background image

Fi

d

b

b il

&

h

B il

M

l

Finned copper tube gas boilers & water heaters – Boiler Manual

12

F

F

Flow Switch

Th e fl ow switch supplied with the boiler/water heater must be 

wired to the terminal strip in the control panel to prevent the boiler 

from fi ring unless there’s adequate water fl ow through the unit. Th e 
fl ow switch must be installed in the supply piping adjacent to the 
boiler outlet connection.

  Failure to properly install the fl ow 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 qualifi ed 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 in

25 mm

 must be maintained 

between heating system pipes and all combustible construction. 

All heating system piping must be supported by suitable hangers 

not the boiler. Th e thermal expansion of the system must be 
considered when supporting the system. A minimum system 
pressure of 

12 psig

82.7 kPa

 must be maintained.

Bleed Air From Boiler

Open the water heater piping bleed valves one at a time, to purge 
the air trapped in the primary and secondary heat exchangers. Refer 
to piping drawings (Figures 9, 10 & 11) for bleed locations. 

Heating Boiler Piping Connections

Th e supply and return connections should be sized to suit the system, 

see Table 7. 

Table 7 

Supply & Return Pipe Sizing

 Model Size 

  Supply Size 

Return Size  

500 thru 1000 

 2” NPT 

 2” NPT 

1250  thru  2000                          

2  1/2”  NPT

2  1/2”  NPT

Pump Requirements

Th is low mass boiler requires a continuous minimum water fl ow 

for proper operation. Th e boiler pump is sized to overcome the 
head loss of the boiler and the near piping in order to achieve the 
required temperature rise. Th e temperature rise across the boiler 
must never exceed 

35°F

19.4°C

. Th e adjustable pump delay turns 

the pump on each time the burner fi res and runs the pump for 20 
to 600 seconds aft er the call for heat is satisfi ed.

  Th e maximum allowable primary heat exchanger 

temperature rise is 

35°F

19.4°C

Th

  e maximum allowable fl ow rate through a Futera Fusion boiler 

is 97 GPM, 

6.1 L/s

 on 500 through 1000 models and 136 GPM, 

8.6 L/s

 for 1250 through 2000 models. Th

  e Cupro-Nickel heat 

exchanger allows for 108 GPM, 

6.8 L/s

 on 500 through 1000 models 

and 151 GPM, 

9.5 L/s

 on 1250 through 2000 models.

Factory Supplied - On Board - Circulating Pump

Th e factory installed - on board - pump is sized to work the total 

boiler head loss plus an additional (30 ft ) of pipe and (6 elbows) 

- (min pipe diameter of inlet/outlet boiler water connections - see 

Table 7).  Please consult factory for systems outside these parameters.

Low Water Cutoff 

If a boiler is installed above any radiation elements it must be fi tt ed 
with a low water cutoff  device. 

Refer to the wiring diagram supplied with the boiler/water heater 

for proper wiring connections.

Expansion Tank & Air Separator 

An expansion tank or other means to control thermal expansion 

must be installed in the heating system. An expansion tank must 
be installed close to the boiler on the suction side of the pump. An 
air scoop and automatic air vent must also be installed to eliminate 
air trapped in the system.

Primary/Secondary Piping 

Figure 10 shows a typical primary/secondary piping system. Boilers 

connected to heating systems using zone valves, zone pumps, or 
systems that have excessive fl ow rates  must be isolated from these 
systems to protect the boiler. 

Multiple Boiler Systems

Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 11. 

Piping For Use With Cooling Units

Th e boiler, when used in connection with a refrigeration system, 

must be installed so the chilled medium is piped in parallel with 
the boiler. Appropriate valves must be used to prevent the chilled 

water from entering the boiler.

When a boiler is connected to a heating coil that may be exposed 

to refrigerated air from an air handling device, the piping system 
must be equipped with fl ow-control valves or some other automatic 
means of preventing gravity circulation of the boiler water during 
the cooling cycle.

Summary of Contents for Gas boilers

Page 1: ...ction 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 ca...

Page 2: ...RESSURE VESSEL CODE SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRES SURE OF 160 PSI 1103 kPa WATER BEFORE YOU START 2 RATINGS CAPACITIES 3 BOILER WATER HEATER LOCATION 3 COMBUSTION AIR VENTILATION 3 G...

Page 3: ...se to a chimney or outside wall and have adequate fresh air forcombustion Ensurethattheboiler waterheaterislevelfrom front to back and from side to side Use metal shims to level the boiler water heate...

Page 4: ...ely communicate with the outdoors must be present The upper opening 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 30...

Page 5: ...e building structure and not by the boiler water heater Appropriate thimbles and fire stops must be used where required Common vent systems must be properly engineered and sized please contact the fac...

Page 6: ...exceed5 ft 1 5 m they must be supported at 3 ft 0 9 m intervalswith overhead hangers Theventsystemmust bepitcheddown towardthe ventterminal 1 4 in ft 20 mm m If anypartofasinglewallmetalventsystempass...

Page 7: ...on air and venting for single or multiple units exhaust and combustion air terminalsmustbeinstalledonthesameplane outsidewall in order to prevent pressure differences due to prevailing winds Incoldcli...

Page 8: ...3 Vertical Air Intake and Venting for a Direct Vent System Locate exhaust terminal downwind to reduce flue gas recirculation Figure 4 Horizontal Air Intake and Venting for Multiple Direct Vent Systems...

Page 9: ...ng A through inspection of the masonry chimney must be performed to ensure that the chimney is clean properly constructed lined and sized Exterior masonry chimneys should not be used unless properly l...

Page 10: ...If horizontal runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The vent connector should be sloped up toward the chimney at a minimum rate of 1 4in ft 21 mm...

Page 11: ...served 1 AcontinuousflowofwaterthroughtheunitMUSTbemaintained The pump responsible for flow through the boiler water heater must run continuously 2 An ethylene glycol water mixture suitable for the mi...

Page 12: ...the pump on each time the burner fires and runs the pump for 20 to 600 seconds after the call for heat is satisfied The maximum allowable primary heat exchanger temperature rise is 35 F 19 4 C The max...

Page 13: ...Drain Valve Typ 3 Way Mixing Valve Item Number Description 1 3 Way Valve 2 Air Purging Valves 3 Flow Switch 4 Circulator 5 Pressure Relief Valve 6 T P Gauge 7 Primary Heat Exchanger Drain Valves 8 Co...

Page 14: ...boiler is filled Use purge valves provided Purge valve may be located on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 3 All boiler...

Page 15: ...m 3 way valve after the boiler is filled Use purge valves provided Purge valve may be located on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for...

Page 16: ...be consulted when these water conditions are encountered See Table 8 RBI water heaters are designed to run scale free Due to the extreme variables of water conditions world wide it is necessary to con...

Page 17: ...w Rate gph t deg f Flow Rate gph t deg f Flow Rate gph t deg f 60 614 96 833 106 1050 112 1460 101 1664 106 1859 111 2118 111 80 753 76 998 86 1245 92 1768 81 2000 86 2205 91 2520 91 100 999 56 1268 6...

Page 18: ...d heater flow 5 Hot water tanks should be equipped with a combination temperature pressure relief valve 6 MA Code requires an 1 8 in hole in check valve to compensate for thermal expansion 7 Boiler an...

Page 19: ...mum combined heater flow 5 Hot water tanks should be equipped with a combination temperature pressure relief valve 6 MA Code requires an 1 8 in hole in check valve to compensate for thermal expansion...

Page 20: ...hould be used in conjunction with Table 11 to ensure that the gas supply piping has the capacity to meet the demand Figure 14 depicts the proper way to connect the boiler water heater to the gas suppl...

Page 21: ...of 14 awg Use appropriate wiring materials for units installed outdoors The wire size must be compatible with the total amp draw of the circuit Refer to the wiring diagram supplied with the boiler wa...

Page 22: ...if any part 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...

Page 23: ...lbow pressure Table 13 The low fire O2 CO2 can be adjusted in the field by opening the low fire adjustment door located on the forward facing side of the main gas valve see Figure 15 Inserting an alle...

Page 24: ...setting 2 Turnoffallelectricpowertotheboilerifserviceistobeperformed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 R glez le thermostat la tem...

Page 25: ...follows LP Nat Minimum in WC 2 2 Maximum in WC 14 14 Measure pressure when the boiler is firing at full rate Low gas pressure could indicate undersized gas line or insufficient gas supply Static and...

Page 26: ...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 On multiple boiler i...

Page 27: ...nned copper tube gas boilers water heaters Boiler Manual Finned copper tube gas boilers water heaters Boiler Manual 27 F RIOM 86 Figure 19 RBI Field Wiring to HeatNet Board BoardRevision 2 0 and Great...

Page 28: ...he display will also list faults should the unit fail to operate An explanation of each status message and fault can be locatedinHeatNetControlManualunderstatusscreenfaultdisplay section STATUS SCREEN...

Page 29: ...on or use as a field interlock The interlock is located on J11B SPARE 4 FAULT SYSTEM SET 160 F INTERLOCK SPARE 4 FLOW SWITCH ERROR Once the Futera Fusion series boiler receives a call for heat it clos...

Page 30: ...TEM SET 160 F OPEN OUTSIDE SENSOR SHORTED SENSOR If the shorted sensor fault is displayed the sensor in the position reported was originally detected but has since shorted The boiler will shut down on...

Page 31: ...l with some types of gases Black soot indicates poor combustion Green deposits indicate condensation due to low return water temperatures In either case the heat exchanger must be cleaned thoroughly a...

Page 32: ...pressure If it does 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 Theaquastathighl...

Page 33: ...k for 24 VAC on J11A 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 b...

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 21 Repair Parts REPAIR PARTS 34...

Page 35: ...Finned copper tube gas boilers water heaters Boiler Manual Finned copper tube gas boilers water heaters Boiler Manual 35 F REPAIR PARTS CONTINUED...

Page 36: ...ket 06 0022 1 1 1 1 1 1 1 NS Gas Injectors NG 10 1009 1 1 1 1 Gas Injectors NG 10 1002 1 1 1 Gas Injectors LP 10 1010 1 1 1 1 1 1 1 21 Firing Valve 1 11 0456 1 1 Firing Valve 1 1 4 11 0457 1 1 Firing...

Page 37: ...on prior to 0209 must replace 70 2516 1R 1 combustion chamber top panel 36 70 2517 1R 1 70 2518 1R 1 70 2519 1R 1 70 2520 1R 1 70 2521 1R 1 Heat Exchanger Assembly Copper 70 2186 1R 1 Bronze 70 2187 1...

Page 38: ...4 Main Board HeatNet green 16 0038 1 1 1 1 1 1 1 55 Display Board HeatNet 40 0088 1 1 1 1 1 1 1 NS Ribbon Cable 40 0115 1 1 1 1 1 1 1 NS Power Switch 48 0013 1 1 1 1 1 1 1 NS Toggle Switch Remote Loca...

Page 39: ...1 1 1 1 1 Pilot Orifice LP 10 0139 1 1 1 1 1 1 1 82 Mini Peeper C7027A 16 0009 1 1 1 1 1 1 1 85 Turbo Pilot Torch 70 2559 1 1 1 1 1 1 1 86 1 2 Aluminum Tubing 62 0103 1 1 1 1 1 1 1 NS Spark Rod Assem...

Page 40: ...the bottom 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 ignitio...

Page 41: ...F 15 TIMES THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROP ER FLOW BEFORE YOU LEAVE THE JOB SITE YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 35o F 19 4o C NOR BE LO...

Page 42: ...t 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 OBST...

Page 43: ...tructions 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 i...

Page 44: ...ht 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 rbiwaterhe...

Reviews: