FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
11
GENERAL PIPING 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 hardness causing
scaling in the copper heat exchanger tubes is NOT
covered under the manufacturer’s warranty, see Table
7. Excessive pitting and erosion of the internal surface
of the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result of high
water fl ow rates, see Table 7.
NOTE: Shut off valves and unions should be installed
at the inlet and outlet connections of the boiler/hot
water heater to provide for isolation of the unit should
servicing be necessary.
Freeze Protection
Installations in areas where the danger of freezing exists
are not recommended unless proper freeze protection is
provided. The following precautions MUST be observed:
1. A continuous fl ow of water through the unit MUST be
maintained! The pump responsible for fl ow through the
boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed to
must be used. The pump must be capable of producing
a minimum of 15% more fl ow and overcoming a 20%
increase in head loss. Domestic water systems must be
isolated from the water heater by the use of a heat
exchanger or other approved method.
3. If the unit must be shut off for any reason the electric,
gas and water supplies MUST be shut off and the unit
and its pump completely drained.
CAUTION: Improper outdoor installation of this unit
can cause boiler failure voiding the manufacturer’s
warranty!
Condensate Piping
The condensate trap provided with the boiler must be
attached to the bottom pan and piped to a suitable fl oor
drain or condensate pump. If a condensate neutralization
device is installed, it must be positioned prior to boiler room
drain. Condensate fi ll trap must be maintained with fl uid.
Relief Valve
Pipe the discharge of the pressure relief valve as shown
in Figure 8.
WARNING: Never install any type of valve between
the boiler/water heater and the relief valve or an
explosion causing extensive property damage,
severe personal injury or death may occur!
Flow Switch
The 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. The fl ow switch must be installed in the
supply piping adjacent to the boiler outlet connection.
CAUTION: 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. The 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 & 11) for
bleed locations.
Heating Boiler Piping Connections
The supply and return connections should be sized to suit
the system, see Table 6.
Table 6 – 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
This low mass boiler requires a continuous minimum
water fl ow for proper operation. The boiler pump is sized
to overcome the head loss of the boiler and the near
piping in order to achieve the required temperature rise.
Table 7 provides the heat exchanger pressure drop and
temperature rise fi gures. The temperature rise across the
boiler must never exceed
35˚F
,
19.4˚C
. The adjustable
pump delay turns the pump on each time the burner fi res
and runs the pump for 20 to 600 seconds after the call for
heat is satisfi ed.
