FTII-IOM-15R

82-0253

Finned Copper Tube

Gas Boilers (FB) &
Water Heaters (FW)

Boiler Manual
Installation and Operation
Instructions

This manual is intended only for use by a qualified heating 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. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified
service technician, and to follow all guidelines in the User’s Information Manual.

12/2021 Copyright 2014 Mestek, Inc.

 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

CONTENTS BEFORE YOU START

BEFORE YOUR START ... . . . . . . . . . . . . . . . . . . . . . . . . . . 2 This manual covers the application, installation, operation
and maintenance of a Futera II Series finned copper
RATINGS & CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 heating boiler/water heater.

BOILER/WATER HEATER LOCATION. . . . . . . . . . . . . . . . 3 To obtain the safe, dependable, efficient operation and long
life for which this heating boiler/water heater was designed,
COMBUSTION AIR & VENTILATION. . . . . . . . . . . . . . . . . 3 these instructions must be read, understood and followed.
GENERAL VENTING GUIDELINES . . . . . . . . . . . . . . . . . 5
The Futera II Series finned copper heating boiler/water
OUTDOOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 heaters have been design certified by CSA for use with
natural and propane gas under the latest revision of
COMMON VENT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 17 ANSI-Z21.10.3/CSA 4.3, Gas Water Heaters, ANSI-Z21.13/
CSA 4.9, Gas-Fired Low Pressure Steam and Hot Water
GENERAL PIPING REQUIREMENTS . . . . . . . . . . . . . . . . 17 Boilers. Each unit has been constructed and hydrostatically
tested for a maximum working pressure of 160 psi,
HEATING SYSTEM PIPING. . . . . . . . . . . . . . . . . . . . . . . . . 19
1103 kPa in accordance with Section IV of the A.S.M.E.
DOMESTIC WATER SUPPLY PIPING . . . . . . . . . . . . . . . 23 Boiler and Pressure Vessel Code.

GAS SUPPLY PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 All aspects of the boiler/water heater installation must
conform to the requirements of the authority having juris-
ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 diction, or, in the absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
revision. Where required by the authority having jurisdiction,
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . 28 the installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers, ANSI/
CHECKING & ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . 30 ASME CSD-1.

CONTROL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 32 In Canada, the installation must be in accordance with the

requirements of CSA B149.1 or .2, Installation Code for
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Gas Burning Appliances and Equipment.
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
The owner should maintain a record of all service work
TROUBLE-SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 performed with the date and a description of the work done.
Include the name of the service organization for future
REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 reference.
START UP SHEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Direct all questions to your RBI distributor or contact the
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 RBI Customer Service Department at:

U.S. —
260 North Elm Street
Westfield, MA 01085

Canada —
7555 Tranmere Drive
Mississauga ONT L5S 1L4

Always include the model and serial numbers from the

rating plate of the boiler/water heater in question.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

RATINGS & CAPACITIES 6. NEVER place this boiler/water heater in a location that
Before undertaking the installation of the Futera II Series would subject it to temperatures at or near freezing.
boiler/water heater check the rating plate to ensure that the See the “Freeze Protection” section on page 18.
unit has been sized properly for the job. The “Net Ratings”
specify the equivalent amount of direct copper radiation CAUTION: Units installed outdoors MUST be protected
that the unit can supply under normal conditions. Also from ice and snow accumulation or the unit will be
ensure that the unit has been set up for the type of damaged voiding the warranty!
gas available at the installation site. Other important
considerations are the availability of an adequate electrical WARNING: Never store combustible materials,
supply, fresh air for combustion and a suitable chimney or gasoline or any product containing flammable
vent system. vapors or liquids in the vicinity of the boiler/water
heater. Failure to comply with this warning can
BOILER/WATER HEATER LOCATION result in an explosion or fire causing extensive
1. This boiler/water heater is suitable for indoor and property damage, severe personal injury or death!
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 COMBUSTION AIR & VENTILATION
minimum clearances between adjacent construction
and the boiler/water heater as listed in Table 1. WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
NOTE: Service clearances are not mandatory, but are Section 5.3, Air for Combustion & Ventilation, of the
recommended to ensure ease of service should it be latest revision of the National Fuel Gas Code, ANSI
required. Z223.1/NFPA 54 and all applicable local building
codes. Canadian installations must comply with
Table 1 CAN/ CGA B149.1 or .2 Installation Code for Gas
Clearance to Service Burning Appliances and Equipment, or applicable
Combustibles Clearance provisions of the local building codes. Failure to
in mm in mm provide adequate combustion air for this boiler/
Top 24 610 30 762 water heater can result in excessive levels of
Back 14 356 24 610 carbon monoxide which can result in severe
Left Side 6 153 12 306 personal injury or death!
Right Side 6 153 12 306
Front 8 203 30 762 To operate properly and safely this boiler/water heater
requires a continuous supply of air for combustion. NEVER
2. An optimum site will be level, central to the piping store objects on or around the boiler/water heater!
system, close to a chimney or outside wall and have
adequate fresh air for combustion. Ensure that the CAUTION: Combustion air contaminated with
boiler/water heater is level from front to back and from fluorocarbons or other halogenated compounds such
side to side. Use metal shims to level the boiler/water as cleaning solvents and refrigerants will result in the
heater. Electrical and electronic components must also formation of acids in the combustion chamber. These
be protected from exposure to water during operation acids will cause premature failure of the boiler/water
and maintenance. DO NOT install this boiler/water heater voiding the warranty!
heater in a location that would subject any of the gas
ignition components to direct contact with water or CAUTION: If the boiler/water heater is operated while
excessive moisture during operation or servicing. the building is under construction it MUST be
3. Ensure that the floor is structurally sound and will protected from wood, concrete, sheet rock and other
support the weight of the boiler/water heater. types of dust. Failure to properly protect the unit from
construction dust will damage the unit voiding the
NOTE: The Futera II may be installed directly on warranty!
combustible flooring, but never on carpeting.
Buildings will require the installation of a fresh air duct or
4. Locate the boiler/water heater in an area that will other means of providing make-up air if the intake air option
prevent water damage to adjacent construction should isn’t used. Any building utilizing other gas burning
a leak occur or during routine maintenance. If such a appliances, a fireplace, wood stove or any type of exhaust
location doesn’t exist, a suitable drain pan that’s fan must be checked for adequate combustion air when all
adequately drained must be installed under the unit. of these devices are in operation at one time. Sizing of an
5. DO NOT place this boiler/water heater in a location that outside air duct must be done to meet the requirements
would restrict the introduction of combustion air into of all such devices.
the unit or subject it to a negative pressure, see
“GENERAL VENTING GUIDELINES”.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Table 2 – Make-up Air Louver Sizing

WARNING: Never operate the Futera II in an Required Cross Sectional Area
environment subjected to a negative pressure Input 1/4 in 6.4 mm 75% Free Area 25% Free Area
unless it is Direct Vented. Failure to comply with (MBH) Wire Screen Metal Louvers Wooden Louvers
this warning can result in excessive levels of in2 cm2 in2 cm2 in2 cm2
carbon monoxide causing severe personal injury 500 125 806 167 1077 500 3226
or death! 750 187 1206 250 1613 750 4839
1000 250 1613 333 2148 1000 6452
All Air From Inside The Building 1250 313 2019 416 2684 1250 8065
If the Futera II is to be located in a confined space, the 1500 375 2419 500 3226 1500 9677
minimum clearances listed in Table 1 must be maintained 1750 437 2819 583 3761 1750 11,290
between it and any combustible construction. When 1950 486 3135 649 4187 1950 12,580
installed in a confined space without the intake air
option, Figures 7, 8 and 9, two permanent openings Canadian installations must comply with CSA B149.1 when
communicating with an additional room(s) are required. The air supply is provided by natural air flow from the outdoors
combined volume of these spaces must have sufficient for natural draft, partial fan-assisted, fan-assisted, or
volume to meet the criteria for an unconfined space. The power draft-assisted burners, there shall be a permanent
total air requirements of all gas utilization equipment, air supply opening(s) having a cross-sectional area of not
fireplaces, wood stoves or any type of exhaust fan must less than 1 in2 per 7,000 Btuh (310 mm2 per kW) up to
be considered when making this determination. Each and including 1 million Btuh, plus 1 in2 per 14,000 Btuh
opening must have a minimum free area of 1 in2/1000 Btu/ (155 mm2 per kW) in excess of 1 million Btuh.
hr, 2200 mm2/kW based on the total input rating of ALL
gas utilization equipment in the confined area. Each Intake Air Option – General Guidelines
opening must be no less than 100 in2, 64,516 mm2 in size. This configuration provides combustion air directly to the
The upper opening must be within 12 in, 305 mm of, but boiler/water heater’s air intake using a dedicated pipe when
not less than 3 in, 76 mm from, the top of the enclosure. using the direct vent option. The RBI air intake adapter
The bottom opening must be within 12 in, 305 mm of, but must be fitted to the blower inlet. Combustion air can be
not less than 3 in, 76 mm from, the bottom of the drawn in horizontally through the same outside wall which
enclosure. terminates the exhaust gases or vertically through the roof,
see Figures 2, 3, 4, 5 & 6.
All Air From Outside The Building
When installed in a confined space without utilizing the WARNING: Common intake air systems may be
intake air option two permanent openings communicating used provided the common duct is sized properly
directly with, or by ducts to, the outdoors or spaces that and an intake combustion air damper is installed
freely communicate with the outdoors must be present. The in the intake air pipe of each heater. Improper
upper opening must be within 12 in, 305 mm of, but not installation can result in excessive levels of carbon
less than 3 in, 76 mm from, the top of the enclosure. The monoxide which can cause severe personal injury
bottom opening must be within 12 in, 305 mm of, but not or death!
less than 3 in, 76 mm from, the bottom of the enclosure.
All joints in metal intake air systems must be secured using
Where directly communicating with the outdoors corrosion resistant fasteners and sealed using a suitable
or communicating with the outdoors through vertical Silicone caulk. If PVC or CPVC is used, the joints must be
ducts, each opening shall have a minimum free area of cleaned with a suitable solvent and connected using a
1 in2/4000 Btu/hr, 550 mm2/kW of the total input rating solvent based PVC cement. The combustion air system
of all of the equipment in the enclosure. MUST be supported by the building structure not the
boiler/water heater.
Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of CAUTION: A combustion air damper interlocked with
1 in2/2000 Btu/hr, 1100 mm2/kW of the total input rating the unit should be installed in the intake air pipe when
of all of the equipment in the enclosure. the infiltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
When ducts are used, they must have the same cross-
sectional area as the free area of the opening to which Intake Air Option – Vertical Guidelines
they connect. The maximum equivalent length for the vertical intake air
pipe is 60 ft, 18.3 m. Each 90° elbow and the intake air
When calculating the free area necessary to meet the terminal are equal to 10 linear ft, 3.1 m of pipe.
make-up air requirements of the enclosure, consideration
must be given to the blockage effects of louvers, grills and An approved, nonrestrictive intake air terminal must be
screens. Screens must have a minimum mesh size of used. The intake air terminal must terminate as shown in
1/4 in, 6.4 mm. If the free area through a louver or grill is Figure 5. The penetration point in the roof must be properly
not known, ducts should be sized per Table 2. flashed and sealed.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Intake Air Option – Horizontal Guidelines

The maximum equivalent length for the horizontal WARNING: To avoid spillage into the room of
combustion air pipe on installations that used the Direct dangerous flue gas containing carbon monoxide,
Vent option is 60 ft, 18.3 m. The maximum equivalent length the opening in damper must never face against the
for the horizontal combustion air pipe on installations that flow of flue gas.
use the Horizontal Power Vent option is 100 ft, 30.5 m. Each
90° elbow and the combustion air terminal are equal to 10 WARNING: Boiler/Water Heater shall not be
linear ft, 3.1 m of pipe. If horizontal runs exceed 5 ft, 1.5 m connected to a chimney flue serving a separate
they must be supported at 3 ft, 0.9 m intervals with overhead appliance designed to burn solid fuel.
hangers. The certified combustion air terminal from RBI
must be used and installed as shown in Figures 3 and 4. VENT SYSTEM OPTIONS
The Futera II may be vented the following ways:
GENERAL VENTING GUIDELINES
1) Direct Vent, Positive Pressure, Category III uses a
WARNING: The vent installation must be in vent system certified to UL 1738 for installations in the
accordance with Part 7, Venting of Equipment, of United States, ULC S636 for installations in Canada.
the National Fuel Gas Code, ANSI Z223.1/NFPA 54- Combustion air is piped from the outdoors to the
latest revision or applicable provisions of the local blower inlet.
building codes. Canadian installations must
comply with CAN/CGA B149.1 or .2 Installation Code. 2) Side Wall Vent, Positive Pressure, Category III uses
See Figure A for added Clarity. Improper venting can a vent system certified to UL 1738 for installations in the
result in excessive levels of carbon monoxide which United States, ULC S636 for installations in Canada.
can result in severe personal injury or death! Combustion air is obtained from the space in which
the unit is installed.
All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropriate 3) Horizontal Vent, Negative Pressure, Category I for
thimbles and fire-stops must be used where required. horizontal vent runs equivalent to more than 60 ft,
18.3 m (use Table 3 for the equivalent lengths per fitting),
WARNING: Common vent systems must be a dedicated wall mounted power venter must be used.
properly engineered and sized to provide a The vent system can be single wall galvanized steel or
negative draft of 0.01 to 0.08 in, 0.25 to 2.0 mm W.C. type B vent pipe. Combustion air is obtained from the
at the flue outlet. Common positive pressure vent space in which the unit is installed or from the outdoors.
systems are not to be used. Improper installation
can result in excessive levels of carbon monoxide, A power venter including a barometric damper must
which can cause severe personal injury or death! be installed when the horzontal run is longer than 60
equivalent feet (use Table 3 for the equivalent lengths
NOTE: Multi-story, common venting systems shall be in per fitting).
accordance with the National Fuel Gas Code, ANSI
Z223.1/ NFPA 54 and/or the CSA B149.1, Natural Gas 4) Ver tical/Chimney Vent, Negative Pressure,
and Propane Installation Code (Current Editions), Category I uses an approved metal chimney system
local codes and vent manufacturer's installation or masonry chimney. Combustion air is obtained from
instructions. Size the chimney and breeching using the space in which the unit is installed. A barometric
generally accepted engineering practices. (Consult damper must be installed near the flue outlet when
factory for vertical heights beyond 60 ft.) venting vertically.

NOTE: A single acting barometric damper must be 5) Outdoor Installation uses the outdoor option kit.
installed directly to the boiler/water heater flue outlet, if Barometric damper is not required.
required. This does not apply to outdoor units or direct
vent positive pressure units. NOTE: All venting, combustion air material supplied by
installer.
NOTE: Some venting applications may require the stop
to be removed for smooth operation. The barometric WARNING: The maximum equivalent length
damper should be located after the flue collector, refer for the flue outlet vent system for Category III
to Figures 2, 7A and 8 for proper location. Be sure that conditions is 60 ft, 18.3 m. Use Table 3 for the
the damper is mounted horizontally (never vertically). equivalent lengths per fitting. Table 3 “Category
Carefully follow the instructions provided with the III Equivalent Length Per Fitting” chart is meant
barometric damper. as a guideline for preliminary sizing. If vent length
approaches 75% of maximum length listed an
In Canada, B149 (7.25 Draft Regulators) states the engineered vent system calculation must be
damper shall be of double-acting type. performed, consult factory.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual

Figure A - Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

Clearance above grade, veranda, porch,
A= 12 in (30 cm) 12 in (30 cm)
deck, or balcony
6 in (15 cm) for appliances < 10,000 6 in (15 cm) for appliances < 10,000 Btuh
Btuh (3 kW); 12 in (30 cm) for appliances (3 kW); 9 in (23 cm) for appliances >
B= Clearance to window or door that may > 10,000 Btuh (3 kW) and < 100,000 10,000 Btuh (3 kW) and < 50,000 Btuh
be opened Btuh (30 kW); 36 in (91 cm) for (15 kW); 12 in (30 cm) for appliances >
appliances > 100,000 Btuh (30 kW) 50,000 Btuh (15 kW)
Clearance to permanently closed
C=
window
Vertical clearance to ventilated soffit
located above the terminal within a
D=
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
Per local installation codes
E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line

H= extended above meter / regulator 3 ft (91 cm) within a height of 15 ft (4.6m)
assembly

Clearance to service regulator 3 ft (91 cm)

I=
vent outlet

6 in (15 cm) for appliances < 10,000 6 in (15 cm) for appliances < 10,000 Btuh
Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances (3kW); 9 in (23 cm) for appliances >
J= inlet to building or the combustion air > 10,000 Btuh (3 kW) and < 100,000 10,000 Btuh (3 kW) and < 50,000 Btuh (15
inlet to any other appliance Btuh (30 kW); 36 in (91 cm) for kW); 12 in (30 cm) for appliances > 50,000
appliances > 100,000 Btuh (30 kW) Btuh (15 kW)

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 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual
FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure A - Direct Vent Terminal Clearances - Concluded

Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m)

K= 6 ft (1.83 m)
supply inlet horizontally
Clearance above paved sidewalk Vents for Category II and IV appliances
L= or paved driveway located on 7 ft (2.13 m)† cannot be located above public walkways
public property or other areas where condensate or vapor
can cause a nuisance or hazard
Clearance under veranda, porch, 12 in (30 cm)‡
M= Per local installation codes
deck, or balcony

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
3) If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

Figure A - Other Than Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm)
A=
deck, or balcony
6 in (15 cm) for appliances < 10,000
Btuh (3 kW); 12 in (30 cm) for appliances
Clearance to window or door that may 4 ft (1.2 m) below or to side of opening;
B= > 10,000 Btuh (3 kW) and < 100,000
be opened 1 ft (300 mm) above opening
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
Clearance to permanently closed
C=
window
Vertical clearance to ventilated soffit
located above the terminal within a
D=
horizontal distance of 2 ft (61 cm)
from the center line of the terminal

E= Clearance to unventilated soffit

Per local installation codes
F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line

H= extended above meter/regulator 3 ft (91 cm) within a height of 15 ft (4.6m)
assembly

Clearance to service regulator vent 3 ft (91 cm)

I=
outlet

6 in (15 cm) for appliances < 10,000 4 ft (1.2 m) below or to side of opening;
Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances 1 ft (300 mm) above opening
J= inlet to building or the combustion air > 10,000 Btuh (3 kW) and < 100,000
inlet to any other appliance Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)

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 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure A - Other Than Direct Vent Terminal Clearances - Concluded

Clearance to a mechanical air supply 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)

K=
inlet horizontally
Clearance above paved sidewalk or Vents for Category II and IV appliances
L= paved driveway located on public 7 ft (2.13 m)† cannot be located above public walkways
property or other areas where condensate or vapor
can cause a nuisance or hazard
Clearance under veranda, porch, deck, 12 in (30 cm)‡
M= Per local installation codes
or balcony

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
3) If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Table 3 – Category III Equivalent Length Per Fitting The vent system must be both gas tight and watertight. All
Equivalent Feet of Straight Pipe (ft) - Futera II Series seams and joints in metal pipes must be joined and sealed
Model/Outlet K 500 750 1000 1250 1500 1750 2000
in accordance with the vent system manufacturer’s
6" 8" 9" 10" 10" 12" 12" instructions.
Standard Tee 1.25 25 ft 35 ft 35 ft 40 ft 40 ft 40 ft 40 ft
Boot Tee 0.65 15 ft 15 ft 15 ft 20 ft 20 ft 20 ft 20 ft When horizontal vent runs exceed 5 ft, 1.5 m they must be
Cap - Low Res (UL) 0.50 10 ft 15 ft 15 ft 15 ft 15 ft 15 ft 15 ft supported at 3 ft, 0.9 m intervals with overhead hangers.
45° w/Bird Screen 0.40 10 ft 10 ft 10 ft 15 ft 15 ft 15 ft 15 ft The vent system must be pitched down, toward the vent
Elbow - 90° 0.38 10 ft 10 ft 10 ft 15 ft 15 ft 15 ft 15 ft terminal, 1/4 in/ft, 20 mm/m. If any part of a single wall metal
Elbow - 45° 0.15 5 ft 5 ft 5 ft 7 ft 7 ft 7 ft 7 ft vent system passes through an unheated space it must be
*Equivalent lengths based on listed K-Factors 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 from any adjacent public walkway.
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 – Figure 5

The maximum equivalent length for the vertical pipe is
60 ft, 18.3 m. If any part of a single wall metal vent
DIRECT VENT, system passes through an unheated space, it must be
POSITIVE PRESSURE, CATEGORY III insulated with insulation rated for 400°F, 204°C. Structural
In this configuration the boiler/water heater blower is used penetrations must be made using approved fire-stops.
to push the flue products to the outdoors while drawing
combustion air from the outdoors. The equivalent length An approved nonrestrictive intake air teminal must be
of the vent system must not exceed 60 ft., 18.3 m. The used. The top of a vertical vent system must extend at least
Intake Air Option instructions under the “COMBUSTION 51/2 ft, 1.7 m above the roof surface and maximum snow
AIR & VENTILATION” section must be followed! The vent line that it passes through, 4 ft, 1.2 m above the intake air
system must be sized per Figure 2, Outlet Sizes. terminal, see Figure 5.

Horizontal Direct Vent Systems – Figures 3 & 4 In addition the vent system must conform to the dimensions
The vent materials used in horizontal vent systems must shown in Figure 5. The penetration point in the roof must
be certified to UL 1738 for installations in the United States, be properly flashed and sealed.
ULC S636 for installations in Canada. The certified vent
terminal from RBI must also be used. The vent system must be gas tight. All seams and joints
in metal pipes must be joined and sealed in accordance
The maximum equivalent length for the horizontal vent with the vent system manufacturer’s instructions.
pipe is 60 ft, 18.3 m. If any part of a single wall
metal vent system passes through an unheated Combination Direct Vent Systems – Figure 6
space, it must be insulated with insulation rated for The boiler/water heater can be vented vertically with the
400°F, 204°C. Structural penetrations must be made using intake air piped horizontally through an outside wall. Follow
approved fire-stops. For best results, horizontal vent the instructions in the Intake Air Option – Horizontal
systems should be as short and straight as possible. Guidelines on page 5. Also follow the general instructions
in the “COMBUSTION AIR & VENTILATION” and
“GENERAL VENTING GUIDELINES” sections.

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 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 1 - Air Intake Vertical or Thru Wall

Figure 2 - Venting Thru Wall/Vertical

10
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 3 – Horizontal Air Intake and Venting for a Single Direct Vent System

10 ft (3.1 m) 1/4 IN. PER FOOT

20 mm/m

16 FT 4.9 m

1.5 FT 0.5 m

9
WARNING: When running horizontal
8
combustion air and venting for single or
7
Vertical Distance, Y

multiple units, exhaust and combustion air

6 2000 & Larger
terminals must be installed on the same
5 1201 To 2000
plane (outside wall) in order to prevent
4 901 To 1200
pressure differences due to prevailing 3 200 To 900
winds. In cold climates, double-wall or 2 1000 BTU'S
insulated inlet pipe recommended to 1
prevent condensation. 0
0 5 10 15 20
Horizontal Distance, X

Figure 4 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems

11
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 5 - Vertical Air Intake and Venting for Direct Vent System

10 FT 3.1 m

4 FT
1.2 m 5 1/2 FT
1.7 m

1.5 FT
0.5 m

5 FT
1.5 m

Figure 6 – Combination Direct Vent Systems

3 FT. 1 m

10 FT. 3.1 m

1.5 FT. .5 m

12
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

SIDE WALL VENT, VERTICAL/CHIMNEY VENT,

POSITIVE PRESSURE, CATEGORY III NEGATIVE PRESSURE, CATEGORY I
In this configuration the boiler/water heater blower is used The Futera II is listed as a Category I appliance when
to push the flue products horizontally to the outdoors, see vented vertically into a listed metal chimney system or
Figure 7. The air for combustion is taken from the space properly sized masonry chimney, Figures 8 & 9. The
in which the unit is installed. The applicable instructions chimney must provide a negative pressure of 0.01 to 0.08
under the “COMBUSTION AIR & VENTILATION” section in, 0.25 to 2.0 mm WC at the boiler/water heater flue collar
must be followed! The vent guidelines under the Horizontal with the unit running. A barometric damper must be
Direct Vent Systems section must also be followed. attached directly to the flue collar increaser as shown.

HORIZONTAL VENT, Multiple Futera II’s can be vented into a single vertical
NEGATIVE PRESSURE, CATEGORY I chimney provided that the breeching and chimney are
In this configuration a wall-mounted power venter must be properly sized per the latest revision of the National Fuel
used to pull the flue products horizontally from the unit and Gas Code, ANSI Z223.1.
vent them to the outdoors, see Figures 3, 4 & 7A. The air
for combustion is taken from the space in which the unit is When more than one appliance is connected to the same
installed, or from the outdoors. The applicable instructions chimney flue, the flue must be large enough to safely vent
under the “COMBUSTION AIR & VENTILATION” section the combined output of all of the appliances.
must be followed!
WARNING: If an appliance using any type of a
To maximize the performance of single wall sheet metal mechanical draft system operating under positive
vent systems locate 90° elbows as far from the boiler as pressure is connected to a chimney flue, never
possible and from one another. For best results, horizontal connect any other appliances to this flue. Doing
vent systems should be as short and straight as possible. so can result in excessive levels of carbon
monoxide which can cause severe personal injury
When horizontal vent runs exceed 5 ft, 1.5 m they or death!
must be supported at 3 ft, 0.9 m intervals with overhead
hangers. The vent system must be pitched down, toward Chimney Inspection & Sizing
the vent terminal, 1/4 in/ft, 21 mm/m. If any part of a single A thorough inspection of the masonry chimney must be
wall metal vent system passes through an unheated space performed to ensure that the chimney is clean, properly
it must be insulated with insulation rated for 400°F, 204°C. constructed and properly sized. Exterior masonry
chimneys should not be used unless properly lined to
Horizontal vent systems shall terminate at least 4 ft, prevent condensation and draft problems. Table 5 lists the
1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft, mimimum riser connection diameters, negative pressure
0.30 m above any door, window or gravity air inlet required for the boiler/water heater.
into any building. It must not terminate less than
4 ft, 1.2 m horizontally from, and in no case above Table 5 - Minimum Riser Connection, Negative
or below, unless a 4 ft, 1.2 m horizontal distance Pressure
is maintained, from electric meters, gas meters, regulators Model Size Pipe Diameter
and relief equipment and not less than 7 ft, 2.1 m from in mm
any adjacent public walkway.The bottom of the vent 500 8 203
terminal(s) shall be located at least 5 ft, 1.5 m above 750, 1000 10 254
the air intake terminal(s) unless there is a minimum 5 ft, 1250, 1500 12 305
1.5 m horizontal separation between them. Avoid terminal 1750, 1950 14 356
locations likely to be affected by winds, snowdrifts, people Note: Vent system must be sized per tables contained in NFPA 54 or
and pets. Protect building materials and vegetation from an engineered system.
degradation caused by the flue gases.
Vent Connections
To determine the appropriate power venter for the Locate the boiler/water heater as close to the chimney as
boiler/water heater, see Table 4. Follow the power venter possible. Use the shortest, straightest vent connector
manufacturer’s installation instructions. possible for the installation. If horizontal runs exceed 5 ft,
1.5 m they must be supported at 3 ft, 0.9 m intervals with
Table 4 - Power Venter Sizes overhead hangers. Use a type B, single wall stainless or
Futera II Power Venter Max. Pipe Length single wall galvanized steel vent pipe the same diameter
Model Model FT m as the flue collar to connect the boiler/water heater to a
500 - 750 HS-3 100 31 masonry chimney, see Figure 2. When using a listed metal
1000-1250 HS-4 100 31 chimney system use the appropriate vent connector.
1500-1950 HS-5 100 31

13
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

The vent connector should be sloped up toward the WA R N I N G : Fa i l u r e t o m a i n t a i n m i n i mu m

chimney at a minimum rate of 1/4 in/ft, 21 mm/m. On clearances between vent connectors and any
masonry chimneys the connector must terminate flush with combustible material can result in a fire causing
the inside of the chimney flue, Figure 9. Fasten each single extensive property damage, severe personal injury
wall vent connection with at least 3 corrosion resistant or death!
sheet metal screws.

Always provide a minimum clearance of 6 in, 152 mm

between single wall vent pipe and any combustible
materials. Type B1 vent may be used, clearance between
it and any combustible material must be as listed.

Figure 7 – Side Wall Venting, Positive Pressure

4 FT
1.2 m

1/4 IN. PER F00T 20 mm/m

3 FT
0.9 m
24"
0.6 m

7 FT
2.1 m
1.5 FT 0.5 m

Figure 7A – Power Venting, Negative Pressure

14
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 8 – Vertical Venting with a Metal Chimney System

15
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 9 – Vertical Venting using a Masonry Chimney

OUTDOOR VENTING
When installed outdoors the Futera III must be fitted with Avoid locations where wind deflection off of adjacent walls,
the factory supplied outdoor hood, air intake adapter with buildings or shrubbery might cause a downdraft. The
filter and exhaust terminal, see Figure 7A. Multiple units unit(s) shouild be located at least 3 ft, 1 m from structures.
must be spaced per Figure 7B. Outdoor installations are not recommended in areas where
the danger of snow blockage exists.
The boiler/heater must be at least 2 ft, .62 m from any
door, window or gravity air inlet into any building and at CAUTION: Do not place the boiler/water heater in a
least 3 ft, 1 m from any overhang unless local codes dictate location that would subject it to runoff from adjacent
differently. buildings or damage may occur voiding the warranty!

Figure 10 – Outdoor Venting Figure 11 – Multiple Outdoor Units

2 FT
DISCHARGE VENT (0.62 M)

AIR INLET
UNDER COWLING
GAS TRAIN COWLING
3 FT
(1 M)

RIOM-60 REV. A

16
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

COMMON VENT SYSTEMS e) Test for spillage at the draft hood relief opening after 5
If an existing boiler/water heater is removed from a minutes of main burner operation. Use the flame of a
common venting system, the common venting system may match or candle, or smoke from a cigarette, cigar or pipe.
then be too large for the proper venting of the remaining
appliances connected to it. At the time of removal of an Faire fonctionner le brûleur principal pendant 5 min
existing boiler/water heater, the following steps shall be ensuite, déterminer si le coupe-tirage déborde à
followed with each appliance remaining connected to the l’ouverture de décharge. Utiliser la flamme d’une
common venting system placed in operation, while the allunette ou d’une chandelle ou la fumée d’une
other appliances remaining connected to the common cigarette, d’un cigare ou d’une pipe.
venting system are not in operation.
h) After it has been determined that each appliance remaining
Au moment du retrait d’une chaudière existante, les connected to the common venting system properly vents
mesures suivantes doivent être prises pour chaque when tested as outlined above, return doors, windows,
appareil toujours raccordé au système d’évacuation exhaust fans, fireplace dampers and any other gas-burning
commun et qui fonctionne alors que d’autres appareils appliance to their previous condition of use.
toujours raccordés au système d’évacuation ne fonction-
nent pas: système d’évacuation Une fois qu’il a été d éterminé, selon la métode indiquée
ci-dessus, que chaque appareil raccordé au système
a) Seal any unused openings in the common venting system. d’évacuation est mis à l’air libre de façor adéquate. Remettre
les portes et les fenêtres, les ventilateurs, les registres de
Sceller toutes les ouvertures non utilisées du sys- cheminées et les appareils au gaz à leur position originale.
tème d’évacuation.
g) Any improper operation of the common venting system
b) Visually inspect the venting system for proper size and should be corrected so the installation conforms with
horizontal pitch and determine there is no blockage or the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
restriction, leakage, corrosion and other deficiencies When resizing any portion of the common venting
which could cause an unsafe condition. system, the common venting system should be resized
to approach the minimum size as determined using the
Inspecter de façon visuelle le système d’évacu-ation appropriate tables in Appendix F in the National Fuel
pour déterminer la grosser et l’inclinaison horizontale Gas Code, ANSI Z223.1/ NFPA 54 and or CAN/CGA
qui conviennent et s’assurer que le système est exempt B149 Installation Codes.
d’obstruction, d’étranglement de fruite, de corrosion et
autres défaillances qui pourraient présenter des risques. Tout mauvais fonctionnement du systéme d’évacu-tion
commun devrait étré corrigé de façor que l’installation
c) Insofar as is practical, close all building doors and soit conforme au National Fue Gas Code, ANSI
windows and all doors between the space in which the Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/
appliances remaining connected to the common venting CGA-B149. Si la grosseur d’une section du système
system are located and other spaces of the building. Turn d’ évacuation doit étré modifiée, le système devrait étré
on clothes dryers and any appliance not connected to the modifié pour respecter les valeurs minimales des
common venting system. Turn on any exhaust fans, such tableaux pertinents de l’appendice F du National Fuel
as range hoods and bathroom exhaust, so they will operate Gas Code, ANSI Z223.1/ NFPA 54 et (ou) des codes
at maximum speed. Do not operate a summer exhaust d’installation CAN/CGA-B149.
fan for a boiler installation. Close fireplace dampers.
GENERAL PIPING REQUIREMENTS
Dans la mesure du possible, fermer toutes les portes
et les fenêtres du bâtiment et toutes les portes entre CAUTION: Improper piping of this boiler/water heater
l’espace où les appareils toujours raccordés du système will void the manufacturer’s warranty and can cause
d’évacuation sont installés et les autres espaces du boiler failure resulting in flooding and extensive
bâtiment. Mettre en marche les sécheuses, tous les property damage! Excessive water hardness causing
appareils non raccordés au système d’évacuation scaling in the copper heat exchanger tubes is NOT
commun et tous les ventilateurs d’extraction comme les covered under the manufacturer’s warranty. Excessive
hottes de cuisinère et les ventilateurs des salles de bain. pitting and erosion of the internal surface of the copper
S’assurer queces ventilateurs fonctionnent à la vitesse heat exchanger tubes is NOT covered under the
maximale. Ne pas faire fonctionner les ventilateurs manufacturer’s warranty if the result of high water flow
d’été. Fermer les registres des cheminées. rates, see Table 5. Return water temperatures below
125°F, 52°C will result in heat exchanger damage from
d) Place in operation the appliance being inspected. Follow excessive condensation voiding the manufacturer’s
the lighting instructions. Adjust thermostat so appliance warranty, see Primary / Secondary Piping, Figure 13.
will operate continuously.
NOTE: Shut off valves and unions should be installed
Mettre l’appareil inspecté en marche. Suivre les at the inlet and outlet connections of the boiler/hot
instructions d’allumage. Régler le thermostat de façon water heater to provide for isolation of the unit should
que l’appareil fonctionne de façon continue. servicing be necessary.
17
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Freeze Protection The water used for dilution of concentrated heat transfer fluids
This boiler/water heater is CSA designed certified for out- must be distilled, de-ionized, or equivalently clean as stated
door installation. Outdoor installations in areas where the above. De-ionized water by itself can be aggressive towards
danger of freezing exists are not recommended unless many metals, but is perfectly safe when used for dilution of
proper freeze protection is provided. The following DOWFROST, DOWTHERM or UCARTHERM as specified
precautions MUST be observed: by the manufacturer.
1. A continuous flow of water through the unit MUST be
maintained! The pump responsible for flow through the Relief Valve
boiler/water heater must run continuously! Pipe the discharge of the pressure relief valve as shown
2. A propylene glycol/water mixture suitable for the in Figure 12.
minimum temperature that the unit will be exposed to
must be used. The pump must be capable of producing WARNING: Never install any type of valve between
a minimum of 15% more flow and overcoming a 20% the boiler/water heater and the relief valve or an
increase in head loss. Domestic water systems must explosion causing extensive property damage,
be isolated from the water heater by the use of a heat severe personal injury or death may occur!
exchanger or other approved method.
3. If the unit must be shut off for any reason the electric, Flow Switch
gas and water supplies MUST be shut off and the unit The flow switch supplied with the boiler/water heater must
and its pump completely drained. be wired to the terminal strip in the control panel to prevent
the boiler from firing unless there’s adequate water flow
CAUTION: Improper outdoor installation of this unit can through the unit. The flow switch must be installed in the
cause boiler failure voiding the manufacturer’s warranty! supply piping adjacent to the boiler outlet connection.

For systems requiring glycol for freeze protection use a glycol/ CAUTION: Failure to properly install the flow switch
water mix that prevents foaming. Air entrapped within foam may result in damage to the boiler/water heater heat
significantly decreases heat transfer and can result in damage exchanger voiding the warranty!
to the heat exchanger. Products such as DOWFROST,
DOWTHERM, UCARTHERM or an equivalent product must
be used to ensure proper protection to the boiler.

Figure 12 – Futera II Piping

130°F 54°C

1in 25 mm

18
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

HEATING SYSTEM PIPING Table 7 - Temperature Rise

∆T = 20°F ∆T = 11.1°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
General Piping Requirements
Number GPM Ft L/s kPa
All heating system piping must be installed by a qualified 500 42.5 0.53 2.7 1.5
technician in accordance with the latest revision of the 750 63.8 1.57 4.0 4.6
ANSI/ASME Boiler and Pressure Vessel Code, Section IV, 1000 85.0 3.44 5.4 10.1
and ANSI/ASME CSD-1, Standard for Controls and Safety 1250 106.3 2.11 6.7 6.2
Devices for Automatically Fired Boilers. All applicable local 1500 127.5 3.57 8.0 10.5
codes and ordinances must also be followed. A minimum ∆T = 25°F ∆T = 13.9°C
clearance of 1 in, 25 mm must be maintained between Model Flow Rate Pres. Drop Flow Rate Pres. Drop
heating system pipes and all combustible construction. All Number GPM Ft L/s kPa
heating system piping must be supported by suitable 500 34.0 0.35 2.1 1.0
750 51.0 1.04 3.2 3.1
hangers not the boiler. The thermal expansion of the
1000 68.0 2.27 4.3 6.7
system must be considered when supporting the system. 1250 85.0 1.40 5.4 4.1
A minimum system pressure of 12 psig, 82.7 kPa must 1500 102.0 2.36 6.4 7.0
be maintained. 1750 119.0 3.67 7.5 10.8
1950 132.6 5.14 8.4 15.1
Heating Boiler Piping Connections ∆T = 30°F ∆T = 16.7°C
The supply and return connections should be sized to suit Model Flow Rate Pres. Drop Flow Rate Pres. Drop
the system, see Table 6. Number GPM Ft L/s kPa
750 42.5 0.70 2.7 2.2
1000 56.7 1.60 3.6 4.8
Table 6 – Supply & Return Pipe Sizing 1250 70.8 1.00 4.5 2.9
Model Size Supply Size Return Size 1500 85.0 1.70 5.4 5.0
500 thru 1000 2" NPT 2" NPT 1750 99.2 2.60 6.3 7.7
1950 110.5 3.70 7.0 10.8
1250 thru 1950 2 1/2" NPT 2 1/2" NPT
∆T = 35°F ∆T = 19.4°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Pump Requirements Number GPM Ft L/s kPa
This low mass boiler requires a continuous minimum water 750 36.4 0.60 2.3 1.6
flow for proper operation. The system pump must be sized 1000 48.6 1.20 3.1 3.6
to overcome the head loss of the boiler and the heating 1250 60.7 0.70 3.8 2.2
system in order to achieve the required temperature rise. 1500 72.9 1.30 4.6 3.7
Table 7 provides the heat exchanger pressure drop and 1750 85.0 2.00 5.4 5.8
temperature rise figures. The temperature rise across the 1950 94.7 2.80 6.0 8.1
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 6 to 600 seconds after the call for
heat is satisfied.

CAUTION: A temperature rise outside of the range

listed in Table 7 indicates that the flow rate through
the heat exchanger is incorrect which will damage
the heat exchanger voiding the warranty! The
maximum allowable temperature rise is 35°F, 19.4°C.

The maximum allowable flow rate through a Futera II

boiler is 97 GPM, 6.1 L/s on 500 through 1000 models
and 136 GPM, 8.6 L/s for 1250 through 1950 models.
The Cupro-Nickel heat exchanger allows for 108 GPM,
6.8 L/s on 500 through 1000 models and 151 GPM,
9.5 L/s on 1250 through 1950 models.

19
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Low Water Cutoff Low Return Water Temperatures

If a boiler is installed above any radiation elements it must To prevent the problems associated with condensation
be fitted with a low water cutoff device. of the products of combustion due to low return water
temperatures a primary/secondary piping system with a
Refer to the wiring diagram supplied with the boiler/water bypass and bypass valve must be installed, see Figure
heater for proper wiring connections. 14 and 14A. The bypass and bypass valve must be sized
the same as the secondary piping. A balancing valve must
Expansion Tank & Air Separator also be installed in the supply side of the secondary piping
An expansion tank or other means to control thermal downstream of the bypass. The balancing valve should be
expansion must be installed in the heating system. An adjusted to divert some of the heated discharge water into
expansion tank must be installed close to the boiler on the the return water until the required inlet water temperature
suction side of the pump. An air scoop and automatic air is achieved. The primary and secondary pumps should be
vent must also be installed to eliminate air trapped in the sized to provide the required flow through each system.
system. The secondary piping connections to the primary system
piping must not be more than 10X pipe diameters apart
Primary/Secondary Piping to ensure zero pressure drop in the primary system, see
Boilers connected to heating systems using zone valves, Figure 14.
zone pumps, or systems that have excessive flow rates or
return water temperatures less than 125°F, 52°C must be Multiple Boiler Systems
isolated from these systems to protect the boiler. Figure Systems using multiple boilers can also be installed using
13, shows a typical primary/secondary piping system. A a primary/secondary manifold system, Figure 15.
dedicated pump is used to maintain a constant water flow
through the boiler. This boiler pump is sized to overcome Piping For Use With Cooling Units
the head loss of the boiler and near-boiler piping system The boiler, when used in connection with a refrigeration
while supplying the flow rate required to maintain the system, must be installed so the chilled medium is piped in
desired temperature rise across the boiler heat exchanger. parallel with the boiler. Appropriate valves must be used to
The system pump is sized to provide the required flow prevent the chilled water from entering the boiler.
to the heating system. The boiler piping connections to
the heating system piping must be a maximum 10X pipe When a boiler is connected to a heating coil that may be
diameters between centers to ensure zero pressure drop exposed to refrigerated air from an air handling device, the
in the primary system. Flow must be properly accounted piping system must be equipped with flow-control valves
for in the design of primary/secondary systems. In order or some other automatic means of preventing gravity
to prevent boiler(s) short cycling the system flow must be circulation of the boiler water during the cooling cycle.
equal to or higher than the boiler(s) local flow.

20
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 13 - Typical Boiler Primary/Secondary Piping System

(See Notes) Pump

Gate Valve

Globe Valve

Angle Valve

NOTES:
Bufferfly Valve
1. Boiler circuit piping must be sized
large enough to handle maximum
Balance Valve
flow through unit.
2. Boiler pump sized to boiler design
flow requirements.
Ball Valve
3. All boilers furnished with factory
mounted outlet water temperature
gauge. Motorized Valve
4. Boiler pump purging required.
Use terminals supplied.
Solenoid
Notice: These drawings show suggested Operated Valve

piping configuration and valving.

Check with local codes and ordinances H-1 Rev 4
for specific requirements. Self-Operated
Valve

Pressure
Figure 14 - Low Temperature Piping with Thermostatic Valve Reducing Valve

(See Notes)
Check Valve

Pressure
Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure
Regulator

Automatic
Air Vent

Backflow-
Prevention
Device

H-18 Rev 3 3-Way Valve

NOTES: Expansion
Tank

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 precalibrated for 140°F return temperature.

Notice: These drawings show suggested piping configuration and valving.

Check with local codes and ordinances for specific requirements.

21
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 14A - Low Temperature Boiler Piping

(See Notes and Adjustment Procedures)

Pump

Gate Val ve

Globe Val ve

Angle Val ve

NOTES:
Adjustment Procedure 1. Boiler circuit piping must be Bufferfly Val ve
To Maintain Inlet Temperature sized large enough to handle
Above Dew Point maximum flow through unit.
Balance Val ve
T1-Temp-Min=110°F For Atmospheric 2. Boiler pump sized to boiler
T1-Temp-Min=125°F Sealed Combusion design flow requirements.
3. All boilers furnished with
1. Turn heater on and open valves A & B. factory mounted outlet Ball Valve
2. After steady-state operation, if T1 is less water temperature gauge.
than Temp-Min slowly close valve B until 4. Boiler pump purging required. Motorized Val ve
T1 climbs to desired operating temperature Use terminals supplied.
above Temp-Min. Notice: These drawings show
3. If T1 is greater than desired operating suggested piping configuration Solenoid
temperature, slowly close valve A to adjust to and valving.Check with local Operated Val ve

lower desired temperature above Temp-Min. codes and ordinances for

4. Check after system operating temperature specific requirements.
has stabilized. Make final adjustments. Self-Operated
Va lve
5. Follow same adjustment procedure for H-3 Rev 6
sealed combustion.
Pressure
Reducing Val ve

Figure 15 - Multiple Boiler Piping Check Val ve

(See Notes and Adjustment Procedures)

Pressure
Relief Val ve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure
Regulator

Automatic
Air Vent

Backflow-
Prevention
Device

Expansion
Tank

NOTES:

1. Boiler circuit piping must be 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 terminals supplied. H-15 Rev 5
5. Secondary loop pipe diameter must be sized large enough to
handle maximum flow through all units.

Notice: These drawings show suggested piping configuration and valving.

Check with local codes and ordinances for specific requirements.

22
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

DOMESTIC WATER SUPPLY PIPING A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water
CAUTION: Proper controls must be used to prevent conditions are encountered. See Table 8.
water supplied for domestic use from exceeding 130°F,
54°C or a scald injury will occur! When higher water CAUTION: The maximum allowable flow rate through a
temperatures are required for appliances such as a Futera II water heater is 97 GPM, 6.1 L/s on 500 through
dishwasher, a mixing valve or some other tempering 1000 models and 136 GPM, 8.6 L/s for 1250 through 1950
means must be installed. Households with small models. The Cupro-Nickel heat exchanger allows for
children may require water temperatures less than 108 GPM, 6.8 L/s on 500 through 1000 models and
120°F, 49°C. Local codes must be complied with! 151 GPM, 9.5 L/s on 1250 through 1950 models. See Table
9.
General Piping Requirements
Ensure that the water heater is equipped with bronze RBI water heaters are designed to run scale free. Due to
headers. Piping and components connected to the water the extreme variables of water conditions world wide it is
heater must be suitable for use with potable water. The necessary to consider pH values and water hardness in
water heater must not be connected to any heating system relationship to scaling. It is crucial to consider these two
piping or components previously used with a non-potable variables when making heat exchanger and pump
water heating appliance. No toxic chemicals, such as those selection. If local water conditions are extreme, follow the
used for boiler treatment, are to be introduced into the guidelines in the Heat Exchanger Selection Table (Table
potable water used for space heating. If a hot water storage 8) and the Pumping Performance Table (Table 9). Scale
tank is used in the system it must be equipped with a free operation can be achieved by using water with a
temperature and pressure relief valve that complies with hardness between 8 and 18 and by maintaining the pH
ANSI Z21.22 or CAN-4.4 and CAN-4.6. between 5 and 9. Follow the conditions listed under
NORMAL in the table. In some areas of the country
NOTE: The storage tank must be located as close to additional precautions must be observed due to unusual
the water heater as possible to prevent excessive head characteristics of the local water supply. Call the nearest
loss which will reduce flow. RBI representative for details.

Water Chemistry To properly size the pump a grain hardness and pH test
The required temperature rise across the water heater must be taken at the installation site before order is placed.
is based on water having a hardness between 8 and 18 Proper pump sizing will improve heater performance and
grains per gallon with a level of dissolved solids not help ensure heater longevity.
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 level of dissolved solids
exceeding 350 ppm will require a recalculation of the pump
size and temperature rise.

23
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Table 8 - Futera II Heat Exchanger Selection

Table 9 - Futera II Pumping Performance Requirement

24
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Expansion Tank A balancing valve should be installed on the outlet side of

An expansion tank or other means to control thermal the water heater for purposes of adjusting the flow rate
expansion must be installed in the water heating system if through the heat exchanger. Thermometers are installed
back flow prevention devices are installed. on both the inlet and outlet of the water heater for
determining the temperature rise through the unit.
Pump Requirements
This low-mass water heater requires a continuous mini- The proper velocity through the water heater must
mum water flow for proper operation. The low water flow be maintained in accordance with Table 9 for efficient
switch provided for this unit will shut down the water operation and long life. If the temperature rise through the
heater if flow falls below the required minimum level. Table water heater is lower than recommended the water velocity
9 provides the heat exchanger pressure drop chart and is too high. Premature erosion of the heat exchanger will
temperature rise table. The temperature rise across the occur. Conversely, if the temperature rise is higher than
water heater must never exceed 35°F, 19.4°C. recommended in Table 9 the flow rate is too low. Scaling
and softening of the heat exchanger will occur.
Cold Water Supply
The cold water supply must be piped to the water heater’s Thermostatic Mixing Valve – Water Above 140°F, 60°C
outlet piping between the water heater and the hot water Water can be stored at temperatures above 140°F, 60°C
storage tank. This will prevent untempered water from provided that a thermostatically controlled mixing valve is
entering the water heater, see the Temperature Rise used to temper the hot water to an acceptable temperature
Control section below. Two typical water heating systems before it’s supplied for domestic use.
are shown in Figures 16 & 17.
The mixing valve MUST be set to prevent a scald injury
Temperature Rise Control from occurring, see the caution against scalding.
Water returned to the water heater inlet must not be
less than 125°F, 52°C or excessive condensation of the Storage of water for domestic use above 140°F, 60°C will
products of combustion will damage the water heater provide an increased quantity of tempered water and help
voiding the warranty. The method outlined below can be prevent the growth of water born bacteria.
employed to prevent this condition from occurring.

25
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 16 - Typical Water Heating Piping (FW Models Only)

(See Notes) Pump

Valve

3
1 Globe Valve

8
4
Angle Valve

7
Bufferfly Valve

2
Balance Valve

D-1 Rev 6
Ball Valve

Motorized Valve

Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Solenoid
Operated Valve

Figure 17 - Multiple Water Heating Piping (FW Models Only)

(See Notes) Self-Operated
Valve

SELF BALANCING DOUBLE REVERSE

RETURN MAKE-UP & SUPPLY, CIRCULATION Pressure
Reducing Valve

4
3 Check Valve

8
6
4 Pressure
Relief Valve

1
7
Flow Switch

7
Thermometer

Aquastat Union
6
D-4 Rev 6
Pressure Switch

Attention:
Not all RBI stock storage tanks Gas Pressure
Regulator
incorporate this tapping: See Note 1.

NOTES: Automatic
Air Vent
1. Optional cold water make up and recirculation line location.
2. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.
3. Thermal expansion tank may be required, check local codes.
4. When using optional factory mounted pump, max pipe length 30 ft. total, 6-90° elbows, full pipe size.
5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE. Temperature &
The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and Pressure
Pumping Performance Table before making selection. Relief Valve
6. Common piping must be sized for maximum combined heater flow.
7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
8. MA Code requires an 1/8 in. hole in check valve to compensate for thermal expansion.
9. Boilers may require a mixing application in order to prevent flue gas condensation and premature failure caused by fireside corrosion. (Figure Vacuum
14A) - "Adjustments Procedure To Maintain Inlet Temperature Above Dew-point." Relief Valve
10.A thermostatic mixing valve may be required at the outlet of the tank in order to limit the mixed water to a desirable temperature helping to
prevent scalding and injury. Consult local codes.

Notice: These drawings show suggested piping configuration and valving.

Drain Valve
Check with local codes and ordinances for specific requirements. (Typ.)
26
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

GAS SUPPLY PIPING Table 11 – Equivalent Pipe Length

Nominal Type of pipe fitting
WARNING: Check the boiler/water heater rating Iron Pipe 90˚ Elbow Tee1 Gate Valve2 Gas Cock2
plate to make sure that the boiler/water heater is Size Equivalent pipe length, (ft)
for the type of gas that will be used. If it isn’t, do not 1" 2.6 5.2 0.6 1.5
connect the boiler/water heater to the gas supply. 1 1/4" 3.5 6.9 0.8 1.9
Gas supply piping must be in accordance with the 1 1/2" 4.0 8.0 0.9 2.3
National Fuel Code, ANSI Z223.1-latest revision or 2" 5.2 10.3 1.2 3.0
applicable provisions of the local building codes. Notes: 1. For flow through branch.
Canadian installations must comply with CAN/CGA 2. For flow at full open.
B149.1 or .2 Installation Code. Failure to comply
with this warning can result in extensive property
damage, severe personal injury or death! Figure 18 – Gas Supply Piping

The Futera II 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.

NOTE: A minimum gas supply pressure of 5 in, 127 mm

W.C. natural or 11 in, 279 mm WC propane and
maximum 14 in, 356 mm WC natural or propane, must
be available at the safety shutoff valve inlet with the
unit(s) operating, and not to exceed (1.0 in WC) drop
when firing from minimum input to full load of the gas
supply line and all appliances running.

Do not size the gas supply line nominal iron pipe size based
only on the boiler gas inlet connection size. The gas supply
line (feed) to the boiler gas inlet connection must be designed
per an engineered method and utilizing (Table 10) to ensure CAUTION: Always use a wrench on the gas valve body
that the gas supply piping is sized properly. Do not neglect the when making gas connections to it. Never over-tighten
pressure drop due to pipe fittings. (Table 10) should be used the piping entering the gas valve body or gas valve
in conjunction with (Table 11) to ensure that the gas supply failure may result!
piping has the capacity to meet the demand. If more than one
appliance is supplied by the same supply pipe, the piping When applicable, provisions for vent, bleed and gas relief
must be sized based on the maximum possible demand. lines must be made in accordance with the latest revision
of ANSI Z223.1/NFPA 54.
Figure 18 depicts the proper way to connect the boiler/ water
heater to the gas supply piping. The manual shut- Safe lighting and other performance criteria were met with
off valve MUST be installed in the supply piping. It should the gas manifold and control assembly provided on the
be installed 5 ft, 1.5 m above the floor where required by boiler. All gas connections MUST be leak tested before
local codes. Provide a sediment trap at the bottom of the vertical putting the boiler into operation.
section of the gas supply pipe upstream of the gas controls.
WARNING: Never use an open flame to test for gas
A ground joint union should be installed between the boiler leaks. Always use an approved leak detection
gas controls and the supply piping. Each of these items method. Failure to comply with this warning can
are needed to ensure long life and ease of servicing. Always cause extensive property damage, severe personal
use a pipe sealant that is suitable for use with LP gas. injury or death!

Table 10 – Gas Pipe Capacity Whenever the gas supply piping is pressure tested the
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas boiler/water heater gas controls must be protected. If the
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop. test pressure is equal to, or less than 1/2 psig, 3.5 kPa
Nominal Pipe length in feet isolate the boiler/water heater by closing it’s manual shut
Iron Pipe 10 20 30 40 50 60 80 100 150 off valve, see Figure 18. If the test pressure is greater than,
Size Maximum gas volume of pipe, (ft3/hr) or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/water
1" 520 350 285 245 215 195 170 150 120 heater and its individual shut-off valve.
1 1/4" 1050 730 590 500 440 400 350 305 250
1 1/2" 1600 1100 890 760 670 610 530 460 380
2" 3050 2100 1650 1270 1270 1150 990 870 710
Note: Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr.
Multiply the propane flow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
27
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

ELECTRICAL WIRING Hydronic Heating Boilers

Open the make-up water valve and slowly fill the boiler and
Electrical Power Connections all of the radiation with water. Ensure that all bleed and
drain valves are closed.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper Adjust the make-up water pressure regulator so a minimum
and dangerous operation! Verify proper operation after 12 psig, 82.7 kPa system pressure is maintained at the
servicing. highest point in the system piping. If a make-up water pump
is used adjust it to maintain a minimum 12 psig, 82.7 kPa
AT T E N T I O N : Au m o m e n t d e l ’ e n t r e t i e n d e s system pressure.
commandes, étiquetez tous les fils avant de les
débrancher. Des erreurs de câblage peuvent entraîner Open the system bleed and drain valves, one at a time, to
un fonctionnement inadéquat et dangereux. S’assurer purge the air trapped in the heating system piping.
que l’appareil fonctionne adéquatement une fois
l’entretirn terminé. With the boiler off, run the system pump for at least 30
minutes and bleed the system piping using the bleed
The electrical connections to this boiler/water heater must valves. If strainers are used in the system piping, the make- up
be made in accordance with all applicable local codes and water valve should be closed and the strainers checked
the latest revision of the National Electrical Code, ANSI/ and cleaned.
NFPA-70. Installation should also conform with CSA C22.1
Canadian Electrical Code Part I if installed in Canada. The system expansion tank should be checked to ensure
that the correct water level in the tank is maintained. The
Install a separate 120 volt 15 amp circuit for the boiler/water tank should be less than half full of water with the system
heater. A properly rated shut-off switch should be located full and adjusted to the correct operating pressure.
at the boiler/water heater. The boiler/water heater must be
grounded in accordance with the authority having Start the boiler as described in the “OPERATING
jurisdiction, or if none, the latest revision of the National INSTRUCTIONS” section. Run the boiler for at least an
Electrical Code, ANSI/NFPA-70. hour. The system pump(s) and all radiation units must be
operated during this time. Ensure that the make-up water
Line voltage field wiring of any controls or other devices valve is open.
must conform to the temperature limitation of type T wire
at 95°F, 35°C above room temperature. Use copper Shut the boiler off and open the bleed valves to purge the
conductors with a minimum size of #14 awg. Use air trapped in the heating system piping. Close the make-
appropriate wiring materials for units installed outdoors. up water valve and check and clean the strainers and
make-up water pressure reducing valve.
Refer to the wiring diagram supplied with the boiler/water
heater for proper wiring connections. Open the make-up water valve and adjust the system
pressure if necessary. The system should be checked and
GENERAL OPERATION bled after three days of operation.

WARNING: Before proceeding read and fully OPERATING INSTRUCTIONS

understand the instructions contained in this FOR YOUR SAFETY READ BEFORE OPERATING.
manual. Do not attempt to operate this boiler/water
heater if it has not been installed in accordance POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN
with the guidelines set forth in this manual. Failure MARCHE
to comply with this warning can result in extensive
property damage, severe personal injury or death! A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
Should overheating occur or the gas supply fail to shut off, the pilot by hand.
turn off the manual gas control valve to the appliance. Do
not interrupt water flow through the boiler/water heater. Cet appareil est muni d’un dispositif d’allumage qui
allume automatiquement la veilleuse. Ne tentez pas
En cas de surchauffe ou si l’alimentation en gaz ne s’arrête d’allumer la veilleuse manuellement.
pas, fermez manuellement le robinet d’arrêt de l’admission
de gaz. B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.

28
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

DANGER: Propane gas may not always be detected 5. Wait five (5) minutes to clear out any gas. Then smell
by smell. Propane gas is heavier than air and can for gas, including near the floor. If you smell gas,
collect in low areas. STOP! Follow “B” in the safety information above
(to the left) on this label. If you do not smell gas, go
Propane gas can ignite or explode if an ignition to the next step.
source is present and result in death, serious 6. Connect a manometer having a minimum capacity of
injury and property damage! 20 in, 508 mm WC to the gas pressure test port, see
Figure 22. Make sure that the gas supply piping has
FOR YOUR SAFETY been purged of air and that all gas joints up to the gas
• Have only qualified licensed professionals install, valve have been thoroughly checked for leaks.
service and maintain this appliance and your gas 7. Open the manual pilot valve.
system in accordance with all applicable codes. 8. Turn on all electric power to the boiler.
• If you suspect a leak: 9. Set the operating control or thermostat to the desired
1. Have everyone leave the building immediately. setting.
2. Do not attempt to light any appliance. 10. The pilot should automatically light. Do not try to light
3. Do not touch any electrical or electronic switches the pilot by hand!
in the building. 11. With the pilot lit, open the main gas shut-off valve.
4. Do not use any phone in the building. 12. The burner should light with proper boiler operation.
5. Call your gas supplier from a phone outside of the
building. INSTRUCTIONS DE MISE EN MARCHE
6. If you cannot reach your gas supplier call the fire 1. ARRÊTEZ! Lisez les instructions de sécurité sur la
department. portion supérieure de cette étiquette.
2. Réglez le thermostat à la température la plus basse.
AVANT DE FAIRE FONCTIONNER, reniflez tout autour de 3. Coupez l’alimentation électrique de l’appareil.
l’appareil pour déceler une odeur de gaz. Reniflez près du 4. Cet appareil est muni d’un dispositif d’allumage qui
plancher, car certains gaz sont plus lourds que l’air et allume automatiquement la veilleuse. Ne tentez pas
peuvent s’accumuler au niveau du sol. d’allumer la veilleuse manuellement.
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: 6. Attendre cinq (5) minutes pour laisser échapper tout
• Ne pas tenter d’allumer d’appareil. le gaz. Reniflez tout autour de l’appareil, y compris
• Ne touchez à aucun interrupteur; ne pas vous servir près du plancher, pour déceler une odeur de gaz. Si
des téléphones se trouvant dans le bâtiment. vous sentez une odeur de gaz, ARRÊTEZ! Passez à
• Appelez immédiatement votre fournisseur de gaz l’étape B des instructions de sécurité sur la portion
depuis un voisin. Suives les instructions du fournisseur. supérieure de cette étiquette. S’il n’y a pas d’odeur de
• Si vous ne pouvez rejoindre le fournisseur, appelez le gaz, passez à l’étape suivante.
service de incendies. 7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.
8. Mettez l’appareil sous tension.
C. Do not use this appliance if any part has been under 9. Réglez le thermostat à la température désirée.
water. Immediately call a qualified service technician 10. Si l’appareil ne se met pas en marche, suivez les
to inspect the appliance and to replace any part of the instructions intitulées «Comment couper l’admission de
control system and any gas control that has been gaz de l’appareil» et appelez un technicien qualifié ou
under water. le fournisseur de gaz.

N’utilisez pas cet appareil s’il a été plongé dans l’eau, To Turn Off Gas To Appliance
même partiellement. Faites inspecter l’appareil par un 1. Set the operating control or thermostat to its lowest
tecnicien qualifié et remplacez toute partie du système setting.
de contrôle et toute commande qui ont été plongés 2. Turn off all electric power to the appliance if service is
dans l’eau. to be performed.
3. Close the manual main and pilot gas shut-off valves.
CAUTION: To prevent being burned, stand clear of the
boiler during ignition and don’t touch any hot metal Comment Couper L’Admission De Gaz De L’Apareil
parts! 1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut
Operating Instructions procéder à l’entretien.
1. STOP! Read the safety information above. If, at any 3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
time, the appliance will not operate properly, follow the
instructions “TO TURN OFF GAS TO APPLIANCE”.
2. Set the operating control or thermostat to off or its
lowest setting.
3. Turn off all electric power to the appliance.
4. Close the manual main and pilot gas shut-off valves.

29
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

CHECKING & ADJUSTMENTS Without this spacer it won’t be possible to consistently

On initial light-off, the installer may alter the preset factory set the low-fire pressure to 2.4 in, 61 mm WC.
settings to attain satisfactory combustion. An accurate 2. Follow the instructions in the “OPERATING
manometer and flue gas analyzer must be used. Please INSTRUCTIONS” section starting on page 28 to fire
see Fire Testing section 4 for combustion guidelines. the main burner. Upon ignition of the main burner
adjust the high fire adjusting screw to obtain the high
Spark Gap fire pressure listed in Table 12. On a two-stage unit
With the main and pilot gas manual valves in the closed disconnect the power from the high fire side of the gas
position energize the unit. Observe the trial for ignition to valve and adjust the low fire, regulator. If the unit short
confirm that the spark is strong and continuous. If not, cycles on low fire adjust the air box pressure and gas
check and adjust the spark gap as shown in Figure 19. back pressure as outlined below.

Figure 19 – Spark Gap CAUTION: Never force the regulator adjustment screw
beyond the stop limits or damage to the regulator will
occur!

Table 12 – Pressure Settings, Inches W.C.

Model Natural Gas LP Gas

Size Low High Low High
in mm in mm in mm in mm
500 n/a n/a 2.3 58 n/a n/a 4.0 102
750 2.4 61 3.0 76 6.0 152 7.0 178
1000 2.4 61 3.0 76 6.0 152 7.0 178
1250 2.4 61 3.0 76 6.0 152 7.0 178
1500 2.4 61 3.0 76 6.0 152 7.0 178
1750 2.4 61 3.0 76 6.0 152 7.0 178
1950 2.4 61 3.0 76 6.0 152 7.0 178

3. When fire tested at the factory the unit’s input was

rated and the gas pressure(s) recorded on the test
label affixed to the jacket next to the junction box. To
confirm the input of the unit follow the instructions in
Pilot Operation the INPUT RATE section below. The gas pressure
The pilot pressure has been factory set at 3 in. WC for natural setting(s) for dual fuel units may vary; refer to the test
and LP gas and shouldn’t need adjustment. To check the label on the unit.
pilot pressure close the manual main shut-off valve and the 4. An undiluted flue gas sample must be taken at the
pilot gas shut-off valve, Figure 18. Remove the 1/8" pipe plug flue outlet using a calibrated flue gas analyzer. Allow
from the pilot tee and connect a manometer having a the unit to run for 15 minutes before taking
minimum range of 6 in, 152 mm WC to it. Open the pilot gas the sample. For a natural gas unit the low fire CO2
shut-off valve. With the unit powered, generate a call for heat. reading should be 7.3%-7.5% and 8.5%-8.8%
When the prepurge is complete the ignition/pilot trial will for propane gas. The high fire CO2 reading should be
begin. At this point put the Honeywell RM7800 test switch in 7.5%-8.0% and 8.8%-9.4% for propane gas.
the test position. The control will hold in the ignition/pilot Exceeding 8.0% on natural gas or 9.4% on propane
sequence allowing you to check the pressure. gas CO2 will shorten the life of the burner. Adjust the
inlet air damper to achieve the correct CO2 readings.
To adjust the pilot the following steps must be taken: 5. If the pressure settings vary from those listed in Table
1. Remove the pilot gas pressure regulator cap. 8, please affix a new label or notice to the boiler, which
2. Turn the pressure regulator adjustment screw clock- shows these new settings. However, do not sacrifice
wise to increase the flame and counterclockwise to or compromise safe combustion, carbon monoxide
decrease it. limits, or safety settings to achieve these figures. The
3. Replace the pressure regulator adjustment screw cap. pressures listed in Table 12 are guidelines obtainable
under ideal conditions.
Fire Testing 6. To test the ignition safety shutoff device, close the
1. For an on/off unit confirm that the low-fire side of the manual shutoff valve in the gas supply line. Within 5
two-stage gas valve is set to its maximum setting. seconds of main burner flame extinction, the main gas
For a two-stage unit a 1/16 in. thick silicon spacer valve solenoid should close with an audible noise. After
should be installed under the low-fire adjusting screw. 15 seconds the module should lockout and the trial for

30
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

ignition end. After 5 minutes a second trial for ignition Required Gas Pressure
should occur. Open the manual shutoff valve in the gas Connect a manometer to the gas pressure test port
supply line and reset the ignition control system. A upstream of the firing valve, Figure 22. Close the manual
normal ignition sequence should take place. If the shut off valve for the pilot gas. Ensure that the firing valve
burner hasn’t lit after the last ignition try, the gas valve is in the open position. Energize the unit and allow it to try
will close and the system will go into lock out only on for ignition until it goes into flame failure. If the gas back
CSD-1 units otherwise, the boiler will retry every 5 pressure is significantly different from that listed in Table 13
minutes. Inspect the ignition system to determine what the air/gas mixing tube may be misaligned.
the problem is.
7. With the main burner in operation, close the manual Provide gas supply pressure at inlet to boiler gas train as
firing valve. As soon as the main burner flames go out, follows:
open the manual firing valve. A normal ignition LP Nat
sequence should take place. If the burner fails to light Minimum (in WC) 11 5
the system will make one more ignition attempt. Maximum (in WC) 14 14
8. With the burners in operation, interrupt the power to
the control circuit by lowering the operating control or Measure pressure when the boiler is firing at full rate. Low
thermostat. The main burners should go out. Reset the gas pressure could indicate undersized gas line or
operating control or thermostat, a normal ignition insufficient gas supply.
sequence should follow.
“Static and operating gas pressure required at the gas
Air Box Pressure valve inlet is between 5 in. WC and 14 in. WC for natural
Connect a manometer to the air box pressure tap located gas and 11 in. WC and 14 in. WC for propane and not to
behind the control cover, Figure 21. exceed a maximum of (1.0 WC) drop when firing from
minimum input to full load of the gas supply line and all the
Table 13 lists the factory settings for the air box pressure appliances running. If the gas pressure is above this limit,
and gas back pressure that were set using a minimum a lock-up style regulator suitable for dead end service such
length of vent pipe. It may be necessary to adjust the air as an Equimeter or Fisher must be installed to prevent
shutter on the blower to achieve acceptable combustion increase (creep) of gas pressure when the units are not
readings for certain installations. operating. This pressure regulator (supplied by others) may
be installed at the service entrance to each unit or a
Figure 21 – Air Box Pressure Tap “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.”

Figure 22 – Air Adjustment & Gas Pressure Test Port

If vented vertically ensure that the barometric damper is

capable of maintaining the air box pressure listed in Table
13. An air box pressure lower that that listed in Table 13 can
significantly reduce the life of the burner.

Long horizontal vents will result in an air box pressure

higher that that listed in Table 13. It may be necessary
to open the air damper to obtain the correct combustion
settings.

31
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Table 13 – Pressure Settings, WC CONTROL DESCRIPTION

Model Air Box Pres. Gas Back Pres. Low Water Cutoff
Size in mm in mm If the boiler is to be installed above radiation or if required
500 1.3 33 0.3 7.6 by other codes or regulations, install a low water cutoff in
750 2.1 53 0.6 15.2 appropriate piping. Wire the switch and any external
1000 3.0 76 0.6 15.2 controls in series to the “Interlock” contacts in the control
1250 2.1 53 0.3 7.6 box, see the wiring diagrams included with the unit
1500 2.5 64 0.3 7.6 for details. Ensure that the low water cutoff device(s)
1750 3.2 81 0.3 7.6 will function properly.
1950 3.4 86 0.3 7.6
Boiler Thermostat
Input Rate, Natural Gas If a thermostat is to be used to control the boiler always
Gas appliances are rated based on sea level operation with follow the instructions included with the thermostat. Proper
no adjustment required at elevations up to 2000 ft, 610 m. location of the thermostat will ensure efficient trouble-free
At elevations above 2000 ft, 610 m input ratings should operation of the boiler. Mount the thermostat to an inside
be reduced by 4% for each 1000 ft, 305 m. wall at a height approximately 5 ft, 1.5 m above the floor.
Check the input rate as follows: Avoid placing the thermostat in areas that will not provide
1. Turn off all other gas appliances that use the same gas an accurate measurement of the room temperature.
meter as the boiler/water heater. Locating the thermostat behind a door, in an alcove, close
2. Call your gas supplier and ask for the heating value to a source of thermal radiation or in a drafty area will
of the gas. cause poor or sporadic heating.
3. Start the boiler/water heater and let it run for 15
minutes. For a thermostat that employs an adjustable heat
4. Using the gas meter and a stopwatch, clock the time anticipator, adjust the anticipator to match the current
that it takes to burn 10 ft3, 0.28 m3 of gas and divide measured in the thermostat circuit. An increased anticipator
this time by 10. setting may be necessary if the unit cycles frequently. If
5. Insert the heating value and the time, in seconds, into the room temperature over-shoots the thermostat setting,
the formula below. reduce the anticipator setting.
6. Input = (heating value, Btu/hr)(3600)/(time, seconds)
7. If the computed rate deviates by more than 5% from Operating Control
the rated input value of the unit adjust the manifold The operating control on the water heater is set to its lowest
pressure accordingly. DO NOT adjust the manifold setting when the water heater leaves the factory. The
pressure by more than 5%. If a proper rate cannot be preferred control setting for potable hot water is 130°F,
maintained without adjusting the manifold pressure 54°C. The operating control should be set to the lowest
beyond the 5% limit, the main burner orifices must be setting that will satisfy the consumer's needs.
replaced. If the input rate is too low, go to the next
larger size of main burner orifices. If the input rate is Instructions To Change Degrees Fahrenheit To Celsius
too high, go to the next smaller size. Press the “P” button once, the display should read “SP”.
With display reading SP, press and hold the “P & Up &
CAUTION: Never increase the input to the boiler/water Down” buttons simultaneously for more than 5 seconds,
heater above that for which it is rated. Doing so can display should indicate “Pb.1”. Press the P button (not
cause premature failure of the boiler! holding) several times until “Y.0” is displayed then press and
hold for “P” for 2 seconds. Display should read “C111” press
“P” once to display “C112”, using the up / down buttons
select the number that corresponds to measurement unit
and number of decimal points desired.

Note: If you don’t enter the configuration codes (C111,

C112, etc.) thru Y.0 parameter, you will only be able to read
the setting and not change it.

32
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

The display unit C or F and the decimal place is determined DIAGNOSTICS

by parameter. You can also use this procedure to change
sensor type in an emergency if an exact replacement probe The Futera II has a number of indicator lights that are
is not readily available. (C111) intended to display the current operation and to indicate
any possible problems. The function of each light is listed
The RBI Digital Temperature Controller has three buttons: below.
“P”, “up” and “down”. The controller will display the current
inlet water temperature to the boiler. Press the “P” button On/Off Switch: The toggle switch will illuminate when power
once to enter the adjust menu. From there you can access is being supplied to the unit.
these settings:
Call For Low Fire: This green light will illuminate when there
SP Setpoint or Target Temperature: is a low fire heat demand either from the RBI Temperature
The Setpoint is the inlet water temperature that the Controller or a Building Management Control.
operating control will try to match by staging the boiler
between Off, Stage 1 and Stage 2. Call For High Fire: This green light will illuminate when
there is a high fire heat demand either from the RBI
D1 Boiler Differential: Temperature Controller or a Building Management Control.
The Boiler Differential is centered around the setpoint so
that when the sensor reads 1/2 of D1 below the setpoint, Trial Ignition: This yellow light will illuminate when the pilot
stage 1 will be energized. When the sensor reads a gas valve is energized.
temperature 1/2 of D1 above the setpoint, stage will turn
off. Main Burner: This green light will illuminate when the main
gas valve is energized.
D2 Interstage Differential:
The Interstage Differential is the difference in temperature High Limit: This red light will illuminate when the outlet
between stage 1 being called on, and stage 2 being called water temperature has exceeded the setting on the High
on. Limit control during call for heat.

WARNING: Setting the thermostat or operation Low Water: This red light will illuminate when there is not
control too high can result in scalding resulting in proper water flow during a call for heat.
severe personal injury!
Low Air Flow: This red light will illuminate when there is
High Limit (Aquastat) not proper combustion air flow during a call for heat.
The high limit is located in the top control area of the boiler/
water heater. A remote capillary bulb is run to a well on Flame Failure: Illuminate whenever the ignition control is
the outlet side of the supply header. The high limit can be unable to establish a pilot flame within the trial for ignition
reset by depressing the red button. period. This light will also illuminate if the Flame Safeguard
Ignition Control is in lockout for other reasons.
The water heater high limit should be set 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.

33
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

MAINTENANCE 7. A badly corroded or damaged heat exchanger must

be replaced, see the Heat Exchanger Repair &
WARNING: Disconnect electrical power and close Replacement section.
the manual gas shut off valve before performing
maintenance or severe personal injury may result! Heat Exchanger Cleaning
1. Close the shut off valves in the inlet and outlet piping.
CAUTION: Servicing, inspection and adjustment must On heating systems close the system fill valve and
be done by a trained technician in accordance with all relieve the system pressure from the boiler by carefully
applicable local and national codes. Improper servicing lifting the relief valve or opening the drain valve.
or adjustment can damage the boiler /water heater! 2. Disconnect the boiler/water heater from the system piping.
3. Remove the eight bolts on the rear pipe enclosure panel.
The boiler/water heater combustion system must be 4. Remove the front jacket panel and combustion
inspected at least once a year and before each heating chamber door.
season. Make sure that the burner and ignition components 5. Slide the heat exchanger out of the unit.
are free from dust, soot, dirt, corrosion or other deposits that 6. Remove the “V” baffle straps and “V” baffles.
would impair the boiler/water heater’s performance. Refer to 7. Thoroughly clean the heat exchanger with water from
page 37 for component identification. a high-pressure hose. Use a soft bristle brush if necessary.
8. Replace the cleaned heat exchanger and other
CAUTION: Improper burner servicing can result in components in the reverse order of their removal.
premature burner failure voiding the warranty! Follow section "Operating Instructions" for
recommissioning. (Record pressure readings
Burner/Heat Exchanger Inspection and combustion values for next inspection
1. Close the manual shutoff valves in the gas supply lines cycle).
and turn off electrical power to the boiler/water heater.
Heat Exchanger Repair & Replacement
2. Remove the jacket top panel.
1. A leaking or otherwise damaged tube(s) can be
3. Remove the combustion chamber top panel.
replaced as outlined in steps 2 through 8.
4. Remove the air gas mixing tube.
2. Remove the heat exchanger from the boiler/water
5. Disconnect the pilot tubing and ignition/sensing lead
heater as outlined in the Heat Exchanger Cleaning
from the burner.
section.
6. Remove the four nuts that attach the burner to the heat
3. Remove the pipe plugs from the inlet/outlet and return
exchanger.
headers opposite from the ends of the tube(s) being
7. Carefully lift the burner out of the unit.
replaced.
8. Inspect the burner for damage or signs of deteri-
4. Carefully cut the damaged tube(s) in half taking care
oration. Use a brush or compressed air to remove any
not to damage the adjacent tubes and remove.
debris from the burner ports.
5. Install and swage/expand in place the new tube(s).
9. DO NOT install a damaged or badly corroded burner,
6. Replace the pipe plugs using a suitable tread sealant
replace it.
on each one.
10. Inspect heat exchanger, proceed to the following sections,
7. Sagging or distorted heat exchanger tubes are an
(page 31), if further inspection or cleaning is required.
indication of low water flow through the system. A
11. Install the burner making sure that the burner gasket
damaged heat exchanger must be replaced and the
is not torn or deteriorated. If it is, replace it.
condition that caused the damage resolved before the
12. Reassemble the unit following the removal steps in
boiler/water heater is returned to service.
reverse order.
8. Replace the heat exchanger and other components in
the reverse order of their removal.
Heat Exchanger Inspection
9. The torque values for the bolts that secure the
1. Close the manual shutoff valves in the gas supply lines
removable headers are 30-50 ft lbs. Once bolts have
and turn off electrical power to the boiler/water heater.
been started and secured the tightening sequence is
2. Remove burner following the instructions in the Burner
as follows:
Removal & Inspection section.
1) Middle top
3. Remove the front jacket panel and combustion
2) Middle Bottom
chamber door.
3) Right Top
4. Inspect the inside and outside of the heat exchanger
4) Left Bottom
for signs of damage, sooting or corrosion.
5) Left Top
5. The outside surfaces of the copper tubes should be free
6) Right Bottom
of any soot deposits. A slight black smudge is normal with
some types of gases. Black soot indicates poor combustion.
Air Intake & Vent System
Green deposits indicate condensation due to low return
Thoroughly inspect the vent system for any signs of
water temperatures. In either case the heat exchanger must
blockage, corrosion or leakage and periodically clean
be cleaned thoroughly and the problem resolved before the
screen in vent terminal (where applicable). Immediately
boiler/water heater is returned to service.
replace any unsound vent system piping.
6. If there are no signs of damage, sooting or corrosion,
reassemble the unit following the previous steps in
reverse order.
34
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Controls
Use the “GENERAL OPERATION” and “CHECKING AND WARNING: A yellow, floating flame indicate a lack
ADJUSTMENTS” sections of this manual for reference. of combustion air. Do not operate the boiler/water
1. Check the thermostat or operating controls for proper heater until the problem is solved or severe
operation. personal injury or death may occur!
2. A float type low water cutoff device must be flushed
out per the manufacturers’ instructions. The probe on
a probe low water cut off must be removed, cleaned Figure 23 – Main Burner Flame
and inspected at least once a year. Ensure that the
low water cutoff operates properly. If not, replace them.
3. The flow switch contacts must be open when water
flow is not present.
4. The relief valve should not weep or discharge water
at normal system pressure - this may be due to
thermal expansion in a closed water supply system. 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!
5. The aquastat high limit controls the maximum water
temperature in the boiler. It is adjustable from 140°F,
60°C to 250°F, 121°C. If the water temperature reaches
the set temperature before the demand for heat has
been met, the aquastat high limit should shut the boiler
off. The water temperature should never exceed the
maximum set point of 250°F, 121°C. The aquastat high
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 Figures 19 & 23.

35
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

TROUBLE-SHOOTING

OPERATIONAL PROBLEMS CORRECTIVE ACTION

1. The On/Off toggle switch doesn’t illuminate. Ensure that proper voltage is being supplied to the unit.
Inspect the circuit breaker for the boiler/water heater
circuit.
Ensure that the power switch operates properly and is
wired correctly.
Check the transformer for proper operation.
2. The “Low Water” indicator light illuminates. Ensure that the boiler/water heater has been completely
purged of air.
Ensure that the pump is operating properly/rotating in the
proper direction.
Ensure that all system valves are in the correct position
and that no restrictions in the piping are present.
Confirm that the flow switch is wired correctly and
functions properly.
3. The “Low Air Flow” indicator light illuminates. Check the light.
Inspect the vent and air intake systems to ensure that
blockages are not present.
Ensure that the vent and air intake systems conform to
the guidelines in this manual.
Confirm that the blocked flue switch connections are
correct and that it is functioning properly.
Ensure that the blower air inlet damper & pressure switch
are adjusted for the correct air box pressure.
4. The “Trial for Ignition” indicator light illuminates, Confirm that the ignition module is properly wired.
but the igniter does not spark. Confirm that the ignition lead isn’t grounded out.
Inspect the igniter and ensure that the spark gap is
correct.
Ensure that the ignition module is properly grounded.
5. The “Main Burner” ignites, but the natural gas Ensure that at least the minimum inlet pressure is
high fire manifold pressure is less than 2.5 in. WC supplied at the inlet of the gas valve.
6. The Boiler/Water Heater rumbles on start up. Ensure that the burner is set up per the "CHECKING &
ADJUSTMENTS" section.
Ensure that the unit is properly vented.

36
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Figure 24 – Exploded View

14
32

19
57

58 33
9
16
12

SEE VIEW "C" 21

27
18 15
56 37 6 41
7
47
2

34
17
VIEW A
SCALE 1 : 8

5
8
10
20 4

11

20

SEE VIEW "B"

44

31 SEE VIEW "A"

7

43

39
41
51
53 40

52

38

14 23D
23A

23C 23

19

23B

16
49

46
21

15
45

VIEW B
SCALE 1 : 5
26 48
34

VIEW A
SCALE 1 : 8 22

10

VIEW C
SCALE 1 : 8

37
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950
4 Combustion Chamber Top Panel 03-1731 1 1 1
03-1732 1 1 1 1
7 Upper Rear Panel (prior to 1009) 03-1753 1 1 1
03-1755 1 1
03-1409 1 1
Upper Rear Panel SS (prior to 1009) 03-1753.1 1 1 1
03-1755.1 1 1
03-1409.1 1 1
9 Light Board, 120V 40-0071 1 1 1 1 1 1 1
11 Air/Gas Mixing Tube Assembly 70-2183 1 1 1
70-2184 1 1 1 1
12 Fan Assembly, 1/4HP 70-2200K 1 1 1
Fan Assembly, 1/2HP 70-2201K 1 1
Fan Assembly, 3/4HP (*must replace upper
70-2204K* 1 1
rear panel prior to 1009)
Motor (Old Style) 12-0104 1 1
Impeller (Old Style) 12-0301 1 1
13 Pilot Tube Assembly 70-2185 1 1 1
70-2185.1 1 1 1 1
Pilot Screw 57-0356 2 2 2 2 2 2 2
Pilot Nut 57-0456 2 2 2 2 2 2 2
14 Spark Generator 16-0036 1 1 1 1 1 1 1
NS Purge Timer, ST7800 16-0007 1 1 1 1 1 1 1
NS Rocker Switch On/Off 48-0012 1 1 1 1 1 1 1
NS Ignition Reset Switch (CSD-1) 48-0005 1 1 1 1 1 1 1
15 Pump Delay Relay, 115AC 15-0114 1 1 1 1 1 1 1
16 Pump Contactor 1PH (fan relay) 15-0118 1 1 1 1 1 1 1
NS Pump Contactor 3PH 15-0111 1 1 1 1 1 1 1
NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 1 1 1 1 1 1
NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1 1
NS Flame Failure Relay, 120V (R1) 15-0125 1 1 1 1 1 1 1
17 Pressure Relief Valve 50# 30-0360 1
Pressure Relief Valve 50# 13-0040 1
Pressure Relief Valve 50# 30-0374 1 1
Pressure Relief Valve 50# 30-0379 1 1
Pressure Relief Valve 50# 13-0002 1
Pressure Relief Valve 125# 30-0364 1 1 1 1 1 1 1
18 Tridicator 0-100 psi (PRV 30 - 50 psi) 13-0308 1 1 1 1 1 1 1
Tridicator 0-230 psi (PRV 60 - 160 psi) 13-0305 1 1 1 1 1 1 1
19 Pilot Orifice NG 10-0142-001 1
10-0142-002 1 1 1 1 1 1
Pilot Orifice LP 10-0143-001 1 1 1 1 1 1 1
20 Blocked Flue Switch 11-0420 1 1 1 1 1 1 1
Air Intake Switch 11-0416 1 1 1 1 1 1 1
21 Pressure Switch (Cabinet) 11-0420 1 1 1 1 1 1 1
Mounting Ring 57-0732 1 1 1 1 1 1 1
22 Ball Valve 11-0395 1 1 1 1 1 1 1
NS Manual Pilot "B" Valve 11-0031 1 1 1 1 1 1 1
23 Turbo Pilot Spark Rod Assembly NG 70-4303-001 1
(not compatible w/burners prior to 0614) 70-4303-002 1 1
70-4303-003 1 1 1 1
Turbo Pilot Spark Rod Assembly LP 70-4304-001 1
(not compatible w/burners prior to 0614) 70-4304-002 1 1
70-4304-003 1 1 1 1
23a Electrode 16-0335 1 1 1 1 1 1 1
Electrode/Spark Rod (prior to 0614) 16-0301 1 1 1 1 1 1 1
23b Gasket 06-0055 1 1 1
06-0056 1 1 1 1
23c View Port Assembly 70-2205 1 1 1 1 1 1 1
View Port Glass 20-0006 1 1 1 1 1 1 1
23d Mini Peeper, C7027A 16-0009 1 1 1 1 1 1 1
24 Ignition Cable 44-0063 1 1 1 1 1 1 1
25 Pressure Switch Tubing 06-0051 2 2 2 2 2 2 2
26 Pilot Valve 11-0079 1 1 1 1 1 1 1
27 Flow Switch 14-0203 1 1 1 1 1 1 1
Flow Switch (Outdoor) 14-0205 1 1 1 1 1 1 1
Flow Switch (Potter) 14-0201 1 1 1 1 1 1 1
Flow Switch (Outdoor Potter) 14-0202 1 1 1 1 1 1 1
NS Combustion Chamber Gasket 66-0101 25 25 25 25 25 25 25
NS 3/4" PVC Foam Gasket (per ft / per roll 75') 06-0151 75 75 75 75 75 75 75
NS 1" PVC Foam Gasket (per ft / per roll 50') 06-0152 50 50 50 50 50 50 50
NS Red Silicone Gasket (per foot / per roll 50') 06-0146 50 50 50 50 50 50 50

38
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950
30 Jacket Gasket Material (per ft / per roll 50') 66-0102 100 100 100 100 100 100 100
31 Burner Gasket (must order as kit 21-2007) 500-1000
(must order as kit 21-2008) 1250-2000
32 Flame Safeguard, RM7896C 16-0002 1 1 1 1 1 1 1
NS Keyboard Display Module, S7800A 16-0010 1 1 1 1 1 1 1
NS UV Amplifier, R7849A 16-0006 1 1 1 1 1 1 1
33 High Limit, L4008E, (FW) 14-0105 1 1 1 1 1 1 1
High Limit, L4008E, (FB) 14-0112 1 1 1 1 1 1 1
34 Operator, Jumo 16-0025 1 1 1 1 1 1 1
NS Temperature Probe Sensor 16-0026 1 1 1 1 1 1 1
NS Operator, T6031A (pool heater) 14-0003 1 1 1 1 1 1 1
37 Top Panel View Port Frame & Glass 20-0032 1 1 1 1 1 1 1
38 Heat Exchanger "V" Baffle Strap 03-1619 2 2 2
03-1620 2 2 2 2
44 Complete Burner Assembly, Turbo Pilot, NG 70-4301-001 1
70-4301-002 1
70-4301-003 1
70-4301-004 1
70-4301-005 1
70-4301-006 1
70-4301-007 1
Complete Burner Assembly, Turbo Pilot, LP 70-4302-001 1
70-4302-002 1
70-4302-003 1
70-4302-004 1
70-4302-005 1
70-4302-006 1
70-4302-007 1
Main Burner Assembly, UV Flame 120V 70-2300** 1
**(prior to 0415 recommend upgrade to 70-2214** 1
turbo pilot) 70-2215** 1
70-2216** 1
70-2217** 1
70-2218** 1
70-2219** 1
45 On/Off Gas Valve, L8214G, 1", 120V 11-0371 1 1
On/Off Gas Valve, L8214G, 1 1/4", 120V 11-0364 1 1 1 1 (LP) 1 (LP)
On/Off Gas Valve, L8214G, 1 1/2", 120V 11-0365 1 1
46 2 Stage Gas Valve, V4944B, 1", 120V 11-0166 1 1
2 Stage Gas Valve, V4944B, 1 1/4", 120V 11-0167 1 1 1
2 Stage Gas Valve, V4944B, 1 1/2", 120V 11-0168 1 1
2 Stage Gas Valve, V4944L, 1", 120V 11-0180 1 1
2 Stage Gas Valve, V4944L, 1 1/4", 120V 11-0170 1 1 1 1 1
47 Main Gas Orifice, NG 10-0051 1
10-0052 1
10-0053 1
10-0054 1
10-0055 1
10-0056 1
10-0057 1
Main Gas Orifice, LP 10-0058 1
10-0059 1
10-0060 1
10-0061 1
10-0062 1
10-0063 1
10-0064 1
48 "A" Valve, 1" 11-0465 1 1
"A" Valve, 1 1/4" 11-0466 1 1 1 1 (LP) 1 (LP)
"A" Valve, 1 1/2" 11-0467 1 1
49 Firing Valve, 1" 11-0456 1 1
Firing Valve, 1 1/4" 11-0457 1 1 1
Firing Valve, 1 1/2" 11-0458 1 1
50 Inlet Adapters (Flanged) 01-0044GL 1 1 1
01-0045GL 1 1 1 1
Outlet Adapters (Flanged) 01-0046GL 1 1 1
01-0047GL 1 1 1 1
Outlet Adapters (Threaded) 01-0042 1 1 1
01-0043 1 1 1 1
Inlet/Outlet Header Gasket (must order as kit 21-2007) 500-1000
(must order as kit 21-2008) 1250-2000

39
 FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

Futera II Model Size with Item Quantities Below

Ref # Name of Part Part # 500 750 1000 1250 1500 1750 1950
51 Heat Exchanger Assembly (Copper) 70-2515R 1
Cast Iron (prior to 2009 must replace with bronze 70-2516R 1
or change combustion chamber top panel to 70-2517R 1
adapt to cast iron) 70-2518R 1
70-2519R 1
70-2520R 1
70-2521R 1
Heat Exchanger Assembly (Copper) Bronze 70-2186R 1
70-2187R 1
70-2188R 1
70-2189R 1
70-2190R 1
70-2191R 1
70-2192R 1
Individual copper/cupronickel tubes (available for field repair)
Call for pricing
model and serial number required
Tube Expansion Tool 30-0761 1 1 1 1 1 1 1
Heat Exchanger Assembly (Cupronickel) 70-2522R 1
Cast Iron (prior to 2009 must replace with bronze 70-2523R 1
or change combustion chamber top panel to 70-2524R 1
adapt to cast iron) 70-2525R 1
70-2526R 1
70-2527R 1
70-2528R 1
Heat Exchanger Assembly (Cupronickel) Bronze 70-2193R 1
70-2194R 1
70-2195R 1
70-2196R 1
70-2197R 1
70-2198R 1
70-2199R 1
52 Heat Exchanger "V" Baffle 03-1612 20
03-1613 20
03-1614 20
03-1615 28
03-1616 28
03-1617 28
03-1618 28
53 High Limit Well, 3/8 x 3 13-0104 2 2 2 2 2 2 2
57 Air Filter 09-0497 1 1 1
09-0498 1 1
09-0499 1 1
NS Rating Plate 82-0054 1 1 1 1 1 1 1
NS FII Overlay 82-0196 1 1 1 1 1 1 1
NS Silicone 66-0151 1 1 1 1 1 1 1
NS Silicone Tubing 06-0051 2 2 2 2 2 2 2
NS Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1 1
Vent Termination Hood 12" 09-0116 1 1
Vent Termination Hood 14" 09-0141 1 1
NS Air Intake Hood 10" 09-0104 1 1 1
Air Intake Hood 12" 09-0105 1 1
Air Intake Hood 14" 09-0106 1 1
NS Barometric Damper 8" 09-0404 1
NS Barometric Damper 10" 09-0403 1 1
NS Barometric Damper 12" 09-0401 1 1
NS Barometric Damper 14" 09-0402 1 1

40
 FUTERA II START UP SHEET
Date of Start Up:
RBI Ref. #:
Serial # ('s): Boiler #1 Model#
Boiler #2
Boiler #3
Boiler #4
Boiler #5
The above information will be used to identify each boiler in the system. You should make every attempt
to affix the boiler number as noted here to the boiler physically.

START UP PROCEDURE AND DATA

Readings Or Checks By Boiler Number
STEP DESCRIPTION 1 2 3 4 5
1 No leaks, valves open, pump running, exchanger full
2 Gas lines purged, no leaks, no missing test plugs
3 Manometer installed in test port upstream of firing valve
4 Manometer installed to air box pressure tap
5 Wiring checked and verified with supplied diagram
6 All terminals identified properly and tight
7 Fan (no gas): Verify no air leaks through outer cabinet
8 With fan running: Record air box pressure "WC"
9 With fan running: Record back pressure "WC"
10 Vent configuration (HOR: horizontal VER: vertical)
11 Equivalent vent length (each fitting is 10' equivalent)
12 Breaching size:
13 Barometric installed/location:
14 Through wall venting with factory supplied termination:
15 Pilot adjusted to within 1 turn of max (natural gas only)
16 Spark is strong and continous w/o gas:
17 Pilot fires-advances to main several times (main gas off)
18 Voltage:
19 Manifold pressure "WC" (see tag on boiler) High Fire
20 Manifold pressure "WC" (see tag on boiler) Low Fire
21 O2 Lo Fire%
22 O2 Hi Fire %
23 CO2 Lo Fire %
24 CO2 Hi Fire %
25 CO Lo Fire PPM
26 CO Hi Fire PPM
27 Efficiency Lo Fire %
28 Efficiency Hi Fire %
29 Inlet Temp (F)
30 Outlet Temp (F)
31 Temp. rise across the exchanger (don’t exceed 35°F, 19.4°C)
41
SAFETY CHECKS AND ADJUSTMENTS
Readings Or Checks By Boiler Number
STEP DESCRIPTION 1 2 3 4 5
1 Low water cut off
2 Low gas pressure
3 High gas pressure
4 Operator okay and set @:
5 High limit okay and set @:
6 Blocked flue switch drops out at ("WC"):
7 Flame fail time:
8 With fan running: Record air box pressure "WC"
9 With fan running: Record back pressure "WC"

COMMISSIONING THE UNIT

Readings Or Checks By Boiler Number
STEP DESCRIPTION 1 2 3 4 5
1 Remove manometers and replace plugs
2 Complete this start up form for rep
3 Fill out factory start up form (w/boiler)
4 Correct each boiler’s settings sticker:
5 Replace all covers (no air leaks):
6 All valves opened and adjusted:
7 Boiler pump is running
8 Final operator setting:
9 Final high limit setting:
10 Boiler left in operation:
11 Boiler to require return visit:
12 End user instructed on operation:
13 Contractor instructed on operation:
14
15
16

Start up report and procedure completed by: (please print)

From (company name)
Phone #:

AUTHORIZED TECH’S SIGNATURE:

Date:

Notes/Comments:

42
 FUTERA II START UP CHECK LIST
The following items must be field verified as complete
prior to the scheduling of factory authorized start up.

1. All electrical is installed and checked: ............................................................  Yes  No

2. All water connections are made:.....................................................................  Yes  No
3. System is flooded and pressure tested:..........................................................  Yes  No
4. All pumps (primary or secondary) are running:...............................................  Yes  No
5. Flow switches installed and adjusted:.............................................................  Yes  No
6. Drain valve installed on outlet prior to isolation (boiler only):..........................  Yes  No
7. T/P gauge installed on outlet prior to isolation (boiler only):...........................  Yes  No
8. Low water cut off installed and wired:.............................................................  Yes  No
9. Lead/lag/external controls installed and tested:..............................................  Yes  No
10. All gas connections are complete:..................................................................  Yes  No
11. Gas pressure verified between 5" and 14" WC...............................................  Yes  No
12. Gas lines purged and tested for leaks:...........................................................  Yes  No
13. All stacks/vents connected per spec:..............................................................  Yes  No
14. Air inlet duct work and related items installed:................................................  Yes  No
15. All boiler related equipment operational:.........................................................  Yes  No
16. .......................  Yes  No
17. .......................  Yes  No
18. .......................  Yes  No
19. .......................  Yes  No
20. .......................  Yes  No

43
 LIMITED WARRANTY

Finned Copper Tube 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 and replacement heat exchangers 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” warrants 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 Instructions 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, (125°F, 52°C fan assist combustion - Dominator/LCD/Futera II), (140°F, 60°C fan assist combustion
- Futera III/Futera XLF). If a lower temperature is required, an external bypass should be installed to prevent
condensation (bypass and valve arrangement included on the Futera Fusion Series). The manufacturer’s warranty
does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts thereof.
(c) 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 warranty 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

Westfield, MA 01085  Mississauga, Ontario L5S 1L4 Canada
Phone: (833) 265-5371 Phone: (905) 670-5888
www.rbiwaterheaters.com