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Finned copper tube gas boilers & water heaters – Boiler Manual

4

F

F

  Combustion air contaminated with fl uorocarbons 

or other halogenated compounds such as cleaning 
solvents and refrigerants will result in the formation 
of acids in the combustion chamber. Th ese acids will 
cause premature failure of the boiler/water heater 

voiding the warranty!

  If the boiler/water heater is operated while the building 

is under construction it MUST be protected from 

wood, concrete, sheet rock and other types of dust. 
Failure to properly protect the unit from construction 

dust will damage the unit voiding the warranty!

Buildings will require the installation of a fresh air duct or other 

means of providing make-up air if the intake air option isn’t used. 

Any building utilizing other gas burning appliances, a fi replace, wood 

stove or any type of exhaust fan must be checked for adequate 
combustion air when all of these devices are in operation at one 
time. Sizing of an outside air duct must be done to meet the 
requirements of all such devices.

Never operate the Futera III in an environment 

subjected to a negative pressure unless it is Direct 

Vented.  Failure to comply with this warning can result 

in excessive levels of carbon monoxide causing severe 
personal injury or death!

All Air From Inside The Building 

If the Futera III is to be located in a confi ned space, the minimum 

clearances listed in Table 1 must be maintained between it and any 
combustible construction. When installed in a confi ned space 

without the intake air option,

 Figures 5, 6 and 7, two permanent 

openings communicating with an additional room(s) are required. 

Th e combined volume of these spaces must have suffi  cient volume 

to meet the criteria for an unconfi ned space. Th e total air 
requirements of all gas utilization equipment, fi replaces, wood stoves 
or any type of exhaust fan must be considered when making this 
determination. Each opening must have a minimum free area of 

1 in

2

/1000 Btu/hr

2200 mm

2

/kW

 based on the total input rating 

of ALL gas utilization equipment in the confi ned area. Each opening 
must be no less than 

100 in

2

64,516 mm

2

 in size. Th e upper 

opening must be within 

12 in

,

 305 mm

 of, but not less than 

3 in

76 mm

 from, the top of the enclosure. Th e bott om opening must 

be within 

12 in

305 mm

 of, but not less than 

3 in

76 mm

 from, 

the bott om of the enclosure.

All Air From Outside The Building 

When installed in a confi ned space 

without utilizing the intake 

air option

 two permanent openings communicating directly with, 

or by ducts to, the outdoors or spaces that freely communicate 

with the outdoors must be present. Th e upper opening must be 
within 

12 in

305 mm

 of, but not less than 

3 in

76 mm

 from, the 

top of the enclosure. Th e bott om opening must be within 

12 in

305 mm

 of, but not less than 

3 in

76 mm

 from, the bott om of 

the enclosure.

Where directly communicating with the outdoors or communi-

cating with the outdoors through vertical ducts, each opening shall 
have a minimum free area of 

1 in

2

/4000 Btu/hr

550 mm

2

/kW

 

of the total input rating of all of the equipment in the enclosure.

Where communicating with the outdoors through horizontal 

ducts, each opening shall have a minimum free area of 

1 in

2

/

2000 Btu/hr

1100 mm

2

/kW

 of the total input rating of all of 

the equipment in the enclosure. 

When ducts are used, they must have the same cross-sectional area 

as the free area of the opening to which they connect.

When calculating the free area necessary to meet the make-up air 

requirements of the enclosure, consideration must be given to the 
blockage eff ects 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.

Canadian installations must comply with CSA B149.1 when 

air 

supply

 is provided by natural air fl ow from the outdoors for 

natural 

draf

t, partial fan-assisted, fan-assisted, or power draft -assisted 

burners

, there shall be a permanent 

air supply

 opening(s) having 

a cross-sectional area of not less than 

1 in

2

 per

 

7,000 Btuh

 

(310 mm

2

 per kW)

 up to 

and including

 

1 million Btuh,

 plus 

1 in

2

 per 14,000 Btuh

 

(155 mm

2

 per kW)

 

in excess of

 

1 million Btuh

Table 2 

Make-up Air Louver Sizing

Required Cross Sectional Area

Input

(MBH)

1/4 in

 

6.4 mm

Wire Screen

75% Free Area

Metal Louvers

25% Free Area

Wooden Louvers

 

in

2

cm

2

in

2

cm

2

in

2

cm

2

  500

125

  

806

167

1077

  

500

   

3226

  750

187

1206

250

1613

  

750

  

 4839

1000

250

1613

333

2148

1000

  

 6452

1250

313

2019

416

2684

1250

   

8065

1500

375

2419

500

3226

1500

   

9677

1750

437

2819

583

3761

1750

11,290

1999

500

3226

667

4303

2000

12,900

Intake Air Option – General Guidelines 

Th is confi guration provides combustion air directly to the boiler/

water heater’s air intake adapter using a dedicated pipe when using 

the direct vent option. Combustion air can be drawn in horizontally 
through the same outside wall which terminates the exhaust gases 
or vertically through the roof, see Figures 1, 2, 3 & 4.

 

Common intake air systems may be used provided the 

common duct is sized properly. An intake combustion 
air damper should be installed if the common vent 
option is used in the intake air pipe of each heater. 

Improper installation can result in excessive levels of 

carbon monoxide which can cause severe personal 
injury or death!

Single wall galvanized smoke pipe, single wall aluminum pipe, 
fl exible aluminum pipe, PVC or CPVC pipe can be used for the 
intake air pipe. It must be sized per Table 3.

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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