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

...

FTXL-I-O_100059358_2000005000_Rev U

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

 WARNING

Save this manual for future reference.

 is manual must only be used by a quali ed 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.

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 deﬁ nitions

 e following de ned 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.

Please read before proceeding

 WARNING

NOTICE

 WARNING

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

User –  is 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 quali ed 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  led immediately against the transportation company by the consignee.

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  re or explosion may result causing property damage, personal injury or loss of life.

 is appliance MUST NOT be installed in any location where gasoline or  ammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

When servicing boiler –

Boiler operation –

Boiler water –

Freeze protection ﬂ uids –

Installation & Operation Manual

 WARNING

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

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

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

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

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

•  oroughly  ush 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.  e high-e ciency 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.

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

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.

• 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  re department.

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

The FTXL - How it works...

1. Stainless steel heat exchanger

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

2. Heat exchanger top plate

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

3. Blower

 e blower 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

 e gas valve senses the negative pressure created by the blower, allowing gas to  ow only if the gas valve is powered and combustion air is  owing.

5. Venturi

 e venturi controls air and gas  ow into the burner.

6. Flue gas sensor (limit rated)

 is sensor monitors the  ue gas exit temperature.  e control module will modulate and shut down the boiler if the  ue gas temperature gets too hot.  is protects the  ue pipe from overheating.

7. Boiler outlet temperature sensor (limit rated)

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

8. Boiler inlet temperature sensor

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

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

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

10. Electronic LCD display

 e display 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  ber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of  ring 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

 readed pipe connection of 1".  is pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

16. SMART SYSTEM Control Module

 e SMART 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 modi ed 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

 e junction 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

 e connection 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

 e condensate 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

 e quartz glass window provides a view of the burner surface and  ame.

27. Gas shuto valve (Models 500 - 850 only)

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

28. Relief valve ( eld installed, not shown)

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

29. Flame sensor

Used by the control module to detect the presence of burner  ame.

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

 e pump relay board is used to connect the boiler, system and DHW pumps.

34. Transformer

 e transformer 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 cuto 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  ue collector

Flue gas and condensate enter the stainless steel  ue collector through the  retubes. A 1" drain connection allows condensate to  ow through the collector into a condensate trap for disposal.

38. Reset switch

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

39. Test switch

 e test 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  ue vent which provides access for a combustion analyzer probe.

41. Burner plate (not shown)

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

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

Models 400 - 850

Installation & Operation Manual

Front View

Rear View

16 33

38 39

Left Side (inside unit)

DIR #2000544916 00

Right Side (inside unit)

Ratings

Installation & Operation Manual

FTXL Boiler

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

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

NOTICE

Min Max

Maximum allowed working pressure is located on the rating plate.

Notes:

1.  e 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 su cient 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.

Input MBH

(Note 4)

Gross

Output

MBH

(Note 1)

Other Speciﬁ cations

Net

AHRI

Ratings

Water,

MBH

(Note 2)

6. Ratings have been con rmed 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.  e manual reset high limit provided with the FTXL is listed to UL353.

Boiler

Water Content Gallons

13.2 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”

Water

Connections

Gas

Connections

Air

Size

Vent Size

(Note 3)

3. FTXL boilers require special gas venting. Use only the vent materials and methods speci ed 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.  e 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.  e 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 di erent 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 a xed to the unit.

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

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

IMG01068

Figure A High Altitude Label Location

1 Determine boiler location

Installation & Operation Manual

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

 e FTXL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests speci ed 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.  e pan must not restrict combustion air  ow. 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  ammable liquids.

 WARNING

4.  e 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 le from existing piping, if not  ushed 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.

 WARNING

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.

 WARNING

 is appliance is certi ed 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.

 is appliance requires a special venting system.  e vent connection to the appliance must be made with the starter CPVC/ stainless steel pipe section provided with the appliance.  e  eld provided PVC vent  ttings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement speci ed in this manual to make the vent connections. Failure to follow this warning could result in  re, 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.  is would be considered a closet for a FTXL Boiler.

 WARNING

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.  e 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  re, 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.

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

 WARNING

18" (457 MM) TOP

VENTILATING AIR OPENING

CLOSED DOOR

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  re,

personal injury, or death.

0" LEFT

14" (356 MM) REAR

AREA OF EACH OPENING

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

6" (152 MM) FRONT

0" RIGHT

VENTILATING AIR OPENING

IMG00982

Figure 1-2 Alcove Installation - Minimum Required Clearances

ALCOVE INSTALLATION

1/4" (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1" (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPE

 WARNING

18" (457 MM)

TOP

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  re, personal injury, or death.

OPEN DOOR

0" LEFT

14" (356 MM) REAR

6" (152 MM) FRONT

0" RIGHT

IMG00983

1 Determine boiler location

Installation & Operation Manual

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-ﬁ red 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

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).

 e 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.

Flooring and foundation

Flooring

 e FTXL is approved for installation on combustible  ooring, but must never be installed on carpeting.

 WARNING

If  ooding is possible, elevate the boiler su ciently to prevent water from reaching the boiler.

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

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  oor.

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

Vent and air piping

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

 e 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 speci ed. 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.  e 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.  ese areas will always contain contaminants.

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/ uorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water so ening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric so eners 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 re nishing areas and establishments

New building construction

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

 WARNING

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  ue 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  ue producing condensate.

• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot.  e 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  t 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.

Failure to follow all instructions can result in  ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Remodeling areas

Garages with workshops

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

 WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in  ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

 DANGER

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 de ciencies, 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  replace dampers.

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

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.

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 dra hood relief opening a e r

5 minutes of main burner operation. Use the  ame of a match or candle, or smoke from another source.

f. A er 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,  replace dampers, and any other gas-burning appliance to their previous conditions of use.

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.

 e equipment room MUST be provided with properly sized openings and/or be of su cient volume to assure adequate combustion air and proper ventilation for all gas  red appliances in the equipment room to assure adequate combustion air and proper ventilation.

 e requirements shown are for the appliance only; additional gas  red 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.

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).

IMG01075

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  red 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).  is 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 speci ed 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 di erent 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).

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 cm

per kW).  is 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  oor of the equipment room. Each opening must have a net free area as speci ed in Table 1B. Single openings shall commence within 12" (30 cm) of the ceiling.  e 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.

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

 e 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 downdra in the venting system. Spillage of  ue 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

2 Ducts Delivered from Interior

Space

Same Story

Top

Opening, in

(cm2)

400

(2,581)

500

(3,226)

600

(3,871)

725

(4,677)

850

(5,484)

Opening, in

Bottom

400

(2,581)

500

(3,226)

600

(3,871)

725

(4,677)

850

(5,484)

(cm2)

*Outside Air from

1 Opening Directly from

Outdoors, in

(cm2)

134

(865)

167

(1,078)

200

(1,291)

242

(1,561)

284

(1,832)

Model

Number

FTX400

FTX500 FTX600

FTX725

FTX850

*Outside Air from

2 Openings Directly from

Bottom

Opening, in

(cm2)

100

(646)

125

(807)

150

(968)

182

(1,174)

213

(1,374)

Outdoors

Top

Opening, in

(cm2)

100

(646)

125

(807)

150

(968)

182

(1,174)

213

(1,374)

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

(cm2)

200

(1,291)

250

(1,613)

300

(1,936)

363

(2,342)

425

(2,742)

Bottom

Opening, in

(cm2)

200

(1,291)

250

(1,613)

300

(1,936)

363

(2,342)

425

(2,742)

 e above requirements are for the appliance only; additional gas  red 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  red appliances. Buildings MUST NOT be of *“Tight Construction”

Outside air openings shall directly communicate with the outdoors.

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

”Tight Construction” is de ned 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.

2 Prepare boiler

Remove boiler from wood pallet

1. A er removing the outer shipping carton from the boiler, remove the parts box.

2. To remove the boiler from the pallet (a er removing the front door):

a. Remove the three (3) lag bolts from inside the front of the boiler (FIG. 2-1). b. Remove the two (2) L-brackets and the two (2) lag 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.

NOTICE

Figure 2-1 Boiler Mounted on Shipping Pallet

Do not drop the boiler or bump the jacket on the  oor or pallet. Damage to the boiler can result.

FRONT

REAR

Installation & Operation Manual

Models 400 and 500 Only (Venturi w/LP Oriﬁ ces)

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

2. Disconnect the air inlet piping from the venturi by loosening the band clamp around the rubber boot coupling. Slide the rubber boot o of the venturi.

3. Disconnect gas piping from the venturi by loosening the 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:

a.  e UP arrow on the plastic housing is indeed

pointing up.

b.  e threaded connection for the gas piping is facing

towards the front of the unit. Reinstall the bolts connecting the venturi to the fan.

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.

REMOVE THE LAG BOLTS (QTY. 3) FROM INSIDE THE FRONT OF THE BOILER

Gas conversions

 WARNING

Table 2A LP Conversion Kit

For a boiler already installed, you must turn o gas supply, turn o power and allow boiler to cool before proceeding. You must also completely test the boiler a er 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.

REMOVE THE L-BRACKETS (QTY. 2) AND LAG BOLTS (QTY. 2)

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

8. A er 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

A er 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-ring

 DANGER

when the blower is disassembled.  e 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.

Model Description Kit Number

400 - 500

LP Kit 100189174

2 Prepare boiler (continued)

Installation & Operation Manual

Figure 2-2A 400 Model_Venturi with LP Oriﬁ ce

BLOWER

O-RING

VENTURI

SCREWS QTY. 3

GAS VALVE

IMG01069

Figure 2-2B 500 Model_Venturi with LP Oriﬁ ce

BLOWER

O-RING

Models 600 - 850

1. Li 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. A er 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

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

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

COVER

VENTURI

SCREWS QTY. 5

GAS COCK

GAS VALVE

IMG01070

LLEN WRENCH

ADJUSTMENT SCREW

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

IMG01060

Two Pipe Sidewall

See page 24 for more details

Direct venting options - Vertical Vent

IMG01061

PVC/CPVC Concentric Sidewall

Models 400 - 600 Only

See page 28 for more details

IMG01062

Two Pipe Vertical

See page 31 for more details

IMG01063

PVC/CPVC

Concentric Vertical

Models 400 - 600 Only

See page 33 for more details

IMG01064

Vertical Vent, Sidewall Air

3 General venting (continued)

Install vent and combustion air piping

 DANGER

 WARNING

NOTICE

 WARNING

 e 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  nished 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.

 is appliance requires a special venting system. Use only approved stainless steel,

PVC, CPVC or polypropylene pipe and  ttings listed in Tables 3E, 3F, and 3H for vent pipe, and  ttings. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT mix components from di erent systems.  e vent system could fail, causing leakage of  ue products into the

living space. Mixing of venting materials will void the warranty and certi cation 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.

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  re, personal injury, or death.

Installation & Operation Manual

 e 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.  e resultant installation is direct vent (sealed combustion).

 e FTXL is certi ed 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  tting is provided on the unit for  nal 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  tting is provided on the unit for  nal connection. 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

 CAUTION

NOTICE

 WARNING

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.

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.

IMG00986

3 General venting

Installation & Operation Manual

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certi ed to ULC-S636.

2.  e  rst three (3) feet of plastic vent pipe from the appliance  ue outlet must be readily accessible for visual inspection.

3.  e components of the certi ed vent system must not be interchanged with other vent systems or unlisted pipe/ ttings. For concentric vent installations, the inner vent tube must be replaced with  eld supplied certi ed vent material to comply with this requirement.

4.  e 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

 e FTXL uses model speci c combustion air intake and vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

Model

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%

NOTICE

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.

NOTICE

Pipe Diameter De-rate per 25 feet of Vent

Air Intake Vent Direct Vent Room Air

Increasing or decreasing combustion air or vent piping sizes is not authorized.

 e appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Model Kit Number

400 100140484 5' (1.5 m)

500 - 600 100140484 30' (9 m)

Equivalent

Vent Length

Air inlet pipe materials:

 e 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 roo op air inlet) Galvanized steel vent pipe with joints and seams sealed as speci ed in this section. Type “B” double-wall vent with joints and seams sealed as speci ed in this section. AL29-4C, stainless steel material to be sealed to speci cation of its manufacturer.

*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

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical roo op 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.

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

 e 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.

3 General venting (continued)

Installation & Operation Manual

 e 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.  e 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  ex 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 roo op 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  ue gas recirculation, spillage of  ue products and carbon monoxide emissions causing severe personal injury or death.

Optional room air

NOTICE

Commercial applications utilizing the FTXL boiler may be installed with a single pipe carrying the  ue 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.

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

•  e 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

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

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

 WARNING

Table 3C Optional Room Air Kit

Model Description Kit Number

400 - 850

Air contamination

Pool and laundry products and common household and hobby products o en contain  uorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids.  e acid can eat through the boiler wall, causing serious damage and presenting a possible threat of  ue 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

When utilizing the single pipe method, 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.

Room Air Kit 100157616

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.

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.

Installation & Operation Manual

Table 3D Flue Damper Kits

Flue Damper Kits

Model Damper Size Kit Number

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

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

4. A condensate drain must be installed above the  ue 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.  e 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.  e Cascade (Members) must be controlled by the FTXL Leader boiler using the Lead/Lag Cascade option.

For approved common vent sizing, contact the factory.

 WARNING

NOTICE

When FTXL boilers are common vented, the criteria above MUST BE followed. Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.

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 collection section MUST BE installed directly above the back ow preventer.

400 4" 100056141 500 4” 100056141 600 4” 100056141 725 6” 100056142 850 6” 100056142

PVC/CPVC

 is 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

 WARNING

 e 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.  e  eld provided vent  ttings 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 speci ed in Table 3E to make the vent connections. Failure to follow this warning could result in  re, personal injury, or death.

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

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).

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

3 General venting (continued)

Installation & Operation Manual

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

Vent ﬁ ttings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

NOTE: In Canada, CPVC and PVC vent pipe,  ttings and cement/ primer must be ULC-S636 certi ed.

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and  ttings 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

PVC - DWV ANSI/ASTM D2665 CPVC Schedule 40, 80 ANSI/ASTM F441 PVC Schedule 40 ANSI/ASTM D2466 PVC Schedule 80 ANSI/ASTM D2467 CPVC Schedule 80 ANSI/ASTM F439 PVC - DWV ANSI/ASTM D2665 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493

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

VENT

5. Dry  t vent or air piping to ensure proper  t up before assembling any joint.  e pipe should go a third to two-thirds into the  tting to ensure proper sealing a er cement is applied.

6. Priming and Cementing: a. Handle  ttings and pipes carefully to prevent contamination of surfaces.

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

c. Apply a second primer coat to the  tting socket.

d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the  tting socket along with an even coat of approved cement to the  tting socket.

e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into

the  tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, su cient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly so en the pipe.

VENT

4" COUPLING ( FIELD SUPPLIED )

4" CPVC STARTER PIECE ( FACTORY SUPPLIED )

4" CPVC PIPE SUPPLIED WITH 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.

IMG00987

6" COUPLING

( FIELD SUPPLIED )

6" CPVC

STARTER PIECE

( FACTORY SUPPLIED )

6" CPVC PIPE SUPPLIED WITH 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

IMG00988

3”

4”

Installation & Operation Manual

3 General venting

Polypropylene

 is 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 o ering.

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  ex 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

uravent

“A” DIM

3” FLEX

3” RIGID

10 FT 20 FT 30 FT

40 FT

50 FT 60 FT 70 FT 80 FT

90 FT

Centrotherm 3”

“A” DIM

3” FLEX

3” RIGID

10 FT

20 FT 30 FT 40 FT 50 FT

60 FT

70 FT 80 FT 90 FT

60 FT 53 FT 47 FT 40 FT 33 FT 27 FT 20 FT 13 FT

7 FT

45 FT 40 FT

35 FT 30 FT 25 FT 20 FT 15 FT 10 FT

5 FT

“B” DIM

4” FLEX

“B” DIM

4” FLEX

90 FT 80 FT 70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT

90 FT

80 FT 70 FT 60 FT 50 FT

40 FT

30 FT 20 FT 10 FT

CHIMNEY

CAP

*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.

Table 3F Polypropylene Vent Pipe and Fittings

uravent

“A” DIM

4” RIGID

10 FT 20 FT

30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT

Centrotherm 4”

“A” DIM 4” RIGID

10 FT 20 FT

30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT

“B” DIM

4” FLEX

30 FT 27 FT 23 FT 20 FT 17 FT 13 FT 10 FT

7 FT 3 FT

“B” DIM 4” FLEX

33 FT 29 FT 26 FT 22 FT 18 FT 15 FT 11 FT

7 FT 4 FT

5” FLEX

90 FT 80 FT 70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT

IMG00840

NOTICE

 e installer must use a speci c vent starter adapter at the  ue collar connection.  e 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

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

 WARNING

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

 WARNING

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

NOTICE

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

4” POLYPROPYLENE ADAPTER

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

4” POLYPROPYLENE ADAPTER

MODELS 400 - 600

IMG00990

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems InnoFlue SW/Flex

Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex

6” POLYPROPYLENE PIPE

6” POLYPROPYLENE ADAPTER

Table 3G Approved Polypropylene Terminations

Model Manufacturer Vent Model Vent Type Adapter Number Joint Connector Sidewall Kit*

Single-Wall

Flex

Single-Wall

Flex

Single-Wall

Flex

Single-Wall

Flex

ISAAL0404 IANS04 --

4PPS-AD 4PPS-LB 4PPS-HLK --

ISAAL0606 -- --

6PPS-06PVCM-

6PPF

-- 6PPS-HLK --

400-600

725-850

Centrotherm

Eco Systems

DuraVent

(M & G)

Centrotherm

Eco Systems

DuraVent

(M & G)

Innoﬂ ue PolyPro

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

MODELS 725 - 850

Retaining Bracket /

ISTAGL0404

IATP0606 /

ISTAGL0606

IMG00989

Adapter*

IATP0404/

3 General venting (continued)

Stainless steel vent

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

 WARNING

NOTICE

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.

Use only the materials, vent systems, and terminations listed in Tables 3G and 3I. DO NOT mix vent systems of di erent types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

 e installer must use a speci c vent starter adapter at the  ue 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 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 should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

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

DuraVent (M & G)

(Fas-N-Seal)

Heat Fab (Saf-T-Vent) 9401PVC 9401PVC

Z-Flex (Z-Vent) 2SVSLA04 2SVSLA04

Flue Intake Flue Intake

FSA-4PVCM-4FNSF F303759

Adapter Termination

400-600

Metal Fab (Corr/Guard) 4CGPVCA 4CGPVCA

725-850

Security Chimney

(Secure Seal)

Jeremias SWKL4-PVC SWKL4-PVC SWKL4-WRC SWKL4-90ET

DuraVent (M & G)

(Fas-N-Seal)

Heat Fab (Saf-T-Vent) 9601PVC 9601PVC 9601PVC 9601PVC

Metal Fab (Corr/Guard) 6FCGPVCA 6FCGPVCA

Security Chimney

(Secure Seal)

ICC HE-6DSA-F --

Jeremias SWKL6-PVC SWKL4-PVC SWKL6-WRC SWKL4-90ET

SS4PVCU SS4PVCU

FSA-6PVCM-6FNSF

300538

SS6PVCU SS6PVCU

FSBS4

FSRC4 (R.C.)

0492

5400CI

2SVSTP04

2SVSRCX04

4CGSWHT

4CGSWC

SS4STU

SS4RCBU

F303759 FSBS6

6FCGSWMC

6FCGSWC

SS6STU

SS6RCBU HE-6MC-F

HE-6RC-F

FSAIH04

303888

9414TERM

2SVSTEX0490

4CGSW90LT

SS4ST90AU

FSAIH04

303888

6CGSW90L

SS6ST90AU

Installation & Operation Manual

4 Sidewall direct venting

Vent/air termination – sidewall

 WARNING

 CAUTION

NOTICE

Determine location

Locate the vent/air terminations using the following guidelines:

1.  e 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.  e  ue 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  ue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of  ue products with people or pets. e. Do not locate the terminations where wind eddies could a ect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

 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.

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.

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.

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

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  nishes.

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

3.  e air piping must terminate in a down-turned elbow as shown in FIG. 4-1A.  is arrangement avoids recirculation of  ue products into the combustion air stream.

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

 WARNING

Do not exceed the maximum lengths of the 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.

Figure 4-1B PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

TO BOILER

INTAKE AIR

CONNECTION

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVERHANG

12" MIN

Table 4A Sidewall Vent Kits

Centerline

Width

5 5/8"

(143 mm)

7 3/4"

(197 mm)

Model Kit Number Air Vent

400 - 600 100157611

725 - 850 100157613

(102 mm)

(152 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

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

12" (305 MM) MIN

GRADE OR SNOW LINE

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

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

BIRD SCREEN

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)

TO BOILER INTAKE

NOTICE

AIR CONNECTION

FROM BOILER VENT PIPE CONNECTION

GRADE OR SNOW LINE

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

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

12" (305 MM) MIN

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” (305 MM)

MIN

12” (305 MM)

MIN

Figure 4-3B Clearance to Gravity Air Inlets

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

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  oors 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

7' MIN. ABOVE ANY

PUBLIC WALKWAY

36"

MIN.

FORCED AIR

INLET

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

TERMINATION PLATE

VENT

PIPING

BIRD SCREEN

ELBOW

BIRD SCREEN

GALVANIZED THIMBLE

(WHEN REQUIRED BY LOCAL CODES)

ELBOW

AIR PIPING

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  ush 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.

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