the rated input value of the unit adjust the manifold pressure accordingly DO NOT adjust the manifold pressure by more than 5 If a proper rate cannot be maintained without adjusting the manifold pressure beyond the 5 limit the main burner orifices must be replaced If the input rate is too low go to the next larger size of main burner orifi...

Page 30: ...n temperature between stage 1 being called on and stage 2 being called on WARNING Setting the thermostat or operation control too high can result in scalding resulting in severe personal injury High Limit Aquastat The high limit is located in the top control area of the boiler water heater A remote capillary bulb is run to a well on the outlet side of the supply header The high limit can be reset ...

Page 31: ...case the heat exchanger must be cleaned thoroughly and the problem resolved before the boiler water heater is returned to service 6 If there are no signs of damage sooting or corrosion reassemble the unit following the previous steps in reverse order 7 A badly corroded or damaged heat exchanger must be replaced see the Heat Exchanger Repair Replacement section Heat Exchanger Cleaning 1 Close the s...

Page 32: ...e technician to have it inspected NEVER try to clean or repair the relief valve If the valve fails to operate properly have it replaced 5 The aquastat high limit controls the maximum water temperature in the boiler It is adjustable from 140 F 60 C to 250 F 121 C If the water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the boil...

Page 33: ... systems to ensure that blockages are not present Ensure that the vent and air intake systems conform to the guidelines in this manual Confirm that the blocked flue switch connections are correct and that it is functioning properly Ensure that the blower air inlet damper pressure switch are adjusted for the correct air box pressure 4 The Trial for Ignition indicator light illuminates Confirm that ...

Page 34: ...34 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 24 Exploded View ...

Page 35: ...embly 1 2HP 70 2201 1 1 Fan Assembly 3 4HP 70 2204 1 1 Fan Assembly Old Style 70 2202 1 1 Motor Old Style 12 0104 1 1 Impeller Old Style 12 0301 1 1 13 Pilot Tube Assembly 70 2185 1 1 1 70 2185 1 1 1 1 1 14 Spark Generator Q652B 16 0008 1 1 1 1 1 1 1 NS Purge Timer ST7800 16 0007 1 1 1 1 1 1 1 NS Mini Peeper C7027A 16 0009 1 1 1 1 1 1 1 NS Rocker Switch 48 0012 1 1 1 1 1 1 1 NS Ignition Reset Swit...

Page 36: ... 1 1 1 1 1 1 28 View Port Assembly 70 2205 1 1 1 1 1 1 1 29 View Port Glass 20 0006 1 1 1 1 1 1 1 NS Combustion Chamber Gasket 66 0101 25 25 25 25 25 25 25 30 Jacket Gasket Material 66 0102 25 25 25 25 25 25 25 31 Burner Gasket 06 0011 1 1 1 06 0012 1 1 1 1 32 Flame Safeguard RM7896C 16 0002 1 1 1 1 1 1 1 NS RM7800 Base 16 0003 1 1 1 1 1 1 1 NS Keyboard Display Module S7800A 16 0010 1 1 1 1 1 1 1 ...

Page 37: ...0 2061 1 1 Handle 20 0044 1 1 1 1 1 1 1 41 Jacket Left Side Panel 03 1767 1 03 1768 1 03 1769 1 03 1770 1 03 1771 1 03 1772 1 03 1773 1 Jacket Left Side Panel SS 03 1767 1 1 03 1768 1 1 03 1769 1 1 03 1770 1 1 03 1771 1 1 03 1772 1 1 03 1773 1 1 Jacket Right Side Panel 03 1774 1 03 1775 1 03 1776 1 03 1777 1 03 1778 1 03 1779 1 03 1780 1 Jacket Right Side Panel SS 03 1774 1 1 03 1775 1 1 03 1776 1...

Page 38: ...On Off Gas Valve V48A 1 1 4 120V 11 0364 1 1 1 On Off Gas Valve V48A 1 1 2 120V 11 0365 1 1 46 2 Stage Gas Valve V4944B 1 120V 11 0166 1 1 2 Stage Gas Valve V4944B 1 1 4 120V 11 0167 1 1 1 2 Stage Gas Valve V4944B 1 1 2 120V 11 0168 1 1 2 Stage Gas Valve V4944L 1 120V 11 0180 1 1 2 Stage Gas Valve V4944L 1 1 4 120V 11 0170 1 1 1 1 1 47 Main Gas Orifice NG 10 0051 1 10 0052 1 10 0053 1 10 0054 1 10...

Page 39: ...70 2522 1 Cast Iron 70 2523 1 70 2524 1 70 2525 1 70 2526 1 70 2527 1 70 2528 1 Heat Exchanger Assembly Cupronickel 70 2193 1 Bronze 70 2194 1 70 2195 1 70 2196 1 70 2197 1 70 2198 1 70 2199 1 52 Heat Exchanger V Baffle 03 1612 20 03 1613 20 03 1614 20 03 1615 28 03 1616 28 03 1617 28 03 1618 28 53 High Limit Well 3 8 x 3 13 0104 2 2 2 2 2 2 2 55 Heat Exchanger Flange Bolts 57 0124 8 8 8 8 8 8 8 5...

Page 40: ...0 2274 1 1 1 NS Air Filter Holder Assembly 70 2269 1 1 1 70 2270 1 1 70 2271 1 1 Air Filter Holder Assembly SS 70 2269 1 1 1 1 70 2270 1 1 1 1 70 2271 1 1 1 NS Rating Plate 82 0054 1 1 1 1 1 1 1 NS FII Overlay 82 0196 1 1 1 1 1 1 1 NS Paint 66 0013 1 1 1 1 1 1 1 NS Silicone 66 0151 1 1 1 1 1 1 1 NS Vent Termination Hood 8 09 0113 1 Vent Termination Hood 10 09 0115 1 1 Vent Termination Hood 12 09 0...

Page 41: ... tight 7 Fan no gas Verify no air leaks through outer cabinet 8 With fan running Record air box pressure W C 9 With fan running Record back pressure W C 10 Vent configuration HOR horizontal VER vertical 11 Equivalent vent length each fitting is 10 equivalent 12 Breaching size 13 Barometric installed location 14 Through wall venting with factory supplied termination 15 Pilot adjusted to within 1 tu...

Page 42: ...umber STEP DESCRIPTION 1 2 3 4 5 1 Remove manometers and replace plugs 2 Complete this start up form for rep 3 Fill out factory start up form w boiler 4 Correct each boiler s settings sticker 5 Replace all covers no air leaks 6 All valves opened and adjusted 7 Boiler pump is running 8 Final operator setting 9 Final high limit setting 10 Boiler left in operation 11 Boiler to require return visit 12...

Page 43: ...valve installed on outlet prior to isolation boiler only Yes No 7 T P gauge installed on outlet prior to isolation boiler only Yes No 8 Low water cut off installed and wired Yes No 9 Lead lag external controls installed and tested Yes No 10 All gas connections are complete Yes No 11 Gas pressure verified between 5 and 14 W C Yes No 12 Gas lines purged and tested for leaks Yes No 13 All stacks vent...

Page 44: ...side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above...

Page 45: ...nstructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identi...

Page 46: ... and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer s warranty See Installation Instructions for proper pump performance Chemical corrosion no corrosive chemical freon dry cleaning chemicals degreasing liquids chlorine or any chemicals that produce hydrochloric acid can be present in the boiler room as it rap...

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Page 48: ...TION AND OPERATION INSTRUCTIONS www rbiwaterheaters com 260 North Elm Street 7555 Tranmere Drive Westfield MA 01085 Mississauga Ontario L5S 1L4 Canada Phone 413 568 9571 Phone 905 670 5888 Fax 413 568 9613 Fax 905 670 5782 ...

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