RBI FUTERA XLF Series User manual

01/16 Copyright 2015 Mestek, Inc.
XLF-I0M-9
82-0317
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.
Finned Copper Tube
Gas Boilers (MB) &
Water Heaters (MW)

Finned copper tube gas boilers & water heaters – Boiler Manual
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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
12. DP switch — blower prov-
ing
13. DP switch — pilot air prov-
ing
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
1
6
7
8
2
9
4
5
17
18
19
21
20
10
11
12
13
14
15
16 3
XLF
Rear view
Air chamber cover removed
RBI Futera XLF-Series boilers — Overview
See the Futura XLF Control manual
for electrical component locations.

Finned copper tube gas boilers & water heaters – 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/
water heater/pool heater (Canada Only).
To obtain the safe, dependable, efficient operation and long life
for which this heating boiler/water heater was designed, these
instructions must be read, understood and followed.
e Futera XLF Series nned copper heating boiler/water heaters
have been design certied by CSA for use with natural and propane
gas under the latest revision of ANSI Z21.10.3/CSA4.3, Gas Water
Heaters, ANSI-Z21.13/CSA4.9, Gas-Fired Low Pressure Steam
and Hot Water Boilers ANSI-Z21.56/CSA 4.7 Gas Fired Pool
Heaters (Canada Only) and CAN1-3.1, Industrial and Commercial
Gas Fired Packaged Boilers. Each unit has been constructed and
hydrostatically tested for a maximum working pressure of 160psi,
1103kPa in accordance with Section IV of the ASME Boiler and
Pressure Vessel Code.
All aspects of the boiler/water heater installation must conform
to the requirements of the authority having jurisdiction, or, in the
absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA54-latest revision. Where required by the authority
having jurisdiction, the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.
In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for Gas Burning
Appliances and Equipment.
If installed in the Commonwealth of Massachusetts, you MUST
FOLLOW the additional instructions contained in RBI’s instruction
sheet, MACODE-3, located in the back of this manual.
The owner should maintain a record of all service work
performed with the date and a description of the work done.
Include the name of the service organization for future reference.
Direct all questions to your RBI distributor or contact the
RBI 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/water heater in question.
Before You Start . . . . . . . . . . . . . . . . . . . . . . . 3
Ratings & Capacities . . . . . . . . . . . . . . . . . . . . . 4
Boiler/Water Heater 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
Option 2: Vertical Venting Positive Pressure, Category IV
Figure 5 Or Figure 6 . . . . . . . . . . . . . . . . . . . . . 11
Option 3: Side Wall Venting Positive Pressure — Category IV
Figure 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option 4: Vertical Chimney Venting Negative Pressure —
Category II (Multiple Boilers With Common Venting)
Figure 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Category II Chimney Inspection & Sizing . . . . . . . . . . . 13
Category II Vent Connections. . . . . . . . . . . . . . . . . 13
Outdoor Venting . . . . . . . . . . . . . . . . . . . . . . . 14
General Piping Requirements . . . . . . . . . . . . . . . . 16
Heating System Piping . . . . . . . . . . . . . . . . . . . . 16
Domestic Water Supply Piping . . . . . . . . . . . . . . . .21
Temperature Rise Control. . . . . . . . . . . . . . . . . . . 21
Gas Supply Piping . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . 25
General Operation . . . . . . . . . . . . . . . . . . . . . . 26
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . .26
Wiring & Control Set-up. . . . . . . . . . . . . . . . . . . . 26
Controls & Interlocks . . . . . . . . . . . . . . . . . . . . . 26
Sequence Of Operation. . . . . . . . . . . . . . . . . . . . 27
Operating Instructions . . . . . . . . . . . . . . . . . . . .28
To Turn Off Gas To Appliance . . . . . . . . . . . . . . . . . 30
Checking & Adjustments . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 32
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . 35
Start-up Report . . . . . . . . . . . . . . . . . . . . . . . .40

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RATINGS & CAPACITIES
Before undertaking the installation of the Futera XLF Series boiler/
water heater 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/WATER HEATER LOCATION
1. This boiler/water heater is suitablefor indoor and outdoor
installations. Locate the boiler/water heater in an area
that provides good access to the unit. Servicing may
require the removal of jacket panels. Allow the minimum
clearances between adjacent construction and the boiler/water
heater as listed in Table1.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1 Required Clearances
From
Clearance to
combustible surfaces
Service
clearances
Inches mm Inches mm
Top 6153 30 762
Back 6153 24 610
Left side 6153 12 306
Right side 6153 12 306
Front 6153 30 762
2. An optimum site will be level, central to the piping system, close
to a chimney or outside wall and have adequate fresh air for
combustion. Ensure that the boiler/water heater is level from
front to back and from side to side. Use metal shims to level the
boiler/water heater. Electrical and electronic components must
also be protected from exposure to water during operation and
maintenance. DO NOT install this boiler/water heater in a
location that would subject any of the gas ignition components
to direct contact with water or excessive moisture during
operation or servicing.
3. Ensure that the oor is structurally sound and will support the
weight of the boiler/water heater.
The Futera XLF may be installed directly on
combustible ooring, but never on carpeting.
4. Locate the boiler/water heater in an area that will prevent water
damage to adjacent construction should a leak occur or during
routine maintenance. If such a location doesn’t exist, a
suitabledrain pan that’s adequately drained must be installed
under the unit.
5. DO NOT place this boiler/water heater in a location that
would restrict the introduction of combustion air into the unit
or subject it to a negative pressure, see “GENEL VENTING
GUIDELINES”.
6. NEVER place this boiler/water heater 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 ammable vapors or liquids in the
vicinity of the boiler/water heater. Failure to comply
with this warning can result in an explosion or fire
causing extensive property damage, severe personal
injury or death!
COMBUSTION AIR & VENTILATION
This boiler/water heater must be supplied with
combustion air in accordance with Section 5.3, 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/ water heater can result
in excessive levels of carbon monoxide which can result
in severe personal injury or death!
To operate properly and safely this boiler/water heater requires a
continuous supply of air for combustion. NEVER store objects on
or around the boiler/water heater!
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. ese acids will
cause premature failure of the boiler/water heater
voiding the warranty!
If the boiler/water heater is operated while the building
is under construction it MUST be protected from
wood, concrete, sheet rock and other types of dust.
Failure to properly protect the unit from construction
dust will damage the unit voiding the warranty!
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!

Finned copper tube gas boilers & water heaters – Boiler Manual
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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
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 directlycommunicating with the outdoors or 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 grill is not known, ducts should be sized per Table2.
Canadian installations must comply with CSA B149.1 when air
supply is provided by natural air 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
2500 625 4031 833 5382 2500 16127
3000 750 4838 1000 6452 3000 19354
3500 875 5645 1167 7522 3500 22581
4000 1000 6452 1334 8592 4000 25808
5000 1250 8065 1666 10748 5000 32258
Intake air option — General guidelines
is conguration provides combustion air directly to the boiler/
water heater’s air intake adapter using a dedicated pipe when using
the direct vent option. Combustion air can be drawn in horizontally
through the same outside wall which terminates the exhaust gases or
vertically through the roof, see Figure1 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
2500/3000 10 254 8203
3500/4000 12 305 10 254
5000 14 356 14 356
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/water heater.
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.

Finned copper tube gas boilers & water heaters – Boiler Manual
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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.
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. Improper venting can
result in excessive levels of carbon monoxide which can
result in severe personal injury or death!
All vent systems must be fully supported by the building structure
and not by the boiler/water heater. 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!
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!
EXISTING COMMON VENT SYSTEMS
If an existing boiler/water heater is removed from an existing
common venting system, the common venting system may then
be too large for the proper venting of the remaining appliances
connected to it. At the time of removal of an existing boiler/water
heater, the following steps shall be followed with each appliance
remaining connected to the common venting system placed in
operation, while the other appliances remaining connected to the
common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visuallyinspectthe ventingsystem forpropersizeand horizontalpitch
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 conformswiththeNationalFuelGasCode,
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 54andor CAN/CGA B149 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 mayoccurinthe venting system.
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% ofmaximumlength listed,an engineered
ventsystemcalculationmustbeperformed, consultfactory.
The Futera XLF may be vented the following ways:
1. OPTION 1 — Direct Vent, Positive Pressure
Category IV (individual venting only)
Combustion air is piped from the outdoors to the blower inlet.
Vent system is certied to UL 1738 for installations in the United
States, ULC S636 for installations in Canada.
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 vent systems must be 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 & water heaters – Boiler Manual
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3. OPTION 3 — Side Wall Vent, Positive Pressure
Category IV (individual venting only)
Combustion air is obtained from the space in which the unit is
installed. Vent system is certied 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 must becertied to UL 1738 forinstallations in the United
States, ULC S636 for installations 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
2500
8"
3000
8"
3500
10”
4000
10"
5000
12"
Standard Tee 1.25 35 ft 35 ft 40 ft 40 ft 50 ft
Boot Tee 0.65 15 ft 15 ft 20 ft 20 ft 25 ft
Cap - Low Res (UL) 0.5 15 ft 15 ft 15 ft 15 ft 20 ft
45° w/Bird Screen 0.4 10 ft 10 ft 15 ft 15 ft 15 ft
Elbow - 90° 0.38 10 ft 10 ft 15 ft 15 ft 15 ft
Elbow - 45° 0.15 5 ft 5 ft 7 ft 7 ft 7 ft
*Equivalent lengths based on K - factors and (5X) pipe
diameters straight length between fittings.
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/water heater 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.Forbestresults,horizontalventsystemsshouldbeasshortand
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/
, 20 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.

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8
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
e boiler/water heater can be vented vertically with the intake air
piped horizontally through an outside wall. Follow the instructions
in the Intake Air Option — Horizontal Guidelines. 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 & water heaters – Boiler Manual
9
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 & water heaters – Boiler Manual
10
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 & water heaters – Boiler Manual
11
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.Exterior masonrychimneys should notbe used unless
properly lined to prevent condensation and dra problems. When
applied as Category I or II see Table 5 & 5a 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 0.02 in, 0.50 to 0.10, 2.5mm WC at the
boiler/water heater ue collar with the unit running. 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 & water heaters – Boiler Manual
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Figure 7 VENT OPTION 3: SIDE WALL VENT — Side wall venting
Recommended
(12" (0.3 m)
minimum required)
OPTION 3: SIDE WALL VENTING
POSITIVE PRESSURE CATEGORY IV
FIGURE 7
In this configuration the boiler/water heater blower is used
to push the flue products horizontally to the outdoors, see
Figure 7. The air for combustion is taken 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 & water heaters – Boiler Manual
13
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/water heater 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 5a Equivalent breaching & chimney size, negative pressure
(Category I)
Input — MBH in mm
2500 - 3000 10 254
3500 - 4000 12 305
5000 14 356
Note: ese sizes are based on a 20 , 6.1m chimney height.
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5 & 5a lists the minimum riser sizes required for the XLF
boiler/water heater.
Table 5 Equivalent breaching & chimney size, negative pressure
(Category II)
Input — MBH in mm
2500/3000 12 305
3500/4000/5000 14 356
Note: ese sizes are based on a 20 , 6.1m chimney height.
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/water heater 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, 21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 & water heaters – Boiler Manual
14
OUTDOOR VENTING 25005000
When installed outdoors the Futera XLF must be ed with the fac-
tory supplied outdoor hood, air intake adapter with lter and exhaust
terminal, see Figure 7A. Multiple units must be spaced per Figure 7B.
e boiler/heater must be at least 2 , .62 m from any door, window
or gravity air inlet into any building and at least 3 , 1 m from any
overhang unless local codes dictate dierently.
Avoid locations where wind deection o of adjacent walls, buildings
or shrubbery might cause a downdraft. The unit(s) shouild be
located at least 3 , 1 m from structures. Outdoor installations are
not recommended in areas where the danger of snow blockage exists.
Do not place the boiler/water heater in a location that
would subject it to runo from adjacent buildings or
damage may occur voiding the warranty!
e boiler and system must be lled with an ethylene
glycol/water antifreeze mixture not to exceed 50%
glycol by volume. All water piping exposed to low
temperatures must be insulated.
Figure 7A Outdoor Venting
2 FT
(0.62M)
3 FT
(1M)
RIOM-60 REV.B
RIOM-87 RIOM-87
RIOM-87

Finned copper tube gas boilers & water heaters – Boiler Manual
15
Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations
See Table 5 & 5a 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 5 & 5a)
6. Size the chimney and breeching per local codes and vent pipe
manufacturer's recommendations, using generally accepted
engineering practices.
† Consult factory for vertical heights beyond 100 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 & water heaters – Boiler Manual
16
Figure 7B Multiple Outdoor Units
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler/water heater 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 8.
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 7. 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/hot water
heater to provide for isolation of the unit should
servicing be necessary.
Freeze protection
Installations in areas where the danger of freezing exists are not
recommended unless proper freeze protection is provided. The
following precautions MUST be observed:
1. A continuous flow of water through the unit MUST be
maintained! The pump responsible for flow through the
boiler/water heater must run continuously!
2. An ethylene 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 water heater 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.
Improper outdoor installation of this unit can cause
boiler failure voiding the manufacturer’s warranty!
Relief valve
Pipe the discharge of the pressure relief valve as shown in Figure9.
Never install any type of valve between the boiler/
water heater and the relief valve or an explosion causing
extensive property damage, severe personal injury or
death may occur!
Flow Switch
e ow switch supplied with the boiler/water heater 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/water heater heat exchanger
voiding the warranty!
HEATING SYSTEM PIPING
General piping requirements
All heating system piping must be installed by a qualied technician
inaccordancewiththelatest revisionoftheANSI/ASMEBoilerand
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 systempipingmustbe supportedbysuitablehangersnotthe
boiler.ethermalexpansionofthesystemmust beconsideredwhen
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6.
Table 6 Supply & Return Pipe Sizing
Input
MBH
Supply
size
Return
size
2500 - 5000 4" FLANGE 4" FLANGE
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7
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

Finned copper tube gas boilers & water heaters – Boiler Manual
17
Figure 9 Futera XLF Piping
time the burner res and runs the pump for 20 to 600 seconds aer
the call for heat is satised. A temperature rise outside of the range listed in Table7
will result in damage to the heat exchanger, voiding the
warranty! e maximum allowable temperature rise
through the boiler is 35oF, 19.4oC.

Finned copper tube gas boilers & water heaters – Boiler Manual
18
e maximum allowable ow rate through a Futera
XLF boiler is 260 GPM, 16.4 L/s when equipped
with copper tubes. A cupronickel heat exchanger allows
for 315 GPM, 19.9 L/s.
Table 7 Temperature Rise Table
Model
Number
T = 20oF∆T = 11.1oC
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
2500 217.5 10.05 13.7 29.6
3000 261.0 15.20 16.5 44.8
3500 304.5* 20.26 19.2* 59.7
4000 NA NA NA NA
5000 NA NA NA NA
Model
Number
T = 25oF∆T = 13.9oC
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
2500 174.0 6.45 11.0 19.0
3000 208.8 9.73 13.2 28.7
3500 243.6 13.40 15.4 39.5
4000 278.4* 17.30 17.6* 51.0
5000 NA NA NA NA
Model
Number
T = 30oF∆T = 16.7oC
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
2500 145.0 3.71 9.1 10.9
3000 174.0 6.75 11.0 19.9
3500 203.0 9.56 12.8 28.2
4000 232.0 12.00 14.6 35.4
5000** 290.0 21.20 18.3 62.5
Model
Number
T = 35oF∆T = 19.4oC
Flow Rate Pres. Drop Flow Rate Pres. Drop
GPM Ft L/s kPa
2500 124.3 2.79 7.8 8.2
3000 149.1 4.65 9.4 13.7
3500 174.0 7.19 10.9 21.2
4000 198.9 10.48 12.5 30.9
5000** 248.6 19.70 15.7 58.0
* This flow rate exceeds the recommended maximum for a boiler with
a standard copper heat exchanger. Use a greater temperature rise or
consult manufacturer. Consider a cupro-nickel heat exchanger, because
its maximum flow rate is 315 GPM.
** Cupronickel standard on Model 5000 only.
Low water cutoff
If a boiler is installed above any radiation elements it must be ed
with a low water cuto device.
Refer to the wiring diagram supplied with the boiler/water heater for
proper wiring connections.
Expansion tank and air separator
An expansion tank or other means to control thermal expansion
must be installed in the heating system. An expansion tank must be
installed close to the boiler on the suction side of the pump. An air
scoop and automatic air vent must also be installed to eliminate air
trapped in the system.
Primary/secondary piping
Boilers connected to heating systems using zone valves, zone pumps,
or systems that have excessive ow rates or return water temperatures
less than 140oF, 60oCmust be isolated from these systems to protect
the boiler.
Variable water flows
Figure10, shows a typical primary/secondary piping system. A
dedicated pump is used to maintain a constant water flow
through the boiler. is boiler pump is sized to overcome the head
loss of the boiler and near-boiler piping system while supplying the
ow rate required to maintain the desired temperature rise across the
boiler heat exchanger. The system pump is sized to provide the
required ow to the heating system. e boiler piping connections
to the heating system piping must be a maximum 6 pipe diameters
between centers to ensure zero pressure drop in the primary system.
Low return water temperatures
To prevent the problems associated with condensation of the
products of combustion due to low return water temperatures a
primary/secondary piping system with a bypass and bypass valve
must be installed, see Figure11. e bypass system must be sized
the same as the secondary piping. e primary and secondary
pumps should be sized to provide the required ow through each
system. e boiler piping connections to the heating system piping
must be a maximum 6 pipe diameters between centers to ensure
zero pressure drop in the primary system.
Multiple boiler systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure13.
Piping for use with cooling units
e boiler, when used in connection with a refrigeration system, must
be installed so the chilled medium is piped in parallel with the boiler.
Appropriate valves must be used to prevent the chilled water from
entering the boiler.

Finned copper tube gas boilers & water heaters – Boiler Manual
19
Figure 10 Typical Primary/Secondary Piping System (See Notes)
Figure 11 Low Temperature Piping with Thermostatic Valve
(See Notes and Adjustment Procedure)
NOTES:
1. For pump selection consult factory.
2. Boiler pump sized to boiler and thermostatic
3-way valve design flow requirements.
3. Boiler circuit piping must be sized large enough
to handle maximum flow through unit.
4. All boilers furnished with factory mounted
outlet water temperature gauge.
5. Boiler pump purging required. Use terminals
supplied.
6. Valve is pre-calibrated for 140oFreturn temperature.
7. For HeatNet operation a sensor is required and
installed at a minimum of 12” from primary loop tee.
supplied.
Notice: These drawings show suggested piping
configuration and valving.
Check with the local codes and ordinances for specific
requirements.
NOTES:
1. Boiler circuit piping must be sized
large enough to handle maximum
flow through unit.
2. Boiler pump sized to boiler design
flow requirements.
3. All boilers furnished with factory
mounted outlet water temperature
gauge.
4. Boiler pump purging required.
Use terminals supplied.
5. For HeatNet operation, a sensor is
required and installed at a minimum
of 12” from primary loop tee.
Notice: These drawings show suggested
piping configuration and valving.
Check with the local codes and ordinances
for specific requirements.
These drawings show
suggested piping con-
guration and valving.
Check with local codes
and ordinances for spe-
cic requirements.
H-1 Rev 5
H-18 Rev 4

Finned copper tube gas boilers & water heaters – Boiler Manual
20
NOTES:
1. Boiler circuit piping must be sized large enough to handle maximum flow through unit.
2. Boiler pump sized to boiler design flow requirements.
3. All boilers furnished with factory mounted outlet water temperature gauge.
4. Boiler pump purging required. Use terminals supplied.
5. Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units.
6. For HeatNet operation, a sensor is required and installed at a minimum of 12” from primary loop tee.
Notice: Theses drawings show suggested piping configuration and valving.
Check with local codes and ordinances for specific requirements.
Figure 13 Multiple Boiler Piping (See notes)
These drawings show
suggested piping con-
guration and valving.
Check with local codes
and ordinances for spe-
cic requirements.
H-15 Rev 6