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Finned copper tube gas boilers & water heaters – Boiler Manual

23

F

F

Figure 15 

HeatNet Control Panel

17.  Close main isolation gas valve (fi eld supplied), Figure 14.
18. Remove the manometer fi tt ing from the pilot test port and 

replace the plug. Place monitor tube on to the test port tee 
located along the1/3" hose piped directly off  of the manifold 
test port, Figure 14(a).

19.  Switch the Honeywell 7800 back to “run”.

20.  Create a min input demand as before (enable Low Fire Hold 

switch.) Th e boiler will begin the start sequence.

21.  Monitor the fl ame current on the 7800. No fl ame current should 

be detected and the 7800 should lock out. If fl ame current is 
detected at any time up to the 7800 locking out, the 120V wiring 
on the ignition transformer must be reversed and the test run 
again to insure that no fl ame is detected.

Improper wiring of the ignition transformer can result 

in an explosion causing extensive property  damage, 
severe personal injury or death!

22.  Open main isolation gas valve (fi eld supplied).
23.  Reset the Honeywell 7800. Th e boiler will start and will run 

at minimum input rate. 

MANUAL RESET 

PUMP MOTOR

RELAY

TRANSFORMER

FLAME

SAFEGUARD
MODULE

HEAT NET
CONTROL
BOARD

PROTOCESSOR
MODULE
(OPTIONAL)

LOCAL REMOTE

SWITCH

TEST RUN
SWITCH

POWER SWITCH

IGNITION STATUS

WINDOW

SELECT BUTTON

BACK

BUTTON

DISPLAY

WINDOW

UP BUTTON

DOWN BUTTON

24.  

Sett ing the low fi re:

 Allow the low fi re to sett le out for a few 

minutes and observe the combustion reading. Refer to 

“Combustion Reading” table for proper combustion readings 

and elbow pressure, Table 12.

 

Th e low fi re O

2

-CO

2

 can be adjusted in the fi eld by opening 

the low fi re adjustment door located on the forward facing side 
of the main gas valve, see Figure 14(a). Inserting an allen wrench 
and rotating the allen screw clock-wise will increase the CO

and lower the O

2

, rotating counter clock-wise will decrease the 

CO

2

 and increase the O

2

DO NOT LEAVE THE BURNER 

IN AN INFRA

 RED STATE.

 A few random speckles of red 

are fi ne, but large concentrations of spots or large areas of red 
are not. If large amounts of red concentrations are observed, 

verify combustion readings. 

25.  Jumper the “AA” terminals located on the HeatNet control board. 

Th e boiler input will rise to its maximum input, “Run 100%”, 

see Figure 17.

26.  Allow the boiler to reach steady state and verify supply gas 

pressure and check input rates as explained in the “Gas Supply 

Piping” section. Also, refer to “Combustion Reading” table for 

proper combustion readings and elbow pressure, Table 12. Th e 
high fi ve trim is located on the outlet fl ange of the gas valve, 
see Figure 14(a). O

2

-CO

2  

can be adjusted by inserting a screw 

driver and rotating clockwise to increase the CO

and lower 

the O

. Rotating counterclockwise will decrease the CO

2

 and 

increase the O

2

.

27.  Remove jumper “AA” and allow boiler to sett le into minimum 

input. Observe the combustion readings and make any fi nal 
adjustments. When fi nished disable the Low Fire Hold Switch 
and replace test ports to normal state. 28.  Boiler  allows  for 
many modes of operation and control methods. Reference the 

“HeatNet Control  Manual”. 

Table 12 

Combustion Readings

Natural Fuel 

Propane Fuel

CO

2

 %

8.0 - 8.5 (min.)

9.4 - 9.9  (min.)

8.8 - 9.8 (100%)

10.3 - 11.5 (100%)

O

2

 %

6.6 - 5.8  (min.)

6.6 - 5.8  (min.)

5.2 - 3.5 (100%)

5.2 - 3.5 (100%)

For factory set gas manifold (elbow) pressures see label on
inner cabinet door.

Summary of Contents for FUTERA III Series

Page 1: ...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 b...

Page 2: ...vent this unit can cause excessive amounts of carbon monoxide resulting in severe personal injury or death DESIGNED AND TESTED ACCORDING TO A S M E BOILER AND PRESSURE VESSEL CODE SECTION IV FOR A MA...

Page 3: ...earance in mm in mm Top 6 153 30 762 Back 6 153 24 610 Left Side 6 153 12 306 Right Side 6 153 12 306 Front 6 153 30 762 2 An optimum site will be level central to the piping system close to a chimney...

Page 4: ...ning must be within 12 in 305 mm of but not less than 3 in 76 mm from the top of the enclosure The bottom opening must be within 12 in 305 mm of but not less than 3 in 76 mm from the bottom of the enc...

Page 5: ...tions must comply with CAN CGA B149 1 or 2 Installation Code Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death All vent systems mus...

Page 6: ...ion rated for 400 F 204 C Horizontal vent systems shall terminate at least 4 ft 1 2 m below 4 ft 1 2 mhorizontallyfromor1 ft 0 30 maboveanydoor window or gravity air inlet into any building It must no...

Page 7: ...single or multiple units exhaust and combustion air ter minals must be installed on the same plane outside wall in order to prevent pressure differences due to prevailing winds Incoldclimates double...

Page 8: ...s boilers water heaters Boiler Manual 8 F F Figure 3 Vertical Air Intake and Venting for a Direct Vent System Figure 4 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...

Page 9: ...chimney system manufacturer s instructions must be followed Masonry chimneys when used must be lined with a metal liner certified for Category IV venting When more than one appliance is connected to t...

Page 10: ...rate of 1 4 in ft 21 mm m On masonry chimneys the connector must terminate flush with the inside of the chimney flue Figure 7 Fasten each single wall vent connection with at least 3 corrosion resista...

Page 11: ...ing system Scellertouteslesouverturesnonutilis esdusyst med vacuation b Visuallyinspecttheventingsystemforpropersizeand horizontal pitch and determine there is no blockage or restriction leakage corro...

Page 12: ...property damage Excessive water hardness causing scaling in the copper heat exchanger tubes is NOT covered under the manufacturer s warranty see Table 8 Excessive pitting and erosion of the internal...

Page 13: ...l expansion of the system must be considered when supporting the system A minimum system pressure of 12 psig 82 7 kPa must be maintained Heating Boiler Piping Connections Thesupplyandreturnconnections...

Page 14: ...ump An air scoop and automatic air vent must also be installed to eliminate air trapped in the system Primary Secondary Piping Boilersconnectedtoheatingsystemsusingzonevalves zonepumps or systems that...

Page 15: ...low through unit 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 supplie...

Page 16: ...Valve Gate Valve Globe Valve Balance Valve Backflow Prevention Device H 15 Rev 4 NOTES 1 Boiler circuit piping must be large enough to handle maximum flow through unit 2 Boiler pump sized to boiler de...

Page 17: ...ess between 8 and 18 and by maintaining the pH between 5 and 9 Follow the conditions listed under NORMAL in the table In some areas of the country additional precautions must be observed due to unusua...

Page 18: ...Fi d b b il h B il M l Finned copper tube gas boilers water heaters Boiler Manual 18 F F Table 8A Futera III Heat Exchanger Selection Graph Table 8B Futera III Pumping Performance Requirement...

Page 19: ...ing selection 6 Common piping must be sized for maximum combined heater flow 7 Hot water tanks should be equipped with a combination temperature pressure relief valve 8 MA Code requires an 1 8 hole in...

Page 20: ...nt trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls A ground joint union should be installed between the boiler gas controls and the supply piping Each of...

Page 21: ...ing materials for units installed oudoors The wire size must be compatible with the total amp draw of the circuit Refer to the wiring diagram supplied with the boiler water heater for proper wiring co...

Page 22: ...has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water N utilisez pas...

Page 23: ...ow fire O2 CO2 can be adjusted in the field by opening the low fire adjustment door located on the forward facing side ofthemaingasvalve seeFigure14 a Insertinganallenwrench and rotating the allen scr...

Page 24: ...setting 2 Turn off all electric power to the boiler if service is to be performed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 R glez le ther...

Page 25: ...easure pressure when the boiler is firing at full rate Low gas pressure could indicate undersized gas line or insufficient gas supply Static and operating gas pressure required at the gas valve inlet...

Page 26: ...Fi d b b il h B il M l Finned copper tube gas boilers water heaters Boiler Manual 26 F F RBI FIELD WIRING TO HEATNET BOARD Figure 17...

Page 27: ...ethods in which a 4 20mA signal can be used to control HeatNet equipped boilers Method 1 A 4 20mA signal can be used to directly modulate each boiler from a remote panel or building management system...

Page 28: ...on The display will also list faults should the unit fail to operate An explanation of each status message and fault can be located in HeatNet Control Manual under status screen fault display section...

Page 29: ...ck The interlock is located on J11B SPARE 4 FAULT SYSTEM SET 160 F INTERLOCK SPARE 4 FLOW SWITCH ERROR Once the FIII series boiler receives a call for heat it closes the circulator pump relay It then...

Page 30: ...AULT SYSTEM SET 160 F OPEN OUTSIDE SENSOR SHORTED SENSOR If the shorted sensor fault is displayed thesensorinthepositionreportedwasoriginallydetected but has since shorted The boiler will shut down on...

Page 31: ...tion Green deposits indicate condensation due to low return water temperatures In either case the heat exchanger must be cleaned thoroughly and the problem resolved before the boiler water heater is r...

Page 32: ...s contact a qualified service 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 Theaquastathighlimitcontrolsthemax...

Page 33: ...11A J11B to identify which interlock has tripped Reset the Interlock or check for disconnected wiring or shorts The Air Pressure from UV Sensor interlock if displayed will allow the boiler to function...

Page 34: ...Fi d b b il h B il M l Finned copper tube gas boilers water heaters Boiler Manual 34 F F Figure 19 Exploded View REPAIR PARTS...

Page 35: ...Fi d b b il h B il M l Finned copper tube gas boilers water heaters Boiler Manual 35 F F REPAIR PARTS CONTINUED...

Page 36: ...rt CSD 1 11 0354 1 1 1 1 1 1 1 NS Flange 1 Outlet 11 0228 1 1 1 1 NS Flange 1 Inlet 11 0231 1 1 1 1 NS Flange 1 1 4 11 0213 2 NS Flange 1 1 2 Inlet 11 0214 2 2 NS Flange 1 1 2 Outlet 11 0229 1 1 1 NS...

Page 37: ...1 1 1 NS Air Filter 09 0483 1 1 1 09 0484 1 1 1 1 45 Tridicator 30 60 psi 13 0308 1 1 1 1 1 1 1 Tridicator 75 160 psi 13 0305 1 1 1 1 1 1 1 46 Heat Exchanger Assembly Copper Cast Iron prior to 0209 mu...

Page 38: ...7 1 1 1 1 1 1 1 52 Spark Generator Q652B 16 0008 1 1 1 1 1 1 1 53 Flame Safeguard RM78957C 16 0024R 1 1 1 1 1 1 1 NS Keyboard Display Module S7800A 16 0010 1 1 1 1 1 1 1 54 Main Board HeatNet green 16...

Page 39: ...1 70 2567 1 1 1 1 84 Electrode 16 0335 1 1 1 1 1 1 1 NS Spark Rod O ring 06 0008 1 1 1 1 1 1 1 NS Silicone 66 0151 1 1 1 1 1 1 1 NS Silicone Tubing 66 0051 2 2 2 2 2 2 2 NS Vent Termination Hood 5 09...

Page 40: ...ttom of the electrical panel Disable any external call for heat and toggle the remote local switch to REMOTE 1 Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition 2 Se...

Page 41: ...THE DELTA T BETWEEN THE HEATER INLET AND OUTLET IS CRITICAL TO PROPER FLOW BEFORE YOU LEAVE THE JOBSITE YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 35 F 19 4 C NOR BE LOWER THAN 20 F 11...

Page 42: ...terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRU...

Page 43: ...bes 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...

Page 44: ...t 2012 Mestek Inc 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 www rbiwaterhea...

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