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FUTERA III / FUSION

START UP SHEET

DATE:

JOB NAME:

TECHNICIAN:

LOCATION:

COMPANY:

MODEL

PHONE NUMBER:

SERIAL #:

PRE-START UP CHECK LIST

NO VISUAL DAMAGE TO UNIT

PIPING PROPERLY CONNECTED

BOILER CIRCULATOR WIRED

VENT/STACK CONNECTED

INLET AIR FILTER INSTALLED AND CLEAN

PROPER SERVICE CLEARANCE PROVIDED

PUMP RUNNING, HEAT EXCHANGER FULL

GAS LINES PURGED, NO LEAKS, NO MISSING

TEST PLUGS

BOILER START UP SEQUENCE

Note:

Locate the AA terminals in the bottom-right of

the electrical panel on the control relay board and the min-hold

switch located on the display board. Also locate the gas pressure tapping upstream of the main gas valve.

1. Cycle boiler and hold at trial for pilot ignition.

2. Set pressure to 2 - 2.5" W.C. (Flame signal should read 5.0 V DC)

3. Cycle boiler to main flame trial for ignition.

4. Place boiler to min hold (jumper T1 terminals for min input). Check for stable flame.
5. Record combustion and elbow pressure. (Reference factory start-up sticker)

6. Release boiler from min hold to run. (Jumper AA terminals for 100% input)

7. Record combustion and elbow pressure. (Reference factory start-up sticker)

8. Check all combustion results using a calibrated flue gas analyzer.

9. Remove jumper at terminals “AA” then make any final adjustments on low fire.

10. Remove jumper at terminals T1 and release boiler to RUN mode.

Содержание FUTERA FUSION Series

Страница 1: ...Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electri...

Страница 2: ...vice des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz The Futera Series finned copper heating boiler w...

Страница 3: ...ction 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...

Страница 4: ...given to 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 Ta...

Страница 5: ...tems must be fully supported by the building structure and not by the boiler water heater Appropriate thimbles and fire stops must be used where required WARNING Common vent systems must be properly e...

Страница 6: ...04 C 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 le...

Страница 7: ...e same plane outside wall in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation 5 FT 1 5 m 1 5 FT 0...

Страница 8: ...3 Vertical Air Intake and Venting for Direct Vent System Note Locate exhaust terminal downwind to reduce flue gas recirculation Figure 4 Combination Direct Vent Systems 10 FT 3 1 m 4 FT 1 2 m 5 FT 1 5...

Страница 9: ...r combustion is taken from the space in which the unit is installed The applicable instructions under the COMBUSTION AIR VENTILATION section must be followed The vent guidelines under the Horizontal D...

Страница 10: ...ndraft The unit s shouild be located at least 3 ft 1 m from structures Outdoor installations are not recommended in areas where the danger of snow blockage exists CAUTION Do not place the boiler water...

Страница 11: ...l 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 flow switch supplie...

Страница 12: ...igure 8 Futera Fusion Piping Air Vent Aquastat Union Automatic Thermometer Flow Switch Pressure Relief Valve Reducing Valve Check Valve Pressure Pump Valve Balance Valve Vacuum Relief Valve Temperatur...

Страница 13: ...lve and piping Low Water Cutoff If a boiler is installed above any radiation elements it must be fitted with a low water cutoff device Refer to the wiring diagram supplied with the boiler water heater...

Страница 14: ...ated on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 3 All boilers furnished with factory mounted outlet water temperature gauge No...

Страница 15: ...flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 4 All boilers furnished with factory mounted outlet water temperature gauge 5 Condensate l...

Страница 16: ...ugh a Futera Fusion water heater is 97 GPM 6 1 L s on 500 through 1000 models and 136 GPM 8 9 L s for 1250 through 2000 models The cupro nickel heat exchanger allows for 108 GPM 6 8 L s on 500 through...

Страница 17: ...xchanger Selection Graph To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed Proper pump sizing will improve heater performance and...

Страница 18: ...with a combination temperature pressure relief valve 6 MA Code requires an 1 8 hole in check valve to compensate for thermal expansion 7 Use balance valve to set the temperature rise through the boile...

Страница 19: ...bination temperature pressure relief valve 6 MA Code requires an 1 8 hole in check valve to compensate for thermal expansion 7 Use balance valve to set the temperature rise through the boiler Delta T...

Страница 20: ...your RBI representative to resolve the problem NOTE A minimum gas supply pressure of 2 in 51 mm W C natural or propane and maximum 14 in 356 mm W C natural or propane must be available at the safety...

Страница 21: ...outdoors 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 connections GENERAL OPERATION WARN...

Страница 22: ...r 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 a qualified service technician to inspect the...

Страница 23: ...ttle out for a few minutes and observe the combustion reading Refer to Combustion Reading table for proper combustion readings and elbow pressure Table 12 The low fire O2 CO2 can be adjusted in the fi...

Страница 24: ...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 thermostat la temp rature l...

Страница 25: ...els of carbon monoxide or an explosion resulting in severe personal injury or death Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows LP Nat Minimum in W C 2 2...

Страница 26: ...ork For all other member boilers the dip switches will remain in the off position Dip switches J3 and J6 need to be placed in the on position to terminate a modbus communication network when used 2 0...

Страница 27: ...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 installations th...

Страница 28: ...ithout adequate water flow through the heat exchanger DIAGNOSTICS TheFuteraFusionhasadisplaythatindicatesthesequenceof operation The display will also list faults should the unit fail to operate An ex...

Страница 29: ...ET 160 F GAS PRESSURE INTERLOCK SPARE 4 This is also a spare interlock similar to INTERLOCK SPARE 3 for future expansion or use as a field interlock The interlock is located on J11B SPARE 4 FAULT SYST...

Страница 30: ...If the open sensor fault is displayed the sensor in the position reported was originally detected but has since opened The boiler will shut down on any OPEN sensor FAULT SYSTEM SET 160 F OPEN OUTSIDE...

Страница 31: ...rner together from the boiler water heater taking care not to damage the spark rods and or their alignment 8 Disconnect the compression nut from the inside of the transition piece 9 Remove the transit...

Страница 32: ...and CHECKING AND ADJUSTMENTS sections of this manual for reference 1 Check the operating controls for proper operation 2 A float type low water cutoff device must be flushed out per the manufacturers...

Страница 33: ...Last limit in the Limit String to Ignition Control Have We received the BLOWER signal CALL FOR HEAT PRE_PURGE Interlocks OK Are we below the Temp Band YES fire the boiler NO Send 120 VAC BLOWER signa...

Страница 34: ...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 but...

Страница 35: ...rts SEE VIEW A SEE VIEW B 15B 15A 41 32 36 57 46 13 35 40 33 31 23 27 60A 24 62 28 47 39 15 SEE VIEW C 38 37 25 67 66 62 65 30 63 43 42 60 14 29 64 33 45 68 69 10 4 11 75 12 5 2 7 74 1 73 71 12 8 70 1...

Страница 36: ...FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 36 VIEW B ROTATE D VIEW 16 18 VIEW A VIEW C RIOM 74 REV A 77 54 54A RIOM 74 REV A RIOM 74 REV A...

Страница 37: ...3 1 1 1 70 2344 1 1 1 1 15 Burner Pilot Orifice Assembly 70 2529 1 70 2530 1 70 2531 1 70 2532 1 70 2533 1 70 2534 1 70 2535 1 15a Transition Gasket 06 0026 1 1 1 06 0027 1 1 1 1 15b Burner Gasket 06...

Страница 38: ...ear 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 3111 1 03 3112 1 03 3113 1 03 3114 1 03 3115 1 03 3116 1 03 3117 1 3...

Страница 39: ...ly CW 70 2563 1 1 1 70 2564 1 1 1 1 42 Air Filter 09 0489 1 1 1 09 0498 1 1 09 0499 1 1 44 Pilot Tube Assembly 70 9024 1 1 1 70 9024 1 1 1 70 9025 1 1 NS Pilot Train Assembly NG 70 9026 1 1 1 1 1 1 1...

Страница 40: ...1 1 1 1 1 NS Terminal Block 6P 48 0157 1 1 1 1 1 1 1 NS Terminal Block 4P 48 0161 1 1 1 1 1 1 1 NS Resistor Assembly 70 9001 1 1 1 1 1 1 1 NS Mini Peeper C7027A 16 0009 1 1 1 1 1 1 1 NS UV Amplifier...

Страница 41: ...2 2 2 2 2 2 2 74 Bottom Horizontal Frame Extension Profile 04 1072 2 2 2 04 1070 2 2 2 2 75 Vertical Center Extension Profile 04 1062 2 04 1063 2 04 1064 2 04 1065 2 04 1066 2 04 1067 2 04 1068 2 76 F...

Страница 42: ...board Also locate the gas pressure tapping upstream of the main gas valve 1 Cycle boiler and hold at trial for pilot ignition 2 Set pressure to 2 2 5 W C Flame signal should read 5 0 V DC 3 Cycle boil...

Страница 43: ...OMER COMMISSIONED BY _____________________________ SIGNATURE DATE ___________________ THE DELTA T BETWEEN THE HEATERS INLET AND OUTLET IS CRITICAL TO PROPER FLOW BEFORE YOU LEAVE THE JOBSITE YOU MUST...

Страница 44: ...t OA Setpoints Water Temp At High OA Temp Water Temp At Low OA Temp PUMP OPTIONS System Pump Post Purge Time Always Enabled Summer Pump Jog Local Pump Delta Temp Enab Delta Temp Post Prge Time s Alway...

Страница 45: ...ol H Net Master Local Address Console Address Modular Boiler Set Add Boiler Delay Shed Boiler Delay Modulate Delay Time Mod Max Last Fire Stop Band Offseet Boiler Start Time Modulation PID P roportion...

Страница 46: ...side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjace...

Страница 47: ...instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS...

Страница 48: ...ult of the equipment and is not covered under the manufacturer s warranty Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is...

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