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Manuel d`installation et d`opération (anglais)

1. 3 13 the conditions listed under NORMAL we i DAR CALL RBI FACTORY in the table In some areas of the country a OR REPRESENTATIVE additional precautions must be observed i0 due to unusual characteristics of the 3 lt local water supply Call the nearest RBI 9 8 i representative for details 7 CuNi Copper CuNi Qa 6 USE SOFT USE NORMAL USE HARD To properly size the pump a grain hardness oc 5 WATER PUMP PUMP WATER PUMP and pH test must be taken at the installation S x site before the order is placed Proper pump 3 D illi heat fi d CALL RBI FACTORY sizing will improve heater performance an 2 OR REPRESENTATIVE help ensure heater longevity 1 LI o 34 56 7 8 9101112131415 1617 18 19 20 21 22 23 24 25 26 27 Expansion Tank SOFT NORMAL HARD GRAINS OF HARDNESS An expansion tank or other means to control Grains of SKARE is equal to N divided by 17 1 thermal expansion must be installed in the Copyright Pending MESTEK 12 03 water heating system if back flow prevention devices are installed Table9 Futera XLF Pumping Performance Requirements Pump Requirements Maximum Hard 18 Grains This low mass water heater requires a Die Calculated continuous minimum water flow for proper operation The low water flow GPM PD FT PD kPa AT F switch provided for this unit will s
2. Ref Name of Part Part 2500 3000 3500 4000 NS Handle 20 0063 1 1 1 1 35 Lower Front Jacket Panel 70 3535 1 70 3536 1 70 3537 1 70 3538 1 36 Combustion Chamber Top Panel 70 3561 1 1 1 1 Manning Glass Insulation per square foot 05 0104 9 9 9 9 39 Pressure Relief Valve 50 30 0384 1 1 1 1 Pressure Relief Valve 125 13 0053 1 1 1 1 NS Latch 20 0045 2 2 2 2 NS Ball Valve 11 0395 1 1 1 1 44 Tridicator 30 60 psi 13 0308 1 1 1 1 Tridicator 75 160 psi 13 0305 1 1 1 1 45 LWCO 550LSV 14 0256 1 1 1 1 46 Heat Exchanger Assembly Copper 70 3584 1 1 Cast Iron 70 3585 1 1 70 3586 1 1 70 3587 1 1 Heat Exchanger Assembly Copper 70 3576 1 1 Bronze 70 3577 1 1 70 3578 1 1 70 3579 1 AXLF Il REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Model Size with item Quantities Below Ref Name of Part Part 2500 3000 3500 4000 Heat Exchanger Assembly Cupronickel 70 3588 1 1 Cast Iron 70 3589 1 1 70 3590 1 1 70 3591 1 1 Heat Exchanger Assembly Cupronickel 70 3580 1 1 Bronze 70 3581 1 1 70 3582 1 1 70 3583 1 1 47 Flange Gasket 06 0062 2 2 2 2 48 Frequency Drive 15 0230 1 1 1 1 49 Flame Safeguard RM7895C 16 0024R 1 1 1 1 50 Spark Generator 16 0008 1 1 1 1 51 Air Pressure Switch 11 0419 1 1 1 1 52 Fan Pr
3. 1 K 3 o 2 amp in line Pump fuses boiler fuse Pump contactor Power relay Overload relay R hi q RIOM 110 VFD fuses Finned copper tube gas boilers amp water heaters Boiler Manual SEQUENCE OF OPERATION NO DEMAND Standby 1 The boileris idle with no interlocks in the fault condition Pre Purge 1 The blower operates at purge RPM The water flow interlock must make within 15 seconds after the demand signal is initiated 2 The Honeywell 7800 starts a 10 second purge delay once the air prove switch contacts close Pilot Run Input 1 The blower operates at minimum ignition setting See the calibration section in the HeatNet Control IOM to enter the calibration menus 2 The ignition transformer is energized The pilot solenoid valve opens for the 10 second pilot ignition trial Main Run lnput 1 The main gas valve opens 2 The ignition transformer is de energized 3 The pilot solenoid valve closes 4 The blower stays at the minimum input setting for 3 seconds then operates at demand input See the calibration section in the HeatNet Control IOM to enter the calibration menus NO DEMAND Post Purge 1 The main gas valve closes 2 The blower operates at purge RPM for 10 seconds 3 The boiler is idle with no interlocks in the fault condition XL F Il
4. WARNING The following start up procedure assumes that all water piping gas piping and electrical connections are correct as stated in this manual and the installation meets all State Local and City codes See the Futera XLF Control IOM for troubleshooting information and control operation OPERATING INSTRUCTIONS Operating instructions l 10 11 12 13 14 If at any time the boiler will not operate properly follow the instructions TO TURN OFF GAS TO APPLIANCE page 28 and call your service technician or gas supplier Turn off all electrical power to the boiler Close main gas shut off valve field supplied Figure 16 page 22 Purge the gas piping up to the boiler s manual gas valve located ahead of the main gas valve When the bleeding is complete check all gas joints up to the gas valve for leaks Wait five 5 minutes to clear out any gas Make sure all limits pressures switches and safety device contacts are closed Open the main gas shut off valve Disable any external call for heat such as from a building management system or remote operating controller Toggle the remote local switch in control cabinet see Figure 18 to REMOTE Turn on electrical power to the boiler Turn the power switch on the front of the boiler control cabinet to ON The HeatNet display will light up when the power is on If all interlocks are properly closed the display will say STA
5. All heating system piping must be installed by a qualified 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 inch 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 ofthe system must be considered when supporting the system A minimum system pressure of 12 psig 82 7 kPa must be maintained Heating boiler piping connections The supply and return connections should be sized to suit the system per Table 6 Table6 Supply amp Return Pipe Sizing Input Supply Return MBH size size 2500 3000 4 FLANGE 4 FLANGE 3500 4000 4 FLANGE 4 FLANGE Pump requirements This low mass boiler requires a continuous minimum water flow for proper operation The boiler pump must be sized to overcome the head loss of the boiler and the near boiler piping in order to achieve the required temperature rise Table 7 provides the heat exchanger pressure drop and temperature rise figures 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 fires and runs the pump for 20 to 600
6. Expansion tank and 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 Boilers connected to heating systems using zone valves zone pumps or systems that have excessive flow rates or return water temperatures less than 140 F 60 C must be isolated from these systems to protect the boiler Variable water flows Figure 10 shows a typical primary secondary piping system A dedicated pump is used to maintain a constant water flow through the boiler This boiler pump is sized to overcome the head loss ofthe boiler and near boiler piping system while supplying the flow rate required to maintain the desired temperature rise across the boiler heat exchanger The system pump is sized to provide the required flow to the heating system The boiler piping connections to the heating system piping must be a maximum 6 pipe diameters between centers to ensure zero pressure drop in the primary system 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 11 The bypass system must be
7. ag Minimum Zz to adjacent building K dei Minimum between terminals RBl supplied terminals e __ Combustion air V ayn Between terminals Leg 1 5 ft 0 5 m Minimum distance from intake to maximum snow line RIOM 59 A WARNING When running horizontal combustion air and venting for single or multiple units exhaust and combustion air terminals must be installed on the same plane outside wall in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe is recommended to prevent condensation Vertical Distance Y O gt NGOO P UM DN DO O 0 5 10 15 20 Horizontal Distance X Figure 2 VENT OPTION 1 DIRECT VENT Horizontal air intake and venting for multiple direct vent systems Vent pipe and air pipe equivalent lengths must not exceed 100 feet each See Table 3 or 4 for min pipe diameters Exhaus terminal bank i Combustion air ye intake terminal bank 1 2 in 50 mm Minimum between terminals ay s 1 5 ft 0 5m Minimum distan
8. 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The boiler vent connectors should be sloped up toward the breeching at a minimum rate of 14 in per ft 21 mm per m On masonry chimneys the connector must terminate flush with the inside of the chimney liner as shown in Figure 6 page 10 Always provide a minimum clearance of 6 inches 152 mm between single wall vent pipe and any combustible materials WARNING Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive property damage severe personal injury or death Exit cones are favorable when used to increase the velocity of the flue gas exiting the stack and may also help in cold climates to reduce ice build up Exit cone terminations must be supplied by others installed per manufacturer s instructions and meet local and federal code Ln generic exit cone AXLE N Figure 8 Finned copper tube gas boilers amp water heaters Boiler Manual OPTION 4 VERTICAL CHIMNEY VENTING Vertical venting multiple boiler installations See Table 5 page 12 for minimum riser diameter dimension F DO NOT common vent more than the following number of Futera XLF boilers I Vent XLF 2500 3000 4 boilers max
9. 6 VENT OPTION 2 VERTICAL CHIMNEY VENTING Vertical venting using a lined masonry chimney See Figure 4 page 7 for minimum pipe diameters lt Approved non restrictive cap Chimney Approved liner J ren ges I l Thimble m Sa J May require ion for ei ZA provision mm drain at low H DN pointinliner TC DON T_T ae EZ N I I a mm ll l l Cleanout Zh Condensate drain with pigtail AXLF Finned copper tube gas boilers amp water heaters Boiler Manual N OPTION 3 SIDE WALL VENTING POSITIVE PRESSURE CATEGORY IV FIGURE 7 VENT AIR PIPE EQUIVALENT LENGTHS UP TO 100 FEET MAXIMUM Combustion Air amp Ventilation section must be followed The vent i i i guidelines under the Horizontal Direct Vent Systems section must In this configuration the boiler water heater blower is used also be followed to push the flue products horizontally to the outdoors see Figure 7 The air for comb
10. 610 Left side 6 153 12 306 Right side 6 153 12 306 Front 6 153 30 762 2 An optimum site will be level central to the piping system close to a chimney or outside wall and have adequate fresh air for combustion Ensure that the boiler water heater is level from front to back and from side to side Use metal shims to level the boiler water heater Electrical and electronic components must also be protected from exposure to water during operation and maintenance DO NOT install this boiler water heater in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing 3 Ensure that the floor is structurally sound and will support the weight of the boiler water heater The Futera XLF may be installed directly on combustible flooring but never on carpeting 4 Locate the boiler water heater in an area that will prevent water damage to adjacent construction should a leak occur or during routine maintenance If such a location doesn t exist a suitable drain pan that s adequately drained must be installed under the unit 5 DO NOT place this boiler water heater in a location that would restrict the introduction of combustion air into the unit or subject it to a negative pressure see GENERAL VENTING GUIDELINES Finned copper tube gas boilers amp water heaters Boiler Manual 6 NEVER place this boiler water heater in a l
11. CATEGORY II MULTIPLE BOILERS WITH COMMON VENTING FIGURE 8 22202 e eee 12 CATEGORY II CHIMNEY INSPECTION amp SIZING 12 CATEGORY II VENT CONNECTIONS 12 GENERAL PIPING REQUIREMENTS 14 HEATING SYSTEM PIPING 2 2 2 0 02 ee uuae 14 DOMESTIC WATER SUPPLY PIPING 005 19 TEMPERATURE RISE CONTROL 20005 19 GAS SUPPLY PIPING 2 2 20 eee ee 22 ELECTRICAL WIRING 2 eee ee 23 GENERAL OPERATION 0 0022 eu uuae 24 PROPANE GAS 2 2 eee ee eeeeen 24 WIRING amp CONTROL SET UP 1 2 2200 unas 24 CONTROLS amp INTERLOCKS 22 20000 u 24 SEQUENCE OF OPERATION 00002 uue 25 OPERATING INSTRUCTIONS 2 00000 26 TO TURN OFF GAS TO APPLIANCE 2 4 28 CHECKING amp ADJUSTMENTS 0000 28 MAINTENANCE 1 ee mee eeeneen 30 REPAIR PARTS aen ennen eee eeeeen 33 START UP REPORT 2 0 0 eee ee ee 38 Finned copper tube gas boilers amp water heaters Boiler Manual BEFORE YOU START This manual covers the application installation operation and maintenance of a Futera XLF Series finned copper heating boiler water heater pool heater Canada Only To obtain the safe dependable efficient operation and long life for which this heating boiler water heater was designed these instructions must be read understood and followed The Futera XLF Series finned copper heating boiler water heaters have been design certified by CSA for use with natura
12. Futera XLF Series boilers Overview XLF PRIMARY COMPONENTS Electrical enclosure rear Blower and motor Air inlet connection Flue outlet connection Gas entrance Boiler water return Boiler water supply Gas valve Power entrance box DP switch blocked air inlet DP switch blocked flue DP switch blower prov Ing DP switch pilot air prov Ing Ignitor Pilot gas valve and pilot gas pressure regulator Flow switch Low water cutoff Pressure temperature gauge Relief valve High gas pressure switch Low gas pressure switch XLF Rear view Air chamber cover removed See the Futura XLF Control manual for electrical component locations FUTER TE BEFORE YOU START 0 0022 eee n nen 3 RATINGS amp CAPACITIES 1 22 eee 4 BOILER WATER HEATER LOCATION 005 4 COMBUSTION AIR amp VENTILATION sasssa 4 GENERAL VENTING GUIDELINES 002 6 EXISTING COMMON VENT SYSTEMS 6 VENT SYSTEM OPTIONS 00000 cena 6 OPTION 1 DIRECT VENT POSITIVE PRESSURE CATEGORY IV HORIZONTAL OR VERTICAL 7 OPTION 2 VERTICAL VENTING POSITIVE PRESSURE CATEGORY IV FIGURE 5 OR FIGURE 6 VENT PIPE EQUIVALENT LENGTH UP TO100 FEET MAXIMUM 10 OPTION 3 SIDE WALL VENTING POSITIVE PRESSURE CATEGORY IV FIGURE 7 VENT AIR PIPE EQUIVALENT LENGTHS UP TO100 FEET MAXIMUM 11 OPTION 4 VERTICAL CHIMNEY VENTING NEGATIVE PRESSURE
13. REV D SEE VIEW A Exploded view REPAIR PARTS Figure 24 FUTER TLE REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Figure 25 Figure 20 Electrical components 2500 amp 3000 GAS TRAIN RIOM 108 REV D VIEW D REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Model Size with item Quantities Below Ref Name of Part Part 2500 3000 3500 4000 15 Burner 10 0322 1 10 0293 1 10 0323 1 10 0294 1 15a Burner O ring 06 0006 1 1 1 1 15b Burner Gasket 06 0038 1 1 1 1 17 High Gas Pressure Switch Manual Reset 11 0421 1 1 1 1 18 Gas Valve MBC 11 0227 1 1 11 0218 1 1 NS Flange 1 1 2 11 0214 2 2 Flange 2 11 0219 2 2 19 Low Gas Pressure Switch Manual Reset 11 0422 1 1 1 1 21 Firing Valve 1 1 2 11 0458 1 1 Firing Valve 2 11 0459 1 1 22 A Valve 1 1 2 11 0467 1 1 A Valve 2 11 0454 1 1 23 Blower 12 0019 1 1 1 1 NS Gas Injectors NG 10 1005 1 10 1007 1 10 1002 2 2 NS Gas Injectors LP 10 1006 1 10 1008 1 10 1004 1 1 26 Flow Switch 14 0203 1 1 1 1 27 Jacket Top Panel 70 2413 1 1 1 1 1 28 Air Filter 09 0485 1 1 1 1 REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Model Size with item Quantities Below
14. damage to the regulator will occur Required gas pressure Provide gas supply pressure at inlet to boiler gas train as follows Gas supply pressure Nat LP 1 Inches mm water column water column Minimum in W C 3 5 88 9 Maximum in W C 14 356 Measure pressure when the boiler is firing at full rate Low gas pressure could indicate undersized gas line or insufficient gas supply 2 Static and operating gas pressure required at the gas valve inlet is listed in the Table above Finned copper tube gas boilers amp water heaters Boiler Manual WARNING If the gas pressure is above the limit in the table below a lock up style gas pressure regulator suitable for dead end service such as an Equimeter or Fisher must be installed to prevent increase creep of gas pressure when the units are not operating This pressure regulator supplied by others may be installed at the service entrance to each unit or a master regulator sized to handle multiple units may be utilized Consult local gas utility or regulator manufacturer for recommendations to meet specific job site requirements Input rate Natural gas Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft 610 m At elevations above 2000 ft 610 m input ratings should be reduced by 4 for each 1000 ft 305 m Check the input rate as follows I Turn off all o
15. for domestic use from exceeding 130 F 54 C ora scald injury will occur When higher water temperatures are required for appliances such as a dishwasher a mixing valve or some other tempering means must be installed Households with small children may require water temperatures less than 120 F 49 C Local codes must be complied with General piping requirements Ensure that the water heater is equipped with bronze headers Piping and components connected to the water heater must be suitable for use with potable water The water heater must not be connected to any heating system piping or components previously used with a non potable water heating appliance No toxic chemicals such as those used for boiler treatment are to be introduced into the potable water used for space heating Ifa hot water storage tank is used in the system it must be equipped with a temperature and pressure relief valve that complies with ANSI Z21 22 or CAN 4 4 and CAN 4 6 The storage tank must be located as close to the water heater as possible to prevent excessive head loss which will reduce flow Water chemistry The required temperature rise across the water heater is based on water having a hardness between 8 and 18 grains per gallon with a level of dissolved solids not exceeding 350 ppm Water having a hardness less than 8 grains can cause excessive corrosion of the heat exchanger Water that has a hardness greater than 18 grains per gallon and or a
16. nes MAKE UP Low Temperature Piping with Thermostatic Valve See Notes and Adjustment Procedure MAXIMUM 6 PIPE DIAMETERS BETWEEN CENTERS Figure 11 SYSTEM RETURN X Z BACKFLOW H PREVENTION E DEVICE H 18 Rev 2 COLD WATER MAKE UP NOTES 1 For pump selection consult factory 2 Boiler pump sized to boiler and thermostatic 3 way valve design flow requirements 3 Boiler circuit piping must be sized large enough to handle maximum flow through unit 4 All boilers furnished with factory mounted outlet water temperature gauge 5 Boiler pump purging required Use terminals supplied 6 Valve is pre calibrated for 140 F return temperature FU 7 ERE Finned copper tube gas boilers amp water heaters Boiler Manual SYSTEM SUPPLY These drawings show suggested piping con figuration and valving Check with local codes and ordinances for spe cific requirements SYSTEM SUPPLY Pump Pressure Relief Valve Gate Valve Globe Valve Flow Switch Angle Valve Thermometer Bufferfly Valve 4 Balance Valve Jr Ball Valve Motorized Valve e Solenoid Operated Valve Backflow Prevention Device Self Operated be Valve S 3 Way Valve Pressure Reducing Valve N Expansion Tank Check Valve x Aquastat Union t Pressure Switch FOR Gas Pressure Regulator Automatic Air Vent gt FU TER LF Finned copper tu
17. other components in the reverse order of their removal Heat exchanger repair amp 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 S Install and swage expand in place the new tube s FUTER TE Finned copper tube gas boilers amp water heaters Boiler Manual 6 Replace the pipe plugs using a suitable thread sealant on each one Figure 21 Main Burner Flame 7 Sagging or distorted heat exchanger tubes are an indication oflow water flow through the system A damaged heat exchanger must BURNER TUB be replaced and the condition that caused the damage resolved before the boiler water heater is returned to service FLAME PATTER 8 Replace the heat exchanger and other components in the reverse order of their removal Air intake amp 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 filter and wash with warm water and soap if dirty Controls RIOM 18 REV B Use
18. return make up and supply circulation ATTENTION Not all RBI stock storage tanks incorporate this tapping See Note 1 NOTES 1 2 an P w oN Optional cold water make up and recirculation line location When using intermittent pump and pump delay locate remote aquastat well in lower 1 3 of tank Install aquastat with heat sensing compound Thermal expansion tank may be required check local codes When using optional factory mounted pump max pipe length 30 total 6 90 elbows full pipe size CAUTION MEASURE WATER HARDNESS AND pH AT JOB SITE The pH and water hardness must be measured before selecting heat exchanger and pump Consult the Heat Exchanger Graph and Pumping Performance Table before making selection Common piping must be sized for maximum combined heater flow Hot water tanks should be equipped with a combination temperature amp pressure relief valve MA Code requires an 1 8 hole in check valve to compensate for thermal expansion LEGEND Boiler Loop Supply Loop Angle Valve SIS Bufferfly Valve Balance Valve E Ball Valve Motorized Valve K Solenoid Operated Valve Self Operated Valve FOR Pressure Reducing Valve Check Valve Pressure Relief Valve Flow Switch Thermometer A Aquastat Union Pressure Switch FOR Gas Pressure Regulator A Automati
19. sized the same as the secondary piping The primaryand secondary pumps should be sized to provide the required flow through each system The boiler piping connections to the heating system piping must be a maximum 6 pipe diameters between centers to ensure zero pressure drop in the primary system Multiple boiler systems Systems using multiple boilers can also be installed using a primary secondary manifold system Figure 13 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 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 flow control valves or some other automatic means ofpreventing gravity circulation ofthe boiler water during the cooling cycle Typical Primary Secondary Piping System See Notes Maximum 6 pipe diameters between centers Figure 10 SYSTEM RETURN NOTES 1 Boiler circuit piping must be sized large enough to handle maximum flow through unit 2 Boiler pump sized to boiler design flow requirements 3 All boilers furnished with factory mounted outlet water temperature gauge 4 Boiler pump purging required Use termi nals supplied BACKFLOW PREVENTION DEVICE COLD WATER
20. structure and not by the boiler water heater Appropriate thimbles and fire stops must be used where required J Common vent systems must be properly engineered and sized to provide a negative draft of 0 02 inch 0 5 mm to 0 1 inch 2 5 mm WC at the flue outlet Common positive pressure vent systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death J Common vent systems The boiler closest to the vertical vent must be assigned as the master boiler and always fired FIRST to ensure proper draft and reliable operation Consult the factory if any questions Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death EXISTING COMMON VENT SYSTEMS If an existing boiler water heater is removed from an existing common venting system the common venting system may then be too large for the proper venting of the remaining appliances connected to it At the time of removal of an existing boiler water heater the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine ther
21. used to push the flue products to the outdoors while drawing combustion air from the outdoors The Intake Air Option instructions under the Combustion air amp ventilation section must be followed The vent system must be sized per Table 4 Horizontal direct vent systems Figures 1 amp 2 The vent materials used in horizontal vent systems must be certified to UL 1738 for installations in the United States ULC S636 for installations in Canada The certified vent terminal from RBI must also be used The maximum equivalent length for the horizontal vent pipe is 100 ft 30 5 m Each 90 elbow and the vent terminal are equal to 10 linear ft 3 0 m of pipe Ifany part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F 204 C Structural penetrations must be made using approved fire stops For best results horizontal vent systems should be as short and straight as possible Finned copper tube gas boilers amp water heaters Boiler Manual The vent system must be both gas tight and water tight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions When horizontal vent runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The vent system must be pitched down toward the vent terminal 1 4 in ft 20 mm m If any part ofa single wall metal vent s
22. vent system must extend at least 5 5 ft 1 7 m above the roof surface and maximum snow line that it passes through 4 ft 1 2 m above the intake air terminal see Figure 3 In addition the vent system must conform to the dimensions shown in Figure 3 page 9 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 Combination direct vent systems Figure 4 vent air pipe equivalent lengths up to100 feet maximum 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 6 Also follow the general instructions in the Combustion Air amp Ventilation and General Venting Guidelines sections Finned copper tube gas boilers amp water heaters Boiler Manual FUTER TE Figure 1 VENT OPTION 1 DIRECT VENT Horizontal air intake and venting for a single direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each See Table 3 or 4 for min pipe diameters Wall mounted power Pitch pipes down towards terminal caps venter where used Va inch per foot 20 mm per m must be supplied by others must be corrosion resistant 16 ft 4 9m Exhaust i
23. 5645 1167 7522 3500 22581 4000 1000 6452 1334 8592 4000 25808 Intake air option General guidelines This configuration provides combustion air directly to the boiler water heater s air intake adapter using a dedicated pipe when using the direct vent option Combustion air can be drawn in horizontally through the same outside wall which terminates the exhaust gases or vertically through the roof see Figure 1 page 8 through Figure 4 page 9 MENTS Common intake air systems may be used provided the common ductis sized properly An intake combustion air damper should be installed if the common vent option is used in the intake air pipe of each heater Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death Table 3 Intake air pipe sizing Input Vertical Horizontal MBH e 3 in mm in mm 2500 3000 10 254 8 203 3500 4000 12 305 10 254 All joints in metal intake air systems must be secured using corrosion resistant fasteners and sealed using a suitable Silicone caulk If PVC or CPVC is used the joints must be cleaned with a suitable solvent and connected using a solvent based PVC cement caution The combustionair system MUST be supported by the building structure not the boiler water heater caution A combustion air damper interlocked with the unit should be installed in the intake air pipe when the infiltration
24. 7 030 6 640 5 890 5 330 4 910 4 560 4 050 13 600 12 700 12 000 10 600 9 650 8 880 8 260 7 320 6 67 600 46 500 37 300 31 900 28 300 25 600 23 600 22 000 20 600 19 500 17 200 15 600 14 400 13 400 11 900 Note For propane piping Multiply the gas volume capacities above by 0 62 for propane flow capacities in ft hr Multiply the propane flow capacity by 2500 Btu ft to determine the propane Btu hr capacity for a given pipe size and length AXLE Il Table 11 Equivalent length feet for typical fittings Pipe Fitting or valve size 90 elbow Tee Gate Gas branch flow valve cock 2 5 2 10 3 1 2 3 0 232 6 2 12 3 1 4 3 5 3 7 7 15 3 1 8 4 5 4 10 1 20 2 2 4 6 0 5 12 6 25 2 2 9 7 3 6 15 2 30 4 3 5 13 4 Equivalent lengths above are for threaded fittings Multiply values above by 0 75 for flanged fittings A ground joint union should be installed between the boiler gas controls and the supply piping Each of these items are needed to ensure long life and ease of servicing Always use a pipe sealant that is suitable for use with LP gas CAUTION Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body or gas valve failure may result When applicable provisions for vent bleed and gas relie
25. HONE NUMBER SERIAL PRE STARTUP CHECK LIST Q NO VISIBLE DAMAGE TO UNIT Q INLET AIR FILTER INSTALLED AND CLEAN Q PIPING PROPERLY CONNECTED CL PROPER SERVICE CLEARANCES PROVIDED Q BOILER CIRCULATOR WIRED Q PUMP RUNNING HEAT EXCHANGER FULL Q VENT STACK CONNECTED LJ GAS LINES PURGED NO LEAKS NO MISSING TEST PLUGS BOILER STARTUP SEQUENCE Note Locate the AA terminals and minimum hold switch in the bottom right of the electrical panel on the main HeatNet board Also locate the manometer test manifold in the bottom of the electrical panel 1 Disable any external call for heat and toggle the remote local switch to REMOTE Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition Set pressure to 3 3 5 w c flame signal should read 5 0 VDC Release boiler to main flame trial for ignition Check for stable flame Record combustion and pressure signal Ps at minimum firing rate Reference XLF Boiler IOM Jumper the AA terminals to force 100 input Record combustion and pressure signal Ps Reference XLF Boiler IOM po oN DoH AWN Remove the AA jumper to place the boiler at minimum rate 10 Record combustion and pressure signal Ps Reference XLF Boiler IOM 11 Check all combustion results using a calibrated flue gas analyzer 12 Release the LOW FIRE switch to place boiler in standby In addition to completing the Futera XLF start up report complete the control set up information
26. N Improper burner servicing can result in premature burner failure voiding the warranty Pilot and burner removal 1 Close the manual shutoff valves in the gas supply line and turn off electrical power to the boiler water heater 2 Remove the jacket top panel 3 Remove wires from the spark rods and remove the UV sensor from the transition piece 4 Remove the pilot assembly a Disconnect the compression nut at the front of the pilot block b Remove the pilot gas tubing c Remove the 2 screws from the pilot block d Remove the pilot assembly 5 Disconnect the flexible gas line from the manifold 6 Disconnect the wires to the fan and remove the 2 bolts and the fan hold down plates that secure the fan to the transition piece 7 Lift and remove the fan housing from the boiler water heater taking care not to damage the spark rods and or their alignment 8 Remove the four nuts holding the transition piece to the heat exchanger 9 Remove the transition piece taking care not to damage the o ring 10 Remove the burner taking care not to damage the gasket 11 Replace all components after servicing Heat exchanger inspection 1 Close the manual shutoff valves in the gas supply lines and turn off electrical power to the boiler water heater 2 Remove burner following the instructions in the Burner Removal section Finned copper tube gas boilers amp water heaters Boiler Manual 3 Remove the fron
27. NDBY If not refer to the XLF HeatNet Control IOM for troubleshooting Slide the HeatNet controls low fire switch on HeatNet control board to the LOW FIRE position The boiler will begin the start up sequence 15 Allow the boiler to pre purge and enter the pilot ignition cycle 16 17 18 If pilot lights indicated by a good flame signal 5 0 V DC proceed to step 18 See Honeywell R7800 literature for use of a meter to check flame signal ifkeypad readout is not available If pilot is unstable indicated by a low or erratic flame signal causing pilot flame failure toggle the low fire switch to DISABLE then back to ENABLE to start another cycle reset the Honeywell control if necessary Repeat for one or two more times to ensure the pilot line is purged ofall air If pilot is still unstable the pilot gas pressure may need to be increased See step 18 Pilot pressure adjustment a Switch the Honeywell control to TEST position within the first 10 seconds of the pilot ignition sequence Finned copper tube gas boilers amp water heaters Boiler Manual Figure 18 Figure 19 b Connect one side of a manometer or pressure gauge to the manometer pressure port barbed on the pressure test manifold located inside control panel See Figure 18 Leave the other side of the manometer open to the room Manometer connections to the test manifold in control cabinet c Measure pilot gas pressure by pressing
28. OM 104 FUTER TE Table7 Temperature Rise Table Finned copper tube gas boilers amp water heaters Boiler Manual Model AT 20 F AT 11 1 C Number Flow Rate Pres Drop Flow Rate Pres Drop GPM Ft L s kPa 2500 217 5 10 05 13 7 29 6 3000 261 0 15 20 16 5 44 8 3500 304 5 20 26 19 2 59 7 4000 NA NA NA NA Model i N 9 His Flow Rate Pres Drop Flow Rate Pres Drop GPM Ft L s kPa 2500 174 0 6 45 11 0 19 0 3000 208 8 9 73 13 2 28 7 3500 243 6 13 40 15 4 39 5 4000 278 4 17 30 17 6 51 0 Model V 0 i 6 Number Flow Rate Pres Drop Flow Rate Pres Drop GPM Ft L s kPa 2500 145 0 3 71 9 1 10 9 3000 174 0 6 75 11 0 19 9 3500 203 0 9 56 12 8 28 2 4000 232 0 12 00 14 6 35 4 Model i i 9 4 Number Flow Rate Pres Drop Flow Rate Pres Drop GPM Ft L s kPa 2500 124 3 2 79 7 8 8 2 3000 149 1 4 65 9 4 137 3500 174 0 7 19 10 9 21 2 4000 198 9 10 48 125 30 9 This flow rate exceeds the recommended maximum for a boiler with a standard copper heat exchanger Use a greater temperature rise or consult manufacturer Consider a cupro nickel heat exchanger because its maximum flow rate is 315 GPM Low water cutoff Ifa 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 for proper wiring connections
29. XLF IOM 3 82 0317 FU ZER Finned copper tube Gas boilers MB amp Water heaters MW Boiler manual Installation and operation instructions Also read and follow HeatNet Control manual This manual is intended only for use by a qualified SEET installer technician Read and follow this manual all supplements and related instructional information provided with the boiler Install start and service the boiler only in the sequence and methods given in these instructions Failure to do so can result in severe personal injury death or substantial property damage Do not use the boiler during construction 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 can only be operated with a dust free air supply Follow the instruction manual procedures to duct air to the boiler air intake Ifthe boiler has been contaminated by operation with contaminated air follow the instruction manual guidelines to clean repair or replace the boiler if necessary CAUTION Affixthese instructions near to the boiler Instruct the E owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual 4 12 Copyright 2012 Mestek Inc XL E Finned copper tube gas boilers amp water heaters Boiler Manual RBI
30. accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform with CSA C22 1 Canadian Electrical Code Part I if installed in Canada Install a separate 240 volt circuit breaker for the boiler water heater See Table 12 A properly rated shut offswitch should be located at the boiler water heater The boiler water heater must be grounded in accordance with the authority having jurisdiction or ifnone the latest revision of the National Electrical Code ANSI NFPA 70 Table 12 Futera XLF Electrical Requirements Futera XLF Required FLA Model Circuit Breaker amps 2500 4000 25 17 Use separate circuit breaker that is properly sized for pump and pump contactor Line voltage field wiring of any controls or other devices must conform to the temperature limitation of type TEW or equivalent at 189 F 105 C 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 water heater for proper wiring connections and wire size FUTER TE GENERAL OPERATION IM Before proceeding read and fully understand the i instructions contained in this manual Do not attempt to operate this boiler water heater if it has not been installed in accordance with the guidelines set forth in this manual Failure to co
31. and holding the service valve marked PILOT GAS d Set pilot gas pressure to 3 0 inches w c 0 5 inch by adjusting the pilot gas pressure regulator inside the air box Access from the boiler top cover See Figure 19 Access to air trim adjustment and pilot regulator Pilot regulator e Check pilot air pressure using service valve marked PILOT AIR L Pilot air pressure should be 0 60 inches w c 0 10 inches Combustion readings must be in the range specified in the following instructions Adjust the boiler as necessary to ensure proper combustion FUTER TE Verify low fire operation 1 Connect a manometer or Magnehelic gauge with the pressure side to the manifold pressure port See Figure 18 page 26 for locations 2 Set Honeywell R7800 control to RUN position The boiler will 3 Measure the flue gas CO with the boiler running at low fire Set operate at low fire because the low fire switch is in the low fire position low fire CO to 8 0 8 5 by adjustment on the Dungs valve using a 3mm Allen wrench a Turn the wrench in small increments 10 degrees at a time b Allow time after each adjustment for the boiler to reach steady state 4 After setting the CO measure the pressure signal Ps a Press the Ps signal button and read the pressure The pressure at low fire should be as shown in Figure 18 b Ifthe pressure is outside this range follow instructions in the XLF Con
32. be gas boilers amp water heaters Boiler Manual Figure 13 Multiple Boiler Piping See notes SYSTEM Pump RETURN These drawings show 4h suggested piping con Valve 5 MAXIMUM 6 PIPE Z figuration and valving e DIAMETERS BETWEEN Check with local codes Globe Valve CENTERS ig i and ordinances for spe cific requirements lt gt Angle Valve Bufferfly Valve Balance Valve D I D I D I Z D I A SS Ball Valve A A A A A O a Motorized Valve CD Fe C V Solenoid X N Ka Operated Valve BACKFLOW R PREVENTION Self Operated Val DEVICE E SYSTEM ye S U P P LY de 7 Reducing Valve NOTES ZA N rower Check Valve 1 Boiler circuit piping must be large enough to handle maximum flow through unit 7 15 Rev 4 COLD WATER L 2 Boiler pump sized to boiler design flow requirements MAKE UP K 3 All boilers furnished with factory mounted outlet water temperature gauge ge 4 Boiler pump purging required Use terminals supplied Relief Valve 5 Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units Flow Switch Thermometer VAR Aquastat Union Pressure Switch Gas Pressure Regulator Automatic Air Vent 2 Temperature amp Pressure Relief Valve TF Vacuum Relief Valve AXLF DOMESTIC WATER SUPPLY PIPING CAUTION Proper controls must be used to prevent water supplied
33. c Air Vent dk Temperature amp Pressure Relief Valve Vacuum Relief Valve Drain Valve Typ XL Il 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 Gas supply piping must be in accordance with the National Fuel Code ANSI Z223 1 latest revision or applicable provisions of the local building codes Canadian installations must comply with CAN CGA B149 1 or B149 2 Installation Code Failure to comply with this warning can result in extensive property damage severe personal injury or death The Futera XLF comes from the factory ready to be piped to the gas supply If for any reason the boiler water heater is not for the type of gas available at the installation site call your RBI representative to resolve the problem NOTICE Withall units operating the gas supply pressure natural H g the gas supply p gas at the safety shutoff valve inlet must be Minimum 3 5 in 88 9 mm WC Maximum 14 in 356 mm WC Tables 10 and 11 should be used to ensure that the gas supply piping is sized properly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 10 should be used in conjunction w
34. cal codes and vent pipe manufacturer s recommendations using generally accepted engineering practices t Consult factory for vertical heights beyond 100 ft FUTER TE 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 8 page 20 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 ofhigh water flow rates See Table 7 page 16 Return water temperatures below 140 F 60 C will result in heat exchanger damage from excessive condensation voiding the manufacturer s warranty see Primary Secondary Piping See Figure 9 page 15 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 flow of water through the unit MUST be maintained The pump responsible for flow through the boiler water heater must run continuously 2 An eth
35. ce from intake to maximum snow line GE ee Seege EE eg RIOM 11 REV A N AXLF Finned copper tube gas boilers amp water heaters Boiler Manual Approved non restrictive terminal 10 ft 3 7m __ Minimum to adjacent building Lo Figure 3 VENT OPTION 1 DIRECT VENT Combination direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each See Table 3 or 4 for min pipe diameters 3 ft 1 m Minimum Maximum snow line mg Exhaust RBI supplied terminal SCH a Combustion air Maximum snow line 1 5 ft 0 5 m Minimum distance from intake to maximum snow line _ RIOM 13 REV A Figure 4 VENT OPTION 1 DIRECT VENT Vertical air intake and venting for direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each See Table 3 or 4 for min pipe diameters Approved non restrictive 1 10 ft 3 1m Minimum to wall or adjacent building terminal 4 ft 1 2m 5 ft 1 7m Minimum Minimum D i Maximum Roof flashing 1 5 ft 0 5 m snow line Minimum Me ke NN RIOM 12 Clearances per vent ei manufacturer s instructions Combustion air Pee Pee Metal chimney system gem 5 ft 1 5 m KS Minimum Locate exhaust terminal downwind from air intak
36. e to reduce potential for flue gas recirculation Failure to comply could result in severe personal injury or death FU ER LF Finned copper tube gas boilers amp water heaters Boiler Manual OPTION 2 VERTICAL VENTING POSITIVE PRESSURE CATEGORY IV FIGURE 5 OR FIGURE 6 VENT PIPE EQUIVALENT LENGTH UP TO 100 FEET MAXIMUM CIENT Masonry chimneys when used must be lined with a metal liner certified for Category IV venting A thorough 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 lined to prevent condensation and draft problems Table 4 lists the equivalent breeching and flue sizes required for the boiler water heater Figure 5 VENT OPTION 2 VERTICAL CHIMNEY VENTING Vertical venting with a metal chimney system See Figure 4 page 7 for minimum pipe diameters A 2 ft 0 6 m Minimum above the highest point within 10 ft 3 7 m Storm collar Roof flashing Clearances per vent manufacturer s instructions Offset only if necessary Firestop Framing members Joists between joists ae Insulation Clearances per vent manufacturer s instructions l 2 ft 0 6 m Minimum Recommended 12 0 3 m minimum required Condensate drain with pigtail ies ZZ E RIOM 102 Figure
37. e is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting Finned copper tube gas boilers amp water heaters Boiler Manual system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan for a boiler installation Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame ofa match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When resizing any portion of t
38. ease the HeatNet control s maximum rate setting above 90 unless needed for high altitude installations c If Ps is too high reduce the HeatNet controls maximum firing rate setting by 2 Then slide the calibration switch to NORMAL and exit the HeatNet controls calibration screens Replace the jumper on A A and allow the boiler to return to high fire Return to step 2 to repeat the process If necessary repeat this sequence reducing the firing rate by 2 each time d If Psis too low increase the firing rate setting by 2 Then slide the calibration switch to NORMAL and exit the HeatNet control s calibration screens Replace the jumper on A A and allow the boiler to return to high fire Return to step 2 to repeat the process If necessary repeat this sequence increasing the firing rate by 2 each time e Check the pressure signal again If the signal is now correct reconnect the jumper on AA and proceed to step 5 f Ifthe pressure signal is still not correct verify that the air trim adjustment Figure 19 page 26 is in the half open factory setting position If it is at factory setting you will need to contact technical support at the factory to troubleshoot the pressure signal issue If the pressure signal is correct measure the flue gas CO It should be between 9 and 9 5 a IfCO is correct proceed to step 6 b FCO is not within this range adjust the air trim adjustment slightly see Figure 19 page 26 on top
39. emperature rise through the unit The proper velocity through the water heater must be maintained in accordance with Table 9 page 20 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 ifthe temperature rise is higher than recommended in Table 9 page 20 the flow rate is too low Scaling and softening of the heat exchanger will occur Thermostatic Mixing Valve Water Above 140 F 60 C Water can be stored at temperatures above 140 F 60 C provided that a thermostatically controlled mixing valve is used to temper the hot water to an acceptable temperature before it s supplied for domestic use The mixing valve MUST be set to prevent a scald injury from occurring see the caution against scalding Storage of water for domestic use above 140 F 60 C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria Finned copper tube gas boilers amp water heaters Boiler Manual FUTER TE Selection Table Table 8 and the Pumping Table8 Futera XLF Heat Exchanger Selection Performance Table Table 9 Scale free operation can be achieved by using water with a hardness between 8 and 18 and by EAT EXCHANGER SELECTION GRAPH maintaining the pH between 5 and 9 Follow
40. ent system is certified to UL 1738 for installations in the United States ULC 636 for installations in Canada Maximum equivalent length of vent piping must not exceed 100 feet AXLE 3 OPTION 3 Side Wall Vent Positive Pressure Category IV individual venting only page 11 Combustion air is obtained from the space in which the unit is installed Vent system is certified to UL 1738 for installations in the United States ULC 636 for installations in Canada Maximum equivalent length of vent and air piping must not exceed 100 feet each mug To ensure proper boiler operation boilers that are vented side wall and use room air must not be fired at less than 33 input 4 OPTION A Vertical Vent Negative Pressure Category II common venting page 12 Requires negative pressure in vent natural draft Requires a metal chimney system approved for Category II venting This method is required if common venting multiple XLF boilers myg All venting and combustion air material supplied by installer All venting materials must be approved for the application Consult the vent manufacturer s product literature Table 4 Category IV venting vent pipe size Vent options 1 2 or 3 Input Pipe diameter MBH in mm 2500 3000 8 203 3500 4000 10 254 OPTION 1 DIRECT VENT POSITIVE PRESSURE CATEGORY IV HORIZONTAL OR VERTICAL In this configuration the boiler water heater blower is
41. flines must be made in accordance with the latest revision of ANSI Z223 1 NFPA 54 The main Dungs gas valve supplied with boiler water heater does not require external venting Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler All gas connections MUST be leak tested before putting the boiler into operation WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this warning can cause extensive property damage severe personal injury or death Whenever the gas supply piping is pressure tested the boiler water heater gas controls must be protected If the test pressure is equal to or less than 1 2 psig 3 5 kPa isolate the boiler water heater by closing it s manual shut off valve see Figure 16 page 22 If the test pressure is greater than or equal to 1 2 psig 3 5 kPa disconnect the boiler water heater and its individual shut off valve Finned copper tube gas boilers amp water heaters Boiler Manual ELECTRICAL WIRING Electrical power connections CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to comply could result in severe personal injury death or substantial property damage The electrical connections to this boiler water heater must be made in
42. gh limit cannot be repaired If it fails to function properly replace it 6 Visually check the pilot and main burner flames to ensure proper operation see Figure 21 2 Figure 23 page 32 shows the sensor hose connections inside the MTN A yellow floating flame indicates a lack of combustion Futera XLF air box air Do not operate the boiler water heater until the problem is solved or severe personal injury or death may occur FU 7 ERM Finned copper tube gas boilers amp water heaters Boiler Manual Figure 23 Futera XLF pressure sensor hose routing SWITCH SETTINGS IN W C SWITCH FOR 2500 3000 3500 4000 MAIN PSt Lat ower 2 20 0 20 0 20 0 20 BLOCKED PS2 FLUE 3 0 3 0 2 0 2 0 BLOCKED PS5 INLET 2 0 2 0 2 0 s6 bor AIR 0 36 0 36 0 36 0 36 P AIR CHAMBER OUTLET SIDE PS5 1 moren TOP E SWITCH GAS MANIFOLD E TAPPING PLUGGED COMB CHAMBER FOR XLF 2500 amp 3000 ots PS2 Pa d MIDDLE D 005 JEWEL FEEDBACK NT XLF 3500 amp 4000 ONLY SWITCH ORIFICE TO DUNGS GAS VALVE BLOCKED N FLUE REGULATOR PS1 BOTTOM TEST PORT SWITCH HOOK UP MAIN BLOWER TO ROOM VIA BULKHEAD CONNECTION TO CONTROL PANEL CONTROL PANEL TOP VIEW MANOMETER RIOM 111 REV D SEE VIEW B VW Finned copper tube gas boilers amp water heaters Boiler Manual RIOM 107
43. he common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate Tables in Appendix F in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 Installation Codes VENT SYSTEM OPTIONS The flue products in the vent system may be cooled below their dew point and form condensate in the flue The materials used for a Category IV vent must be resistant to any corrosive damage from flue gas condensate The flue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system 7 Category IV vent air piping lengths must not exceed 100 equivalent feet If longer runs are required use a Category II negative pressure vent system specially engineered designed to meet all applicable codes FE i The Futera XLF may be vented the following ways 1 OPTION 1 Direct Vent Positive Pressure Category IV individual venting only page 7 Combustion air is piped from the outdoors to the blower inlet Vent system is certified to UL 1738 for installations in the United States ULC 636 for installations in Canada Maximum equivalent length of vent and air piping must not exceed 100 feet each 2 OPTION 2 Vertical Vent Positive Pressure Category IV individual venting only page 10 Combustion air is obtained from the space in which the unit is installed V
44. hut 2500 315 18 86 55 6 14 down the water heater if flow falls below the 3000 315 19 75 58 2 17 required minimum level Table 9 provides the heat exchanger pressure drop chart and 3500 315 20 65 60 8 19 temperature rise table The temperature rise 4000 315 21 54 63 5 22 across the water heater must never exceed e SS 35 F 19 4 C ecommended Normal 8 18 Grains Calculated GPM PD FT PD kPa AT F Cold Water Supply i 2500 210 9 34 27 5 21 The cold water supply must be piped to 3000 10 9 76 288 25 the water heater s outlet piping between the water heater and the hot water storage 3500 210 10 18 30 0 29 tank This will prevent untempered water 4000 210 10 61 31 3 33 from entering the water heater See the Temperature Rise Control section page 19 Two typical water heating systems are shown in Figures 14 and 15 FU 7 ERM Finned copper tube gas boilers amp water heaters Boiler Manual Figure 14 Typical Water Heating Piping MW Models Only See Notes 3 T P Se el Daf Be gi ls he d wat nz Q col up gro mak af P iat 2 ATTENTION Not all RBI stock storage oe 2 tanks incorporate this tapping See Note 1 Bae Figure 15 NOTICE These drawings show sug gested piping configuration and valving Check with local codes and ordinances for specific requirements Multiple Water Heating Piping MW Models Only See Notes Self balancing double reverse
45. icient volume to meet the criteria for an unconfined space The total air requirements of all gas utilization equipment fireplaces wood stoves or any type of exhaust fan must be considered when making this determination Each opening must have a minimum free area of 1 in 1000 Btu hr 2200 mm kW based on the total input rating of ALL gas utilization equipment in the confined area Each opening must be no less than 100 in 64 516 mm in size The upper opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the top of the enclosure The bottom opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the bottom of the enclosure All air from outside the building When installed in a confined space without utilizing the intake air option two permanent openings communicating directly with or by ducts to the outdoors or spaces that freely communicate with the outdoors must be present The upper opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the top of the enclosure The bottom opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the bottom of the enclosure Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 in 4000 Btu hr 550 mm2 kW of the total input rating of all of the equipment in the enclosure Where com
46. iler water heater voiding the warranty If the boiler water heater is operated while the building is under construction it MUST be protected from wood concrete sheet rock and other types of dust Failure to properly protect the unit from construction dust will damage the unit voiding the warranty CAUTION Buildings will require the installation of a fresh air duct or other means of providing make up air if the intake air option isn t used Any building utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an outside air duct must be done to meet the requirements of all such devices TEEN tel Never operate the Futera XLF in an environment subjected to a negative pressure unless it is Direct Vented Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death AXLF Il All air from inside the building Ifthe Futera XLF is to be located in a confined space the minimum clearances listed in Table 1 page 4 must be maintained between it and any combustible construction When installed in a confined space without the intake air option as in Figure 5 page 10 through Figure 8 page 13 two permanent openings communicating with an additional room s are required The combined volume of these spaces must have suff
47. imum Dag XLF 3500 4000 3 boilers maximum gg Cc B gt 7 Y Vent D l 3 O7 D D e e e e e i TR i 24 inches 24 inches 24 inches L L L kd NOS bei BOILER 3 BOILER 2 BOILER 1 IF REQUIRED IF REQUIRED RIOM 113 Legend for Figure 8 WATTS It is recommended that the boiler nearest the vertical chimney must always be fired first when the horizontal exceeds 50 of the vertical A negative pressure of 0 02 to 0 10 inches w c is required in each boiler s riser when all boilers are operating at full input Provide clearance from the boiler of no less than 6 inches to combustible surfaces or 24 inches for service 1 A barometric damper must be installed on the riser of each boiler 24 inches above the vent elbow Exception If the vent system is designed using accepted engineerin pieces and the design calculations prove there is no need for barometric dampers the barometric dampers may be omitted When required by applicable codes install a thermal spill switch on each barometric damper 2 Install a thermal spill switch on each barometric damper when required by applicable codes 3 Connect each boiler riser to the common vent with a Y connection or Boot T 4 Install an approved vent cap at the vent termination 5 DIMENSIONS B breeching length C chimney height D breeching diameter F riser diameter no smaller than the dimension given in Table 5 page 12 6 Size the chimney and breeching per lo
48. in the rear of the Futera XLF Control Installation and operation manual FUTER2 Finned copper tube gas boilers amp water heaters Boiler Manual ei DS EES ome perucrewemne SAFETY TEST CHECKLIST Q FLOW SWITCHES Q AIR SWITCH Q FLAME SAFEGUARD Q LOW WATER CUT OFF Q HIGH LIMITS NOTICE Verify that the piping and controls ensure the boiler return water temperature does NOT drop below 140 F 60 C Operating at lower return temperatures is likely to cause condensation in the primary heat exchanger resulting in corrosion and possible failure of the heat exchanger COMMISSIONING THE BOILER WATER HEATER Q UNIT CYCLED MINIMUM OF 15 TIMES THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROPER FLOW BEFORE YOU LEAVE THE JOBSITE Q ALL COVERS REPLACED YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 35 F 19 4 C NOR BE LOWER THAN 20 F 11 1 C DETAT I CUSTOMER INSTRUCTED I CUSTOMER GIVEN MANUAL I TARGET TEMPERATURE SET PER CUSTOMER COMMISSIONED BY SIGNATURE DATE ADDITIONAL NOTES AND COMMENTS NOTICE XL Inthe Commonwealth of Massachusetts the installation 1 must be performed by alicensed plumber or gas fitter For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure seed in whole or in part for residential purposes including those owned or operated by the commonweal
49. ipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and b Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in hele or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED a When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include i Detailed instructions for the installation of the venting system design or the venting system components and i A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED a When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer i The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and ii The special venting systems shall be Product Approved by the Board and the instructions for that system
50. ith Table 11 to ensure that the gas supply piping has the capacity to meet the demand Figure 16 depicts the proper way to connect the boiler water heater to the gas supply piping The manual shut off valve MUST be installed in the supply piping It should be installed 5 ft 1 5 m above the floor where required by local codes Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls Table 10 Gas pipe capacities natural gas Finned copper tube gas boilers amp water heaters Boiler Manual Figure 16 Gas Supply Piping G supai Shut off valve Gas supply pressure test port Ke RIOM 105 Maximum pipe capacity in ft hr based on 0 60 specific gravity natural gas at a pressure of 0 5 psig or less and a 0 5 w c pressure drop for iron pipe with nominal size below and for total equivalent length in feet 5 41 800 28 700 23 000 19 700 17 500 15 800 14 600 Gs 10 20 30 40 50 60 70 80 90 100 125 150 175 200 250 2 4 020 2 760 2 220 1 900 1 680 1 520 1 400 1 300 1 220 1 160 1 020 928 854 794 704 2 2 6 400 4 400 3 530 3 020 2 680 2 430 2 230 2 080 1 950 1 840 1 630 1 480 1 360 1 270 1 120 3 11 300 7 780 6 250 5 350 4 740 4 290 3 950 3 670 3 450 3 260 2 890 2 610 2 410 2 240 1 980 4 23 100 15 900 12 700 10 900 9 660 8 760 8 050 7 490
51. l and propane gas under the latest revision of ANSI Z21 10 3 CSA 4 3 Gas Water Heaters ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 56 CSA 4 7 Gas Fired Pool Heaters Canada Only and CAN 1 3 1 Industrial and Commercial Gas Fired Packaged Boilers Each unit has been constructed and hydrostatically tested for a maximum working pressure of 160 psi 1103 kPa in accordance with Section IV of the ASME Boiler and Pressure Vessel Code All aspects of the boiler water heater installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 In Canada the installation must be in accordance with the requirements of CSA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment If installed in the Commonwealth of Massachusetts you MUST FOLLOW the additional instructions contained in RBI s instruction sheet MACODE 3 located in the back of this manual The owner should maintain a record of all service work performed with the date and a description of the work done Include the name of the service organization for future reference Direct all questions to your RBI distributor or contact the RBI C
52. level of dissolved solids exceeding 350 ppm will require a recalculation of the pump size and temperature rise A cupronickel heat exchanger may also be required The manufacturer should be consulted when these water conditions are encountered See Table 8 page 20 CAUTION Themaximum allowable flowrate through a Futera XLF water heater is 260 GPM 16 4 L when equipped with copper tubes The cupronickel heat exchanger allows for 315 GPM 19 9 L s See Table 9 page 20 RBI water heaters are designed to run scale free Due to the extreme variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling It is crucial to consider these two variables when making heat exchanger and pump selections If local water conditions are extreme follow the guidelines in the Heat Exchanger Finned copper tube gas boilers amp water heaters Boiler Manual TEMPERATURE RISE CONTROL f Water returned to the water heater inlet must not be less than 140 F 60 C or excessive condensation of the products of combustion will damage the water heater voiding the warranty The method outlined below can be employed to prevent this condition from occurring A balancing valve should be installed on the outlet side of the water heater for purposes of adjusting the flow rate through the heat exchanger Thermometers are installed on both the inlet and outlet of the water heater for determining the t
53. me Ensure that the make up water valve is open Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping Close the make up water valve and check and clean the strainers and make up water pressure reducing valve Open the make up water valve and adjust the system pressure if necessary The system should be checked and bled after three days of operation Finned copper tube gas boilers amp water heaters Boiler Manual WIRING amp CONTROL SET UP MeN Follow the instructions in the Futera XLF Control installation and operation instruction manual shipped with the boiler to wire the boiler and set up the HeatNet control The control must be set up before attempting to fire the boiler See Figure 17 page 25 for location of electrical components In addition to the information in the Futera XLF Control IOM see the following information on controls and interlocks CONTROLS amp INTERLOCKS Low Water Cutoff If the boiler is to be installed above radiation or if required by other codes or regulations install a low water cutoff in appropriate piping Wire the switch to the Interlock contacts as illustrated on Field Wiring schematic Ensure that the low water cutoff device s will function properly Operating Control The operating control should be set to the lowest setting that will satisfy the consumer s needs myg Setting the thermostat or operation control t
54. mply with this warning can result in extensive property damage severe personal injury or death Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance Do not interrupt water flow through the boiler water heater Hydronic heating boilers Open the make up water valve and slowly fill the boiler and all ofthe radiation with water Ensure that all bleed and drain valves are closed Adjust the make up water pressure regulator so a minimum 12 psig 82 7 kPa system pressure is maintained at the highest point in the system piping Ifa make up water pump is used adjust it to maintain aminimum 12 psig 82 7 kPa system pressure Open the system bleed and drain valves one at a time to purge the air trapped in the heating system piping With the boiler off run the system pump for at least 30 minutes and bleed the system piping using the bleed valves If strainers are used in the system piping the make up water valve should be closed and the strainers checked and cleaned The system expansion tank should be checked to ensure that the correct water level in the tank is maintained The tank should be less than half full of water with the system full and adjusted to the correct operating pressure Start the boiler as described in the Operating Instructions section Run the boiler for at least an hour The system pump s and all radiation units must be operated during this ti
55. municating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in 2000 Btu hr 1100 mm KW of the total input rating of all of the equipment in the enclosure When ducts are used they must have the same cross sectional area as the free area of the opening to which they connect When calculating the free area necessary to meet the make up air requirements of the enclosure consideration must be given to the blockage effects of louvers grills and screens Screens must have a minimum mesh size of 1 4 inch 6 4 mm If the free area through a louver or grill is not known ducts should be sized per Table 2 Canadian installations must comply with CSA B149 1 when air supply is provided by natural air flow from the outdoors for natural draft partial fan assisted fan assisted or power draft assisted burners there shall be a permanent air supply opening s having a cross sectional area of not less than 1 in per 7 000 Btuh 310 mm per kW up to and including 1 million Btuh plus 1 in per 14 000 Btuh 155 mm per kW in excess of 1 million Btuh Finned copper tube gas boilers amp water heaters Boiler Manual Table 2 Make up Air Louver Sizing Input Required cross sectional area we Wire screen Metal louvers Wooden louvers Va inch 6 4mm 75 free area 25 free area in cm in cm in cm 2500 625 4031 833 5382 2500 16127 3000 750 4838 1000 6452 3000 19354 3500 875
56. ng infrared operation A few random speckles of red are acceptable but large concentrations of spots or large areas of red are not If large amounts of red concentrations are observed verify combustion readings DO NOT LEAVE THE BURNER IN AN INFRARED STATE Finned copper tube gas boilers amp water heaters Boiler Manual Leave the manometer connected to the test manifold It will be needed for high fire operation testing Verify high fire operation 1 WARNING S Jumper the AA terminals on the HeatNet board and allow the boiler to rise to maximum 100 input Allow the boiler to reach steady state combustion at high fire Verify high fire blower speed as follows a With the manometer or gauge connected to the test manifold press the Ps signal button and read the pressure b The pressure at low fire should be as shown in Figure 18 c Ifthe pressure is NOT correct follow step 4 If the high fire signal pressure is not correct a Remove the jumper on A A The boiler will return to low fire b Follow the instructions in the XLF Control IOM to calibrate the high fire firing rate Slide the HeatNet control calibrate switch to CAL Follow the Control IOM procedure to navigate to the HeatNet control calibration screen The maximum firing rate value in the HeatNet control is factory set at 90 At this setting at sea level and with typical vent length the boiler will be at rate DO NOT incr
57. ocation that would subject it to temperatures at or near freezing see the FREEZE PROTECTION section on page 14 MENTS Never store combustible materials gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler water heater Failure to comply with this warning can result in an explosion or fire causing extensive property damage severe personal injury or death COMBUSTION AIR amp VENTILATION Went This boiler water heater must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest revision of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and all applicable local building codes Canadian installations must comply with CAN CGA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Failure to provide adequate combustion air for this boiler water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death To operate properly and safely this boiler water heater requires a continuous supply of air for combustion NEVER store objects on or around the boiler water heater CAUTION Combustion air contaminated with fluorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber These acids will cause premature failure of the bo
58. of mixing box to achieve a CO of 9 9 5 c If adjusting the air trim adjustment does not correct the problem contact technical support at the factory to troubleshoot the problem 6 IfCO and pressure signal are correct allow the boiler to reach steady state and verify supply gas pressure and check input rates as explained in the Gas Supply Piping section 7 Removejumper on AA and allow boiler to settle into minimum input Observe the combustion readings to ensure the boiler is operating correctly 8 When finished disable the low fire hold switch and replace test ports to normal state Remove the manometer connections and close the control panel door 9 The Futera XLF boiler allows for many modes of operation and control methods Reference the XLF HeatNet Control IOM TO TURN OFF GAS TO APPLIANCE 1 Set the operating control to its lowest setting 2 Turn off all electric power to the boiler if service is to be performed 3 Close the manual main and pilot gas shut off valves Finned copper tube gas boilers amp water heaters Boiler Manual CHECKING amp ADJUSTMENTS WARNING Proper polarity of the ignition transformer wiring is import Improp er wiring of the ignition transformer can result in an explosion causing extensive property damage severe personal injury or death Spark gap With the main and pilot gas manual valves in the closed position energize the unit Look through the sight glas
59. of subfreezing air could occur otherwise the unit could freeze up voiding the warranty Intake air option Vertical guidelines The maximum equivalent length for the vertical intake air pipe is 100 ft 30 5 m Each 90 elbow and the intake air terminal are equal to 10 linear ft 3 0 m of pipe see Table 3 An approved nonrestrictive intake air terminal must be used The intake air terminal must terminate as shown in Figure 3 page 9 The penetration point in the roof must be properly flashed and sealed AXL F Intake air option Horizontal guidelines The maximum equivalent length for the horizontal intake air pipe is 100 ft 30 5 m Each 90 elbow and the intake air terminal are equal to 10 linear ft 3 0 m of pipe If horizontal runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers The certified intake air terminal from RBI must be used see Figure 1 page 8 Figure 2 page 8 and Figure 4 page 9 GENERAL VENTING GUIDELINES J The vent installation must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision or applicable provisions of the local building codes Canadian installations must comply with CAN CGA B149 1 or 2 Installation Code Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death All vent systems must be fully supported by the building
60. ons 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 in the boiler room as it rapidly destroys the heating equipment and voids the warranty All copper fin boilers should not operate with a return water temperature less than 110 F 43 C atmospheric combustion 12 F 52 C fan assist combustion If a lower temperature is required an external bypass should be installed to prevent condensation The manufacturer s warranty does not cover damage done by condensation to any expenses including labor or material incurred during removal or reinstallation of the Product or parts thereof to damage as a result of settlement distortion collapse or cracking of any foundation area beams or pipes surrounding the Product d to any workmanship of any installer of the Product or to Products installed outside the continental United States or Canada This limited warranty is conditional upon a shipment to the Manufacturer of that part of the Product thought to be defective Goods can only be returned with prior written approval from the Manufacturer All returns must be freight prepaid b determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship Repair or replacement of any part under this Limited Warranty shall not extend the duration of the wa
61. oo high can result in scalding resulting in severe personal injury High Limits Aquastats The high limits are located in the top control area of the boiler water heater Remote capillary bulbs run to wells on the outlet side of the supply header The high limit can be reset by depressing the red button The water heater high limit should be set to a minimum of 20 F 11 C higher than the operating control Refer to the HOT WATER SUPPLY section for the proper supply water temperature Flow Switch A flow switch is provided in the water outlet piping to prevent the boiler water heater from firing without adequate water flow through the heat exchanger PROPANE GAS TEEN NTS Propane gas may not always be detected by smell Propane gas is heavier than air and can collect in low areas Propane gas can ignite or explode if an ignition source is present and result in death serious injury and property damage FUTER TE Figure 17 HeatNet Control Panel Transformer Automatic reset Test run Flame anual reset switch safeguard Local Remote HeatNet switch control board RIOM 109 Display N window Ignition status window Back button Up button MAIN MENU ey Down button Power switch U RIOM 109 Select button
62. ove Switch 11 0420 1 1 1 1 11 0419 1 1 1 1 53 Transformer 50 VA 15 0007 1 1 1 1 NS High Limit Jumo MB 14 0013 1 1 1 1 NS High Limit Jumo MW 14 0014 1 1 1 1 NS High Limit Jumo MB Auto Reset 14 0114 1 1 1 1 NS High Limit Jumo MW Auto Reset 14 0115 1 1 1 1 NS Thermometer Well 3 8 x 3 13 0104 1 2 2 2 NS High Limit Well 3 8 x 3 13 0104 1 2 2 2 54 Main Board 16 0038 1 1 1 1 NS Display Board 40 0088 i 1 1 1 NS Ignition Cable 44 0063 1 1 1 1 NS Ribbon Cable 40 0115 1 1 1 1 XL F Il REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Model Size with item Quantities Below Ref Name of Part Part 2500 3000 3500 4000 NS Power Switch 48 0013 1 1 1 1 NS Toggle Switch Remote Local 48 0014 1 1 1 1 NS 10K Temperature Sensor 14 0325 3 3 3 3 NS Purge Timer ST7800 16 0007 1 1 1 1 NS Keyboard Display Module S7800A 16 0010 1 1 1 1 58 Pilot Flame Rod Kit 70 3615 1 1 1 1 58a Electrode 16 0335 2 2 2 2 58b O ring 06 0008 1 1 1 1 58c View Port Assembly 70 2205 1 1 1 1 58d Mini Peeper C7027A not included in 70 3615 16 0009 1 1 1 1 NS Turbo Pilot Torch 70 2559 1 1 1 1 NS UV Amplifier R7849B 16 0037 1 1 1 1 60a Blower O Ring 06 0004 1 1 1 1 62 Mini Fan 12 0021 1 1 1 1 64 Solenoid Valve w Regulator NG 11 0372 1 1 1 1 Solenoid Valve w Regulator LP 11 0374 1 1 1 1 65 Air Shu
63. owever that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed e APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified f SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building ata minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the GEN 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 OBSTRUCTIONS o INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not Finned copper tube gas boilers amp water heaters Boiler Manual Commonwealth of Massachusetts Installation Requirements MACODE 3 approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 J Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death 2 Exemptions The following equipment is exempt from 248 CMR S 08 2 a 1 through 4 a The equipment listed in Chapter 10 entitled Equ
64. rranty with respect to such repaired or replaced part beyond the stated warranty period THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION 260 North Elm Street 7555 Tranmere Drive KS Westfield MA 01085 Mississauga Ontario L5S 1L4 Canada 4 Phone 413 568 9571 Phone 905 670 5888 SE A MESTEK COMPANY a Bei Fax 413 568 9613 Fax 905 670 5782 www rbiwaterheaters com Copyright 2012 Mestek Inc
65. s in the pilot tube to observe the trial for ignition Make sure that the spark is strong and continuous If not check and adjust the spark gap as shown in Figure 20 Figure 20 Spark Gap Pilot tube Flush to 1 16 inch WE 1 8 inch minimum gap to ID RIOM 106 FUTER TE Pilot adjustment 1 The pilot pressure has been factory set at 3 inches w c and shouldn t need adjustment a With the boiler powered generate a call for heat b When the prepurge is complete the ignition pilot trial will begin To adjust the pilot the following steps must be taken a Put the Honeywell RM7800 test switch in the test position The control will hold in the ignition pilot sequence allowing you to check the pressure b Connect one side of a manometer or pressure gauge to the manometer pressure port barbed on the pressure test manifold located inside control panel See figure 18 Leave the other side of the manometer open to the room c Measure pilot gas pressure by pressing and holding the service valve marked PILOT GAS d Set pilot gas pressure to 3 0 inches w c 0 5 inch by adjusting the pilot gas pressure regulator inside the air box Access from the boiler top cover See Figure 19 e Check pilot air pressure using service valve marked PILOT AIR L Pilot air pressure should be 0 60 inches we 0 10 inches caution Never force the regulator adjustment screw beyond the stop limits or
66. seconds after the call for heat is satisfied AXLF Finned copper tube gas boilers amp water heaters Boiler Manual WARNING A temperature rise outside of the range listed in Table 7 WARNING The maximum allowable flow rate through a Futera will result in damage to the heat exchanger voiding the XLF boiler is 260 GPM 16 4 L s when equipped with warranty The maximum allowable temperature rise copper tubes A cupronickel heat exchanger allows for through the boiler is 35 F 19 4 C 315 GPM 19 9L s Figure 9 Futera XLF Piping Check valve for multiple SES a boiler systems vas ED een ae al I Loge I S ee L i Balancing valve for low Optional field supplied low water toed H 7 temperature systems where cutoff probe or float eee Ped ke rr un i return temperature is 140 F 60 C or below ee Union Qa E Pressure relief valve S S d KE econdary boiler pump penne Flow switch KR nion ye Discharge pipe size equal to relief valve outlet RR RR T RR wt A _ J DO NOT restrict flow Dial thermometer LWCO 1 in 25 mm clearance must be maintained between piping and combustible construction Exhaust Drain valves Follow applicable codes RBI supplied Contractor field supplied Discharge so as to avoid exposure of persons to hot liquid or vapor and allow complete drainage of relief valve and piping Schematic does not show actual pipe routing RI
67. shall include a parts list and detailed installation instructions A copy ofall installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all ventin instructions all parts lists for venting instructions and or a venting design instructions shall remain with the appliance or equipment at the completion of the installation Improper venting can result in excessive levels ofcarbon monoxide which can cause severe personal injury or death Copyright 2008 Mestek Inc LIMITED WARRANTY Boilers Water Heaters Industrial Commercial and Other Non Residential Use The Manufacturer warrants to the original owner at the original installation site that the heat exchanger of the Industrial Commercial and other Non Residential Use Boiler the Product will be free from defects in material or workmanship for ten 10 years from the date of installation Additional twenty one 21 year thermal shock warranty on heat exchanger If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the Manufacturer will repair or replace at its option that part of the Product which is shown to be defective All other RBI supplied Boiler Water Heater parts are warranted against defects in material and workmanship for one 1 year from date of installation or 18 months from date of shipment from RBI The Manufacturer warran
68. t Off Valve 11 0376 1 1 1 1 66 Pilot Orifice 052 NG 10 0140 1 1 1 1 Pilot Orifice 040 LP 10 0139 1 1 1 1 67 Pilot Tube 3 8 62 0102 2 2 2 2 70 Power Relay 15 0118 1 1 1 1 71 VFD Contactor 15 0211 1 1 1 1 REPAIR PARTS continued Finned copper tube gas boilers amp water heaters Boiler Manual Model Size with item Quantities Below Ref Name of Part Part 2500 3000 3500 4000 72 Relay Overload 5 5 8 Amp 15 0214 1 1 1 1 Relay Overload 9 13 Amp 15 0215 1 1 1 1 Relay Overload 2 5 4 Amp 15 0216 1 1 1 1 Relay Overload 4 6 Amp 15 0217 1 1 1 1 Relay Overload 12 18 Amp 15 0219 1 1 1 1 73 Fuse 2HP 230V pump 48 0626 3 3 3 3 Fuse 3HP 230V pump 48 0627 3 3 3 3 Fuse 2HP 460V pump 48 0624 3 3 3 3 Fuse 3HP 460V pump 48 0625 3 3 3 3 Fuse 5HP 460V pump 48 0631 3 3 3 3 74 Fuse 25Amp 600V VFD 48 0622 2 2 2 2 79 Keypad Overlay 82 0189 1 1 1 1 NS Rating Plate 82 0054 1 1 1 1 NS Futera III Overlay 82 0192 1 1 1 1 NS Silicone Tubing 06 0051 per foot NS Silicone 66 0151 1 1 1 1 NS Vent Termination Hood 8 09 0113 1 1 Vent Termination Hood 10 09 0115 1 1 NS Air Intake Hood 8 09 0103 1 1 Air Intake Hood 10 09 0104 1 1 FUTER TE Finned copper tube gas boilers amp water heaters Boiler Manual START UP REPORT DATE JOB NAME TECHNICIAN LOCATION COMPANY MODEL P
69. t jacket panel and combustion chamber door Inspect the inside and outside of the heat exchanger for signs of damage sooting or corrosion 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 In either case the heat exchanger must be cleaned thoroughly and the problem resolved before the boiler water heater is returned to service 6 Ifthere 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 amp Replacement section 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 Disconnect the boiler water heater from the system piping Remove the eight bolts on the rear pipe enclosure panel Remove the front jacket panel and combustion chamber door Slide the heat exchanger out of the unit Remove the V baffle straps and V baffles Thoroughly clean the heat exchanger with water from a high pressure hose Use a soft bristle brush ifnecessary Sy a 8 Replace the cleaned heat exchanger and
70. ted metal chimney system the chimney system manufacturer s instructions must be followed WARNING The vent piping must be large enough to safely vent the combined output of all of the appliances connected to the system If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney flue never connect any other appliances to this flue Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death Finned copper tube gas boilers amp water heaters Boiler Manual CATEGORY II CHIMNEY INSPECTION amp SIZING Masonry chimneys when used must be lined with a metal liner certified for Category IV venting A thorough 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 lined to prevent draft problems Table 5 lists the minimum riser sizes required for the XLF boiler water heater Table5 Riser diameters to common vent for Category II venting Input MBH in mm 2500 3000 12 305 3500 4000 14 356 Note These sizes are based on a 20 ft 6 1m chimney height CATEGORY II VENT CONNECTIONS Locate the boiler water heater as close to the chimney as possible Use the shortest straightest vent connector possible for the installation If horizontal runs exceed 5 ft 1
71. th and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied d INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or asfitter shall observe that a hard wired carbon monoxide CES with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors i In the event that the 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 adjacent floor level i Inthe event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided h
72. the GENERAL OPERATION 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 Manometer test port manifold manufacturers instructions 1 The Futera XLF includes a manometer test manifold Connect the manometer pressure hose to the Pressure Tap port shown in Figure 22 These pressure signals may be used for troubleshooting when specified by factory support a The probe ona probe low water cut off must be removed cleaned and inspected at least once a year b Ensure that the low water cutoffs operate properly If not replace them 3 The flow switch contacts must be open when water flow is not Figure 233 Manometer connections to manifold 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 S The aquastat high limit controls the maximum water temperature in the boiler a Ifthe water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the boiler off b The water temperature should never exceed the maximum set point of 250 F 121 C for boilers and 210 F 99 C for water heaters c The aquastat hi
73. ther gas appliances that use the same gas meter as the boiler water heater Call your gas supplier and ask for the heating value of the gas Start the boiler water heater and let it run for 15 minutes _ Using the gas meter and a stopwatch clock the time that it takes to burn 10 ft 0 28 m of gas and divide this time by 10 Insert the heating value and the time in seconds into the formula below 6 Input heating value Btu hr 3600 time seconds Ifthe computed rate deviates by more than 5 from the rated input value of the unit consult factory caution Never increase the input to the boiler water heater above that for which it is rated Doing so can cause premature failure of the boiler FUTER TE MAINTENANCE MEET Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment can damage the boiler water heater CAUTION The boiler water heater must be cleaned and inspected at least once a year and before each heating season Make sure that the burner and ignition components are free from dust soot dirt corrosion or other deposits that would impair the boiler water heater s performance Refer to Figure 20 page 28 for component identification CAUTIO
74. trol IOM to calibrate the firing rate Increase rate if the pressure signal is low or decrease rate if the signal is high c Return to step 1 to adjust low fire CO after changing low fire firing rate other than low fire Pressure signal will reach up to 9 inches when the boiler is at high fire and can cause fluid to be pulled out ofthe manometer into the boiler Should this occur immediately shut down the boiler and contact the factory for procedure Preferably use a Magnehelic gauge instead ofa U tube manometer to measure the pressure to avoid this potential hazard Table 13 Pressure signal Ps Nat Gas If using a U tube manometer turned sideways for low pressure readings you MUST turn the manometer upright before attempting to measure pressures at Firing XLF 2500 XLF 3000 XLF 3500 XLF 4000 bi Signal Signal Signal Signal Inches w c Inches w c Inches w c Inches w c 100 9 50 11 00 6 0 8 5 20 0 50 1 0 50 1 0 50 1 0 50 1 To determine signal in mm w c multiply signal pressure by 25 4 For LP Gas All units are tested at factory LP Combustion Values are located on Combustion Data label mme To ensure proper boiler operation boilers that use 5 room air and vented side wall must not be fired at less than 33 input Observe the burner flame after setting low fire Make sure the flame is stable but not too tight on the burner causi
75. ts to the original owner at the original installation site that the heat exchanger of the Industrial Commercial and other Non Residential Use Water Heater the Product will be free from defects in material or workmanship for five 5 years from the date of installation Additional twenty one 21 year thermal warranty on heat exchanger If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the Manufacturer will repair or replace at its option that part of the Product which is shown to be defective All other RBI supplied Boiler Water Heater parts are warranted against defects in material and workmanship for one 1 year from date of installation or 18 months from date of shipment from RBI This limited warranty does not apply a if the Product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with the furnished written instructions or has been altered or modified in any way These include but not limited to Excessive water hardness causing a lime build up in the heat exchanger tubes is not a fault 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 not covered by the manufacturer s warranty See Installation Instructi
76. ustion is taken from the space PIN To ensure proper boiler operation boilers that are in which the unit is installed The applicable instructions under the vented side wall and use room air must not be fired at less than 33 input Figure 7 VENT OPTION 3 SIDE WALL VENT Side wall venting Vent pipe and air pipe equivalent lengths must not exceed 100 feet each Aft 1 2m ml Maximum building overhang r Pitch down toward terminal inch per foot 20 mm m of run to allow for condensate drainage Openings per instructions 3 ft 0 9m 24in 0 6m Recommended Minimum minimum Recommended 12 0 3 m l minimum required Exhaust 1 5 ft 0 5 m Minimum distance from exhaust to maximum snow line Condensate drain with pigtail RIOM 101 OPTION 4 VERTICAL CHIMNEY VENTING NEGATIVE PRESSURE CATEGORY II MULTIPLE BOILERS WITH COMMON VENTING FIGURE 8 WARNING Category II venting is required for multiple XLF boilers connected to a common vent Common vent systems cannot be pressurized The Futera XLF is listed as a Category II appliance when vented vertically into a listed metal chimney system See Figure 8 page 13 multiple boilers The chimney must provide a negative pressure not greater than 0 10 inch 2 5 mm w c at the boiler water heater flue collar with the unit running When usinga lis
77. ustomer Service Department at U S 260 North Elm Street Westfield MA 01085 Canada 7555 Tranmere Drive Mississauga ONT LSS 1L4 Always include the model and serial numbers from the rating plate of the boiler water heater in question FUTER TE RATINGS amp CAPACITIES Before undertaking the installation ofthe Futera XLF Series boiler water heater check the rating plate to ensure that the unithas been sized properly for the job The Net I B R Ratings specify the equivalent amountofdirectcastironradiationthatthe unitcan supply undernormal conditions Also ensure that the unit has been set up for the type of gas available at the installation site Other important considerations are the availability of an adequate electrical supply fresh air for combustion anda suitable chimney or vent system BOILER WATER HEATER LOCATION 1 This boiler water heater is suitable for indoor and outdoor installations Locate the boiler water heater in an area that provides good access to the unit Servicing may require the removal of jacket panels Allow the minimum clearances between adjacent construction and the boiler water heater as listed in Table 1 NOTICE Service clearances are not mandatory but are recommended to ensure ease of service should it be required Table 1 Required clearances From Clearance to Service combustible surfaces clearances Inches mm Inches mm Top 6 153 30 762 Back 6 153 24
78. ylene 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 flow 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 Relief valve Pipe the discharge of the pressure relief valve as shown in Figure 9 page 15 FEET 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 Finned copper tube gas boilers amp water heaters Boiler Manual 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 The flow switch must be installed in the supply piping adjacent to the boiler outlet connection CAUTION Failure to properly install the flow switch may result in damage to the boiler water heater heat exchanger voiding the warranty HEATING SYSTEM PIPING General piping requirements
79. ystem passes through an unheated space it must be insulated with insulation rated for 400 F 204 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 less than 4 ft 1 2 m horizontally from and in no case above or below unless a 4 ft 1 2 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 ft 2 1 m above adjacent public walkway Canadian installations require a minimum of 6 ft 18 3 m clearance from electric meters gas meters regulators and relief equipment for compliance with CAN B149 1 The bottom of the vent terminal s shall be located at least 5 ft 1 5 m above the air intake terminal s unless there is a minimum 5 ft 1 5 m horizontal separation between them Avoid terminal locations likely to be affected by winds snowdrifts people and pets Protect building materials and vegetation from degradation caused by the flue gases Vertical direct vent systems Figu re 3 vent air pipe equivalent lengths up to100 feet maximum If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F 204 C Structural penetrations must be made using approved fire stops An approved nonrestrictive vent terminal must be used The top of a vertical

Manuel d`installation et d`opération (anglais)

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Manuel d`installation et d`op&eacute;ration (anglais)

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Manuel d`installation et d`opération (anglais)