Condensing High Efficiency Domestic Water Heaters, Pool Heaters

FFC-7
Condensing High Efficiency
Domestic Water Heaters,
Pool Heaters and Boilers
Fully Condensing –
Ultra Efficient
The gas-fired Futera Fusion Series brings the field-proven
performance of RBI boilers and water heaters to the ultimate levels
of efficiency and reliability.
Fusion’s innovative design makes it the ideal choice for
applications with low operating, return or make-up water
temperatures. Unlike most condensing products on the market
today which publish the highest efficiencies at the lowest inputs,
the Fusion Series can attain efficiencies as high as 99% at full
input!
The fully modulating firing system continuously varies the energy
Premium Performance & Superior Reliability
input to precisely match the heating load without over-firing and
• 99% Maximum Efficiency
wasting fuel providing extremely high part-load efficiencies.
• Full Modulation up to (5:1 Fusion XLF / 4:1 Fusion)
• Sealed Combustion/Direct Vent
If you’re looking to maximize operating efficiency, reliability, and
• Symmetrically Air/Fuel Coupled
flexibility in domestic hot water and hydronic heating applications,
• Commercial Combustion Controls
the Fusion Series is your ­­heating solution.
• Linked Operating Control System for Multiple Unit Applications
• Gasket-­less Heat Exchanger Assembly
Features and Benefits
• 500 – 2000 MBH (Fusion)
Optional Features
• 2500 – 4000 MBH (Fusion XLF)
• BACnet or LonWorks Interface Module
• Copper 4-Pass Heat Exchanger (160 PSI)
• Cupro-nickel Finned Tubes
• Stainless Steel Secondary Heat Exchanger
• Freeze Protection Package
• PVC & Polypropylene (PP) Venting
• Honeywell Keyboard Display Module S7800
• HeatNet Integrated Boiler Control Platform
• Outdoor Sensor with Housing
• Modulating Temperature Control Mixing Valve
• Outdoor Installation
• Variable Speed Blower
• Knockdown Ready (Fusion XLF)
• Flame Safeguard
• Knockdown Available (Fusion)
• Category II & IV Venting
• Flow Switch (Mounted & Wired)
• Integral Primary Pump
• Service Friendly Design
Up To
99%
• Pool Heating
In the interest of product improvement, RBI reserves the right to
make changes without notice.
2
Advanced Heat
Exchanger Technology
The Fusion’s heat exchanger was designed using the most efficient
Smart Service Design
and dependable heat transfer materials available today. The
Large capacity in a small footprint offers greater flexibility and
(boiler) or bronze (water heater) and finned copper or cupronickel
ease of installation in a space-saving design that leaves more
tubing for superior heat transfer, resistance to scaling, and
elbowroom in the mechanical room. The rugged structural steel
protection against thermal shock.
low-mass, gasket-less primary heat exchanger has solid cast iron
base is designed to fit through a standard 30" doorway. A variety
of venting options provides added installation flexibility. Quick-
The condensing secondary heat exchanger is solid stainless
release latches allow for easy access to all components to make
steel and designed to operate at the boiler’s full flow rate. It
short work of service and maintenance.
operates in full condensing mode at all times, while a state of
the art temperature mixing system protects the boiler’s primary
The Turbo Pilot®: Reliability At Its Best
heat exchanger. Each Fusion carries a full non-prorated 20 year
The Futera Series independent “Turbo-Pilot” system with UV
This design also offers a larger heat transfer surface area than any
detection is far more durable and reliable than any competitive
competitive product currently available. This
ignition system available today.
translates into the highest available -efficiencies
warranty against damage from condensate or thermal shock.
There’s simply no better way to protect an owner’s investment.
– at full operating input! We challenge you to
At 8,000 btu’s the “Turbo-Pilot” provides
look closely at competing products’ efficiency
a sure-fire source for burner ignition while
data. No other water heater or boiler on the
providing continuous performance feedback
market has full input efficiencies as high as the
through the HeatNet control platform.
Fusion’s.
3
Symmetric
Air/Fuel Coupling
Fusion Series units operate safely and efficiently at all times by
reacting to changes in the air or fuel flow which can compromise
combustion. Air/Fuel coupling automatically adjusts to any changes
in the environment by reducing input levels to maintain optimum
combustion quality while providing the highest degree of safety.
Air/Fuel coupling further increases application flexibility by
allowing installation of Fusion units in areas of variable air inlet
and gas pressures without compromising safety or performance.
Advanced gas train design monitors and
regulates gas input based on combustion air pressure, which in turn provides
highly repeatable air/fuel ratio throughout the operating range.
Space-saving Footprint
The compact footprint of Futera Fusion boilers allows for multiple
boiler installations while conserving valuable boiler room space for
ease of service and maintenance access.
4
IGNITION
STATUS
FUSION
OPERATION
STATUS
BACK
SELECT
POWER
ON
OFF
Intelligence Built In
HeatNet, RBI’s proprietary integrated boiler management system,
is the driving force behind RBI’s energy optimization philosophy
for its high-efficiency equipment. HeatNet is designed for precise
system control and is standard on all Futera Series boilers.
Through continuous monitoring of several system characteristics,
including boiler temperatures, limit circuit inputs, and overall
system demands, HeatNet modulates boiler firing rates to
maximize turndown ratios to maintain peak efficiency regardless of
the load.
Versatile
In addition to maintaining peak efficiency in our stand-alone
boilers, HeatNet can operate as part of a multi-boiler Master/
inputs. Boiler firing rotations can be programmed for First On/First
Member network of up to 16 boilers, where typical Master/Member
Off, First On/Last Off or “True Rotation.” HeatNet also modulates
systems using 2, 3, 4 or 5 boiler configurations can see total
the local boiler pump for Primary/Secondary systems, ensuring
turndown ratio of 8, 10, 12, 15, 20 or even a maximum of over
optimum boiler Delta T.
28:1* depending on the number of units in the application.
Straightforward
HeatNet can also function as a boiler management system,
HeatNet’s intuitive interface, with plug-and-play connections,
incorporating a mix of both condensing and non-condensing
speeds the installation, set-up, and diagnostic process for
boilers, or in base-load applications with existing boilers,
technicians. HeatNet’s electronics are conveniently located in a
eliminating the need for costly additional third-party, wall-mounted
self-contained control enclosure, with all internal components and
control platforms.
terminal blocks easily accessible. The standard HeatNet control
uses a Modbus protocol with optional protocessor boards for
HeatNet “learns” the optimal firing rates of a given application,
BACnet- and Lon Works-based building management systems. Its
thereby determining the system’s load for maximum energy
proprietary design allows for seamless flash drive or laptop-driven
efficiency. The variable control settings for Mod/Max firing rates
updateable firmware, adding continuous value and boiler system
allow technicians to adjust the maximum firing rates, enabling
control without physical control platform updates that can make
all boilers to run at extremely efficient levels until all units in
some equipment obsolete.
the sequence have fired. HeatNet keeps the firing rate as low
as possible, taking advantage of increased efficiencies at lower
*Total turndown ratio's based on multiple units linked in a master/member
configuration controlled through HeatNet.
5
Ø10"
AIR INLET
48 7/16
(1230mm)
9 7/16
(240mm)
Fusion XLF 4000
Top View
29 1/8
(740mm)
31 1/8
(791mm)
Ø3"
SUPPLY
2" NPT
GAS TRAIN
Ø3"
INLET
69"
(1753mm)
46 13/16
(1189mm)
Ø10"
EXHAUST FLUE
39 3/16
(995mm)
24 3/8
(619mm)
15"
(381mm)
3/4" NPT DRAIN
OUTLET
CONDENSATION
DRAIN
9 11/16
(246mm)
84"
(2134mm)
14 9/16
(370mm)
3/4" NPT CONDENSATION
DRAIN OUTLET
Side View
Back View
Models
CB = Boiler
CW = Water Heater
Futera Fusion XLF — Dimensions and Ratings*
Flue Vent
Cat IV Positive (Up to 60')
Cat II
UL Listed
Stainless
PVC/PP
Size
MBH
kW
MBH
kW
Steel
Option
Negative
2500
733
2350
689
8"
8"
Common
2500
3000
879
2820
826
8"
8"
Vent
3000
3500
1026
3290
964
10"
10"
Engineered
3500
4000
1172
3760
1102
10"
10"
Systems**
4000
* Ratings reflect boilers only. For boiler efficiency information please visit www.ahridirectory.org.
** Diameters may vary based on system design.
Input
Output
Shipping
Weight
Connections
Air Intake
8"
8"
10"
10"
Gas
1½"
1½"
2"
2"
Water
3"
3"
3"
3"
Lbs
2330
2384
2614
2726
Kg
1057
1081
1186
1236
Futera Fusion XLF — Delta T/Boiler Recovery Table - Fahrenheit
Size
Inlet
Temp
(°F)
60
80
100
120
140
2500
Flow
Rate
(gph)
2794
3316
4203
5903
10457
3000
∆t
(°F)
105
85
65
45
25
Flow
Rate
(gph)
3171
3717
4617
6250
9804
3500
∆t
(°F)
111
91
71
51
32
Flow
Rate
(gph)
3700
4337
5386
7292
11438
4000
∆t
(°F)
111
91
71
51
32
Flow
Rate
(gph)
4228
4956
6156
8334
13072
∆t
(°F)
111
91
71
51
32
Futera Fusion XLF — Delta T/Boiler Recovery Table - Celsius
Size
Inlet
Temp
(°C)
16
27
38
49
60
6
2500
Flow
Rate
(l/h)
10560
12536
15886
22314
39529
3000
∆t
(°C)
58
47
36
25
14
Flow
Rate
(l/h)
11987
14051
17452
23627
37058
3500
∆t
(°C)
62
51
39
28
18
Flow
Rate
(l/h)
13984
16393
20360
27564
43234
4000
∆t
(°C)
62
51
39
28
18
Flow
Rate
(l/h)
15982
18735
23269
31502
49411
∆t
(°C)
62
51
39
28
18
19 7/8
(505mm)
Fusion 2000
Ø12" AIR INTAKE
(Ø305mm)
31 1/8
(791mm)
1 1/2 NPT
GAS TRAIN
2 1/2 NPT
SUPPLY
69"
(1753mm)
60 1/2
(1537mm)
2 1/2 NPT
INLET
50 3/4
(1289mm)
41 1/4
(1048mm)
24 7/8
(632mm)
13 3/8
(340mm)
14 9/16
(370mm)
1/2 NPT DRAIN
OUTLET
CONDENSATE DRAIN
Side View
Models
CB = Boiler
CW = Water Heater
5 9/16
(141mm)
Back View
Futera Fusion — Dimensions and Ratings*
Input
Output
Flue Vent
Cat IV Positive (Up to 60')
UL Listed
Stainless
PVC/PP
Steel
Option
7"
8"
7"
8"
7"
8"
8"
8"
8"
8"
10"
10"
10"
10"
Cat II
Shipping
Weight
Connections
Size
MBH
kW
MBH
kW
Negative
500
147
476
139
500
Common
750
220
713
209
750
Vent
1,000
293
952
279
1000
Engineered
1,250
366
1189
348
1250
Systems**
1,500
440
1430
419
1500
1,750
513
1668
489
1750
1,999
586
1904
558
2000
* Ratings reflect boilers only. For boiler efficiency information please visit www.ahridirectory.org.
** Diameters may vary based on system design.
Air Intake
8"
8"
8"
10"
10"
12"
12"
Gas
1"
1"
1-1⁄4"
1-1⁄4"
1-1⁄4"
1-1⁄2"
1-1⁄2"
Water
2"
2"
2"
2-1⁄2"
2-1⁄2"
2-1⁄2"
2-1⁄2"
Lbs
875
900
1000
1257
1350
1440
1500
Kg
397
408
454
570
612
653
680
Futera Fusion — Delta T/Boiler Recovery Table - Fahrenheit
Size
Inlet
Temp
(°F)
60
80
100
120
140
500
Flow
Rate
(gph)
614
753
999
1513
3336
750
∆t
(°F)
96
76
56
36
16
Flow
Rate
(gph)
833
998
1268
1770
3072
1000
∆t
(°F)
106
86
66
46
26
Flow
Rate
(gph)
1050
1245
1546
2083
3321
1250
∆t
(°F)
112
92
72
52
32
Flow
Rate
(gph)
1460
1768
2293
3320
6354
1500
∆t
(°F)
101
81
61
41
21
Flow
Rate
(gph)
1664
2000
2530
3532
6130
1750
∆t
(°F)
106
86
66
46
26
Flow
Rate
(gph)
1859
2205
2758
3737
6026
2000
∆t
(°F)
111
91
71
51
31
Flow
Rate
(gph)
2118
2520
3136
4247
6855
∆t
(°F)
111
91
71
51
31
Futera Fusion — Delta T/Boiler Recovery Table - Celsius
Size
Inlet
Temp
(°C)
16
27
38
49
60
500
Flow
Rate
(l/h)
2322
2846
3777
5718
12609
750
∆t
(°C)
53
42
31
20
9
Flow
Rate
(l/h)
3148
3773
4792
6690
11612
1000
∆t
(°C)
59
48
37
26
14
Flow
Rate
(l/h)
3968
4707
5844
7873
12552
1250
∆t
(°C)
62
51
40
29
18
Flow
Rate
(l/h)
5517
6683
8669
12551
24016
1500
∆t
(°C)
56
45
34
23
12
Flow
Rate
(l/h)
6289
7561
9563
13350
23172
1750
∆t
(°C)
59
48
37
26
14
Flow
Rate
(l/h)
7028
8336
10427
14126
22777
2000
∆t
(°C)
62
51
39
28
17
Flow
Rate
(l/h)
8007
9527
11852
16054
25913
∆t
(°C)
62
51
39
28
17
7
Futera Fusion Series Efficiency
(Water Heaters & Boilers)
99
97
Low
Efficiency
95
High
93
91
89
87
85
60
80
100
120
140
Return Water Temp (°F)
95.1% is AHRI Certified Product Performance Thermal Efficiency
97% Is AHRI Certified Product Performance Combustion Efficiency
Performance values based on 500MBH boiler Official AHRI Certified Performance Ratings
260 North Elm Street, Westfield, MA 01085
Tel. (413) 568-9571 Fax (413) 568-9613
7555 Tranmere Drive, Mississauga, Ontario L5S 1L4
Tel. (905) 670-5888 Fax (905) 670-5782
www.rbiwaterheaters.com