Lochinvar FTX400N, FTX500N, FTX600N, FTX725N, FTX850N Installation Manual

FTXL-I-O_100059358_2000005000_Rev U

Installation & Operation Manual Models: 400, 500, 600, 725, & 850

This manual must only be used by aWARNING qualified heating installer / service technician. Read all instructions, including this manual and the FTXL Service Manual, before installing.

Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Save this manual for future reference.

Contents

HAZARD DEFINITIONS ....................................................	2
PLEASE READ BEFORE PROCEEDING ........................	3
THE FTXL -- HOW IT WORKS.......................................	4-5
RATINGS ...........................................................................	6
1. DETERMINE BOILER LOCATION
Provide Air Openings to Room ..........................................	9
Flooring and Foundation ...................................................	9
Residential Garage Installation ..........................................	9
Vent and Air Piping ............................................................	9
Prevent Combustion Air Contamination.............................	9
Corrosive Contaminants and Sources .............................	10
Using an Existing Vent System to Install a New Boiler	... 10
Removing a Boiler from Existing Common Vent..............	11
2. PREPARE BOILER
Remove Boiler from Wood Pallet.....................................	14
Gas Conversions.........................................................	14-15
Model 400 - 500..........................................................	14
Models 600 - 850........................................................	15
3. GENERAL VENTING
Direct Venting Options .....................................................	16
Install Vent and Combustion Air Piping ...........................	17
Requirements for Installation in Canada..........................	18
Sizing ...............................................................................	18
Min./Max. Combustion Air & Vent Piping Lengths ............	18
Materials............................................................................	18
Optional Room Air............................................................	19
PVC/CPVC ..................................................................	20-21
Polypropylene...................................................................	22
Stainless Steel Vent .........................................................	23
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall...................................	24-27
Determine Location................................................	24-26
Prepare Wall Penetrations.....................................	26-27
Multiple Vent/Air Terminations .........................................	27
Sidewall Termination - Optional Concentric Vent .......	28-30
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical ....................................	31-32
Determine Location.....................................................	31
Prepare Roof Penetrations .........................................	32
Multiple Vent/Air Terminations .........................................	32
Vertical Termination - Optional Concentric Vent.........	33-34
Alternate Vertical Concentric Venting .........................	35-36

6. HYDRONIC PIPING
System Water Piping Methods.........................................	37
Low Water Cutoff Device .................................................	37
Chilled Water System.......................................................	37
Freeze Protection.............................................................	37
General Piping Information ..............................................	37
Relief Valve Installation ...................................................	38
Near Boiler Piping Components.......................................	39
Circulator Sizing ...............................................................	39
Near Boiler Piping Connections .......................................	40
Piping Diagrams .....................................................	42-47
7. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................	48
Natural Gas ......................................................................	49
Pipe Sizing for Natural Gas ........................................	49
Natural Gas Supply Pressure Requirements	............. 49
Propane Gas ....................................................................	49
Pipe Sizing for Propane Gas ......................................	49
Propane Supply Pressure Requirements ...................	49
Check Inlet Gas Supply ...................................................	50
Gas Pressure ...................................................................	51
Gas Valve Replacement ..................................................	51
8. FIELD WIRING
Line Voltage Connections ................................................	52
Low Voltage Connections ................................................	52
Wiring of the Cascade......................................................	54
9. CONDENSATE DISPOSAL
Condensate Drain ............................................................	56
10. STARTUP .............................................................	57-63
11. OPERATING INFORMATION
General.............................................................................	64
Cascade ...........................................................................	68
Sequence of Operation ...............................................	69-70
FTXL Control Module .......................................................	71
Status Display Screens ...............................................	72-74
12. MAINTENANCE
Maintenance and Annual Startup................................	75-79
13. DIAGRAMS
Wiring Diagram ...........................................................	80
Ladder Diagram .........................................................	81
Revision Notes ..................................................	Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

DANGER

WARNING

CAUTION CAUTION NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

2

Installation & Operation Manual

Please read before proceeding

WARNING

NOTICE

Installer – Read all instructions, including this manual and the FTXL Service Manual, before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler

– Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

WARNING DO NOT install units in rooms or environments that contain corrosive

contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.

When servicing boiler –

•To avoid electric shock, disconnect electrical supply before performing maintenance.

•To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation –

•Do not block flow of combustion or ventilation air to the boiler.

•Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

•Do not use this boiler if any part has been under water. T he possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

WARNING

WARNING

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

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 near by phone. Follow the gas supplier’s instructions.

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

•Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

Boiler water –

•Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

3

The FTXL - How it works...

1.Stainless steel heat exchanger

Allows system water to flow around specially designed tubes for maximum heat transfer, while providing protection against flue gas corrosion.

2.Heat exchanger top plate

Removal of the top plate allows access to the combustion chamber and tube sheet.

3.Blower

T e blowerh pulls in air and gas through the venturi (item 5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

4.Gas valve

T e gash valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

5.Venturi

T e venturih controls air and gas flow into the burner.

6.Flue gas sensor (limit rated)

T is sensorh monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if the flue gas temperature gets too hot. This protects the flue pipe from overheating.

7.Boiler outlet temperature sensor (limit rated)

T is sensorh monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.

8.Boiler inlet temperature sensor

T is sensorh monitors return water temperature (system return). If `selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.

9.Temperature and pressure gauge (field installed, not shown)

Monitors the outlet temperature of the boiler as well as the system water pressure.

10.Electronic LCD display

T e displayh features a high resolution liquid crystal screen, four (4) buttons, and a navigation dial. A serial and USB port support additional communication with the control.

11.Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the boiler.

12.Burner (not shown)

Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

13.Water outlet (system supply)

A 2" or 2-1/2" NPT (depending on the model) water connection that supplies hot water to the system.

14.Water inlet (system return)

A 2" or 2-1/2" NPT (depending on the model) water connection that returns water from the system to the heat exchanger.

15.Gas connection pipe

T readedh pipe connection of 1". This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

16.SMART SYSTEM Control Module

T e SMARTh SYSTEM Control responds to internal and external signals to regulate the blower, gas valve, and pump functions to meet heating demand. An optional remote connectivity allows boiler settings to be monitored and modified when connected to the internet.

17.Manual air vent

A manual air vent is used to remove trapped air from the heat exchanger shell.

18.Air intake adapter

Allows for the connection of the PVC air intake pipe to the boiler.

19.High voltage junction box

T e junctionh box contains the connection points for the line voltage power and all pumps.

20.Boiler drain connection

A 1" NPT drain connection is provided for easy access in the event the boiler needs to be drained .

Installation & Operation Manual

21.Low voltage connection board

T e connectionh board provides easy access for connecting external low voltage devices.

22.Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

23.Condensate trap

T e condensateh trap is sized for a 1/2" PVC outlet connection pipe.

24.Bezel (hinged)

Provides access to the gas train, heat exchanger, and display.

25.Ignition electrode

Provides direct spark for igniting the burner.

26.Flame inspection window

T e quartzh glass window provides a view of the burner surface and flame.

27.Gas shutoff valve (Models 500 - 850 only)

A manual valve is provided to isolate the gas valve from the boiler.

28.Relief valve (field installed, not shown)

Protects the heat exchanger from an over pressure condition. T e reliefh valve provided with the unit is set at 50 PSI.

29.Flame sensor

Used by the control module to detect the presence of burner f amel.

30.Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

31.Front panel

Removable panel to gain access to the internal components.

32.Power switch

Turns 120 VAC ON/OFF to the boiler.

33.Pump relay board

T e pumph relay board is used to connect the boiler, system and DHW pumps.

34.Transformer

T e transformerh provides 24V power to the integrated control.

35.High limit sensor (housed with the outlet temperature

sensor)

Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.

36.Low water cutoff probe (LWCO)

Protects the heat exchanger from overheating, by ensuring adequate water is supplied to the boiler. In the event of inadequate water levels, the boiler will shut down.

37.Stainless steel flue collector

Flue gas and condensate enter the stainless steel flue collector through the firetubes. A 1" drain connection allows condensate to flow through the collector into a condensate trap for disposal.

38.Reset switch

Reset switch for the low water cutoff. Hold the switch for 10 seconds to reset.

39.Test switch

T e testh switch permits manual triggering of the LWCO safety circuit to test the contacts and evaluate the integrity of the circuit. Hold the switch for 10 seconds to test.

40.Combustion measurement port

A port near the flue vent which provides access for a combustion analyzer probe.

41.Burner plate (not shown)

T e burnerh plate attaches the blower to the burner and the heat exchanger. Removal allows easy access to the burner for inspection or replacement.

4

Installation & Operation Manual

The FTXL - How it works... (continued)

Models 400 - 850

Front View	Rear View

19

27

21

18

17

4

26

36

16 33

38

39

20

23

DIR #2000544916 00

Left Side (inside unit)
	Right Side (inside unit)

5

Installation & Operation Manual

Ratings

FTXL Boiler

AHRI Rating

Model Number		Input				Net
		MBH			Gross	AHRI
					Output	Ratings
Note: Change “N” to		(Note 4)			MBH	Water,
						MBH
“L” for L.P. gas models.
	Min		Max		(Note 1)	(Note 2)
FTX400N	40		399	392		341
FTX500N	50		500	489		425
FTX600N	85.7		600	585		509
FTX725N	103.5		725	705		613
FTX850N	121.5		850	825		717

Other Specifications

Boiler				Vent
Water	Water	Gas	Air
Content	Connections	Connections	Size	Size
Gallons
				(Note 3)
13.2	2"	1"	4"	4"
11.9	2"	1"	4"	4"
11.9	2"	1"	4"	4"
17.2	2 1/2"	1"	4"	6"
15.9	2 1/2”	1”	4”	6”

NOTICE Maximum allowed working pressure is located on the rating plate.

Notes:

1.The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2.Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3.FTXL boilers require special gas venting. Use only the vent materials and methods specified in the FTXL Installation and Operation Manual.

4.Standard FTXL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

5.High altitude FTXL boilers are equipped to operate from 3,000 to 12,000 feet only. The boiler will not de-rate up to 5,400 feet and will de-rate by 1.6% for each 1,000 feet above 5,400 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in Fig. A) is also affixed to the unit.

De-rate values are based on proper combustion calibration and CO2’s adjusted to the recommended levels.

6.Ratings have been confirmed by the Hydronics Section of AHRI.

7.FTXL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the FTXL is listed to UL353.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

IMG01068

Figure A High Altitude Label Location

6

WARNING

WARNING

Installation & Operation Manual

1 Determine boiler location

Installation must comply with:

•Local, state, provincial, and national codes, laws, regulations, and ordinances.

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

•Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

•National Electrical Code.

•For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE	The FTXL gas manifold and controls
	met safe lighting and other performance
	criteria when the boiler underwent tests
	specified in ANSI Z21.13 – latest edition.

Before locating the boiler, check:

1.Check for nearby connection to:

•System water piping

•Venting connections

•Gas supply piping

•Electrical power

2.Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the

appliance. The pan must not restrict combustion air f ow.l Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3.Check area around the boiler. Remove any combustible materials, gasoline and other flammable liquids.

Failure to keep boiler area clear and free

WARNING of combustible materials, gasoline, and

other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

4.The FTXL must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

5.If a new boiler will replace an existing boiler, check for and correct system problems, such as:

•System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

•Incorrectly-sized expansion tank.

•Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

•Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.

6.Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1A on page 10). Prevent combustion air contamination. Remove any of

these contaminants from the boiler area.

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10).

Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING

WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Do not install the appliance where the relative humidity may exceed 93%. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC/ stainless steel pipe section provided with the appliance. The field provided PVC vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Closet and alcove installations

A closet is any room the boiler is installed in which is less than 171 cubic feet for FTX400 models, 193 cubic feet for FTX500 models, 223 cubic feet for FTX600 models, 247 cubic feet for FTX725 models and 278 cubic feet for FTX850 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 5 feet long, 4 feet wide, and 8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would be considered a closet for a FTXL Boiler.

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC or stainless steel vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury,

or death.

Provide clearances:

Clearances from combustible materials

1.Hot water pipes—at least 1/4" (6 mm) from combustible materials.

2.Vent pipe – at least 1" (25 mm) from combustible materials.

3.See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.

Clearances for service access

1.See FIG.’s 1-1 and 1-2 on page 8 for recommended service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

7

18" (457 MM) TOP

Installation & Operation Manual

1 Determine boiler location (continued)

Figure 1-1 Closet Installation - Minimum Required Clearances

CLOSET INSTALLATION

1/4" (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES

1" (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

0"
LEFT	6"
14" (356 MM)	0"
REAR	RIGHT
	6" (152 MM)
	FRONT

*AREA OF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES.

WARNING				For	closet	installations,		CPVC,
				polypropylene			or stainless steel
				vent material MUST BE used in
				a closet structure due to elevated
				temperatures.			Failure to	follow
				this	warning	could result in fire,
		VENTILATING	* personal injury, or death.
		AIR OPENING

CLOSED DOOR

VENTILATING *

AIR OPENING

IMG00982

Figure 1-2 Alcove Installation - Minimum Required Clearances

ALCOVE INSTALLATION

1/4" (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES

1" (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

0" LEFT

14" (356 MM) REAR

6" (152 MM)

FRONT

WARNING

18" (457 MM)

TOP

OPEN DOOR

0"

RIGHT

IMG00983

For alcove installations, CPVC, polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

8

Installation & Operation Manual

1 Determine boiler location

Provide air openings to room:

FTXL alone in boiler room

1.No air ventilation openings into the boiler room are needed when clearances around the FTXL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Recommended service clearances

FRONT	- 30" (762 mm)
TOP	- 18" (610 mm)
REAR	- 24" (610 mm)

FTXL in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

WARNING The space must be provided with combustion/ventilation air openings

correctly sized for all other appliances located in the same space as the FTXL.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

2.Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the FTXL because it takes its combustion air from outside (direct vent installation).

Flooring and foundation

Flooring

The FTXL is approved for installation on combustible flooring, but must never be installed on carpeting.

WARNING Do not install the boiler on carpeting even if foundation is used. Fire can result,

causing severe personal injury, death, or substantial property damage.

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

•Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.

•The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.

Vent and air piping

The FTXL requires a special vent system, designed for pressurized venting.

The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see the General Venting Section. Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the FTXL using any other means.

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the FTXL as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

WARNING	You must pipe combustion air to the boiler
	air intake. Ensure that the combustion air
	will not contain any of the contaminants
	in Table 1A, page 10. Contaminated
	combustion air will damage the boiler,
	resulting in possible severe personal
	injury, death or substantial property
	damage. Do not pipe combustion air
	near a swimming pool, for example. Also,
	avoid areas subject to exhaust fumes from
	laundry facilities. These areas will always
	contain contaminants.
			9

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

When using an existing vent system to install a new boiler:

WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide

emissions, causing severe personal injury or death.

Check the following venting components before installing:

•Material - For materials listed for use with this appliance, see Section 3 - General Venting. For polypropylene or stainless steel venting, an adapter of the same manufacturer must be used at the flue collar connection.

•Size - To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.

•Manufacturer - For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with flue producing condensate.

•Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

•Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3H for the manufacturer of the installed vent.

•Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.

With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on pages 20 and 21.

If any of these conditions are not met,WARNING the existing system must be updated

or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

10

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

	DANGER	Do not install the FTXL into a common
		vent with any other appliance. This
		will cause flue gas spillage or appliance
		malfunction, resulting in possible severe
		personal injury, death, or substantial
		property damage.

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.

a.Seal any unused openings in the common venting system.

b.Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c.Test vent system – 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. Do not operate a summer exhaust fan. Close fireplace dampers.

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

e.Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from another source.

f.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g.Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

11

Installation & Operation Manual

1 Determine boiler location

Combustion and ventilation air requirements for appliances drawing air from the equipment room

Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

The equipment room MUST be provided with properly sized openings and/or be of sufficient volume to assure adequate combustion air and proper ventilation for all gas fired appliances in the equipment room to assure adequate combustion air and proper ventilation.

The requirements shown are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances.

IMG01075

Figure 1-4_Combustion Air Through Ducts

2.If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-4).

No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances and the building MUST NOT be of “Tight Construction”3.

A combination of indoor and outdoor combustion air may be utilized by applying a ratio of available volume to required volume times the required outdoor air opening(s) size(s). This must be done in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1.

IMG01076

Figure 1-5_Combustion Air from Interior Space

3. If air is taken from another interior space combined with the equipment room:

(a) Two spaces on same story: Each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-5).

(b) Two spaces on different stories: One or more openings should have a net free area of two square inches per 1000 Btu/hr (44 cm2 per kW).

		IMG01074
Figure 1-3_Combustion Air Direct from Outside
1. If air	is	taken directly from outside the building
with	no	duct, provide two permanent openings to

the equipment room each with a net free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW) (see FIG. 1-3).

	12		IMG01077
			Figure 1-6_Combustion Air from Outside - Single Opening

Installation & Operation Manual

1 Determine boiler location (continued)

4.If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure (see FIG. 1-6).

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN/CSA B149.1. Check all local code requirements for combustion air. All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.

Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the equipment room. Each opening must have a net free area as specified in Table 1B. Single openings shall commence within 12" (30 cm) of the ceiling. The minimum dimension of air openings shall not be less than 3" (80 mm).

CAUTION Under no circumstances should the equipment room ever be under negative

pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

	FIG. 1-3				FIG. 1-4				FIG. 1-5						FIG. 1-6
									Inside Air from
	*Outside Air from				*Outside Air from				2 Ducts Delivered from Interior						*Outside Air from
Model	2 Openings Directly from				2 Ducts Delivered from						Space2
Number	Outdoors1				Outdoors1				Same Story						1 Opening Directly from
															Outdoors, in2
															(cm2)1
	Top	2	Bottom	2	Top	2	Bottom	2	Top	2		Bottom
	Opening, in		Opening, in		Opening, in		Opening, in		Opening, in				2	)
												2
	(cm2)		(cm2)		(cm2)		(cm2)		(cm2)			Opening, in	(cm
FTX400	100		100		200		200		400			400			134
	(646)		(646)		(1,291)		(1,291)		(2,581)			(2,581)			(865)
FTX500	125		125		250		250		500			500			167
	(807)		(807)		(1,613)		(1,613)		(3,226)			(3,226)			(1,078)
FTX600	150		150		300		300		600			600			200
	(968)		(968)		(1,936)		(1,936)		(3,871)			(3,871)			(1,291)
FTX725	182		182		363		363		725			725			242
	(1,174)		(1,174)		(2,342)		(2,342)		(4,677)			(4,677)			(1,561)
FTX850	213		213		425		425		850			850			284
	(1,374)		(1,374)		(2,742)		(2,742)		(5,484)			(5,484)			(1,832)

The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances.

No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per

1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”3.

1Outside air openings shall directly communicate with the outdoors.

2Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.

3”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight Construction”, provide air openings into the building from outside.

13

Installation & Operation Manual

2 Prepare boiler

Remove boiler from wood pallet

1.After removing the outer shipping carton from the boiler, remove the parts box.

2.To remove the boiler from the pallet (after removing the front door):

Models 400 and 500 Only (Venturi w/LP Orifices)

1.Remove the top bezel from the unit (no tools required for removal).

2.Disconnect the air inlet piping from the venturi by loosening

a.Remove the three (3) lag bolts from inside the front the band clamp around the rubber boot coupling. Slide the

of the boiler (FIG. 2-1).

rubber boot off of the venturi.

b.Remove the two (2) L-brackets and the two (2) lag 3. Disconnect gas piping from the venturi by loosening the

bolts inside the L-brackets on the rear of the boiler. Once the lag bolts have been removed, re-install the screws on the rear of the boiler.

c.Disconnect the ribbon cable and remove the bezel (no tools required for removal) before removing the boiler from the pallet or moving the boiler.

threaded nut on the venturi (replace gasket if damaged).

4.Remove the bolts connecting the venturi to the fan and then proceed to remove the Natural venturi from the unit (FIG.’s 2-2A and 2-2B).

5.Install the LP venturi onto the fan taking note of the following:

NOTICE	Do not drop the boiler or bump the jacket
	on the floor or pallet. Damage to the boiler
	can result.

Figure 2-1 Boiler Mounted on Shipping Pallet

a.The UP arrow on the plastic housing is indeed pointing up.

b.The threaded connection for the gas piping is facing towards the front of the unit. Reinstall the bolts connecting the venturi to the fan.

FRONT	REAR

REMOVE THE			REMOVE THE
LAG BOLTS (QTY. 3)			L-BRACKETS (QTY. 2)
FROM INSIDE THE FRONT			AND LAG BOLTS (QTY. 2)
OF THE BOILER

Gas conversions

WARNING For a boiler already installed, you must turn off gas supply, turn off power and

allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

For the 400 and 500 Models you must install a propane venturi to operate the FTXL on propane gas.

Models 600 - 850 do not require a venturi change for propane operation, but they will require a valve adjustment.

6.Reassemble the gas pipe to the threaded connection on the venturi. Install the new gasket provided in the kit and ensure it is seated properly before tightening the nut.

7.Reconnect the rubber boot on the air inlet to the venturi inlet and tighten the band clamp at this connection.

8.After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the rear of the boiler underneath the gas supply piping.

9.Replace the top bezel removed in Step 1 and resume operation.

WARNING After converting to LP, check combustion per the Start-up procedure in Section 10

of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

Models 400 and 500: Inspect the O-ringDANGER when the blower is disassembled. The O-ring

must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Table 2A LP Conversion Kit

Model	Description	Kit Number
400 - 500	LP Kit	100189174

14

2 Prepare boiler (continued)

Figure 2-2A 400 Model_Venturi with LP Orifice

BLOWER

O-RING

VENTURI

SCREWS

QTY. 3

GAS VALVE

IMG01069

Figure 2-2B 500 Model_Venturi with LP Orifice

BLOWER

O-RING

VENTURI

SCREWS

QTY. 5

GAS COCK

GAS VALVE

IMG01070

Installation & Operation Manual

Models 600 - 850

1. Lift the top bezel (prop the bezel up for service).

2. Remove the cover on top of the gas valve (FIG. 2-3).

3. Use a combustion analyzer to verify CO2 is within the range of 9.0 – 11.0%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3).

4. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the rear of the boiler underneath the gas supply piping.

5. Replace the gas valve cover and lower the bezel.

WARNING Failure to check and verify combustion could result in severe personal injury,

death, or substantial property damage.

Figure 2-3 Gas Valve Adjustment - Models 600 - 850

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

15

Installation & Operation Manual

3 General venting

Direct venting options - Sidewall Vent

IMG01061

IMG01060

	PVC/CPVC Concentric Sidewall
Two Pipe Sidewall	Models 400 - 600 Only
See page 24 for more details	See page 28 for more details

Direct venting options - Vertical Vent

IMG01062	IMG01063

IMG01064

	Two Pipe Vertical	PVC/CPVC	Vertical Vent, Sidewall Air
	See page 31 for more details	Concentric Vertical
		Models 400 - 600 Only
		See page 33 for more details

16

Installation & Operation Manual

3 General venting (continued)

Install vent and combustion air piping

DANGER The FTXL boiler must be vented and supplied with combustion and ventilation

air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

WARNING

WARNING

NOTICE

This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed in Tables 3E, 3F, and 3H for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Mixing of venting materials will void the warranty and certification of the appliance.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

WARNING

CAUTION NOTICE

For closet and alcove installations, CPVC, polypropylene or stainless steel material

MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

Improper installation of venting systems may result in injury or death.

Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.

WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a

common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

The FTXL boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the FTXL boiler using any other means.

You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 19 of this manual. The resultant installation is direct vent (sealed combustion).

The FTXL is certified as a Category II/IV boiler. All venting systems used with this boiler must be suitable for Category IV operation except for factory approved common vent systems operating as allowed in the Common Venting Section on page 20.

Air intake/vent connections

1.Combustion Air Intake Connector (FIG. 3-1) - Used to provide combustion air directly to the unit from outdoors. A f tting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2.Vent Connector (FIG.'s 3-2 thru 3-7) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for f naliconnection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 3-1 Near Boiler Air Piping

AIR

IMG00986

17

Installation & Operation Manual

3 General venting

Requirements for installation in Canada

1.Installations must be made with a vent pipe system certified to ULC-S636.

2.The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3.The components of the certified vent system must not be

Table 3B Concentric Vent Kit Equivalent Vent Lengths

	Model	Kit Number	Equivalent
			Vent Length
	400	100140484	5' (1.5 m)
	500 - 600	100140484	30' (9 m)

Air inlet pipe materials:

interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certifiedvent material to comply with this requirement.

4.The 4" Concentric Vent Kit available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 4" Concentric Vent Kit available from IPEX are both approved for use on the FTXL (400 - 600 models only) boiler. Both kits are listed to the ULC-S636 standard for use in Canada.

Sizing

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC, Polypropylene or ABS

Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet)

Galvanized steel vent pipe with joints and seams sealed as specified in this section.

Type “B” double-wall vent with joints and seams sealed as specified in this section.

AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

The FTXL uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

	Model	Pipe Diameter			De-rate per 25 feet of Vent
		Air Intake		Vent	Direct Vent	Room Air
	400	4" (102 mm)		4" (102 mm)	0.00%	0.00%
	500	4" (102 mm)		4" (102 mm)	0.40%	0.40%
	600	4" (102 mm)		4" (102 mm)	1.20%	1.20%
	725	4" (102 mm)		6" (152 mm)	1.20%	1.20%
	850	4" (102 mm)		6" (152 mm)	1.40%	1.40%
			Increasing or decreasing combustion air
	NOTICE
			or vent piping sizes is not authorized.

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:

Combustion Air = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

Vent = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows +

(3) 45° elbows + (1) concentric vent kit (100140484) = 49 equivalent feet (15 m) of piping.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

WARNING

NOTICE

Using air intake materials other than those specified can result in personal injury, death or property damage.

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply

System:

a.Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

b.Do not install seams of vent pipe on the bottom of horizontal runs.

c.Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

d.Ensure that the air inlet pipes are properly supported.

	NOTICE			The appliance output rating will reduce
				by up to 1.5% for each 25 feet of vent
	18			length.

3 General venting (continued)

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

Follow the polypropylene manufacturer’s instructions when using polypropylene material as an inlet pipe.

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

	DANGER	Failure to properly seal all joints and seams
		as required in the air inlet piping may
		result in flue gas recirculation, spillage
		of flue products and carbon monoxide
		emissions causing severe personal injury
		or death.
	Optional room air
		Optional room air is intended for
	NOTICE
		commercial applications. Combustion
		air piping to the outside is recommended
		for residential applications.

Commercial applications utilizing the FTXL boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

•The unit MUST be installed with the appropriate bird screen (Table 3C).

•The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.

•Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.

•Vent system and terminations must comply with the standard venting instructions set forth in this manual.

NOTICE	There will be a noticeable increase in the
	noise level during normal operation from
	the inlet air opening.

Installation & Operation Manual

When utilizing the single pipe method,WARNING provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of

the local building codes.

Table 3C Optional Room Air Kit

Model	Description	Kit Number
400 - 850	Room Air Kit	100157616

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

WARNING

WARNING

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

19

3 General venting

Common venting

FTXL boilers may be common vented; however, the following criteria MUST BE followed:

1.Only FTXL boilers may be connected to the common vent. DO NOT mix other manufacturer’s appliances or other Lochinvar models.

2.FTXL boilers connected to the common vent must all be of the same size.

3.Each FTXL boiler must have a Lochinvar supplied flue damper installed (see Table 3D).

4.A condensate drain must be installed above the flue damper.

5.Only vertical direct vent, positive pressure, Category IV or vertical/chimney vent, negative pressure, Category II may be used when common venting FTXL boilers. Sidewall common venting is not allowed.

6.FTXL boilers in a common vent must be connected and controlled with the integral FTXL SMART SYSTEM Cascade.

a.The Leader may be controlled through the FTXL SMART SYSTEM control through BMS (external 0 - 10V signal), ModBus, BACnet, or its own internally calculated set point.

b.The Cascade (Members) must be controlled by the FTXL Leader boiler using the Lead/Lag Cascade option.

For approved common vent sizing, contact the factory.

When FTXL boilers are common vented,

WARNING the criteria above MUST BE followed. Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.

	NOTICE	When FTXL boilers are common vented,
		hot water generators must be piped
		to the primary heating loop and tank
		thermostats must not be connected to the
		FTXL.
		A field supplied inline condensate
	NOTICE
		collection section MUST BE installed
		directly above the backflow preventer.

Installation & Operation Manual

Table 3D Flue Damper Kits

Flue Damper Kits

Model	Damper Size	Kit Number
400	4"	100056141
500	4”	100056141
600	4”	100056141
725	6”	100056142
850	6”	100056142

PVC/CPVC

This product has been approved for use with the PVC/CPVC vent materials listed in Table 3E on page 21.

Installing vent and air piping

WARNING

NOTICE

The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3E to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

NOTICE	All PVC vent pipes must be glued, properly
	supported, and the exhaust must be
	pitched a minimum of a 1/4 inch per foot
	back to the boiler (to allow drainage of
	condensate).

WARNING	Insulation should not be used on PVC
	or CPVC venting materials. The use of
	insulation will cause increased vent wall
	temperatures, which could result in vent
	pipe failure.

20

Installation & Operation Manual

3 General venting (continued)

Table 3E PVC/CPVC Vent Pipe and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

	Item	Material	Standard
		PVC Schedule 40, 80	ANSI/ASTM D1785
	Vent pipe	PVC - DWV	ANSI/ASTM D2665
		CPVC Schedule 40, 80	ANSI/ASTM F441
		PVC Schedule 40	ANSI/ASTM D2466
	Vent fittings	PVC Schedule 80	ANSI/ASTM D2467
		CPVC Schedule 80	ANSI/ASTM F439
		PVC - DWV	ANSI/ASTM D2665
	Pipe Cement /	PVC	ANSI/ASTM D2564
	Primer	CPVC	ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

5.Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.

6.Priming and Cementing:

a.Handle fittings and pipes carefully to prevent contamination of surfaces.

b.Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth.

c.Apply a second primer coat to the fitting socket.

d.While primer is still wet, apply an even coat of approvedcementtothepipeequaltothedepthof the fitting socket along with an even coat of approved cement to the fitting socket.

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/						e.	Apply a second coat of cement to the pipe.
primer must be ULC-S636 certified.						f.	While the cement is still wet, insert the pipe into
1.	Work from the boiler to vent	or air termination. Do not					the fitting, if possible twist the pipe a 1/4 turn as
	exceed the lengths given in this manual for the air or vent						you insert it. NOTE: If voids are present,
	piping.						sufficient cement was not applied and joint could
2.	Cut pipe to the required lengths		and	deburr the	inside	g.	be defective.
	and outside of the pipe ends.						Wipe excess cement from the joint removing
3.	Chamfer outside of each	pipe	end	to ensure	even		ring or beads as it will needlessly soften the

cement distribution when joining.	pipe.

4.Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

Figure 3-2 Near Boiler PVC/CPVC Venting - Models 400 - 600 Figure 3-3 Near Boiler PVC/CPVC Venting - Models 725 - 850

VENT

VENT

4" COUPLING
( FIELD SUPPLIED )
		6" COUPLING
4" CPVC		( FIELD SUPPLIED )
		6" CPVC
STARTER PIECE
		STARTER PIECE
( FACTORY SUPPLIED )
		( FACTORY SUPPLIED )
4" CPVC PIPE SUPPLIED WITH	IMG00987	IMG00988
BOILER MUST BE USED FOR VENT CONNECTION		6" CPVC PIPE SUPPLIED WITH
NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND		BOILER MUST BE USED FOR VENT CONNECTION
		NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND
VENT FITTINGS MUST BE USED IN CLOSET AND
ALCOVE INSTALLATIONS.		VENT FITTINGS MUST BE USED IN CLOSET AND
		ALCOVE INSTALLATIONS

21

3 General venting

Polypropylene

This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3F.

All terminations must comply with listed options in this manual and be a single-wall vent offering.

For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.

When determining equivalent combustion air and vent length for polypropylene single-wall piping:

•1 foot of Duravent 4 inch single-wall pipe is equivalent to 1.6 feet of piping

Flexible polypropylene

For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations (FIG. 3-4).

Figure 3-4 Near Boiler Flexible Polypropylene Venting

CAP

Duravent 3”

Duravent 4”

CHIMNEY

“A” DIM

“B” DIM

“A” DIM

“B” DIM

3” RIGID

3” FLEX

4” FLEX

4” RIGID 4” FLEX 5” FLEX

10 FT

60 FT

90 FT

10 FT

30 FT

90 FT

20 FT

53 FT

80 FT

20 FT

27 FT

80 FT

B

30 FT

47 FT

70 FT

30 FT

23 FT

70 FT

40 FT

60 FT

40 FT

20 FT

60 FT

40 FT

50 FT

33 FT

50 FT

50 FT

17 FT

50 FT

60 FT

27 FT

40 FT

60 FT

13 FT

40 FT

70 FT

20 FT

30 FT

70 FT

10 FT

30 FT

80 FT

13 FT

20 FT

80 FT

7 FT

20 FT

90 FT

7 FT

10 FT

90 FT

3 FT

10 FT

		Installation & Operation Manual
		The installer must use a specific vent starter
	NOTICE
		adapter at the flue collar connection. The
		adapter is supplied by the vent manufacturer
		to adapt to its vent system. See Table 3F
		for approved vent adapters. Discard CPVC
		starter piece.

NOTICE

WARNING

WARNING

NOTICE

All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-5).

Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

Use only the adapters and vent system listed in Tables 3F and 3G. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

NOTICE	Installation of a polypropylene vent system
	should adhere to the vent manufacturer’s
	installation instructions supplied with the
	vent system.

Figure 3-5 Near Boiler Polypropylene Venting

A		Centrotherm 3”				Centrotherm 4”
		“A” DIM	“B” DIM
						“A” DIM	“B” DIM
		3” RIGID	3” FLEX	4” FLEX		4” RIGID	4” FLEX
		10 FT	45 FT	90 FT		10 FT	33 FT
		20 FT	40 FT	80 FT		20 FT	29 FT
		30 FT	35 FT	70 FT		30 FT	26 FT
		40 FT	30 FT	60 FT		40 FT	22 FT
		50 FT	25 FT	50 FT		50 FT	18 FT
		60 FT	20 FT	40 FT		60 FT	15 FT
		70 FT	15 FT	30 FT		70 FT	11 FT
		80 FT	10 FT	20 FT		80 FT	7 FT
		90 FT	5 FT	10 FT		90 FT	4 FT

*NOTES: 1) FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION

2)ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE EQUIVALENT LENGTHS.

3)SECTION A IS EQUIVALENT FEET OF RIGID PIPE, WHICH MAY INCLUDE 45 AND 90° ELBOWS. PLEASE SEE SIZING SECTION FOR DETERMINING EQUIVALENT FEET.

IMG00840

4” POLYPROPYLENE ADAPTER

4” POLYPROPYLENE JOINT CONNECTOR REQUIRED AT ALL THE COMPONENTS OF THE VENT SYSTEM

4” POLYPROPYLENE ADAPTER

IMG00990

MODELS 400 - 600

	Table 3F Polypropylene Vent Pipe and Fittings
	Approved Polypropylene Vent Manufacturers
		Make		Model			6” POLYPROPYLENE PIPE
	Centrotherm Eco Systems			InnoFlue SW/Flex			6” POLYPROPYLENE ADAPTER
	Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex
	Table 3G Approved Polypropylene Terminations						MODELS 725 - 850		IMG00989
	Model	Manufacturer Vent Model		Vent Type	Adapter Number	Joint Connector	Sidewall Kit*	Retaining Bracket /
								Adapter*
				Single-Wall
		Centrotherm	Innoflue		ISAAL0404	IANS04	--	IATP0404/
	400-600	Eco Systems		Flex				ISTAGL0404
		DuraVent	PolyPro	Single-Wall	4PPS-AD	4PPS-LB	4PPS-HLK		--
		(M & G)		Flex
		Centrotherm	Innoflue	Single-Wall	ISAAL0606	--	--	IATP0606 /
	725-850	Eco Systems		Flex				ISTAGL0606
					6PPS-06PVCM-
		DuraVent	PolyPro	Single-Wall		--	6PPS-HLK		--
		(M & G)		Flex	6PPF

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 27).

22

3 General venting (continued)

Stainless steel vent

This product has been approved for use with stainless steel using the manufacturers listed in Table 3H.

	WARNING	Use only the materials, vent systems, and
		terminations listed in Tables 3G and 3I.
		DO NOT mix vent systems of different
		types or manufacturers. Failure to comply
		could result in severe personal injury,
		death, or substantial property damage.
		The installer must use a specific vent starter
	NOTICE
		adapter at the flue collar connection,
		supplied by the vent manufacturer to
		adapt to its vent system. See Table 3I for
		approved vent adapters. Discard CPVC
		starter piece.
		Installations must comply with applicable
	NOTICE
		national, state, and local codes. Stainless
		steel vent systems must be listed as a
		UL-1738 approved system for the United
		States and a ULC-S636 approved system
		for Canada.
		Installation of a stainless steel vent system
	NOTICE
		should adhere to the stainless steel vent
		manufacturer’s installation instructions
		supplied with the vent system.

Table 3H Stainless Steel Vent Pipe and Fittings

Approved Stainless Steel Vent Manufacturers

Manufacturer	Model
Dura Vent (M & G)	FasNSeal Vent / FasNSeal Flex*
Z-Flex	Z-Vent
Heat Fab	Saf-T Vent
Metal Fab	Corr/Guard
Security Chimney	Secure Seal
ICC	VIC
Jeremias	--

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.

Installation & Operation Manual

Figure 3-6 Near Boiler Stainless Steel Venting Models 400 - 600

4" STAINLESS STEEL PIPE

4" STAINLESS STEEL ADAPTER

IMG00991

Figure 3-7 Near Boiler Stainless Steel Venting Models 725 - 850

STAINLESS

STEEL PIPE

STAINLESS

STEEL ADAPTER

IMG00992

Table 3I Approved Stainless Steel Adapters and Terminations
Model	Manufacturer	Adapter			Termination
		Flue		Intake	Flue	Intake
	DuraVent (M & G)	FSA-4PVCM-4FNSF		F303759	FSBS4	FSAIH04
	(Fas-N-Seal)				FSRC4 (R.C.)	303888
	Heat Fab (Saf-T-Vent)	9401PVC		9401PVC	0492	9414TERM
					5400CI
	Z-Flex (Z-Vent)	2SVSLA04		2SVSLA04	2SVSTP04	2SVSTEX0490
400-600					2SVSRCX04
	Metal Fab (Corr/Guard)	4CGPVCA		4CGPVCA	4CGSWHT	4CGSW90LT
					4CGSWC
	Security Chimney	SS4PVCU		SS4PVCU	SS4STU	SS4ST90AU
	(Secure Seal)				SS4RCBU
	Jeremias	SWKL4-PVC		SWKL4-PVC	SWKL4-WRC	SWKL4-90ET
	DuraVent (M & G)	FSA-6PVCM-6FNSF		F303759	FSBS6	FSAIH04
	(Fas-N-Seal)	300538				303888
	Heat Fab (Saf-T-Vent)	9601PVC		9601PVC	9601PVC	9601PVC
	Metal Fab (Corr/Guard)	6FCGPVCA		6FCGPVCA	6FCGSWMC	6CGSW90L
725-850					6FCGSWC
	Security Chimney	SS6PVCU		SS6PVCU	SS6STU	SS6ST90AU
	(Secure Seal)				SS6RCBU
	ICC	HE-6DSA-F		--	HE-6MC-F	--
					HE-6RC-F
	Jeremias	SWKL6-PVC		SWKL4-PVC	SWKL6-WRC	SWKL4-90ET
								23

4 Sidewall direct venting

Vent/air termination – sidewall

WARNING

WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING

CAUTION

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe except as noted in Section 3 on page 20. Failure to comply could result in severe personal injury, death, or substantial property damage.

Sidewall venting commercial products will result in large exhaust plumes in cold climates. Consideration should be taken when locating in proximity to windows, doors, walkways, etc.

	NOTICE	Installation must comply with local
		requirements and with the National
		Fuel Gas Code, NFPA 54 / ANSI Z223.1
		for U.S. installations or CSA B149.1 for
		Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

Installation & Operation Manual

f.Do not terminate above any door or window. Condensate can freeze, causing ice formations.

g.Locate or guard vent to prevent condensate damage to exterior finishes.

Figure 4-1A PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings

3.The air piping must terminate in a down-turned elbow as shown in FIG. 4-1A. This arrangement avoids recirculation of flue products into the combustion air stream.

4.The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1A.

Do not exceed the maximum lengths of theWARNING outside vent piping shown in FIG. 4-1B.

Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

1.The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 18 of this manual.

2.You must consider the surroundings when terminating the vent and air:

a.Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b.The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c.Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d.Avoid possibility of accidental contact of flue products with people or pets.

e.Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

WARNING Sidewall vent and air inlet terminations must terminate in the same pressure

zone.

24

Figure 4-1B PVC/CPVC/Polypropylene Sidewall

Termination of Air and Vent

				TO BOILER
				INTAKE AIR
				CONNECTION
		FROM BOILER
		VENT PIPE
		CONNECTION				12"
		POSSIBLE ORIENTATIONS				MIN
						TO
						OVER-
						HANG
				VENT / AIR
				TERMINATION
						12"
						MIN
					GRADE OR
					SNOW LINE
	Table 4A Sidewall Vent Kits
	Model	Kit Number		Air	Vent	Centerline
						Width
	400 - 600	100157611		4"	4"	5 5/8"
			(102 mm) (102 mm)			(143 mm)
	725 - 850	100157613		4"	6"	7 3/4"
			(102 mm) (152 mm)			(197 mm)

Installation & Operation Manual

4 Sidewall direct venting (continued)

Vent/air termination – sidewall

Figure 4-2A PVC/CPVC/ Polypropylene Sidewall Termination Models 400 - 850 w/Field Supplied Fittings

BIRD SCREEN

TO BOILER

INTAKE AIR

CONNECTION

12" (305 MM) MIN 15" (381 MM) MAX

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

12" (305 MM) MIN

GRADE OR

SNOW LINE

Figure 4-2B Stainless Steel Sidewall Termination Models 725 - 850 w/Field Supplied Fittings

TO BOILER INTAKE

AIR CONNECTION

12" (305 MM) MIN

15" (381 MM) MAX

FROM BOILER VENT

PIPE CONNECTION

12" (305 MM) MIN

GRADE OR

SNOW LINE

NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.

c.Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally.

6.Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Figure 4-3A Clearance to Gravity Air Inlets w/Field Supplied Fittings

12” (305 MM)

MIN

BIRD

SCREEN (TYPICAL)

12” (305 MM) MIN

12” (305 MM) MIN

Figure 4-3B Clearance to Gravity Air Inlets

5.Maintain clearances as shown in FIG.’s 4-1A thru 4-4B, pages 24 thru 26. Also maintain the following:

a.Vent must terminate:

•At least 6 feet (1.8 m) from adjacent walls.

•No closer than 12 inches (305 mm) below roof overhang.

•At least 7 feet (2.1 m) above any public walkway.

•At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m).

•No closer than 12 inches (305 mm) below or horizontally from any door or window or any other gravity air inlet.

b.Air inlet must terminate at least 12 inches (305 mm) above grade or snow line; at least 12 inches (305 mm) below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches (610 mm) vertically outside the building.

12"

MIN.

VENT / AIR

TERMINATION

12" MIN.

12" MIN.

25

4 Sidewall direct venting

Vent/air termination – sidewall

Figure 4-4A Clearance to Forced Air Inlets w/Field Supplied Fittings

IF LESS

THAN 10’ (3 M)

Installation & Operation Manual

3.Use a sidewall termination plate as a template for correct location of hole centers.

4.Follow all local codes for isolation of vent pipe when passing through floors or walls.

5.Seal exterior openings thoroughly with exterior caulk.

36” (914 MM)

MIN

FORCED AIR

INLET

BIRD

SCREEN (TYPICAL)

7’ (2.1 M) MIN ABOVE ANY

PUBLIC WALKWAY

Figure 4-4B Clearance to Forced Air Inlets

IF LESS

THAN 10’

VENT / AIR

TERMINATION 36"

MIN.

FORCED AIR

INLET

7' MIN. ABOVE ANY PUBLIC WALKWAY

Prepare wall penetrations

1.Air pipe penetration:

a.Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

2.Vent pipe penetration:

a.Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

•5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe

•7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe

b.Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-5A.

Figure 4-5A A Typical Sidewall Termination Assembly - Models 400 - 850 PVC/CPVC/ Polypropylene or Stainless Steel

SIDEWALL	GALVANIZED
	THIMBLE (WHEN REQUIRED BY LOCAL CODES)
TERMINATION PLATE	ELBOW
VENT
PIPING	AIR PIPING

BIRD SCREEN

ELBOW

BIRD SCREEN

Prepare wall penetrations (Factory Supplied Option)

1.Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.

Air pipe penetration:

a.Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

Vent pipe penetration:

a.Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

•5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe

•7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

2.For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3G on page 22 into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate (FIG. 4-4A).

3.For PVC/CPVC Only: Install the vent and air intake piping through the wall into the vent plate openings. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3E on page 21 to seal the vent pipe.

26