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FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS

CONTENTS

Before Your Start

page    2

Ratings & Capacities

page    3

Boiler/Water Heater Location

page    3

Combustion Air & Ventilation

page    3

General Venting Guidelines

page    5

Common Vent Systems

page  11

General Piping Requirements

page  12

Heating System Piping

page  13

Domestic Water Supply Piping

page  17

Gas Supply Piping

page  21

Electrical Wiring

page  22

General Operation

page  22

Operating Instructions

page  23

Checking & Adjustments

page  25

Control Description

page  26

MPA Staging Control

page  26

Diagnostics

page  27

Maintenance

page  28

Trouble-Shooting

page  30

Repair Parts

page  31

Startup Sheet

page  37

BEFORE YOU  START

This manual covers the application, installation, operation
and maintenance of a Futera III Series finned copper
heating boiler/water heater.

To obtain the safe, dependable, efficient operation and long
life for which this heating boiler/water heater was designed,
these instructions must be read, understood and followed.

AVERTISSMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour
réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel,
toute blessure ou la mort

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à
proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le
   bâtiment.
• Appelez immédiatement votre fournisseur de gas depuis un voisin.  Suivez les intructions du
   fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien
qualifié ou par le fournisseur de gaz.

The Futera III Series finned copper heating boiler/water
heaters have been design certified by CSA for use with
natural and propane gas under the latest revision of ANSI-
Z21.10.3/CSA 4.3, Gas Water Heaters, ANSI-Z21.13/CSA
4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers
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 absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest
revision. Where required by the authority having jurisdiction,
the installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.

In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for
Gas Burning Appliances and Equipment.

If installed in the Commonwealth of Massachusetts, you
MUST FOLLOW the additional instructions contained in
RBI’s instruction sheet MA IOM. If you don’t have a copy
call your RBI representative.

The owner should maintain a record of all service work
performed with the date and a description of the work done.
Include the name of the service organization for future
reference.

Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at: 260 North Elm
Street, Westfield, MA 01085 for US or 1300 Midway
Boulevard, Mississauga ONT L5T 2G8 for Canada. Always
include the model and serial numbers from the rating plate
of the boiler/water heater in question.

Summary of Contents for FUTERA III Series

Page 1: ...m WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammab...

Page 2: ...tion et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz The Futera III Series finned copper heating boiler water heaters have been de...

Page 3: ...tion 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 o...

Page 4: ...o 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 Ta...

Page 5: ...take air terminal must terminate as shown in Figure 3 The penetration point in the roof must be properly flashed and sealed Intake Air Option Horizontal Guidelines The maximum equivalent length for th...

Page 6: ...Horizontal vent systems shall terminate at least 4 ft 1 2 m below 4 ft 1 2 m horizontally from or 1 ft 0 30 m above any door window or gravity air inlet into any building It must not terminate less t...

Page 7: ...d 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 recomm...

Page 8: ...AND OPERATION INSTRUCTIONS Figure 3 Vertical Air Intake and Venting for 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 1 2 FT 1 7 m 1 5 FT...

Page 9: ...E CATEGORY IV In this configuration the boiler water heater blower is used to push the flue products horizontally to the outdoors see Figure 5 The air for combustion is taken from the space in which t...

Page 10: ...onry chimney When using a listed metal chimney system use the appropriate vent connector The vent connector should be sloped up toward the chimney at a minimum rate of 1 4 in ft 21 mm m On masonry chi...

Page 11: ...tion commun et tous les ventilateurs d extraction comme les hottes de cuisin re et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonc...

Page 12: ...REQUIREMENTS CAUTION Improper piping of this boiler water heater will void the manufacturer s warranty and can cause boiler failure resulting in flooding and extensive property damage Excessive water...

Page 13: ...thru 1000 2 NPT 2 NPT 1250 thru 2000 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...

Page 14: ...ated pump is used to maintain a constant water flow through the boiler This secondary pump is sized to overcome the head loss of the boiler and secondary piping system while supplying the flow rate re...

Page 15: ...ntain Inlet Temperature Above Dew Point T1 Temp Min 110 For Atmospheric T1 Temp Min 125 Sealed Combustion NOTES 1 Boiler circuit piping must be sized large enough to handle maximum flow through unit 2...

Page 16: ...obe Valve Balance Valve Backflow Prevention Device 5 Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units NOTES 1 Boiler circuit piping must be sized large...

Page 17: ...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 siz...

Page 18: ...changer Selection Graph Table 8B Futera III Pumping Performance Requirement To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed Pro...

Page 19: ...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...

Page 20: ...e remote aquastat well in lower 1 3 of tank Install aquastat with heat sensing compound 3 Thermal expansion tank may be required check local codes 4 When using optional factory mounted pump max pipe l...

Page 21: ...e 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 accordance with the National Fuel Code ANSI Z223 1 latest revision or...

Page 22: ...ions GENERAL OPERATION WARNING Before proceeding read and fully understand the instructions contained in this manual Do not attempt to operate this boiler water heater if it has not been installed in...

Page 23: ...voisin Suives les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies C Do not use this appliance if any part has been under water Immediately call...

Page 24: ...lumage 14 R glez la pression de la veilleuse tel qu indiqu la section V RIFICATION ET R GLAGES 15 Commutez nouveau le Honeywell 7895C en mode marche 10 Monitor the flame current on the Honeywell Burne...

Page 25: ...ot gas manual valves in the closed position energize the unit Observe the trial for ignition to confirm that the spark is strong and continuous If not check and adjust the spark gap as shown in Figure...

Page 26: ...ion 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...

Page 27: ...ns off the control keeps the boiler pump running for the time selected This setting allows purging of any excess heat out of the boiler after the boiler is shut off When PMP DLY is set to OFF there is...

Page 28: ...perly Also check to see if the sensor is shorted or open using an ohmmeter MAINTENANCE WARNING Disconnect electrical power and close the manual gas shut off valve before performing maintenance or seve...

Page 29: ...water heater is returned to service 8 Replace the heat exchanger and other components in the reverse order of their removal Air Intake Vent System Thoroughly inspect the air intake and vent systems f...

Page 30: ...ove setpoint temperature Lockout gas pressure is displayed with a call for heat Ensure that the manual main gas valve is open Ensure that there is sufficient gas pressure supplying the boiler Check pr...

Page 31: ...31 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 Exploded View RIOM 20 REV B SEE VIEW A SEE VIEW B 15C 15B SEE VIEW C...

Page 32: ...32 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS VIEW B ROTATED VIEW 16 18 VIEW A VIEW C RIOM 37 REV B...

Page 33: ...Gas Train Support Bracket Assembly 70 2344 1 1 70 2345 1 1 1 70 2346 1 1 15 Burner 10 0280 1 10 0309 1 10 0308 1 10 0286 1 10 0288 1 10 0290 1 10 0292 1 15a Burner Gasket 06 0026 1 1 1 06 0027 1 1 1 1...

Page 34: ...412 1 1 1 70 2413 1 1 1 1 28 Upper Rear Panel 70 2414 1 1 1 70 2415 1 1 1 1 29 Rear Pipe Enclosure Assembly 70 2333 1 1 1 70 2334 1 1 1 1 30 Lower Rear Jacket Panel 03 2822 1 03 2823 1 03 2824 1 03 28...

Page 35: ...Heat Exchanger Cupronickel 70 2193 1 70 2194 1 70 2195 1 70 2196 1 70 2197 1 70 2198 1 70 2199 1 47 Air Damper Assembly 70 2351 1 1 1 70 2353 1 1 70 2354 1 1 48 High Limit L4008E MB 14 0112 1 1 1 1 1...

Page 36: ...043 1 1 1 06 0044 1 1 1 1 61 Relay 2P 15 0107 1 1 1 2 2 2 2 NS Stainless Steel Wipes 66 0050 1 1 1 1 1 1 1 NS Rating Plate 82 0054 1 1 1 1 1 1 1 NS Paint 66 0013 1 1 1 1 1 1 1 NS Silicone 66 0151 1 1...

Page 37: ...right of the electrical panel on the control relay board Also locate the gas pressure tapping upstream of the main gas valve 1 Create head demand jumper the T1 terminals on the control board 2 With g...

Page 38: ...TS BOIL MAX MOTOR SPEED SAFETY TESTS CHECKLIST FLOW SWITCH LOW WATER CUTOFF AIR SWITCH HIGH LIMIT COMMISSIONING THE BOILER WATER HEATER UNIT CYCLED MIN OF 15 TIMES CUSTOMER INSTRUCTED ALL COVERS REPLA...

Page 39: ...39 FUTERA III INSTALLATION AND OPERATION INSTRUCTIONS...

Page 40: ...260 North Elm Street 1300 Midway Boulevard Westfield MA 01085 Mississauga Ontario L5T 2G8 Canada Phone 413 568 9571 Phone 905 670 5888 Fax 413 568 9613 Fax 905 670 5782 www rbiwaterheaters com...

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