Laars FTHW User Manual

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Page 1

Installation and Operation Instructions Document 1342H

Installation and Operation Instructions for

THE

Wall-Mounted, Modulating Gas, Condensing, Heating Only, Boiler

Model FTHW

SERIES

80,000 BTU/hr 100,000 BTU/hr 120,000 BTU/hr 140,000 BTU/hr 199,000 BTU/hr

• Natural Gas (NG) - Factory Conguration

• Propane Gas (LP) - Field-Convertible

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,

qualied in hot water boiler and heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in ue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.

WARNING

If the information in this manual is not

followed exactly, a re or explosion may result causing property damage, personal

injury or loss of life.

Do not store or use gasoline or other

ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's

instructions.

• If you cannot reach your gas supplier, call the re department.

Installation and service must be performed by a qualied installer, service agency, or gas supplier.

AVERTISSEMENT

Assurez-vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inammables dans le à proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE

GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dans le bâtiment où vous vous trovez.

• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions

du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le sservice des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualié

ou par le fournisseur de gaz.

H2375000H

Page 2

SECTION 1 Product Accessories

1.1 Introduction ...................................................... 3

1.2 Included with the Unit ....................................... 3

SECTION 2 Product Characteristics

2.1 Model Nomenclature (model number) ..............4

2.2 Specications, 80 MBH and 100 MBH ............. 5

2.3 Dimensions ...................................................... 8

2.4 Names of Components .................................. 10

2.5 Product Flow Paths and Characteristics ........ 13

4.14.7 Multiple units using zones pumps

and an indirect for DHW

4.15 Pressure Relief Valve ..................................... 47

4.16 Disposal of Condensate ................................. 48

4.17 Electrical Wiring Connections ........................ 49

4.18 DIP Switches .................................................. 50

4.19 Control Board, Electrical Diagram ................. 51

4.20 Ladder Diagram ............................................. 52

4.21 Electrical Connections .................................... 53

................................ 46

SECTION 3 Safety Regulations

3.1 Safety Symbols .............................................. 14

3.2 Safety Precautions and Proper Use ............... 16

SECTION 4 Installation

NOTE: For Cascading Installations, please refer to

document 1349 ‘Cascading the FT Series Boiler’,

available online.

4.1

4.1 Location and Clearances ............................... 17

4.2 Wall Mount Bracket ........................................ 18

4.3 Combustion Air ...............................................19

4.4 Venting (Exhaust) ...........................................21

4.5 General Location Guideline ............................22

4.6 Locations for Vent Pipe Terminator ................ 23

4.6.1 Direct Venting Clearances ............................. 23

4.6.2 Venting Requirements in

the Commonwealth of Massachusetts ........... 24

4.7 Air Supply and Vent Connections ................... 26

4.7.1 Vent / Air Pipe Lengths ................................... 26

4.7.2 Direct Venting ................................................. 26

4.7.3 Indoor Combustion Air ................................... 27

4.8 Vent / Air Pipe Termination ............................. 27

4.9 Gas Supply and Piping ................................... 30

4.10 Gas Supply Pressure ..................................... 35

4.11 Gas Setup and Adjustment ............................ 36

4.12 High Altitude Installations. ........................... 37

4.13 Natural Gas to Propane Conversion ........... 38

4.14 Plumbing Guidelines ..................................42

4.14.1 External Plumbing and

Water Connection Guidelines ......................... 42

4.14.2 Applicable Backow Preventer ....................... 42

4.14.3 Diaphragm type Expansion tank .................... 42

4.14.4 Zoning with zone valve ................................... 43

4.14.5 Zoning with circulation pumps ........................ 44

4.14.6 Indirect Water Heating .................................... 45

SECTION 5 Control Display and Operation

5.1 Control Dial and Buttons ................................ 55

5.2 LCD Overview ............................................... 56

5.3 Operating Mode ............................................. 57

5.4 Setting the Clock ............................................ 58

5.5 CH Set Point Change Mode ........................... 59

5.6 Status Display Mode ...................................... 60

5.7 Installer Mode ................................................. 61

5.8 Storage Mode ................................................ 64

5.9 Outdoor Reset Adjustment ............................. 65

5.10 External Set Point Temperature Control ......... 65

5.11 Error Mode ..................................................... 66

SECTION 6 Error Codes

6.1 Error Code Table ............................................ 67

6.2 Fault Tree Analysis ........................................ 70

SECTION 7 Trouble Shooting

7.1 Diagnostics ..................................................... 72

7.2 Suggested Corrective Actions ........................ 73

SECTION 8 Maintenance

8.1 Annual startup & general maintenance .......... 75

8.2 Flushing the Boiler ......................................... 77

8.3 Freeze Protection ........................................... 77

SECTION 9 Installation Check

9.1 Quick View ..................................................... 78

9.2 Final Check Lists ............................................ 79

SECTION 10 Parts

10.1 Parts Lists & Illustrations (models 080-140) ... 80

10.2 Parts Lists & Illustrations (model 199) ............ 86

Page 3

The FT Series Heating Only, Boiler

SECTION 1 Product Accessories

1.1 Introduction

This manual provides information necessary for the installation, operation, and maintenance of the FT Series

Heating Only , Boiler. All application and installation

procedures must be read and reviewed completely before proceeding with the installation. Consult the manufacturer (see the back cover), or your local manufacturer’s representative, with any problems or questions regarding this equipment. Experience has shown that most operating problems are caused by improper installation.

1.2 Included with the Unit

Item Description Qty

Page 3

All installations must be made in accordance with

1) American National Standard Z223.1/NFPA54-Latest Edition

“National Fuel Gas Code” or

2) CSA B149.1 “Natural Gas and Propane Installation Code” and with the requirement of the local utility or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions contained herein.

All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70-latest Edition, or 2) CSA STD. C22.1 “Canadian Electrical Code - Part 1”. This appliance must be electrically grounded in accordance with these codes.

Wall Mounted Boiler

FTHW (all sizes)

Installation Instructions and

User’s Manual

Condensate Hose

Wall Mount Bracket

2 types of Wall Anchors

FT1894

Pressure Relief Valve

(CH LINE 3/4

30psi)

Model: CASH ACME F-82

Mesh Screens

3”

Page 4

1.2 Included with the Appliance (continued) Items Descriptions Qty

Propane Conversion Orice

80 / 100 / 120 / 140 MBH

O-Ring and Gasket Kit 1

Outdoor Temperature Sensor

with anchors and screws

Auto Fill Valve and Backow Preventer Valves are NOT

included (Field Supplied).

199 MBH

SECTION 2 Product Characteristics

2.1 Model Nomenclature (model number)

The Model Nomenclature is shown on your Rating Plate and consists of a series of letters and numbers ( Nomenclature ) that further identies the characteristics of your FT.

2 3 4 5 6 7 8 9 10 11 12 13

F T H W A 1 X N

SERIES

H - Heating Only

CONFIG

W - Wall Hung

SIZE

MBTU/h

80 100 120 140 199

FUEL

N - Natural P - Propane

ALTITUDE

A -

0 -10,000 Feet

REVISION

1 -

First

OPTIONS

X - Standard

MODEL NUMBER

N - with Pump

PUMP

Page 5

The FT Series Heating Only, Boiler

2.2 Specications, 80 MBH and 100 MBH

Model Name FTHW80 FTHW100

Page 5

Gas Input Rate

Installation Indoor / Wall hung type

Flue System

Vent Run 2˝(50ft*) , 3˝(100ft) Schedule 40 CPVC, PP

Orice Size

Gas Supply Pressure

Manifold Pressure

Power Supply

Ignition System

Burner System

MAX 80,000 Btu/h 100,000 Btu/h

MIN 16,000 Btu/h 20,000 Btu/h

Sealed Combustion Direct / Single Vent /Sidewall

NG 0.2”(5.05mm) 0.215˝ (5.45mm)

LP 0.157”(4.0mm) 0.169˝ (4.3mm)

NG 3.5˝ WC to 10.5˝ WC

LP 8.0˝ WC to 13.0˝ WC

Gas type LP NG

Max re

Min re

Main Supply 120V 60Hz / 4A

Maximum Power

Consumption

-0.102

WC -0.102˝ WC

0.00

WC 0.00˝ WC

Direct Electronic Ignition / Automatic Flame

Single Orice Premixed Fuel Modulation Metal

Vent

160W

Sensing

Ceramic Infrared

Gas Valve System Combination modulating (Current proportional)

Dimensions W17.3˝ - H29.0˝ – D14.9˝

Shipping Weight

Main Controller / Control Display NGTB-900CP / P-950EH

Water Pressure CH Min 15 ~ Max 30 PSI

CH Supply/Return 1 ¼˝ NPT

Connection Sizes

Gas Inlet 3/4˝ NPT

Casing Cold Rolled Carbon Steel

Materials

Heat Exchanger

Safety Devices

*Allowable 2” vent length for propane is 25’

98 lbs (44 kg)

Primary Heat Exchanger : Stainless Steel

Sub Heat Exchanger : Stainless Steel

Flame Rod, Overheat Cut Off Device, Gas Valve

Operation Detector, Water Temperature Sensor,

Over-heat Limit Switch,

Page 6

2.2 Specications, 125 MBH and 140 MBH

Model Name FTHW120 FTHW140

Gas Input Rate

Installation Indoor / Wall hung type

Flue System

Vent Run 2˝(50ft*) , 3˝(100ft) Schedule 40 CPVC, PP

Orice Size

Gas Supply Pressure

Manifold Pressure

Power Supply

Ignition System Direct Electronic Ignition / Automatic Flame Sensing

MAX 120,000 Btu/h 140,000 Btu/h

MIN 24,000 Btu/h 28,000 Btu/h

Sealed Combustion Direct / Single Vent /Sidewall

NG 0.213˝ (5.4mm) 0.255˝ (6.5mm)

LP 0.173˝ (4.4mm) 0.191˝ (4.85mm)

NG 3.5˝ WC to 10.5˝ WC

LP 8.0˝ WC to 13.0˝ WC

Gas type LP NG

Max re

Min re

Main Supply 120V 60Hz / 4A

Maximum Power

Consumption

-0.216

WC -0.216˝ WC

0.00

WC 0.00˝ WC

Vent

160W

Burner System

Gas Valve System Combination modulating (Current proportional)

Dimensions W17.3˝ - H29.0˝ – D14.9˝

Shipping Weight 102 lbs (46 kg)

Main Controller / Control Display NGTB-900CP / P-950EH

Water Pressure CH Min 15 ~ Max 30 PSI

CH Supply/Return 1 ¼˝ NPT

Connection Sizes

Gas Inlet 3/4˝ NPT

Casing Cold Rolled Carbon Steel

Materials

Heat Exchanger

Safety Devices

*Allowable 2” vent length for propane is 25’

Single Orice Premixed Fuel Modulation Metal

Ceramic Infrared

Primary Heat Exchanger : Stainless Steel

Sub Heat Exchanger : Stainless Steel

Flame Rod, Overheat Cut Off Device, Gas Valve

Operation Detector, Water Temperature Sensor,

Over-heat Limit Switch,

Page 7

The FT Series Heating Only, Boiler

2.2 Specications, 199 MBH

Model Name FTHW199

Page 7

Gas Input Rate

Installation Indoor / Wall hung type

Flue System Sealed Combustion Direct / Single Vent / Concentric Vent

Vent Run 2˝(50ft*) , 3˝(100ft) Schedule 40 CPVC, PP

Orice Size

Gas Supply Pressure

Manifold Pressure

Power Supply

Ignition System Direct Electronic Ignition / Automatic Flame Sensing

MAX 199,000 Btu/h

MIN 19,900 Btu/h

NG 0.326˝ (8.3mm)

LP 0.244˝ (6.2mm)

NG 3.5˝ WC to 10.5˝ WC

LP 8.0˝ WC to 13.0˝ WC

Gas type

Max re

Min re

Main Supply 120V 60Hz / 4A

Maximum Power

Consumption

LP NG LP NG

-0.169

WC -0.129”W.C -0.173˝ WC -0.134˝ WC

-0.015”W.C -0.015”W.C -0.015

160W

WC -0.015˝ WC

Burner System

Gas Valve System Combination modulating (Current proportional)

Dimensions W19.6˝ - H32.0˝ – D16.2˝

Shipping Weight 118 lbs (54 kg)

Main Controller / Control Display NGTB-900CP / P-950EH

Water Pressure Min 15 ~ Max 30 PSI

Connection Sizes

Materials

Safety Devices

CH Supply/Return 1 ¼˝ NPT

Gas Inlet 3/4˝ NPT

Casing Cold Rolled Carbon Steel

Heat Exchanger

Detector, Water Temperature Sensor, Over-heat Limit Switch,

*Allowable 2” vent length for propane is 25’

Single Orice Premixed Fuel Modulation Metal Ceramic

Infrared

Primary Heat Exchanger : Stainless Steel

Sub Heat Exchanger : Stainless Steel

Flame Rod, Overheat Cut Off Device, Gas Valve Operation

Page 8

2.3 Dimensions

FTHW

80/100/120/140

Heating only boiler

Description Diameter

A Air Intake Collar 3˝

B Vent Pipe Collar 3˝ C 'CH' Supply D 'CH' Return E Gas Inlet 3/4˝ F Condensate Line 1/2˝

1 1

¼˝

Page 9

The FT Series Heating Only, Boiler

2.3 Dimensions

Page 9

FTHW

Heating only boiler

199

Description Diameter

A Air Intake Collar 3˝

B Vent Pipe Collar 3˝ C 'CH' Supply D 'CH' Return E Gas Inlet 3/4˝ F Condensate Line 1/2˝

1 1

¼˝

Page 10

2.4 Names of Components

FTHW

80/100

Heating only boiler

4 SCREWS

CONTROL

DISPLAY COVER

(HINGES UPWARD)

NO Name of Component

Air Vent (air eliminator)

Air Intake Collar

Air / Gas Mixing Pipe

Gas Inlet Pipe 2

Gas Valve

Exhaust Duct

Low Water Temperature Sensor

OP Sensor

Flame Detecting Sensor

Main PCB

Control Display

Manual ON/OFF Power Switch

Gas Inlet Pipe 1

‘CH’ Internal Pump

Gas Inlet Adapter

‘CH’ Supply Adapter

To remove the cover, unthread the 4 phillips head screws. Keep the screws in a safe place for re-application of cover. This is typical for all models of the FT.

NO Name of Component

CH Pressure Gauge

‘CH’ Return Adapter

Condensate Trap

Condensate Adapter

CH Return Temperature Sensor

Condensate Air Pressure Switch

Terminal Block

Heat Exchanger

Ignition Transformer

Sight Glass

Burner Overheat Switch

Igniter

BLDC Fan (blower)

Exhaust Temperature Sensor

Air Pressure Sensor

Vent Pipe Collar

Page 11

The FT Series Heating Only, Boiler

2.4 Names of Components (continued)

Page 11

FTHW

120/140

Heating only boiler

NO Name of Component

Air Vent (air eliminator)

Air Intake Collar

Air / Gas Mixing Pipe

Gas Inlet Pipe 2

Gas Valve

Exhaust Duct

Low Water Temperature Sensor

OP Sensor

Flame Detecting Sensor

Main PCB

Control Display

Manual ON/OFF Power Switch

Gas Inlet Pipe 1

‘CH’ Internal Pump

Gas Inlet Adapter

‘CH’ Supply Adapter

NO Name of Component

CH Pressure Gauge

‘CH’ Return Adapter

Condensate Trap

Condensate Adapter

CH Return Temperature Sensor

Condensate Air Pressure Switch

Terminal Block

Heat Exchanger

Ignition Transformer

Sight Glass

Burner Overheat Switch

Igniter

BLDC Fan (blower)

Exhaust Temperature Sensor

Air Pressure Sensor

Vent Pipe Collar

Page 12

2.4 Names of Components (continued)

FTHW

Heating only boiler

199

NO Name of Component

Air Vent (air eliminator)

Air Intake Collar

Gas Valve

Gas Inlet Pipe 2

Air / Gas Mixing Pipe

Gas Inlet Pipe 1

Exhaust Duct

OP Sensor

Low Water Level Sensor

Main PCB

Flame Detecting Sensor

Control Display

Manual ON/OFF Power Switch

‘CH’ Internal Pump

Gas Inlet Adapter

‘CH’ Supply Adapter

NO Name of Component

CH Pressure Gauge

‘CH’ Return Adapter

Condensate Trap

Condensate Adapter

CH Return Temperature Sensor

Condensate Air Pressure Switch

Terminal Block

Heat Exchanger

Ignition Transformer

Sight Glass

Burner Overheat Switch

Igniter

BLDC Fan (blower)

Exhaust Temperature Sensor

Air Pressure Sensor

Vent Pipe Collar

Page 13

The FT Series Heating Only, Boiler

Gas

Input

Air Intake

2.5 Product Flow Paths and Characteristics

Water in the heating pipe is used for space heating.

Combustion

Air

Page 13

Vent

CH Supply CH Return

CH = Central Heat

Page 14

SECTION 3 Safety Regulations

3.1 Safety Symbols

WARNING

To avoid product damage, personal injury, or even

possible death, carefully read, understand, and

follow all the instructions in the Installation and

Operation manual before installation, operation

and service the Boiler.

Manufacturer cannot anticipate every circumstance that might involve a potential

hazard. Therefore, all possible incidents are not included in our warnings. Proper installation, operation, and service are your responsibility. You must make sure that the operation and

settings of the Boiler are safe for you and for

others.

This manual provides Safety Symbols. When the user fails to adhere to the following requirement, it may cause death, serious injury, and substantial property damage.

For safety symbols, ‘DANGER’, ‘WARNING’, CAUTION’ are indicated and the denitions for these terms are as follow:

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

WARNING

FOR YOUR SAFETY READ BEFORE OPERATING

If you do not follow these instructions exactly, a re or explosion could result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It

is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the oor because some gas is heavier than air and will settle on the oor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the

re department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualied service technician. Force or attempted repair may result in a re or explosion.

D. Do not use this appliance if any part has

been under water. Immediately call a qualied

service technician to inspect the appliance and to replace any part of the control system and

any gas control which has been under water.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices and hazards involving only property damage.

WARNING

Cancer and Reproductive Harm.

www.P65WARNINGS.CA.GOV.

as required by the state of California Proposition 65.

This appliance must be installed in accordance with local codes if any; if not, follow ANSI Z224.1/NFPA 54 or CAN/CSA B149.1, Natural Gas and Propane Installation Code, as applicable.

This appliance is certied for use at altitudes up to 4,500ft(1,370m) in accordance to the latest CSA/ CGA 2.17-M91 Gas-Fired Appliances for Use at High Altitudes.

Page 15

The FT Series Heating Only, Boiler

DANGER

Vapors from ammable liquids will explode and

catch on re. These will cause death or severe burns.

Do not use or store ammable products such as

gasoline, solvents or adhesives in the same room

or area near the appliance.

Keep ammable products

Far away from boiler

In approved containers Tightly closed

Out of children’s reach

Vapors

Cannot be seen are heavier than air

spread on the oor

Can spread from other rooms to the main burner

by air currents

Do not install the appliance where ammable products will be stored. Read and follow boiler warnings and instructions thoroughly. If owner’s manual is missing, contact the retailer or manufacturer.

This boiler must be installed by a qualied plumber,

a licensed gas tter, and/or a professional service technician.

Improper installation and/or operation will cause a

potentially hazardous situation, such as serious injury or death. Also, it will void the warranty.

• The National Fuel Gas Code NFPA 54 / ANSI Z224.1

• National Electric Code ANSI/NEPA 70

• All applicable local, state, national and provincial codes, regulations and laws.

Proper care is your responsibility. Carefully read and

understand the Operating Information in this manual

before operating the Manufacturer Boiler.

Be aware of the location of the gas shut-off valve

and operation method. Close the gas shut-off valve immediately if the appliance is subjected to re, overheating, ood, physical damage, or any other

Page 15

damaging condition that might affect the operation

of the unit. Boiler must be checked by a qualied technician before resuming operation.

DO NOT use this Boiler if any part has been under

water. Immediately call a qualied technician for

inspecting the Boiler and replacing any part of the

control system and gas control which have been under water.

Do not power up the unit until the gas and water

supply valves are fully opened. Make sure that the fresh air intake port and exhaust gas port are opened and functional.

DO NOT attempt to install, repair, or service this

Boiler by yourself. Do not change any part of the Boiler. Contact a qualied technician if the Boiler needs

repair or maintenance. Ask your gas supplier for a list of qualied service providers.

DO NOT use spray paint, hair spray, or any other

ammable spray near Boiler or near the exterior fresh

air inlet port. DO NOT place any items in or around

the exterior exhaust gas outlet port and/or fresh air

inlet port. These could restrict or block the ow in or

out of the vent system.

“Caution: While repairing control, all wires are

labeled. You must connect the wires in accordance

with the instruction.

Wiring errors can cause improper and dangerous

operation.

“Verify proper operation after servicing operation”

This consists of the gas ignition system components

which are protected from water (dripping, spraying, rain,

etc.) during operation and service (circulator replacement,

condensate trap, control replacement, etc.).

After installing the heater, safety devices must be

tested.

This boiler is equipped with a blocked vent shutoff

system.

If the error code ‘41’ occurs, follow the instructions below.

- First, turn off the manual gas valve.

- Make sure that there is no foreign object in the vent passage or rodent screen.

- If you do not nd any problem, do the following.

- Turn off the error state by pressing the power button of Control Display.

- If the error occurs repeatedly, call your service

technician or gas supplier.

Page 16

3.2 Safety Precautions and Proper Use

Before Operation

1. Check the Gas Type (NG/LP) When using or moving the unit for the rst time, check if gas type matches with the gas type of the Boiler. Check whether the gas type which is supplied is NG (Natural Gas) or LP (Propane) and also check the Boiler gas type.

The gas type is indicated on the rating plate on side of

the Boiler.

2. Check the Power (120V 60Hz) Check that the appliance is connected properly.

3. Check the Cold Water

Inlet valve

Please keep the

appliance water

inlet valve open

at all times. The appliance will not ignite when insufcient water or no water is in the heating pipes. (valve: always open position)

open

When in Operation

1. Caution for Gas leak Frequently check for a gas leak at the gas connection portion with soapy water.

Steps to take if you have a Gas leak.

1. Shut down the boiler as soon as gas fumes are detected.

2. Close the intermediate gas valve.

3. Open windows for ventilation.

4. Call a qualied service technician for immediate repair.

2. Caution for Ventilation

Make sure that there is sufcient inow and outow of air ventilation while using the unit.

If the ventilation is improper, combustion quality may deteriorate inside the appliance and cause shortened life

of the appliance.

3. Burn Warning

Be careful not to burn yourself on the ue or pipes. They become extremely hot during operation.

CAUTION

4. Check the Gas Valve

Check that the manual gas shut-off valve

that supplies the FT is opened.

5. Check the area around the appliance and remove any combustible or ammable materials. Remove

laundry or any other items that are on or near the

boiler or vent pipe.

Carbon monoxide poisoning

If vent pipe fumes enter the room, it could cause

poisoning by carbon monoxide gas. Check that the vent pipes are properly connected. Open windows for ventilation. Call a qualied service technician for immediate repair.

Gas leakage test.

Gas supply line must be inspected regularly.

WARNING

Do not use the appliance for any other purpose other

than for residential hydronic heating. Do not store combustibles or ammable material such as gasoline near the appliance. Do not store other items on or near this boiler. Do not store combustible (ammable) materials such as

papers.

Do not hang clothes on the vent pipe. This may start a

re.

Do not shut off the Boiler.

When you leave home for a long time, do not shut off

Boiler. The Boiler has a freeze protection function. The ceramic heater is installed inside of the heater’s internal pipe to protect the heater from freezing.

Do not wipe the appliance or Control Display

with wet cloth. Electric shock may occur, or internal

parts may fail due to the exposure to moisture.

Do not disassemble the Boiler.

If repair is required, call your local qualied technician.

Page 17

The FT Series Heating Only, Boiler

SECTION 4 Installation

Page 17

NOTE: For Cascading Installations, please refer

to document 1349 ‘Cascading the FT Series

Boiler’, available online.

4.1 Location and Clearances

The FT must be mounted to a suitable wall by a qualied heating contractor under the guidelines of a boiler. The wall may be of concrete or wood. Suitable fasteners for concrete or wood must be used. Failure to wall mount this boiler using correct fasteners will affect

the performance and life expectancy of the boiler and

will void the warranty.

WARNING

Installations must comply with

• All the local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – The latest version.

• National Electrical Code.

• A National Standard of Canada CAN/CSA-B149.1

Check before placing the Boiler

• Always check the connected components which are near to the heater. The components are below.

Water piping position / Venting adapter / Gas supply

piping / Electrical power / Condensate drain hose.

• Inspect area around Boiler. Remove any combustible materials, gasoline and other ammable liquids. Failure to keep Boiler area clear and free of combustible materials, gasoline and other ammable

liquids and vapors can result in severe personal

injury, death or substantial property damage.

• The Boiler which has gas control system

components must be protected from any possible

danger during operation and service.

• If new Boiler replaces an existing appliance, check

and correct system problems, for example:

- Do not install if: System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

Provide clearances

• If the heater was installed in a narrow space or corner, please ensure that there is sufcient space for service and maintenance access. For regular maintenance, gas and water lines must be accessible.

The boiler must be installed on a wall that can bear its weight.

Minimum clearances to Combustibles.

For installation from

Non-Combustibles and Combustibles

Suggested Service

Clearance

TOP of appliance 18 in (46 cm) 18 in (46 cm)

BACK of appliance 0 in (0 cm) 0 in (0 cm)

FRONT of appliance 24 in (60 cm) 40 in (101 cm)

SIDE of appliance 3 in (7 cm) 8 in (20 cm)

BOTTOM of appliance 12 in (30 cm) 24 in (61 cm)

Table 1. Minimum Clearances

WARNING

CLEARANCES FOR SERVICE ACCESS

• If you do not provide the minimum clearances

shown, it might not be possible to service the boiler without removing it from the space.

• Space must be provided with combustion / ventilation air openings correctly sized for

all other appliances located in the same

space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

to Combustibles and for Service.

Page 18

4.2 Wall Mount Bracket

4.2.2 The installation height and location

for your FT depends on your installation scenario. With all

clearances considered, and given adequate positioning for

air supply and venting, you will need to determine the best position to mount the Wall Mount Bracket. The wall must be concrete, wood, or plywood over studs, and must be

strong enough to hold the boiler!

• Start by familiarizing yourself to how the included Wall Mount Bracket hooks underneath the two Hangers that are attached to the back of the boiler. The ‘hooks’ of the Wall Mount Bracket will be 3” from the Top of the boiler once the boiler is hung.

• Position the Wall Mount Bracket at the location that it will go, being sure that it is level, and then drill 4 holes (0.47”dia) with a 1/2” drill bit, into the wall through the Bracket.

• If mounting to a concrete wall, then use the concrete anchors. If onto wood or 5/8” (16 mm) plywood, then use the wood screws. Do not hang the FT onto sheetrock unless

it is possible to fasten directly

into the structural studs. If the

included anchors do not suit your installation, you must use

‘Field Supplied’ anchors that are appropriate for the wall’s construction.

Bolts (4)

Anchors

(4)

Wall Mount

Bracket

3" to Top of Unit

Concrete, Wood,

or 5/8" Plywood

Wall Mount

Bracket

Hangers (2)

(fastened to the back of unit)

4.2.1 Hang the Boiler

• Lift the boiler up, align the Hangers on the back of the boiler with the hooks on the Wall Mount Bracket, and hang the boiler onto the Wall Mount Bracket. Do a visual inspection to make sure that the boiler is hanging properly onto the hooks of the Wall Mount Bracket.

• Fasten the bottom of the boiler to the wall using 2 suitable wall anchors (eld supplied).

Page 19

The FT Series Heating Only, Boiler

4.3 Combustion Air

Page 19

FT boilers must have provisions for combustion

and ventilation air in accordance with the applicable requirements for Combustion Air Supply and Ventilation in the National Fuel Gas Code, ANSI Z223 1; or in

Canada, the Natural Gas and Propane Installation Code,

CSA B149.1. All applicable provisions of local building codes must also be adhered to.

A FT unit can take combustion air from the space in which it is installed, or the combustion air can be ducted directly to the unit. Ventilation air must be provided in either case.

4.3.1 Combustion Air from Room

In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow.

Where ducts are used, they shall be of the same cross-

sectional area as the free area of the openings to which they connect.

Method 1: Two permanent openings, one commencing

within 12” (300mm) of the top and one commencing within 12” (300mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when

communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1

square inch per 4000 Btu/hr (550 square mm/kW) of total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts,

each opening shall have a minimum free area of not

less than 1 square inch per 2000 Btu/hr (1100 square mm/kW) of total input rating of all equipment in the enclosure.

Method 2: One permanent opening, commencing

within 12” (300mm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall

have a minimum free area of 1 square inch per 3000

Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure. This opening

must not be less than the sum of the areas of all vent

connectors in the conned space.

Other methods of introducing combustion and ventilation air are acceptable, providing they conform to

the requirements in the applicable codes listed above.

In Canada, consult local building and safety codes or, in

absence of such requirements, follow CAN/CGA B149.1

4.3.2 Ducted Combustion Air

The combustion air can be taken through the wall, or through the roof. When taken from the wall, it must be taken from out-of-doors by means of the Manufacturer horizontal wall terminal. When taken from the roof, a eld-supplied rain cap or an elbow arrangement must be used to prevent entry of rain water.

Use ABS, PVC, CPVC, polypropylene, or galvanized pipe for the combustion air intake. Route the intake to the boiler as directly as possible. Seal all joints. Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. Maximum

linear pipe length allowed is shown in Table 5. Subtract

5 allowable linear ft. (1.5m) for every elbow used.

The connection for the intake air pipe is at the top of the unit.

In addition to air needed for combustion, air shall also be supplied for ventilation, including air required for

comfort and proper working conditions for personnel.

COMBUSTION AIR INSTALLATION STANDARDS

MATERIAL UNITED STATES CANADA ABS ANSI/ASTM D1527 PVC, sch 40 ANSI/ASTM D1785 or D2665 Air pipe material must be chosen CPVC, sch 40 ANSI/ASTM F441 CPVC, sch 40, ANSI/ASTM, Polypropylene

Polypropylene UL1738, ULC S636. based upon the intended application of the boiler. Single wall galv. steel 26 gauge

Table 2. Required Combustion Air Pipe Material.

Page 20

The instructions for the installation of the venting

system shall specify that the horizontal portions of

the venting system shall be supported to prevent

sagging; the methods of and intervals for support shall be specied. These instructions shall also

specify that the venting system:

Category I, II and IV boilers must be installed so that horizontal sections have a slope of at least ¼ inch per foot (21 mm/m) to prevent accumulation of

condensate; and

For Category II and IV boilers, where necessary, have means provided for drainage of condensate.

NOTICE

CAUTION

The FT is standard as a Natural Gas Boiler and

must be converted if propane is the desired gas, unless

specically manufactured for propane.

Adequate drainage

• The appliance should be installed not to damage

the adjacent area. If such locations cannot be

avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the

appliance. The pan must not block combustion air ow.

Les instructions d'installation du système d'évacuation doivent préciser que les sections

horizontales doivent être supportées pour prévenir le échissement. Les méthodes et les intervalles de support doivent être spéciés. Les instructions

doivent aussi indiquer les renseignements suivants:

les chaudières de catégories I, II et IV doivent présenter des tronçons horizontaux dont la pente montante est d'au moins ¼ po par pied (21 mm/m) entre la chaudière et l'évent; les chaudières de catégories II et IV doivent être installées de façon à empêcher l'accumulation de condensat;

et si nécessaire, les chaudières de catégories II et IV doivent être pourvues de dispositifs d'évacuation du condensat.

AVIS

Connecting the Water Supply

• To conserve water and energy, insulate all water piping—especially the hot and recirculation water lines. Never cover the drain or pressure relief valve.

Having a backow preventer in the cold water

supply line will prevent thermal expansion backow. Contact the water supplier or local plumbing inspector for information about how to control this situation.

If overheating occurs or the gas supply fails to shut

off, turn off the manual gas valve.

This installation must conform with below section

• “Air for Combustion and Ventilation” of the National Fuel Gas Code, ANSI Z224.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Page 21

The FT Series Heating Only, Boiler

4.4 Venting, Exhaust

Page 21

DO NOT COMMON VENT FT UNITS.

never permitted to share a vent with

Category I appliances.

For Cascading Installations, please refer to

document 1349 ‘Cascading the FT Series Boiler’,

The ue temperature of the FT changes dramatically with changes in operating water temperature. Therefore, it is necessary to assess the application of the boiler to determine the required certied vent class. If the FT is installed in an application where the ambient temperature is elevated, and/or installed in a closet/alcove, CPVC, polypropylene, or stainless steel material is required. If the system temperatures

are unknown at the time of installation, stainless,

polypropylene or CPVC material is recommended.

The FT is a Category IV appliance and may be installed with PVC, CPVC or polypropylene that complies with

ULC-S636, ANSI/ASTM D1785 F441 (see Table 3) or

a stainless steel venting system that complies with UL

1738 Standard and ULC S636.

Failure to use the appropriate vent material, installation

techniques, glues/sealants could lead to vent failure causing property damage, personal injury or death.

All venting must be installed according to this manual

and any other applicable local codes, including but not

limited to, ANSI Z224.1/NFPA 54, CAN/CSA B149.1 and ULC-S636. Failure to follow this manual and

applicable codes may lead to property damage, severe

injury, or death.

NOTICE

available online.

WARNING

FT units are

NE PAS ÉVENT COMMUNE FT UNITÉS.

unités ne sont jamais autorisés à partager un évent Catégorie I avec les appareils.

AVIS

___________________________________________

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in non-metallic

venting systems is prohibited and covering non-

metallic vent pipe and ttings with thermal insulation is

prohibited.

_________________________________________

INSTALLATIONS IN CANADA require the use of

venting material certied to ULCS636. All Gas vents connected to the FT, plastic, stainless steel or otherwise must be certied to this ULC standard. Appropriate selection of vent material is very important for proper performance and safe operation of the FT.

The ue temperature of the FT changes dramatically with changes in operating water temperature. Therefore, it is necessary to assess the application of the boiler to determine the required certied vent class. If the FT is installed in an application where the outlet water temperature exceeds 145°F, and/or installed in a closet, class IIB or higher vent material is required. If the system temperatures are unknown at the time of installation, class IIB or higher venting material is

recommended. IN CANADA all venting used must meet the

following requirements:

1. ULC-S636 certied and marked

2. The rst 3 feet of venting must be accessible for visual inspection.

3. All components used in the vent system must

WARNING

VENTING INSTALLATION STANDARDS

MATERIAL UNITED STATES CANADA Stainless Steel UL 1738 Venting must be ULC-S636 certied for use as PVC, sch 40 ANSI/ASTM D1785 venting material. The venting material must be chosen

CPVC, sch 40 ANSI/ASTM F441 based upon the intended application of the boiler. Polypropylene UL1738 or ULC-S636

Table 3. Required Exhaust Vent Material.

Page 22

4.4 Venting, Exhaust (continued)

be from a certied manufacturer.

4 . Vent system components must not be mixed

with alternate manufacturers certied components and/or unlisted components.

5 . The venting must be installed according

to the vent manufacturers installation

instructions.

The unit’s vent can terminate through the roof, or through an outside wall.

Vent pipe must pitch upward, toward the vent terminal, not less than 1/4” per foot, so that condensate will run back to the FT to drain. Route vent pipe to the heater as directly as possible. Seal all joints and provide adequate hangers as required in the venting system manufacturer’s Installation Instructions. Horizontal portions of the venting

system must be supported to prevent sagging and

may not have any low sections that could trap condensate. The unit must not support the weight of the vent pipe.

WARNING

Failure to vent this Boiler in accordance with

these instructions could cause a re, resulting in severe property damage, personal injury or death.

Do not interchange vent systems or materials

unless it is specied.

The use of thermal insulation covering pipe and

ttings is prohibited.

Do not apply an electric damper, draft hood or

vent damper with this Boiler.

Do not locate vent termination where exposed

to prevailing winds. Moisture and ice may fall on surface around vent termination. To prevent

deterioration, surface must be in good repair

(sealed, painted, etc.).

4.5 General Location Guideline

1. Vent system installation must be in accordance with Local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z224.1 /NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

2. The Boiler is designed to be installed as a Direct Vent (sealed combustion) type. The air for

combustion must be supplied directly from the

outside to the burner. Also, the ue gases must be vented directly to the outdoors (through wall or roof).

3. Do not install venting system components on the exterior of building except as specically required by

these instructions

- Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.

- Maintain the correct clearance and orientation

between the vent and air intake terminals.

The vent and air intake terminals must be at the

same height and their center lines must be spaced

apart 12˝ minimum.

- The bottom of the vent and air intake terminal must

be at least 12˝ above the normal snow line. In no case should they be less than 12˝ above grade level.

- Do not install the vent terminal directly over

windows or doors.

- Air intake terminal must not terminate in areas that

might contain combustion air contaminates, such

as near swimming pools.

- For sidewall venting, the minimum horizontal distance between any adjacent individual Module (Boiler) vent terminations is twelve (12) inches. It

is better to be far more than 12 inches for avoiding

frost damage to building surfaces where vent terminations are placed.

- The minimum horizontal distance between any adjacent individual module (boiler) roof vent endpiece is one (1) foot.

Page 23

The FT Series Heating Only, Boiler

4.6 Locations for Vent Pipe Terminator

4.6.1 Direct Venting Clearances

Page 23

U.S. Installations (see note 1) Canadian Installations (see note 2)

A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony See note 6 See note 6

B= Clearance to window or door that may be Direct vent only: 12 inches (30cm); 36 inches (91 cm) opened Other than Direct vent: 4 ft (1.2m) below or to NT 80 only - 12 inches (30 cm)

side of opening; 1 ft (30cm) above opening

C= Clearance to permanently closed window See note 4 See note 5 D= Vertical clearance to ventilated soft located

above the terminal within a horizontal See note 4 See note 5 distance of 2 feet (61cm) from the center line of the terminal

E= Clearance to unventilated soft See note 4 See note 5 F= Clearance to outside corner See note 4 See note 5 G= Clearance to inside corner See note 4 See note 5 H= Clearance to each side of center line 3 feet (91 cm) within a height 15 feet

extended above meter/regulator assembly See note 4 above the meter/regulator assembly

I= Clearance to service regulator vent outlet See note 4 3 feet (91 cm) J= Clearance to nonmechanical air supply Direct vent only: 12” (30cm) 80-285; 36” (91cm)

inlet to building or the combustion air inlet 399-850. Other than Direct vent: 4 ft (1.2m) below 36 inches (91 cm) to any other appliance or to side of opening; 1 ft (30cm) above opening NT 80 only - 12 inches (30 cm)

K= Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m) 6 feet (1.83 m)

horizontally

L= Clearance above paved sidewalk or paved Vent termination not allowed in this location 7 ft (2.1 m) driveway located on public property for category IV appliances. See note 5

M= Clearance under veranda, porch, deck, See note 4 12 inches (30 cm) (see note 3)

or balcony

Notes:

1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.

2. In accordance with the current CAN/CSA-B149.1 Installation Codes.

3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.

4. For clearances not specied in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of the gas supplier.

5. For clearances not specied in CAN/CSA-B149, clearance is in accordance with local installation codes and the requirements of the gas supplier.

6. IMPORTANT: Terminal must be placed such that it remains a minimum 12” above expected snow line. Local codes may have more specic requirements, and must be consulted.

Table 4. Direct Vent Clearances

Page 24

4.6.2 Venting Requirements in the Commonwealth of Massachusetts

In Massachusetts the following items are required if the side-wall exhaust vent termination is less than seven (7) feet above nished grade in the area of the venting, including but not limited to decks and porches. From Massachusetts Rules and

regulations 248 CMR 5.08

1. Installation of Carbon Monoxide Detectors

At the time of installation of the side wall

vented gas fueled appliance, the installing plumber

or gastter shall observe that a hard-wired carbon monoxide detector with an alarm battery back-up is installed on the oor level where the gas appliance is to be installed. In addition, the installing plumber or gastter shall observe that a battery operated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontally vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualied licensed professionals for installation of hard-wired carbon monoxide detectors.

a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide with alarm and battery back-up may be installed on the next adjacent oor level.

b. In the event that the requirements of the

subdivision cannot be met at the time of completion

of installation, the owner shall have a period of thirty (30) days to comply with the above requirements, provided, however, that during said thirty (30) day

period, a battery operated carbon monoxide detector

with an alarm be installed.

2. Approved Carbon Monoxide Detectors

Each carbon monoxide detector shall comply

with NFPA 720 and be ANSI/UL 2034 listed and IAS certied.

3. Signage. A metal or plastic identication plate

shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet

above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print no less than one-half (1/2) inch in size: “GAS VENT DIRECTLY BELOW, KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. Inspection The state or local gas inspector of

the side-wall horizontally vented gas fueled appliance

shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide

detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1-4.

Page 25

The FT Series Heating Only, Boiler

Page 25

DO NOT COMMON VENT FT UNITS.

NOTICE

FT units

are never permitted to share a vent with Category I appliances.

Common Vent Test

NOTE: This section does not describe a method for

common venting FT units. It describes what must

be done when an existing unit is removed from a common vent system.

At the 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 Not Used openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch 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 exhausts, so they will operate at maximum speed.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance will operate continuously.

5. Operate the main burner for 5 minutes then, determine if the cut-draw overows to the discharge opening. Use the ame of a match or a candle or the smoke of a cigarette, a cigar or

a pipe

6. Once it has been determined, according to the method

indicated above, that each device connected to the drainage

system is placed in the open air in an adequate manner. Install the doors and windows, fans, the registers of chimneys

and gas appliances to their original position

7. Any malfunction of the venting system should be corrected so

that the installation conforms to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 and (or) the installation codes CAN/ CSA-B149.1. If the size of a section of the evacuation system must be changed, the system should be modied to comply with the minimum values of the relevant tables of appendix F of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and (or) the installation codes CAN/CSA-B149.1

NOTICE

NE PAS ÉVENT COMMUNE FT UNITÉS.

AVIS

FT unités

ne sont jamais autorisés à partager un évent Catégorie I avec les appareils.

Au moment du retrait d'une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé

au système d'évacuation commun et qui fonctionne alors que

d'autres appareils toujours raccordés au système d'évacuation ne

fonctionnent pas:

1. Sceller toutes les ouvertures non utilisées du système d'évacuation.

2. Inspecter de façon visuelle le système d'évacuation pour déterminer la grosseur et l'inclinaison horizontale qui conviennent

et s'assurer que le système est exempt d'obstruction, d'étranglement, de fuite, de corrosion et autres défaillances qui

pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l'espace où les appareils toujours raccordés au système d'évacuation sont installés et les autres espaces du bâtiment. Mettre en marche

les sécheuses, tous les appareils non raccordés au système d'évacuation commun et tous les ventilateurs d'extraction comme

les hottes de cuisinière et les ventilateurs des salles de bain. S'assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d'été. Fermer les registres des cheminées.

4. Mettre l'appareil inspecté en marche. Suivre les instructions d'allumage. Régler le thermostat de façon que l'appareil fonctionne de façon continue.

5. Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l'ouverture de décharge. Utiliser la amme d'une allumette ou d'une chandelle ou la fumée d'une cigarette, d'un cigare ou d'une pipe.

6. Une fois qu'il a été déterminé, selon la méthode indiquée ci-

dessus, que chaque appareil raccordé au système d'évacuation

est mis à l'air libre de façon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

7. Tout mauvais fonctionnement du système d'évacuation commun devrait être corrigé de façon que l'installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d'installation CAN/CSA-B149.1. Si la grosseur d'une section du système d'évacuation doit être modiée, le système devrait être modié pour respecter les valeurs minimales des tableaux pertinents de l'appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) les codes d'installation CAN/CSA-B149.1

AVIS

Page 26

4.7 Air Supply and Vent Connections

4.7.1 Vent / Air Pipe Lengths

Boiler model

FTHW (all sizes)

Table 5. Maximum Vent / Air Pipe Lengths for either 3” or 2 “ Pipes

NOTE: For each elbow, reduce the maximum allowable length

• 5 feet (1.5M) for each 3-inch 90-degree elbow

• 2.5 feet (0.75M) for each 3-inch 45-degree elbow

• 8 feet (2.4M) for each 2-inch 90-degree elbow

• 4 feet (1.2M) for each 2-inch 45-degree elbow

• Max 6 elbows for 3” vent, Max 4 elbows for 2” vent

NOTE: The FT is factory set to operate

using 3” piping for Intake and Vent. For

3” Pipe vent, the default setting for DIP

4 is ON. If your installation is using a 2” vent pipe, DIP Switch 4 must be in the

OFF position. Refer to Section 4:18

3˝ Combustion Air / Vent Pipe 2˝ Combustion Air / Vent Pipe

Max

100´ (30M)

50´

Propane models are limited to 25

equivalent feet of 2” vent

WARNING

• Use of cellular core CPVC, or Radel (polyphenolsulfone) in venting systems is prohibited.

• Covering non-metallic vent pipe and ttings with thermal insulation is prohibited.

• Do not obstruct the ow of combustion and ventilated air.

Max

(15M*)

4.7.2 Direct Venting

The FT boiler can use 3˝ or 2˝ diameter exhaust and 3˝ or 2˝ diameter intake air ducts. To ensure the draw of air directly from and exhaust of air directly

to the outside of the building, create an airtight seal

from the boiler collar to the vent termination.

(For installations in Canada) eld-supplied plastic vent piping must comply with CAN/CSA B149.1 (latest edition) and be certied by the Standard For Type BH Gas Venting Systems, ULC-S636.

Components of this listed system must not be

interchanged with other vent systems or unlisted pipes or ttings. All plastic components and specied primers and glues of the certied vent

system must be from a single system manufacturer

and must not be intermixed with another system manufacturer’s parts.

Tightening — Boiler Collar (Socket) to Vent

Pipe & Inlet Pipe

- Clean and dry your selected PVC, CPVC vent pipe and Manufacturer Boiler collar (socket).

- You can select to the size of vent pipe(2˝ & 3˝), according to the installation conditions.

- Push the pipe into the collar (socket) until it touches the bottom of the socket tting.

- For 2” installations, install a eld supplied 3” to 2” adaptor. Adaptor must be installed in vertical section of piping only.

3” pipe

2” pipe connected, using an adapter

3” to 2” adapter

is NOT included.

Page 27

The FT Series Heating Only, Boiler

4.7.3 Indoor Combustion Air

Read and Follow Sections 4.3 Guidelines First.

1. Insert the termination end cap into the intake air duct.

2. Provide two openings to allow for circulation of combustion air as specied by ANSI Z224.1/NFPA 54. In Canada refer to CAN/CSA B-149.1

NOTE: The FT needs fresh air for safe operation and must

be installed so there are provisions for adequate

combustion and ventilation air.

Model FTHW80 FTHW100 FTHW120 FTHW140 FTHW199

Maximum Input (BTU/H) 80,000 100,000 120,000 140,000 199,000

Page 27

Indoor make up air is provided,

a minimum free area of 1 in2

per 1,000 BTU/H

80 in

13 1/4˝

(W) x 13 1/4˝ (H)

100 in

13 1/4˝

(W) x 13 1/4˝ (H)

120 in

13 1/4˝

(W) x 13 1/4˝ (H)

140 in

13 1/4˝

(W) x 13 1/4˝ (H)

199 in

13 1/4˝

(W) x 13 1/4˝ (H)

Table 6. Adequate Free Area

4.8 Vent / Air Pipe Termination

All Terminations:

• After connecting terminals, install vent screens on both the vent and air inlet.

Two 3” vent screens are included with each unit. Additional replacement screens are available for purchase.

2” Vent Screen P/N - FT1508 3” Vent Screen P/N - FT1730

Vertical Vent Termination

• Direct Vent - Vertical Terminations with Sloped Roof

Vent Screens

are required

Page 28

SIDE VIEW

FRONT VIEW

Exhaust Screen

12” MIN

1” MIN

Exhaust

Combustion

Intake

Air Intake Screen

Exterior Wall

NOTE: Must be 12”

Minimum distance

above highest anticipated snow level or grade, whichever is

greater (TYP).

NOTE: The Exhaust must

be equal to or above the

Combustion Intake while at

a Minimum of 12” apart.

12” MIN

Apart

Exhaust

90o Elbow

Exhaust Screen

Exhaust

12” MIN

1” MIN

Sill

Combustion

Intake

Combustion

Intake

SIDE VIEWFRONT VIEW

Exterior Wall

NOTE: Must be 12”

Minimum distance

above highest anticipated snow level or grade, whichever is

greater (TYP).

12” MIN

12”

MIN

Exhaust Screen

Exhaust

12” MIN

1” MIN

Sill

Combustion

Intake

Combustion

Intake

SIDE VIEWFRONT VIEW

Air Intake Screen

90o Elbow

Exterior Wall

12”

NOTE: Must be 12”

Minimum distance

above highest anticipated snow level or grade, whichever is

greater (TYP).

Exhaust

MIN

Horizontal Vent Termination

• Direct Vent - Sidewall Termination

4.8 Vent / Air Pipe Termination (continued)

Vent Screens are required

Vent Screens

are required

Vent

Screens are

required

Page 29

The FT Series Heating Only, Boiler

• Direct Vent - Optional Side wall Terminations

4. Concentric Vent Termination

• Direct Vent - Optional Horizontal and Vertical Concentric Vent

12” (30cm) Minimum

clearance above

highest anticipate

snow level.

Vent

12” Minimum clearance

above highest anticipated

snow level or grade,

whichever is greater.

Side Wall Kit

(2” or 3”)

Exterior Wall

Exhaust

Combustion Air

12” Minimum clearance

above highest anticipated

snow level or grade,

whichever is greater.

Side Wall Kit

(2” or 3”)

Exterior Wall

Exhaust

Concentric Vent Termination

• Direct Vent - Optional Horizontal

and Vertical Concentric Vent

Page 29

Exterior Wall

1" (25mm) to

12” Minimum clearance

above highest anticipated

snow level or grade, whichever

4" (100mm)

is greater.

Strap

Side Wall Kit

(2” or 3”)

12” Minimum clearance

above highest anticipated

snow level or grade,

whichever is greater.

Combustion Air

Vent

Exhaust

12” (30cm) Minimum

clearance above

highest anticipate

snow level.

Vent

Combustion Air

Page 30

4.9 Gas Supply and Piping

Gas piping should be supported by suitable hangers or

oor stands, not the appliance.

Review the following instructions before proceeding with the installation.

1. Verify that the appliance is tted for the proper type of gas by checking the rating plate. FT will function

properly at elevations up to 10,000 feet

(3050 m). Refer to Section 4.12 for High Altitude Settings.

2. For minimum and maximum gas supply pressures. See Section 2.2 on page 5

3. Refer to Table 7, Table 8 and Table 9 to size piping.

4. Run gas supply line in accordance with all applicable codes.

5. Locate and install manual shutoff valves in accordance with state and local requirements.

6. A sediment trap must be provided upstream of the gas controls.

7. All threaded joints should be coated with piping compound resistant to action of liqueed petroleum gas.

8. The appliance and its individual shutoff valve

must be disconnected from the gas supply piping during any pressure testing of that system at test

pressures in excess of 1/2 PSIG (3.45kPa).

9. The unit must be isolated from the gas supply

system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than

1/2 PSIG (3.45kPa).

10. The appliance and its gas connection must be leak tested before placing it in operation.

11. Purge all air from gas lines.

CAUTION

PRV (included) must be installed immediately at the

top of boiler outlet to PRV, with no valves between.

Refer to Section 4.15

__________________________________________

WARNING:

Open ame can cause gas to ignite and result in property damage, severe injury, or loss of life.

NOTE: The FT appliance and all other gas appliances

sharing the gas supply line must be ring at maximum capacity to properly measure the inlet supply pressure.

The pressure can be measured at the supply pressure

port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line.

SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY

NOMINAL PIPE SIZE @ 11" W.C. INLET AND 0.5" W.C. PRESSURE DROP

SIZE 1/2" 3/4" 1"

LENGTH MAXIMUM CAPACITY IN THOUSANDS OF BTU PER HOUR

20 200 418 787 40 137 287 541 60 - 231 434 80 - 197 372 100 - 175 330

NOTES: 1. Follow all local and national propane gas codes for line sizing and equipment requirements. 2. Verify that inlet gas pressure remains between 4 and 13 inches of water column before and during operation.

Source: ANSI Z223.1-80 National Fuel Gas Code.

UNDILUTED PROPANE

Table 7. Nominal Pipe Size, Propane

SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY NATURAL GAS

NOMINAL PIPE SIZE @ 0.30" W.C. PRESSURE DROP

LENGTH 3/4" 1"

FT CUBIC FEET OF GAS PER HOUR

20 190 350 40 130 245 60 105 195 80 90 170 100

Table 8. Nominal Pipe Size, Natural Gas

ATTENTION

PRV (inclus) doit être installé immédiatement en haut de la chaudière sortie de PRV, sans les vannes entre. Se reporter à la Section 4.15

__________________________________________

EQUIVALENT LENGTHS OF STRAIGHT PIPE FOR TYPICAL SCH 40 FITTINGS

NOMINAL PIPE SIZE

FITTING 1/2" 3/4" 1"

LINEAR FEET

90° ELBOW 3.6 4.4 5.2

TEE 4.2 5.3 6.6

Table 9. Equivalent Pipe Lengths

Page 31

The FT Series Heating Only, Boiler

Natural Gas Pipe Sizing (Maximum)

Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 0.5psi or less and a pressure drop of 0.5 Inch water column. (Based of a 0.60 Specic gravity gas)

For reference only. Referenced from gas pipe manufacturer specications for actual delivery capacity. The

DOE standard for Natural Gas is 1100 BTU/ ft3. Contact the local gas supplier for actual BTU/ ft3 rating.

Page 31

Pipe

Length (ft)

size

10 20 30 40 50 60 80 100 150 200

1/2˝ 82 58 47 41 37 37 29 26 20 18

3/4˝ 192 137 112 97 87 80 69 62 48 44

1˝ 383 269 218 188 168 153 132 118 91 82

1-1/4˝ 639 456 374 325 292 267 232 208 171 148

1-1/2˝ 1260 888 723 625 559 509 440 393 320 277

2˝ 2930 2080 1700 1470 1320 1200 1040 933 762 661

Table 10. Length of Corrugated Stainless Steel Pipe.

(Refer to the ANSI Z223.1 NATIONAL

FUEL GAS CODE 2012 EDITION)

Pipe

Length (ft)

size

10 20 30 40 50 60 80 100 150 200

1/2˝ 172 118 95 81 72 65 56 50 40 34

3/4˝ 360 247 199 170 151 137 117 104 83 71

1˝ 678 466 374 320 284 257 220 195 157 134

1-1/4˝ 1390 957 768 657 583 528 452 400 322 275

1-1/2˝ 2090 1430 1150 985 873 791 677 600 482 412

2˝ 4020 2760 2220 1900 1680 1520 1300 1160 928 794

Table 11. Length of Black Iron Pipe (Schedule 40 Metallic)

(Refer to the ANSI Z223.1 NATIONAL

FUEL GAS CODE 2012 EDITION)

Page 32

4.9 Gas Supply and Piping (continued)

Propane Gas Pipe Sizing (Maximum)

Intended use : Pipe Sizing Between Single-or Second-Stage (Low Pressure) Regulator and Appliance.

For reference only. Referenced from gas pipe manufacturer specications for actual delivery capacity. The

DOE standard for Natural Gas is 1100 BTU/ft3. Contact the local gas supplier for actual BTU/ft3 rating.

Inlet Pressure : 11 in. w.c / Pressure Drop : 0.5in. w.c / Specic Gravity : 1.5

Pipe

Length (ft)

size

10 20 30 40 50 60 80 100 150 200

1/2˝ 129 91 74 64 58 53 45 41 31 28

3/4˝ 303 216 177 153 137 126 109 98 75 69

1˝ 605 425 344 297 265 241 208 186 143 129

1-1/4˝ 971 661 528 449 397 359 307 270 217 183

1-1/2˝ 1990 1400 1140 988 884 805 696 621 506 438

2˝ 4640 3290 2680 2330 2080 1900 1650 1480 1210 1050

Table 12. Length of Corrugated Stainless Steel Pipe.

(Refer to the ANSI Z223.1 NATIONAL

FUEL GAS CODE 2012 EDITION)

Length (ft)

Pipe

size

10 20 30 40 50 60 80 100 150 200

1/2˝ 291 200 160 137 122 110 101 94 84 67

3/4˝ 608 418 336 287 255 231 212 197 175 140

1˝ 1150 787 632 541 480 434 400 372 330 265

1-1/4˝ 2350 1620 1300 1110 985 892 821 763 677 543

1-1/2˝ 3520 2420 1940 1660 1480 1340 1230 1140 1010 814

2˝ 6790 4660 3750 3210 2840 2570 2370 2200 1950 1570

Table 13. Length of Black Iron Pipe (Schedule 40 Metallic)

(Refer to the ANSI Z223.1 NATIONAL

FUEL GAS CODE 2012 EDITION)

Page 33

The FT Series Heating Only, Boiler

Page 33

The gas connection tting on the unit is 3/4˝ male

NPT.

The supply line must be sized for the maximum

output of the boiler model being installed. If there

are additional gas appliances from the main

supply line, you must measure sizes of the supply

line according to the COMBINED total maximum

BTUH draw for the appliances as if they were all operating at the same time.

Measure the length of the gas supply line from

the gas meter to the Boiler. Use the tables in this manual or refer to the gas

line manufacturers sizing information to determine the correct supply pipe size.

The gas shut-off valve in the gas supply line

should be installed close to the unit.

To facilitate any future maintenance, it is also

recommended that an approved gas union tting be installed in the supply line between the shut-off

valve and the

Boiler.

1) Install an approved gas line pipe to gas line connection under the Boiler. Include manual shut off valve and gas union

connection, as shown.

2) Test gas pressure to make sure it meets the

minimum standards and does not exceed the

maximum standards for the boiler.

3) Leak test the gas line pipe before placing the unit in operation. Use approved leak detector liquid solutions only to check for leaks.

Do Not Operate the boiler until all connections have

been completed, checked for leaks, and the heat exchanger is lled with water.

/4˝ male NPT connection on the

UNION FITTING

MANUAL SHUT OFF VALVE

GAS PIPE

CLOSED POSITION

Page 34

4.9 Gas Supply and Piping (continued)

Suggested Natural Gas (NG) Layout

Sediment

Trap

Other Appliance

Suggested Propane Gas (LP) Layout

Sediment Trap

Gas Regulator

(Supply Press 12˝ )

LP GAS TANK

Other Appliance

Boiler must be installed downstream of the gas meter for adequate gas supply.

Boiler gas connection pipe not less than a 1/2”.

Page 35

The FT Series Heating Only, Boiler

4.10 Gas Supply Pressure

The minimum and maximum inlet gas line pressures must be

Natural Gas LP Gas

Maximum Pressure 10.5˝ WC Maximum Pressure 13.0” WC

Minimum Pressure 3.5˝ WC Minimum Pressure 8.0” WC

Gas Valve

80 - 140 MBH Inlet Gas Pressure Port

Page 35

Manifold Pressure Port

Gas Valve

199 MBH

Inlet Gas Pressure Port

CAUTION

The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any

pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve

during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 psi (3.5 kPa).

Loosen the pressure port screws before you check the gas inlet pressure.

Page 36

Document 4296D

Table B DIP Switch Settings

These 3 bottom switches must be set per unit SIZE.

Per Table B, set DIP Switch

5 to OFF

for LP Propane.

Turn ON the GAS and WA TER supply to the FT. Turn ON the FT.

Connect a manometer to the manifold pressure port. For dual port manometers, use the positive pressure side. Check for proper manifold gas pressure. Refer to Table C.

ON OFF

MIN Fire Normal Operation

MAX Fire Normal Operation

NG Natural LP Propane

3” Vent Size

2” Vent Size

ON OFF ON OFF ON

OFF ON ON OFF OFF

OFF OFF OFF ON ON

Figure D

Gas Valve for 80 to 140 MBH

Gas Valve for

199 MBH

The gas valve on

the smaller models is

mounted vertically.

Manifold Pressure Port

Manifold pressure Propane Gas (LP) Natural Gas (NG)

MFTHW 80/100

-0.102˝ WC -0.102˝ WC

0.00˝ WC 0.00˝ WC

MFTHW 120/140

-0.216˝WC -0.216˝WC

0.00˝ WC 0.00˝ WC

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

Refer to the below table.

Manifold pressure Propane Gas (LP) Natural Gas (NG)

MFTHW 80/100

-0.102˝ WC -0.102˝ WC

0.00˝ WC 0.00˝ WC

MFTHW 120/140

-0.216˝WC -0.216˝WC

0.00˝ WC 0.00˝ WC

MFTHW 175

-0.169˝ WC -0.129˝ WC

-0.015˝ WC -0.015˝ WC

MFTHW 199

-0.173WC -0.134˝ WC

-0.015˝ WC -0.015˝ WC

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

Refer to the below table.

Shown is a

Model 140

with 3"

Venting and using

Natural Gas

Document 4296D

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

All sizes

(and all altitudes)

4.11 Gas Setup and Adjustment

For the Step by step process to measure CO2 values on the FT, please refer to Steps 12 thru Step 22 in Section 4.13 of this Installation Manual.

WARNING

Installer is required to verify combustion settings as part of

the installation process.

Standard Factory Setting is for MAX Fire. 9.0%

@ 0-2,000 ft altitude (Natural Gas).

Table 14. CO2 Values

Table 15. Manifold Pressures

All sizes

and all altitudes

Page 37

The FT Series Heating Only, Boiler

AUTODESK � � � ��

4.12 High Altitude Installations. 2,000’ to 10,000’

The FT is shipped with a default factory setting for installation at an altitude of 0 to 2000’ (approx). For maximum efciencies at higher altitudes (2,000’ to 10,000’), the FT does have an adjustment in the

Installer Parameters Mode.

Follow these instructions if your installation is at 2,000’ - 10,000’.

1. With the Power turned OFF, press the 'Modes button' for

5 seconds to get into the Installer Parameters Mode.

Page 37

2. Turn the dial (E) until ‘

33:HA’ appears.

3. Press the dial (E).

4. Set the high altitude value by turning the dial.

Refer to table.

# Altitude of Installation 0 0~1999 ft (0~609 m) 1 2,000~4,499 ft (610~1,645 m) 2 4,500~7,699 ft (1,646~2,346 m) 4 7,700~10,000 ft (2,347~3,048 m)

5. Press the dial again (E) to save the setting.

6. Press the ‘Modes button’ for one second, to Save the number and to go back to initial status.

Page 38

Document 4296D

The FT Series, Heating Only, Gas Conversion Kit

AUTODESK � � � � � � � � � �

4.13 Natural Gas to Propane Conversion

Kit # R20773

The FT Series, heating only, condensing boiler

is conﬁ gured for Natural Gas (NG) from the

factory.

Kit is included with every FT. The gas conversion kit will show you how to convert your FT boiler to propane gas. If your FT does not have the bag containing the conversion kit, a replacement kit can be obtained. Contact the manufacturer and request a replacement gas conversion kit.

If your installation altitude is greater than 2000 ft, check that the ‘High Altitude’ Installer Setting has been adjusted to suit your installation altitude. Refer to Section 4.12 of the Installation and Operation Instructions (Document 1342).

This boiler has been assembled at the factory to burn natural gas, but can be converted to burn LP gas. Be

sure to conﬁ rm that the gas at this installation is propane

gas (LP), before performing this conversion, and then placing the boiler into operation.

A Natural Gas to Propane Conversion

NOTICE

CAUTION

ON / OFF

Steps 1 thru 24

Turn OFF the FT. The

ON / OFF button is located at the bottom left of the Control Display . Turn OFF the GAS and WATER supply to the FT (valves

are located on the plumbing pipes.)

Model Nat Gas (NG) Part # Propane (LP) Part #

FTHW FTHW FTHW

80 100 120

FT1943 FT1946 FT1944 FT1947 FT1945 FT1948

Nozzles

WARNING

This conversion shall be installed by a qualified service agency in accordance with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these

instructions is not followed exactly, a ﬁ re, an explosion

or production of carbon monoxide may result causing property damage, personal injury or loss of life. The

qualiﬁ ed service agency is responsible for the proper

and complete installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer's instruction supplied with the kit. Installation must conform to local codes and the latest edition of the National Fuel Gas Code, ANSI Z223.1 and CAN-B149.1. Failure to follow instructions could result in serious injury or

property damage. The qualiﬁ ed agency performing this work

assumes responsibility for gas conversion.

FTHW FTHW

140

199

FT1412N FT1412P

FT1780 FT1802

Table A. Gas Conversion Parts

A VERTISSEMENT

Ce conversion doit être installé par un organisme de service conformément aux instructions du fabricant et tous les codes et

les exigences de l’autorité compétente. Si les informations contenues dans ces instructions n’est pas suivi à la lettre, un incendie, une explosion ou de la production de monoxyde de carbone mais résultat causant des dommages matériels, des blessures ou des pertes de vie. Le service est responsable pour la bonne et complète l’installation de ce kit. L’installation n’est pas correcte et complète jusqu’à

ce que le fonctionnement de l’appareil converti est vériﬁ ée

comme spéciﬁ é dans le manuel d’instruction fourni avec le kit.

L'installation doit être conforme aux codes locaux et la dernière édition du National Code de gaz combustible, ANSI Z223.1 et peut-B149.1. Non-respect des instructions peut entraîner des blessures graves ou des dommages matériels. L'organisme qualifié effectuant ce travail suppose la responsabilité de conversion au gaz.

Oriﬁ ce

pg 1 of 4

Page 39

The FT Series Heating Only, Boiler

Document 4296D

The FT Series, Heating Only, Gas Conversion Kit

BLOWER

GAS VALVE

COMBUSTION TEST PORT

COVER

BLOWER

COVER

GAS INLET PIPE

( FTHW

80/100120/140

) ( FTHW

199

)

Figure A

( FTHW

80/100/120/140

) ( FTHW

199

)

BRASS FITTINGS

NOZZLE

BRASS FITTINGS

PACKING

ORIFICE

Using a Phillips screwdriver, remove the 4 screws on the front cover. See Figure A.

Locate the Gas Inlet Pipe at the top of the unit as is shown in Figure A, and loosen the Brass Fittings at both ends of the Gas Inlet Pipe.

Completely un-thread the Brass Fittings at the blower end of the Gas Inlet Pipe, and then carefully swing the Gas Inlet Pipe to the left, just enough so that it is out of the way . See Figure B.

Remove the existing Natural Gas Nozzle (or Oriﬁ ce). Save the Packing for re-use. It is also advised to

save the

nozzle or oriﬁ ce just in case the unit needs to be converted back to natural gas at any time in the future.

Replace the old Nozzle (or Oriﬁ ce) with the new one for LP (propane). Re-use the Packing from previous.

Return the Gas Inlet Pipe to its original position and tighten both of the Brass Fittings.

Figure B

Flat Side Inward

Page 39

Page 40

Document 4296D

The FT Series, Heating Only, Gas Conversion Kit

Manifold pressure Propane Gas (LP) Natural Gas (NG)

MFTHW 80/100

-0.102˝ WC -0.102˝ WC

0.00˝ WC 0.00˝ WC

MFTHW 120/140

-0.216˝WC -0.216˝WC

0.00˝ WC 0.00˝ WC

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

Refer to the below table.

Manifold pressure Propane Gas (LP) Natural Gas (NG)

MFTHW 80/100

-0.102˝ WC -0.102˝ WC

0.00˝ WC 0.00˝ WC

MFTHW 120/140

-0.216˝WC -0.216˝WC

0.00˝ WC 0.00˝ WC

MFTHW 175

-0.169˝ WC -0.129˝ WC

-0.015˝ WC -0.015˝ WC

MFTHW 199

-0.173WC -0.134˝ WC

-0.015˝ WC -0.015˝ WC

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

Refer to the below table.

4.13 Natural Gas to Propane Conversion (continued)

ON OFF

MIN Fire Normal Operation

MAX Fire Normal Operation

NG Natural LP Propane

3” Vent Size

ON OFF ON OFF ON OFF ON ON OFF OFF OFF OFF OFF ON ON

MBH 80 100 120 140 N/A 199

These 3 bottom switches must be set per unit SIZE.

Table B DIP Switch Settings

Per Table B, set DIP Switch

Turn ON the GAS and WA TER supply to the FT.

10.

Turn ON the FT.

11.

Connect a manometer to the manifold pressure port. For dual port manometers, use the positive pressure

12.

side. Check for proper manifold gas pressure. Refer to Table C.

2” Vent Size

5 to OFF

ON ON ON

Model 140

Venting and using

for LP Propane.

Shown is a

with 3"

Natural Gas

Manifold Pressure Port

13.

Manifold Pressure Port

Figure D

The gas valve on

the smaller models is

mounted vertically.

Gas Valve for 80 to 140 MBH

Table C

Establish a call for heat. You may need to disconnect the outdoor reset if you are making this gas conversion during warm weather.

Gas Valve for

199 MBH

pg 3 of 4

Page 41

The FT Series Heating Only, Boiler

Document 4296D

The FT Series, Heating Only, Gas Conversion Kit

CO2 value

Propane Gas (LP) Natural Gas (NG)

2˝ VENT 3˝ VENT 2˝ VENT 3˝ VENT

MFTHW 80/100

120/140/175/199

9.5~11% 8.5~10.5%

9~10.5 % 8~10%

Page 41

All sizes

(and all altitudes)

Table D

Setup your combustion analyzer and place the sensor into the combustion test port

14.

Per Table B for Max Fire

15.

WAIT for your combustion analyzer to stabilize. This may take up to 3 minutes depending on your

16.

combustion analyzer. Then measure the CO combustion readings Do NOT adjust CO2 at MAX Fire. ONLY in MIN Fire, so...

Per Table B for MIN Fire, change dip switch 6 to OFF and 7 to ON. The unit will cycle down to MIN Fire.

17.

WAIT for your combustion analyzer to stabilize. Then measure the CO

18.

acceptable MIN ﬁ re combustion readings

Open the Gas Valve Adjustment Port by removing the cap screw with a 4mm Allen wrench.

19.

Then use the 4 mm Allen wrench to make a minor adjustment (1/8 turn) to either increase or decrease CO2.

20.

It may be necessary to go back and forth between HI Fire and LOW Fire several times (and making

21.

adjustments only at LOW Fire), before CO2 at both are within acceptable levels. Be sure to put the adjustment port cap screw back onto the valve when done.

change dip switch 6 to ON and 7 to OFF. The unit will cycle up to MAX ﬁ re.

for MAX ﬁ re. Refer to Table C for acceptable MAX ﬁ re

for MIN ﬁ re. Refer to Table D for

Once the CO2 and manifold pressure measurements for both MIN and MAX Fire are acceptable per Table

22.

C, set DIP switches 6 and 7 to the OFF position for Nominal Fire (normal operation).

Write in the correct conversion date and the technicians name to the included gas conversion sticker. See

23.

Figure E. Then apply that sticker adjacent to the rating plate.

Put the boiler cover back on and assemble/tighten the 4 screws that hold the cover in place.

24.

This unit was converted on ____/____/___to _____gas with kit #____________by______________________ (name and company __________________________ accountable)_________________________________ ___________________________________________ Cette unité a été converti ____/____/____ten ______gaz en utilisant le kit numéro _____ par______________ (nom et société_________________________________ responsable)___________________________________ _____________________________________________

Figure E (Conversion label)

pg 4 of 4

Page 42

4.14 Plumbing Guidelines

4.14.1 External Plumbing and Water Connection Guidelines

- Ensure pipe material meets local codes and

industry standards.

- The pipe end must be clean and free of debris.

- Do not apply torch heat within 12˝ of the bottom

connections of the unit.

- The CH supply and return connections are 1-1/4”.

The system piping must be a minimum of 1-1/4”. (See Sections 1.14.4 & 4.14.5)

- Isolation valves(Shutoff valve) will be used.

- All piping should be insulated.

4.14.2 Backow Preventer and Boiler Feed

Valve

- Apply a Backow Preventer and Boiler Feed

Valve to the unit as required by local codes.

4.14.3 Diaphragm type Expansion tank

- The air in a diaphragm-type expansion tank is

separated from the water by a exible rubber membrane. When the tank is installed in and connected to the piping of the system, water enters the other side of the tank chamber and presses down on the diaphragm.

- You should always install an ‘Automatic Air Vent

on the top of the air separator to remove

residual air from the system.

- Automatic air vent has been installed on the

inside of the boiler.

- The installation of an additional air vent is

optional.

- If the boiler is installed in a closed water supply

system, such as one having a backow preventer in the cold water supply line, it will control thermal expansion.

CAUTION

Use at least the MINIMUM pipe size for the entire

boiler loop piping (connecting boiler to and from

the primary/secondary connection). Use only primary/secondary piping as shown.

Failure to follow these guidelines could result in system problems.

CH pipe minimum size : 1-1/4˝

CAUTION

For guidelines in the use of Glycol Products. Please refer to Section on page 78

CAUTION

Scalding Risk: Manufacturer strongly recommends the use of an anti-scald mixing

valve at domestic hot water outlet (boiler location) to reduce potential for scalding.

Contact Manufacturer for recommended models. Check with local codes.

__________________________________________

Page 43

The FT Series Heating Only, Boiler

PRIMARY LOOP

CH SUPPLY

1”

Min

Piping

(SPACE HEATING)

ZONE 1

ZONE 2

ZONE 3

SECONDARY LOOP (SPACE HEATING)

Do not exceed

12" See Note

Make-Up Water

DHW Pump

PRIMARY LOOP

CH SUPPLY

CH RETURN

1”

Min

Piping

(SPACE HEATING)

ZONE 1

ZONE 2

ZONE 3

SECONDARY LOOP (SPACE HEATING)

Do not exceed

12" See Note

Make-Up Water

DHW Pump

Indirect DHW Tank

4.14 Plumbing Guidelines

4.14.2 Zoning with zone valves

- In a valve based system, there is one circulator pump at the boiler and each

heating zone has a zone valve which opens when the zone demands it.

- Each thermostat is wired directly to the corresponding zone valve. Contacts in the zone valves provide a proper signal to the boiler when the valve is opened.

Page 43

Differential

Pressure By-Pass

Expansion tank (Diaphragm-type)

Automatic air vent Air separator

Circulation pump

Check valve Drain valve valve

Backflow preventer

Pressure Relief Valve

Anti-scald rated Mixing Valve

Auto Fill Valve

and Backow Preventer

Valves are NOT included

(Field Supplied).

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

5. Install a check valve on the return line to the boiler.

6. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet

(boiler location) to reduce potential for scalding.Contact Manufacturer for recommended models.

Check with local codes.

Page 44

PRIMARY LOOP

CH SUPPLY

CH RETURN

(SPACE HEATING)

ZONE 1

ZONE 2

ZONE 3

1”

Min

Piping

Do not exceed

12" See Note

SECONDARY LOOP (SPACE HEATING)

Make-Up Water

Circulation pump

Check valve Drain valve Gate valve

Backflow preventer

Pressure Relief Valve

Expansion tank

Air separator

(Diaphragm-type) Automatic air vent

Anti-scald rated Mixing Valve

PRIMARY LOOP

CH SUPPLY

(SPACE HEATING)

ZONE 1

ZONE 2

ZONE 3

1”

Min

Piping

Do not exceed

12" See Note

SECONDARY LOOP (SPACE HEATING)

Make-Up Water

4.14 Plumbing Guidelines

4.14.3 Zoning with

circulation pumps

- Each heating zone of a pump based system has its own circulator pump which runs when that zone demands it.

- Each zone thermostat goes to a controller which controls the pumps.

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

5. Install a check valve on the return line to the boiler.

6. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet

(boiler location) to reduce potential for scalding.Contact Manufacturer for recommended models.

Check with local codes.

Page 45

The FT Series Heating Only, Boiler

CH SUPPLY

CH RETURN

ZONE 1

ZONE 2

ZONE 3

Make-Up Water

DHW Pump

Indirect DHW Tank

4.14 Plumbing Guidelines

4.14.4 Indirect Water Heating

- Installer is responsible for all equipment and detailing required by local codes.

- The minimum pipe size of CH piping should be 1 ¼˝ in diameter.

and Backow Preventer

Valves are NOT included

Page 45

Auto Fill Valve

(Field Supplied).

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

5. Install a check valve on the return line to the boiler.

6. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet

(boiler location) to reduce potential for scalding.Contact Manufacturer for recommended models.

Check with local codes.

Page 46

4.14 Plumbing Guidelines

4.14.5 Multiple units using

zones pumps and an

indirect for DHW

ZONE 1

ZONE 2

ZONE 3

Expansion tank

(Diaphragm-type)

Automatic air vent

CASCADE

SYSTEM

SENSOR

SECONDARY LOOP (SPACE HEATING)

Do not exceed

12"

See

Note

”

Min

Piping

Make-Up Water

Follower Leader

Air separator

Circulation pump

Check valve

Drain valve Gate valve

Backflow preventer

Pressure Relief Valve

Anti-scald rated Mixing Valve

PRIMARY LOOP

(SPACE HEATING)

SUPPLY

CH RETURN

SUPPLY

DHW Pump

CH RETURN

Indirect DHW Tank

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

5. Install a check valve on the return line to the boiler.

6. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet

(boiler location) to reduce potential for scalding.Contact Manufacturer for recommended models.

Check with local codes.

7. Auto Fill Valve and Backow Preventer Valves are NOT included (Field Supplied).

8. DHW Sensor/Aquastat must connect to LEAD boiler

Page 47

The FT Series Heating Only, Boiler

4.15 Pressure Relief Valve

External pressure relief valves must be installed.

Observe the following. Failure to comply with the

guidelines on installing the pressure relief valve and

discharge piping can result in personal injury, death or substantial property damage.

WARNING

Do not operate this appliance before the

pressure relief valve supplied is installed with sufcient relieving capacity in accordance with the ASME Rating Plate on the boiler.

Page 47

This boiler is provided with 30 psi safety relief valve

that complies with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers).(Model : CASE ACME F-82)

This safety relief valve (30 psi) is shipped loose for eld

installation.

For safety, the relief valve(s) must be installed into it’s

designed location and not be removed or plugged. Failure to comply with the guidelines on installing the

pressure relief valves and discharge piping can result in

personal injury, death or substantial property damage.

Direct the discharge piping of the pressure relief valve

so that hot water will not splash on anyone or any nearby equipment. Attach the discharge line to the pressure relief valve and run the end of the line within 6-12″ (150-300mm) of the oor.

WARNING

DO NOT install a CH pipe line relief valve with a

pressure higher than 30psi. This is the maximum allowable relief valve setting for the boiler.

Test the operation of the valve after lling and

pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve. Ensure that

the discharge capacity of the pressure relief valve is equal to or greater than the maximum pressure rating

of the boiler.

Ensure that the maximum BTU/H rating on the

pressure relief valve is equal to or greater than the

maximum input BTU/H rating of the boiler.

Pressure Relief Valve must be installed on the CH

supply line as close to the unit as possible. (CH supply line: maximum 30psi). No other valves should be placed between the pressure relief valve and the appliance.

This appliance has a high-temperature shut off switch

built in as a standard safety feature .Therefore a “pressure only” relief valve is required.

3/4” 30psi Relief Valve

Page 48

4.16 Disposal of Condensate

High efciency gas condensing Boilers create

condensation when operating. Condensation has acidic (pH) of approximately 4-5.

Condensate must be drained in accordance with all

local regulations. Follow your local code with regards to the disposal of condensation.

One of 4 disposal methods must be followed

1. to oor drain

2. to neutralizer (optional kit)

3. to laundry tub

4. to condensate pump (eld supplied)

If a neutralizer is installed, periodic replacement of the

lime stone (or neutralizing agent) will be required. The

rate of depletion of the lime stone varies upon usage

of the boiler. During the rst year of operation, please check the neutralizer every few months for depletion.

Apply only corrosion-resistant materials for the

condensate drain lines such as 1/2˝ PVC, CPVC, Polypropylene pipe or included plastic hose.

Condensate Trap

Condensate drain pipe

Category II & IV water heaters must be installed with a means provided for the drainage of condensate.

les chaudières de catégories II et IV doivent être installées de façon à empêcher l'accumulation de condensat; et

si nécessaire, les chaudières de catégories II et IV doivent être pourvues de dispositifs d'évacuation du condensat.

Condensate is mildly acidic (pH=5), and may harm

some oor drains and/or pipes, particularly those that are metal. Ensure that the drain, drainpipe, and anything that will come in contact with the condensate can withstand the acidity, or neutralize the condensate before disposal. Damage caused by failure to install

a neutralizer kit or to adequately treat condensate will not be the manufacturer’s responsibility.

Contact Manufacturer to order Neutralizer Kit# A2123601

_________________________________________

NOTICE

AVIS

CAUTION

2 3

Various condensate disposal methods

Page 49

The FT Series Heating Only, Boiler

4.17 Electrical Wiring Connections

WARNING

Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the

absence of such requirements, follow the National Electrical Code, NFPA 70, and/or CSA C22.1 Electrical Code-Part 1 in Canada.

ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service

entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

This appliance must be electrically grounded. Ensure the electrical receptacle that the boiler will be plugged

into, is properly grounded; if wiring directly.

Do not attach the ground wire to either the gas or the water piping as plastic pipe or dielectric unions may

isolate the Boiler electrically. The wiring diagrams contained in this manual are for reference purposes only. Refer to these diagrams and diagrams from external controls used with this appliance. Read, understand,

and follow all wiring instructions. Do not disconnect the power supply when the unit is in normal operation. Damage caused by freezing is not

covered under the warranty. Manual (Rocker) switch maximum allowable current for each circulator is 16 amps at 125VAC.

( Housing : Nylon #66 UL 94V-2 , Rocker : Nylon #66 UL 94V-2, Terminal : Copper Alloy )

Terminal block (External power connector) : DFT-20A-10P (20 amps at 300VAC)

Page 49

Manual Switch

Electrical Connections

External Power Connections

Low Voltage Connections

( O/S : Outdoor sensor connector )

DHW and CH pump terminals for external pump are live 120V limited to 2.0 A. They operate respective to an external call (e.g T-T) for heat.

Page 50

Document 4296D

The FT Series, Heating Only, Gas Conversion Kit

Table B DIP Switch Settings

MBH 80 100 120 140 N/A 199

These 3 bottom switches must be set per unit SIZE.

Per Table B, set DIP Switch

5 to OFF

for LP Propane.

10.

Turn ON the GAS and WA TER supply to the FT.

11.

Turn ON the FT.

ON OFF

MIN Fire Normal Operation

MAX Fire Normal Operation

NG Natural LP Propane

3” Vent Size

2” Vent Size

ON OFF ON OFF ON

OFF ON ON OFF OFF

OFF OFF OFF ON ON

Shown is a

Model 140

with 3"

Venting and using

Natural Gas

4.18 DIP Switches

DIP switches 6 and 7 have to be set in the OFF position when the boiler is running normally. DIP switches 1, 2, and 3 are system switches and are factory set to the boiler model and size

and should not be touched.

System Control Setting

Maximum ame detecting voltage 2.4V

Pre-purge time Tp Maximum 10s, minimum 1s

Safety Time (igniting time) Ts 1.5s

Igniting interval time 10s

Post-purge time Tip 120S (1st : 60s + 2nd 60s)

Over-heating 1,2,3 protection detection time <2s

High & Low Water Level detection time <5s

High & Low Water Level Recover time <5s

Temperature sensor anomaly detection time <3s

APS sensor detection time <3s

Page 51

The FT Series Heating Only, Boiler

4.19 Control Board, Electrical Diagram

Control Board

Page 51

Page 52

4.20 Ladder Diagram

Page 53

The FT Series Heating Only, Boiler

4.21 Electrical Connections

Connector

#, Location, Type PIN Label

Page 53

Description HT SELV

CN9

65001WS-12

CN6

LW6A4-03

CN1

SMW250-05D

CN4

LWD1140-06D

CN8

SMW250-04D

CN11

LWD 1140-16

1 2 L Power Supply Line HT (120V~) 3 CP1 Central Heating Pump HT (120V~) 4 IT Ignitor HT (120V~)

5 HEAT/CP2 CH Pump HT (120V~) 6 GV Gas Valve HT (120V~)

7 8 N Power Supply Neutral HT (120V~)

9-12

1 3 HT (120V~) 1 2 RS485 - SELV (5V) 3 - 4 RS485 + SELV (5V) 5 RS485 - SELV (5V) 1 2 GND SELV (30V) 3 VDD SELV (14V) 4 Fan power(start coil) SELV (30V) 5 Fan power(end coil) SELV (30V) 6 Fan speed feedback signal SELV (14V) 1 2 ISP /Reset port SELV (5V) 3 ISP TOOL0 Data port SELV (5V) 4 VCC SELV (5V) 1 9 2

CP3 DHW Pump connection

RS-485

FAN

MCU ISP

HWL AC 24V Input Heat Demand SELV (12V~)

LWL Low Water Level Leakage Sensor SELV (12V~)

HD Central Heating Demand SELV (5V)

APS Unuse -

EL Unuse -

BL Burner Limit SELV (14V)

HL Condensate Block SELV (14V)

CASE GROUND HT (120V~)

- -

AC Power COM Line HT (120V~)

HT (120V~)

RS485 + SELV (5V)

Unuse -

GND SELV (5V)

Connect to the Display Control(Thermostat)

SELV (14V)

Page 54

4.21 Electrical Connections (cont)

Connector

#, Location, Type PIN Label

CN7

LWD1140-14

1 8 2 9 3

F.S Flame Detect Sensor SELV (5V)

OP.S Operating water temperature sensor SELV (5V)

DH.S Exhaust temperature sensor SELV (5V)

I.S

BG.S

ST.S

SP.S CH over-heat temperature sensor SELV (5V)

Description HT SELV

CH Return temperature sensor

DHW temperature sensor or Mechanical aquastat connection

System temperature sensor

SELV (5V)

CN3

SMW250-06D

1 2 GND SELV (5V) 3 Voltage input SELV (5V)

4-6 FLUX1 Unuse -

APS

VCC SELV (5V)

Page 55

The FT Series Heating Only, Boiler

SECTION 5 Control Display and Operation

5.1 Control Dial and Buttons

The Control Display

Page 55

Status Light

(constant green

when operating

normally)

The Control Display has a Control Dial (E), 4 buttons (A, B, C, D), and a Liquid

Crystal Display (with 72 back-lit segments). This section of this manual gives instruction on how to navigate into the many functions of the FT and to change temperature set points, set system variables and controller parameters.

Buttons

B Modes Tap to return to menu

Display Power

Heating

Water

Time / Date

Set

Scroll / Select

Turns Control Display ON / OFF

PRESS (Tap) PRESS and HOLD (5 seconds)

CH set-point change mode

(Maxium 82

Menu select or value

up(+)/down(-) or setting dial.

°C(180°F))

No Change To SET: Year/Month/Week/Day/Time/Min

Functionality

(If Display Power was On )

(If Display Power was Off ) Installer Mode

Status Display Mode

• Temperature Specications Operating ambient Temperature Range : -10 to 60°C. Operating Relative Humidity up to: 90% at 40°C. Shipping & Storage Temperature Range of : -20 to 80°C.

WARNING

Do not use this appliance if any part has been under

water. Immediately call a qualied service technician

to inspect the appliance and to replace any part of the control system and any gas control that may have

been under water.

Page 56

5.2 LCD Overview

Symbol Name Description

Service Reminder mode Service Reminder mode indication

Outside Temperature Mode Outside Temp setting indication

Anti-freeze mode Anti-freeze mode indication

Storage mode Storage mode indication

Information mode Information mode indication

Communication state Communication state indication

Time setting mode Time /Dispaly/Install mode indication

Fan operating mode Fan operating mode indication

Flame signal Flame Signal indication

CH pump mode CH pump mode indication

Storage pump mode Storage pump mode indication

Internal recirculation mode Internal recirculation mode indication

Celsius mode Indicated as Celsius temperature

Fahrenheit mode Indicated as Fahrenheit temperature

Heat demand mode Heat demand mode indication

DAY mode Current day mode indication

Cascade System connecting

mode

Cascade System operating mode

The LCD will illuminate when a user action is detected (a button is pressed) and will turn back off after 20 seconds.

Cascade System connecting mode

indication

Cascade System operating mode

indication

Page 57

The FT Series Heating Only, Boiler

5.3 Operating Mode

Operating Mode

After the Power is turned on, and/or the Control Display is turned on , the Control Display

will go through a ‘Start Up’ checklist and briey show a sequence of diagnostic codes before entering into the ‘Operating Mode. It will then display the following information.

B C

Page 57

A D

Indicate Indicator

Current Operating Temperature Set-Point

If the Fan is operating

If a ame is detected

Celsius or Fahrenheit Date and Time indicator

If Outside Temperature Sensor is operating

If there is a Demand for Central Heat (CH)

If CH pump state is If Internal recirculation pump is operating

operating

If Communication state is activated

The Control Display can operate through user and service modes that have specic LCD output and dedicated controls:

• Set-point change mode • Lock mode • Error mode • Status display mode

• Outside Temperature mode • Installer mode

* Control Display will not allow changing of button in case of lock mode activated.

Page 58

5.4 Setting the Clock

B C A D

The P-950EH Control Display does NOT have a daily timer or programmable thermostat.

Setting the Clock

a. Press and hold the ‘Clock button’ for about 5 seconds. Set the ‘Year’ by turning the dial E. And

then, press the dial E to Save. b. Set the ‘MON’ (Month) by turning the dial E to the desired month number. Then press the dial E to Save. c. Set the ‘DATE’ (1-31, Day of the Month) by turning the dial E. Then press the dial E to Save. d. Set the ‘HOUR’ (1-24, Hour of the Day) by turning the dial E. Then press the dial E to Save. e. Set the ‘MIN’ (1-60, Minute of the Hour) by turning the dial E. Then press the dial E to Save. f. Set the ‘Day’ (Sun - Sat) by turning the dial E. Then press the dial E to Save.

To Exit at any time, tap the button.

Page 59

The FT Series Heating Only, Boiler

5.5 CH Set Point Change Mode

CH Set point Change Mode

B C

Page 59

A D

To change CH Setpoint, press the C

CH Setpoint will ash.

Turn the E dial clockwise to increase, and counterclockwise to decrease CH setpoint, until

desired temperature is reached.

Press E dial to save changes and to Exit.

Indicate Indicator

Current CH Temperature Set-Point

Celsius or Fahrenheit If Communication state is activated

If ame is detected

Date and Time indicator

button. The CH Icon and current

If CH pump is operating

If there currently a Demand for Central Heat (CH)

Default CH set-point is 180°F (82°C)

CH set-point range is 86°F ~180°F (30.0°C ~ 82.0°C)

Page 60

5.6 Status Display Mode

To change any Status Parameter,

Press and Hold Button B

to get into the Status Display Mode. Rotate Dial E until you nd the Parameter that you wish to change. Tap Dial E to enter that Parameter. Adjust to the setting that you require and then press (tap) Dial E to save and to Exit.

NOTE: For Cascading

Installations, please refer to

document 1349 ‘Cascading

B C

the FT Series Boiler’,

available online.

A D

Digital Display

O: ot Outdoor temperature Current outdoor sensor temperature A: In 0-10 V display Current voltage of (0-10V input)

b: tt CH target temperature in cascade system

C: It CH return water temperature Current CH return water temperature d: Fr FAN speed ( rpm) Current FAN speed ( RPM) E: oP F: Eh Exhaust gas temperature Current exhaust gas temperature

Status Display Parameter

CH supply temperature (Operating temperature)

Description

Current CH target temperature or Current

System target temperature in a cascade system

Current heating temperature

Indirect DHW tank temperature

H: dH

I: oH Overheat water temperature Current Overheat water temperature

1: PH 2: rh

L: rt

M: CC

N: St

3: rH

4: It Cycle for ignition

5: IH

SELF Percentage of self units running. Percentage of self units running.

ALL

F1 – F 19

* If temperature sensor is not connected then it will display with 0°F (0°C).

Time for supply power

Time for burner operation

Burner Operation Time

Capacity for all operating cascade units

Capacity for individual boilers

System Temperature (cascade mode) * If system temperature sensor is not connected then it will display with 0°F (0°C).

Time for burner operation

Cycle for ignition

Percentage of all cascade units running. This screen shows the overal cascade power output. The range of this value of boilers communicating with theMaster x 100. For example, if 8 boilers are connected and communicating, the maximum cascade power is 800%. Range: 0-100%

Percentage of each cascade units running. Ex. F1, F2, ….

Current System Temperature (cascade mode)

Current DHW tank temperature

Unit : 1000hour Unit : 1hour

L: rt on display on sub menu

Unit : 1,000hour Cycle : 10 times the

displayed unit Cycle : 10,000 times the

displayed unit

Page 61

The FT Series Heating Only, Boiler

5.7 Installer Mode

These changes are to be made only by a qualied technician.

B C

Page 61

A D

To c hange any of the Installer Parameters,

Display Control.

Then, with the power OFF, Press and HOLD (more than 5 seconds) the Button B to get into the Installer Mode.

Rotate Dial E until you nd the Installer Parameter (full list on facing page) that you wish to change. Tap Dial E to enter that Parameter.

Adjust to the setting that you require and then press (tap) Dial E to save and to Exit.

Finish by pressing button B

Index

Numbers

1: EH 2: cE

Error history up to 10 Check last 10 error codes (E0 - E9) Delete Error history

Parameter Description

Select “ON” to delete error code history Range: ON or OFF,Default OFF

Start by turning OFF the Power to the

3: In

4: OH

5: OL

6: cH

System initialize Select “ON” to reset to factory setting,Default OFF

When used with an outdoor sensor, sets the maximum outdoor

Maximum Outdoor Temperature

Minimum Outdoor Temperature

Maximum Supply

temperature

design temperature for the system design. Maximum outdoor

temperature must be set at least 9°F above the minimum outdoor

temperature. Range: (Minimum Outdoor Temperature + 9°F) to

110°F , Default 68°F

Sets the minimum outdoor design temperature for the system. Minimum outdoor temperature must be set at least 9°F below the maximum outdoor temperature. Range: -4°F to (Maximum Outdoor Temperature - 9°F), Default 5°F

Sets the maximum design supply temperature based on the minimum outdoor design temperature. Maximum supply temperature must be set at least 9°F above the minimum supply temperature. Range: (Minimum Supply Temperature + 9°F) - 180°F, Default 180°

Page 62

5.7 Installer Mode (continued)

Numbers

7: cL

8: OF

9: bt

10: bd

11: bI

12: FH

13: FL

14: dr

15: dI

16: Ft

17: bo

18: cb

19: db

20:PE

21: dH

22: dd

23: Pr

24: dP

25: St

26: FP

Index

Parameter Description

Sets the design supply water temperature based on the

Minimum Supply

temperature

Warm Weather

Shutdown

Boost Function

Boost Degree

Boost Interval

Maximum Fan speed

Minimum Fan speed

Initialized burner

operation time

Initialized ignition cycle

CH Anti-Cycling time

Set differential

temperature to turn burner “ON”

Heating capacity

DHW capacity Heating Pump Post-

Purge Time,

T/T Satised

Indirect Storage Tank Temperature Set Point

Indirect Storage Tank Differential Set Point

DHW Pump Post Run

Time DHW Priority Timer

Boiler Supply Indirect Storage Tank

Temperature

System Freeze

Protection Mode

maximum outdoor design temperature. Minimum supply temperature must be set at least 9°F below the maximum supply temperature. Range: 40°F to (Maximum Supply

T emperature - 9°F) , Default 86 °F

This warm weather temperature setting will shut down CH Mode Range : 50 °F- 110°F, Default 68 °F

This function boosts CH temperature to the maximum if

set point is not reached within the set period of time. Range: 0 - 120 min, Default 0

The boiler will add this temperature to the boiler target set

point based on outdoor reset curve. Range: 5-15°F

Default: 10°F

The boiler will index the temperature based on time

interval set on 11 bI. Range: 0-120 MIN

Default: 20 MIN

Adjusts Maximum Fan Speed Range: -30 to +30,Default 00

Adjusts Minimum Fan Speed Range: -30 to +30,Default 00

Select ON to Initialize burner operation time Range: NO or YES,Default NO

Select ON to Initialize ignition cycles Range: NO or YES,Default NO

This function delays burner operation during CH mode

Range: 0 - 20 min, Default 1

When set, the appliance will operate to heat CH water when water temperature falls below a differential setting.

Example: If set point is 180°F and differential is 27°F, the

appliance will turn on when CH water temperature falls below 153°F. Range: 5°F - 30°F, Default 30°F

Set Heating combustion rate Range: 50 - 100%,

Default 100

Set DHW combustion rate Range: 50 - 100% , Default 100

Allows the user to set the appliance pump post purge time once the thermostat is satised. Range: 1-5 minutes ,

Default 1

Sets Maximum Indirect storage tank Temperature Range:95 - 180°F , Default 120 °F

DHW Differential Set Point Range: 5°F-30°F, Default 7 °F

DHW Pump Post Run Time Range: 0-10 Min , Default 1 Min

DHW Priority Timer

Range: 0 – 60 Min , Default 30 Min

Boiler Supply Indirect Tank Temperature Range: 120 °F– 180 °F , Default 180 °F

System Freeze Protection Mode. This mode should be turned OFF for snow melt application. NOTE: This mode should be ON during normal operation. Range: ON/OFF

Page 63

The FT Series Heating Only, Boiler

Page 63

Numbers

27: Cn

28: CP

29: Eh

30:Cr

31: Ct

32: Cd

33: HA

Index

Auto

Cr:Ct

AP:cP

Parameter Description

Cascade Number

Cascade Parameter

Common Vent

Automatic rotation

Cascade Rotation time

Cascade System

temperature

Cascade System

Temperature Differential (burner ON)

High Elevation Mode

Internal CH Pump, CH Pump and DHW Indirect Pump Test Mode

Cascade Number

Range: 0 (Master), 1(slave 1), …., 19(slave 19) “29: CP” has to be set with the total number of units in the cascade before “28: Cn” can be set. Default 0

Number of units cascaded

Range: 1- 20 , Default 1

Common Vent Range: ON / OFF, Default OFF

The rst unit to operate when there is a T/T call is the unit that ran the least amount of time during the prior heat calls.

Cascade Rotation time Range: 0-240 Hours, Default 48 Hours

Cascade System temperature: Range: 9°F – 180°F, Default 180°F

Cascade System Temperature Differential (burner ON) Range: 5°F-30°F, Default 10°F

High Elevation Mode ( 0-2, 2-5, 5-8, 8-10 ),

Default HA 0

This function sets the time to run both the Internal CH and

Internal DHW Storage pumps to purge air from the system. Range: 1 – 30 minutes,Default 5

P1:oF or

34:AP

P1:on P2:oF

or P2:on

SS:Sd

35: SS

SS: br

FAH(°F)

36: UC

CEL(°C)

37: CM OFF

38: dM OFF

AquA

39: SA

SEnS

Internal CH Pump and CH Pump Test Mode

Internal CH Pump and DHW Indirect Pump Test Mode

Allows the user to set the

year of next service reminder

Allows the user to set the

service reminder based

on BURNER RUN HOURS

Allows the user to

change the unit

CH Step Modulation

DHW Step Modulation

Select Aquastat (contact)

Type

Select DHW NTC Sensor Type

Turn this function on to activate Internal CH and CH pump

testing. Only works in installation mode. Turns off when in normal mode. Default OFF

Turn this function on to activate Internal CH and DHW

Indirect pump testing. Only works in installation mode. Turns off when in normal mode. Default OFF

Allows the user to set the year of next service reminder XX / XX / XXXX (MONTH / DAY / YEAR)

Allows the user to set the service reminder based on BURNER RUN HOURS

(0: OFF, 1~9000Hours) , Default 0

Allows the user to change the unit Range: °F or °C

Allows the user to turn ON the step modulation, which regulates burner output in six steps at one minute intervals. Step modulation will start at the last modulation rate of the boiler and work up one minute at a time. Default: OFF (Selection: OFF or ON).

This mode is aquastat (contact) type.

This mode is NTC sensor type.

NOTE: If Parameter 39 does not appear in the Installer

mode, reset the unit using Parameter 3. After a factory reset,

Parameter 39 will again appear.

Page 64

5.8 Storage Mode

Storage Mode / Indirect Water Heater

B C A D

To change Storage Mode Temp, First turn OFF the power to the Control Display.

Then Press and Hold Button B

Rota te Dial E until you nd 25:St Tap Dial E to enter Storage Mode. Storage Mode indicates that the

boiler is heating the water held in an indirect water heater. When Storage Mode is active, the display will

appear as shown.

Turn the E dial clockwise to increase, and counterclockwise to decrease setting.

Press E dial to save changes and to Exit.

Indicate Indicator

Current CH set-point of temperature

Celsius or Fahrenheit

If ame detected

to get into the Installer Mode.

Storage mode indication

If there is a Demand for Central Heat (CH)

Page 65

The FT Series Heating Only, Boiler

5.9 Outdoor Reset Adjustment

Outdoor Reset varies the control setpoint based on the outdoor temperature. The reset function works as shown in Figure ‘CH Outdoor Reset’. When the

outdoor air temperature reaches 4:OH “high outdoor temperature setpoint”, the control point setting is

adjusted to 7:cL “low boiler temperature setpoint”.

When the outdoor air temperature reaches 5:OL “low outdoor temperature setpoint” the control setpoint is

adjusted to 6:cH “high boiler temperature”.

Page 65

Operating condition

Default outdoor reset setpoint is 100°F (38°C) The Outdoor Temperature Mode Icon on the display

will ash if an Outdoor Sensor or 0-10 Volt is not connected to the appliance. To check the CH Target Temperature while using

Outdoor Temperature Mode, press the

while the appliance is operational and the display panel is powered on.

Connect to terminal strip as outlined 4.17 Electrical Connections.

NOTE: 0 - 10VDC terminals may not be used for both outdoor reset and 0 - 10VDC temp

setpoint simultaneously.

button

Outdoor Reset

5.10 External Set Point Temperature Control

A signal from a building management system may be connected to the appliance to enable remote control. This signal should be a 0-10 volt DC signal. When this input is enabled, a building control

system can be used to control the set point temperature of the appliance.

(warm weather shutdown)

The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the appliance will be in standby mode, not ring. When the signal rises above 1.5 volts, the appliance will ignite. As the signal continues to rise

towards its maximum of 10 volts, the appliance will increase in set point temperature. Adjust 6:cH and 7:cL to set MIN and MAX boiler water temperatures respectively.

Connect a building management system or other auxiliary control signal to the terminals marked for this purpose on the appliance terminal block (shown in Piping Diagrams, this manual). Caution should be used to ensure that the 0-10 VOLT + connection does not become connected to ground.

Connect to terminal strip as outlined 4.17 Electrical Connections.

NOTE: 0 - 10VDC terminals may not be used for both outdoor reset and 0 - 10VDC temp

setpoint simultaneously.

Page 66

5.11 Error Mode

The Control Display will show the following information when an Error is presented.

Indicate Indicator

Flashing

Error ‘ Er : ’ sign Segment

Error Code If Communication state is activated

NOTE: When communication between the Control Display and the main controller is lost, the

will not be displayed.

Er:11

Page 67

The FT Series Heating Only, Boiler

SECTION 6 Error Codes

6.1 Error Code Table

Page 67

Error

Code

Error Code

Description

Flame has Extinguished 8 (Eight) Times

Ignition has Failed 10 (Ten) Times

Operating

Temperature Sensor

detects Water Temperature Greater than 203°F (95°C)

Condensate – Closed

is Normal, Open is Fault (Condensate Drain Trap)

Overheat Sensor Open or Short

DHW Sensor Open or Short

CH Temperature

Sensor Open or Shor t

Possible Remedies

Press the Power button to clear the Error Code.

If Error happens again:

1. Monitor the gas pressure to the appliance while in operation. Ensure pressure is between 3.5" to 10.5” WC (Natural Gas) and 8" to 13" WC (Propane).

2. Check gas valve wire. Ensure connection is secure.

3. Check ame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

4. Check vent terminations. Ensure there are no blockages.

5. Assure that the ame is stable when lit.

6. If the problem persists, replace the main control.

Press the Power button to clear the Error Code.

If Error happens again:

1. Monitor the gas pressure to the appliance while in operation. Ensure pressure is between 3.5" to 10.5” WC (Natural Gas) and 8" to 13" WC (Propane).

2. Check gas valve wire. Ensure connection is secure.

3. Check ame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

4. Check igniter transformer for proper connection.

5. Clean the spark igniter with steel wool to remove oxides. Ensure proper separation (3-4 mm).

6. Replace the spark igniter if damaged.

7. Assure that the ame is stable when lit.

8. If the problem persists, replace the main control.

Press the Power button to clear the Error Code.

If Error happens again:

1. Check if dip switch Max Fire setting is ON. Switches 6 and 7 should be OFF for normal operation.

2. Check if CH inlet pipe is blocked. Ensure there is enough water owing to the appliance.

3. Check Operating Temperature sensor at CH heat exchanger outlet. If resistance is zero, replace the sensor.

4. If the problem persists, replace the main control

Press the Power button to clear the Error Code.

1. Check Condensate and main controller connections. Ensure all are secure.

2. Check Condensate sensor resistance. If resistance is zero, replace the switch.

3. Check Condensate hose. Ensure it is connected and in good condition.

4. Check condensate line and termination for blockages.

5. Check Vent Pipe for blockages.

6. If the problem persists, replace the main control.

This Error Code will go away when CH temperature decreases.

If Error happens again:

1. Check overheat temperature sensor. Ensure connections are secure.

2. Check overheat sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

This Error Code will go away when outlet DHW temperature decreases.

If Error happens again:

1. Check DHW outlet temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

This Error Code will go away when CH temperature decreases.

If Error happens again:

1. Check CH temperature sensor. Ensure connections are secure.

2. Check CH sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

Recover

methods

Hard

Lock

Hard

Lock

Hard

Lock

Hard

Lock

Soft Lock

Page 68

Error Code Table (continued)

Error Code

37 Abnormal Supply Frequency

42 LWCO Jumper Disconnected

Error Code Description Possible Remedies

Venting (Exhaust) Sensor Open or Short

Error Appears When Control Stores Data, but Data is not Saved

Gas Leakage is Detected for

Greater than 5 seconds, or

three times within 10 minutes

Fan Speed too High with

Flame On

Burner Overheat Switch

Open

Air Pressure Sensor (APS) Fault

Air Pressure Sensor (APS) Open

Fan Speed Feedback Signal Abnormal

This Error Code will go away when exhaust temperature decreases.

If Error happens again:

1. Check Venting (exhaust) temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. Check vent pipes for blockage.

4. If the problem persists, replace the main control

Supply frequency is too high to operate. This Error Code will go away when supply frequency returns to normal operating range.

If Error happens again:

1. Ensure appliance is properly wired to a power source meeting the requirements on the rating plate.

2. If problem persists, replace the main control.

Press the Power button to clear the Error Code. Replace the main control.

IMPORTANT: If you smell gas, STOP! Follow the instructions on page 2, this manual, and call a qualied ser vice technician or the fuel gas utility. Press the Power button to clear the Error Code.

If Error happens again:

1. Check the appliance cover. Ensure it is secure.

2. Check gas connections for leakage with a soapy solution. Fix any leaks.

3. Check condition of the burner assembly.

4. If the problem persists, replace the main control.

Press the Power button to clear the Error Code.

If Error happens again:

1. Check the vent connections for blockages.

2. Check the burner assembly.

3. Check fan operation. If fan appears to be operating normally but RPMs are too high, replace the fan.

4. If the problem persists, replace the main control.

Press the Power button to clear the Error Code.

If Error happens again:

1. Ensure the LWCO Jumper is properly connected.

2. If the problem persists, replace the main control.

Press the Power button to clear the Error Code.

If Error happens again:

1. Check burner overheat switch connections. Ensure connections are secure.

2. Check switch resistance. If resistance is zero, replace the switch.

3. If the problem persists, replace the main control.

Press the power button to reset

If error happens again:

1. Check the vent pipe for blockages.

2. Check the vent pipe for blockages.

3. If error do not clear, replace the APS

4. If the problem persists, replace the main control.

Check the aps connection.

1.If APS is closed and connections are secure, check APS connection.

2. If the problem is not happen, replace the APS

3. If the problem persists, replace the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Check the connections to the fan. Ensure all are secure.

2. If the fan does not rotate during the ignition sequence, check for AC8V~26.5V power at the fan connection. If AC8V~26.5V power is present at the control, replace the fan. If the blower does not have AC8V~26.5V power, check power at the control. If AC8V~26.5V power is not present at the control, replace the control.

3. If the problem persists, replace the main control.

Recover

methods

Soft Lock

Hard Lock

Soft Lock

Hard Lock

Soft Lock

Page 69

The FT Series Heating Only, Boiler

Page 69

Error Code

78 Cascade Error Please refer to Manufacturer Document 1349 for Cascading the FT.

81 Low Water Level Circuit

Error Code Description Possible Remedies

Flame Signal Detected before

Ignition

Poor Communication (Control Display)

Low Water Level Sensor (Low Water Level Detected

Four (4) Consecutive times)

Freeze Protection (Appliance has detected water temperature below

34°F(1°C)

Exhaust Sensor detects Vent

Temperature is Greater than 190oF (88oC)

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Turn power OFF and ON at the main power switch internal to the appliance.

2. If the problem persists, replace the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Check the appliance cover. Ensure it is secure. Flame detection sensor can detect an external light source.

2. Check flame detection sensor. Ensure connections are secure. Normal operating

settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

3. If the problem persists, replace the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Check connections from main control to display panel.

2. If the problem persists, replace the display and/or the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Ensure all valves are open to the appliance and there are no leaks.

2. Ensure all air has been purged from the system.

3. Check wiring connections to low water level sensor. Ensure all are secure.

4. Check low water level sensor resistance. If resistance is zero, replace the sensor.

5. If the problem persists, replace the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Ensure all valves are open to the appliance and there are no leaks.

2. Check wiring connections to low water level sensor. Ensure all are secure.

3. Check low water level sensor resistance. If resistance is zero, replace the sensor.

4. If the problem persists, replace the main control.

This Error Code will go away when the freezing condition is remedied.

If Error happens again:

1. Ensure appliance is located in a mechanical room protected from freezing conditions.

2. Ensure all valves are open to the appliance, there are no leaks.

2. Check wiring connections to low water level sensor. Ensure all are secure.

3. Check low water level sensor resistance. If resistance is zero, replace the sensor.

4. If the problem persists, replace the main control.

This Error Code will go away when the condition is remedied.

If Error happens again:

1. Check if dip switch Max Fire setting is ON. Switches 6 and 7 should be OFF for

normal operation.

2. Check exhaust temperature sensor. Ensure connections are secure.

3. Check sensor resistance. If resistance is zero, replace the sensor.

4. Check exhaust vent for blockage.

5. If the problem persists, replace the control.

6. If the problem persists, replace the heat exchanger.

Recover

methods

Soft Lock

Page 70

6.2 Fault Tree Analysis

1. Flame detection

Page 71

The FT Series Heating Only, Boiler

6.2 Fault Tree Analysis (continued)

2. Gas Detection

Page 71

3. ‘Storage’, ‘DHW’, ‘OP’, ‘CH overheat’, ‘Exhaust heat’ Sensor detects

Error code contents

E28 DHW NTC open or short E33 OP NTC open or short E35 Exhaust NTC open or short

Page 72

SECTION 7 Trouble Shooting

7.1 Diagnostics

Question Answer

Make sure that the ON/OFF button on the Control Display has been turned ON.

If the monitor on the Control Display is blank, make sure the power cord is plugged and 4A fuses on the main controller in the units are good.

Burner does not ignite

when the hot water is opened.

Make sure that there is water supplied to the unit. The unit activates once the inlet water ow is over 0 gpm.

Make sure the cold and hot water lines are not plumbed in reverse side.

Make sure that the cold water and gas supply lines are opened.

Make sure that the water lines are not frozen.

Check that the setting temperature on the unit is not too low

Make sure that the lter in the cold water supply line is not clogged with debris.

Water is not hot enough.

Water is too hot.

Hot water temperature uctuates at the opened tap.

The blower is still

operating after the

combustion stops.

Temperature Rise

too Quickly

Abnormal sounds come

from unit during

operation.

Heater doesn’t re when DHW ow is initiated

CH Temp drops lower

than expected before

unit re-res

Make sure that the gas supply type is correct.

Check the supply and manifold gas pressures are in accordance with specications.

Make sure that the water ow sensor with three wires has been properly connected on the top of heat exchanger.

Make sure that the setting temperature on the unit is not too hot.

Make sure that the lter in the cold water supply line is not clogged with debris.

Make sure that the gas supply type is correct.

Make sure that the lter in the cold water supply line is clean.

Make sure that the gas supply type is correct.

Check the supply gas pressure is sufcient.

This is normal because the blower keeps operating for 1 minute to vent (exhaust) the ue gas from the chamber once the combustion has stopped.

Occurs when supply water temperature in heat exchanger rises faster than 2°F per second during the rst two minutes the burner is on. Automatically resets after a few minute delay or using manual reset on Control Display. See message displayed TEMPERATURE SENSOR and follow procedure for loose connections.

A leak of combustion gas between sealed chamber and exhaust tube inside the unit. Call a qualied service technician for evaluation.

Improper venting termination, make sure that the venting termination complies with specication.

Check the supply gas pressure is sufcient. Insufcient gas pressure will cause unstable burner ame and noise.

Potentially the domestic water ow is too low. Min allowable is 0.75 gpm. Check in Manual Mode OTO AGA

Change Parameter 14:bo to 10degrees F (5.5 degrees C)

Page 73

The FT Series Heating Only, Boiler

7.2 Suggested Corrective Actions

This controller is able to record information about the boiler’s condition at the time of the ve previous faults or errors. Refer to the Section ‘5.10 Error Mode’ of this manual.

Display Condition Diagnostic Corrective Action(s)

Page 73

Nothing shown

on display Control Display

and blower

running at full

speed.

Nothing is shown

in display Control Display and no other boiler components are

operating.

Control is not

receiving power.

Control is not

receiving 120V power.

Check wiring for short

circuit or incorrect

wiring.

Check transformer

connection to the

control per wiring diagram. Check for 12V output of transformer.

Check service switch and/or circuit breaker to boiler turned is on.

Is there 120 Volts at the service switch?

Is the ON/OFF POWER SWITCH (inside boiler case) turned on?

Check for 120 volts at

the line voltage

terminal block located inside the boiler case.

Correct wiring per wiring diagram

including connection of transformer to

the control.

Replace transformer if it is receiving 120V, but not outputting 12Vac.

Turn on service switch to power boiler.

Troubleshoot and correct the power supply to the manual switch.

Turn ON the manual power switch inside the boiler case.

Correct wiring inside the boiler case using the wiring diagram in this manual.

Nothing is shown

on Control Display, but boiler is

operating.

Occurs when the

communication is lost from the control to the

display.

Inspect the fuse. Replace if necessary.

Check for loose

connections and

proper pin alignment/

engagement on the

Control's plug.

Cycle power off and on using boiler power switch and check for operation.

Replace the fuse with proper part

found in the replacement part section

of this manual. If fuse blows again recheck wiring per diagram.

Check for continuity on the wire harness from the display to the control. See repair parts section for proper replacement part.

Replace with new display module. See

repair parts section for proper

replacement part.

Page 74

7.2 Suggested Corrective Actions (continued)

Fault Condition Diagnostic Corrective Action(s)

Occurs when a

temperature

TEMPERATURE SENSOR

FLAME FAULT

sensor has electrically shorted

(SHORT) or has

become disconnected

(OPEN).

Occurs when ame is detected when

there should be

no ame.

Reset using manual

reset screen on

Control Display. (Power button)

Reset using manual

reset screen on

Control Display. (Power button)

Check all the temperature readings of the boiler on the DIAGNOSTICS

- TEMPERATURES menu to determine

if any sensors are currently displayed

as SHORT or OPEN.

Check wire harness for loose

connections and pin engagement at sensor Connection and Control

module.

If problem persists after checking items above replace Control. Refer to repair parts section for kit number.

Burner may be operating too hot due

to incorrect combustion. Inspect ame and conduct combustion test.

Check for ame at burner via ame current with burner off. Turn boiler off and watch ame through observation port. If ame continues after shutdown replace gas valve.

Check wire harness for loose

connections and pin engagement at

blower. Connections.

BLOWER FAULT

IGNITION

FAU LT

GAS VALVE FAU LT

Blower unable

to reach required speed or does not

reach 0 RPM when turned off.

Even if boiler

went through 8

ignitron attempts, but cannot detect

ame

The Control has detected a

problem with it

gas valve

output circuit.

Reset using manual

reset screen on

Control Display. (Power button)

Power off and on.

Reset using manual

reset screen on

Control Display. (Power button)

Boiler in standby mode and blower not running. If BLOWER SPEED is not 0 RPM then replace blower.

If blower does not rotate during ignition sequence check for 120V power at blower connection. If 120Vac power at blower motor and it doesn't start replace blower. Check power at Control. If 120Vac is not present at Control when boiler is powered replace Control.

Dirty burner and/or heat exchanger will cause high back pressure and poor ignition. Visual inspection of ue ways often will not be able to diagnose condition.

Check incoming gas pressure with boiler off and at Max re. Adjust within limits on rating label.

Check for ue pipe and intake pipe restrictions or blockage

Check burner fasteners and gaskets

Check air intake pipe and proper propane orice

Check wire harness connections between gas valve and Control.

If lockout re-occurs replace Control.

Page 75

The FT Series Heating Only, Boiler

SECTION 8 Maintenance

8.1 Annual startup & general maintenance

Page 75

Regular Maintenance

- This Manual should be placed in a safe and dry

location near the Boiler. Maintenance instructions should be carried out by the following guidelines.

Maintenance procedures [ Daily ]

- Check that the boiler casing is closed.

Check if there is any problem with the Boiler casing

and the two upper and lower screws are tightened well. Boiler casing must be closed while it is running.

WARNING

To prevent potential severe personal injury,

death or substantial property damage,

remove all contaminated materials.

If contaminants are found:

Remove products immediately from the area. In order to check the status of Boiler, call

a qualied service technician to inspect

the Boiler for possible damage from acid

corrosion.

WARNING

DO NOT store combustible materials, gasoline

or any other ammable vapors or liquids near the Boiler. Remove them immediately or store them other places.

- Check the power source. Make sure that the power cord is correctly connected. The main power line is connected to the manual switch box inside a Boiler. (Power line

through the strain relief in the bottom of the boiler

casing and x it.)

- Check the status of the Control Display

Check status of the power supply. Please check for any debris on the button.

Maintenance procedures [ Monthly ]

- Check the vent pipe.

Visually inspect the ue gas vent piping for detecting any signs of blockage, leakage or deterioration of the piping. Please contact a qualied service technician immediately if you nd any problem.

- Check the air inlet pipe.

Visually inspect the air inlet to be sure it is unobstructed. Inspect entire length of air piping for ensuring that piping is intact and all joints are properly sealed. Call your qualied service technician if you notice any problems.

- Check the relief valve.

Inspect the Boiler relief valve and the relief valve

discharge pipe for any signs of weeping or leakage. If the relief valve often weeps, immediately contact your qualied service technician for inspecting the Boiler and system.

- Check the condensate outlet.

While the Boiler is running, check the discharge end of the condensate drain tubing. Make sure that no ue gas is escaping from the condensate drain tubing. If ue gas is continuously escaping, it is a serious problem. Call your qualied service technician for inspecting the Boiler and condensate line. Also, rell the condensate trap if problem persists regularly.

- Check the vent terminal screen vent (rodent

screen).

If you encounter a problem of combustion

specications, visually inspect the terminal screen. And then replace it with spare parts or clean the screens.

Page 76

8.1 Annual startup & general maintenance (continued)

- Check the air vent

If the air vent valve seems to work freely without leaking, replace cap “A” by twisting all the way on. Loosen cap “A” one turn to allow vent to operate. If vent does not operate correctly, replace the vent.

lever completely, the valve or discharge line may be

blocked. Shut down the Boiler immediately. Call your qualied service technician to inspect the boiler and system.

- Check the burner state

You can clean the exterior of burner. However, if you

need to clean the inside of the burner stage, you

should call an expert.

Maintenance procedures [Every 6 Months]

- Check the boiler piping (gas and water) Visually inspect for leaks around internal water piping. Also inspect external water piping, circulators, relief valve and ttings. Immediately call a qualied service technician to repair any leaks. Leaks must be xed by a qualied service technician immediately. Failure to comply with this instruction could result in severe personal injury, death or substantial property damage.

- Check the operate relief valve

WARNING

Leaks must be xed by a qualied service technician immediately. Failure to comply with this instruction could result in severe personal injury, death or substantial property damage. This discharge line must be installed by a qualied heating installer or a service technician.

8.2 Flushing the Boiler

- Flushing the Boiler

Flushing the Heat Exchanger of boiler is a complicated

procedure. Refer to the following instructions carefully before attempting the procedure. If you

do not understand about the procedure, contact an

authorized technician or licensed professional. Keep

in mind that improper maintenance can void your

warranty.

Before proceeding the procedures, verify that relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of scalding from

hot water. If water ows freely, release the lever and allow the valve to seat. Watch the end of the

relief valve discharge pipe to ensure that the valve

does not weep after the line has had time to drain. If the valve weeps, lift the seat again to attempt to clean the valve seat. If the valve continues to weep, contact your qualied service technician for inspecting the valve and system. If water does not ow from the valve even though you have lifted the

1. Disconnect electric power to the boiler.

2. Close the shutoff valves on both hot water outlet and cold water inlet lines. (V1 & V2)

3. Connect one hose “D1” to the valve “V3” and place the free end in the bucket. Connect one

of the hoses “D3” to the circulation pump outlet

and the cold water inlet line at the valve “V4”.

Connect other hose “D2” to the circulation pump

inlet and place the free end in the bucket.

Page 77

The FT Series Heating Only, Boiler

4. Pour the cleaning solution into the bucket.

Place the drain hose (D1) and the hose (D2) to the

pump inlet into the cleaning solution.

5. Open service valves (V3 & V4) on the hot water outlet and cold water inlet lines.

6. Turn on the circulation pump (Operate the pump and allow the cleaning solution to circulate through the

boiler for at least 1 hour at a rate of 4 gallons per

minute.)

7. Rinse the cleaning solution from the boiler as follows:

- Remove the free end of the drain hose (D1) from the bucket.

- Close service valve, (V4), and open shut off valve, (V2).

Do not open shut off valve, (V1).

- Allow water to ow through the boiler for 5 minutes.

- Close shut off valve (V2).

Page 77

8. Ensure service valves (V3 & V4) are closed and shut off valves (V1 & V2) are open.

9. Disconnect all hoses.

10. Remove the cold water inlet lter from the boiler and clean out any residues.

11. Reinsert the lter and ensure the lter cap is securely tightened.

12. Connect electrical power to the boiler.

8.3 Freeze Protection

FT Series Boilers are certied for indoor use only, and are not design-certied for placement outdoors. Proper precautions for freeze protection are recommended for boiler installations in areas where the danger of freezing exists.

Power outage, interruption of gas supply, failure of system components, activation of safety devices, etc., may prevent a boiler from ring. Any time a boiler

is subjected to freezing conditions, and the boiler is not able to re, and/or the water is not able to circulate, there is a risk of freezing in the boiler or in the pipes in the system. When water freezes,

it expands which may result in bursting of pipes, or damage to the boiler, which could result in leaking or ooding conditions.

Different glycol products may provide varying degrees

of protection. Glycol products must be maintained

properly in a heating system, or they may become

ineffective. Consult the glycol specifications, or the

glycol manufacturer, for information about specific products, maintenance of solutions, and set up

according to your particular conditions.

Not all pumps are capable of maintaining the reduced

temperature rise required with glycol concentrations greater than 35%.

NOTICE

Page 78

Freeze Protection (continued)

WARNING

Do NOT use automotive antifreeze or ethylene glycol. Use only inhibited propylene glycol solutions which are specially formulated for

hydronic systems. Ethylene glycol is toxic and can attack gaskets, seals, and metallic

components used in hydronic systems. A correct glycol concentration and inhibitor level

is critical.

Some items to consider are

• Consider the effects of reduced heat transfer and an increase in head pressure against the system

circulator. For example: A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.

• Glycol mixtures should not exceed 50%. A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator.

• The glycol solution should be tested as recommended by the glycol manufacturer but not

less than annually. Some items of concern are pH additive breakdown, inhibitor reduction, etc.

• Glycol/antifreeze solutions expand more than water; therefore, system design must take this into account. For example: a 50% by volume solution expands

4.8% in volume for a temperature increase from 32◦F to 180◦F, while water expands 3% over the same temperature rise.

Caution

It is highly recommended to follow the manufacturers

recommended concentrations, expansion

requirements, and maintenance recommendations. You must carefully calculate the additional friction loss in the system as well as the reduction in the heat

transfer coefcients.

_________________________________________

SECTION 9 Installation Check

9.1 Quick View

Before Installing

- Make sure that there is enough space for installing Water and gas line.

Verify vent/air termination is located as required.

- All models need for propane Conversion which requires a separate gas conversion manual.

Install Water Piping

- Boiler loop piping must be sized to the minimums listed in the Boiler manual. Using smaller piping will cause performance problems.

Install Vent & Air Piping

- Slide the air inlet pipe and vent pipe into the Boiler pipe connector.

- Make sure the terminations are placed as required in the manual and that air intakes are at least 12 inches above normal snow line.

- Refer to the material check list in this guide for a list of items needed.

Install Condensate Piping / Tubing &

Components

- Fill out the material check list in this guide to ensure you have the tubing or PVC pipe and all components needed for the condensate piping.

- Connect internal components that are supplied with the Boiler.

Install Gas Piping

- Install a union and shutoff valve.

Wire the Boiler

- Connect power wiring and control wiring per boiler manual wiring diagram.(Section 4.19)

Start up, Adjust & Test

- Follow the Boiler manual instructions to clean the system if needed, then ll and check water chemistry.

Page 79

The FT Series Heating Only, Boiler

9.2 Final Check Lists

Page 79

Final check : Installation Conditions.

• Is the Boiler properly mounted on the wall?

• Is there space for a drain which is close to the Boiler?

• Are there any combustible materials near the Boiler and vent pipe?

• Is the air supply sufcient for proper operation of the Boiler?

• Are the proper service clearances maintained?

• Is the distance between the Boiler and point of vent termination minimized?

• Is the proper distance from windows, doors, and other intake vents maintained?

Final check : Gas pipe installation

• Is the gas supply line equipped with a manual shut off valve?

• Is the gas supply line a minimum of 3/4˝ inner diameter?

• Is the gas supply line length and diameter

adequate to deliver the required BTU’s?

• Has the gas supply line pressure been

measured?

• Does the supply gas type match the type

indicated on the boiler rating plate?

Final check : Connecting the power supply

• Please check that the power is 120V AC.

• Have you checked the polarity of the electrical connection?

Final check : Pressure relief valve

• Have you properly installed an approved pressure

relief valve on the boiler?

Final check : Burner ames

• The burner ame must be checked periodically for a constant proper blue color.

• If the ame does not appear normal, the burner may need to be cleaned.

• If the burner needs to be cleaned, it must be

performed by a qualied service technician.

Final check: Air/Vent pipe installation

• Has the Boiler been vented with 3˝ or 2” PVC, CPVC, Polypropylene or BH Special

Gas Vent (S636 PVC, CPVC) for Category IV

appliances in accordance with this manual and/or your local code?

• Is the vent termination at least 12˝ above the exterior grade?

• Is the total vent length within the maximum vent length restriction?

• Have you checked the air/vent piping for leaks?

• Have you properly supported the vent

termination?

• Are all vent runs properly supported?

• Is the vent sloped upward toward the vent termination at a rate of 1/4˝ per foot (2% grade)?

Final check : Condensate drain installation

• Have you installed a condensate drain line from

the Boiler to a drain or laundry tub?

Final check : Setting the DIP switches

• Are all DIP switches correctly set on the main board?

Sight Glass

Blue ame

Page 80

Feature

Casing _ List

Note

R2080602

No. Description

Terminal block (6P)

Terminal block (12P)

Front cover

Control

display cover /

window

Pressure gauge

Intake/Exhaust sealing pad

Wall

hung bracket (top) FT1924

Wall Mount Bracket

Wall hung bracket (bottom)

No. Description

Part

Number

Notes

Terminal block (6P)

FT1827

SECTION 10 Parts

10.1 Parts Lists and Illustrations (80-140)

Casing Parts (80 MBH to 140 MBH)

No. Description

O-7 O-Ring P7 FT1601

7 Exhaust vent duct Assembly FT1002

Stainless band (Ø100)

7-1

Packing

7-2

Exhaust vent duct

7-3

Exhaust testing c ap

7-4

O-Ring P85

7-5

Exhaust vent adaptor(Inside)

7-6

O-Ring P75

7-7

8 Air inlet duct Assembly FT1010

Air inlet duct

8-1

Air inlet adaptor (Inside)

8-2

9 Air vent FT1321 10 Air vent adaptor FT1548 11 Air vent rubber pad FT1939 12 Air pressure sensor(80) FT1804 13 Control bracket FT1049 14 Ignition transf ormer ST1006 15 Control sub-bracket FT1050 16 Display Control (P-950EH) FT1053 17 Bracket FT1051

Condensate blockage,

Air pressure switc h

19 PCB Cont rol (NGTB-900CP) FT1052

Part

Number

FT1603 FT1604 FT1611 FT1606 FT1607 FT1608 FT1609

FT1605

FT1612

FT1022

20 Powe r swit c h FT1020

22 Terminal block (12P) FT1618 23 Front cover FT1956

Control display cover /

window

25 Pressure gauge FT1058

Intake/Exhaust sealing pad

26 27

Wall hung bracket (top) FT1924

28 Wall Mount Bracket FT1894 29 Wall hung bracket (bottom) FT1936

FT1024

FT1771

Page 81

The FT Series Heating Only, Boiler

Page 81

Page 82

Heat Exchanger _ List

No. Description

36 Temperature sensor FT1324 37 Low level sensor FT1325

Flame detector sensor bracket

39 Flame detector sensor FT1327 40

Flame detector sensor cover

41 CH Outlet Pipe (80,100K) FT1853

CH Outlet Pipe (120,140K) FT1070 42 CH Return Pipe-2 FT1072 43 Pump FT1672 44 CH Return sensor FT1635 45 CH Return pipe-1 FT1071 46 Condensate trap A ss em bly FT1783

No. Description

Part

Number

No tes

36 Temperature sensor FT1324

FT1071

Heat Exchanger Parts

(80 MBH to 140 MBH)

No. Description

Part

Number

O-22 O-Ring P22

P-3 3/8" Packing P-5 3/4" Packing

P-6 1" Packi ng

30 Exhaust pipe

Exhaust sensor brack et FT1529

31 32 EX-Adaptor FT1784 33 Exhaust overheat s ensor FT1307 34 Exhaust pipe packing (lower) FT1666

Heat Exchanger Assembly

(80,100K) Heat Exchanger Assembly (120,140K)

35-1 Burner A ss em bly FT1925 35-2 Overheat s ensor FT1310 35-3 Burner upper c ase FT1926 35-4 Burner P ack ing FT1927

FT1644 FT1060 FT1646

FT1691

FT1067

FT1852

FT1068

35-5 Burner FT1314 35-6 Burner case sealing O-ring FT1661 35-7 Ignition rod FT1315 35-8 Igni tion rod gasket FT1316 35-9 Burner downside c ase FT1928

35-10 Refractory FT1665

37 Low level sensor FT1325 38 39 Flame detector sensor FT1327 40 41 CH Outlet Pipe (80,100K) FT1853

42 CH Return Pipe-2 FT1072 43 Pump FT1672

Flame detector sensor bracket

Flame detector sensor cover

CH Outlet Pipe (120,140K) FT1070

FT1669

FT1069

44 CH Return sensor FT1635 45 CH Return pipe-1 46 Condensate t rap As sem bly FT1783

Page 83

The FT Series Heating Only, Boiler

Feature

Page 83

Page 84

Fan & Gas Valve _ List

Notes

No. Description

60 Gas valve Assembly FT1413

60-1 Gas valve outlet adaptor FT1919 60-2 Gas valve O-Ring FT1727 60-3 Gas va l ve FT1416 60-4 Gas valve inlet adaptor FT1538 60-5 Gas valve bracket FT1539

61 Gas pi pe (upper/ 80,100K) FT1860

Gas pipe (upper/120,140K) FT1879

62 Gas pi pe (down) FT1086 63 1/2" Spiral packing FT1710 64 Gas inlet adaptor FT1893

Wire Harness 80-100 FT1905

Note

Blower Parts

(80 MBH to 140 MBH)

No. Description

50N Fan guide FT1940

51 Damper packing FT1955

51N Damper packing FT1941

52 Damper body FT1915

52N Damper body FT1942

53 Fan rubber packing (1.6t) FT1082 54 Mesh FT1720 55 Fan Assembly(80K) FT1862

Fan Assembly (100K) FT1863 Fan Assembly (120K) FT1864

Fan Assembly (140K) FT1407 55-1 Fan FT1406 55-2 Fan seal i ng O-Ring ST1038

55-3 Gas mixer housing FT1409 55-4 Intake orifice (80K) FT1865

Intake orifice (100K) FT1866

Intake orifice (120K) FT1867

Intake orifice (140K) FT1535

56 Stainless band (Ø60) FT1078 57 Air intake hose (80,100K) FT1878

Air intake hose (120,140K) FT1533

Part

Number

Gas Valve Parts (80 MBH to 140 MBH)

No. Description

60 Gas valve Assembly FT1413

60-1 Gas valve outlet adaptor FT1919 60-2 Gas valve O-Ring FT1727 60-3 Ga s valve FT1416 60-4 Gas valve inlet adaptor FT1538 60-5 Gas valve bracket FT1539

61 Gas pipe (upper/80,100K ) FT1860

Gas pipe (upper/120,140K) FT1879

62 Gas pipe (down) FT1086 63 1/2" Spiral packing FT1710

Part

Number

58 Nylon Barb Fitting FT1918

59A Nozzle (natural/80K) FT1943

Nozzle (natural/100K) FT1944 Nozzle (natural/120K) FT1945 Nozzle (natural/140K) FT1412N

59B Nozzle (Propane/80K) FT1946

Nozzle (Propane/100K) FT1947 Nozzle (Propane/120K) FT1948 Nozzle (Propane/140K) FT1412P

64 Gas inlet adaptor FT1893

Wire Harness 80-100 FT1905

Page 85

The FT Series Heating Only, Boiler

Page 85

Before January of 2018

After January of 2018

Page 86

Feature

Notes

R2080602

Casing _ List

No. Description

21 Terminal block (6P) 22 Terminal block (12P) 23 Front cover

Control

display cover /

window

25 Pressure gauge 26 Intake/Exhaust sealing pad 27 Wall hung bracket( top)

2829Wall Mount Bracket

Wall hung bracket(bottom)

No. Description

Part

Number

Notes

10.2 Parts Lists and Illustrations (199)

Casing Parts (199 MBH)

No. Description

O-7 O-Ring P7

7 Exhaust vent duct Assembly 7-1 Stainless band (Ø100) 7-2 Packing 7-3 Exhaust vent duct 7-4 Exhaust testi ng cap 7-5 O-Ring P85 7-6 Exhaust vent adaptor(Inside) 7-7 O-Ring P75

8 Air inlet duct Assembly

8-1 Air inlet duct

9 Air vent 10 Air vent adaptor

11 Air vent rubber pad

12 Air pressure sensor(80) 13 Control bracket 14 Ignition transformer 15 Control sub-bracket

Part

Number

FT1601 FT1002 FT1603 FT1604 FT1611 FT1606 FT1607 FT1608 FT1609 FT1909 FT1605 FT1321 FT1548 FT1939 FT1804 FT1751

ST1006

FT1752 16 Display Control (P-950EH) 17 Bracket

Condensate blockage,

Air pressure switch

PCB Control (NGT B-900CP) FT1052

20 Po we r swit c h FT1020

21 Terminal block (6P) 22 Terminal block (12P) 23 Front cover

Control display cover /

window

25 Pressure gauge 26 Intake/Exhaust sealing pad 27 Wall hung bracket( top)

2829Wall Mount Bracket

Wall hung bracket(bottom)

FT1053

FT1753

FT1022

FT1827 FT1618 FT1949

FT1024

FT1058 FT1771 FT1924

FT1894 FT1936

Page 87

The FT Series Heating Only, Boiler

Page 87

Page 88

Heat Exchanger _ List

Notes

No. Description

36 Temperature sensor 37 Low level sensor

Flame detector sensor bracket

39 Flame detector sensor 40 Flame detector sensor cover 41 CH Outlet pipe 42 CH Return pipe-2 43 Pump 44 CH Return sensor 45 CH Return pipe-1 46 Condensate trap Assembly

No. Description

Part

Number

Notes

Heat Exchanger Parts

(199 MBH)

No. Description

O-22 O-Ring P22

P-3 3/8" Packing P-5 3/4" Packing P-6 1" Packing

30 Exhaust pipe 31 Exhaust sensor bracket 32

EX-Adaptor 33 Exhaust overheat sensor 34 Exhaust pipe packing (lower) 35 Heat Exchanger Assembly

35-1 Burner Assembly 35-2 Burner upper cas e 35-3 Burner pack ing 35-4 Burner 35-5 Igniti on rod 35-6 Igniti on rod gasket

Part

Number

FT1644 FT1060 FT1646 FT1691 FT1823

FT1529

FT1784 FT1307 FT1836 FT1758 FT1796 FT1760 FT1824 FT1762 FT1763

FT1316 35-7 Overheat sens or 35-8 Burner downside c ase 35-9 Refractory

36 Temperature s ens or 37 Low level sensor

Flame detector sensor

bracket

39 Flame detector sensor 40 Flame detector sensor cover 41 CH Outlet pipe 42 CH Return pipe-2 43 Pump 44 CH Return sensor 45 CH Return pipe-1 46 Condensate trap Assembly

FT1310

FT1764

FT1826

FT1324 FT1325

FT1669 FT1327

FT1069 FT1765 FT1768 FT1767 FT1635 FT1071 FT1783

Page 89

The FT Series Heating Only, Boiler

Feature

Page 89

Page 90

Notes

Blower Parts (199 MBH)

No. Description

50 Fan guide 51 Damper packing 52 Damper body 53 Fan rubber packing (1.6t) 54 Fan guide packing

55 Fan Assembly 55-1 Fan 55-2 Fan sealing O-Ring 55-3 AGM Venturi 55-4 AGM O-Ring 55-5 AGM Body

56 Stainless band (Ø100)

57 Air intake hose

58 Nylon barb Y fitting

Part

Number

FT1769 FT1770 FT1915 FT1082 FT1772 FT1916 FT1406 ST1038 FT1917 FT1774 FT1775 FT1603 FT1846

FT1918

59 Stainless band (Ø89) 60 Gas valve assembly

60-1 Gas valve outlet adaptor 60-2 Gas valve O-Ring 60-3 Gas valve 60-4 Gas valve inlet adaptor 60-5 Gas valve bracket

Nozzle (natural)

Nozzle (propane) 62 Gas pipe (upper) 63 1/2" S pi ral packing 64 Gas pipe (down) 65 Gas inlet adaptor 66 Wire harness

FT1777 FT1950 FT1919 FT1727 FT1416 FT1538 FT1779 FT1780 FT1802 FT1781 FT1710 FT1782 FT1893 FT1906

Page 91

The FT Series Heating Only, Boiler

Feature

Page 91

Page 92

Notes:

For Product and

Service VIDEOS

Dimensions and specications subject to change without notice in accordance with our policy of continuous product improvement.

H2375000H

Customer Service and Product Support: 800.900.9276 • Fax 800.559.1583

20 Industrial Way, Rochester, NH, USA 03867

20-01 Document 1342H

Laars FTHW User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

SECTION 1 Product Accessories

1.1 Introduction

1.2 Included with the Unit

SECTION 2 Product Characteristics

2.1 Model Nomenclature (model number)

2.3 Dimensions

2.4 Names of Components

2.5 Product Flow Paths and Characteristics

SECTION 3 Safety Regulations

3.1 Safety Symbols

3.2 Safety Precautions and Proper Use

SECTION 4 Installation

4.1 Location and Clearances

4.2 Wall Mount Bracket

4.3 Combustion Air

4.4 Venting, Exhaust

4.5 General Location Guideline

4.6 Locations for Vent Pipe Terminator

4.7 Air Supply and Vent Connections

4.8 Vent / Air Pipe Termination

4.9 Gas Supply and Piping

4.10 Gas Supply Pressure

4.11 Gas Setup and Adjustment

4.12 High Altitude Installations. 2,000’ to 10,000’

4.13 Natural Gas to Propane Conversion

4.14 Plumbing Guidelines

4.14 Plumbing Guidelines

4.15 Pressure Relief Valve

4.16 Disposal of Condensate

4.17 Electrical Wiring Connections

4.18 DIP Switches

4.19 Control Board, Electrical Diagram

4.20 Ladder Diagram

4.21 Electrical Connections

SECTION 5 Control Display and Operation

5.1 Control Dial and Buttons

5.2 LCD Overview

5.3 Operating Mode

5.4 Setting the Clock

5.5 CH Set Point Change Mode

5.6 Status Display Mode

5.7 Installer Mode

5.8 Storage Mode

5.9 Outdoor Reset Adjustment

5.10 External Set Point Temperature Control

5.11 Error Mode

SECTION 6 Error Codes

6.1 Error Code Table

6.2 Fault Tree Analysis

SECTION 7 Trouble Shooting

7.1 Diagnostics

7.2 Suggested Corrective Actions

SECTION 8 Maintenance

8.1 Annual startup & general maintenance

8.2 Flushing the Boiler

8.3 Freeze Protection

SECTION 9 Installation Check

9.1 Quick View

9.2 Final Check Lists

SECTION 10 Parts

10.1 Parts Lists and Illustrations (80-140)

Notes: