RBI FUTERA XLF MB6000 User manual

LSXLF-IOM-4
82-0652
Boiler Manual
Installation and Operation
Instructions
Also read and follow:
HeatNet Control 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.
2/2021 Copyright 2017 Mestek, Inc.
Finned Copper Tube
Gas Boilers
(MB6000, MB8000,
MB10000)

Finned copper tube gas boilers – Boiler Manual
2
XLF PRIMARY COMPONENTS
1. Electrical enclosure (rear)
2. Blower and motor
3. Air inlet connection
4. Flue outlet connection
5. Gas entrance
6. Boiler water return
7. Boiler water supply
8. Gas valve
9. Power entrance box
10. DP switch — blocked air inlet
11. DP switch — blocked flue
XLF
Rear view
Air chamber cover removed
RBI Futera XLF-Series boilers — Overview
See the Futura XLF Control manual
for electrical component locations.
14 Spark generator13 Pilot air proving switch
10 Blocked air switch
2Blower and motor
15 Pilot gas valve and
pilot gas pressure regulator
17 LWCO
Boiler water inlet
8Gas valve
20 High gaspressure switch
21 Low gas pressure switch
Power box
4Flue outlet connection
Boiler water outlet
16
Flow switch
19Relief valve
18
Pressure/temperature gauge
3
Air inlet connection
1Electrical enclosure (rear)
5
Gas entrance
11 Blocked flue switch
12
Blower proving switch
7
9
6
12. DP switch — blower proving
13. DP switch — pilot air proving
14. Ignitor
15. Pilot gas valve and pilot gas pressure regulator
16. Flow switch
17. Low water cutoff
18. Pressure/temperature gauge
19. Relief valve
20. High gas pressure switch
21. Low gas pressure switch
RIOM-0120

Finned copper tube gas boilers – Boiler Manual
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BEFORE YOU START
This manual covers the application, installation, operation and
maintenance of a Futera XLF Series nned copper heating boiler.
To obtain the safe, dependable, ecient operation and long life for
which this heating boiler was designed, these instructions must be
read, understood and followed.
e Futera XLF Series nned copper heating boiler have been
design certified by CSA for use with natural and propane gas
under the latest revision of ANSI-Z21.13/CSA4.9, Gas-Fired Hot
Water Boilers. Each unit has been constructed and hydrostatically
tested for a maximum working pressure of 160psi, 1103kPa
in accordance with Section IV of the ASME Boiler and Pressure
Vessel Code.
All aspects of the boiler installation must conform to the
requirements of the authority having jurisdiction, or, in the absence
of such requirements, to the National Fuel Gas Code, ANSI Z223.1/
NFPA54-latest revision. Where required by the authority having
jurisdiction, the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.
In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for Gas Burning
Appliances and Equipment.
If installed in the Commonwealth of Massachusetts, you MUST
FOLLOW the additional instructions contained in RBI’s instruction
sheet, MACODE-3, located in the back of this manual.
The owner should maintain a record of all service work
performed with the date and a description of the work done.
Include the name of the service organization for future reference.
Direct all questions to your RBI distributor or contact the
RBI Customer Service Department at:
U. S. —
260 North Elm Street
Westeld, MA 01085
Canada —
7555 Tranmere Drive
Mississauga ONT L5S 1L4
Always include the model and serial numbers from the rating plate
of the boiler in question.
Before You Start . . . . . . . . . . . . . . . . . . . . . . . 3
Ratings & Capacities . . . . . . . . . . . . . . . . . . . . 4
Boiler Location . . . . . . . . . . . . . . . . . . . . . . . 4
Combustion Air & Ventilation . . . . . . . . . . . . . . . . 4
General Venting Guidelines . . . . . . . . . . . . . . . . . 6
Existing Common Vent Systems . . . . . . . . . . . . . . 6
Vent System Options . . . . . . . . . . . . . . . . . . . . 6
Option1: Direct Vent Positive Pressure — Category IV
Horizontal Or Vertical . . . . . . . . . . . . . . . . . . . . 7
Approved Stainless Steel Vent Manufacturers . . . . . . . 8
Approved Manufacturers Stainless Boiler Transition
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Option 2: Vertical Venting Positive Pressure, Category IV
and Vertical Venting Negative Pressure, Category I & II
Figure 5 Or Figure 6 . . . . . . . . . . . . . . . . . . . . . 13
Option 3: Side Wall Venting Positive Pressure — Category IV
Figure 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Option 4: Vertical Chimney Venting Negative Pressure —
Category I & II (Multiple Boilers With Common Venting)
Figure 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Category II Chimney Inspection & Sizing . . . . . . . . . .15
Category II Vent Connections . . . . . . . . . . . . . . . .15
General Piping Requirements . . . . . . . . . . . . . . . .20
Heating System Piping . . . . . . . . . . . . . . . . . . . 20
Domestic Water Supply Piping . . . . . . . . . . . . . . . 25
Temperature Rise Control . . . . . . . . . . . . . . . . . . 25
Gas Supply Piping . . . . . . . . . . . . . . . . . . . . . .28
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . 29
General Operation . . . . . . . . . . . . . . . . . . . . . .30
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . .30
Wiring & Control Set-up . . . . . . . . . . . . . . . . . . .30
Controls & Interlocks . . . . . . . . . . . . . . . . . . . . 30
Sequence Of Operation . . . . . . . . . . . . . . . . . . .31
Operating Instructions . . . . . . . . . . . . . . . . . . . 32
To Turn Off Gas To Appliance . . . . . . . . . . . . . . . . 34
Checking & Adjustments . . . . . . . . . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .35
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . 39
Start-up Report . . . . . . . . . . . . . . . . . . . . . . . 44

Finned copper tube gas boilers – Boiler Manual
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RATINGS & CAPACITIES
Before undertaking the installation of the Futera XLF Series
boiler check the rating plate to ensure that the unit has been sized
properly for the job. e AHRI specify the equivalent amount of
direct cast iron radiation that the unit can supply under normal
conditions. Also ensure that the unit has been set up for the type of
gas available at the installation site. Other important considerations
are the availability of an adequate electrical supply, fresh air for
combustion and a suitablechimney or vent system.
BOILER LOCATION
1. is boiler is suitablefor indoor installation. Locate the boiler
in an area that provides good access to the unit. Servicing
may require the removal of jacket panels. Allow the minimum
clearances between adjacent construction and the boiler as listed
in Table1.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Required Clearances
From
Clearance to
combustible surfaces
Service
clearances
Inches mm Inches mm
Top 6153 36 914
Back 6153 24 610
Left side 6153 24 610
Right side 6153 24 610
Front 6153 36 914
2. An optimum site will be level, central to the piping system, close
to a chimney or outside wall and have adequate fresh air for
combustion. Ensure that the boiler is level from front to back and
from side to side. Use metal shims to level the boiler. Electrical
and electronic components must also be protected from
exposure to water during operation and maintenance. DO NOT
install this boiler in a location that would subject any of the gas
ignition components to direct contact with water or excessive
moisture during operation or servicing.
3. Ensure that the oor is structurally sound and will support the
weight of the boiler.
The Futera XLF may be installed directly on
combustible ooring, but never on carpeting.
4. Locate the boiler in an area that will prevent water damage to
adjacent construction should a leak occur or during routine
maintenance. If such a location doesn’t exist, a suitabledrain pan
that’s adequately drained must be installed under the unit.
5. DO NOT place this boiler in a location that
would restrict the introduction of combustion air into the unit
or subject it to a negative pressure, see “GENEL VENTING
GUIDELINES”.
6. NEVER place this boiler in a location that would
subject it to temperatures at or near freezing,
see the “FREEZE PROTECTION” section.
Never store combustible materials, gasoline or any
product containing flammable vapors or liquids in
the vicinity of the boiler. Failure to comply with this
warning can result in an explosion or fire causing
extensive property damage, severe personal injury or
death!
COMBUSTION AIR & VENTILATION
is boiler must be supplied with combustion air in
accordance with Section 9.3, Air for Combustion &
Ventilation, of the latest revision of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and all applicable
local building codes. Canadian installations must
comply with CAN/ CGA B149.1 or .2 Installation
Code for Gas Burning Appliances and Equipment,
or applicable provisions of the local building codes.
Failure to provide adequate combustion air for this
boiler can result in excessive levels of carbon monoxide
which can result in severe personal injury or death!
To operate properly and safely this boiler requires a continuous
supply of air for combustion. NEVER store objects on or around
the boiler!
Combustion air contaminated with fluorocarbons
or other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. These acids
will cause premature failure of the boiler voiding the
warranty!
If the boiler is operated while the building is under
construction it MUST be protected from wood,
concrete, sheet rock and other types of dust. Failure to
properly protect the unit from construction dust will
damage the unit voiding the warranty!
Buildings will require the installation of a fresh air duct or other
means of providing make-up air if the intake air option
isn’t used. Any building utilizing other gas burning appliances, a
replace, wood stove or any type of exhaust fan must be checked for
adequate combustion air when all of these devices are in operation
at one time.
Sizing of an outside air duct must be done to meet the requirements
of all such devices.
Never operate the Futera XLF in an environment
subjected to a negative pressure unless it is Direct
Vented. Failure to comply with this warning can result
in excessive levels of carbon monoxide causing severe
personal injury or death!
All air from inside the building
If the Futera XLF is to be located in a conned space, the minimum
clearances listed in Table1, must be maintained between it and
any combustible construction. When installed in a confined
space without the intake air option (as in Figure5 through
Figure8) two permanent openings communicating with an
additional room(s) are required. e combined volume of these

Finned copper tube gas boilers – Boiler Manual
5
spaces must have sufficient volume to meet the criteria for an
unconned space. e total air requirements of all gas utilization
equipment, fireplaces, wood stoves or any type of exhaust fan
must be considered when making this determination. Each
opening must have a minimum free area of 1 in2/1000 Btu/hr,
2200mm2/kW based on the total input rating of ALL gas utilization
equipment in the conned area. Each opening must be no less than
100 in2, 64,516 mm2in size. e upper opening must be within
12in, 305 mm of, but not less than 3 in, 76 mm from, the top of
the enclosure. e boom opening must be within 12 in, 305 mm
of, but not less than 3 in, 76 mm from, the boom of the enclosure.
All air from outside the building
When installed in a conned space without utilizing the intake air
option two permanent openings communicating directly with, or
by ducts to, the outdoors or spaces that freely communicate with
the outdoors must be present. e upper opening must be within
12in, 305 mm of, but not less than 3 in, 76 mm from, the top of
the enclosure. e boom opening must be within 12 in, 305 mm
of, but not less than 3 in, 76 mm from, the boom of the enclosure.
Where directlycommunicatingwith the outdoorsor communicating
with the outdoors through vertical ducts, each opening shall have a
minimum free area of 1 in2/4000 Btu/hr, 550 mm2/kW of the
total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 in2/2000 Btu/
hr, 1100 mm2/kW of the total input rating of all of the equipment
in the enclosure.
When ducts are used, they must have the same cross-sectional area
as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure, consideration must be given to the
blockage eects of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 in, 6.4 mm. If the free area through a
louver or grille is not known, ducts should be sized per Table2.
Canadian installations must comply with CSA B149.1 when air
supply is provided by natural air ow from the outdoors for natural
dra, partial fan-assisted, fan-assisted, or power dra-assisted burners,
there shall be a permanent air supply opening(s) having a cross-
sectional area of not less than 1 in2per 7,000 Btuh, 310 mm2per
kW up to and including 1 million Btuh, plus 1 in2per 14,000 Btuh,
155 mm2per kW in excess of 1 million Btuh.
Table 2 Make-up Air Louver Sizing
Input
MBH
Required cross-sectional area
Wire screen
¼ in (6.4 mm)
Metal louvers
75% free area
Wooden louvers
25% free area
in2cm2in2cm2in2cm2
6000 1500 89676 2000 12904 6000 38708
8000 2000 12904 2668 17184 8000 51616
10000 2500 16130 3332 21496 10000 64516
Intake air option — General guidelines
is conguration provides combustion air directly to the boiler’s
air intake adapter using a dedicated pipe when using the direct vent
option. Combustion air can be drawn in horizontally through the
same outside wall which terminates the exhaust gases or vertically
through the roof, see Figure1 through Figure4.
Common intake air systems may be used provided the
common duct is sized properly. An intake combustion
air damper should be installed if the common vent
option is used in the intake air pipe of each heater.
Improper installation can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Table 3 Intake Air Pipe Sizing
Input
MBH
Vertical Horizontal
in mm in mm
6000 12 305 12 305
8000 14 356 14 356
10000 18 458 18 458
All joints in metal intake air systems must be secured using corrosion
resistant fasteners and sealed using a suitableSilicone caulk. If PVC
or CPVC is used, the joints must be cleaned with a suitablesolvent
and connected using a solvent based PVC cement.
e combustion air system MUST be supported by the
building structure not the boiler.
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
inltration of subfreezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake air option – Vertical guidelines
e maximum equivalent length for the vertical intake air pipe is
100, 30.5m. Each 90oelbow and the intake air terminal are equal
to 10linear, 3.0m of pipe, see Table3.
An approved, nonrestrictive intake air terminal must be used. e
intake air terminal must terminate as shown in Figure3. The
penetration point in the roof must be properly ashed and sealed.
Intake air option – Horizontal guidelines
e maximum equivalent length for the horizontal intake air pipe is
100 , 30.5 m. Each 90oelbow and the intake air terminal are equal
to 10 linear , 3.0 m of pipe. If horizontal runs exceed 5 , 1.5 m
they must be supported at 3 , 0.9m intervals with overhead hangers.
e certied intake air terminal from RBI must be used, see Figure1,
Figure2 and Figure4.

Finned copper tube gas boilers – Boiler Manual
6
GENERAL VENTING GUIDELINES
e vent installation must be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54–latest revision or
applicable provisions of the local building codes.
Canadian installations must comply with CAN/CGA
B149.1 or .2 Installation Code. See Figure A for added
clarity. Improper venting can result in excessive levels
of carbonmonoxide which canresultin severepersonal
injury or death!
All vent systems must be fully supported by the building structure
and not by the boiler. Appropriate thimbles and re-stops must be
used where required.
Common vent systems must be properly engineered
and sized to provide a negative draft of 0.02 in,
0.5mm to 0.1 in, 2.5 mm WC at the flue outlet.
Common positive pressure vent systems are not to
be used. Improper installation can result in excessive
levels of carbon monoxide which can cause severe
personal injury or death! Boiler/Water Heater shall
not be connected to a chimney ue serving a separate
appliance, designed to burn solid fuel.
Common-vent systems — It is required that the
boiler nearest the vertical chimney be fired first
when the horizontal distance exceeds 50% of the
vertical distance. Refer to the HeatNet manual on
how to select the lead boiler. Consult the factory if
any questions. Improper installation can result in
excessive levels of carbon monoxide which can cause
severe personal injury or death!
For Category II and IV appliances the vent shall not
terminate:
1) over public walkways; or
2) near sot vents or crawl spaces or other areas where
condensate or vapor could create a nuisance or hazard or
cause property damage; or
3) where condensate vapor could cause damage or could
be detrimental to the operation of regulators, relief valves,
or other equipment.
EXISTING COMMON VENT SYSTEMS
If an existing boiler is removed from an existing common venting
system, the common venting system may then be too large for the
properventingof theremainingappliancesconnected to it. Atthe time
of removal of an existing boiler, the following steps shall be followed
with each appliance remaining connected to the common venting
system placed in operation, while the other appliances remaining
connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visuallyinspectthe ventingsystemfor propersizeandhorizontalpitch
and determine there is no blockage or restriction, leakage, corrosion
and other deciencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhaust, so they
will operate at maximum speed. Do not operate a summer
exhaust fan for a boiler installation. Close replace dampers.
4. Place in operation the appliance being inspected. Follow the
lighting instructions. Adjustthermostat so appliance will operate
continuously.
5. Test for spillage at the dra hood relief opening aer 5 minutes
of main burner operation. Use the ame of a match or candle, or
smoke from a cigaree, cigar or pipe.
6. After it has been determined that each appliance remaining
connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
replace dampers and any other gas-burning appliance to their
previous condition of use.
7. Any improper operation of the common venting system should be
correctedsothe installation conformswiththe NationalFuelGasCode,
ANSI Z223.1/NFPA 54. When resizing any portion of the common
venting system, the common venting system should be resized to
approach the minimum size as determined using the appropriate
Tablesin Appendix F in the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 andor CAN/CGAB149 InstallationCodes.
VENT SYSTEM OPTIONS CATEGORY I, II, IV
Correctly identify the type of vent system the appliance
requires before proceeding. Category identication is
noted on the unit rating plate.
e ue products in a Category II and IV vent system may be cooled
below their dew point and form condensate in the ue. e materials
used for a Category II and IV vent must be resistant to any corrosive
damage from ue gas condensate. e ue from a Category II and IV
vent system must have a condensate drain with provisions to properly
collect anddisposeofanycondensate that mayoccur inthe ventingsystem.
e maximum equivalent length for the ue outlet vent
system forCategory IV conditions is100 , 30.5 m. Use
Table 4 for the equivalent lengths per ing. Table 4 -
“Category IV Equivalent Length per Fiing” chart is meant
as a guideline for preliminary sizing. If vent length
approaches 75% ofmaximum lengthlisted,an engineered
ventsystemcalculationmustbe performed,consult factory.
The Futera XLF may be vented the following ways:
1. OPTION 1 — Direct Vent, Positive Pressure
Category IV (individual venting only)
Positive Pressure, Category IV requires a stainless steel vent system
certied to UL 1738 for installations in the United States, ULC S636
for installations in Canada. Combustion air is piped from the outdoors
to the blower inlet.
2. OPTION 2 — Vertical Vent, Positive Pressure
Category IV and Negative Pressure Category I & II
(individual venting only)
Combustion air is obtained from the space in which the unit is
installed. Category II & IV requires a stainless steel vent system
certied to UL 1738 for installations in the United States, ULC
S636 for installations in Canada. Category I vent systems use an
approved metal chimney or masonry chimney.

Finned copper tube gas boilers – Boiler Manual
7
3. OPTION 3 — Side Wall Vent, Positive Pressure
Category IV (individual venting only)
Positive Pressure, Category IV requires a stainless steel vent
system certified to UL 1738 for installations in the United
States, ULC S636 for installations in Canada. Combustion air is
obtained from the space in which the unit is installed.
To ensure proper boiler operation, boilers that are
vented side wall and use room air must not be red at
less than 33% input.
4. OPTION 4 — Vertical Vent, Negative Pressure
Category I & II (common venting)
Requires negative pressure in vent (natural draft). Category II
venting requires a stainless steel vent system certied to UL 1738
forinstallationsintheUnited States,ULC S636 forinstallations in
Canada. Category I vent systems use an approved metal chimney
or masonary chimney.
All venting and combustion air material supplied by
installer. All venting materials must be approved for the
application. Consult the vent manufacturer’s product
literature.
Table 4 Category IV Equivalent Length Per Fitting
Model/Outlet
Diameter *K
Equivalent Feet
of Straight Pipe
6000
12"
8000
14"
10000
16"
Standard Tee 1.25 50 ft 55 ft 65 ft
Boot Tee 0.65 25 ft 30 ft 35 ft
Cap - Low Res (UL) 0.5 20 ft 25 ft 30 ft
45° w/Bird Screen 0.4 15 ft 15 ft 20 ft
Elbow - 90° 0.38 15 ft 20 ft 25 ft
Elbow - 45° 0.15 5 ft 7 ft 10 ft
*Equivalent lengths based on K - factors and (5X) pipe
diameters straight length between fittings.
e RBI Futera XLF is supplied with a factory installed
Z-Flex flue outlet adapter. A manufacturers supplied
stainless steel transition piece must be used when
installed with different vent systems. Do not mix vent
systems of dierent manufacturers. Use only listed vent
manufacturers (Table 5), terminations (Table 6), and
transition adapters (Table 7). The chimney systems
manufacturer's installationinstructionsmustbefollowed.
Must consult factory when venting single or multiple
unit(s) over 100 equivalent feet. Mechanical system
may be required.
OPTION 1: DIRECT VENT
POSITIVE PRESSURE  CATEGORY IV
HORIZONTAL OR VERTICAL
In this configuration the boiler blower is used
to push the ue products to the outdoors while drawing combustion
air from the outdoors. e Intake Air Option instructions under the
“Combustion air & ventilation” section must be followed! e vent
system must be sized per Table4.
Horizontal direct vent systems — Figures 1 & 2
The vent materials used in horizontal vent systems must
be certied to UL 1738 for installations in the United States, ULC
S636 for installations in Canada. e certied vent terminal from
RBI must also be used.
If any part of a single wall metal vent system passes through an
unheated space, it must be insulated with insulation rated for 400oF,
204oC. Structural penetrations must be made using approved re-
stops.For bestresults,horizontalventsystems shouldbeasshort and
straight as possible.
e vent system must be both gas tight and water-tight. All seams and
joints in metal pipes must be joined and sealed in accordance with
the vent system manufacturer’s instructions.
When horizontal vent runs exceed 5 ft, 1.5 m they must be
supported at 3 , 0.9 m intervals with overhead hangers. e vent
system must be pitched down, toward the vent terminal, 1/4 in/
, 6.4 mm/m. If any part of a single wall metal vent system passes
through an unheated space it must be insulated with insulation rated
for 400oF, 204oC.
Horizontal vent systems shall terminate at least 4, 1.2mbelow, 4,
1.2m horizontally from or 1 , 0.30 m above any door, window or
gravity air inlet into any building.
It must not terminate less than 4, 1.2m horizontally from, and in
no case above or below, unless a 4, 1.2m horizontal distance is
maintained, from electric meters, gas meters, regulators and relief
equipment; and not less than 7ft, 2.1m above adjacent public
walkway.
Canadian installations require a minimum of 6ft,
18.3m clearance from electric meters, gas meters,
regulators and relief equipment for compliance with
CANB149.1.
e boom of the vent terminal(s) shall be located at least 5, 1.5m
above the air intake terminal(s) unless there is a minimum 5, 1.5m
horizontal separation between them.
Avoid terminal locations likely to be aected by winds, snowdris,
people and pets. Protect building materials and vegetation from
degradation caused by the ue gases.

Finned copper tube gas boilers – Boiler Manual
8
Table 5 Approved Stainless Steel Vent Manufacturers (CAT II/IV)
Make Model
DuraVent FasNSeal Vent
M&G DuraVent DuraSeal Vent
Heatfab Saf-T Vent
Metal-Fab CORR/GUARD
Security Chimneys Secure Seal
Schebler Chimney Systems e Vent
VAN-PACKER CS
Z-Flex Z-Vent
Jeremias GOV
ICC VIC
Table 6 Approved Intake/Exhaust Terminations (CAT IV - Sidewall/Horizontal Direct Vent)
Exhaust
Termination
Hood
Exhaust
90 deg
Exhaust
Tee
Exhaust
45 deg
Exhaust
Straight
*With bird screen

Finned copper tube gas boilers – Boiler Manual
9
Table 7 Approved Manufacturers Stainless Steel Boiler Transition Adapters (CAT II/IV)
Model
Size
Z Flex M&G DuraVent
(DuraSeal) ICC Metal-Fab
Boiler Flue
Outlet* Flue Transition Adapter Flue Transition Adapter Flue Transition Adapter Flue
6000 A6004899
Z-Flex
DS12FFNSAU
DSD12FFNSAUK
DS
DSD
HM-12AC
HM-12SDA
VIC-SW
VIC-DW
12FCSLCA
Corr/Guard8000 A6004820 DS14FFNSAU
DSD14FFNSAUK
HM-14AC
HM-14SDA 14FCSLCA
10000 A6004856 DS16FFNSAU
DSD16FFNSAUK
HM-16AC
HM-16SDA 16FCSLCA
Model
Size
Heatfab
(Saf-T Vent)
Security Chimneys
(Secure Seal) Jeremias RBI
Transition
Adapter Flue Transition Adapter Flue Transition Adapter Flue Boiler Adapter*
Exhaust
Termination
6000 91201MAD
EZ/GC
CI Plus
SS12FFNSAU
SSD12FFNSAUK
SS
SSD
SWKL12-S2D
–
DWKL
SWKL
09-0602-001 09-0116
8000 91401MAD SS14FFNSAU
SSD14FFNSAUK
SWKL14-S2D
–09-0602-002 09-0141
10000 91601MAD SS16FFNSAU
SSD16FFNSAUK
SWKL16-S2D
–09-0602-003 N/A
Model
Size
VAN-PACKER DuraVent Schebler Chimney
Systems (e-Vent)
Transition
Adapter Flue Transition Adapter Flue Transition Adapter Flue
6000 C12VLSL/M
CS
FSVL612 - 810003467
FasNSeal
ESW-UNAK-12R
EVD-UNAK-12R
ESW
EVD
8000 C14VLSL/M FSVL614 - 810003508 ESW-UNAK-14R
EVD-UNAK-14R
10000 C16VLSL/M FSVL616 - 810003543 ESW-UNAK-16R
EVD-UNAK-16R
*Factory Installed
eRBI FuteraXLF is suppliedwithafactory installedZ-Flexue outletadapter.A manufacturerssupplied stainlesssteel
transitionpiecemustbeusedwheninstalledwithdierentventsystems.Donot mix ventsystemsofdierentmanufacturers.
Useonly listedventmanufacturers(Table5),terminations(Table6),andtransitionadapters(Table7).e chimney systems
manufacturer's installationinstructionsmustbefollowed.

Finned copper tube gas boilers – Boiler Manual
10
Vertical direct vent systems — Figure 3
If any part of a single wall metal vent system passes through an
unheated space, it must be insulated with insulation rated for 400oF,
204oC. Structural penetrations must be made using approved re-
stops.
An approved, nonrestrictive vent terminal must be used. e top of a
vertical vent system must extend at least 5.5, 1.7m above the roof
surface and maximum snow line that it passes through, 4, 1.2m
above the intake air terminal, see Figure3.
In addition the vent system must conform to the dimensions shown
in Figure3. The penetration point in the roof must be properly
ashed and sealed.
The vent system must be gas tight. All seams and joints in metal
pipes must be joined and sealed in accordance with the vent system
manufacturer’s instructions.
Combination direct vent systems — Figure 4
The boiler can be vented vertically with the intake air piped
horizontally through an outside wall. Follow the instructions in the
Intake Air Option — Horizontal Guidelines. Also follow the general
instructions in the “Combustion Air & Ventilation” and “General
Venting Guidelines” sections.
Figure 1 VENT OPTION 1: DIRECT VENT — Horizontal Air Intake and Venting for a Single Direct Vent System (CATEGORY IV)
10 3.1
When running horizontal combustion
air and venting for single or multiple units,
exhaust and combustion air terminals must
be installed on the same plane (outside wall)
in order to prevent pressure differences due
to prevailing winds. In cold climates, double-
wall or insulated inlet pipe is recommended to
prevent condensation.

Finned copper tube gas boilers – Boiler Manual
11
Figure 2 VENT OPTION 1: DIRECT VENT — Horizontal Air Intake and Venting for Multiple Direct Vent Systems (CATEGORY IV)
Figure 3 VENT OPTION 1: DIRECT VENT — Combination Direct Vent System (CATEGORY IV)

Finned copper tube gas boilers – Boiler Manual
12
Locate exhaust terminal downwind
from air intake to reduce potential for ue
gas recirculation. Failure to comply could
result in severe personal injury or death.
Figure 4 VENT OPTION 1: DIRECT VENT — Vertical Air Intake and Venting for Direct Vent System (CATEGORY IV)

Finned copper tube gas boilers – Boiler Manual
13
Figure 5 VENT OPTION 2: VERTICAL CHIMNEY VENTING
Vertical Venting — with a listed metal chimney
system
Figure 6 VENT OPTION 2: VERTICAL CHIMNEY VENTING
Vertical Venting — using a lined masonry chimney
Recommended
(12" (0.3 m)
minimum
required)
OPTION 2: VERTICAL VENTING
POSITIVE PRESSURE CATEGORY IV,
NEGATIVE PRESSURE CATEGORY I & II
FIGURE 5 & FIGURE 6
Masonry chimneys, when used, must be lined with a
metal liner certied for Category II & IV venting.
Correctly identify the type of vent system the appliance
requires before proceeding. Category identication is
noted on the unit rating label.
A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly constructed,
lined andsized. Exteriormasonry chimneys shouldnot beusedunless
properly lined to prevent condensation and dra problems. When
applied as Category I or II see Table 8 & 8a for vent diameters. When
applied as Category IV see Table 4 for minimum vent diameters. e
Futera XLF when listed as a Category I or II appliance and vented
vertically into a listed metal chimney system, must provide a negative
pressure not greater than 0.01 to 0.10 in, 0.25 to 2.5mm WC at the
boiler ue collar with the unitrunning. A barometric damper must be
installed between the ue collar and vent connector when negative
pressures exceed 0.10 in, 2.5 mm WC.

Finned copper tube gas boilers – Boiler Manual
14
Figure 7 VENT OPTION 3: SIDE WALL VENT — Side Wall Venting
Recommended
(12" (0.3 m)
minimum required)
Pitch down toward the boiler condensate drain with pigtail
OPTION 3: SIDE WALL VENTING
POSITIVE PRESSURE CATEGORY IV
FIGURE 7
In this configuration the boiler blower is used to push
the flue products horizontally to the outdoors, see
Figure 7. The air for combustion is taken from the space
in which the unit is installed. e applicable instructions under the
“Combustion Air & Ventilation” section must be followed! e vent
guidelines under the Horizontal Direct Vent Systems section must
also be followed.
To ensure proper boiler operation, boilers that are
vented side wall and use room air must not be red at
less than 33% input.

Finned copper tube gas boilers – Boiler Manual
15
OPTION 4: VERTICAL CHIMNEY VENTING
NEGATIVE PRESSURE  CATEGORY I & II
MULTIPLE BOILERS WITH COMMON VENTING
FIGURE 8
Common vent systems cannot be pressurized.
e FuteraXLF is listed as a CategoryI or II appliance when vented
vertically into a listed metal chimney system. See Figure8 (multiple
boilers). e chimney must provide a negative pressure not greater
than 0.10in, 2.5 mm WC at the boiler ue collar with the unit
running.
When usinga listed metal chimney system the chimney
system manufacturer’s instructions must be followed.
Masonry chimneys, when used with Category II
appliances, must be lined with a metal liner certied
to UL 1738 for installations in the United States and
ULC S636 for installations in Canada.
e vent piping must be large enough to safely vent the
combined output of all of the appliances connected to
the system.
If an appliance using any type of a mechanical dra
system operating under positive pressure is connected
to a chimney ue, never connect any other appliances
to this ue. Doing so can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Correctly identify the type of vent system the appliance
requires before proceeding. Category identication is
noted on the unit rating label.
Table 8a Minimum Riser Connection, Negative Pressure
(Category I)
Input — MBH in mm
6000 16 406
8000 18 457
10000 20 508
Note: Vent system must be sized per tables contained in NFPA 54 or an
engineered system
CHIMNEY INSPECTION & SIZING 
CATEGORY I & II
A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly constructed,
lined and sized. Exterior masonry chimneys should not be used
unless properly lined to prevent dra problems.
Table8 & 8a lists the minimum riser sizes required for the XLF boiler.
Table 8 Mimimum Riser Connection, Negative Pressure
(Category II)
Input — MBH in mm
6000 16 406
8000 18 457
10000 20 508
Note: Vent system must be sized per an engineered system
Correctly identify the type of vent system the appliance
requires before proceeding. Category identication is
noted on the unit rating label.
VENT CONNECTIONS
Locate the boiler as close to the chimney as possible. Use the shortest,
straightest vent connector possible for the installation. If horizontal
runs exceed 5 , 1.5 m they must be supported at 3 , 0.9 m intervals
with overhead hangers.
e boiler vent connectors should be sloped up toward the breeching
at a minimum rate of ¼in per ft, 6.4mm per m. On masonry
chimneys the connector must terminate ush with the inside of the
chimney liner (as shown in Figure6).
Always provide a minimum clearance of 6 in, 152 mm between
single wall vent pipe and any combustible materials.
Failure to maintain minimum clearances between vent
connectors and any combustible material can result
in a fire causing extensive property damage, severe
personal injury or death!
Exit cones are favorable when used to increase
the velocity of the ue gas exiting the stack and,
may also help, in cold climates, to reduce ice
build-up. Exit cone terminations must be
supplied by others, installed per manufacturer’s
instructions, and meet local and federal code.
generic exit cone

Finned copper tube gas boilers – Boiler Manual
16
Canadian Installations¹ US Installations²
A = Clearance above grade, veranda, porch,
deck, or balcony 12 in (30 cm) 12 in (30 cm)
B = Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000
Btuh (3 kW); 12 in (30 cm) for appliances
> 10,000 Btuh (3 kW) and < 100,000
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW); 9 in (23 cm) for appliances >
10,000 Btuh (3 kW) and < 50,000 Btuh
(15 kW); 12 in (30 cm) for appliances >
50,000 Btuh (15 kW)
C = Clearance to permanently closed
window
D =
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
E = Clearance to unventilated soffit
F = Clearance to outside corner
G = Clearance to inside corner
H =
Clearance to each side of center line
extended above meter / regulator
assembly
I = Clearance to service regulator
vent outlet 3 ft (91 cm)
J =
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000
Btuh (3kW); 12 in (30 cm) for appliances
> 10,000 Btuh (3 kW) and < 100,000
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3kW); 9 in (23 cm) for appliances >
10,000 Btuh (3 kW) and < 50,000 Btuh (15
kW); 12 in (30 cm) for appliances > 50,000
Btuh (15 kW)
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual
Per local installation codes
Figure A- Direct Vent Terminal Clearances
3 ft (91 cm) within a height of 15 ft (4.6m)

Finned copper tube gas boilers – Boiler Manual
17
K = Clearance to a mechanical air
supply inlet 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m) horizontally
L =
Clearance above paved sidewalk
or paved driveway located on
public property
7 ft (2.13 m)†
M = Clearance under veranda, porch,
deck, or balcony
12 in (30 cm)‡
†
‡
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
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.
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual
Per local installation codes
Canadian Installations¹ US Installations²
A = Clearance above grade, veranda, porch,
deck, or balcony 12 in (30 cm) 12 in (30 cm)
B = Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000
Btuh (3 kW); 12 in (30 cm) for appliances
> 10,000 Btuh (3 kW) and < 100,000
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening;
1 ft (300 mm) above opening
C = Clearance to permanently closed
window
D =
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm)
from the center line of the terminal
E = Clearance to unventilated soffit
F = Clearance to outside corner
G = Clearance to inside corner
H =
Clearance to each side of center line
extended above meter/regulator
assembly
I = Clearance to service regulator vent
outlet 3 ft (91 cm)
Per local installation codes
Figure A- Other Than Direct Vent Terminal Clearances
Figure A- Direct Vent Terminal Clearances - Concluded
J =
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000
Btuh (3kW); 12 in (30 cm) for appliances
> 10,000 Btuh (3 kW) and < 100,000
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening;
1 ft (300 mm) above opening
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
Vents for Category II and IV appliances
cannot be located above public walkways
or other areas where condensate or vapor
can cause a nuisance or hazard
3 ft (91 cm) within a height of 15 ft (4.6m)

Finned copper tube gas boilers – Boiler Manual
18
K = Clearance to a mechanical air supply
inlet 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)
horizontally
L =
Clearance above paved sidewalk or
paved driveway located on public
property
7 ft (2.13 m)†
M = Clearance under veranda, porch, deck,
or balcony
12 in (30 cm)‡
†
‡
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.
Per local installation codes
Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual
Figure A- Other Than Direct Vent Terminal Clearances - Concluded
Vents for Category II and IV appliances
cannot be located above public walkways
or other areas where condensate or vapor
can cause a nuisance or hazard

Finned copper tube gas boilers – Boiler Manual
19
Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical Venting — Multiple-Boiler Installations
See Table 8 & 8a for minimum riser diameter (dimension F)
Legend for Figure 8
It is recommended that the boiler nearest the
vertical chimney must always be red rst when the
horizontal exceeds 50% of the vertical. Refer to the
HeatNet manual on how to select the lead boiler.
A negative pressure of 0.02 to 0.10inwc is required
in each boiler's riser when all boilers are operating at
full input.
Provide clearance from the boiler of no less than
6 in to combustible surfaces or 24in for service.
1. A barometric damper must be installed on the riser of each boiler,
24 in above the vent elbow. [Exception: If the vent system is
designed using accepted engineering practices, and the design
calculations prove there is no need for barometric dampers,
the barometric dampers may be omitted.] When required by
applicable codes, install a thermal spill switch on each barometric
damper.
2. Install a thermal spill switch on each barometric damper (when
required by applicable codes).
3. Connect each boiler riser to the common vent with a Y
connection or Boot T.
4. Install an approved vent cap at the vent termination.
5. DIMENSIONS:
B - breeching length
C - chimney height
D - breeching diameter
F - riser diameter (no smaller than the dimension given in
Table 8 & 8a)
6. Multi-story, common venting systems shall be in accordance with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the
CSA B149.1, Natural Gas and Propane Installation Code (Current
Editions), local codes and vent manufacturer's installation
instructions. Size the chimney and breeching using generally
accepted engineering practices. (Consult factory for vertical
heights beyond 60 ft.)
Correctly identify the type of vent system the
appliance requires before proceeding. Category
identication is noted on the unit rating plate.

Finned copper tube gas boilers – Boiler Manual
20
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler will void the
manufacturer’s warranty and can cause boiler failure
resulting in ooding and extensive property damage!
Excessive water hardness causing scaling in the copper
heat exchanger tubes is NOT covered under the
manufacturer’s warranty. See Table 11. Excessive
piing and erosion of the internal surface of the copper
heat exchanger tubes is NOT covered under the
manufacturer’s warranty if the result of high
water ow rates. See Table 10. Return water
temperatures below 140oF, 60oCwill result in heat
exchanger damage from excessive condensation
voiding the manufacturer’s warranty, see Primary/
Secondary Piping. See Figure9.
Shut o valves and unions should be installed at the
inlet and outlet connections of the boiler to provide
for isolation of the unit should servicing be necessary.
Freeze protection
Installations in areas where the danger of freezing exists are not
recommended unless proper freeze protection is provided. The
following precautions MUST be observed:
1. A continuous flow of water through the unit MUST be
maintained! The pump responsible for flow through the
boiler must run continuously!
2. A propylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used. e
pump must be capable of producing a minimum of 15% more
ow and overcoming a 20% increase in head loss. Domestic water
systems must be isolated from the boiler by the use of a heat
exchanger or other approved method.
3. If the unit must be shut o for any reason the electric, gas and
water supplies MUST be shut off and the unit and its pump
completely drained.
For systems requiring glycol for freeze protection use a glycol/water
mix that prevents foaming. Air entrapped within foam signicantly
decreases heat transfer and canresultin damage to theheatexchanger.
Products such as DOWFROST, DOWTHERM, UCARTHERM
or an equivalent product must be used to ensure proper protection
to the boiler.
The water used for dilution of concentrated heat transfer fluids
must be distilled, de-ionized, or equivalently clean as stated above.
De-ionized water by itself can be aggressive towards many metals,
but is perfectly safe when used for dilution of DOWFROST,
DOWTHERM or UCARTHERM as specied by the manufacturer.
Relief valve
Pipe the discharge of the pressure relief valve as shown in Figure9.
Neverinstallanytype ofvalve betweenthe boiler andthe
relief valve or an explosion causing extensive property
damage, severe personal injury or death may occur!
Flow Switch
The flow switch supplied with the boiler must be wired to the
terminal strip in the control panel to prevent the boiler from ring
unless there’s adequate water ow through the unit. e ow switch
must be installed in the supply piping adjacent to the boiler outlet
connection.
Failure to properly install the ow switch may result
in damage to the boiler heat exchanger voiding the
warranty!
HEATING SYSTEM PIPING
General piping requirements
All heating system piping must be installed by a qualied technician
inaccordancewiththelatest revision of theANSI/ASME Boiler and
PressureVesselCode,SectionIV,andANSI/ASMECSD-1,Standard
for Controls and Safety Devices for Automatically Fired Boilers. All
applicable local codes and ordinances must also be followed. A
minimum clearance of 1 in, 25 mm must be maintained between
heating system pipes and all combustible construction. All
heating systempipingmustbesupported bysuitablehangersnotthe
boiler.ethermalexpansionofthesystemmustbeconsideredwhen
supporting the system. A minimum system pressure of 12 psig,
82.7 kPamustbe maintained.
Heating boiler piping connections
e supply and return connections should be sized to suit the system,
per Table9.
Table 9 Supply & Return Connections
Input
MBH
Supply
size
Return
size
6000 4" FLANGE 4" FLANGE
8000/10000* 6" FLANGE 6" FLANGE
*Supply/Return piping must be a minimum of 6" diameter
Pump requirements
This low mass boiler requires a continuous minimum
water flow for proper operation. e boiler pump must be
sized to overcome the head loss of the boiler and the near-boiler
piping in order to achieve the required temperature rise. Table10
provides the heat exchanger pressure drop and temperature rise
gures. e temperature rise across the boiler must never exceed
35oF, 19.4oC. e adjustablepump delay turns the pump on each
time the burner res and runs the pump for 20 to 600 seconds aer
the call for heat is satised.