FTII-IOM-3 FUTERA II SERIES FINNED COPPER GAS BOILERS & WATER HEATERS INSTALLATION & OPERATING INSTRUCTION DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI WATER. 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.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS 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.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS RATINGS & CAPACITIES CAUTION Units installed outdoors MUST be protected from ice and snow accumulation or the unit will be damaged voiding the warranty! Before undertaking the installation of the Futera II Series boiler/water heater check the rating plate to ensure that the unit has been sized properly for the job. The “Net I=B=R Ratings” specify the equivalent amount of direct cast iron radiation that the unit can supply under normal conditions.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS must be given to the blockage effects of louvers, grills and screens. Screens must have a minimum mesh size of 1/ 4" (6.4mm). If the free area through a louver or grill is not known ducts should be sized per Table 2 above. All Air From Inside The Building If the Futera II is to be located in a confined space the minimum clearances listed in Table 1 must be maintained between it and any combustible construction.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS GENERAL VENTING GUIDELINES Horizontal Direct Vent Systems – Figures 1 & 2 The vent materials used in horizontal vent systems must be certified to UL 1738 for installations in the United States, ULS636 for installations in Canada. The certified vent terminal from RBI must also be used. WARNING The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS In addition the vent system must conform to the dimensions shown in Figure 3. The penetration point in the roof must be properly flashed and sealed. The vent system must be gas tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 3 - Vertical Air Intake and Venting for Direct Vent System Combination Direct Vent Systems – Figure 4 The boiler/water heater can be vented vertically with the intake air piped horizontally through an outside wall. Follow the instructions in the Intake Air Option – Horizontal Guidelines on page 4. Also follow the general instructions in the COMBUSTION AIR & VENTILATION and GENERAL VENTING GUIDELINES sections.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS SIDE WALL VENT (POSITIVE PRESSURE) under the COMBUSTION AIR & VENTILATION SECTION must be followed! The vent guidelines under the Horizontal Direct Vent Systems section must also be followed. 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 the unit is installed.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS The vent system should be sloped up toward the chimney at a minimum rate of 1/4 inch/foot (2 cm/m). On masonry chimneys the connector must terminate flush with the inside of the chimney flue, Figure 7. Fasten each single wall vent connection with at least 3 corrosion resistant sheet metal screws. Always provide a minimum clearance of 6 inches (152 mm) between single wall vent pipe and any combustible materials.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 7 – Vertical Venting using a Masonry Chimney OUTDOOR VENTING Do not place the boiler/water heater in a location that would subject it to runoff from adjacent buildings. When installed outdoors the Futera II must be fitted with the factory supplied outdoor hood, air intake adapter with filter and exhaust terminal, see Figure 8.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS COMMON VENT SYSTEMS e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. If an existing boiler/water heater is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS 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. Flow Switch The flow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent the boiler from firing unless there’s adequate water flow through the unit.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Table 7 – Temperature Rise Table Temperature Rise Across Heat Exchanger 20˚F Model Size Flow 30˚F 25˚F Pressure Drop Flow Pressure Drop GPM L/s feet kPa GPM L/s feet kPa 500 42 2.6 1.0 2.9 34 2.1 0.7 2.0 750 64 4.0 2.4 7.2 51 3.2 1.5 1000 85 5.4 4.0 12.0 68 4.3 85 1250 Flow Pressure Drop GPM L/s feet kPa 4.6 42 2.6 1.1 3.3 2.6 7.7 57 3.6 2.2 6.6 6.9 71 106 1500 127* 1750 149* 6.7 3.6 11.0 5.4 2.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Low Return Water Temperatures To prevent the problems associated with condensation of the products of combustion due to low return water temperatures a primary/secondary piping system with a bypass and bypass valve must be installed, see Figure 12. The bypass and bypass valve must be sized the same as the secondary piping. A balancing valve must also be installed in the supply side of the secondary piping downstream of the bypass.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Piping For Use With Cooling Units The 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, see Figure 14. NOTE: The storage tank must be located as close to the water heater as possible to prevent excessive head loss which will reduce flow.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS The proper velocity through the water heater must be maintained in accordance with Table 7 for efficient operation and long life. If the temperature rise through the water heater is lower than recommended the water velocity is too high. Premature erosion of the heat exchanger will occur. Conversely, if the temperature rise is higher than recommended in Table 5 the flow rate is too low. Scaling and softening of the heat exchanger will occur.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS GAS SUPPLY PIPING Figure 17 – Gas Supply Piping WARNING Check the boiler/water heater rating plate to make sure that the boiler/water heater is for the type of gas that will be used. If it isn’t, do not connect the boiler/water heater to the gas supply. Failure to comply with this warning can result in extensive property damage, severe personal injury or death! The Futera II comes from the factory ready to be piped to the gas supply.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS ATTENTION. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé. valves. If strainers are used in the system piping the make- up water valve should be closed and the strainers checked and cleaned.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS 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 gaz depuis un voisin. Suives les instructions du fournisseur. • Si vous ne pouvez rejoindre le fournisseur, appelez le service de incendies. l’étape B des instructions de sécurité sur la portion supérieure de cette étiquette.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 19 – Spark Rod Position Detail CAUTION Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur! TABLE 10 – Pressure Settings Model Size 500 750 1000 1250 1500 1750 1950 Pilot Operation With the manual main gas valve and manual pilot gas valve closed energize the unit and allow it to try for ignition until it goes into flame failure.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Air Box Pressure Connect a manometer to the air box pressure tap located behind the control cover, Figure 20. TABLE 11 – Pressure Settings Model Size 500 750 1000 1250 1500 1750 1950 Figure 20 – Air Box Pressure Tap Air Box Pres. (in. w.c.) 1.3 2.0 3.0 2.0 2.5 2.8 3.2 Gas Back Pres. (in. w.c.) 0.3 0.6 0.6 0.3 0.3 0.3 0.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS For a thermostat that employs an adjustable heat anticipator, adjust the anticipator to match the current measured in the thermostat circuit. An increased anticipator setting may be necessary if the unit cycles frequently. If the room temperature over-shoots the thermostat setting, reduce the anticipator setting. CAUTION Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Cleaning 1. Close the shut off valves in the inlet and outlet piping. On heating systems close the system fill 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.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE-SHOOTING OPERATIONAL PROBLEMS CORRECTIVE ACTION 1. The “Power On” light doesn’t illuminate. Ensure that proper voltage is being supplied to the unit. Inspect the circuit breaker for the boiler/water heater circuit. Check the light. Ensure that the power switch operates properly and is wired correctly. Check the transformer for proper operation. 2. The “Power On” light illuminates, a call for heat is initiated, but the blower does not purge.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Figure 23 – Exploded View 25
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # 1 Name of Part Part # 500 750 1000 Base Panel Assembly 70-2163 1 1 1 1 1 1 70-2164 2 Base Panel Heat Exchanger Legs 3 Combustion Chamber Rear/Side Panel Assy 03-1599 03-1600 70-2144 1250 1500 1750 1950 1 1 1 1 1 1 1 1 1 70-2145 1 70-2146 1 70-2147 1 70-2148 1 70-2149 1 70-2150 4 Combustion Chamber Top Panel 1 03-1552 1 1 1 03-1553 5 Rear Pipe Enclosure Pan
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # 13 Name of Part Jacket Gasket Material, 25 feet Part # 500 750 1000 1250 1500 1750 1950 66-0101 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 Gas Train Support Bracket 03-1639 1 1 1 15 Fan Assembly 70-2200 1 1 1 70-2201 70-2202 16 17 18 Firing Valve, 1" 11-0456 Firing Valve, 1 1/4" 11-0457 Firing Valve, 1 1/2" 11-0458 Main Gas Valve, HW V88A, 1" 11-0156 Main
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # 32 Name of Part Light Package Assy, Plain - 24 V Part # 500 750 1000 70-2113 1 1 1 1 1 1 Light Package Assy, Plain - 24 V 70-2114 Light Package Assy, w/ Operator - 24 V 70-2115 Light Package Assy, w/ Operator - 24 V 70-2116 Light Package Assy, w/ High Limit - 24 V 70-2117 Light Package Assy, w/ High Limit - 24 V 70-2118 Light Pkg. Assy., w/ OP & H L - 24 V 70-2119 Light Pkg. Assy.
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS Futera II Model Size with Item Quantities Below Ref # 43 Name of Part Heat Exchanger Assy, Bronze Headers Optional SB111 Cupro Nickel Tubes, ASME Part # 500 70-2193 1 70-2194 750 1000 1250 1500 1750 1 70-2195 1 70-2196 1 70-2197 1 70-2198 1 70-2199 44 Heat Exchanger “V” Baffle 1 03-1612 1 03-1613 1 03-1614 1 03-1615 1 03-1616 1 03-1617 1 03-1618 45 Heat Exchanger “V” Baffle Strap 1950 1 03-1619 1 1 1 03-1620 1 1
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260 North Elm Street 1300 Midway Boulevard Westfield, MA 01085 Mississauga, Ontario L5T 2G8 Canada 䡲 Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.
