28
FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
5. The outside surfaces of the copper tubes should
be free of any soot deposits. A slight black smudge
is normal with some types of gases. Black soot
indicates poor combustion. Green deposits indicate
condensation due to low return water temperatures.
Water returned to the water heater inlet must not be
less than
125°F
,
52°C
or excessive condensation of the
products of combustion will damage the water heater
voiding the warranty. In either 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 shut off valves in the inlet and outlet piping.
On heating systems close the system fi ll valve and
relieve the system pressure from the boiler by carefully
lifting the relief valve or opening the drain valve.
2. Disconnect the boiler/water heater from the system
piping.
3. Remove the eight bolts on the rear pipe enclosure
panel.
4. Remove the front jacket panel and combustion
chamber door.
5. Slide the heat exchanger out of the unit.
6. Remove the “V” baffl e straps and “V” baffl es.
7. Thoroughly clean the heat exchanger with water from
a high-pressure hose. Use a soft bristle brush if
necessary.
8. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
Heat Exchanger Repair & Replacement
1. A leaking or otherwise damaged tube(s) can be
replaced as outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler/water
heater as outlined in the
Heat Exchanger Cleaning
section.
3. Remove the pipe plugs from the inlet/outlet and return
headers opposite from the ends of the tube(s) being
replaced.
4. Carefully cut the damaged tube(s) in half, taking care
not to damage the adjacent tubes and remove.
5. Install and swage/expand in place the new tube(s).
6. Replace the pipe plugs using a suitable thread sealant
on each one.
7. Sagging or distorted heat exchanger tubes are an
indication of low water fl ow through the system. A
damaged heat exchanger must be replaced and the
condition that caused the damage resolved before the
boiler/water heater is returned to service.
8. Replace the heat exchanger and other components in
the reverse order of their removal.
RIOM-18-REV.
A
Air Intake & Vent System
Thoroughly inspect the air intake and vent systems for
any signs of blockage, corrosion or leakage. Immediately
replace any unsound vent system piping. Inspect the air
fi lter and wash with warm water and soap if dirty.
Controls
Use the “GENERAL OPERATION” and “CHECKING AND
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A fl oat type low water cutoff device must be fl ushed
out per the manufacturers’ instructions. The probe on
a probe low water cut off must be removed, cleaned
and inspected at least once a year. Ensure that the
low water cutoffs operate properly. If not, replace
them.
3. The fl ow switch contacts must be open when water
fl ow is not present.
4. The relief valve should not weep or discharge water
at normal system 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. 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 boiler
off. The water temperature should never exceed the
maximum set point of
250°F
,
121°C
. The aquastat high
limit cannot be repaired. If it fails to function properly,
replace it.
6. Visually check the pilot and main burner fl ames to
ensure proper operation, see Figures 16 & 17.
WARNING: A yellow, fl oating fl ame indicates a lack
of combustion air. Do not operate the boiler/water
heater until the problem is solved or severe
personal injury or death may occur!
Figure 17 – Main Burner Flame
