Mestek RBI FUTERA FUSION User manual

08/16 Copyright 2008 Mestek, Inc.
FTF-PVCVO-4
82-0340
Optional PVC
VentSystem
Installation Instructions
Supplement
Also read and follow:
Futera Fusion Installation
and Operation Manual
is manual is intended only for use by a qualied 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. e 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.
Ax these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualied service technician,
and to follow all guidelines in the User’s Information Manual.
Condensing
Finned Copper
Gas Boilers (CB) &
Water Heaters (CW)

Optional PVC vent system installation instructions supplement
2
ese instructions are specic to using schedule 40 PVC pipe as the
vent system for the RBI Fusion. e instructions contained in the
Fusion Installation and Operation Manual, including all applicable
Combustion Air & Ventilation and Venting instructions must be
followed.
Venting of the Futera Fusion with PVC material
requires the factory supplied PVC adapter kit. e vent
system must conform to local codes and/or the latest
edition of the National Fuel Gas Code ANSI Z223.1/
NFPA 54. Failure to properly vent this product can
result in CO poisoning causing severe personal injury
or death!
The return water temperature entering the Futera
Fusion using the PVC venting option must not exceed
155°F. Higher return water temperatures will result in
a reduction of the ring rate.
The PVC vent adapter, Figures 2 and 3, comes fitted with a flue
temperature sensor and flue temperature high limit switch. This
system provides redundant over-temperature protection for the PVC
vent system. e ue temperature sensor continuously monitors the
temperature of the ue gas exiting the Fusion. If the return water
temperature exceeds 155°F the HeatNet Control, via the flue
temperature sensor, will recognize the resultant increase in flue
temperature and reduce the ring rate of the Fusion. Should the
sensor fail, the manual reset high limit switch will trip and shut down
the Fusion before the ue temperature can exceed a safe limit.
Figure 1 PVC Vent Adapter Installation
Carefully push the PVC Vent Adapt (500-2000) or PVC Vent
Adapter with ller pipe assembly (2500-4000) into the Secondary
Heat Exchanger outlet vent collar until it booms against the stop
bead on the adaptor and tighten the ring clamp to secure the vent
adaptor to the Fusion vent collar, Figures 2, 3, and Table 1.
RING CLAMP
INTERNAL RIBBED SEAL
RING CLAMP
O-RING SEAL
STOP BEAD
JUMO HIGH LIMIT
FITTING
STACK TEMPERATURE
SENSOR
12" VENT PIPE
(2500-4000 ONLY)
RIOM-063_B
Figure 2 PVC Vent Horizontal Adapter Kit

Optional PVC vent system installation instructions supplement
3
PVC VENT ADAPTOR INSTALLATION
Improper installation of the PVC vent adaptor can
cause pooling of corrosive condensate and result in
premature failure of the vent adaptor voiding the
manufacturer’s warranty!
Remove the right rear jacket panel to gain access to the Fusion’s
economizer cabinet. With the PVC vent adaptor positioned at the
rear of the unit carefully insert the manualresethighlimit through the
ue pipe opening in the rear cabinet panel. Mount the high limit to
the economizer bracket as shown in Figure 1.
Do notkink ordamage thehighlimit capillary tubeorthe
limit may be ruined voiding the manufacturer’s
warranty!
Place the small end of the vent adaptor through the vent pipe opening
in the rear cabinet panel. Position the vent adaptor so the high limit
switch capillary is at the top of the adaptor, Figures 2 and 3.
Table 1 PVC Vent Adapter Kits
Figure 3 PVC Vent Vertical Adapter Kit
RING CLAMP
O-RING SEAL
STOP BEAD
RING CLAMP
INTERNAL RIBBED SEAL
12" VENT PIPE
(2500-4000 ONLY)
JUMO HIGH LIMIT
FITTING
STACK TEMPERATURE
SENSOR RIOM-0092_B
PVC VENT ADAPTOR WIRING
Failure to properly connect the uetemperature sensor
and ue temperature high limit switch will prevent the
Fusion from operating.
Locate the wire harness inside the economizer cabinet. Connect the
two wires with the 1/4 in. quick connects to the ue temperature
high limit switch. Connect the two wires with the 3/16 quick
connects to the ue temperature sensor.
PVC VENT SYSTEM INSTALLATION
Never insulate or encapsulate the PVC vent system or
overheating and failure of the vent system may occur.
e PVC vent system must be exposed to ambient air
and readily visible for inspection. Failure to properly
vent this product can result in CO poisoning causing
severe personal injury or death! Exception: Per
NFPA=54 Secion 12.6.8: The remaining space
surrounding a chimney liner, gas vent, special gas vent
or plastic piping installed within a masonry chimney
shall not be used to vent another appliance.
e PVC vent adapter has been engineered to directly accept PVC
vent pipe. e internal gasket in the vent adaptor will form a gas and
water tight seal. No glues or sealants are required at this connection.
Slide the required horizontal length of PVC pipe into the vent
adaptor and tighten the ring clamp to secure it in place. e vent
system must be sized per Table 2.
Model Size Pipe Diameter
Horizontal Adapter Vertical Adapter
500-1000 70-4195 40-4217
1250-1500 70-4196 40-4218
1750-2000 70-4197 40-4219
2500-3000 70-4201-001 70-4220-001
3500-4000 70-4201-002 70-4220-002

Optional PVC vent system installation instructions supplement
4
Table 2 Vent System Size
e maximum equivalent length for a positive pressure vent system
is 60 ,18.3 m. Each 90° elbow and the vent terminal are equal to 10
linear , 3.0 linear m of pipe.
To maximize the performance of the vent system, locate 90° elbows
as far from the Fusion and one another as possible.
When horizontal vent runs exceed 5 , 1.5 m they must be supported
at 3 , 0.98 m pitched intervals with overhead hangers. The vent system
mustbe down,toward theventterminal,1/4 in/, 21 mm/m.
If the vent system contains vertical sections horizontal vent runs
between the Fusion and the vertical section must be pitchedback,
toward the economizer, 1/4 in/, 21 mm/m,topreventcondensatefrom
poolinginthevent.
PVC VENT PIPE PREPARATION
& ASSEMBLY
Only schedule40 PVCpipe sizedper Table 1istobe used.
e use of heavier wall pipe may prevent the Fusion from
operating properly!
1. Cut pipe ends squarely and remove all burrs, ridges and
foreign maer using the appropriate tools and materials.
Failure to remove burrs or ridges will result in the
cement in the fitting socket being scraped from the
socket surface producing a dry joint which will have a
high probability of failure.
2. Before applying any cement dry t pipe and ings together
to ensure that the parts t properly.
3. Disassemble dry ed parts and clean the pipe and ing
surfacestobejoinedwith a PVCcleaner.Surfacestobejoined
must be free of dirt, moisture, oil and other foreign maer.
All primers, cleaners and cements must meet all local
codes. Before using primers, cleaners and cements, stir
or shake well, making sure the contents are liquid. Do
not use if found to be lumpy or in a jelly-like state. Do
not add solvents or thinners to reclaim thickened or
lumpy material. Primers and cement should be NSF
and/or UPC listed. Failure to use proper materials
when venting this product can result in CO poisoning
causing severe personal injury or death
Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel (polyphenolsulfone) in venting
systems shall be prohibited.
Covering non-metallic vent pipe and fittings with
thermal insulation shall be prohibited.
Primers, cleaners and cements are extremely ammable
and harmful or fatal if swallowed. Always store primers,
cleaners and cements in a cool, dry, well ventilated
place. Do not store them near heat, sparks or ames.
Keep containers closed when not in use. Wear
impervious clothing while handling. Do not smoke, eat
or drink while handling primers, cleaners and cements.
Wash thoroughly after handling and before eating.
Wear eye protection when handling. The harmful
vapors can be absorbed through the skin and may
irritate eyes and skin. If inhaled, get fresh air and seek
medical aention if ill feelings persist. In case of eye
and/or skin contact, immediately ush with plenty of
water for 15 minutes and seek medical attention if
irritation persists. If swallowed, drink water, do not
induce vomiting and call a physician or poison control
center immediately. Failure to read and observe all
safety information printed on primer, cleaner and
cement containers can result in severe personal injury
or death!
Cleaners and primers are intended for different
functions and should not be considered inter-
changeable. Verify with vent material manufacturer for
specic requirements.
Model Size Pipe Diameter
In mm
500-1500 8203
1750-2000 10 254
2500-3000 8203
3500-4000 10 254

Optional PVC vent system installation instructions supplement
5
4. Apply acoatofprimertothepipeand ingsurfacesthatwill
be joined.
5. Apply a thin coat of cement to the ing surface that will be
joined making sure not over apply the cement which can
cause puddling inside the ing.
6. Apply a liberal coat of cement to the pipe surface that will be
joined making sure to completely coat the area so it is free of
voids.
7. QUICKLY assemble the parts while the cement is uid! If
the cement dries before the parts are assembled, re-coat the
surfaces with cement then assemble them.
8. Push the end of the pipe completely into the ing socket so
it booms out and rotate the ing or pipe at least 1/4 turn
to achieve proper cement spread. Make sure the parts are in
the correct orientation before the cement cures. e cement
bondsbymeltingthePVCsooncethejointismadeitcannot
be disassembled.
9. Hold the pipe and ing for 30 seconds to allow the joint to
suciently cure then carefully clean o any excess cement
with a cloth.
10. Followthe PVCcementmanufacturer’sinstructionstoallow
the connections sucient time to cure before puing any
stress on the joint.
PVC VENT TERMINALS
When vented horizontally the vent and air intake systems may be
terminated using standard PVC ings with 1/4 in stainless steel
bird-screen inserts as shown below. e minimum distance from the
wall must be maintained as shown in the Figures below.
Figure 4 Horizontal PVC TEE Terminal
Figure 5 Horizontal PVC 45° Elbow Terminal
Figure 6 Horizontal PVC 90° Elbow Terminal
Figure 7 Horizontal PVC Coupling Terminal
10'' Min
1/4'' SS Bird Screen
In Opening
8'' Min
1/4'' SS Bird Screen
In Openings
8'' Min
1/4'' SS Bird Screen
In Openings
10'' Min
1/4'' SS Bird Screen
In Opening

Optional PVC vent system installation instructions supplement
6
Figure 8 Vertical PVC Terminal
e input of the unit must be set per Table 3 or nuisance shutdowns
may occur under strong wind conditions.
Table 3 Turn Down vs Combustion Air Source
When vented vertically the vent and air intake systems should be
terminated using standard 45° and 90° PVC Elbow ings with a
1/4 in stainless steel bird-screen insert as shown below.
e rest of the applicable Combustion Air & Ventilation and Venting
instructions contained in the INSTALLATION & OPETION
MANUAL MUST BE FOLLOWED.
Terminal Type Combustion Air Turn Down Ratio
Tee Indoor 3:1
Outdoor 4:1
45° Elbow Indoor n/a
Outdoor 3:1
90° Elbow Indoor 3:1
Outdoor 4:1
Coupling Indoor 3:1
Outdoor 4:1
1/4'' SS Bird Screen
In Opening

Optional PVC vent system installation instructions supplement
7

Copyright 2008 Mestek, Inc.
260 North Elm Street 7555 Tranmere Drive
Westeld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.rbiwaterheaters.com