RBI FUTERA XLF Series, Manual

Page 1: ...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...

Page 2: ...DP switch blocked air 10 inlet DP switch blocked flue 11 DP switch blower prov 12 ing DP switch pilot air prov 13 ing Ignitor 14 Pilot gas valve and pilot gas 15 pressure regulator Flow switch 16 Low...

Page 3: ...ommonwealth of Massachusetts you MUST FOLLOW the additional instructions contained in RBI s instruc tion sheet MACODE 3 located in the back of this manual The owner should maintain a record of all ser...

Page 4: ...it abledrainpanthat sadequatelydrainedmustbeinstalledunder the unit DO NOT place this boiler water heater in a location that 5 would restrict the introduction of combustion air into the unit or subjec...

Page 5: ...ating 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 s...

Page 6: ...nd win 3 dows and all doors between the space in which the ap pliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appl...

Page 7: ...be joined and sealed in accordance with the vent system manufacturer s instructions Whenhorizontalventrunsexceed5ft 1 5mtheymustbesupported at 3 ft 0 9 m intervals with overhead hangers The vent syst...

Page 8: ...nning 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...

Page 9: ...ot exceed 100 feet each See Table 3 or 4 for min pipe diameters Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation Failure to complycouldresultinsevere per...

Page 10: ...ed and sized Exterior masonry chimneys should not be used unless properly lined to prevent condensation and draft problems Table 5 lists the equivalent breeching and flue sizes required for the boiler...

Page 11: ...alent lengths up to100 feet maximum In this configuration the boiler water heater blower is used to push the flue products horizontally to the outdoors see Figure 7 The air for combustion is taken fro...

Page 12: ...s than 33 input Category II chimney inspection 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...

Page 13: ...vent system is designed using accepted engineering practices and the design calculations prove there is no need for barometric dampers the barometric dampers may be omitted When required by ap plicab...

Page 14: ...proved method If the unit must be shut off for any reason the electric 3 gas and water supplies MUST be shut off and the unit and its pump completely drained Improper outdoor installation of this unit...

Page 15: ...15 Finned copper tube gas boilers water heaters Boiler manual FTXLF IOM HN 1 110308 Copyright 2008 Mestek Inc Futera XLF Piping Figure 9...

Page 16: ...rmal 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 installe...

Page 17: ...2 requirements All boilers furnished with factory mounted 3 outlet water temperature gauge Boiler pump purging required Use termi 4 nals supplied All primary secondary piping systems re 5 quire a rem...

Page 18: ...intain Inlet Temperature Above Dew Point T1 Temp Min 140o F 60o C Sealed Combustion 1 Turn heater on and open valves A B 2 After steady state operation if T1 is less than Temp Min slowly close valve B...

Page 19: ...ghaFuteraXLF water heater is 260 GPM 16 4 L when equipped with coppertubes Thecupronickelheatexchangerallowsfor 315 GPM 19 9 L s See Table 9 page 20 RBI water heaters are designed to run scale free Du...

Page 20: ...ditional precautions must be observed due to unusual characteristics of the local water supply Call the nearest RBI representative for details To properly size the pump a grain hardness andpHtestmustb...

Page 21: ...th 30 total 6 90 4 o elbows full pipe size CAUTION MEASURE WATER HARDNESS AND pH AT JOB SITE 5 The pH and water hardness must be measured before selecting heat exchanger and pump Consult the Heat Exch...

Page 22: ...y piping has the capacity to meet the demand Figure16depictstheproperwaytoconnecttheboiler waterheater to the gas supply piping The manual shut off valve MUST be in stalled in the supply piping It sho...

Page 23: ...Gate valve Gas cock 2 5 2 10 3 1 2 3 0 2 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 v...

Page 24: ...the heating system piping Close the make upwatervalveandcheckandcleanthestrainersandmake upwater pressure reducing valve Openthemake upwatervalveandadjustthesystempressureifnec essary The system shou...

Page 25: ...loweroperatesatminimumignitionsetting Seethecalibra 1 tionsectioninthe HeatNetControl IOM to enter the calibra tion menus The ignition transformer is energized The pilot solenoid valve 2 opens for the...

Page 26: ...tch on HeatNet control 13 board to the LOW FIRE position The boiler will begin the start up sequence 14 Allow the boiler to pre purge and enter the pilot ignition cycle 15 Ifpilotlights indicatedbyago...

Page 27: ...ARED STATE 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 Le...

Page 28: ...orrectly When finished disable the low fire hold switch and replace test 8 portstonormalstate Removethemanometerconnectionsand close the control panel door The Futera XLF boiler allows for many modes...

Page 29: ...could indicate undersized gas line or insufficient gas supply Staticandoperatinggaspressurerequiredatthegasvalveinletis 2 listed in the Table above If the gas pressure is above the limit above a lock...

Page 30: ...he gas supply lines and turn 1 off electrical power to the boiler water heater RemoveburnerfollowingtheinstructionsintheBurnerRemoval 2 section Remove the front jacket panel and combustion chamber doo...

Page 31: ...does contact a qualified service technician to have it inspected NEVERtrytocleanorrepairthereliefvalve Ifthevalve fails to operate properly have it replaced Theaquastathighlimitcontrolsthemaximumwater...

Page 32: ...32 Finned copper tube gas boilers water heaters Boiler manual FTXLF IOM HN 1 110308 Copyright 2008 Mestek Inc Futera XLF pressure sensor hose routing Figure 23...

Page 33: ...33 Finned copper tube gas boilers water heaters Boiler manual FTXLF IOM HN 1 110308 Copyright 2008 Mestek Inc Exploded view Figure 24 Repair parts...

Page 34: ...34 Finned copper tube gas boilers water heaters Boiler manual FTXLF IOM HN 1 110308 Copyright 2008 Mestek Inc Repair parts continued Figure 20 Electrical components Figure 25...

Page 35: ...11 0412 1 1 NS Flange 2 11 0219 2 2 19 Low Gas Pressure Switch Manual Reset 11 0422 1 1 NS Firing Valve 3 4 11 0461 1 1 NS Ball Valve 11 0395 1 1 20 Gas Hose 53 4001 1 1 21 Firing Valve 2 11 0459 1 1...

Page 36: ...252 1 1 46 Heat Exchanger Assembly Copper 70 3577 1 70 3579 1 Heat Exchanger Assembly cupronickel 70 3581 1 70 3583 1 47 O ring 06 0007 2 2 48 Frequency Drive 15 0230 1 1 49 Flame Safeguard RM7897C 16...

Page 37: ...0 Collar Fan Transition 01 0201s 1 1 60a Gasket 06 0004 1 1 60b Fan Hold Down Plate 04 0596 1 1 61 Pump Contactor Relay 15 0118 2 2 62 Mini Fan 12 0021 1 1 63 Air Funnel 04 1016 1 1 64 Solenoid Valve...

Page 38: ...h 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 Disable any external call for heat and toggle the...

Page 39: ...pbelow140 o F 60o C Operating atlowerreturntemperaturesislikelytocausecondensationintheprimaryheatexchanger resultingincorrosionandpossible failure of the heat exchanger COMMISSIONING THE BOILER WATER...

Page 40: ...ead in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OB STRUCTIONS INSPECTION The state or local gas inspector of the side g wall horizontally vented gas...